Introduction

With the rapid growth of the electric vehicle market, many AC charging stations for electric vehicles are being installed in India, Turkey and around the world:

• household burden
• Commercial parking spaces
• Shopping centers
• fleet charging stations
• public charging station networks

However, unlike conventional household appliances, an electric vehicle charger contains the following components:

• AC/DC converter
• power switching devices
• Battery charging circuits
• High-frequency switching components

These electronic components can generate the following:

• Alternating short-circuit current
• pulsed continuous residual current
• Continuous and soft residual flow

In particular, leakage current from soft DC can cause failure of conventional type A residual current circuit breakers.

Therefore, the IEC 62955 standard states that electric vehicle chargers must be capable of detecting a DC short-circuit current of 6 mA.

Real-life example #1: Why did the standard differential protection fail at an electric vehicle charging station?

Context of the case

An Indian manufacturer of electric vehicle wallboxes has developed a 7kW single-phase charger for electric vehicles.

First draft of the plan:

• Electric vehicle charging station
  ↓
  Type A residual current circuit breaker
  ↓
  Power grid

During the tests the following observations were made:

If the insulation of the vehicle charging module is damaged:

• The flow of continuous leakage gradually increased.
• The differential switch type A failed to operate.
• The higher level protection system has lost sensitivity.

Cause:

A residual current device (RCD) type A can detect only the following substances:

• ✔ AC leakage
  ✔ DC impulse leakage

However, it is impossible to prove this reliably.

✘ Soft DC leakage

Ultimately, the client should add the following:

East German type B

However, a problem arises:

Cost of GDR type B services:

As a rule, this figure is many times higher than for type A.

lead to:

• Increased costs for the range of chargers
• Decrease in product competitiveness

The Indian market’s price demands were not met.

Solution:

Increase:

Module HYCA-16-PD IEC 62955 RDC-DD

The system will work as follows:

• Electric Vehicle Charger
  ↓
  HYCA-16-PD
  ↓
  Type A Residual Current Circuit Breaker

When the DC leakage current reaches 6mA:

HYCA-16-PD output protection signal,

Eliminate risks in advance.

Result:

• ✔ Complies with IEC 62955
  ✔ Reduces protection costs
  ✔ Simplifies planning of electric vehicle charging stations

Case Study #2: Turkish Electric Vehicle Charger Manufacturer Improves European Market Compliance

Client context

A Turkish manufacturer of electric vehicle chargers plans to export its products:

• Türkiye
• Europe
• Middle East

Clients note that projects in the European market typically require the following:

• IEC 61851
  IEC 62955

Original design:

Standard leakage current sensor + residual current circuit breaker type A

questions:

In European installation standards, more and more attention is paid to:

• DC leakage current protection.

Customer needs:

Compact design

printed circuit board assembly

Reliable DC detection

After implementation of HYCA-16-PD:

integrated:

• ✔ AC/DC short-circuit current detection
  ✔ 6mA DC current detection
  ✔ Self-diagnosis function
  ✔ Compact PCB mounting

Customer Support:

• Reduce the size of the charger.
• Improving preparation for certification
• Simplified security architecture

Why is 6mA DC current detection so important for EV chargers?

DC leakage current can cause failure of conventional residual current circuit breakers.

Example:

Charging stations for electric vehicles are being built:

DC leakage current:

• 3 mA → Normal
• 6 mA → Danger threshold

As DC leakage increases:

Traditional type A of the GDR:

It may be impossible to act.

HYCA-16-PD:

Detect residual DC current as early as possible.

 

How does HYCA-16-PD work in an electric vehicle charger?

Typical architecture:

• net
• ↓
• Communication input
• ↓
• Power module for electric vehicle charger
• ↓
• battery
• ↓
• Leakage path
• ↓
• HYCA-16-PD
• ↓
• regulator
• ↓
• Nature conservation measures

 

HYCA-16-PD Monitor:

• Residual current waveform
• DC leakage current
• Protection status
• Key Benefits of HYCA-16-PD

 

1.Detect 6mA DC current according to IEC 62955 standard.

Scope of insurance coverage:

3-6 mA DC

Typical travel patterns:

4.5 mA DC

Target audience:

AC charger for electric vehicles

wall box

charging station

 

2.Sensitive AC/DC detection

Support:

Leak type	Detection
air conditioner	✔
pulsed direct current	✔
CC soft	✔

 

3.Integrated self-diagnosis function

Electric vehicle charging manufacturers are facing a serious problem:

How to check if the protection system is working properly before charging?

HYCA-16-PD offers:

Check the input functionality.

In front of the store:

The controller can simulate leak scenarios.

Exam:

• ✔ Sensor function
  ✔ Protective circuit response

 

Application examples

Wall-mounted distribution box for residential buildings

Application:

• 7kW/11kW AC charger
• Demand:
• Compact size
• low costs
• High level of security

Solution:

• HYCA-16-PD
• commercial charging stations

Application:

parking payment system

Demand:

Continuous operation

Reliable protection

Solution:

• Several HYCA modules are integrated into the cargo cabinet.
• Charging a fleet of electric vehicles

Application:

Logistics fleet for bus stations

Demand:

High reliability

Easy to maintain

Solution:

Protection system based on RDC-DD.

Why did Indian EV charger manufacturers choose the HYCA-16-PD model?

Characteristics of the Indian market:

• Demand for affordable electric vehicle charging stations is high.
• Intense price competition
• Increasingly stringent safety requirements

HYCA-16-PD offers:

• ✔ Solution complies with IEC 62955 standard
  ✔ Cost-effective alternative to Type B residual current circuit breakers
  ✔ Benefits of purchasing from Chinese manufacturers
  ✔ OEM customization possible

 

Why do Turkish EV charger manufacturers need RDC-DD?

Relations with Turkey:

• Europe,
  Middle East
  and Asia

Manufacturers of electric vehicle chargers are required to produce products that comply with international standards.

Function of HYCA-16-PD:

• Improving product reliability
• It complies with IEC requirements.
• Support for export projects

 

HYCA-16-PD and conventional current transformers

Functionality	traditional computed tomography	HYCA-16-PD
Detecting leaks in an air conditioning system	✔	✔
DC leakage detection	limit	✔
6mA DC current detection	✘	✔
Application of IEC62955	✘	✔
Self-esteem	✘	✔
Development of charging devices for electric vehicles	Generally	Devotee

Diploma

As the electric vehicle charging market enters a rapid growth phase, security and safety have become a critical competitive factor for device manufacturers.

Detection of residual DC current of 6 mA in accordance with IEC 62955 is becoming an important feature of modern EV charging equipment.

HYCA-16-PD offers:

• ✔ RDC-DD solution according to IEC 62955 standard
  ✔ AC/DC leakage current detection
  ✔ Self-diagnosis function
  ✔ Compact PCB design
  ✔ Support OEM customization

For EV charger manufacturers looking for reliable DRC-DD suppliers, the HYCA-16-PD offers a practical and cost-effective protection solution.

 

Compay：HEYI Electrical Co., Ltd.
Brand: HEYI/ASCT
Contact: Bethy
E-mail: heyi@heyiele.com             
Tel: 86-13968747975

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