The residual current monitoring in EV charging infrastructure market in India is experiencing rapid growth. From individual wallboxes in Mumbai to commercial charging networks operated by companies like Tata Power, Exicom, and Servotech Power Systems, charging infrastructure in India is growing at a steady pace.

However, as the number of charging stations for EV increases, a serious technical problem is becoming increasingly apparent:

Leakage current protection

For Indian EV charging station manufacturers, equipment engineers and charging infrastructure system developers, residual current monitoring has ceased to be an “optional feature” and has become a fundamental requirement to achieve the following objectives:

• IEC 62955 certification
• Electrical safety for consumers
• Charging stations are working properly.
• Compatible with type A residual current circuit breakers.
• Architecture of the intelligent AC charging system

For this reason, more and more Indian charging station manufacturers are starting to integrate charging systems into their EV charging systems.

RDC-DD module

Leakage Current Monitoring Module RCM

Zero Current Transformer (ZCT)

Residual current sensor

 

There are hidden risks at every electric vehicle charging station.

From the outside, an AC charger for electric vehicles looks like a simple charger.

 

However, an electric vehicle’s on-board charger (OBC) actually consists of the following components:

• AC/DC rectifier circuit
• Power Factor Correction (PFC)
• DC/DC converter
• electromagnetic interference filtering system

 

If insulation wears out or components fail, the following problems may occur:

• alternating short-circuit current
• Pulsed continuous leakage current
• continuous leakage current

 

The most dangerous:

Suppression of DC leakage current may cause failure of conventional type A residual current circuit breakers.

According to IEC 62955:

If the DC leakage current in the EV charging system exceeds 6mA, DC leakage current protection must be implemented.

The basic threshold level is:

IΔDC​≥6mA

Once the continuous leakage current exceeds this value, a conventional Type A residual current device (RCD) may fail to function normally due to magnetic saturation, creating a serious risk of electric shock.

Why is IEC 62955 gaining importance in India?

India’s electric vehicle charging infrastructure is gradually adapting to international safety standards.

In India, a growing number of charging station operators are requiring compliance with the following requirements:

MEC 61851

IEC 62752

MEK 62955

The IEC 62955 standard covers, in particular:

RDC-DD protection in Mode 3 of an electric vehicle charger

Technical conditions are determined.

This standard allows charging station manufacturers to apply the following provisions:

Residual current circuit breaker type B
or

DDR and DRC-DD Type A Monitoring Solution

In practice, most Indian manufacturers tend to adhere to the following principles:

“Type A residual current circuit breaker + 6 mA DC leakage current monitoring”

The reason is quite practical:

• Type B residual current circuit breakers are expensive.
• Small charging stations are located in a limited area.
• The Indian market is extremely price sensitive.

The wall-mounted enclosure has a compact internal space for the printed circuit board.

SO:

Miniature residual current transformers are increasingly becoming the standard solution.

Architecture for monitoring residual currents in electric vehicle charging stations.

Modern AC chargers for EV typically include:

• Residual current sensor
• Electric vehicle charger microcontroller or controller
• Relays/Contactors
• Type A residual current circuit breaker

The residual current sensor is responsible for:

• Monitoring leakage current changes in real time.

If the system detects abnormal DC leakage current, the controller immediately breaks the charging circuit.

Typical objects of protection include:

• continuous leakage current 6 mA
• AC leakage current 30 mA
• High frequency leakage current
• DC surge current leakage

 

Why do Indian engineers prefer the compact design of ZCT?

Indian EV charging station manufacturers often face a number of challenges:

 

1.The internal space of the wall unit is very limited.

In particular, we are talking about a 7 kW AC charger.

Engineers prefer:

• small hole
• Small size
• Simple PCB design
• Easy cable installation

 

2.Extremely cost sensitive.

India is among the countries in the world that are most sensitive to electric vehicle prices.

Original equipment manufacturers (OEMs) typically focus on the following aspects:

• Reducing the cost of components
• The certification process is easier to complete.
• Higher cost-benefit ratio.
• Instead of expensive and bulky industrial protection modules.

 

3.High requirements for electromagnetic stability.

The Indian electricity grid is quite complex.

That’s why engineers are very concerned:

• Resistance to violations
• magnetic saturation capacitance
• High frequency response stability
• Abuse prevention capability

Recommended solution: HYCA-07-PD

The HYCA-07-PD device has been specifically designed for monitoring short-circuit currents in compact systems used in electric vehicle charging infrastructure.

Typical application scenarios

7kW AC power outlet

Home charging station for electric vehicles

Portable charger for electric vehicles

Intelligent charging system

A solution for charging small printed circuit boards

Technical advantages

1.Ultra-compact design

The HYCA-07-PD model has small dimensions and is therefore more suitable for installation in compact charging stations for electric vehicles.

Particularly suitable for:

Charging stations in India for private homes

Thin-walled box

A small system of charging stations for electric vehicles

 

2.Highly sensitive leakage current monitoring.

HYCA-07-PD is capable of achieving the following performance levels:

AC leakage current detection

pulsed DC monitoring

Compatible with DC detection in liquid.

This helps charging station manufacturers more easily develop system architectures that comply with the IEC 62955 standard.

 

3.Excellent electromagnetic compatibility performance.

In real charging conditions, electromagnetic interference may cause unexpected activation.

HYCA-07-PD was optimized for the following parameters:

Stable output signal

noise suppression ability

Stable operation in difficult power grid conditions.

It is particularly well adapted to the conditions of the Indian power system.

Recommended solution: HYCA-16-PD

For commercial charging systems with higher output power, the HYCA-16-PD provides greater compatibility and flexibility.

Typical application scenarios

Commercial AC charging stations

Three-phase charger for electric vehicles

public charging stations

vehicle fleet payment system

intelligent energy management system

 

Technical advantages

1.Design with a wider opening

HYCA-16-PD is suitable for:

thicker cable

Higher current systems

more complex installation structure

 

2.Stable long-term monitoring

Applies to:

Use for commercial purposes

Outdoor charging station

Industrial-grade electric vehicle charging platform

 

3.Better suited for integration into IEC systems

We help OEM engineers streamline their processes:

• DRC-DD Integration
• communication with the controller
• Development of protection logic
• Preparing for certification

Comparison of HYCA-07-PD and HYCA-16-PD

configuration	HYCA-07-PD	HYCA-16-PD
Main applications	compact wall box	commercial charging stations
Structural characteristics	ultra-small size	grand opening
the most suitable	home charging station	government spending
installation location	PCB space is limited.	High current system
Billing method	Single-phase alternating current	Single-phase/Three-phase
Integration with OEMs	Compact and easy to install.	Flexible and efficient architecture

Why are major Indian EV manufacturers showing increasing interest in residual current monitoring?

Major Indian companies managing electric vehicle infrastructure are increasingly focusing on the following points:

IEC certification

Cargo security

Device stability

Low maintenance costs

Compact protective design

 

Because:

The stability of charging stations directly affects:

User trust

Charging station efficiency

company profitability

With the development of public charging station networks in India, reliable protection against earth leakage currents has become a key requirement for this sector.

Future Trends in Electric Vehicle Charging Safety in India.

The Indian electric vehicle charging infrastructure market is growing rapidly:

Intelligent platform for electric vehicle charging stations

integrated protection system

Compact architecture from the ground floor to the roof.

The design is carried out in accordance with IEC standards.

For charging station manufacturers:

Residual current sensors are no longer just a “certification requirement”.

Except :

Product stability

Competitiveness of engineering sciences

percentage of successful authentications

reputation in the market

An important element.

Miniature, highly stable residual current sensors such as the HYCA-07-PD and HYCA-16-PD are becoming important components of next-generation EV charging stations in India.

 

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