HYCA series AC/DC leakage current sensor and leakage detection modules are high-reliability AC/DC leakage safety solutions suitable for outdoor electric vehicle charging stations.

The rapid development of the global electric vehicle industry means that the construction of charging infrastructure is also growing at an astonishing rate. Outdoor DC fast charging stations and AC charging stations have become an important part of urban transportation systems in North America, Europe, the Middle East, and Southeast Asia.

In outdoor charging scenarios, the device must be able to withstand:
extreme high temperatures (internal temperature rise of 50 ~ 85°C), high humidity, high salt spray and rain (relative humidity up to 95%), day-night temperature difference, ultraviolet aging, continuous operation for 24 hours, and thermal stress generated by high current and high power conversion.

In such harsh environments, current transformers (CTs) and residual current devices (RCDs)/residual current protection devices (RDC-PDs) are two crucial components determining safety performance. A failure in the current transformer module can lead to:

Leakage current not detected → Risk of electric shock and fire;

Faults (i.e., false tripping) cause frequent shutdowns of the charging station;long-term drift can lead to inaccurate measurements and operational losses;no leakage current under 6mA DC leakage current → does not meet the requirements of IEC 62955 standard.

As one of the most reliable AC/DC composite leakage current detection solutions for outdoor electric vehicle charging stations, HEYI Electric’s HYCA series products, especially the HYCA-07-PD leakage current monitoring module, ensure detection accuracy and stability even in harsh environments. It has become a trusted core component for charging station manufacturers, system integrators, and operators worldwide.

Why must outdoor electric vehicle charging stations use high-specification AC/DC residual current detection modules

IEC standard specification: A 6mA DC leakage current test is required.

According to the IEC 62955 standard (RDC-PD), all electric vehicle charging equipment should have a 6mA DC leakage current detection capability.

The reason is that the DC smoothing current will passivate the ordinary type A residual current device (RCD),
causing the RCD to “malfunction”, thus creating a risk of electric shock.

This is especially important for DC chargers and AC chargers with rectifiers. The HYCA-07-PD natively supports AC + DC + multiple composite waveform detection, directly meeting the requirements of the IEC 62955 standard.

High outdoor temperatures can cause CT drift and reduce triggering accuracy.

High temperatures can cause problems with the magnetic core of traditional CT scanners:drift, saturation,slowed response speed, and electrical parameter deviations.

Ultimately, this can lead to:late triggering (dangerous),excessive trigger current (non-compliant with standards), and leakage detection failure.

The HYCA series can operate over a wide temperature range of -40°C to +85°C, maintaining stable performance even at high temperatures.

• High humidity and condensation can reduce insulation performance.Outdoor charging stations are typically exposed to environments such as rain, fog, salt spray, high-humidity parking lots, and seaside locations.
  Relative humidity can even reach as high as 95%. HYCA uses highly insulating materials for encapsulation, effectively preventing faults caused by leakage current-sensitive drift, insulation breakdown , and low-temperature condensation.
• Charging stations should operate continuously for extended periods, and safety components must not malfunction.Most charging stations operate 24/7, and the failure of any single component can lead to the following consequences:downtime losses, operator complaints, and the risk of safety accidents.

The HYCA-07-PD AC/DC leakage current sensor has a design life of ≥20 years, meeting the requirements of the entire equipment life cycle.

2. The core technological advantages of the HYCA series (outdoor electric vehicle charging scenarios)

• With a wide operating temperature range of -40 to 85°C, HYCA is suitable for extreme climates.
  Whether in hot deserts (UAE, Saudi Arabia), humid tropical regions (Philippines, Malaysia), or cold regions (Northern Europe, Canada), HYCA ensures that current detection accuracy remains stable. Traditional CT scanners often malfunction at high temperatures due to thermal drift of the magnetic core. HYCA avoids this problem by optimizing magnetic materials and MCU calibration.
• 95%RH high humidity tolerance.
  Common risks in high humidity environments include
  zero-point drift due to moisture infiltration, insulation degradation, and metal corrosion. HYCA’s packaging and insulation structure enable it to operate stably under these conditions for extended periods.
• AC/DC composite leakage current detection capability.

The HYCA-07-PD supports:
50Hz AC (22mA typical),Type A waveforms (A0, A90, A135),smoothed DC S-DC waveforms (4.5mA typical), lightning strikes (F waveform), and 2PDC/3PDC multi-pole DC waveforms. This surpasses ordinary AC RCDs and is suitable for various electric vehicle topologies.

2.4 MCU Intelligent Calibration + Self-Test Function.
Functions include CAL automatic calibration, TEST automatic pre-charging test, TRIP high-level alarm, and zero-drift register—achieving autonomous and safe verification.

2.5 Extremely low power consumption ≤110mW.
Ideal for compact AC charging stations (wall-mounted, home, shared), with low heat generation and good long-term stability.

2.6 Theoretical lifespan ≥ 20 years.
Covers and exceeds the typical lifespan of outdoor charging stations (8-12 years).

Application Scenarios

3.1 AC Charging Station (7kW–22kW) – Compliant with IEC 62955 standards, featuring trip protection, OCPP support, suitable for residential and commercial locations.

3.2 DC Fast Charger (30–300kW) – Features IGBT leakage, SiC drift, and stray current protection.

3.3 Public Outdoor Charging Station – Operates in environments with 70–95% humidity, 60–85°C casing temperature, high UV radiation, and salt spray.

3.4Electric Two-Wheeled Vehicle System – Compact, reliable, and low-cost battery replacement/charging detection functionality.

Why Global Manufacturers Choose HYCA AC/DC leakage current sensor

Compliant with IEC 62752 / 62955 standards

AC+DC multi-mode detection

Ultra-wide temperature range

High humidity and corrosion resistance

Intelligent self-test and calibration

Compact structure, low power consumption design

Design lifespan 20 years

Summary

As outdoor charging infrastructure expands, safety and reliability remain paramount. HYCA AC/DC leakage current sensor  (especially the HYCA-07-PD) excels in AC/DC detection, harsh environment tolerance, international compliance, intelligent calibration, and long service life, making it a trusted choice for electric vehicle charging equipment manufacturers and integrators worldwide.

Compay：HEYI Electrical Co., Ltd.

Brand: HEYI/ASCT

Contact: Bethy

E-mail: heyi@heyiele.com             

Tel: 86-13968747975

--- END ---