Empowering Built-in RCD Production in Europe: 6mA DC Leakage Current Sensors for EV Chargers

In times of global electronic component shortages and pandemic-related delivery uncertainties, electric vehicle (EV) charger manufacturers -in particular- have faced real difficulties in sourcing components for their products. 6mA DC Leakage current sensors are key parts for many Mode-3 EV chargers, but production has suffered from these ongoing shortages. To mitigate their supply chain risks, European EV charger manufacturers turned to BITUO. Our leakage current sensors made a huge impact, specifically our BRCS01 series, which is solely 6mA DC rated or combined Type A 30mA and 6mA DC rated, providing high-quality, safe and reliable leakage current detection.

Our European customers had a basic need – to find alternative suppliers who could provide them with reliable 6mA DC leakage current sensors that would mitigate their supply chain risk. Impressively, our team was able to support most of these manufacturers in seamlessly integrating our 6mA DC leakage current sensors into their EV charger production by offering end-to-end support from our team of experts.

Why 6mA DC Leakage Current Sensors are Important for Safe EV Charging

Leakage current sensors, also known as residual current sensors or differential current sensors, are electronic components that measure the current flow summation of the phase and neutral circuits and detect any imbalances. In EV charging, leakage current sensors -with a rated value of 6mA DC- play a crucial role in ensuring safety in the charging process.

The smooth DC residual current resulting from the insulation fault of an OPC can impair the proper function of type-A 30 mA RCD installed upstream of AC EV charging stations or installed inside the AC EV charging stations. In the worst scenario, a type-A RCD will not be able to trip in the occurrence of an electrical accident.

How BITUO’s 6mA DC Leakage Current Sensors Can Help You Charge Your EV with Confidence

With all these models of leakage current sensors in the market, what makes BITUO’s BRCS01 6mA DC leakage current sensors so special? BRCS01 6mA DC leakage current sensors can meet and exceed the needs of EV charger manufacturers, with several highlights:

• Wide installation variants: Standing-on-PCB, Laying-on-PCB and Hanging-around-main-cable variants are available to meet various kinds of customer request

• High-speed detection: Very fast residual current detection- such as response time of 150 mA AC residual current less than 20ms – facilitates a broad selection of switching relays and contactors

• Easy integration: 4 Pin interface of Vcc, GND, Test and Trip facilitating quick integration into EV charging controller, so as to design built-in RDC-DD at EV chargers

• Proven track records: Globally the first residual current sensor certified by TÜV Rheinland compliant to IEC 62955, and tracked large-scale applications in Asia and Europe

• High reliability: Robust mechanical and electrical design suitable for harsh environmental conditions – such as humid air and on-board vibration

• 
  

BRCS01 AC/DC Residual Current Sensors with Different Installation Variants

Rising to the Challenge: Developing Reliable Built-in RCD at EV Chargers

Designing reliable built-in RCD at EV chargers is not without its challenges. Compliance with international standards such as IEC 60947-2, IEC 61008-1, and IEC 62955 is critical to ensure the safety of EV charging systems. But the challenge lies in designing leakage current sensors that can work seamlessly in multi-module coordinated built-in RCD configurations, while still providing proper electrical protection functions to end users.

At BITUO, we understand the importance of safety when it comes to EV charging. Our mission is to help EV charger manufacturers deliver reliable and safe EV chargers to end users. That’s why we made it possible to design built-in RCDs that meet IEC standards, with reliable and robust 6mA DC leakage current sensors. We believe that everyone deserves access to safe and reliable EV charging, and we’re proud to play a role in making this a reality.
 

Leading with Purpose: BITUO’s Pledge to Go Beyond Sensors and Help EV Charging Thrive

But here’s the best part: BITUO isn’t just in the business of selling 6mA DC leakage current sensors. We aren’t only committed to meeting the most basic needs of our clients.

In the face of the challenges in compliant EV RCD technology, our team of experts is dedicated to providing our clients with a holistic approach and active support in delivering compliant and safe EV chargers with built-in RCDs. We are committed to helping EV charging become safer and supporting manufacturers in delivering EV Chargers with proper electrical protection functions to end-users.

As LIU Hualei, R&D Director at BITUO, puts it, our goal is to openly share our in-depth knowledge about RCD design and manufacturing to help EV charger manufacturers deliver reliable built-in RCDs that comply with IEC 60947-2 / IEC 61008-1 and IEC 62955 standards.

To guide our customers, we offer:

• Free consultation on built-in RCD design: We know that integrating sensors against nuisance tripping can be a challenge, especially when used in a harsh environment. That’s why we’re here to help.

• Built-in RCD verification and testing services: Our customers can send their EV chargers to us to conduct critical tests in compliance with IEC 60947-2 / IEC 61008-1 and IEC 62955 standards.

• Large-scale manufacturing consultation: We can help EV charger manufacturers and their external manufacturing service providers set up automated RCD testing.

For example, we recently helped a British EV charger manufacturer improve their built-in RCD design and supported their SMT partner in China to automate the testing of built-in RCD at their charging controllers.

Automated Built-in RCD Testing for Charging Controllers

The Power of Connection: How BITUO’s Supports are Optimizing the EV Charger Supply Chain

Leakage current sensors are a vital part of the EV charger supply chain. When a leakage current of 6mA DC is detected, these sensors further request the switching devices to disconnect the power supply. This, in turn, helps prevent electrical accidents that can cost human lives, promoting a safer and more reliable charging experience for all.

At BITUO, we understand the significance of this responsibility, which is why we are committed to helping EV charger manufacturers deliver products with reliable protection functions to end users. Our BRCS01 series of sensors is a shining example of this commitment, with their wide installation variants, high-speed detection, easy integration, proven track records and high reliability.

We are dedicated to helping our customers succeed and thrive in the competitive world of EV charging, and we believe that our mission is more important now than ever before.

So let us go forth with courage and commitment, knowing that we are making a positive impact on the world of EV charging. We will continue to support the EV charging industry with purpose and passion.