ELECTRICAL

SAFETY
FOR
EV/EVSE
 THE POWER IN
ELECTRICAL VEHICLE
SAFETY
For over 70 years, Bender’s mission has been to make electrical power safe. Our wide portfolio
of cutting-edge electrical safety and monitoring products are used in virtually every industry —
healthcare, solar, oil and gas, electric vehicle, mining, and many more. With more than 50 offices,
representatives and partners around the world, Bender provides customized solutions in electri-
cal safety to meet the needs of the electrical vehicle industry.

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Intelligent Electrical Safety for the Mobile Future

Over the past 70 years, we have learned to think comes to electrical safety provide a response to
ahead in a strategic, future-oriented manner, the mobile challenges of the future - from
creating today what the customer will need electrical installation to charging stations and
tomorrow. Innovative solutions and services, bringing electrical safety into the vehicle.
unique know-how, and global expertise when it

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 Electrical Safety Applications

1 iso165 & IR155-32xx

Provides isolation detection in electrical vehicles
„„ Constant monitoring of the entire electrical system for loss of isolation
„„ Compatible with all electric vehicles currently present on the market
„„ Superior measurement for the entire circuit - from battery to the drive train
„„ Fully adaptive to varying Y-caps

2 CC612
Charge controller for level 2 chargers
„„ Combines electrical safety requirements of AC charging points with the
vehicle charging requirements
„„ Compatible with all electric vehicles currently present on the market
„„ Fully functional interface and compliant with OCPP protocols
„„ Load management functionality
„„ Provides ability to create a fully functional charging network

3 isoEV425 & ISOcha425

Isolation monitor interrupter for level 3 DC fast chargers
„„ Fulfills UL, SAE, and Chademo requirements
„„ Provides electrical safety from shock hazards
„„ Fully compliant with local and international standards
„„ Accurate monitoring and interrupting of high-voltage circuits

3
4 RCMB121-xx
CCID5 & 20 ground fault functionality for fast interrupting
„„ Fulfills UL & IEC requirements
„„ Charge current interruption on ground faults
„„ AC & DC capable
„„ High accuracy over a wide temperature band
„„ Sensors incorporate all necessary electronic circuitry

3
5
4 RCMB104-xx
CCID5 & 20 ground fault functionality for fast interrupting
„„ Fulfills UL & IEC requirements for ground fault interruptions in EVSE
„„ Capable of accepting various larger current transformer sizes
„„ AC & DC capable
„„ High accuracy over a wide temperature band
„„ Sensors incorporate all necessary electronic circuitry
„„ Higher power levels and 3-phase capability

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 1

3
3

1
2
1
2

5 1

From inside the car to charging stations, compliance with requirements such as UL 2231,
Bender devices provide a complete solution for NEC 625, and SAE standards (US), C22.2 NO.281-1
mitigating risks of electric shock, equipment & NO.281.2 (Canada), and NMX-J-668/1-ANCE
failure, and fire damage. Our devices are & NMX-J-668/2-ANCE (Mexico), our equipment
designed specifically for integrating into provides a simple, integratable solution for your
electric vehicles, as well as level 2 and level electrical safety requirements.
3 (fast DC) charging stations. Designed in
55
 Electrical safety
Insulation Monitoring

The power supply system in an electrical vehicle is comprised of

an HV battery, power distribution, and a drive train. This system
is designed to be ungrounded (floating) against the vehicle’s
frame. One of the major challenges lies in detecting insulation
faults early. Causes for insulation faults in normal operation can
be, for example: contamination, salt, humidity, faulty connectors,
mechanical influences, etc.

What are the requirements of the standard?

„„ ISO6469-3:2011
Electrically propelled road vehicles – Safety specifications – Part 3:
Protection of persons against electric shock
"The minimum insulation resistance of the on-board network must be
maintained throughout the service life and under all operating conditions".
ISOMETER® iso165C
The perfect solution:
„„ Permanent monitoring of insulation resistance and isolation with
ISOMETER® series IR155 or iso165C

Major characteristics:
„„ Universal for high and low voltage systems
AC/DC 0…1000 V IR155
AC/DC 0…600 V iso165C
„„ Patented measurement method for preventative detection of
insulation faults 0…10 MΩ
„„ Additional safety via automatic self-test
„„ Permanent monitoring of ground chassis connection
„„ Detection of symmetrical insulation faults
„„ Short-circuit proof outputs for
ISOMETER® IR155
– Fault messaging
– Measured value (PWM signal)
„„ Conformal coating (SL1301EO-FLZ) on IR155
„„ Available for DC 12 V and 24 V supply voltage
„„ Automotive approval e1 according to 72/245/EWG/EEC 2009/19/ G/EC
„„ CAN interface on iso165C

Overview of important standards:

„„ ISO 6469-3:2011-12
Electric propelled road vehicles – Safety inspections – Part 3: Protection of persons against electric shock
„„ ISO 23273-3:2006-11
Fuel cell road vehicles – Safety inspections – Part 3 – Protection of persons against electric shock
„„ UL 2231-1:2002-05
Personnel Protection Systems for Electric Vehicle (EV) Supply Circuits: General requirements
„„ IEC 61557-8:2007-01
Electrical safety in low voltage distribution systems up to 1000 V a.c. and 1500 V d.c. – Equipment for testing
measuring or monitoring protective measures – Part 8: Insulation monitoring devices for IT systems

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Application Example

HV Battery
Inverter
= M
L1 F

In DC ≥ 6 mA (option)

= Air conditioning
PFC

N other loads
=
CP
Control pilot AC on-board
function charger
GND with galvanic IMI LV on-board
separation Insulation network
Monitor =
Interrupter (galvanically
isolated)

Chassis/protective equipotential bonding

RTire

Insulation monitoring in an electric vehicle (EV) with an AC on-board charger with galvanic separation

IMI = Insulation Monitoring Interrupter

PFC = Power Factor Correction

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 Electrical Safety for DC Charging Stations-
Insulation Monitoring
DC charging stations are the means of choice for charging
electrical vehicles quickly. In order to guarantee the
electrical safety of the charging circuit, it is set up as
an ungrounded/floating DC power supply system with
insulation monitoring. During the charging process, the
insulation monitoring device (IMI) monitors the entire
charging circuit from the charging station to the electric
vehicle. This requires coordination with the insulation
monitoring device in the vehicle. The IMI in the vehicle
needs to be disabled during the charging process to
avoid interference.
What are the requirements of the standard?
„„ IEC 61851-23 (2014-03):2014-11
 7.5.101: Monitoring of insulation resistance of the ISOMETER® isoEV425 with IR155-3210 IMI Board
secondary circuit. AGH-EV coupling device
Par. CC.5.1: “The secondary circuit shall be designed
as an IT system and protection measures in The perfect solution:
accordance with Par. 411 of IEC 60364-4-41 shall be
„„ Monitoring of the HVDC charging circuit using
applied. 411”.
ISOMETER® isoEV425 and AGH-EV coupling
„„ SAEJ1772 device (for voltages of up to DC 1000V).
„„ UL2231-1 & UL2231-2 „„ ISOCHA425 IMI device for Chademo electrical
„„ C22.2 NO.281-1 & NO.281.2 safety requirements up to 500V*.
„„ NMX-J-668/1-ANCE & NMX-J-668/2-ANCE
*Higher voltage in development
Application examples

Grounded System (building)

distribution branch
Application example
power source system installation circuit input DC charging station charging cable

L1
L2
L3 Ungrounded Power System
IEC 60364-7-722
N In DC ≥ 6 mA (Option)
GND
GND
contactor
F

DC+

F
RB
DC-
RCD
Typ A isolating
transformer IMI
Grounding at the Control CP
power source pilot CP
function

GND
RPE
Groundng in the
RA
distribution system

RAE

8
LINETRAXX GM420

Major characteristics:
Overview of important
„„ Ground continuity monitoring
EVSE standards:
„„ Two response values that can be set separately
„„ IEC 61851-1 (General) „„ Basic parameter settings
„„ IEC 61851-3 (LEV) „„ LEDs for operation, Alarm 1, Alarm 2
„„ IEC 61851-22 (AC) „„ Internal/external test/reset button
„„ IEC 61851-23 (DC) „„ Two separate alarm relays with single pole
„„ IEC 61851-23-1 (ACD) (one N/O contact each)
„„ IEC 61851-21-2 (CEM) „„ N/O operation, N/C operation, selectable
„„ IEC 62752 (Cordon Mode 2) „„ Fault memory selectable
„„ SAE J1772 „„ Self-monitoring with automatic alarm
„„ GB/T 18487 „„ Multifunctional LC display
„„ UL2231-1 & UL2231-2
„„ C22.2 NO.281-1 & NO.281.2
„„ NMX-J-668/1-ANCE & NMX-
J-668/2-ANCE

LINETRAXX® GM420
For monitoring of the protective
conductor continuity in DC charging
stations.

vehicle vehicle
inlet connector battery electric vehicle (BEV)

DC contactor Battery
F Inverter
DC + F V = M
DC - F
L
In DC ≥ 6 mA (option)

= Air conditioning
PFC

other loads
=
N
Control pilot AC on-board
CP charger
function
PP with galvanic IMI LV on-board
separation (option) power
GND
= (galvanically
isolated)

Chassis/protective equipotential bonding

RTire
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 Electrical safety for AC
Charging level 1 & 2 CCID5, 20, 30

In North America, if the electric vehicle is connected to

a level 1 or 2 EVSE to charge the battery, the protective
measures for ground fault set out in UL2231-1 & -2 must
be complied with.

GFI circuits are based on differential current sensing. In

the EVSE industry they are classified as CCIDs, or charge
current interrupting devices. In North America there is
a CCID 5 and a CCID20. These trigger at 5mA or at 20mA
at ground fault currently respectively. The 20 mA trip is
allowed when an additional ground check circuit has
been installed to monitor for ground wire integrity. Note,
the US based CCID devices are only required to trigger
on AC current. RCMB420EC Residual current monitoring module (model example)

The Europeans prefer a slightly different route and allow for a higher threshold of 30mA AC. However, they added an
additional requirement for 6mA DC current detection.
In the event of a ground fault, if a direct fault current greater than IΔn DC ≥ 6 mA occurs in the charging current circuit, a
trip must occur. The background to this is the fact that the function of a type AC GFI can be negatively impacted by direct
fault currents greater than IΔn DC ≥ 6 mA.

The RCMB series residual current monitors provide a solution which enables direct fault currents IΔn DC ≥ 6 mA to be
detected and evaluated.

What are the requirements of the standard? The perfect solution:

„„ DIN EN 61851-1 (VDE 0122-1):2012-01 „„ The RCMB series residual current monitor
Electrical equipment of electric vehicles – Electric detects direct fault currents and can initiate
vehicle conductive charging system – disconnection via a switching element.
Part 1: General requirements; section 7.6
“The charging system must limit the introduction of Major characteristics:
direct currents and non-sinusoidal currents which „„ Residual current monitoring IΔn DC ≥ 6 mA
could affect the functionality of residual current
„„ Relay types and PCB mount versions available
devices (RCD)...”
for 1ph/3ph systems up to 32 A
„„ IEC 60364-7-722:2015 (Power supply of electric
„„ Permanent connection monitoring of
vehicles)
measuring current transformer
722.531.2.101
„„ LEDs for operation and alarm
"Residual current protective devices (RCD)
„„ Internal test button
• A separate type A residual current device (RCD)
IΔn ≤ 30 mA, min. for each connection point „„ Versions for 6,20mA AC - 6mADC, 30mA AC,
• Suitable measures must be taken for direct fault hybrid versions
currents IΔn DC ≥ 6 mA." „„ Precise measurement by means of digital
„„ UL2231-1-2 measurement method
„„ C22.2 NO.281-1 & NO.281.2 „„ Insensitive to load currents thanks to full
magnetic shielding
„„ NMX-J-668/1-ANCE & NMX-J-668/2-ANCE
„„ With optional analogue measurement output

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Electrical safety for AC
Charging level 1 & 2
Application example: Trip Levels:
The RCBM121-1, 2, 3 are PCB „„ RCMB121-1 (5mA DC, 30mA AC)
mounted CCID5 and 20 sensors
„„ RCMB121-2 (5mA AC, 20mA AC)
recognized to UL2231. IEC
versions are available as well. „„ RCMB121-3 (5mA DC, 20mA AC)
„„ RDC104-4 (5mA DC, 30mA AC)
RDC104 provides the same „„ RCMB420EC (5mA DC, 30 mA AC) Residual current monitoring module RCMB121
functionality but enable the use
of larger current transformers.

RCMB420EC provides the

same functionality as the units
described above but in relay
style with dual CTs.

Residual current monitoring module RDC104

Charging Mode Level 1 Charging Mode Level 2 Charging Mode Level 2

Charging from sockets e.g. private charging station e.g. public charging station

Start
Stop User interface
Switch
IC-CPD Switch

Control Communication
Control pilot Overcurrent
pilot protection Overcurrent
communication Vehicle
communication protection
-
Monitoring In DC ≥ 6 mA RDC104
Loads
Electronic

RCMB121-2 In DC ≥ 6 mA RDC104

RCMB121-2
Power
RCD Typ A supply
In RCD Typ A
AC ≥ 5 mA

In Overvoltage
Überspannung
RCMB121-2
protection Control Overvoltage
AC ≥ 5 mA Überspannung
Monitoring protection
Diagnostic
Remote Energy measurement
maintenance Billing
kWh
8888

Connection to the Connection to the

supply network supply network
Connection to the
Communication supply network

* IC-CPD = In-Cable Control and Protective Device

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 The Challenges of EV

Electrical safety from the charging station to the electric vehicle

Electrical safety both in the electric vehicle itself and in the charging infrastructure is of key importance in the use of
electric vehicles (EV). As in all areas of everyday life, protecting people from the hazards caused by electrical current
is top priority here too.

In the electric vehicle (EV)

In the vehicle, there are various power systems which require careful coordination of protective measures to guard
them. Insulation faults in the high voltage system (on-board network) caused by contamination, humidity, faulty
connections, etc. must be avoided or detected and remedied.

At the charging station

The basic aim is to be able to charge electric vehicles from a variety of charging stations. This means different networks
and protective measures can come together during the charging process. This requires careful coordination and
implementation of all measures in order to guarantee comprehensive electrical safety for the user.

In building installations
The requirements for electrical safety in buildings are defined in detail in the NEC (National Electrical Code) in the US,
and in the CEC (Canadian Electrical Code) in Canada. To make sure that electric vehicles (EV) can be charged safely and
reliably, both the necessary protective measures required for the building and those required for new installations must
be complied with and the system set up in accordance with the normative requirements for the charging process.

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12
AC Charging

The Charge Controller CC612 combines the electrical safety requirements of AC charging
points with the vehicle charging requirements.

It is optionally available with an AC/DC sensitive residual current monitoring device.

Monitoring is done via an externally connected shielded current transformer which is
connected to the CC612. Thereby, the requirements of the standards series DIN VDE 0100 or
rather DIN VDE 61851 regarding protective measures directly in the Charge Controller are
complied with. A residual current device (RCD) type A can be used in the infrastructure.
The measured values are available to the backend system via the integrated modem.

Due to its compact structure and size (114.5 mm x

22.5 mm x 99 mm), the Charge Controller makes
intelligent, small, and cost-effective charging stations
possible. To communicate with the Charge Controller,
a backend system together with a well-known and
reliable communication protocol is required. Since
most of the backend device manufacturers use the
OCPP communication protocol, the Charge Controller is
compatible with OCPP-1.5 and with all electric vehicles
currently present on the market.

Integration tests with the backend implementations of

providers such as Vattenfall, Bosch, NTT, and DRIIVZ have Charge Controller CC612
been successfully carried out. The Charge Controller
can be operated in an "Always-on system", which is Charging is initiated by either holding a valid RFID card
always connected to a mobile network. The controller close to the reader or remotely by the backend system
supports 2.5G Edge and 3G UMTS mobile networks. For via OCPP. In offline operation, the charge controller can
connection to online operation, a SIM card is required. optionally allow charging without authorisation or it can
User interaction is facilitated using an optional RFID authorise users based on RFID and a local white list of
module, which consists of an RFID card reader and LEDs. authorised RFID cards.

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13
 Monitoring of direct fault currents
I Δn DC ≥ 6 mA

Type A residual current device (RCD) are provided in I (mA)

accordance with IEC 61008-1/IEC 61009-1 to trigger for 150°

the following fault currents IΔn: 30

∆t ³ 8,3 ms

20

„„ For sinusoidal alternating fault currents 10

6
„„ For pulsating direct fault currents
-10
If direct fault currents IΔn DC ≥ 6 mA occur, e.g. during
charging, then both the response time and the response -20

level of residual current devices (RCD) can be negatively -30

affected. In the worst case, a type A residual current 10 ms 20 ms 30 ms 40 ms
device will no longer respond to a high level of direct
fault current. In order to prevent this, either type B
residual current devices (RCD) can be used or other
suitable measures taken. Quote from:
DIN EN 61851-1 (VDE 0122-1):2012-01
Suitable measures could be: Detection of Electrical equipment of electric vehicles – Electric vehicle
IΔn DC ≥ 6 mA using RCMB420EC and therefore conductive charging system –
Part 1: General requirements; section 7.6
„„ C
 ontrolling the charging switch in a charging "The charging system must limit the introduction of
station (Mode 3) direct currents and non-sinusoidal currents which
„„ Controlling the relay in an IC-CPD could affect the functionality of residual current
device (RCD)..." (Translation: Bender GmbH & Co KG).
„„ Controlling the vehicle electronics

One of these measures can be used to guarantee that Quote from:

there is no negative impact on the function of (any) DIN VDE 0100-722(VDE 0100-722):2012-10 Low-voltage
type A residual current device (RCD) in the building electrical installations
installation. "722.531.2.101 Residual current devices (RCD)
• A separate type A residual current device (RCD)
Note IΔn ≤ 30 mA, min. for each connection
The use of a detection system for IΔn DC ≥ 6 mA with
• When direct fault currents IΔn DC ≥ 6 mA occur,
RCMB420EC also makes a residual current device
suitable measures must be taken."
(RCD) necessary in accordance with DIN VDE 0100. It
protects the type A residual current device (RCD) against
malfunction.
RCMB104 RCMB121

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Why Bender is Better

In the charging industry the Bender corporation provides electrical safety devices for Level 1, 2, and 3 charging stations
Here it is of utmost importance to ensure reliable and accurate measurements to enable the charging station to interrupt
power when a hazardous electrical situation occurs. These safety circuits have to be able to perform their duty 24/7
in a variety of conditions over a wide temperature range. Benders sensing devices are capable of detecting miniscule
fault currents in the mA range out of multiple to hundreds of amps of full-load current. This for single-phase AC, DC and
even 3-phase systems. The mA current sensors usually provide multiple trip outputs and have self-check capabilities to
enable a safe shutdown in case of a failure. These safety features have been evaluated by UL to UL2231 and enable the
integrator to provide an already approved safety solution in their EVSE.

Chargers
„„ Bender has the highest performing measurement technology on the market
„„ Capable of doing the 6mA DC measurement (required in Europe/IEC market)
„„ Capable of doing AC/DC true RMS measurements in the mA range
„„ Capable of doing the above across a wide temperature range

The powerpack of an EV utilizes high voltages and multiple hundreds of amps to generate the power needed to
propel the vehicle adequately and reliably over long distances. The powersystems on board are comprised of a
battery, electronic equipment (such as inverters), and a drive train which can feature a large variety of motor types.
Such a complex powersystem has multiple potential points of insulation failure to the frame which need to be
adequately monitored with high accuracy to ensure the passengers‘ safety. The Bender IMI (Insulation Monitoring
Interrupters) are capable of providing accurate data on the vehicles insulation status along the entire powersystem.
Its AMP (Adaptive Measuring Pulse) adapts to any vehicles Y-caps and progressively filters out any disturbance to
provide a true ohmic insulation value.

In the vehicle
„„ Accurate insulation measurements from the battery into the drive train
„„ Capable of measuring a de-activated bus
„„ Capable of adjusting to varying Y-caps

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 Bender is located in 70 countries around the world!

Mexico • Ciudad de Mexico, Mexico Chile • Santiago de Chile, Chile

USA • Exton, PA, USA
+56 2.2933.4211 • [email protected]
800.356.4266 / 610.383.9200 • [email protected] +972 517-7147 / + (55) 4955 1198 • [email protected]
www.bender.com.mx www.bender-cl.com
www.benderinc.com
Canada • Missisauga, ON, Canada South America, Central America, Caribbean
800.243.2438 / 905.602.9990 • [email protected] +1 (484) 288-7434 • [email protected]
www.bender-ca.com www.bender-latinamerica.com
14.1E.REV.0 | 10.2019 | © Bender Inc. All Rights Reserved.