Using the charging technology for electric vehicles safely

Residual current sensors for charging cable AC charging (IC-CPD, mode 2)

Safe plug-in solution

Charging cable (IC-CPD)

Since AC charging involves charging the electric vehicle at the domestic socket, the charging cable is the only charging infrastructure required. This special charging cable must feature an integrated monitoring system and the vehicle must provide internal charging electronics. Bender offers residual current monitoring sensors to mode 2 charging cable manufacturers for use in IC-CPDs in accordance with IEC 62752.

Market segment brochure eMobility
Technical paper Charging Electric Vehicles - Protection against Electric Shock by DC Fault Current Sensor Units
Technical paper Connection of charging stations for electric vehicles

Recommended systems for residual current monitoring:

Recommended Charging Stations:

IEC 62752
In-Cable Control and Protection Device for mode 2 charging of electric road vehicles (IC-CPD)


DIN EN 62752

In-Cable Control and Protection Device for mode 2 charging of electric road vehicles (IC-CPD)
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Residual current sensors for charging station/wallbox AC charging (mode 3)

Monitoring and safe charging of electric vehicles

AC charging column

AC charging stations can often be found at home, in hotels or at the workplace, since AC charging uses conventional single or three-phase low voltage. This means AC charging has the benefit that charging infrastructure required can be kept relatively simple. The monitoring sensors can come in the form of a small PCB with a suitable current transformer or as a slightly larger DIN-rail mounted device. Both solutions ensure that the charging station is continuously monitored for residual currents, and if specified values are exceeded, these are quickly and reliably detected and the charging station is switched off if there is a hazard. Due to the permissible combination of residual current sensors and a type A RCD, no expensive type B RCD is required and the vehicle owner can be informed of any deterioration in the residual current values before the charging process is interrupted. The manufacturer of the charging station or wallbox can thus determine the health of the vehicle and inform the owner. In all cases, Bender fulfils all current standards and the user of the charging station is on the safe side.

Market segment brochure eMobility
Technical paper Charging Electric Vehicles - Protection against Electric Shock by DC Fault Current Sensor Units
Technical paper Connection of charging stations for electric vehicles

Recommended systems for residual current monitoring:

Recommended Smart-Grid Charge Controller:

Recommended Charging Stations:

DIN IEC/TS 61439-7
Low-voltage switchgear and controlgear assemblies - Part 7: Assemblies for specific applications such as marinas, camping sites, market squares, electric vehicles charging stations
No news available.

Insulation monitoring for charging station/wallbox DC charging (mode 4)

Electrical safety for electric vehicle charging

DC charging column

Larger charging stations and quick charging stations use DC charging, which is charging by means of direct current. This is typically an unearthed power supply system. DC charging involves applying a DC voltage to the batteries connected in series. In order for current to flow, the applied voltage must be regulated in such a way that it is always slightly higher than the present cell voltage of the batteries connected in series. This requires complex charging control systems as the currents can be up to several 100 A. This process will recharge the battery in about 15 minutes. This concept is ideal for short-term recharging during a break at a motorway service station, for example. In order to prevent the insulation monitoring device in the vehicle and the one in the charging station from influencing each other, the insulation monitoring device in the vehicle is usually deactivated during the charging process. The insulation monitoring device in the charging station then monitors the complete charging circuit. The Bender products are market leaders and offer a very high level of safety.

Market segment brochure eMobility
Technical paper Safe, CHAdeMO-compliant charging at DC charging stations
Technical paper Connection of charging stations for electric vehicles

Recommended systems for insulation monitoring:

Recommended Charging Stations:

DIN IEC/TS 61439-7
Low-voltage switchgear and controlgear assemblies - Part 7: Assemblies for specific applications such as marinas, camping sites, market squares, electric vehicles charging stations  
No news available.