As EV charging equipment becomes increasingly widespread, manufacturers need reliable electrical safety testing solutions to verify product safety and consistency before shipment.
EV charging equipment may require multiple electrical safety tests, including withstand voltage, insulation resistance, grounding resistance, leakage current, power consumption, and startup performance testing.
For production environments, using separate instruments for each test can increase equipment complexity and make test data management more difficult. An integrated electrical safety analyzer provides a more efficient way to perform multiple safety tests within one system.
For this application, the electrical safety testing system needs to support multiple test functions and provide stable, repeatable measurements.
The key requirements include:
To meet these requirements, Sinuo provides Modular Integrated Information Safety Analyzer SN6872F, a 7-in-1 electrical safety analyzer integrating multiple electrical safety test functions into one platform.
The system combines:
| Test Function | Application |
|---|---|
| AC Withstand Voltage | Checks insulation withstand capability under AC voltage |
| DC Withstand Voltage | Checks insulation withstand capability under DC voltage |
| Insulation Resistance | Evaluates insulation performance |
| Grounding Resistance | Verifies protective grounding performance |
| Leakage / Touch Current | Measures leakage and touch current |
| Load Power | Measures voltage and power consumption |
| Low Voltage Start | Checks startup current and voltage |
The modular architecture also allows the testing configuration to be customized according to different product requirements.
The AC withstand voltage function provides an output range of 100–5000 V, with adjustable current limits and test time.
Arc detection is also available to help identify abnormal current conditions during high-voltage testing.
The DC withstand voltage function supports an output range of 200–6000 V with programmable test parameters.
The system also provides automatic discharge functionality to help reduce residual electrical energy after testing.
The insulation resistance function supports test voltages from 200 to 2500 V and resistance measurements up to 50 GΩ, depending on the measurement range.
This function can be used to evaluate the insulation performance of applicable EV charging electrical assemblies.
The grounding resistance function supports test currents from 1.00 to 32.00 A and resistance measurements from 0.1 to 600 mΩ.
It provides an integrated method for checking the protective grounding path of applicable electrical products.
The analyzer provides multiple human-body simulation networks and supports different test configurations.
The touch current measurement range is up to 20 mA, with a resolution of 0.001 mA.
Different measurement networks can be selected according to the applicable testing requirements.
In addition to electrical safety tests, the analyzer integrates load power measurement and low-voltage startup testing.
The power measurement function supports up to 6000 W, while the low-voltage start function supports current measurement up to 20 A.
This allows multiple electrical performance checks to be incorporated into one testing sequence.
One of the key advantages of this solution is the integration of multiple testing functions into one analyzer.
For applicable test combinations, the system supports parallel testing, allowing withstand voltage, insulation, and grounding tests to be performed simultaneously.
This helps reduce the overall testing cycle and improves production efficiency, particularly when the same test sequence needs to be repeated across large quantities of products.
For modern production environments, test results need to be recorded and traced efficiently.
The analyzer provides local test data storage and can connect with MES and other information management systems.
It also supports barcode-based testing, allowing product identification to be associated with corresponding test data.
Communication interfaces include:
This enables the analyzer to be integrated into different production and data management environments.
High-voltage testing requires effective protection for both the operator and the equipment.
The analyzer incorporates several safety functions, including:
Rapid Discharge:
The patented rapid discharge function can discharge the tested object within 50 ms.
High-Voltage Ground Fault Protection:
The system monitors the test circuit in real time and can automatically disconnect the high-voltage output when a personnel contact condition is detected.
Arc Detection:
The system detects abnormal current conditions to help identify defective products.
Fault Self-Diagnosis:
Equipment fault information can be displayed to assist troubleshooting and maintenance.
By integrating seven electrical testing functions into one system, the solution provides a more centralized approach to EV charging equipment safety testing.
Multiple electrical safety tests can be performed on one platform, reducing the need for several independent instruments.
Parallel testing and programmable test sequences help reduce the overall testing cycle.
Local data storage, barcode testing, and communication interfaces help connect test results with individual products.
MES connectivity and multiple communication interfaces support integration with automated production and information management systems.
High-voltage monitoring, automatic discharge, arc detection, and fault protection provide additional safety during electrical testing.
This integrated electrical safety testing solution is suitable for manufacturers and laboratories that need to perform multiple electrical safety tests on EV charging equipment and other electrical products.
Instead of building a testing station from several independent instruments, the 7-in-1 analyzer provides a centralized platform for withstand voltage, insulation, grounding, leakage current, power, and startup testing, while also supporting digital test data management.
The modular design allows the configuration to be adapted to different testing requirements, making the system suitable for both laboratory verification and production-line electrical safety testing.
Sinuo Testing Equipment provides electrical safety testing equipment and customized testing solutions for electrical and electronic products.
For EV charging equipment applications, the test configuration can be selected according to the product structure, electrical specifications, applicable standards, and required production test sequence.
Looking for an integrated electrical safety testing solution for EV charging equipment? Contact Sinuo to discuss your testing requirements.
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