The Benefit and Safety of the Third-Gen Semiconductor in High Energy Consuming Industries

With the latest semiconductor's advantages in withstanding high voltage and low energy consumption, the high-energy consuming industries have improved their energy conversion efficiency. Especially electric vehicles (EVs), industrial motors, and renewable energy industries have benefited from it. Their products' performance and stability are optimized. Therefore, to ensure their products can maintain optimal performance under high voltage, high current, and other harsh environments, manufacturers must fully explore the technology of the latest semiconductor application. At the same time, electrical safety is equally important. In this issue, we will learn more about electrical safety standards and tests through the abovementioned three high-energy consuming industries.

  • EVs Industry

The key to enhancing the endurance of EVs is whether the internal equipment can withstand high voltage and current to reach the goal of shortening the charging time. Implementing the third-generation semiconductors in DC/DC converters and charging stations improves EVs' endurance and charging efficiency. However, as the operating voltages and currents are higher, DC/DC converters and charging stations' safety needs extra attention. They must comply with standards through a series of strict electrical safety tests. Notably, standards vary in different countries. EV charging stations' relevant standards include IEC/EN 61851, UL2202, UL2594, or GB18487.3, and EV DC/DC converters' relevant standard is GB/T 24347.

In general, the electrical safety tests of EV charging stations include Hipot, insulation resistance (IR), and ground bond (GB) tests. The Hipot test generally requires testing on multiple points, such as the main circuit to the chassis, the main to the secondary circuit, and the secondary circuit to the chassis. Depending on the standards and testing points, the testing method has slightly different. The Hipot testing voltage is between 1000Vac and 4400Vac. The passing criterion is no breakdown occurs. For the IR test, the testing voltage is 500 Vdc. The resistance must be greater than 0.1 MΩ. To conduct the GB test is applying 16 to 25A to the ground and measuring the ground impedance. The result should be less than 0.1Ω. DC/DC converters are required to conduct the Hipot and IR tests. The Hipot test voltage is about 2000Vdc (or rated voltage plus 1500Vdc). The converter must withstand this high voltage without breakdown. To conduct the IR test, apply 1000Vdc testing voltage to the DUT and measure the insulation value if greater than 0.5 MΩ.

Many EV-related manufacturers have chosen SE 7441. In addition to its functions that meet the test requirements, the built-in scanner makes the multi-point testing between the main and the secondary circuit easier. Also, it solves the tedious wiring procedures. SE series makes electrical safety tests more efficient, simple, and reliable.

  • Industrial Motors

The output power is one of the indicators of the motor's performance. The third-generation semiconductors boost the motor's output power and obtain better work efficiency. Therefore, the system operation can maintain high quality and efficiency. The electrical safety tests ensure they maintain good quality and safety under optimal performance. Motors' relevant standards include IEC60034-1, UL1004, GB12350-2009, IEEE Std.43-2000, and GB20160.

Generally, the motors' electrical safety tests include Hipot, GB, or IR tests. Depending on the standards and motor input voltage, the Hipot test voltage is between 500V and 5000V. Then, apply this voltage to shorted coils and chassis. IR test voltage is generally 500Vdc. The resistance must be greater than 10MΩ or even 500MΩ. The testing current of the GB test is 25A. The result should be less than 0.1Ω.

The standards do not specify the use of AC or DC voltage in the Hipot test. If you choose to use AC voltage, you need to consider the power (horsepower) and the number of winding turns because it generally varies with the voltage. As the power (horsepower) increases and the number of winding turns increases, the parasitic capacitance value between the opposing coils also increases. Therefore, it is necessary to choose a Hipot tester with a capacity of 500VA, such as the SE 7451 and SE 7452. In addition, to meet IEEE Std.43 and GB20160 testing requirements, the test can add the optional function of true negative DC voltage output to conduct the IR test.

  • Renewable Energy

With the popularity of renewable energy, third-generation semiconductors play an indispensable role. Taking wind power as an example, the sudden sharp increase in wind speed brings abundant electricity. It is necessary to use components that can withstand this high voltage and current to reduce the conversion loss. Therefore, implementing new generation semiconductors can improve the energy conversion rate of wind power converters. Wind power converters' relevant standards include UL 508C, UL 1741, UL 61800, and IEC 62477.

The electrical safety test of the wind power converter is the Hipot test. Depending on the system voltage, apply 1000Vac to 4400Vac testing voltage to 3 different points: the main circuit and the chassis, the main and the secondary circuit, and the secondary circuit and the chassis. They must withstand this high voltage without breakdown.

Most Ikonix customers choose the SE series electrical safety analyzers. It does not only have completed electrical safety testing functions and a built-in scanner but also a user-friendly touch panel and highly flexible and programmable testing parameters setup. It improves the overall testing efficiency to be the best solution for the wind power industry.

With the advent of the third generation of semiconductors and the development of the industry, products' safety must be under strict checks. Ikonix has guarded global electrical safety testing for more than 85 years. We helped many companies solve their electrical safety testing challenges and provided complete solutions to maintain their products' quality and safety. Many companies chose our legendary product SE series. It not only has completed electrical safety testing functions (ACW, DCW, IR, GB) but also the industry's leading arc detection function, high-precision four-wire measurement, and true negative voltage testing to enhance safety. Its maximum output power can reach 500VA, which meets the testing needs of high-power consumption industries, such as motors. Also, the touch panel and barcode scanning make operators' usage more convenient and efficient. A built-in scanner or bundle with a 7006 matrix scanner increases production line test efficiency. It is precisely suitable for the high-energy consuming industries' multi-point Hipot tests. If you like to know more about SE series products or complete solutions for various industries, please contact our sales representative.