Carlo Gavazzi Introduces DRC61 Insulation Monitor for 1,000 V DC Fast-Charging Systems

The single-module device targets Mode 4 DC chargers, with CCS and CHAdeMO compatibility, relay alarms and Modbus RTU diagnostics.

Carlo Gavazzi Automation has introduced the DRC61 Series insulation monitoring device for unearthed DC electrical systems up to 1,000 V DC, positioning it for EV charging infrastructure and Mode 4 DC fast-charging stations.

The DRC61 continuously monitors insulation resistance between DC lines and ground. Carlo Gavazzi said the device can identify both gradual insulation degradation and sudden insulation faults, functions intended to support fault detection in high-voltage DC charging equipment.

For charging-station OEMs and system designers, the notable design claim is that the DRC61 operates directly at up to 1,000 V DC in one module. Carlo Gavazzi said this can remove the need for additional adapters used in some system configurations, potentially reducing panel space and component count.

The device also monitors system voltage for undervoltage and overvoltage conditions. It includes two configurable relay outputs that can be assigned to pre-alarm and alarm functions, allowing a charger controller or site operator to distinguish an emerging insulation issue from a condition requiring a protective response.

Modbus RTU communication supports device configuration and diagnostics, while local and remote test and reset functions are intended for commissioning and operational checks. Carlo Gavazzi lists compatibility with both CCS and CHAdeMO charging architectures, giving equipment makers an option across more than one fast-charging connector design.

The DRC61 is UL listed under UL 2231-1 and UL 2231-2, Carlo Gavazzi said. Those standards address personnel protection systems for electric vehicle supply circuits and are relevant to charging-equipment designs intended for the North American market.

The operational value will depend on how the monitor is integrated into a charger’s control and protection logic. The DRC61 can provide alarms and communications data, but a charging-station designer still needs to define what happens after a pre-alarm, alarm, test failure or communications fault. That may include derating, preventing a charging session from starting, ending an active session, or dispatching maintenance personnel.

Carlo Gavazzi did not disclose monitoring cycle times, fault-response times, pricing, expected service life, or a quantified payback period. As a result, operators cannot yet translate the device into a throughput gain or maintenance-cost reduction from the available information. Its immediate ROI case is more likely to rest on avoided enclosure complexity, reduced adapter hardware and earlier identification of insulation conditions that could take a charger out of service.

For field operations, the DRC61 is an augmentation tool rather than a replacement for electrical technicians. It can flag conditions remotely through the charger’s controls and Modbus network, but qualified personnel will still need to diagnose cable, connector, power-module and enclosure faults after an alarm.