Isolated current sampling solution: CHIPSENSE HK4V H00 current sensor, high insulation withstand voltage, ensuring safe sampling in high-voltage environments.

In high-voltage applications such as industrial automation, new energy vehicles, photovoltaic energy storage, and rail transportation, the safety and accuracy of current sampling directly affect system stability and personnel safety. Traditional non-isolated sampling solutions, due to direct electrical connections, are susceptible to common-mode voltage interference, which can even lead to arcing or equipment damage. CHIPSENSE HK4V H00 series high-performance open-loop Hall current sensor, through its native isolation design and high insulation withstand voltage characteristics, can accurately measure DC, AC, and pulse currents, providing a safe and reliable current sampling solution for high-voltage environments. This article will analyze its technical advantages from three aspects: isolation principle, core performance, and application scenarios.

I. Isolated Design: Cutting Off Interference Risks and Building a Solid Safety Barrier

1. Native Electrical Isolation Architecture
Based on the Hall effect principle, CHIPSENSE HK4V H00 adopts a dual-layer isolation mechanism of "magnetic circuit isolation + signal isolation" to achieve complete electrical isolation between the primary and secondary sides:
Magnetic circuit isolation: Current signals are transmitted through magnetic field coupling, physically severing the direct electrical connection between the primary and secondary sides to prevent common-mode voltage conduction.
Signal isolation: The Hall element output signal is differentially amplified and then isolated from the power supply by a built-in isolation operational amplifier, ensuring stable signal transmission.

Actual test data shows that under 1kV common-mode voltage interference, the output fluctuation of traditional non-isolated sensors reaches ±5%, while the output fluctuation of CHIPSENSE HK4V H00 current senor is only ±0.2%, and the common-mode rejection ratio (CMRR) is improved to 120dB, far exceeding the 60dB required by the IEC 61800-5-1 standard.

2. Arc Resistance and Enhanced Insulation Design

To address the potential arc discharge hazards in high-voltage scenarios, CHIPSENSE HK4V H00 current sensor enhances safety performance through multiple structural optimizations:
Air Gap and Encapsulation: Combined with epoxy resin potting design, the partial discharge initiation voltage (PDIV) is increased to 12kV, effectively preventing high-voltage breakdown.
Electrical Clearance and Creepage Distance: The electrical clearance between the primary and secondary sides is 13mm, and the creepage distance is 28mm. Utilizing double-sided PCB immersion gold technology, CHIPSENSE HK4V H00 meets the pollution level III requirements of IEC60664-1 standard.
Pin Insulation: The primary and secondary side pins employ a double-layer sleeve design. The inner layer is PTFE with a temperature resistance of 260℃, and the outer layer is PVC with a temperature resistance of 105℃, ensuring reliable insulation between the pins.

In the pulse voltage impulse test,the HK4V H00 current sensor from CHIPSENSE transient withstand voltage reached 6.6kV, and the insulation resistance was always >10GΩ. No breakdown or flash-over occurred, while the traditional optocoupler isolation solution experienced insulation failure at 6kV.

II. Core Performance Parameters: Comprehensive Coverage of Harsh Operating Conditions

1. Insulation Withstand Voltage and Environmental Adaptability
CHIPSENSE HK4V H00 current sensor’s insulation system employs a multi-layered protection design to ensure stable operation in extreme environments. 
CHIPSENSE Shell Insulation: The PC+ABS alloy shell is UL94 V-0 flame-retardant certified, and combined with a silicone sealing ring, achieves an IP67 protection rating, resisting dust and moisture intrusion.
Wide Temperature Stable Operation: CHIPSENSE current sensor operating temperature range -40℃~85℃, storage temperature -50℃~105℃, with insulation resistance consistently >20MΩ within this range, meeting the stringent environmental requirements of new energy vehicle battery management systems (BMS), outdoor photovoltaic equipment, and other applications.

2. Precise Measurement and Response Performance
Leveraging precise circuit design and open-loop Hall effect technology, CHIPSENSE HK4V H00 current sensor exhibits superior measurement accuracy and response speed, meeting the demands of high-frequency, high-current scenarios:
Wide Measurement Range: Covering primary-side rated currents from 800A to 5000A, with different models offering measurement ranges from ±1200A to ±6000A, adapting to diverse needs from industrial power distribution to high-power new energy equipment.
High Measurement Accuracy: Linearity error ≤±0.5%, overall accuracy <±1%, zero-point temperature drift controlled within ±0.5mV/℃, avoiding interference from temperature changes on measurement results.
Fast Response Capability: Response time ≤3μs (typical value), bandwidth from DC to 40kHz, accurately capturing 20kHz current harmonics and transient changes, providing real-time data support for system control.

3. Authoritative Certification Guarantee
CHIPSENSE HK4V H00 series current sensor have passed multiple authoritative international certifications, and CHIPSENSE current sensors ensuring safety compliance with major global market standards:
IEC 61010-1: AC isolation withstand voltage test of 3.6kV/1min, no breakdown or arcing, meeting the insulation requirements of high-voltage equipment. 
UL 60950-1: Creepage distance and clearance meet standards under pollution degree II conditions, suitable for complex industrial environments.
GB/T 17626.5: 4kV burst immunity test, output error <0.5%, excellent electromagnetic interference resistance.
Complies with IEC 61800-5-1 standard, ensuring safe application in motor drives, power electronics, and other scenarios.
CHIPSENSE current sensors are developed and manufactured according to various application requirements.

III. Typical Application Scenarios: Guardians of High-Voltage Environments
1. New Energy Sector
New Energy Vehicle Charging Module: Adapted to DC fast charging piles (output voltage 200~1000V), it monitors charging current in real time, blocks common-mode voltage between the charging gun and BMS (up to 1kV), and has an output delay of <3μs under a 1kA current step, meeting the real-time requirements of the CCS/Chademo protocol for current monitoring and preventing equipment damage caused by grounding faults.
Photovoltaic Energy Storage System: Monitors large currents on the DC side of string inverters (DC input voltage 1500V). A 40kHz bandwidth accurately captures current harmonics, providing accurate data for the Maximum Power Point Tracking (MPPT) algorithm, improving system power generation efficiency and operational safety. Simultaneously, its 10kV insulation capability covers the highest DC bus voltage to ground.

2. Industrial and Power Sector
Industrial High-Power Power Distribution: Used for online current monitoring of busbars in distribution cabinets, enabling system load analysis, energy management, and overload protection. Open mounting holes and standardized connectors simplify installation and reduce maintenance costs. This is an issue that CHIPSENSE current sensor has always considered for its customers.
Industrial Motor Drives: Compatible with frequency converters (output voltage 3AC 690V), blocking common-mode voltage between the motor and driver (up to 2kV). Output linearity error <0.3% under 500A current fluctuation (frequency 20kHz), meeting the IEC 60034-30-1 standard requirements for motor efficiency testing, and preventing leakage accidents caused by motor insulation aging.

3. Specialty and Transportation Sector
Rail Transit and Marine Electric Propulsion: Provides current feedback for traction inverters in locomotives and ships, adapting to a wide operating temperature range of -40℃ to 85℃, ensuring motor control accuracy and system protection reliability, and coping with complex environments such as vibration and humidity.
Large-scale Specialty Power Supply Equipment: Provides precise current feedback in electroplating, electrolysis, and other equipment to ensure stable process quality; provides high-current monitoring for UPS, battery management, and server power supplies in AIDC power systems, ensuring efficient and stable operation of critical equipment.

IV. Technology Comparison:CHIPSENSE Isolated current sensor vs Non-isolated Solutions

V. Selection Guide and Installation Instructions 
1. Model and Specification Selection
 

2. Safe Use and Installation
 Power Supply Requirements: CHIPSENSE HK4V current sensor ±15V power supply is required to ensure normal sensor operation and prevent voltage fluctuations from affecting measurement accuracy.
Installation Specifications: Conductive parts of the sensor must be protected from external contact. If necessary, a protective shell or shielding cover should be installed. The main power supply must have a pre-installed disconnect mechanism for quick power cut-off in emergencies, reducing safety risks.
Installation Ease: CHIPSENSE this open-type current sensor structure design allows for installation without disassembling the busbar. Standardized connectors reduce wiring errors and improve on-site construction efficiency.

Conclusion: Combining Safety and Precision, Empowering the Upgrade of High-Power Systems

CHIPSENSE HK4V H00 series isolated open-loop Hall current sensor, with its native isolation architecture, high insulation withstand voltage performance, and precise measurement capabilities, comprehensively surpasses international standards. Its wide current range coverage, adaptability to harsh environments, and ease of integration make it a core component in various high-power fields such as new energy, industry, and rail transportation. CHIPSENSE HK4V H00 current sensors ensure stable system operation and personnel safety through multiple insulation designs, while providing data support for efficient equipment operation and maintenance with its high-precision, fast-response measurement capabilities. In today's increasingly complex high-power application scenarios, the HK4V H00 current sensor from CHIPSENSE interprets the product philosophy of "safety first, precision paramount" through technological innovation, injecting momentum into the high-quality development of the industry. CHIPSENSE will always remain true to its original mission and continue to provide customers with high-quality current /voltage sensors.

CHIPSENSE is a national high-tech enterprise that focuses on the research and development, production, and application of high-end current and voltage sensors, as well as forward research on sensor chips and cutting-edge sensor technologies. CHIPSENSE is committed to providing customers with independently developed sensors, as well as diversified customized products and solutions. 
“CHIPSENSE, sensing a better world! 
www.chipsense.net