EV Testing Guide

EV Charger

Electric vehicles are becoming increasingly popular across the world. This is primarily due to their high efficiency levels, low running costs, and improved impact on the environment.

If you drive an electric vehicle, there are a few tasks that you’ll need to perform on a regular basis to ensure that your EV charger car is safe and maintained properly. One of these tasks is EV testing.

In this guide, we’ll provide you with a thorough outline of what EV testing is, what the process involves and how it can help with the upkeep of your electric vehicle.


What is EV Testing?

EV testing, or EVSE testing, is a procedure that seeks to ensure that an EV charging station is safe to use. The process typically involves the use of EV testing equipment to assess the charging interfaces, as well as the associated systems that allow electric vehicles, their charging stations and the back-office systems to effectively communicate with each other. This is known as interoperability or conformance testing.

EV testing can also involve the testing of EV battery packs and their modules, as well as other components such as cables, plugs, connectors, switches and wiring.

Here’s full breakdown of the kind of areas that are covered in EV testing:

  • Electrical safety testing
  • Performance testing
  • Functional safety testing
  • Conformance and interoperability testing
  • Environmental & stress testing
  • Software testing
  • Cyber security testing
  • Wireless testing
  • Cyber security testing
  • EMC testing
  • Chemical testing

As well as the above assessments, electrical testing equipment suppliers Test Instrument Solutions recommend that the following areas should also be tested:

  • Continuity testing (primarily for tethered lead systems)  – This test seeks to ensure that the lead’s Earth conductor is accurately connected.
  • Insulation Resistance Testing (primarily for tethered lead systems) – This assessment will ensure that the lead’s internal conductors have sufficient insulation resistance properties. 
  • Status Checks – This will assess the EVSE’s performance when various fault and con-fault conditions are simulated.
  • Loop Impedance Testing – This test aims to determine if the EVSE has suitable Live-Neutral & Live-Earth Loop Impedance readings back to the supply, as well as accurate associated PSC & PFC values. 
  • Type A RCD Test – This assessment will confirm whether the Type A RCD within the circuit will trip in time under a fault condition. 
  • Type B* & RDC DD** Tests – These tests seek to ensure that the 6mA DC trips will work in situ.


Why is EV testing important?

As the electric vehicle and hybrid car market continues to evolve, it is becoming increasingly important for processes such as EV testing to be conducted. EVSE testing is important as it helps to preserve the safety of both you and your electric vehicle, ensuring that charging points are able to provide electricity safely and efficiently to your electric charger car.

Here are some of the main benefits of EV testing:

  • Ensures user safety when using electrical equipment and infrastructure
  • Confirms product compliance with existing EV standards and regulations
  • Assesses the conformance, interoperability and electromagnetic compatibility of your EV products 


What happens during an EV test?

During an EV test, an electric vehicle connection is simulated using an EV charging unit tester in order to enable accurate results. 

The individual in charge of conducting the EVSE test is required to trigger the charging process by supplying a suitable combination of proximity pilot (PP) and control pilot (CP) signals to the EV charging point. In order for this to occur, and to enable a successful connection of the EV test equipment to the EV charging point, EV test equipment manufacturers have introduced adapters, such as the KEWEVSE EVSE Testing Adapter, which is specifically designed for EV testing.

In most cases, these EV testing adapters come equipped with a Type 2 plug for charging points with a tethered or panel mounted Type 2 socket outlet. Type 2 charging cables are the most popular type of EV charging cables in the UK.

Nevertheless, Type 1 charging cables are used by some electric charger cars so some manufacturers offer a Type 1 plug.


What products are used for EV testing?

There is a range of EV testing equipment available on the market. Here are some examples of the types of products available:

     1. TIS Professional Multifunction Tester, EVSE Testing Capabilities & Adapter

Suitable for both beginners and professionals, this high quality testing kit provides you with everything you need to conduct a full EV test on your charging station. With its included Auto Sequence test, you’ll receive useful guidance through each EV test. This feature provides a detailed explanation of where to place your EV testing leads and informs you of the most effective dial position for each part of the sequence.

Key features

  • Fully-guided Auto Sequence feature for testing EVSE charging stations
  • 6mA DC RCD and ramp test for EVSE charging units
  • 30mA Type A RCD and ramp test to be used for EVSE charging stations
  • Capable of testing Mode 2 and Mode 3 charging units
  • Type 2 charging cable connection
  • Fault simulation (PE and E)
  • Featured phase presence indication 
  • Data saving function using the TIS MFTPRO
  • Data export function through the use of the top view software provided
  • 3-year warranty

     2. KEWEVSE EVSE Testing Adapter

This premium EVSE Testing Adapter is designed to facilitate electrical safety checks of an EV charging station in conjunction with an EVSE enabled MFT, like the KT66DL.

Key features

  • Designed to assess the functionality of the EVSE 
  • Effective for commissioning and troubleshooting
  • Suitable for use on single phase or three phase systems
  • Compact
  • Easy to use

     3. Rolec EV Charging Unit Tester 

This EV charging unit tester from EV powerhouse brand Rolec is manufactured to provide electricians with everything they need to perform a comprehensive and accurate test of EV fast charging stations across the UK.

This quality piece of EV testing equipment can facilitate full EV testing on all 3.6kW (16A) and 7.2kW (32A) single phase, Mode 3, J1772 (Type 1) and IEC 62196 (Type 2) EV charging points.

Key features

  • Designed to simulate an EV charger car
  • Simulates and assesses IEC 61851-1 Mode 3 communication compliance
  • Tests J1772 (Type 1) charging stations
  • Tests IEC 62196 (Type 2) charging points
  • Examines for correct Live - Neutral - Earth polarity
  • Offers test socket for Earth loop impedance assessment 
  • Provides test socket for RCD / RCBO trip time and sensitivity assessment
  • Includes a 1 metre J1772 (Type 1) to IEC 62196 (Type 2) adapter cable
  • Protective ChargeCheck:EV carry bag included

 

EV Testing with YESSS Electrical 

Want more information on EV testing? Don’t hesitate to get in touch with the experts at YESSS Electrical today. Our team has professional knowledge on all things EV and we can help you find the best EV testing equipment for your needs.

We stock EV products from all major brands and we have an extensive catalogue of EV items, from EV testing equipment to EV chargers and charging cables.

Why not visit one of our local branches to browse our excellent range of EV testing equipment and our host of other EV products? We offer both domestic and commercial EV charging solutions, so you can trust that we’ll be able to provide you with the right products for your needs. We also provide EV charging stations at some of our sites so that you can charge up your EV charger car with ease.

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