EOLT Systems

Smart DC Energy Meters

The e-mobility market will require around one million charging points by 2030

To ensure that DC Energy Meters for charging stations operate precisely and in compliance with calibration law, MCD Elektronik developed a modular test system for comprehensive testing and verification of the devices.
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Challenges and concept

EOL testing of Smart DC Energy Meters places high demands on power electronics, measurement technology and process safety. Currents up to 1,500 A and voltages up to 1,000 V must be generated, controlled and measured with an accuracy of ±0.1%. At the same time, the requirements of German calibration law and the European MID Directive must be met.

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Smart DC Energy Meters

Modular EOL test system for DC Energy Meters

MCD Elektronik uses the VTS 2030 platform for this purpose. A fully insulated test hood with two contacting units enables the synchronous testing of two units under test. Bidirectional four-quadrant power supplies simulate realistic charging and discharging processes by reversing the direction of current flow.

An integrated safety chain with high-current contactors and the monitoring of voltage drops and temperatures safeguard high-power operation. The MCD TestSuite controls parameterization, testing, evaluation, MES integration, logging and label printing.

Test current
Up to 1,500 A
Test voltage
Up to 1,000 V
Measurement accuracy
±0.1%
Test and functional scope

The test and functional scope covers all relevant measurement, calibration, simulation and process steps required for reliable EOL validation of the DC Energy Meters:

EOL test stand with two test fixtures
Front view of the test system
Test fixtures, measurement technology and label printer
High-current contacting with copper busbar
Detailed view of the contacting system
Copper busbar and connection components
Wiring in the EOL test system
Detailed view of the system setup
Cables, connection modules and current sensors

Unit-specific parameters are written automatically and communication with the DC Energy Meter is verified.

  • Writing unit-specific parameter sets
  • Communication test via RS485
  • Automated control via the MCD TestSuite
  • Software-supported mandatory sequences for safe user guidance

Current, voltage and energy are precisely calibrated across the entire test range and verified against reference values.

  • Calibration and testing of direct current up to 1,500 A
  • Calibration and testing of DC voltage up to 1,000 V
  • Comparison of energy against a high-precision reference meter
  • Compliance with a measurement tolerance of ±0.1%

Bidirectional power electronics and automated actuation reproducibly simulate real operating states and user interactions.

  • Simulation of charging and discharging processes with four-quadrant power supplies
  • Reversal of the current direction for realistic charging cycles
  • Automated actuation of buttons on the unit under test
  • Software-based evaluation of the system response

High-current contacts and test results are continuously monitored and fully integrated into the production process.

  • Monitoring the voltage drop at the high-current contacts
  • Checking contact resistance
  • MES integration and automated test logging
  • Automated printing of rating plates or error labels
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Synchronous testing at high power

Two specially developed contacting units enable the synchronous testing of two DC Energy Meters. The combination of an insulated test hood, high-current monitoring and an integrated safety chain supports a safe test process at high currents and voltages.

Test methods used and challenges

The design of the test system combines power electronics, high-precision measurement technology, high-current contacting and regulatory requirements. The VTS 2030 platform provides the scalable system basis and enables two units under test to be tested in parallel.

Power and measurement testing
DC current measurement from the milliampere range up to 1,500 A
DC voltage measurement up to 1,000 V
Separate measurement paths for low and high currents
Measurement accuracy of ±0.1% across the relevant test range
Simulation and validation
Bidirectional four-quadrant power supplies for charging and discharging processes
Verification of energy against a reference meter
Automated haptic and response tests
Integration of customer-specific software for validating OCMF data records
Safety and contact monitoring
Integrated safety chain with powerful high-current contactors
Continuous voltage drop measurement at the contact points
Monitoring temperatures at the contact points
Guided and monitored process steps in the high-current and high-voltage range
Process and regulatory integration
Automated control and evaluation via the MCD TestSuite
Implementation of the requirements of German calibration law and the MID Directive
Complete test logging via MES integration
Automated label printing after completion of the test sequence

FREQUENTLY ASKED QUESTIONS

FAQS

These are intelligent direct-current meters that precisely record voltage, current, power and energy in DC systems and provide the measurement data digitally for remote monitoring, control and billing. Their functionality is particularly critical in public EV charging stations because the measured energy consumption forms the basis for correctly billing charging costs.
The EOL test system parameterizes the unit under test by writing specific data to the device memory, calibrates the current and voltage measurements of the DC Energy Meter, and simulates defined charging and discharging currents. OCMF data records are automatically evaluated and verified. Communication with the unit under test, measurement data acquisition and MES integration are fully incorporated into the test sequence.
Testing Smart Energy Meters is particularly demanding because current and voltage must be measured and calibrated with high accuracy across a very wide measurement range. In this system, the test range extends from direct currents in the milliampere range up to 1,500 A and up to 1,000 VDC. This wide dynamic range places high demands on measurement technology, current routing, contacting and the reproducible evaluation of measured values across the entire operating range.
The integrated current transformers allow both very low and high currents to be measured precisely. Four-quadrant power supplies enable operation as both source and sink, allowing the current direction to be reversed deliberately. This enables realistic charging and discharging processes for electric vehicles to be simulated reproducibly while maintaining the required tolerances of ±0.1% across the entire current and voltage range.
Yes. A fundamental requirement during development was ensuring compliance with German calibration law and the European Measuring Instruments Directive (MID). The EOL test system enables exact calibration and verification, which are mandatory for legally compliant billing at public charging stations.

KEY FACTS

Key facts at a glance

Test system
EOL test system / Automated test system
Handling
Manual / automated
Concept
Multi-unit test stand
2 units under test in parallel (synchronously)
Test methods & test scope
Electrical: Voltage, current and power measurement; current and voltage calibration
Mechanical: Button actuation
Communication: RS485, OCMF data verification
Components
MCD TestSuite, MCD tool monitors, VTS 2030 rack system, MCD Controller MIO1616, project-specific high-current contacting, safety controller, emergency stop system, power meter, power supply, mechanical actuation

Downloads

Detailed Information

Technical Report
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Application Note
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REFERENCE PROJECTS

Smart Meter Gateways (SMG)

EV wall-mounted charging station

Smart home systems