EV and EVSE test systems
EVCA Flex: high-power EV and EVSE test system
Test a vehicle with a simulated charging station, or test a station with a simulated vehicle. EVCA Flex brings charging communication, signals, external power equipment and selected measurement or fault modules together in your laboratory test setup.
EVCA Flex at a glance
Published Flex voltage, current and fault configurations
| Parameter | Published scope | Configuration condition |
|---|---|---|
| CCS / NACS voltage | Up to 1,500 V. | The selected interface and complete system define the final voltage range. |
| Charging current | Up to 500 A standard; 600 A or 800 A on customer request. | Customization, voltage, duration and cooling must be specified together. |
| Short-circuit configuration | Up to 1,000 V / 500 A. | Only the approved fault topology, hardware, energy limits and operating conditions apply. |
| Actual operating point | External source, load or bidirectional power system. | Confirm power, continuous and peak duration, cooling, switching energy and facility limits. The listed maxima do not establish a continuous power rating. |
Published ratings and conditions · IEC TestLib software status
Plan your Flex configuration
Use the standard to define the test requirements, then agree the hardware, software release and test cases for the delivered system.
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To configure the system, specify your device under test, charging interface, operating points and required fault cases.
Modular high-power laboratory platform
EVCA Flex: charging simulation with external power and fault hardware
EVCA Flex coordinates charging communication, low-level states, contactors, source or load, measurements and safety supervision for high-power tests. Keep the charging-specific hardware and software workflow as the project power path changes.
Replace or expand rack and cassette hardware without returning the complete test environment when connectors, standards, voltage classes or test objectives change.
Test both sides of the charging interface on one platform.
EV testing with EVSE simulation; EVSE testing with EV simulation
Test the vehicle with EVSE simulation
Coordinate EVSE (electric vehicle supply equipment, or charging station) communication, low-level states and the selected source. Test the EVCC (vehicle-side charging communication controller), charging inlet, onboard systems and complete vehicle under controlled conditions.
- AC and DC EVSE simulation
- Source and grid-emulator integration
- EVCC, battery management system (BMS), OBC and vehicle-state correlation
- Conformance, robustness and regression campaigns
Test the station with EV and battery simulation
Set the EV communication and battery requests, then coordinate the selected load or bidirectional supply and released fault modules for charger development and verification.
- Configurable EV and battery behaviour
- Load or battery-emulator integration
- Output control, protection and shutdown reaction
- IEC 61851-23 and project-specific electrical testing
Modular system architecture
Flex test architecture: simulation, charging interface, power and analysis
EV or EVSE simulation
Choose protocol, low-level states, connector and operating behaviour for the DUT.
Charging connectors and measurement
Use the released connector, voltage class, current path and measurement channels required by the project.
External source, load and optional switching
Integrate power equipment and fault hardware without changing the charging-specific software workflow.
comframe, Test Libraries and automation
Configure the test, analyse the charging event and automate supported sequences. Keep the complete session records for review.
EVCA Flex with the IEC 61851-23 rack
Provoke the electrical fault. Measure how the EVSE responds.
EVCA Flex with dedicated IEC 61851-23 switching and fault hardware addresses the full Annex CC.7.5 test scope in the matching system configuration. comemso demonstrated these test cases on a customer’s charging station in its own laboratory. Define the standard edition, fault cases and operating points for your project.
DC short-circuit test objective: record the charging station’s protection response
| Test element | Configuration and observation |
|---|---|
| Real DUT and setup | A DC charging station is the DUT. EVCA Flex simulates the vehicle; the selected external load or bidirectional system covers the planned charging condition. |
| Configured fault | Use the approved short-circuit hardware path and test sequence for the selected operating point. Confirm voltage, current, fault energy, protection and switching scope before the test. |
| Observed response and verdict | Record the fault trigger, charging communication, voltage and current waveforms, and the EVSE protection or shutdown response. Compare the captured response with the acceptance criteria of the applicable test case. |
| Measurement and software | Specify oscilloscope channels, probes, bandwidth and trigger with the TestLib. The existing IEC 61851-23 demonstration used CANoe; its comframe port is not yet released. comframe remains available for the separately released simulation and analysis functions. |
Illustrative test objective for planning your configuration. Define the electrical fault path, measurement equipment and operating conditions for the approved setup. The rating table and direct FAQ specify the short-circuit limits and required IEC hardware.
Short-circuit configuration · Current IEC TestLib workflow · Synchronised test-action and response analysis
Charging simulation, interfaces, synchronised measurement, power coordination and comframe.
Dedicated switching and fault paths for the selected released test scope.
Test setup and responsibilities
Plan the hardware and measurement path for IEC 61851-23
On smaller screens, scroll the table horizontally to see every column.
| Test function | Primary system element | Project definition |
|---|---|---|
| EV simulation and charging communication | EVCA Flex and comframe | Charging family, protocol edition, certificates, messages and low-level behaviour |
| Voltage, current and power coordination | EVCA Flex with external source, load or bidirectional system | Operating quadrant, dynamics, maximum and continuous envelope, cooling and facility limits |
| Selected IEC 61851-23 electrical paths | IEC 61851-23 rack where required | Released switching and fault modules mapped to the applicable test cases |
| Waveform acquisition | External oscilloscope and measurement equipment | Channels, probes, bandwidth, trigger conditions, isolation and data handover |
| Test sequence and verdict | IEC 61851-23 TestLib; CANoe in the demonstration | Standard edition, annex, Test Library release, project parameters and report requirements |
| Power absorption | External load or bidirectional power system | The load must cover the charger power required by the planned test condition |
Test your charging station in the laboratory
Agree fault cases, voltage, current, power, switching and protection, source or load, measurement channels and TestLib version. Then assess your EVSE in the demonstrated laboratory setup.
Discuss the test scope and demonstrationIEC 61851-23:2023 test structure
IEC 61851-23:2023 systems, annexes and laboratory setup
IEC 61851-23:2023 assigns DC systems A, B and C to Annexes AA, BB and CC and adds general test topics. Confirm the applicable edition, system, Test Library and released hardware; annex coverage is configuration-specific.
System A. CHAdeMO
Test cases for the CHAdeMO charging-system path. Confirm the supported CHAdeMO release and hardware configuration.
System B. GB/T DC
Test cases for the DC GB/T charging-system path. Confirm the released protocol, connector, low-level and electrical scope separately.
System C. DC CCS
The combined Flex, Test Library and IEC-rack path is configured for DC CCS verification according to the released project scope.
General topics and test conditions
Include the applicable general requirements, measurement methods and setup conditions in the complete project definition.
- 1Select the standard scope
Define edition, system, annex and device-under-test role.
- 2Map the test cases
Separate software-controlled sequences from cases that require dedicated electrical hardware.
- 3Configure the physical path
Specify Flex rack, IEC rack, external load, oscilloscope, protection and facility interfaces.
- 4Execute one synchronised test
Run communication, signals, electrical conditions and measurement under coordinated control.
- 5Preserve measurements linked to their test conditions
Keep verdicts, traces, waveforms and limits with the test configuration and report context.
Power and controlled electrical faults
Flex ratings: voltage, current, duty and electrical fault limits
Define continuous and peak operating points for the complete system. Match source or load capability, cable and connector limits, cooling, switching energy, facility infrastructure and protection to the planned test.
Published CCS and NACS high-voltage range
Final voltage range depends on the selected charging interface and complete system configuration.
Standard current range
600 A or 800 A is available on customer request through customization. The quotation defines the selected current rating and operating conditions.
Published short-circuit configuration
Controlled short-circuit testing during charging requires the approved topology, hardware, limits and operating procedure.
Source, load or bidirectional system
Select the dynamics, operating quadrant and power envelope that match the device under test.
Message content and timing
Challenge supported protocol variables, delays, missing messages and deliberately nonconforming behaviour.
Charging signals and states
Apply released Control Pilot (CP), Proximity Pilot (PP) and technology-specific state scenarios at the interface where the DUT must react.
Contactors and isolation-related conditions
Coordinate the released switching paths, measurements and safe shutdown sequence.
Controlled high-power fault path
Use only the approved hardware, energy limits, protection concept and documented operating procedure.
Synchronised records of communication and electrical behaviour
Fault-response analysis: trigger, communication and electrical measurements
EVCA Flex and comframe put communication signals, electrical measurements, fault commands and DUT responses on a common time base. Compare the response with the test requirement and check the suspected cause through controlled tests.
- High-level communicationMessages, sequence, timing, TLS and certificate context according to the configured scope.
- Low-level interfaceCharging states, connection conditions and released signal measurements.
- Power behaviourRequested and measured voltage, current, source or load response and shutdown.
- Test actionFault trigger, switching command, test step, expected condition and actual reaction.
Configure the laboratory system for your test
- DUT direction
EV, EVSE, controller or subsystem
- Charging interfaces
AC, CCS, NACS, CHAdeMO or GB/T
- Power envelope
Voltage, current, direction, dynamics and cooling
- Fault depth
Protocol, signals, switching and high-power faults
- Automation
Libraries, cycles, APIs, evidence and reports
- Environment
HiL (hardware-in-the-loop), EMC, climate, safety and upgrade path
Selected EVCA Flex hardware + external power + comframe capabilities + approved safety concept
Relate measurements and protocol events to expected limits and highlight deviations automatically.
Configure supported message content, timing and deliberately nonconforming partner behaviour.
Execute versioned procedures with automated steps, verdicts and reports according to the released scope.
Run saved charging cycles, variants, endurance sequences and unattended campaigns.
Field to labReproduce supported field behaviour actively at the physical charging interface.
Coordinate supported source, load, HiL and automation systems while retaining the charging-domain workflow.
Charging standards and product selection
AC and DC charging tests with EVCA Flex. Dedicated MCS testing with EVCA MCS.
Specify connector hardware, protocol releases, TLS and certificates, power class, fault modules and Test Libraries independently in the quotation.
AC and DC charging
IEC 61851-1, IEC 61851-23, DIN 70121, ISO 15118 including applicable ISO 15118-20 scope, SAE J1772 and selected NACS interfaces.
CAN-based DC charging
EV and EVSE simulation, communication analysis, measurement and Test Libraries according to the supported release.
Chinese DC charging
GB/T 18487.1 and GB/T 27930 variants according to the selected product and project configuration.
Megawatt Charging System
Choose EVCA MCS for 10BASE-T1S, MCS low-level states, cooled interfaces and megawatt power integration in the dedicated MCS test architecture.
View EVCA MCSApplication first
When does an end-of-line test need EVCA Flex?
Use Easy Chester for repeatable production acceptance. Choose EVCA Flex when your acceptance plan calls for laboratory power integration, advanced electrical conditions or controlled fault tests.
Plan the delivered system
Flex configuration: DUT, interfaces, external power and test scope
Work with the application engineers to define Flex, IEC-rack, external-power and software scope. Agree supplied and external equipment, safety responsibilities and the integration tasks of each party.
EV, EVCC, complete vehicle, EVSE, SECC (station-side charging communication controller), power module or charging subsystem.
AC, CCS, NACS, CHAdeMO or GB/T, including regional connector and protocol variants.
Voltage, current, operating quadrant, continuous and peak power, dynamics, cooling and facility constraints.
Protocol, signals, switching, short circuit, standard edition, annex, Test Library and required IEC-rack paths.
Voltage, current, oscilloscope channels, trigger, time base, reports and data handover.
comframe licences, APIs, external systems, campaign throughput, training, maintenance and future expansion.
Frequently asked questions
EVCA Flex and IEC 61851-23 FAQ
What is EVCA Flex?
EVCA Flex is a modular high-power laboratory system in the comemso EV Charging Analyzer/Simulator platform. It combines charging communication, low-level signals, measurement, external power integration, configured fault functions and comframe for EV and EVSE development.
Can EVCA Flex test both electric vehicles and charging stations?
Yes. For EV testing, it represents the charging-station side and coordinates the selected source and interface. For EVSE testing, it represents the vehicle and battery side and coordinates the selected load or bidirectional system. The exact configuration defines the supported interfaces, power and safety functions.
Can EVCA Flex be configured for 600 A or 800 A?
Yes. The standard current range is up to 500 A. On customer request, EVCA Flex can be customized for 600 A or 800 A. Specify the required current, voltage, duration and cooling conditions when requesting a configuration.
Is the IEC 61851-23 rack included in every EVCA Flex system?
No. The IEC rack is an additional hardware path for selected electrical verification tests. A communication, development or general high-power Flex configuration does not automatically include it. The applicable test cases, switching paths and external measurement equipment must be defined in the project scope.
What does the IEC 61851-23 rack add?
It adds dedicated electrical switching and fault paths required by the released IEC 61851-23 test scope. EVCA Flex remains responsible for the charging simulation, interface, measurement coordination and software workflow. The exact rack content depends on the standard edition, annex and approved test configuration.
Which IEC 61851-23 annexes are relevant?
IEC 61851-23:2023 includes Annex AA for System A (CHAdeMO), Annex BB for System B (GB/T DC), Annex CC for System C (DC CCS), plus further general annexes. The delivered system and Test Library must state which annex and test cases are released. The current combined Flex and IEC-rack project path is positioned primarily around DC CCS Annex CC verification.
Are an external oscilloscope and load required?
Selected electrical tests require an external oscilloscope and suitable measurement equipment. The external load or bidirectional power system must cover the charger power required by the planned test condition. Channels, probes, bandwidth, trigger, isolation and data handover must be included in the system definition.
EVCA system planning
Define your EVCA Flex laboratory system.
Bring together the required source or load, charging interfaces, measurement channels and fault modules for the agreed Flex test scope.
Select the EVCA system by test role
Choose Flex for modular laboratory power and electrical fault tests
Controller communication development, simulation and protocol analysis.
Portable laboratory and fieldMobile simulation, measurement and field-to-lab workflows.
Real EV and real EVSEInvestigate the charging interaction between a real vehicle and station.
EVCA Flex
Modular power integration and electrical fault testing.
10BASE-T1S, MCS signaling, cooled interfaces and megawatt power.