EV Charger Aging Tester | 20-Channel Aging Rack for Type 1 & Type 2 Chargers
The EV Charger Aging Tester is a professional 20-channel burn-in system designed for parallel reliability testing of AC EV chargers with Type 1 and Type 2 connectors.
- 20 Independent Channels โ Enable simultaneous burn-in of up to 20 EV chargers, significantly improving production throughput and shortening testing cycle time
- Dual Connector Support โ Each channel equipped with Type 1 (USA single-phase) and Type 2 (European single/three-phase) connectors for broad compatibility
- Flexible Power Input โ Supports single-phase AC220V and three-phase AC380V (customizable)
- Per-Channel Control & Monitoring โ Individual MCB control with real-time voltage/current display and charging status indicator
- Quick Wiring System โ Dedicated junction box with L1/L2/L3/N/PE terminals for fast and safe setup
- Mobile Industrial Design โ Heavy-duty casters for convenient transfer between production line and aging room
- Load Compatibility โ Works seamlessly with 30kW resistive loads or energy-feedback loads (loads can be used independently)
- Comprehensive Safety Protection โ Overtemperature, over/under-voltage, and emergency stop with audible alarm
EV Charger Aging Tester Description
EV Charger Aging Tester | 20-Channel Aging Rack for Type 1 & Type 2 Chargers
The EV Charger Aging Tester is a robust, high-efficiency 20-channel burn-in system engineered for parallel reliability testing and long-term validation of AC EV chargers. Supporting both Type 1 (USA) and Type 2 (European) connectors, it allows manufacturers to conduct continuous aging tests under controlled electrical loads and thermal stress conditions. This helps identify potential early failures, verify long-term operational stability, and ensure consistent product quality prior to market release. The system is widely adopted in EV charger production lines, R&D laboratories, and third-party certification environments. It is designed in full accordance with IEC 61851 (EV conductive charging systems), IEC 62196 (plugs, socket-outlets and vehicle connectors), and GB/T 18487 standards.
Technical Parameters
| Category | Parameter | Specification | Remark / Notes |
|---|---|---|---|
| Aging Tester | Number of Channels | 20 channels (expandable) | 10 channels per side, double-sided design |
| Channel Isolation | Independent electrical isolation per channel | Ensures safe parallel testing | |
| Input Voltage | AC 220V 1-Phase / AC 380V 3-Phase | Customizable upon request | |
| Connectors per Channel | 1ร Type 1 + 1ร Type 2 | Supports single-phase and three-phase chargers | |
| Monitoring & Control | Monitoring | Real-time voltage & current per channel | Digital display + charging status indicator |
| Control Method | Main contactor + individual MCB | Independent on/off control per channel | |
| Load System | Rated Power | Max 30 kW | Per load unit |
| Maximum Current (L1) | 60 A | Stepped adjustment | |
| Load Accuracy | ยฑ5% | Reliable and repeatable load simulation | |
| General | Mobility | Heavy-duty industrial casters | Easy movement between workshop and aging room |
| Protection Features | Overtemperature, over/under voltage, emergency stop | Audible & visual alarm | |
| Approximate Weight | 500 kg | Robust industrial construction |
The EV Charger Aging Tester is built with a heavy-duty industrial-grade steel frame that ensures excellent structural rigidity and long-term durability in demanding production environments. Each of the 20 channels is equipped with quick-connect terminals and dedicated junction boxes featuring clearly labeled L1, L2, L3, N, and PE connections, enabling fast, error-free wiring and reducing setup time significantly.
Independent electrical isolation and individual MCB (Miniature Circuit Breaker) protection per channel provide maximum operational safety during simultaneous multi-unit aging. The well-organized double-sided 2-layer design maximizes space utilization while maintaining easy access for operators. Furthermore, the separated load architecture allows the aging rack to work flexibly with either traditional resistive loads or advanced energy-feedback loads, offering both cost-effective testing and significant energy savings.
The system incorporates thoughtful engineering details such as clear channel status indicators, real-time monitoring displays, and emergency stop functionality, making it intuitive for technicians and highly suitable for continuous 24/7 burn-in operations.
Testing Principle
The EV Charger Aging Tester connects the AC EV charger under test via Type 1 or Type 2 connectors and applies stable AC power combined with programmable loads to accurately simulate real-world operating conditions.
During the test, the system executes continuous or cyclic aging protocols over extended periods. This comprehensive process evaluates critical aspects including electrical stability, charging efficiency, thermal performance, protection functions, and overall long-term reliability. Real-time per-channel monitoring of voltage and current provides detailed, traceable data that supports failure analysis, design optimization, and certification documentation.
Common Error Mitigation
To ensure accurate results and safe operation, operators should:
- Verify correct phase sequence and tighten all connections before powering any channel.
- Match load steps to the chargerโs rated power to avoid inaccurate simulation or over-stress.
- Monitor voltage and current readings on each channel regularly during aging.
- Maintain proper ventilation around the rack and load units.
- Activate the emergency stop immediately upon detecting any abnormal behavior.
Primary Use Cases & Business Value
The EV Charger Aging Tester allows manufacturers to perform efficient batch reliability validation, significantly shortening testing cycles while enhancing product quality consistency. It is particularly valuable for identifying potential design weaknesses early, confirming long-term stability under real-world stress, and generating credible test data for internal quality assurance and third-party certification.
Industrial Applications & Lab Scenarios
- EV Charger manufacturers โ mass production burn-in and final quality assurance
- New energy vehicle charging equipment R&D centers โ reliability verification and design improvement
- Independent testing and certification laboratories โ compliance evaluation
- Charging infrastructure system integrators โ system-level stability validation
- Quality control departments โ large-scale batch validation and process control
Strategic Procurement Advantages & Global Support
- Compliant with key international standards: IEC 61851, IEC 62196, and GB/T 18487
- Flexible 20-channel expandable design with independent control
- Mobile heavy-duty construction with quick-connect wiring for efficient workflow
- Compatible with both resistive and energy-feedback load systems
- Manufactured under ISO 9001, ISO 14001, and CE certified quality system
- One-year warranty with responsive lifetime technical support from our Dongguan facility
Compliance & Regulatory Assurance
This EV Charger Aging Tester is engineered in strict accordance with IEC 61851-1, IEC 62196, and GB/T 18487. It delivers a standardized, high-reproducibility platform for the long-duration endurance and reliability validation of AC EV charging equipment.
Metrological Integrity & Validation
- Complimentary Calibration: Each unit includes a comprehensive factory calibration certificate as standard to ensure laboratory readiness.
- Traceable Accreditation: Third-party ISO 17025 accredited certification (CNAS/ilac-MRA) is available upon request for regulatory compliance.
- Performance Verification: KingPo recommends annual calibration of load stability and signal feedback modules to maintain audit-grade accuracy.
Technical Inquiry & Expert Support
Contact our engineering team for customized channel configurations, load recommendations, or complete EV charger test system solutions tailored to your production needs.
The Core Value We Deliver
- High-capacity 20-channel parallel aging capability
- Full compatibility with Type 1 and Type 2 connectors
- Independent channel control with real-time monitoring
- Standards-compliant burn-in testing platform
- Professional, reliable solution trusted by EV charger manufacturers worldwide
IEC Standard Test Clause & Required Equipment List
| Clause | Measurement / Testing | Testing / Measuring Equipment / Material Needed | Equipment Classification |
|---|---|---|---|
| 6.3 | Functions provided in each mode of charging for modes 2, 3, and 4 | Power source, Electronic load or resistive load, Measuring instruments, Oscilloscope, High voltage probe, PWM simulation device | R 3PPS |
| 8 | Protection against electric shock | Oscilloscope, High voltage probe, Humidity chamber, Barometer, Insulation test equipment, Electric strength tester, IPXXD IPXXB test probe, Electrical indicator, Force tester, AC source, measuring instruments, Electronic load or resistive load | R 3PPS |
| 11.6 | Strain relief | Apparatus for testing cord retention, Torque test values for cord anchorages | R |
| 12.2.6 | Inrush current | AC source, Electronic load or resistive load, Inrush current device, Oscilloscope, High voltage probe | R |
| 12.3 | Clearances and creepage distances | Caliper, tolerances gauges, tracking test apparatus according to IEC 60112, Oscilloscope, High voltage probe, AC source, Electronic load or resistive load | R 3PPS |
| 12.4 | IP degree | Test equipment up to IP 4x according to IEC 60529 | R |
| Test equipment up to IP x4 according to IEC 60529 | S | ||
| Test equipment above IP 4x and IP x4 according to IEC 60529 | S | ||
| 12.5 | Insulation resistance | Insulation test equipment | R |
| 12.6 | Touch current | AC source, Resistive load, Isolation transformer, Measuring network according to IEC 60990, V-meter, Oscilloscope, High voltage probe | R 3PPS |
| 12.7 | Dielectric withstand characteristics | Electric strength tester, impulse voltage generator (1.2/50 ยตs), Oscilloscope, High voltage probe | R |
| 12.8 | Temperature rise | AC source, measuring instruments, temperature measuring device, Climate chamber, Electronic load or resistive load | R 3PPS |
| 12.9 | Damp heat functional test | Climate chamber, Electronic load or resistive load, Oscilloscope, High voltage probe | R 3PPS |
| 12.10 | Minimum temperature functional test | High & Low temperature chamber, Electronic load or resistive load, Oscilloscope, High voltage probe | R 3PPS |
| 12.11 | Mechanical strength | IK mechanical impact device | R |
| 16 | Marking and instructions | Water, petroleum spirit, piece of cloth | R |
| Annex A | Control pilot function through a control pilot circuit using a PWM signal and a control pilot wire | PWM simulation device, Test simulator of the vehicle (Circuit designed according to figure A.8 or simplified circuit which could perform testing according to clause A.4), Oscilloscope, High voltage probe, Current probe, AC source, Electronic load or resistive load | R 3PPS |
| Annex B | Proximity detection and cable current coding circuits for the basic interface | PWM simulation device, Test simulator of the vehicle (Circuit designed according to figure A.8 or simplified circuit which could perform testing according to clause A.4), Oscilloscope, High voltage probe, Current probe, AC source, Electronic load or resistive load | R 3PPS |
| 8.8 | Check of markings | Water, petroleum spirit, piece of cloth | R |
| 9 | Dimensions | Caliper, projector | R |
| 10 | Protection against electric shock | Figure 3: Standard test finger, electrical indicator
Figure 4: Gauge A, Figure 5: Gauge B |
R |
| 12.2 | Measurement of earthing contact resistance | AC source, resistance measuring instruments | R |
| 12.3 | Short-time current withstanding test of earthing contact | Current source, current measuring instruments | S |
| 13.2 | Test of insertability of conductors | Figure 6: Gauges | R |
| 13.3.1 | Rotation test | Figure 7: Rotation test equipment, weights, screw driver with torquemeter | R |
| 13.3.2 | Pull test | Weights, time meter, screw driver with torquemeter | R |
| 14.1.3 | Electrical interlock test | Pull and push instrument, continuity test instrument, oscilloscope | R |
| 14.1.4 | Mechanical interlock test | Pull and push instrument, continuity test instrument | R |
| 14.1.5 | Interlock withdraw force test | Figure 8: Apparatus for checking the withdrawal force, weights, time meter | R |
| 14.1.6 | Verification of the latching device | Figure 9: Apparatus for verification of the latching device, weights, time meter, continuity test instrument | R |
| 15 | Resistance to ageing | Heating cabinet | R |
| 16.5 | Permissible temperature test of touch parts | Heating cabinet, current source, current measuring instruments, temperature measuring device | R |
| 16.8 | Latch release test | Weights, length meter | R |
| 16.15 | Check of withdrawal force | Appropriate test apparatus, weights | R |
| 17.2 | Contact tubes | Gauges to measure withdrawn force, test plug, weights | R |
| 20.2 | Test of degrees of protection | Test equipment up to IP 4x and IPx4 according to IEC 60529, screw driver with torquemeter, high voltage test equipment | R |
| Test equipment above IP 4x and IPx4 according to IEC 60529 | S | ||
| 20.3 | Humidity treatment | Humidity chamber | R |
| 21.2 | Insulation resistance test | Insulation test equipment | R |
| 21.3 | Dielectric strength test | High voltage test equipment | R |
| 22 | Breaking capacity test | Appropriate test apparatus, power source, adjustable load (resistors and inductors), measuring instruments, high voltage test equipment | S 3PPS |
| 23 | Normal operation test | Appropriate test apparatus, power source, adjustable load (resistors and inductors), measuring instruments, high voltage test equipment | S 3PPS |
| 24 | Temperature rise test | Current source, current measuring instruments, temperature measuring device, screw driver with torquemeter | R |
| 25.3 | Cord anchorage test | Screw driver with torquemeter, test apparatus according to Figure 11 incl. weights, apparatus for torque test | R |
| 26.1 | Cold treatment | Refrigerator | R |
| 26.2 | Ball Impact test | Figure 12: impact test apparatus, steel ball | R |
| 26.3 | Mechanical strength test | Arrangement according to Figure 13 | R |
| 26.4 | Flexing test | Apparatus according to Figure 14 | R |
| 26.5 | Torque test at screwed glands | Appropriate test arrangement incl. metal rods | R |
| 26.6 | Shutter test | Pull and push instrument, electrical indicator | R |
| 26.8 | Change of temperature test | Environment test chamber | R |
| 26.9 | Pull test | Appropriate test apparatus, weights, time meter | R |
| 27.1 | Torque test at screws | Screw driver with torquemeter | R |
| 28 | Creepage distances, clearances | Caliper, appropriate gauges | R |
| 29.2 | Heat treatment | Heating cabinet | R |
| 29.3 | Ball-pressure test | Heating cabinet, ball test apparatus, caliper | R |
| 29.5 | Glow-wire test | Glow-wire test apparatus | R |
| 29.6 | Tracking test | Test apparatus according to IEC 60112 | R |
| 30 | Corrosion test | Chemicals, humidity cabinet, heating cabinet | R |
| 31 | Short-circuit current withstand test | Short-circuit testing arrangement incl. appropriate measuring devices | S 3PPS |
| 33 | Vehicle driveover | Vehicle driveover test apparatus, weights, velometer, tyre pressure meter | R |
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