How to Test the Accuracy of EV Charging Piles Using TUNKIA TK4830(TE1100)

Why Do We Need to Test the Accuracy of EV Chargers?

With the rapid development of new energy vehicles (NEVs) globally, countries are accelerating the construction of charging infrastructure, leading to a continuous growth in the demand for charging stations.

Charging technology is evolving from traditional AC charging to high-power DC ultra-fast charging, with 800V and 500A chargers becoming more common, raising standards for voltage, current, and metering accuracy. Global charging standards (OCPP, GB/T, IEC, CHAdeMO, CCS) are converging, requiring testing equipment to support protocol compatibility.

Stricter government regulations demand the energy metering error of charging stations to comply with ±0.5% or higher standards, requiring traceability in testing. Charging station operators and inspection agencies are increasingly requesting remote monitoring, data sharing, and intelligent operation and maintenance, making smart and portable testing equipment an important trend.

What is EV Charger Metrological Testing

EV chargers metrological testing involves verifying and calibrating the accuracy of the built-in energy metering devices (e.g., energy meters or metering modules) to ensure their energy measurements meet national or industry standards. The purpose of EV chargers metrological testing is to ensure fair charging fees, protect the legal rights of users and operators, and maintain high precision and reliability of charging infrastructure over its long-term operation.

This essay will introduce TUNKIA TK4830 Portable Tester for AC&DC EV Chargers, along with its operation process of testing EV charging stations.

1. TK4830 Portable Tester for AC&DC EV Chargers Overview

TK4830 is an integrated AC/DC EV charger tester designed for the verification of EV chargers. It provides both AC and DC energy measurement with an accuracy of Class 0.1, enabling operating error testing of AC and DC EV chargers.

The device supports European-standard CCS2 DC charging interfaces and Type 2 AC charging interfaces. Testing can be performed using an electric vehicle as the load or with a resistive load. By combining wide dynamic range measurement technology with millisecond-level energy measurement refresh, the system achieves accurate accumulated energy measurement throughout the entire charging process.

Compared with conventional steady-state verification at preset test points, it provides a more realistic evaluation of EV charger performance.

2. Wiring of EV Charger Verification Process

TK4830 Portable Tester for AC&DC EV Chargers On-site Testing Connection

Taking DC EV charger with CCS2 interface testing for example.

Connect the TK4710 DC Resistive Load to the TK4830 EVSE Tester using a dual-gun DC charging cable. Plug the DC charging pile gun into the TK4830.

Connect the TK4830 to the computer via an Ethernet cable for communication; subsequent charger verification will be performed through the software. Connect the GPS module, ensuring the GPS signal receiver is placed in an open area for subsequent time error verification.

Once all connections are completed, open the testing software on the computer and check the device connection status icon in the upper right corner. A green icon indicates successful wiring.

Connection Status Icon in the Upper Right Corner

3. EV Charger Testing Using Dedicated Software

3.1 DC EV Charger Accuracy Testing

EV Charger Operatin Error Testing

The verification of EV charger is to test the its energy accuracy. The user can set up a calibration scheme, or choose a preset one for testing. The default verification standard is set to JJG1149-2022. The user can check and uncheck the test items according to actual testing need.

Two testing method are available for working error test.

• Method 1: Pulse Method – Performs electrical energy error testing by measuring the energy pulses from the charger under test.

• Method 2: Accumulated Energy Method – Tests electrical energy error by displaying the standard cumulative energy value and comparing it with the cumulative energy from the charger under test.

When the preparation is ready, we can start testing. The first test item is the Visual Inspection (Appearance and Function Inspection). Click [Start], then check the appearance and functions of the charger under test against the verification items and record the results.

Click [Next] to proceed to the working error test (Method 2).

Follow the system prompts to swipe the card and activate the charger.

Real-time data will be displayed at the top of the screen, while test progress and duration are shown below.

Once the test is complete, the system will prompt you to read and record the electrical energy data from the charger before and after the test. The Error 1 is calculated based on the tested electric energy.

Swipe the card to activate the charger again for a second round of testing.

After two tests are completed, the system will automatically calculate the error values, average values, and determine whether the verification result is compliant and qualified.

EV Charger Clock Time Error Testing

Click [Stop Timing]– the [Reference Clock Display Time] will automatically read the GPS time.

The user should read the time displayed on the charger and enter it into [Charger Display Time].

The system will automatically calculate the indication error and determine whether the verification result is compliant.

EV Charger Testing Result Review

Click [Data] to view verification records and data. Select the desired data and click [Print].

Choose the required report template to generate the verification report.

To meet specific testing requirements, the device can also be used in a cascade configuration with DC loads.

Connect the cascade charging port of the first load to the power supply port of the second load using a dual-gun charging cable.

3.2 AC EV Charger Accuracy Testing

Use an AC dual-gun charging cable to connect the TK4720 (i.e., TE1100R) AC Resistive Load to the TK4830.

Connect the AC charger gun head. Connect the device to a computer using an Ethernet cable.

Connect the GPS module (the module must be placed in an open area). Open the testing software on the computer.

Subsequent software configuration and testing operations are consistent with the steps described above.

4. TK4830 Portable Tester for AC&DC EV Chargers Operation Video

Watch the operation video of TK4830 Portable Tester for AC&DC EV Chargers for more details.