# EOLT for Electric Wall-Mounted Charging Station > Source: https://mcd.site team.de/en/industries/energy-management-smart-home/eolt-for-electric-wall-mounted-charging-station/ > Last updated: 2026-10-01 --- End-of-Line Test System for # Electric Wall Charging Station [Learn More](#) ![](https://mcd.site team.de/wp-content/uploads/2026/06/2018_Wallbox-front-EOLT-1-1.png) ## No charging stations, no electric cars—and no reliable charging infrastructure without precise testing technology. The transformation in the automotive industry is disruptive: Traditional components are giving way to electric motors, batteries, and complex charging units. As a technology leader in complex, mechatronic, and fully automated test systems, MCD Elektronik offers turnkey solutions precisely tailored to the requirements of electric mobility. From the initial risk analysis to on-site commissioning, this project was completed in just 16 weeks. ## Challenges and Concept ![](https://mcd.site team.de/wp-content/uploads/2026/06/Group_30131.svg) More and more electric cars are being conveniently charged in home garages using wall-mounted charging stations. These stations enable charging speeds up to six times faster than standard household electrical outlets. MCD Elektronik has now developed a system for a leading manufacturer of such wall-mounted charging stations that allows for testing different models under varying current loads. - Precise Functional Test: Even before installation, the electronic circuit board is connected via a pin header, programmed with the appropriate firmware, and tested under the strictest safety precautions (high-voltage adapter of the highest protection class). - Fully Automated EOL Testing: The fully assembled device undergoes a final inspection of all electrical connections and control elements. Even LED bars, touch buttons, and buzzers are validated fully automatically using audio analysis and sensor technology. - Future-proof design: Thanks to interchangeable workpiece holders and a modular software architecture, the system can be quickly reconfigured for new model variants. This enables highly flexible manufacturing that remains cost-effective even for small production runs. ## Scope of Testing and Functionality ![](https://mcd.site team.de/wp-content/uploads/2026/06/Group_30131.svg) Functional Test: - Barcode scan to lock the process and verify the testability of the test item - Reconciliation of test specimen data via the system's data interface - Firmware Programming - Testing the circuit board with different AC voltages - Functional Testing and Stress Testing - Verification of pilot voltage and functionality under an electronically simulated load - Residual Current Test - Temperature Test - Analysis of the Buzzer Signal Using FFT Spectrum Analysis **End-of-Line Test:** - Testing of the fully assembled end device in which the previously tested circuit board is installed - Barcode scan for process interlock and to verify the testability of the end device - Reconciliation of test specimen data by connecting the system via the diagnostic interface - Testing the wall-mounted charging station with different line voltages and loads - Functional and communication testing with the charging connector installed - Verification of pilot voltage and functionality under various electronically simulated loads - High-voltage test at 4.25 kV in accordance with VDE regulations - Protective Conductor Test at 25 A - Temperature Test of the Device - Testing the Buzzer Button - Marking Production Data on the Test Specimen - Functional testing of LED strips through interaction with a tester - After this final inspection, the device is ready for shipment to customers ## Test Methods Used and Challenges ![](https://mcd.site team.de/wp-content/uploads/2026/06/Group_30132.svg) Features: - TestManager CE Testing Software - Control via MCD tool monitors (ElectronicLoad, PowerSupply, Serialline, Multimeter, ULC, SerIO, and SQL) - ULC Multifunction Card - MIO1616 Control Unit - HV Adapter (Highest Safety Class) - High-Voltage Test Chamber - ULC Rack - Safety testers, programmable AC and DC power supplies, and electronic loads Examples of use: - Functional and end-of-line tests on electronic control units and circuit boards - Functional and end-of-line tests for safety-critical components - High-Voltage Testing of Electrical Assemblies - Protective Conductor Tests on Electrical Assemblies in Accordance with VDE Regulations ![](https://mcd.site team.de/wp-content/uploads/2026/06/966cf8e4f3b7117aae2ba1cfc0ab3580.png) ## ECUS FOR LIGHTING CONTROL tested with FCT system - Parallel testing of four PCBs - Manual, semi-automatic or fully automatic adapter - 130 test steps in 95 seconds per test position - Interchangeable needle bed cassettes ## FREQUENTLY ASKED QUESTIONS ### FAQS Which power classes of wall-mounted charging stations can be tested with these systems? The test systems are designed to be flexible and support the testing of various models in the standard power classes ranging from 3.6 kW to 22 kW. What is the difference between the FKT station and the EOLT station? FKT Station (Functional Test): Here, the focus is on the control board. Firmware programming and initial functional tests under load and at various voltages are performed. EOLT Station (End-of-Line Test): Here, the fully assembled end device (circuit board in the housing) undergoes final testing. This includes mechanical aspects, communication via the charging connector, and safety-critical final tests. What safety tests are conducted to ensure compliance with VDE regulations? Safety is our top priority. The systems perform the following checks: - High-voltage test at 4.25 kV in accordance with VDE regulations - Protective conductor test using a current of 25 A - Residual Current Tests to Check Internal Circuit Breakers How is the safety of operating personnel ensured during high-voltage tests? MCD relies on multi-level safety concepts. These include special high-voltage adapters of the highest safety class, as well as an integrated high-voltage test hood that prevents direct contact during the testing process. Can the systems automatically install the firmware at the charging station? Yes, as part of the functional test (FKT), the corresponding firmware is programmed directly into the board’s processor. In addition, at the end of the EOL test, the specific production data is written to the unit under test. Are the wallbox's visual and audio components also tested? Yes, the system checks how the controls interact: - Acoustics: The buzzer signal is checked for correct frequency and proper operation using FFT spectrum analysis - Optics: The functionality of the LED strips is validated during the test sequence How is the system integrated into the existing production IT/database? The systems have a direct data connection (e.g., via SQL Toolmonitor). Process interlocks are triggered by barcode scans, and test specimen data is synchronized and documented in real time. Is the system ready for future model variants? By using interchangeable component solutions (e.g., the HV adapter) and modular software (TestManager CE), the systems can be adapted to new designs or future generations of charging stations with minimal effort. ![](https://mcd.site team.de/wp-content/uploads/2026/05/Multiple-Layers-1.webp) ## KEY FACTS ### Project Duration ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### From inquiry to delivery within 16 weeks ### Performance Class Coverage ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### from 3.6 to 22 kW ### Check with ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### 230V with HV adapter ### The entire project is integrated into two systems ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### both functional testing of circuit boards and end-of-line testing of fully assembled units ### Future-proof and adaptable ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### a wide variety of configurations thanks to interchangeable workpiece holders [DOWNLOAD TECHNICAL REPORT](https://mcd.site team.de/wp-content/uploads/2026/07/MCD_Elektronik-Presseartikel-wallbox_electro_mcd.pdf) The report describes the development of an EOL test system for Webasto charging stations by MCD Elektronik. The solution tests circuit boards and assembled devices fully automatically, with a development time of just 16 weeks. Key features include high safety standards (HV adapters), comprehensive functional tests, and flexible adaptation for future models. ## REFERENCE PROJECTS [![](https://mcd.site team.de/wp-content/uploads/2026/07/EnergyMeter_FCTEOLT_front-inklSpiegelung-scaled.png)](https://mcd.site team.de/en/industries/energy-management-smart-home/eolt-smart-dc-energy-meter/) EOLT smart dc energy meter [![](https://mcd.site team.de/wp-content/uploads/2026/06/5c94d7f52f9e125e677bdeb6f04cab87-1.png)](https://mcd.site team.de/en/industries/energy-management-smart-home/eolt-smart-meter-gateway/) EOLT smart meter gateway [![](https://mcd.site team.de/wp-content/uploads/2026/07/thermostat_PCBS-FKT_front-frei-clean-1024x1024.png)](https://mcd.site team.de/en/industries/energy-management-smart-home/fct-programming-and-testing-station-for-smart-home-systems/) FCT Programming & Testing Station for Smart Home Systems ![](https://mcd.site team.de/wp-content/uploads/2026/05/Multiple-Layers-1.webp)