# EOLT Smart DC Energy Meter > Source: https://mcd.site team.de/en/industries/energy-management-smart-home/eolt-smart-dc-energy-meter/ > Last updated: 2026-10-01 --- END-OF-LINE-TESTER FOR # smarte DC Energy Meter [Learn More](#) ![](https://mcd.site team.de/wp-content/uploads/2026/06/303eeceb60559229cdd7b3da7dacf86e-1.webp) ## The e-mobility market will require about one million charging stations by 2030. To ensure that DC energy meters for charging stations operate accurately and in compliance with metrology regulations, MCD Elektronik developed a modular test system for the comprehensive testing and verification of the devices. ## Challenges and Concept ![](https://mcd.site team.de/wp-content/uploads/2026/07/EnergyMeter_FCTEOLT_SpulenSensoren-scaled.png) ![](https://mcd.site team.de/wp-content/uploads/2026/06/Group_30131.svg) The modular test system was developed in close technical coordination with the customer and in parallel with the product development of the DC Energy Meter, following the principle of simultaneous engineering. A major challenge was the precise generation, regulation, and measurement of currents up to 1,500 A and voltages up to 1,000 V. An accuracy of ±0.1% had to be guaranteed across the entire test range. In addition, full compliance with the requirements of German calibration law and the European MID Directive was necessary to validate the use of the DC Energy Meter for legally compliant billing at public charging stations. MCD Elektronik used the universal VTS-2030 platform as the basis for the test system. A fully isolated test chamber, combined with two contact units designed specifically for this application, enables the synchronous testing of two test specimens, thereby increasing the production line’s throughput. Bidirectional four-quadrant power supplies replicate various operating states of the DC energy meter and allow for the simulation of real-world charging and discharging processes, including the reversal of current flow direction. To ensure the safe execution of high-power tests, the system features an integrated safety chain with high-performance high-current contactors, as well as monitoring of voltage drops and temperatures at the contact points. The MCD TestSuite controls and monitors the entire test sequence. This includes the parameterization of the test specimen, the automated execution and evaluation of the measurement sequences, as well as complete, legally compliant test reporting (MES integration) and the final label printing. ## Scope of Testing and Functionality ![](https://mcd.site team.de/wp-content/uploads/2026/07/EnergyMeter_FCTEOLT_DUT-Einlage-1024x683.png) ![](https://mcd.site team.de/wp-content/uploads/2026/06/Group_30131.svg) The scope of testing and functionality covers all relevant test, measurement, and process steps for the reliable EOL validation of the DC energy meters. - Parameterization & Communication: Writing test-specification-specific parameter sets and performing communication tests via an RS-485 interface - Electrical Calibration: Precise calibration and testing of direct current up to 1,500 A and direct voltage up to 1,000 V. - Verification of energy quantity: Calibration of the measured energy against a high-precision reference meter, maintaining a tolerance of ±0.1%. - Simulation of charging cycles: Reversing the current direction using 4-quadrant power supplies to realistically simulate charging and discharging processes. - Haptic and Response Test: Automated actuation of buttons on the test specimen and software-based evaluation of the corresponding system response. - Monitoring the voltage drop across the high-current contacts to monitor the contact resistance. - System Integration & Documentation: Integration with manufacturing execution systems (MES), as well as automated logging and printing of nameplates or error labels. - User Guidance: Software-based workflows guide users safely through the testing process ## Test Methods Used and Challenges ![](https://mcd.site team.de/wp-content/uploads/2026/06/Group_30132.svg) The system development placed high demands on power electronics, measurement technology, operational safety, and regulatory compliance, and required application-specific technical solutions: - Simultaneous Engineering: The development of the test system and the customer's product development took place in parallel. - Wide measurement and power range: Testing of DC energy meters covers direct currents ranging from the milliampere range up to 1,500 A, as well as direct voltages up to 1,000 V. This wide operating range places high demands on the current and voltage supply and on the precision of the measurement hardware used. - Regulatory Compliance: The testing system had to meet all requirements of German metrology law and the European MID Directive and provide reproducible evidence of compliance. This forms the basis for the use of DC Energy Meters in legally compliant billing. - Scalability: An expandable architecture was incorporated into the system design from the outset to ensure that the test system could be flexibly adapted to future current and voltage classes as well as new product variants. - Compact Design: By using the VTS2030 platform, the test system was designed to be compact. Testing two devices in parallel increases throughput and reduces cycle time in production. Test Methods Used MCD Elektronik has integrated electrical and mechatronic test procedures into a single test system. All tests are automatically controlled and evaluated by the MCD TestSuite: - 4-quadrant simulation: Use of power supplies that function as both sources and sinks to simulate charging and discharging cycles by reversing the current direction. - Dual Test Procedure: Simultaneous testing of two test specimens in a fully insulated test chamber to reduce cycle times. - Precision Monitoring: Continuous monitoring of contact resistance by measuring the voltage drop directly at the high-current contact points. - Two-path current measurement: Use of special paths with and without current transformers to accurately measure both very small currents and high currents. - Haptic and response tests: Automated activation of device buttons, including verification of system-generated feedback. - Software Integration: Integration of customer-specific software for the automated validation of OCMF data sets. - Guided Operating Procedures: Software-guided and monitored process flows in the MCD TestSuite minimize operating errors and ensure safe operation in high-current applications. ![](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 Does the system comply with the requirements of German calibration law? Yes. A key requirement during development was ensuring compliance with calibration laws and the European Measuring Instruments Directive (MID). The system enables precise calibration and verification, which are essential for legally compliant billing at public charging stations. What are the maximum current and voltage levels that can be tested? The system is designed for high-performance applications. It enables the calibration and testing of currents up to 1,500 A DC and voltages up to 1,000 VDC. Thanks to an integrated current transformer, both very small and extremely large currents can be measured with precision. How accurate is the system's measurement? The amount of energy is verified at specified measurement points with extremely high precision. The system maintains tolerances of ±0.1% across the entire current and voltage range. Can different loading and unloading scenarios be simulated? a. By using 4-quadrant power supplies, which can function as both a power source and a load (sink), the direction of current flow can be flexibly reversed. This allows for the precise simulation of real-world charging and discharging cycles of electric vehicles. How is safety ensured at such high currents? Safety is a central component of the design. The system employs an explicit safety concept with high-current contactors to safely switch on currents exceeding 1,500 A. In addition, the contact resistance at the connection points is continuously monitored by measuring the voltage drop to prevent overheating. What are the benefits of this solution? Safety is a central component of the design. The system employs an explicit safety concept with high-current contactors to safely switch on currents exceeding 1,500 A. In addition, the contact resistance at the connection points is continuously monitored by measuring the voltage drop to prevent overheating. Is the system suitable for mass production (end-of-line)? Yes. While testing often begins in the lab, this system is specifically designed as an end-of-line (EOL) system. The dual testing process—that is, the simultaneous testing of two test items—significantly reduces production cycle times. How is the system integrated with my existing IT infrastructure? The system offers comprehensive connectivity. It can be connected to manufacturing execution systems (MES), measurement databases, and OCMF servers via custom middleware. This enables the automated transfer of billing data to a ticketing system. Can the system handle different product variants? The test system is highly flexible. It automatically adapts to different performance variants of the smart meters, loads the corresponding test parameters, and prints the appropriate customer or type label once the test has been passed. ![](https://mcd.site team.de/wp-content/uploads/2026/05/Multiple-Layers-1.webp) ## KEY FACTS Electrical Limits & Precision ### Maximum test current ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### Up to 1,500 A DC ### Maximum test voltage ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### Up to 1,000 VDC ### Measurement Accuracy ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### Compliance with tolerances of ±0.1% across the entire current and voltage range ### Current Paths ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### Dual-path design (with/without current transformers) for precise measurement of both small and large currents System Capacity & Efficiency ### Dual Examination ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### Simultaneous testing of two test specimens in a test chamber to optimize cycle time. ### Four-quadrant operation ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### Use of 4-quadrant power supplies that function as both a source and a sink (load). ### Contact density ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### 4-sided connectors for high current, high voltage, communication, power supply, and programming. Standards & Compliance ### Regulatory Framework ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### Full compliance with German calibration laws and the European MID (Measurement Instruments Directive) ### Platform History ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### Based on the VTS 2030 platform, which has been in use for high-end systems since 2017 ### Communication Standard ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### Verification of Data Transmission Infrastructure Forecasts (Context) ### Vehicle Fleet ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### Forecast of up to 11 million electric vehicles in Germany by 2030 ### Charging Infrastructure ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### Necessary expansion to up to 1 million charging points by 2030 (as of early 2026: approximately 194,000) [DOWNLOAD Application Note](https://mcd.site team.de/wp-content/uploads/2026/07/MCD_Elektronik-ApplicationNote_EnergyMeter-DE-f.pdf) The application report describes the transformation of a laboratory test station into an automated end-of-line test system for smart DC energy meters, which ensures compliance with metrology regulations for electric vehicle charging stations through precise calibration (±0.1%) and middleware integration. [DOWNLOAD Technical Report](https://mcd.site team.de/wp-content/uploads/2026/07/MCD-Elektronik_fachartikel_hanser-automotive_eolt-smartenergymeters.pdf) The technical report in HANSER automotive 03/2026 describes a modular end-of-line test system for DC energy meters in electric vehicle charging stations that, using a dual test method based on the VTS-2030 standard, enables compliance with metrology regulations, testing up to 1,500 A, and reduced cycle times. ## REFERENCE PROJECTS [![](https://mcd.site team.de/wp-content/uploads/2026/07/thermostat_PCBS-FKT_front-frei-clean-scaled.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/2026/06/5c94d7f52f9e125e677bdeb6f04cab87-1.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/2026/07/2018_Wallbox-front-FKT-2-904x1024.jpg)](https://mcd.site team.de/en/industries/energy-management-smart-home/eolt-for-electric-wall-mounted-charging-station/) EOLT for Electric Wall Charging Statio ![](https://mcd.site team.de/wp-content/uploads/2026/05/Multiple-Layers-1.webp)