CCS2 DC Fast Charger Testing: Interface, PLC and Load Planning

Define the CCS2 charger and communication scope

Record the charger model, firmware, Combo 2 connector rating and target market before choosing test equipment. CCS2 identifies the physical charging system, but it does not by itself define every communication version, optional function or acceptance limit required by a project.

List whether the work covers basic connection and startup, DIN SPEC 70121 behavior, a specific part and edition of ISO 15118, interoperability diagnosis or a formal conformance program. The tester, PLC module and test cases must support the same protocol scope as the charger under test.

• ✓ Confirm Combo 2 connection and cable rating
• ✓ Name the protocol and edition in scope
• ✓ Record charger firmware and configured options

Separate communication from high-power loading

The vehicle simulator establishes pilot and high-level communication states, while the external load or laboratory power system absorbs charger output. Verify the tester connection limit separately from the load voltage, current, continuous power, cooling and facility requirements.

Plan normal startup, requested-current changes, charging stop and protective shutdown before applying high power. Synchronize protocol messages, pilot state, voltage, current and load demand so a failed sequence can be traced to communication, power conversion or the test setup.

Retain evidence for diagnosis and comparison

Save the charger configuration, tester configuration, message trace, key waveform or measured values and result rule for every test. A communication trace without electrical timing can miss contactor or output behavior, while electrical data without the message sequence can hide the reason for a charger decision.

Start with one known-good reference session and one controlled fault. Review the final completed state and the first divergence between sessions before expanding the campaign to boundary conditions or repeated interoperability tests.

• ✓ Capture PLC messages and pilot state
• ✓ Record synchronized voltage and current
• ✓ Keep a known-good reference session