Use this AC charger commissioning checklist to verify pre-start safety and performance. It covers electrical, mechanical, software, and documentation checks. Follow the numbered steps to ensure new EV charging equipment is ready for daily service without fault codes or safety risks.
- Verify the electrical connection and protective earth before applying power to the AC charger.
- Confirm that the unit communicates correctly with the vehicle and that the charging session initiates.
- Check mechanical integrity of the housing, cable, connector, and mounting hardware.
- Review all documentation, including commissioning records, warranty cards, and user manuals.
- Log any anomalies during the first charging sessions to catch intermittent faults early.
Why Pre-Start Checks Matter for AC Chargers
An AC charger commissioning process is the bridge between installation and daily operation. Skipping this step often leads to minor faults that become major downtime events. A unit may pass a basic power-on test but fail under real load or weather conditions.
The goal of the commissioning checklist is simple. Confirm that the charger is safe for people, safe for the vehicle, and ready to handle the expected number of charging sessions. This includes verifying the electrical supply, the mechanical assembly, and the software configuration.
Electrical Safety and Supply Verification
The electrical side of the charger determines both safety and performance. Start by confirming that the supply voltage matches the charger’s rated input. For a single-phase unit, this often means verifying the live and neutral conductors. For a three-phase unit, you must check the phase sequence and balance.
Use a calibrated multimeter to measure the voltage at the terminal block. Record the reading for each phase. The values should stay within the manufacturer’s specified tolerance. If the supply is unstable or the phases are unbalanced, the charger may trip its internal protection circuits or damage the internal power electronics.
Next, verify the protective earth connection. The earth pin on the connector and the chassis ground must be solid. A weak earth connection is one of the most common causes of contact protection failures. Touch the earth terminal with the multimeter probe while the charger is powered. You should see a solid connection to the building earth bar.
Check the circuit breaker and the residual current device. The RCD should test correctly. Press the test button and confirm that the charger trips or isolates as expected. If the RCD is missing or not functioning, the charger must not be energized.
Finally, inspect the cable insulation. Look for any cuts, abrasions, or exposed conductors. The cable should be routed away from heat sources and sharp edges. Secure the cable with clamps or trays so it does not sag or pull on the terminal block.
Mechanical Integrity and Housing Checks
The mechanical assembly protects the internal electronics from dust, moisture, and physical impact. Examine the housing for any cracks, dents, or loose panels. A cracked cover can let water into the unit, even if the ingress protection rating is high.
Check the mounting hardware. The wall box or pillar unit should be fixed securely. Tighten all bolts and screws. Verify that the mounting plate is level and that the unit sits flush against the wall or pillar.
Inspect the cable and connector. The cable should be of the length specified in the project design. It should not be kinked or stretched. The connector should be clean and free of debris. Check the latches on the connector. They should engage firmly when the plug is inserted and release cleanly when removed.
If the charger has a built-in display or buttons, test them now. Press each button and confirm that the display responds. Check the screen for any error codes or dim areas. A failing display can make troubleshooting much harder later.
Communication and Software Configuration
An AC charger is not just a power supply. It is a smart device that needs to talk to the vehicle and often to a cloud platform. Verify that the charger is powered on and that the display shows the correct status. Look for a ready icon or a green light.
Connect a vehicle to the charger. The vehicle should detect the charger. This may take a few seconds. If the vehicle does not recognize the charger, check the cable. A loose connector or a damaged data pin can prevent communication.
Once the vehicle is connected, initiate a charging session. The charger should start delivering power. The display should show the current and voltage. The vehicle’s screen should show that charging has begun.
Check the cloud platform or local management system. The charger should appear as online and ready. Verify that the unit ID is correct. If the charger is not showing up, check the network connection. For Wi-Fi units, confirm the signal strength. For Ethernet units, check the cable and the switch port.
Review the configuration parameters. The maximum current setting should match the site design. If the charger is set to 16 A but the installation is designed for 32 A, it will underperform. If it is set higher than the supply can handle, it will trip the breaker.
Pre-Start Performance and Load Testing
A charger that looks healthy on a power-on test may still have issues under load. Perform a load test using a vehicle or a simulated load. Drive the vehicle to a low state of charge if possible. Connect the charger and start a session.
Monitor the current drawn. It should be stable. If the current drops or fluctuates, there may be a loose connection or a failing component. Check the temperature of the terminals. They should not get too hot. Use an infrared thermometer if available.
Run the RCD test again under load. Some chargers have a self-test feature that runs this automatically. If not, do it manually. The charger should isolate the supply if it detects a fault.
Check the charging protocol. The charger and vehicle should negotiate the correct power level. For an 11 kW unit, this means 16 A at 230 V. For a 22 kW unit, this means 32 A at 230 V. If the negotiation fails, the vehicle may not charge or may charge at a reduced rate.
Documentation and Handover
Before you hand the charger over to the end user, complete the documentation. This includes the commissioning report, the warranty card, and the user manual. The commissioning report should record the date, the installer’s name, and the results of each check.
Attach the warranty card to the charger or provide it in the handover folder. Note the start date of the warranty. Many manufacturers require the warranty to be registered within a specific period after installation.
Provide the user manual. For a public site, this might be a QR code on the charger that links to the manual. For a private home, it might be a printed copy in a folder. Ensure that the manual is in the language used by the end user.
Create a maintenance schedule. AC chargers need periodic checks. Inspect the cable and connector every six months. Check the housing and mounting hardware annually. Replace the RCD test log if required by local regulations.
Red Flags and When to Stop
Stop the commissioning process if you see any of the following. A loose or missing earth connection is a stop sign. Do not energize the charger until it is fixed.
A burnt smell or visible smoke is a stop sign. Power down the unit and isolate the supply. Do not attempt to restart it.
An error code that persists after a power cycle is a stop sign. Record the code and contact the manufacturer. Do not put the charger into service until the fault is resolved.
A cable that is cut, cracked, or exposed is a stop sign. Replace the cable. Do not use electrical tape as a temporary fix.
If any of these issues are found, the charger is not ready for service. Fix the problem first. Then repeat the commissioning checklist from the affected section.
Sample Commissioning Record
Use this table to record your checks. Keep it with the other documentation. It provides a clear record of what was done and what was found.
| Check Item | Expected Result | Actual Result | Pass/Fail |
|---|---|---|---|
| Supply Voltage | Within rated tolerance | ||
| Protective Earth | Solid connection | ||
| RCD Test | Trips correctly | ||
| Housing Integrity | No cracks or dents | ||
| Cable Condition | No cuts or abrasions | ||
| Vehicle Communication | Charger detected | ||
| Cloud Status | Online and ready | ||
| Load Test | Stable current |
Final Notes on AC Charger Commissioning
A thorough AC charger commissioning process is not just a formality. It is a safety measure and a performance guarantee. By following this checklist, you ensure that the charger is safe, functional, and ready for the long term.
Keep the checklist accessible. Share it with your installation team. Make it part of the standard handover procedure. This reduces errors and improves the quality of your installations.
If you find a fault during the first few weeks of service, refer back to this checklist. It will help you identify the problem quickly. A well-documented commissioning process is your best tool for troubleshooting.
Frequently asked questions
What is the first thing to check during AC charger commissioning?
Verify the protective earth connection. A solid earth connection is critical for safety and for the charger to operate correctly.
How do I test the RCD on an AC charger?
Press the test button on the RCD. The charger should isolate the supply. If it does not trip, the RCD is faulty and must be replaced.
What should I do if the charger does not appear in the cloud platform?
Check the network connection. For Wi-Fi units, verify the signal strength. For Ethernet units, check the cable and the switch port.
How often should I inspect the AC charger?
Inspect the cable and connector every six months. Check the housing and mounting hardware annually. Follow any specific recommendations in the manufacturer's manual.
Can I use a temporary fix for a damaged cable?
No. A damaged cable must be replaced. Do not use electrical tape or any other temporary fix. A proper repair or replacement is required.
