Domestic EVSE units across Bengaluru, Pune, and NCR routinely face neutral shifts, brownouts, and 440V phase-to-phase transients. We evaluate pilot signal compliance, relay coil saturation, and varistor degradation against IEC 61851 parameters to isolate thermal decay before it compromises vehicle onboard chargers.
Every incoming unit undergoes non-destructive insulation resistance testing at 1000V DC followed by pilot line duty-cycle validation. Components showing elevated ESR or contact oxidation are replaced with rated industrial switchgear rather than temporary jumper work, ensuring multi-year stability.
Every restored unit is sustained at full rated current before release.
No charger leaves the workbench after a simple continuity check. We load every repaired 7.4kW and 22kW system for four continuous hours to verify thermal dissipation across relay terminals and terminal blocks.
Certified bench hardware
Programmable AC active load banks
Simulates continuous 32A and 63A vehicle draw with dynamic resistance adjustments to verify contactor resistance, thermal rise, and breaker trip curves under simulated peak summer conditions.
Isolated digital storage oscilloscopes
Captures microsecond PWM communication waveforms on control pilot pins to diagnose vehicle handshake failures, ground-fault interrupt timing, and logic-side optocoupler drift.
Temperature-controlled micro-soldering station
Enables multi-layer PCB micro-soldering for surface-mount microcontrollers, high-current shunt resistors, and replacement flyback transformer coils without thermal shock to adjacent silicon.