Standard Operating Procedure · Tradvolt Process Library · Vertical: LFP-battery DC fast charging · Doc ID: TRD-SOP-EVSE-CCS2-014 · Rev. 2.1
This document defines the on-site inspection procedure for connector pin wear on liquid-cooled and air-cooled CCS2 charging connectors assembled in the People's Republic of China and imported into the Republic of Poland under DAP Incoterms® 2020 terms. It applies to EVSE units specified for LFP (LiFePO₄) battery-electric vehicles in the B2B fleet and depot-charging segment.
| # | Standard / Doc | Use in this SOP |
|---|---|---|
| 1 | IEC 62196-3:2022 — Plugs, socket-outlets, vehicle connectors and vehicle inlets — Conductive charging of electric vehicles — Part 3: Dimensional compatibility and interchangeability requirements for DC and AC/DC pin and contact-tube vehicle couplers | Geometry, pin tolerances, mating cycle requirements |
| 2 | IEC 61851-1:2017 — Electric vehicle conductive charging system — Part 1: General requirements | EVSE overall safety, pilot function |
| 3 | ISO 2859-1:1999 — Sampling procedures for inspection by attributes — Single sampling plans by AQL | Lot acceptance sampling |
| 4 | UL 2251 (Ed. 4) — Standard for Plugs, Receptacles, and Couplers for Electric Vehicles | Reference for North-American-style couplers — informational only |
| 5 | CE — REGULATION (EU) 2023/814 (LVD) and Directive 2014/35/EU referenced text | CE marking verification |
| 6 | ICC Incoterms® 2020 | DAP (Delivered at Place) hand-over terms |
| 7 | FIATA — Multimodal Transport Document (MTD) guidance, 2022 edition | House bill, combined transport reference |
| 8 | Polish National Revenue Administration — Customs Unified Computer System (CUCS) / PUE CELINA portal | HS classification, duty / VAT lookup |
| Step # | Action | Owner | Input doc | Output doc | Done-when |
|---|---|---|---|---|---|
| 3.1 | Triage commercial file and verify HS code 8537.11.000 matches declared goods. | Customs broker | Commercial invoice, packing list | HS-classification checklist | HS line item confirmed on PUE CELINA portal print-out.[8] |
| 3.2 | Don ESD wrist strap (1 MΩ), nitrile gloves, safety glasses; verify strap continuity. | QA inspector | Toolbox checklist | PPE sign-off sheet | Strap test passes at 0.8–1.2 MΩ. |
| 3.3 | Open IP54 cabinet, de-energise DC bus, wait 5 min for capacitor discharge. | QA inspector + OEM-trained technician | OEM service manual lockout-tagout page | LOTO ticket | Bus voltage reads < 5 V DC on calibrated DMM. |
| 3.4 | Visual inspection of CCS2 DC pins (DC+, DC−, PE, CP, PP) under 10× magnification. | QA inspector | OEM wear-limit reference card | Visual inspection sheet | No pitting, burn marks, plating loss, or debris observed.[1] |
| 3.5 | Measure contact-pin diameter with pin gauge; record against OEM nominal (e.g. 8.0 mm DC, 6.0 mm PE). | QA inspector | OEM datasheet, pin gauge set | Dimensional record | All pins within ±0.05 mm of nominal tolerance. |
| 3.6 | Review last 30 days of charging-session thermal log; flag any contact event > 90 °C peak. | QA inspector | OEM telematics CSV export | Thermal-review memo | Thermal flags reviewed and commented; OR raise NCR if > 90 °C.[2] |
| 3.7 | Apply ISO 2859-1 General Inspection Level II, AQL 1.0 (major) / 4.0 (minor) to the lot. | QA inspector + QA manager | Lot size table | AQL sample-size sheet | Sample size per lot size recorded; Ac/Re numbers documented.[3] |
| 3.8 | Functional lock-test with reference EV simulator: verify CP/PP pilot, interlock, latch current. | QA inspector | EV simulator, OEM hand-shake matrix | Lock-test report | Pilot ratio 4.0 V / 6.0 V / 9.0 V sequence passes; latch < 100 ms.[2] |
| 3.9 | Insulation-resistance test 500 V DC between DC+ and PE for ≥ 60 s. | QA inspector | Megohmmeter (500 V DC) | IR test record | Reading ≥ 1 MΩ recorded; < 1 MΩ → NCR.[2] |
| 3.10 | Non-conformance tagging and segregation if any defect above. | QA inspector | Red RFID tag, NCR form | NCR (Non-Conformance Report) | Failed units physically moved to bonded NCR zone; RFID linked to NCR ID. |
| 3.11 | Decide routing: OEM-authorised pin-set replacement (minor) vs. RTV (major / functional failure) per DAP 2020 risk transfer. | QA manager + client | NCR, OEM RMA form, DAP clause ref. | Disposition note | Disposition signed by client; RMA or RTV booked.[6] |
| 3.12 | Close-out: upload signed report to Tradvolt DMS, archive CMR / MTD reference, notify client, hand off next-shipment RFQ. | Account manager | Inspection report PDF | DMS archive + RFQ ticket | DMS entry timestamped; client email confirmed; RFQ counter incremented. |
| Parameter | Acceptance | Reference |
|---|---|---|
| DC pin diameter (8.0 mm) | 7.95 – 8.05 mm | IEC 62196-3 + OEM datasheet[1] |
| PE pin diameter (6.0 mm) | 5.95 – 6.05 mm | IEC 62196-3[1] |
| Mating cycles (DC contacts) | ≥ 10 000 no-load cycles before refurbish | IEC 62196-3[1] |
| Insulation resistance (500 V DC) | ≥ 1 MΩ | IEC 61851-1[2] |
| Peak contact temperature | < 90 °C at rated current | IEC 62196-3[1] |
| Lot sampling plan | ISO 2859-1 Level II, AQL 1.0 / 4.0 | ISO 2859-1[3] |
| Phase | Activity | Depends on | Indicative duration |
|---|---|---|---|
| T-72 h | Document triage (Step 3.1) | Commercial file receipt | 2 h |
| T-48 h | Toolbox prep + PPE check (Step 3.2) | — | 0.5 h |
| Gate-in | LOTO + cabinet open (Step 3.3) | Container sealed, escort present | 0.5 h |
| Gate-in +2 h | Visual + dimensional (Steps 3.4–3.5) | Step 3.3 complete | 1.5 h per unit |
| Gate-in +3 h | Thermal log review (Step 3.6) | Telematics export available | 0.5 h |
| Gate-in +4 h | AQL sampling (Step 3.7) | Lot size finalised | 0.5 h |
| Gate-in +5 h | Functional + IR test (Steps 3.8–3.9) | Test rig free | 1 h per unit |
| Gate-in +6 h | NCR / disposition (Steps 3.10–3.11) | Any prior NCRs | 1 h |
| Gate-in +8 h | Close-out + RFQ hand-off (Step 3.12) | Client sign-off | 0.5 h |
All amounts shown are indicative — UNCERTAIN pending current supplier quotation, FX rate, and container dwell. They are not a commercial offer.
| Cost line | Indicative value | Note |
|---|---|---|
| Third-party QA inspector, day rate (Poland) | indicative — UNCERTAIN | Confirm with current quotation |
| Bonded warehouse fee, per pallet-day | indicative — UNCERTAIN | Operator-specific |
| Re-issue CE DoC administrative fee | indicative — UNCERTAIN | Only if documents missing |
| OEM pin-set replacement kit | indicative — UNCERTAIN | OEM pricing on request |
| RMA logistics back to CN | indicative — UNCERTAIN | Per Incoterms 2020 routing |
HS classification reference (lookup only — no rates hardcoded).
| HS code (equipment) | 8537.11.000 — Boards, panels, consoles, desks, cabinets and other bases, equipped with two or more apparatus of heading 8535 or 8536, for electric control or distribution of voltages not exceeding 1 000 V — For voltages not exceeding 1 000 V — Numerical control panels |
| HS code (parts) | 8538.90.99 — Other parts suitable for use solely or principally with the apparatus of heading 8537 |
| Import duty rate | PENDING — lookup on Polish CUCS / PUE CELINA portal[8] |
| VAT rate | PENDING — lookup on Polish CUCS / PUE CELINA portal[8] |
| Authoritative portal | Polish National Revenue Administration — Customs Unified Computer System (CUCS) — PUE CELINA e-Customs service. URL: https://puecelina.mf.gov.pl/[8] |
| EU TARIC cross-check | European Commission — Taxation and Customs Union, TARIC consultation. URL: https://ec.europa.eu/taxation_customs/dds2/taric/ |
Disclaimer: Tradvolt does not provide legal or fiscal advice. Duty and VAT rates, exemptions, and binding classification rulings must be confirmed with a licensed customs broker or directly with the Polish National Revenue Administration before each shipment. All values marked PENDING — lookup must be replaced with the broker-confirmed figure on the day of customs clearance.
Files referenced by this SOP. Confirm receipt of each before gate-in.
| # | Filename (literal) | Purpose | Source |
|---|---|---|---|
| D-01 | TRD-SOP-EVSE-CCS2-014_Rev2_1.pdf | This SOP, controlled copy | Tradvolt DMS |
| D-02 | OEM_CCS2_PinWear_ReferenceCard.pdf | Pin tolerances, OEM wear limits | OEM service manual |
| D-03 | IEC_62196-3_2022_Extract.pdf | Geometry and mating cycle clauses | IEC (licensed copy) |
| D-04 | ISO_2859-1_Level_II_Table.xlsx | AQL sample-size calculator | Tradvolt QA team |
| D-05 | FIATA_MTD_Template_2022.pdf | Multimodal transport doc reference | FIATA |
| D-06 | Incoterms_2020_DAP_Excerpt.pdf | DAP clause text | ICC |
| D-07 | PUE_CELINA_HS_Lookup_2026-09.pdf | Polish customs portal print-out | Polish NRA |
| D-08 | Tradvolt_InspectionReport_Template.docx | Report template | Tradvolt DMS |
| D-09 | Tradvolt_NCR_Form_v3.pdf | Non-conformance report | Tradvolt DMS |
| D-10 | Tradvolt_QC_Checklist_CCS2.pdf | On-site pocket checklist | Tradvolt DMS |
This SOP is reviewed every 12 months, or immediately after any of: change to IEC 62196-3, change to Polish HS classification for 8537.11.000, or change to OEM service-manual wear limits. Revision history is held in the Tradvolt DMS under document ID TRD-SOP-EVSE-CCS2-014.
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