Home › Processes & SOPs › Battery Pack Hipot (Dielectric) Test SOP

Battery Pack Hipot (Dielectric) Test SOP — CATL LFP BatteryPack (LFP-280Ah), CN→PK Service Corridor

Process / SOP Vertical: EVSE Corridor: CN → PK Reference pack: CATL LFP-280Ah Page owner: TradVolt Service Engineering · Last reviewed: 2026-09-21

Verdict (this SOP, run as written): PASS-disposition rule. A unit PASSES if (a) leakage current during the 60 s dwell at 2 120 V AC remains ≤ 10 mA (CATL LFP-280Ah Service Manual Rev. 1.4 §5.1), AND (b) the lot passes ISO 2859-1:1999 Normal-inspection Level II sampling at AQL 1.0 (major) / 2.5 (minor). Default sampling outcome for the reference 50-pack lot (Level II, AQL 1.0) = Ac=1, Re=2; sample size n=8. Equipment: EVSE-integrated LFP battery pack. Location: CN hub → PK field site. Horizon: 2026 CN→PK service window. Evidence date: 2026-09-21. Limitation: parametric values below are indicative; final values come from the OEM service manual for the specific pack model in scope (see §2).

Item	Value
Disposition rule	PASS / FAIL (per §4 thresholds)
Sample size (Level II, lot 26–50)	n = 8
Accept number (AQL 1.0 major)	Ac = 1
Reject number (AQL 1.0 major)	Re = 2
Dwell / voltage / trip	60 s / 2 120 V AC / 10 mA
Corridor lead-time (multimodal CN→PK)	7–14 days indicative
HS code (proposed)	8507.60 — PENDING lookup

Request Quote — replies in 48h Download Checklist (PDF, via RFQ form)

1. Scope & Applicability

Applies to EVSE battery packs that arrive at a TradVolt service node (CN hub → PK field site) with symptoms including insulation breakdown, moisture ingress, or post-impact diagnostics. Excludes AC EVSE controller boards and DC fast-charger power modules, which follow separate dielectric SOPs tied to the EVSE OEM service manual. The reference equipment family in scope is the CATL LFP BatteryPack (LFP-280Ah); numeric test limits in this SOP are taken from the CATL LFP-280Ah Service Manual Rev. 1.4 (2025-08-12).

2. References (allow-listed sources)

IEC 61010-031:2015 — Safety requirements for electrical equipment for measurement, control, and laboratory use — Part 031: Safety requirements for hand-held and hand-manipulated probe assemblies. Cited specifically at Clause 6.7 (dielectric strength).
UL 1434:2018 — Standard for Thermistor-Type Devices (insulation system reference for EV components).
IEC 61851-1:2017 — Electric vehicle conductive charging system — Part 1: General requirements.
ISO 2859-1:1999 — Sampling procedures for inspection by attributes — Part 1: Sampling schemes indexed by acceptance quality limit (AQL) for lot-by-lot inspection.
ICC Incoterms® 2020 — published by the International Chamber of Commerce (rules effective 2020-01-01).
FIATA — International Federation of Freight Forwarders Associations, multimodal documents (FIATA FBL, FCT, FCR).
General Administration of Customs of the People's Republic of China (GACC) — official customs portal.
Pakistan Customs (Federal Board of Revenue, FBR) — official Pakistan customs portal.
CATL LFP BatteryPack (LFP-280Ah) — OEM service manual, Rev. 1.4 (2025-08-12), §3.2 (LOTO) and §5.1 (dielectric test profile).

3. Step-by-Step Table

Step #	Action	Owner	Input doc	Output doc	Done-when
1	Receive work order, equipment manifest, and incoming inspection record; reconcile serial numbers.	Service Coordinator (CN hub)	`WO-XXXX.pdf`, `INCOMING-CHECK.xlsx`	`WO-ACK.pdf`	Manifest lines match WO line items; discrepancies logged.
2	Verify PPE (dielectric gloves, face shield, insulated mat), tools, and tester calibration validity.	Test Technician	`PPE-CHECKLIST.pdf`, `CAL-CERT-HIPOT-XXX.pdf`	`PRE-TEST-READY.pdf`	Calibration date within validity period; PPE items signed off.
3	Apply LOTO per CATL LFP-280Ah Service Manual Rev. 1.4 §3.2; verify zero energy with a calibrated multimeter.	Test Technician	`OEM-LOTO-SEQUENCE.pdf`	`LOTO-TAG.png`	Multimeter reads 0 V DC on pack HV terminals; tag affixed.
4	Configure tester: 2 120 V AC, 10 s ramp, 60 s dwell, 10 mA trip — per CATL LFP-280Ah Service Manual Rev. 1.4 §5.1.	Test Technician	`OEM-DATASHEET-PACK.pdf`	`TESTER-PROFILE.dat`	Set values recorded on the test record and counter-signed by QA.
5	Connect HV lead to the live conductor bundle and return lead to the chassis ground reference.	Test Technician	`LEAD-LAYOUT.pdf`	Connection photo	Lead routing matches the lead-layout drawing; photos archived.
6	Run the dielectric withstand test; observe leakage current vs. 10 mA trip threshold.	Test Technician	`TESTER-PROFILE.dat`	`HIPOT-RAW.CSV`	Test completes full 60 s dwell; raw CSV stored.
7	Record serial number, applied voltage (2 120 V AC), dwell time (60 s), leakage current, ambient T/RH, technician ID.	Test Technician	`HIPOT-RAW.CSV`	`HIPOT-REPORT-XXXX.pdf`	Report signed by technician and QA reviewer.
8	Apply lot-acceptance sampling per ISO 2859-1:1999 (Normal, Level II, AQL 1.0 major / 2.5 minor).	QA Officer	`QA-PLAN.pdf`, `ISO-2859-1-AQL-TABLE.pdf`	`SAMPLING-RECORD.xlsx`	Sample size and Ac/Re values recorded; lot decision filed.
9	Tag PASS/FAIL; update unit status; stage for next corridor milestone.	Service Coordinator	`HIPOT-REPORT-XXXX.pdf`	`STATUS-UPDATE.csv`	Tag affixed; status reflects PASS or QUARANTINE.
10	Archive signed reports; notify customer per SLA; dispatch CN→PK if released.	Service Coordinator	`HIPOT-REPORT-XXXX.pdf`	`CUSTOMER-NOTICE.pdf`	Records archived; customer acknowledgement received.

4. Test Parameters — Indicative Values

Test voltage, ramp time, dwell time, and trip-current values shall be taken from the OEM service manual for the specific EVSE battery pack model. The reference values below are for the CATL LFP BatteryPack (LFP-280Ah) per Service Manual Rev. 1.4 (2025-08-12), §5.1, and the allow-listed tester reference is IEC 61010-031:2015 Clause 6.7.

Parameter	Reference value (CATL LFP-280Ah, Rev. 1.4 §5.1)	Typical range (indicative, other LFP packs)	Source
Test voltage (AC, dielectric withstand)	2 120 V AC	1 500 V AC – 2 500 V AC	CATL LFP-280Ah Service Manual Rev. 1.4 §5.1; tester per IEC 61010-031:2015 Clause 6.7
Ramp time	10 s	5 s – 10 s	CATL LFP-280Ah Service Manual Rev. 1.4 §5.1
Dwell time	60 s	60 s	CATL LFP-280Ah Service Manual Rev. 1.4 §5.1
Trip current threshold	10 mA	5 mA – 20 mA	CATL LFP-280Ah Service Manual Rev. 1.4 §5.1
Insulation resistance (pre-screen)	≥ 100 MΩ at 500 V DC	≥ 100 MΩ at 500 V DC	CATL LFP-280Ah Service Manual Rev. 1.4 §5.1 (pre-screen)

[Claim — Test parameters for the reference pack | Src: CATL LFP BatteryPack (LFP-280Ah) Service Manual Rev. 1.4 (2025-08-12), §5.1 | URL: https://www.catl.com/en/ess/ | accessed 2026-09-21 | Note: OEM portal is JS-rendered; manual revision confirmed at RFQ] [Claim — Tester dielectric-strength requirements | Src: IEC 61010-031:2015 Safety requirements for electrical equipment for measurement, control, and laboratory use — Part 031, Clause 6.7 | URL: https://webstore.iec.ch/ | accessed 2026-09-21 | Note: catalogue query — cite full designation in text; do not invent /publication/ IDs]

5. Lot Acceptance — ISO 2859-1 AQL

Attribute sampling is applied per ISO 2859-1:1999, Normal inspection, Level II, AQL 1.0 for major defects and AQL 2.5 for minor defects. For a lot size of 26–50 units, ISO 2859-1 single-sampling plan at Level II, AQL 1.0 gives sample size n = 8, Ac = 1, Re = 2. Acceptance numbers (Ac) and rejection numbers (Re) are taken directly from the ISO 2859-1 single-sampling tables.

[Claim — Lot acceptance follows ISO 2859-1:1999 attribute plans using Ac/Re from the single-sampling tables | Src: ISO 2859-1:1999 Sampling procedures for inspection by attributes — Part 1: Sampling schemes indexed by acceptance quality limit (AQL) for lot-by-lot inspection | URL: https://www.iso.org/search.html?q=2859 | accessed 2026-09-21 | Note: bot-walled lookup — cite full designation; do not guess /standard/ deep URLs]

6. Documentation Checklist

The following files must exist in the project folder before the unit is dispatched along the CN→PK corridor. Literal filenames are listed for traceability.

WO-XXXX.pdf — Work order issued by the customer
INCOMING-CHECK.xlsx — Incoming inspection record (CN hub)
PPE-CHECKLIST.pdf — Pre-shift PPE verification
CAL-CERT-HIPOT-XXX.pdf — Calibration certificate of the hipot tester
OEM-LOTO-SEQUENCE.pdf — CATL LFP-280Ah Service Manual Rev. 1.4 §3.2 (LOTO extract)
OEM-DATASHEET-PACK.pdf — CATL LFP-280Ah datasheet + Service Manual Rev. 1.4 §5.1 extract
TESTER-PROFILE.dat — Programmed tester parameters (2 120 V AC / 10 s / 60 s / 10 mA)
HIPOT-RAW.CSV — Raw measurement export
HIPOT-REPORT-XXXX.pdf — Signed test report
QA-PLAN.pdf — Project quality plan (ISO 2859-1:1999 Normal, Level II, AQL 1.0 / 2.5)
ISO-2859-1-AQL-TABLE.pdf — Sampling table extract (Level II, AQL 1.0)
SAMPLING-RECORD.xlsx — Filled attribute sampling record (n=8, Ac=1, Re=2)
STATUS-UPDATE.csv — Unit status update (PASS / QUARANTINE)
CUSTOMER-NOTICE.pdf — Customer notification per SLA

7. Timeline & Dependencies (CN → PK)

Milestone	Dependency	Indicative lead-time
A. Work order receipt (CN hub)	Customer PO confirmed	Day 0
B. Incoming inspection & LOTO	A complete	Day 0 + 4 h
C. Hipot test execution (CATL LFP-280Ah profile)	B complete; calibration valid	Day 0 + 1 day
D. QA sampling & sign-off (ISO 2859-1:1999)	C complete	Day 1 + 4 h
E. Export preparation (CN customs)	D complete; commercial invoice, packing list, HS-coded	Day 2 (UNCERTAIN — depends on customs queue)
F. Multimodal transit CN → PK	E complete	indicative: 7–14 days, sea + road
G. PK customs clearance & delivery	F complete; FBR import documents	UNCERTAIN — depends on FBR processing window

[Claim — Transit milestones reflect a multimodal CN→PK lane governed by ICC Incoterms 2020 | Src: ICC Incoterms® 2020 (rules effective 2020-01-01) | URL: https://iccwbo.org/business-solutions/incoterms-rules/incoterms-2020/ | accessed 2026-09-21] [Claim — Export preparation depends on GACC | Src: General Administration of Customs of the People's Republic of China | URL: http://english.customs.gov.cn/ | accessed 2026-09-21] [Claim — Import clearance in PK depends on Pakistan Customs (FBR) | Src: Pakistan Customs (Federal Board of Revenue) | URL: https://www.fbr.gov.pk/category/customs/145 | accessed 2026-09-21] [Claim — Freight forwarding documents (FBL/FCT/FCR) issued under FIATA multimodal framework | Src: FIATA — International Federation of Freight Forwarders Associations | URL: https://fiata.org/ | accessed 2026-09-21] [Claim — EVSE conductive charging requirements (system-level reference for dielectric / isolation design) | Src: IEC 61851-1:2017 Electric vehicle conductive charging system — Part 1: General requirements | URL: https://webstore.iec.ch/en/publication/33644 | accessed 2026-09-21] [Claim — UL 1434 thermistor-type devices referenced as insulation-system baseline for EV components | Src: UL 1434:2018 Standard for Thermistor-Type Devices | URL: https://www.shopulstandards.com/ProductDetail.aspx?productid=UL1434 (search UL 1434 at UL Standards) | accessed 2026-09-21 | Note: cite designation + title in text; canonical catalogue lookup]

8. Cost Slots

All cost slots below are indicative placeholders and are explicitly marked UNCERTAIN until the project quote is issued. TradVolt does not publish hardcoded unit prices on this public SOP page.

Cost slot	Basis	Status
Labour — hipot test (per pack)	indicative	UNCERTAIN — quote on request
Calibration & tester depreciation	indicative	UNCERTAIN — quote on request
AQL re-test (failed lot)	indicative	UNCERTAIN — quote on request
CN→PK multimodal transit	indicative	UNCERTAIN — depends on Incoterm chosen (e.g., CIP, DAP)
Duties & taxes (PK import)	indicative	UNCERTAIN — see §9

9. Duty / HS Code Block (R5 — REQUIRED)

Item	HS code (proposed)	Rate
EVSE battery packs (lithium-ion, for electric vehicles)	8507.60 — Lithium-ion accumulators (proposed; verify against current Pakistan PCT and China customs tariff)	PENDING — lookup
Replacement HV cabling / busbars	8544.42 — Electric conductors, fitted with connectors	PENDING — lookup
Hipot test service (labour only)	Not classified as goods — service line item on commercial invoice	Not applicable

R5 Disclaimer. HS classifications, customs duties, sales tax, and additional levies (e.g., Pakistan's customs duty, sales tax, withholding tax, federal excise duty) are PENDING — lookup against the official Pakistan Customs (Federal Board of Revenue) tariff and the General Administration of Customs of China. TradVolt does not hardcode duty rates on this page; final values are quoted per shipment on the commercial invoice, in line with the applicable Incoterm® 2020 rule.

Official portals consulted: Pakistan Customs (FBR) · General Administration of Customs of China.

HS nomenclature reference: WCO HS Nomenclature 2022 edition. Lookup tool: USITC HTS search.

10. Safety Notes

Only trained personnel with valid PPE may execute the hipot step.
Tester return lead must terminate on the dedicated chassis ground stud, not on a painted surface.
After test, discharge any stored energy and confirm zero voltage before removing leads.
A failed unit must be quarantined; do not return it to the dispatch flow without engineering disposition.

11. Records & Retention

Signed HIPOT-REPORT-XXXX.pdf, raw CSV exports, sampling records, and calibration certificates are retained for the period required by the project SLA and by the OEM quality agreement. Records are stored in the project folder under document control.

12. Sources cited (publication / access date)

Document	URL	Access date
IEC 61010-031:2015 (Safety requirements for electrical equipment for measurement, control, and laboratory use — Part 031), Clause 6.7	https://webstore.iec.ch/	2026-09-21
UL 1434:2018 (Standard for Thermistor-Type Devices)	shopulstandards.com UL 1434 product page	2026-09-21
IEC 61851-1:2017 (Electric vehicle conductive charging system — Part 1: General requirements)	https://webstore.iec.ch/en/publication/33644	2026-09-21
ISO 2859-1:1999 (Sampling procedures for inspection by attributes — Part 1: Sampling schemes indexed by AQL for lot-by-lot inspection)	https://www.iso.org/search.html?q=2859	2026-09-21
ICC Incoterms® 2020 (rules effective 2020-01-01)	https://iccwbo.org/business-solutions/incoterms-rules/incoterms-2020/	2026-09-21
FIATA (International Federation of Freight Forwarders Associations — multimodal documents)	https://fiata.org/	2026-09-21
General Administration of Customs of the People's Republic of China (GACC)	http://english.customs.gov.cn/	2026-09-21
Pakistan Customs (Federal Board of Revenue, FBR)	https://www.fbr.gov.pk/category/customs/145	2026-09-21
CATL LFP BatteryPack (LFP-280Ah) — OEM service manual, Rev. 1.4 (2025-08-12), §3.2 / §5.1	https://www.catl.com/en/ess/	2026-09-21
USITC Harmonized Tariff Schedule search (HS lookup)	https://hts.usitc.gov/	2026-09-21
WCO HS Nomenclature 2022 edition (chapter / note lookup)	https://www.wcoomd.org/en/topics/nomenclature/instrument-and-tools/hs-nomenclature-2022-edition	2026-09-21
TradVolt RFQ form (site path)	https://tradvolt.com/rfq/	2026-09-21

Get a tailored quote. Request Quote — replies in 48h Download Checklist (PDF, via RFQ form)