Tradvolt > Process / SOP > Crimp QC (CN→GH, EVSE)
Verdict (decision this SOP enables): A lot of GB/T 20234.2-2015 DC charging cable assemblies (model family: Star Charge FlexDC 1000V 125A liquid-cooled cable, terminated with GB/T 20234.3 DC 125A vehicle and supply couplers) is released for export from Shenzhen to Tema only when every sampled crimp passes UL 486A-486B pull-force, the assembly withstands a 2.5 kV AC / 60 s hipot per IEC 61851-1:2017 Clause 11.4, and the licensed broker signs HS 8544.42 / 8538.90 against the live Ghana Revenue Authority GICIS tariff. Go-criterion: zero critical defects at AQL 1.0 (ISO 2859-1 Normal Level II) + broker-signed HS sheet + SAD reference issued. No-go: any hipot breakdown or pull-force below UL 486A-486B Table 12 minimum for the conductor size. Equipment: GB/T 20234.2-2015 / GB/T 20234.3 DC 125A charging cable set; sample products include Star Charge FlexDC 1000V 125A liquid-cooled charging cable (datasheet Rev. 2024-03). Location: Tradvolt QC staging, Shenzhen (also staged in Ningbo or Shanghai on request). Horizon: D0–D4, total 5 working days. Evidence date: 2026-09-21. Limitation: duty rates, VAT, NHIL and ECOWAS levy are not hardcoded and must be re-queried on GICIS at clearance; non-GB/T connector families (CCS2, NACS, CHAdeMO) are out of scope unless the OEM manual and revision are re-attached.
| Question | Decision | Source / evidence |
|---|---|---|
| Go or no-go for a lot | Go = 0 critical defects at AQL 1.0, ISO 2859-1 Level II, all hipot & pull-force pass | ISO 2859-1:1999 — https://www.iso.org/standard/114483.html |
| Hipot test voltage / time | 2.5 kV AC for 60 s, no breakdown | IEC 61851-1:2017 Clause 11.4 — https://webstore.iec.ch/publication/70323 |
| Pull-force minimum (50 mm² Cu) | ≥ 2 800 N (UL 486A-486B Table 12) | UL 486A-486B — https://www.shopulstandards.com/ProductDetail.aspx?UniqueKey=35225 |
| HS code (cable assembly) | 8544.42 — confirm at clearance on GICIS | EUR-Lex TARIC & GRA GICIS portal |
| HS code (crimped contacts) | 8538.90 — confirm at clearance on GICIS | USITC HTS — https://hts.usitc.gov/?query=8538.90 |
| Total SOP horizon | 5 working days (D0 → D4) | Tradvolt internal cycle, Rev. 2026-09-21 |
Document type: Process / SOP | Vertical: EVSE (GB/T 20234.2-2015 DC) | Corridor: China → Ghana | Revision: 2026-09-21
This SOP governs crimp quality control on GB/T 20234.2-2015 DC charging cable assemblies fitted with GB/T 20234.3 DC 125 A vehicle couplers and supply plugs (cable cross-section 3 × 50 mm² + 2 × 25 mm² + 1 × 6 mm², copper conductor, TPE or XLPE jacket, example product: Star Charge FlexDC 1000V 125A liquid-cooled charging cable, OEM datasheet Rev. 2024-03, https://www.starcharge.com/en/product/FlexDC-1000V-125A) shipped from Shenzhen, Ningbo, or Shanghai to Tema, Ghana, and used as supporting evidence during customs clearance at Tema port. [Claim | Src: GB/T 20234.2-2015 | URL: https://www.chinesestandard.net/PDF.aspx/GBT20234.2-2015 | accessed 2026-09-21]
The procedure references pull-force acceptance criteria consistent with UL 486A-486B (Wire Connectors) Table 12 for copper conductors, applied at the crimp barrel of the GB/T 20234.3 contacts. [Claim | Src: UL 486A-486B | URL: https://www.shopulstandards.com/ProductDetail.aspx?UniqueKey=35225 | accessed 2026-09-21]
Insulation coordination and hipot test levels follow IEC 61851-1:2017 (Electric vehicle conductive charging system — Part 1: General requirements), Clause 11.4 dielectric withstand, applied at the assembled cable set, not bare conductors. [Claim | Src: IEC 61851-1:2017 | URL: https://webstore.iec.ch/publication/70323 | accessed 2026-09-21]
Model assumption: when an importer ships a non-GB/T connector family (CCS2, NACS, CHAdeMO, GB/T AC), the OEM manual title and revision number for that connector must be attached to the job folder and the hipot / pull-force limits in this SOP must be re-validated against the new manual before QC starts. Out-of-scope by default: CCS2, NACS, CHAdeMO, GB/T AC 16 A / 32 A connectors.
The indicative HS classification for an EV charging cable assembly fitted with connectors is 8544.42 ("Other electric conductors, fitted with connectors"), and for spare crimped contacts and connector parts 8538.90 ("Parts suitable for use solely or principally with the apparatus of heading 8537"). Both lines must be re-confirmed by the licensed Ghana broker against the live Ghana Integrated Customs Information System (GICIS) tariff at clearance, because ECOWAS and Ghana Finance Act revisions can move subheadings. [Claim | Src: EUR-Lex TARIC heading 8544 | URL: https://eur-lex.europa.eu/legal-content/EN/TXT/?uri=CELEX:02022R1821-20240101 | accessed 2026-09-21] [Claim | Src: USITC HTS 8538.90 | URL: https://hts.usitc.gov/?query=8538.90 | accessed 2026-09-21] [Claim | Src: ICC Incoterms 2020 | URL: https://iccwbo.org/business-solutions/incoterms-rules/incoterms-2020/ | accessed 2026-09-21]
| Item | Heading | Indicative description | Import duty rate | VAT / NHIL / ECOWAS | Source portal |
|---|---|---|---|---|---|
| GB/T 20234.2-2015 DC charging cable assembly fitted with GB/T 20234.3 DC 125 A connectors (e.g., Star Charge FlexDC 1000V 125A) | 8544.42 | Other electric conductors, fitted with connectors | PENDING — lookup on GICIS at clearance | PENDING — lookup on GRA portal at clearance | Ghana Revenue Authority — GICIS Tariff Portal |
| Crimped copper lugs / spare GB/T 20234.3 DC 125 A contacts | 8538.90 | Parts suitable for use with apparatus of heading 8537 | PENDING — lookup on GICIS at clearance | PENDING — lookup on GRA portal at clearance | Ghana Revenue Authority — GICIS Tariff Portal |
Disclaimer: Duty rates, VAT, NHIL, and ECOWAS levy values are not hardcoded in this SOP. The licensed customs broker must re-query the Ghana Revenue Authority Integrated Customs Information System (GICIS) and the destination country's tariff schedule at the time of each shipment, since rates change per annual Finance Acts.
| Step # | Action | Owner | Input doc | Output doc | Done-when |
|---|---|---|---|---|---|
| 1 | Acknowledge shipment pre-alert, collect commercial invoice, packing list, mill certificate, OEM datasheet (e.g., Star Charge FlexDC 1000V 125A Rev. 2024-03) | Tradvolt Trade Ops (CN) | Shipping advice, CI, PL, mill cert, OEM datasheet | Pre-alert acknowledgement log entry | All five documents filed under job folder with consistent part numbers |
| 2 | Re-confirm HS classification with customs broker for both line items (8544.42 and 8538.90) | Licensed Customs Broker (GH) | Commercial invoice | HS code confirmation sheet | Broker signs HS sheet naming 8544.42 and 8538.90 (or amended codes) |
| 3 | Stage finished GB/T 20234.2 cable lots, apply ISO 2859-1:1999 Normal inspection Level II, AQL 1.0 for critical defects (crimp), AQL 2.5 for major (visual) | Crimp QC Inspector | QC sampling plan | Sampling record sheet | Sample count recorded matches Table 2-A of ISO 2859-1 for the lot size [Claim | Src: ISO 2859-1:1999 | URL: https://www.iso.org/standard/114483.html | accessed 2026-09-21] |
| 4 | Visual and dimensional inspection of GB/T 20234.3 crimp barrel, insulation gap (target 1–3 mm per OEM datasheet), and conductor brush | Crimp QC Inspector | AQL sample units, caliper | Visual inspection form | Zero defects beyond acceptance number for visual class |
| 5 | Pull-force test on sampled crimps using a calibrated tensile rig at 25 mm/min; minimum values per UL 486A-486B Table 12 (e.g., 50 mm² Cu ≥ 2 800 N) | Crimp QC Inspector | AQL sample units, tensile rig | Pull-force test sheet | All tested crimps meet or exceed UL 486A-486B Table 12 pull-out values for conductor size [Claim | Src: UL 486A-486B | URL: https://www.shopulstandards.com/ProductDetail.aspx?UniqueKey=35225 | accessed 2026-09-21] |
| 6 | Continuity and AC hipot test on the assembled cable set, lead-to-lead and lead-to-shield, at 2.5 kV AC / 60 s per IEC 61851-1:2017 Clause 11.4 | Crimp QC Inspector | AQL sample units, hipot tester | Hipot test sheet | No breakdown, leakage current < 5 mA; recorded on sheet [Claim | Src: IEC 61851-1:2017 | URL: https://webstore.iec.ch/publication/70323 | accessed 2026-09-21] |
| 7 | Record all readings on the CRIMP-QC checklist (rev. 2026-09-21) and attach photos | Crimp QC Inspector | Forms from steps 4–6 | Completed CRIMP-QC checklist (PDF) | Checklist signed, dated, and filed under job folder |
| 8 | Disposition the lot: release, rework, or reject; seal passing containers | Tradvolt Trade Ops (CN) | CRIMP-QC checklist | Lot disposition record, seal number log | Seal numbers logged and applied, container photo taken |
| 9 | Pre-lodge Ghana customs declaration via GICIS, attach QC dossier | Licensed Customs Broker (GH) | CI, PL, BL, CRIMP-QC checklist | Single Administrative Document (SAD) draft | SAD reference number issued by GICIS |
| 10 | Archive dossier, share link with consignee, close job in CRM | Tradvolt Trade Ops (CN) | Full job folder | Archived job record, customer share link | Consignee acknowledges receipt of share link |
| Day | Activity | Dependency | Cost slot |
|---|---|---|---|
| D0 | Pre-alert received, job opened, OEM datasheet revision logged | — | Service fee (indicative) |
| D1 | HS confirmation against GICIS, sampling plan prepared (ISO 2859-1) | D0 documents | Broker fee (indicative) |
| D2 | Visual, UL 486A-486B pull-force, IEC 61851-1 hipot tests | Sampling plan ready | QC fee (indicative) |
| D3 | Checklist signed, lot released, container sealed | All tests pass | Sealing fee (indicative) |
| D4 | SAD lodged on GICIS, dossier archived | Sealed container | Customs duty — PENDING (re-query on GICIS) |
Attach the following files to every crimp QC job folder:
CRIMP-QC-checklist_v3_rev2026-09-21.pdf — master QC checklist, 2 pagesAQL-sampling-record_CN-GH.xlsx — ISO 2859-1:1999 sample count logvisual-inspection-form.pdf — visual and dimensional findings on GB/T 20234.3 contactspull-force-test-sheet.pdf — tensile values per UL 486A-486B Table 12hipot-test-sheet.pdf — 2.5 kV AC / 60 s dielectric test results per IEC 61851-1:2017 Clause 11.4lot-disposition-record.pdf — release / rework / reject decisionseal-number-log.xlsx — container seal traceabilityHS-confirmation-sheet_GH.pdf — broker-signed HS sheet naming 8544.42 / 8538.90SAD-draft_GICIS.pdf — Ghana customs declaration draft with SAD referenceOEM-datasheet_GB-T-20234.3-125A.pdf — connector family manual & revision (e.g., Star Charge FlexDC 1000V 125A Rev. 2024-03)Need this SOP run on a specific shipment of GB/T 20234.2-2015 DC charging cable assemblies (e.g., Star Charge FlexDC 1000V 125A) from China to Ghana? Send us your commercial invoice and packing list and we will return a fixed-fee quote.
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Checklist template (PDF, 2 pages, rev. 2026-09-21) is shared with the quote; access path: /rfq?service=crimp-qc-cn-gh-evse&attach=checklist.