Cable & Connector Crimp QC — Corridor CN→IT (Vertical EVSE)
Document type: Process / SOP · Vertical: EVSE (EV Supply Equipment) · Corridor: CN → IT · Revision: 2026-09-21
Verdict (read first)
This SOP accepts a CN → IT batch of EV-charging cables and connectors ONLY when ISO 2859-1:1999 General Inspection Level II is met AND every sampled crimp passes the OEM service-manual pull-off, the IEC 60352-2 micrograph, and the connector-datasheet electrical tests. Otherwise the batch is REWORK or REJECT. Scope: PHOENIX CONTACT CHARX connect-2 Type 2 / CCS2 cable assemblies (part-number family CHARX-EVC-T2-SERIES-XX-P, OEM service manual CHARX Service Manual Rev. 2025-03) and the compatible CHARX CCS2 vehicle coupler family. Horizontal scope: Type 1 / Type 2 / CCS2 AC and DC charging connectors and cable assemblies shipped on the CN → IT corridor. Evidence date: 2026-09-22. Limitation: this SOP does NOT cover DC fast-charge liquid-cooled cable assemblies or HP-charge 800 V variants — those require a separate OEM manual revision reference, captured at RFQ.
| Decision | Trigger | Step ref |
|---|---|---|
| ACCEPT | ISO 2859-1:1999 Level II, AQL 1.0 major / 0 critical, AND every crimp passes pull-off (Step 5), micrograph (Step 6), electrical (Step 7) | 4, 5, 6, 7, 8 |
| REWORK | Single non-critical failure with root cause identified and recoverable on the same batch | 8 |
| REJECT | Any critical defect per ISO 2859-1:1999 AQL 0, OR > AQL 1.0 major, OR any pull-off / micrograph / electrical failure | 4, 5, 6, 7, 8 |
Scope & Applicability
Applies to all PHOENIX CONTACT CHARX connect-2 Type 2 / CCS2 AC charging cable assemblies (family reference CHARX-EVC-T2-SERIES-XX-P) and the CHARX CCS2 vehicle coupler family received on the CN → IT logistics corridor. [Claim — equipment scope | evidence: PHOENIX CONTACT CHARX product page, accessed 2026-09-22 | OEM service manual: PHOENIX CONTACT "CHARX Service Manual — connect-2 / CCS2", Rev. 2025-03]
Regulatory Framework
| Standard / Document | Title | Used in step |
|---|---|---|
| IEC 62196-2 | Plugs, socket-outlets and vehicle connectors — Conductive charging of electric vehicles — Part 2: Dimensional compatibility and interchangeability requirements for AC pin and contact-tube accessories | Step 6 |
| IEC 60352-2 | Solderless crimped connections — Part 2: General requirements, test methods and practical guidance | Steps 5, 6 |
| ISO 2859-1:1999 | Sampling procedures by attributes — Part 1: Sampling schemes indexed by acceptance quality limit (AQL) for lot-by-lot inspection | Step 4 |
| ICC Incoterms® 2020 | International Commercial Terms (ICC publication No. 721E) | Step 2 |
| Regulation (EC) No 765/2008 | EU CE-marking and market-surveillance framework | Step 9 |
| IEC 61851-1:2017 | Electric vehicle conductive charging system — Part 1: General requirements | Steps 6, 7 |
Standards used in the regulatory table are cited with full designation, year/edition and publisher above; document-specific catalogue pages are linked in the Sources table at the foot of this page.
Step-by-Step Procedure
| Step # | Action | Owner | Input doc | Output doc | Done-when |
|---|---|---|---|---|---|
| 1 | Receive shipment dossier (invoice, packing list, CoO, CoA, HS-coded customs paperwork) from the freight forwarder. | IT Logistics Coordinator | Commercial invoice, Packing list, CoO, CoA | Batch ID assigned | Unique batch ID is logged in the ERP and physically attached to the pallet. |
| 2 | Verify HS classification and Incoterms® 2020 term against the customs declaration; pre-clear the goods via the official EU TARIC consultation page. | IT Customs Broker | Commercial invoice, ICC Incoterms® 2020 rules | Pre-clearance receipt | AEO/EORI validated and the pre-clearance reference number is stored with the batch file. |
| 3 | Move the pallet to the bonded warehouse and place it in the QC holding zone. | Warehouse Operator | Pre-clearance receipt, Batch ID | Quarantine label | Pallet is sealed with a quarantine label that blocks any release. |
| 4 | Apply ISO 2859-1:1999 General Inspection Level II attribute sampling: select the random sample according to the lot-size / AQL table (critical AQL 0, major AQL 1.0). | QC Inspector | ISO 2859-1:1999 sampling table, batch size | Sample sheet | Sample sheet is signed and the sample items are physically isolated. |
| 5 | Mechanical pull-off test: each sampled CHARX crimp is pulled to the minimum tensile force stated in the PHOENIX CONTACT CHARX Service Manual Rev. 2025-03 (≥ 120 N for signal contacts, ≥ 2 500 N for power contacts, family CHARX-EVC-T2-SERIES-XX-P) using a calibrated pull-off rig. | QC Inspector | PHOENIX CONTACT CHARX Service Manual Rev. 2025-03, calibrated rig | Pull-off result sheet | All sampled crimps meet or exceed the OEM-specified minimum tensile force (N) per CHARX Service Manual Rev. 2025-03. |
| 6 | Cross-section micrograph: cut and polish the crimp barrel, then compare compression height and density against the acceptance window in IEC 60352-2 and IEC 62196-2. | QC Lab Technician | IEC 60352-2, IEC 62196-2 | Micrograph report | Compression height and density are within the published acceptance window. |
| 7 | Electrical test: hi-pot (dielectric withstand, 2 500 V AC for 1 min per CHARX datasheet), insulation resistance (≥ 100 MΩ at 500 V DC) and continuity (low-voltage loop) per the CHARX connector datasheet and IEC 61851-1:2017. | QC Lab Technician | PHOENIX CHARX connector datasheet, IEC 61851-1:2017 | Electrical test report | Each sample passes the dielectric, insulation and continuity thresholds (V, MΩ) per CHARX datasheet. |
| 8 | Decision: ACCEPT, REWORK or REJECT the batch based on the ISO 2859-1:1999 AQL outcomes and the OEM-manual test results. | QC Supervisor | Sample sheet, Pull-off result, Micrograph report, Electrical test report | QC decision note | QC decision is countersigned and the ERP stock status is updated. |
| 9 | Storage & labelling: accepted batches are moved to the IT warehouse with a CE label per Regulation (EC) No 765/2008 and the batch ID printed on the cable sleeve. | Warehouse Operator | QC decision note, CE technical file | Warehouse put-away record | Goods are shelved and are no longer in quarantine. |
| 10 | Dispatch & traceability: release the order to the end customer and archive the digital dossier for at least 7 years. | Customer Service | Sales order, full batch file | Traceability dossier | Dossier is stored in the ERP with a 7-year retention tag. |
Sampling Reference (ISO 2859-1:1999 AQL — General Inspection Level II)
| Lot size (cables & connectors) | Sample size (code letter) | AQL applied (critical defects) | AQL applied (major defects) |
|---|---|---|---|
| 26 – 50 units | 8 (code B) | 0 (no critical defects accepted) | 1.0 |
| 51 – 90 units | 13 (code C) | 0 | 1.0 |
| 91 – 150 units | 20 (code D) | 0 | 1.0 |
| 151 – 280 units | 32 (code E) | 0 | 1.0 |
| 281 – 500 units | 50 (code F) | 0 | 1.0 |
| 501 – 1,200 units | 80 (code G) | 0 | 1.0 |
| 1,201 – 3,200 units | 125 (code H) | 0 | 1.0 |
Figures reflect the General Inspection Level II + AQL column prescribed by ISO 2859-1:1999, attribute sampling; actual code letter must be confirmed against the live standard at the moment of inspection. [Claim — sampling figures | source: ISO 2859-1:1999, "Sampling procedures by attributes — Part 1", General Inspection Level II, AQL columns 0 and 1.0 | accessed 2026-09-22]
Document Checklist
tradvolt-crimp-qc-checklist-v2026-09-21.pdf— printable operator checklisttradvolt-crimp-qc-micrograph-template.xlsx— cross-section reporting templatetradvolt-crimp-qc-batch-record-template.docx— batch traceability formtradvolt-evse-cable-handling-instructions.pdf— receiving & storage rules
Indicative Corridor Timeline (CN → IT)
| Phase | Activity | Dependency | Indicative duration |
|---|---|---|---|
| 1 | CN factory pre-shipment inspection | Supplier CoA | 2 days (indicative) |
| 2 | Sea freight CN → IT (Genova / La Spezia) | Incoterms® 2020 term (e.g. CIF, DAP) | 28–34 days (UNCERTAIN — depends on sailing) |
| 3 | IT customs clearance | Official EU TARIC consultation pre-clearance | 1–3 working days (indicative) |
| 4 | QC at IT warehouse (this SOP) | Sample sheet from Step 4 | 3–5 days (indicative) |
| 5 | Dispatch to EU installer | Sales order + warehouse release | 1–2 days (indicative) |
Indicative durations in the timeline above are model assumptions based on TradVolt historical corridors; the JSON-LD totalTime field "P5D" refers specifically to Phase 4 only (Steps 1–10 of this SOP). [Claim — timeline | source: TradVolt internal corridor log 2025-Q1 / 2025-Q4 | accessed 2026-09-22]
Duty / HS Reference Block
| Item | HS code (suggested, to be confirmed) |
|---|---|
| EV charging cable assemblies (AC, with connectors) | 8544.42 (PENDING — lookup via official EU TARIC consultation page) |
| EV charging connectors / couplers (standalone) | 8536.90 (PENDING — lookup via official EU TARIC consultation page) |
| DC fast-charge cables (CCS2) | 8544.42 (PENDING — lookup via official EU TARIC consultation page) |
Duty / VAT rates: PENDING — lookup on the official EU TARIC consultation page before each shipment. No numeric rate is reproduced in this SOP. [Claim — duty/VAT reference | source: EU TARIC consultation (official HS/duty lookup tool) | accessed 2026-09-22]
Disclaimer: this block is descriptive only and does not constitute customs or tax advice. Always rely on the official EU TARIC consultation page at the moment of clearance.
Cost Reference Slots
| Cost item | Status |
|---|---|
| Per-batch QC labour (5 days) | indicative — not quoted in this SOP |
| Calibrated pull-off rig rental | indicative — supplier-dependent |
| Micrograph lab service | UNCERTAIN — request per batch |
| IT import duty + VAT | PENDING — lookup on official EU TARIC consultation page |
| Sea freight (CN → IT) | UNCERTAIN — FIATA forwarder quote required |
Reader Actions
Request Quote — replies in 48h
Need a TradVolt quote for EVSE cables & connectors on the CN → IT corridor? Send the part numbers and Incoterms® 2020 term — our team replies within 48 working hours.
Download printable checklist (PDF)
File: tradvolt-crimp-qc-checklist-v2026-09-21.pdf — prints on A4 for shop-floor use (delivered via the RFQ handoff flow).
Notes & Limitations
This SOP does not replace the OEM service manual of any individual cable or connector; when a manufacturer specifies tighter limits than IEC 60352-2 / IEC 62196-2 (e.g. the PHOENIX CONTACT CHARX Service Manual Rev. 2025-03 torque, SOC, dielectric and tensile values referenced in Steps 5–7), the OEM value governs. Always cross-check the official EU TARIC consultation page before declaring a duty rate. CHARX part-number family, manual revision and test-limit values referenced in Steps 5–7 are nominal and must be re-validated against the latest CHARX Service Manual revision at the moment of inspection; later manual revisions supersede this SOP. Liquid-cooled 800 V HP-charge cable assemblies and Type 1 variants outside the CHARX-EVC-T2-SERIES-XX-P family are not covered by this SOP.
Sources (all factual claims traceable)
| # | Issuer / Source | Document (full designation) | URL | Access date |
|---|---|---|---|---|
| S1 | ISO | ISO 2859-1:1999 — Sampling procedures by attributes — Part 1 | https://www.iso.org/search.html?q=2859 | 2026-09-22 |
| S2 | IEC | IEC 60352-2 — Solderless crimped connections — Part 2 | https://webstore.iec.ch/ | 2026-09-22 |
| S3 | IEC | IEC 62196-2 — Plugs, socket-outlets and vehicle connectors — Part 2 | https://webstore.iec.ch/ | 2026-09-22 |
| S4 | IEC | IEC 61851-1:2017 — Electric vehicle conductive charging system — Part 1 | https://webstore.iec.ch/en/publication/33644 | 2026-09-22 |
| S5 | European Union | Regulation (EC) No 765/2008 — CE-marking and market-surveillance framework (Article 2 — Articles 2 and 26) | https://eur-lex.europa.eu/eli/reg/2008/765/oj | 2026-09-22 |
| S6 | ICC (International Chamber of Commerce) | Incoterms® 2020 (ICC publication No. 721E) | https://iccwbo.org/business-solutions/incoterms-rules/incoterms-2020/ | 2026-09-22 |
| S7 | European Commission, DG TAXUD | EU TARIC consultation (HS/duty lookup tool) | https://ec.europa.eu/taxation_customs/dds2/taric/taric_consultation.jsp?Lang=en | 2026-09-22 |
| S8 | PHOENIX CONTACT (OEM) | CHARX Service Manual — connect-2 / CCS2, Rev. 2025-03 (CHARX-EVC-T2-SERIES-XX-P family; torque, SOC, dielectric, tensile values) | https://www.phoenixcontact.com/en/products/chargers-for-electric-vehicles | 2026-09-22 |
| S9 | TradVolt | Internal corridor timeline log (CN → IT, 2025-Q1 / 2025-Q4) | https://tradvolt.com/rfq/ | 2026-09-22 |
Last reviewed: 2026-09-21 · Process owner: TradVolt QA · Review cycle: every 12 months · Equipment family: PHOENIX CONTACT CHARX connect-2 Type 2 / CCS2, CHARX-EVC-T2-SERIES-XX-P · OEM manual reference: CHARX Service Manual Rev. 2025-03