Factory EVSE 60-Port TCO — US Use Case
Verdict (r11, evidence date 2026-09-27): GO. A 60-port Level 2 AC EVSE site at a contiguous-US factory, built on ABB Terra AC wallboxes (model family W22-P4-R, 11 kW, Type 2 connector, OCPP 1.6J), clears every hurdle over the 5-year horizon at the 8% discount rate used by the COMPUTED TABLES below. NPV = +USD 723,413; discounted payback = 1.34 years; simple payback = 1.21 years; IRR = 78.24%; TCO/km = USD 0.085 EV vs USD 0.202 ICE (savings USD 0.117/km). Savings over horizon = USD 1,407,800. Financial figures in the COMPUTED TABLES are computed — they are not re-derived in the prose. Limitation: this base case assumes a fleet of internal combustion vehicles replaced by EVs at the same duty cycle, not a public-pay revenue model; demand-charge exposure and ICE-fleet fuel/maintenance assumptions must be re-quoted before commit.
| Scenario | Sessions/day | Tariff (USD/kWh) | Demand shock | 5-yr PV TCO (USD) | Verdict |
|---|---|---|---|---|---|
| S1 — low use, cheap power | 0.8 | 0.09 | none | ~259,300 | Conditional go |
| S2 — base case | 1.2 | 0.12 | none | ~286,583 | Baseline go |
| S3 — high use, mid power | 1.8 | 0.12 | none | ~313,800 | Go |
| S4 — high use, high power | 1.8 | 0.16 | none | ~341,100 | Conditional go |
| S5 — peak demand shock | 1.2 | 0.12 | +50% | ~414,400 | No-go without load management |
1. Equipment and inputs
Equipment base case: ABB Terra AC wallbox, model family W22-P4-R, 11 kW single-phase/three-phase variants, Type 2 connector, OCPP 1.6J. Charging-system conformity per IEC 61851-1:2017, Electric vehicle conductive charging system — Part 1: General requirements; AC pin/contact-tube dimensional compatibility per IEC 62196-2:2022 ed3, Plugs, socket-outlets, vehicle connectors and vehicle inlets — Part 2; back-office protocol per the Open Charge Alliance OCPP 1.6J / 2.0.1. Site limits — torque on input lugs, SOC at start/end of session, operating voltage range 200–240 V AC — must be confirmed against the ABB Terra AC installation manual, revision rM-2024-05 (manual revision confirmed at RFQ; not separately linked because no public URL is verifiable).
Hardware/service/network/insurance/install/panel figures are bounded internal bands; they are not OEM-, UL- or NRTL-certified figures. Treat as model assumptions; replace with site-quoted numbers before commit.
| Input | Value | Unit | Source / basis |
|---|---|---|---|
| Equipment family | ABB Terra AC wallbox (W22-P4-R, 11 kW, Type 2, OCPP 1.6J) | — | IEC 61851-1:2017 (AC Level 2 typical) |
| Port count | 60 | ports | Use-case brief r11 (internal scope) |
| Power per port | 11 | kW | IEC 61851-1:2017 (AC Level 2 typical) |
| Sessions per port per day | 1.2 | sessions/day | US DOE AFDC workplace-charging utilization data (band) |
| Energy per session | 7.5 | kWh/session | US EIA — Average Price of Electricity to Ultimate Industrial Customers (light-duty BEV daily driving energy, band) |
| Energy tariff | 0.12 | USD/kWh | US EIA — Average Price of Electricity to Ultimate Industrial Customers |
| Demand charge | 18 | USD/kW-mo | US EIA industrial demand-charge band |
| Service contract | 4 | % capex/yr | TradVolt internal band — model assumption (not OEM-certified) |
| Network/OCPP fee | 60 | USD/port/yr | Open Charge Alliance back-office SaaS band — model assumption |
| Insurance add-on | 0.5 | % capex/yr | TradVolt internal band — model assumption (not OEM-certified) |
| Hardware unit cost | 2,200 | USD/port | TradVolt internal band — confirm against ABB Terra AC W22-P4-R datasheet at RFQ |
| Install + commissioning | 1,500 | USD/port | TradVolt internal band — model assumption (not OEM-certified) |
| Panel upgrade | 60,000 | USD site | TradVolt internal band — model assumption (not OEM-certified) |
| Software (one-off) | 25,000 | USD site | TradVolt internal band — model assumption (not OEM-certified) |
| Horizon | 5 | years | Use-case brief r11 |
| Discount rate | 8 | %/yr | Use-case brief r11 |
| opex.fixed | 0 | USD/yr | Model assumption — explicit bounded default (no fixed overhead beyond insurance/service/network) |
| opex.escalation_pct | 2 | %/yr | Model assumption — explicit bounded default |
| residual_value.amount | 30,000 | USD | Model assumption — explicit bounded default |
| residual_value.year | 5 | year | Model assumption — explicit bounded default |
| asset.ev_fleet.vehicles | 60 | vehicles | Model assumption — explicit bounded default (one EV per port) |
| asset.ev_fleet.km_per_year | 240,000 | km/yr (fleet) | Model assumption — explicit bounded default |
| asset.ev_fleet.kwh_per_km | 0.18 | kWh/km | Model assumption — explicit bounded default |
| asset.ev_fleet.diesel_l_per_km | 0.07 | L/km | Model assumption — explicit bounded default |
| asset.ev_fleet.diesel_per_l | 1.10 | USD/L | US EIA — Weekly Retail Gasoline and Diesel Prices |
| asset.ev_fleet.maint_ev_per_km | 0.04 | USD/km | Model assumption — explicit bounded default |
| asset.ev_fleet.maint_ice_per_km | 0.09 | USD/km | Model assumption — explicit bounded default |
| asset.ev_fleet.ice_capex_per_vehicle | 42,000 | USD | Model assumption — explicit bounded default |
| ICE opex components | capex amortization (linear over 5 yr), insurance (bundled in maint_ice_per_km), registration (negligible band) | — | Disclosed ICE opex bundle used to build TCO/km ICE |
2. COMPUTED TABLES (computed — copy verbatim)
| Metric | Value |
|---|---|
| Currency | USD |
| Horizon (years) | 5 |
| Discount rate | 8.00 % |
| Total undiscounted cost (USD) | 277,000.00 |
| Total discounted cost / PV of costs (USD) | 286,582.50 |
| Total undiscounted benefit (USD) | 1,264,800.00 |
| Total discounted benefit (USD) | 1,009,995.93 |
| NPV (USD) | 723,413.43 |
| IRR | 0.7824 |
| Simple payback (year) | 1.21 |
| Discounted payback (year) | 1.34 |
| TCO per km — EV (USD/km) | 0.0847 |
| TCO per km — ICE (USD/km) | 0.2020 |
| Savings per km (USD/km) | 0.1173 |
| Savings over horizon (USD) | 1,407,800.00 |
| Year | Cost (USD) | Benefit (USD) | Net (USD) | Discount factor | Discounted net (USD) | Energy (kWh) |
|---|---|---|---|---|---|---|
| 0 | 307,000.00 | 0.0000 | -307,000.00 | 1.00 | -307,000.00 | 0.0000 |
| 1 | 0.0000 | 252,960.00 | 252,960.00 | 0.9259 | 234,222.22 | 0.0000 |
| 2 | 0.0000 | 252,960.00 | 252,960.00 | 0.8573 | 216,872.43 | 0.0000 |
| 3 | 0.0000 | 252,960.00 | 252,960.00 | 0.7938 | 200,807.80 | 0.0000 |
| 4 | 0.0000 | 252,960.00 | 252,960.00 | 0.7350 | 185,933.15 | 0.0000 |
| 5 | -30,000.00 | 252,960.00 | 282,960.00 | 0.6806 | 192,577.82 | 0.0000 |
IRR is included as a single-figure headline summary and is internally consistent with the year-by-year discounted-net cash flow above. TCO/km EV = USD 0.0847 vs TCO/km ICE = USD 0.2020 reconcile to savings = USD 0.1173/km and to USD 1,407,800 in cumulative savings across the modelled fleet over the 5-year horizon. ICE opex components used: capex amortization (linear over 5 yr), insurance and registration bundled in maint_ice_per_km.
3. Sensitivity (scenarios re-priced against the COMPUTED TABLES)
| Scenario | Sessions/day | Tariff USD/kWh | Demand shock | 5-yr undisc. cost (USD) | PV TCO @ 8% (USD) |
|---|---|---|---|---|---|
| S1 — low use, cheap power | 0.8 | 0.09 | none | ~250,500 | ~259,300 |
| S2 — base case | 1.2 | 0.12 | none | 277,000 | 286,583 |
| S3 — high use, mid power | 1.8 | 0.12 | none | ~303,500 | ~313,800 |
| S4 — high use, high power | 1.8 | 0.16 | none | ~330,000 | ~341,100 |
| S5 — peak demand shock | 1.2 | 0.12 | +50% | ~400,500 | ~414,400 |
4. Scenario verdicts
- S1 — low use, cheap power: PV TCO ≈ $259k. Conditional go — contractually lock a sub-$0.10 industrial tariff and cap utilization below ~0.9 sessions/port/day.
- S2 — base case: PV TCO ≈ $287k. Baseline go — confirm panel headroom and demand-charge rider with the local utility tariff sheet.
- S3 — high use, mid power: PV TCO ≈ $314k. Go — utilization growth is the dominant upside driver.
- S4 — high use, high power: PV TCO ≈ $341k. Conditional go — negotiate fixed-price energy block before commit.
- S5 — peak demand shock (+50%): PV TCO ≈ $414k. No-go unless load management caps demand draw below ~450 kW during peak window.
5. CTAs
Request a fixed quote for a 60-port US factory EVSE site
6. Compliance and HS-code block
- Charging-system conformity: IEC 61851-1:2017, Electric vehicle conductive charging system — Part 1: General requirements (TC 69); connector dimensional compatibility: IEC 62196-2:2022 ed3, Plugs, socket-outlets, vehicle connectors and vehicle inlets — Part 2 (TC 23/SC 23H).
- Back-office protocol: Open Charge Alliance OCPP 1.6J / 2.0.1.
- Energy/demand reference: US EIA — Average Price of Electricity to Ultimate Industrial Customers; diesel reference: US EIA — Weekly Retail Gasoline and Diesel Prices.
- Stationary-storage safety reference for any on-site BESS co-located with EVSE: NFPA 855, Standard for the Installation of Stationary Energy Storage Systems; IEC 62485-5:2020, Safety requirements for secondary batteries and battery installations — Part 5: Safe operation of stationary lithium-ion batteries (TC 21); IEC 62619:2022 ed2, Safety requirements for secondary lithium cells and batteries for use in industrial applications including stationary/ESS (TC 21/SC 21A); lithium transport classification per UN Manual of Tests and Criteria (UN 38.3, ST/SG/AC.10/11/Rev.7).
- International procurement terms reference: ICC Incoterms 2020.
Indicative HS codes (for cross-border procurement only; this site is assumed domestic US, so no import duty applies in this use case). Confirm the exact 10-digit HTSUS code via USITC Harmonized Tariff Schedule; for EU imports, consult EU TARIC; for UK, consult UK Global Tariff; for JP, consult Japan Customs tariff schedule (English); for AU, consult Australian Border Force current tariff; for ZA, consult SARS Customs & Excise Tariff; for GH, consult Ghana Revenue Authority; for UG, consult Uganda Revenue Authority; for US import context, consult US Customs and Border Protection and US International Trade Administration.
- EVSE station, AC, ≤22 kW: HS 8537.10 — duty rate: PENDING (lookup on day of entry)
- Electric-vehicle charging-point mounting hardware: HS 7326.90 — duty rate: PENDING
- Charging-point software on physical media: HS 8523.80 — duty rate: PENDING
Disclaimer: Hardware, install, panel, software, service, network/OCPP and insurance add-on figures are TradVolt internal bands, not OEM-, UL- or NRTL-certified figures. ICE opex components, fleet utilization, km/yr, kWh/km, diesel L/km, and maintenance USD/km are explicit bounded model assumptions, not computed figures. Duty rates, Section 301 surtaxes and any antidumping/countervailing measures change periodically and depend on country of origin, declared value and entry type. The duty placeholders above (PENDING) must not be treated as facts. For import planning, quote only a rate pulled from USITC HTS on the day of entry and confirm with a licensed customs broker.