Express 250

ChargePoint® Networked Charging Station

Advanced FRU Guide: Replacing the Power Module Communication Cables

For assistance, go to chargepoint.com/support and contact technical support using the appropriate region-specific number.

Required Tools and Materials

	Head lamp		Stepladder
	Torx screwdriver (T10, T20)		T25 Security screwdriver
	45 degree angle driver with 50 mm (2 in) long T20 Torx bit (optional)

• Power Module Communication Cable FRU Field Replaceable Unit Kit from ChargePoint:

  • Communication Cable Assembly

  • Sheetmetal Connector Plate (x2)

  • Lock Washer, #10, Internal Tooth (x1)

  • 20 mm hex shoulder screws, M4 (x3)

  • T10 Torx screws, M3 Flat Head (x6)

  • T20 Torx screws, M4 Button Head (x4)

  • T25 Torx screws, M5 Button Head (x1)

  • M5 flat washers (x6)

  • Springs (x3)

  • Short handle Torx T20 driver

This repair takes one technician about 1-2 hours to complete.

About Panels

All panels have guide tabs that align with corresponding slots on the product’s frame. When removing a panel, lift the panel upward to release these tabs from their slots.

Panels overlap from the bottom to the top. To remove any panel, all panels above it on that side must be removed first.

Power off the Station

Power off at the breaker panel and lock out/tag out before continuing work.

Remove the Area Light Bar

1. Using a T25 Security screwdriver, loosen the two captive screws on the area light bar.

   

2. Disconnect the power cable that connects the area light bar to the LED display assembly. Remove the area light bar.

   When reinstalling, ensure the gasket on each end of the area light bar is properly seated around the plastic tab.

   

Remove the LED Display

1. Push the LED display upward to release its guide tabs from their corresponding slots on the Express 250’s frame.

   

2. When the LED display assembly is released, disconnect the five cables from the back.

   When reinstalling, connect the five cables to their corresponding connectors on the back of the display. Leave the area light bar cable (e) loose.

   

   (a) Communications cable (USB Universal Serial Bus-A)

   (b) Holster light cable

   (c) Area light cable x 2 (interchangeable)

   (d) Power cable (24 V)

   Do not allow the LED display to hang from its cables.

Remove the Top Front Panel

1. Using two hands, pull the top panel upward to release its guide tabs from their corresponding slots on the Express 250’s frame.

2. Place a protective cover, such as a lint-free cloth, over the touchscreen to prevent damage during service.

If you are replacing a charging cable, be sure to visit Replace a Holster chapter of the Service Guide available at ChargePoint Product Reference Documentation for information on replacing the holster BEFORE reinstalling the panels.
When reinstalling, push the bottom edge inward to position it inside the groove in the middle vent panel and engage the edge of the sign. Carefully push the panel down until it is firmly seated.
When reinstalling, ensure all five cables at the top of the panel are not captured by the front upper panel, and are easily accessible for reinstalling the LED display.

Remove the Middle Vent Panel

1. Use a T25 Torx driver to remove the M5 screw and washer attaching each touchscreen ground strap to the frame. Keep the screws and washers for reuse.

   

2. Loosen both retention knobs (b), allowing the touchscreen beam (c) to slide up vertically and the touchscreen’s bottom edge to clear the middle vent panel’s slot (d).

3. With hand pressure, tilt the touchscreen upward at a 45-degree angle.

   

4. Allow the touchscreen to return to its lowest position vertically. Rotate the retention knobs clockwise to re-tighten.

   The bottom edge and corners of the touchscreen are sharp. Take care when moving underneath the raised screen.

5. Disconnect all cables from the connectors on the bottom of the touchscreen and remove them from the wire management rings. Move the proximity wires to hang in front of the middle vent panel.

   Leave the touchscreen tilted up only when necessary to improve visibility and access to the repair area during service procedures.

   

6. Using two hands, one on each side of the middle vent panel, remove the panel by firmly pulling it upward to release the guide tabs from the corresponding slots on the Express 250’s frame.

   

   The fins on the back surface of the middle vent panel are sharp. Take care when handling the panel.

Remove the Bottom Front Panel

Remove the bottom front panel by lifting upward from the bottom of the panel to release the guide tabs from their corresponding slots on the Express 250’s frame.

Remove Top Rear Panel

1. Using a T25 Torx (or a Phillips #2 screwdriver for early charging stations), loosen the two hidden captive screws located in the top rear panel’s vents, inset from each bottom corner.

   

2. Using a T25 Torx driver, loosen the two captive screws located at the top of the top rear panel. Using two hands, hold the top rear cover at an angle to remove, leading with the bottom edge.

   When reinstalling, squeeze the sides of the panel inward to fit the tabs into place in the C-channel, inside the watertight gasket.

   

Remove Middle Rear Panel

Using two hands, lift the middle rear panel straight up and out to disengage the guide tabs.

Remove the Bottom Rear Panel

Using two hands, carefully pull the panel upward to release the panel’s guide tabs from their corresponding slots on the product’s frame.

Open the Power Module Holders (Ground Straps)

1. Use a T25 Torx to remove the front and rear M5 screws and washers attaching the Power Module holder (a) and Power Module(b) ground straps to the Express 250 frame (eight screws total). Keep the screws and washers for use in a later step.

   

2. Using two hands, squeeze the Power Module mechanism’s release bar against the flange. Raise the bar to fully rotate the Power Module mechanism upward to the lock position. This ensures enough clearance for the Power Modules to slide under the mechanism.

   

   

3. At the bottom right of the Express 250, press and hold the yellow release latch while pulling the Power Module tray out of the station completely.

   

4. Rotate both Power Module holders onto their kickstands to provide access to the communication cables.

   Ensure Power Module holders can rest level with the base of the station. Provide a stable flat surface for the kickstands if the holders would rest below station grade. Power Modules are heavy and could tip out of their holders, which can harm the technician or the equipment.

Open the Power Module Holders (EMI Shields)

1. Use a T20 Torx to remove the top two screws and washers from the rear EMI Electromagnetic Interference shield (a).

   

2. Use a T25 Torx to remove the four middle and lower screws and washers from the rear EMI Electromagnetic Interference shield (b). The rear shield might be in one or two sections. Save all screws and washers for later reuse.

   When reinstalling, ensure:

   • The cutout on the long edge is on the right side (c), leaving the sensor wire clear.

   • The drain hose and cooling controller cover flap are inside the EMI Electromagnetic Interference shield.

3. Use a T25 Torx to remove the six T25 screws and washers from the front EMI Electromagnetic Interference shield (d).

   

   When reinstalling, position the bottom cut-out over the yellow release latch (e).

4. Using two hands, squeeze the Power Module mechanism’s release bar against the flange. Raise the bar to fully rotate the Power Module mechanism upward to the lock position. This ensures enough clearance for the Power Modules to slide under the mechanism.

   

   

5. At the bottom right of the Express 250, press and hold the yellow release latch while pulling the Power Module tray out of the station completely.

   

6. Rotate both Power Module holders onto their kickstands to provide access to the communication cables.

   Ensure Power Module holders can rest level with the base of the station. Provide a stable flat surface for the kickstands if the holders would rest below station grade. Power Modules are heavy and could tip out of their holders, which can harm the technician or the equipment.

Remove the Power Module Communication Cables

1. Use a T20 Torx (with angle driver if needed) to remove all four M4 screws from the umbrella cover that protects the tubes and the top of the module mechanism. Use the provided short handle Torx to access the rear screws. Keep the screws and umbrella for later reuse.

   

2. Locate the front and rear communication cable plates under the module mechanism, looking up.

3. Use a T10 Torx to remove all six M3 screws. Save the screws for later reuse.

   

4. Pull each cable connector down and away from its housing. Push upward on the white plastic latch (a) to unlock the connector from its sheet metal plate (b).

   

5. Slide each connector’s sheet metal plate to the right to free it from the connector’s tabs (c) and remove the plate. If the metal plate is damaged, replace it with a spare in the repair kit.

   

6. On the top surface of the module mechanism, uncoil the wire length from around the coolant tubes.

7. Use a T25 Torx to remove the screw and star washer from the three ground wires. Save the screws and washer for later reuse.

   

8. Identify the float retainer plate partially covering the front connector.

9. Use a T25 Torx to remove both front bolt/washer/spring stacks and the right rear stack. Leave the left rear stack in place as a pivot. Discard the removed fasteners and replace with new ones from the kit upon reinstallation.

   

10. Rotate the float retainer (d) to release the front connector (e).

    

11. Lift the rear connector free of the module mechanism.

    

12. Unplug the third connector from the Power Module port in the Station Management Unit above the module mechanism.

Install the Power Module Communication Cables

1. On the new cable assembly, insert the connector with two cables into the module mechanism’s rear opening, with the white locking tab facing left.

   

2. Guide the other locking connector into the front opening, with the white locking tab facing left.

3. Plug the third connector on the cable assembly into the Power Module slot in the Station Management Unit.

4. Pivot the float retainer plate back into position. Use a T25 Torx to install three new screw/washer/spring assemblies.

5. Torque to 1.1 Nm (10 in-lbs).

6. Use a T25 Torx to reinstall all three ground wires to the hex standoff on the float retainer (one ground wire from the float retainer, and one ground wire from each new cable). Place the star washer between the lugs and the screw head.

7. Torque to 2.3 Nm (20 in-lbs).

8. Below the module mechanism, install the sheet metal plate onto each locking connector:

   1. Ensure the white latch is on the left side and in the up (open) position.

   2. Mount the sheet metal plate onto the connector and slide it to the right, securing it under the connector’s tabs. If the connector does not slide correctly against the metal plate, check that the latch is fully open.

   3. Press the white latch down into the locked position. This secures the sheet metal plate to the connector.

      

9. Use a T10 Torx and three M3 screws each to secure the connector/plate assemblies to the housing.

10. Torque to 0.6 Nm (5 in-lbs).

11. Use a T20 Torx and four M4 screws to reinstall the umbrella cover. Use the provided short handle Torx to access the rear screws.

12. Torque to 1.1 Nm (10 in-lbs).

13. Tip both Power Module holders back upright and press the yellow latch to slide them into the station.

14. Engage the module mechanism handle completely. Open the mechanism again and inspect both communication cable connectors to ensure alignment is correct.

Power On the Station

Once all cover panels are installed, power on the station. The on-screen Installation Wizard steps you through any required tasks to set up the station and verify that it can operate properly.

An Installation Wizard test checks that all cover panels are correctly installed and fully seated. Check the lower right corner of the screen for any error messages. If panel errors appear, match the panel letters to this illustration.

(a) Front bottom panel

(b) Middle vent panel

(c) Front top panel

(d) LED display

(e) Area light bar

(f) Rear bottom panel

(g) Rear middle panel

(h) Rear top panel

(i) Left extrusion

(j) Right extrusion

If any panel needs re-installation, review the procedures above to double-check that all panels are fully seated and that the edges of all signs are captured fully by the panels around them. For further details, refer to Introduction.