Pair the Charging Stations

To install labels, connect the DC conductors, and connect Ethernet communication if the charging station is being paired, complete the following steps.

If the Express 250 is being installed as a Standalone station, skip this section and continue to Install Cover Panels.

RISK OF SHOCK. Power must be disconnected at the service panel to BOTH Express 250 paired charging stations when servicing. FAILURE TO CORRECTLY MARK THIS FOR FUTURE TECHNICIANS CAN RESULT IN SERIOUS INJURY OR LOSS OF LIFE.

Install New Labels

  1. Identify the ratings label area at the rear of the charging station, just under the charging cable swing arms.

  2. Wipe down the surface area with a lint-free cloth and isopropyl alcohol wipes.

  3. Peel the backing and the protective front strip from the 125 kW label. Carefully affix the new ratings label over the top of the existing ratings on the station so that there are no air bubbles and scratches. The new label reflects the updates in charging station capacity.

  4. Identify the two charging stations to be paired. For each pair, check site plans to see which charging station is designated Station 1 and which is Station 2. If the plans do not define it, designate them now.

  5. Affix the AC disconnect labels in the site’s main language to the disconnect responsible for AC power to this charging station and the disconnect for its Paired partner.

  6. Using permanent marker, write in the last three numbers of both Paired stations’ serial number (found next to the ratings) on each disconnect label, so that future technicians know which disconnect to power off for service. This is especially important for sites with multiple pairs of charging stations.

Disconnect numbers must be written in permanent marker. Normal ballpoint pen ink does not stay legible on the label.

Install the Ethernet Wiring

Follow the below steps to install the Ethernet Wiring:

  1. Measure the length needed to extend the Ethernet wiring from the conduit opening, up the side of the frame, and into the Express 250’s Station Management Unit, located on a rail under the touchscreen (approximately 317.5 cm/125 in). Trim the excess wire.

  2. Route the Ethernet wire up the rear side of the frame, through the plastic P-clips (a), and into the top wiring hole (b).

  1. Route the Ethernet wire across the charging station from right to left between the auxiliary power supply and the contactor assembly. Zip tie the Ethernet wire to the existing cable bundle at each corner (c).

  2. Route the Ethernet wire down behind the touchscreen adjustment bar.

  3. With hand pressure, swing the bottom of the touchscreen out to a 45-degree angle (d).

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

  1. Re-measure the distance to the Ethernet port of the Station Management Unit (e) and trim excess wire.

  2. Strip the end of the Ethernet insulation.

  1. Crimp the Ethernet wire in a straight-through pattern into RJ45 connectors at both ends. Note the location of Pin 1 relative to the clip in the image, and the order of the blue and green wires in the pattern.

  2. Test the Ethernet wire for functionality.

  1. Plug the Ethernet wire into the Ethernet port of the Station Management Unit.

    2. It is easier to access the Ethernet port if the Power Module mechanism handle is temporarily in the down position.

  1. Use the duct seal compound included in the crate to completely seal all DC openings against pest ingress:

    • The inside of the conduit opening
    • Within the rodent guard bracket openings for wiring, to pad any sharp edges and block ingress
    • Around the edges of the rodent guard bracket where it will meet the extrusion

The conduit opening must be sealed to protect the wiring from the environment.

  1. Install the DC wiring cover on the left side of the charging station by pressing on its sides and pushing it inward.