Replace Charging Cable

To replace the charging cable, complete the following steps.

Required Tools and Materials

ChargePoint replacement part for your charging connector type: CCS1, CCS2, CHAdeMO, or NACS North American Charging Standard

Tools
	Torx screwdriver set T20 T25 T40 T60	Torx Security screwdriver T25
	Hex nut driver, 10 mm (3/8 in)	Dielectric grease
	Torque paint pen	Head lamp
	Stepladder

Check the Cable Replacement Kit Contents

Inspect the new part:
- Is this the correct charge cable type to replace the cable on the charging station? (CCS1, CCS2, CHAdeMO, or NACS North American Charging Standard)
- Is the part free from shipping damage (damaged insulation, bent or broken pins, etc.)? If the part has any defects, call ChargePoint Support before beginning work.
Place the outer cable clamp surface on a padded surface to protect it from scratches until installed.

Installation Sequence

Inspect the serial number (a) located below the swing arms and above the rear panels on the back of the station.

Technical illustration depicts the procedural step.

Follow the installation sequence listed below based on the serial number.

Installation Sequence By Station Serial Number
Serial Numbers 2133xxxx and Higher	Serial Numbers 1932xxxx to 2132xxxx	Serial Numbers Prior to 1932xxxx
Power Off the Station Remove the Area Light Bar Remove the LED Display Remove the Top Front Panel Access the Charging Cables Update the Contactor Assembly (Advanced) Replace the Top Cable Reassemble the Station Power On the Station	Power Off the Station Remove the Area Light Bar Remove the LED Display Remove the Top Front Panel Access the Charging Cables Replace the Top Cable or Replace the Bottom Cable Reassemble the Station Power On the Station	Power Off the Station Remove the Area Light Bar Remove the LED Display Remove the Top Front Panel Access the Charging Cables Replace the Top Cable Reassemble the Station Power On the Station

Be aware of these important considerations:

Any station with a serial number less than 1932 is capable of replacing the top cable, but not the bottom cable. If you need to replace the bottom cable on an older station, call ChargePoint Support to request the full swing arm assembly kit.
If the station has a serial number 2133xxxx or higher, you need to remove the contactor box and move the connectors.

Power Off the Station

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

RISK OF SHOCK. Before performing this procedure, disconnect the power to the station at the service panel. Keep power off for this circuit until all cover panels are correctly reinstalled and the work scope is completed. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR LOSS OF LIFE.

Remove the Area Light Bar

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

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

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.

When installing a panel, align these tabs above their corresponding slots and press the panel downward.

Technical illustration depicts the procedural step.

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

Access the Charging Cables

Unholster both cables and put them on a padded surface.
Swing the top arm out for access. Use the provided foam block (a) to hold the arm in place.
Use a T25 Torx screwdriver to loosen the four M5 captive screws that hold the top lid to the station from below. Set the top lid on a padded surface. The top lid must be removed whether the top or bottom cable is being replaced.

Technical illustration depicts the procedural step.

Before continuing, take a picture of which cable lug plugs into which lug landing on the contactor assembly.

Cables are color-coded. Color codes are different for each installed charge connector type.

If the first four digits of the serial number are less than 2133, it is critical that the cables are reattached to their original locations.

CHAdeMO has white and black color codes. NACS North American Charging Standard, CCS1, and CCS2 have red and black color codes.
It is easiest to unfasten all cables for better access, even if only one cable is being replaced.

Charging Cable Color Codes
	CHAdeMo	CCS Combined Charging System	NACS North American Charging Standard
Positive	white	red	red
Negative	black	black	black

Use a 10 mm (3/8 in) nut driver to remove all 8 contactor nuts. Save the nuts for later reinstallation.

Remove all contactor cable lugs (b) from the lug landings (c).

Avoid touching the lug contact area. Handle the cable lugs by their edges.

Take a picture of the position of the two communication cables on the left side of the contactor assembly.
Press the retention tab (d) on the back of each communication cable and remove it from the contactor assembly.

There are three possible charge connector slots (shown as 1, 2, and 3 on the front contactor plastic cover). Note the position of each communication connector before removing the cable.

Gently remove the communication cables from the P-clips mounted between the auxiliary power supply and the contactor assembly. The P-clips open at the top.

Pull all cables (communication and conductor) to hang down at the right side of the charging station in a bundle.
Remove the DC ferrite from the cable bundle.

Save the DC ferrite. It must be reinstalled later.

If you are replacing a CHAdeMo cable with a NACS North American Charging Standard cable, look closely at the upper slot, position 3, on the contactor box (e).

If you do not see a relay through position 3, the station has a 2-relay contactor box and you must remove the contactor box and move the connectors. Complete the steps in Update the Contactor Assembly - Advanced before continuing.

If you can see a relay through slot number three, the station has a 3-relay contactor box and you do not need to remove the contactor box. Continue with the steps in this section.

Use a T20 Torx screwdriver to remove the two M4 screws on each of the lower set of lug landings.

Move the lug landings to position 3.
Choose the charging cable to be replaced.
1. To replace the top cable, continue to the next section.
2. To replace the bottom cable, skip to Replace the Bottom Cable.

Replace the Top Cable

Identify the small data wire attached to the top cable. Unthread it from the tension tab.

The data wire is a different color depending on the type of cable.

If the gasket is installed over the top of the cable clamp as shown, cut the gasket away on the top so that it sits in the channel on either side.

If you can see the screws (a) holding the cable clamp to the station, skip to step 6.

If you cannot see the screws, complete steps 4 and 5.

Use a T25 Torx screwdriver to remove the ten M5 screws securing the cover.

Gently lift the cover (b).

Use a T25 Torx screwdriver to remove the ten M5 screws holding the cable clamp to the station.

Gently move the top cable’s wires to identify them in the overall bundle below. Pulling from inside the top arm, thread the three top cable wires (conductors and communications) up through the body of the station and out through the circular opening at the top of the station.

Remove the entire cable from the station.
Remove the protective wrapping from the new cable clamp and lift the cable clamp up to the top arm. Insert the cable clamp into the arm so that the screw mounting tabs hold it in place to take the weight of the cable.

Use a T25 Torx screwdriver and ten M5 screws to secure the cable clamp assembly to the top arm. Torque to 4.5 Nm (40 in-lbs).
Route the three wires (positive, negative, and communications) through the top arm opening. Reach through the top circular opening in the top arm to assist threading the wires through. Once all three connectors are through the circular gasket at the bottom of the bearing stack, continue routing the wires through from below the arms.
Position the cable clamp in the arm. For the top arm, align the cable clamp so that the second semicircle in the housing (b) matches the gasket line in the arm.

After replacing the top cable, skip to Reassemble the Station .

Replace the Bottom Cable

Swing the bottom arm out for access. Use the provided foam block to hold the arm in place.
Use a T25 Torx screwdriver to loosen the four M5 captive screws that hold the bottom lid to the station from below.

Swing the bottom lid to the outside of the station, to expose the inside of the bottom arm.

Lift up slightly on the bottom lid to help it clear the arm and gasket.

If the gasket is installed over the top of the cable clamp as shown, cut the gasket away only on the top so that it sits in the channel on either side.

Identify the small data wire attached to the top cable. Unthread it from the tensioner tab.

Use a T25 Torx screwdriver to remove the ten M5 screws holding the cable clamp to the station.

Reposition the bottom arm to extend only 45 degrees out from the station. This maximizes the size of the wiring opening. Re-block with the foam block.
Gently move the bottom cable’s wires to identify them in the overall bundle below. Pulling from inside the bottom arm, thread the three bottom cable wires (conductors and communications) up through the body of the station and out. Remove the entire cable from the station.

Remove the protective wrapping from the new cable clamp and lift the cable clamp up to the bottom arm. Insert the cable clamp into the slot in the arm so that the screw mounting tabs hold it in place to take the weight of the cable.

Use a T25 Torx screwdriver and ten M5 screws to secure the cable clamp assembly to the bottom arm. Torque to 4.5 Nm (40 in-lb).
Route the three wires (positive, negative, and communications) through the bottom arm opening where it meets the station. Reach through the top circular opening in the top arm to assist threading the wires through. Once all three connectors are through the circular gasket at the bottom of the bearing stack, continue routing the wires through from below the arms.

Position the cable clamp in the arm. For the bottom arm, align the cable clamp so that the first semicircle in the housing (a) matches the gasket line in the arm.

Proceed to the next section to reassemble the station.

Reassemble the Station

Refer to the images in the procedures above while replacing the station components:

Reinstall the ten screws that hold the cable clamp to its arm. Torque to 4.5 Nm (40 in-lb).
Gently route the data wire through the tensioner, being careful not to overstress or cut the wire.
If you removed the cover to access the cable clamp screws, replace the ten screws that hold the cover in place. Torque to 5.3 Nm (47 In-lb).
Check gasket placement to ensure it sits inside the channel all around the arm.
Replace the lid on top of its arm. From below, use a T25 Torx screwdriver to fasten the four captive screws. Torque to 2.6 Nm (20 in-lb).

For the bottom lid, lift up slightly on the lid to help it clear the arm and gasket.
Remove the foam block used to hold the swing arm open and allow the arm to swing back to home position.
Replace the top lid.
Route the communication cables through the plastic P-clips above the contactor box.
Plug communication cables in on the left side of the contactor assembly, paying attention to which cable belongs in positions 1, 2, and 3.

2-relay contactor boxes (boxes where the connectors were moved) have two active slots. Route the power connectors through slots 1 and 2. Connect the communications cables into slots 2 and 3 respectively.

2-relay contactor box

(a) NACS North American Charging Standard communication cable

(b) NACS North American Charging Standard DC charging cable

(c) CCS Combined Charging System communication cable

(d) CCS Combined Charging System DC charging cable

3-relay contactor box

(a) NACS North American Charging Standard communication cable

(b) NACS North American Charging Standard DC charging cable

(c) CCS Combined Charging System communication cable

(d) CCS Combined Charging System DC charging cable
Apply a thin layer of dielectric grease to the face of each lug on the contact surface.

Ensure that the DC ferrite is reinstalled before replacing the contactor lugs.

Replace contactor lugs with two nuts each, according to the previously taken pictures.
Match positive and negative signs on the conductor labels to the signs imprinted on the plastic face of the contactor assembly. CHAdeMO is always in position 1 (lowest) when present. Torque to 6.8 Nm (60 in-lb) and mark with a paint pen.

Do not install the contactor lugs with reversed positive/negative polarity. Incorrect polarity could damage the station or the vehicle charging from the station.

REVERSE THE ABOVE STEPS TO REPLACE THE TOP FRONT PANEL, LED DISPLAY, AND AREA LIGHT BAR.

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.

Labeled diagram of product, tools or parts.

(a) Front bottom panel

(b) Middle vent 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

RISK OF SHOCK. If a fault exists, turn the power off at the service panel to BOTH product paired charging stations during work and keep it off until all panels are reinstalled. Internal components can present a shock hazard. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR LOSS OF LIFE.

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.

Update the Contactor Assembly - Advanced

You only need to remove the contactor box and move the connectors if you are replacing a charging cable on a station with a 2-relay contactor box. If the station has a 3-relay contactor box, you do not need to complete the procedure in this section.

You must be a licensed electrician and complete online training to become a ChargePoint certified installer. If you do not complete training, you cannot access the ChargePoint network to complete installation. Find online training at: https://www.chargepoint.com/partners/training-certification. If the charging station is not installed by a ChargePoint certified installer, using a ChargePoint approved method, it is not covered under warranty and ChargePoint is not responsible for any malfunctions.

Remove the horizontal 50-pin ribbon cable (a). Push the tabs outward. Rock it gently from left to right as you pull out the cable.

Remove the remaining two cables connected to the left side of the contactor assembly: 24 V DC power (b), and CAN connectors (c).

Each cable is keyed to its corresponding connector except the CAN cables, which are interchangeable.
Open the securing latches (d) on the left and right sides of the contactor box assembly by pushing down on the lock tab and lifting the lever.

Disengage the contactor assembly from the large bus bar connections at the bottom (e) by holding it with two hands near the bottom and rocking the assembly slightly as you pull outward.
Once the bus bar connections release, pull the assembly forward along the support arms (f), then lift it away from the station.

Avoid touching the tab contact area. Handle the cable tabs by their edges.

Move the Connectors

Use a T25 Torx screwdriver to remove the three screws (a) securing the cover.

Remove the cover.

Unplug the connector from position 2 (b) and plug it into position 3 (c).

Unplug the connector from position 1 (d) and plug it into position 2 (b).

Replace the cover. Use a T25 Torx screwdriver and three screws to secure the cover.
Place the included label on the contactor box indicating the updated slot numbers.

Replace the Contactor Assembly

Ensure latch clasps are open and not blocking the contactor assembly before installation.
Rest the alignment pegs of the contactor assembly on the support arm hooks.
Slide the contactor assembly back along the support arms. Push the assembly to engage the bus bars until fully seated.

Ensure the connectors are aligned before pressing in. Do not apply excessive force. Doing so can damage the connectors. Once seated, gently pull the contactor assembly outward as a push-pull test to confirm it is securely seated.

Ensure all cables are accessible without being pinched or caught under the contactor assembly.
Fasten the latches on the right and left sides of the contactor assembly.
Reconnect each cable on the left side of the contactor assembly.

(a) Charge cable communications

(b) DCC Dispenser Charge Controller communication ribbon

Ensure the key aligns with the notch in the socket.

(d) CAN connectors (interchangeable)

Secure connector body to the mating connector on the contactor assembly and ensure the tabs are in the open position. During connection the insertion tabs will automatically close onto the connector housing.

Apply a thin layer of dielectric grease to the face of each lug on the contact surface.

Ensure that the DC ferrite is reinstalled before replacing the contactor lugs.

Replace contactor lugs with two nuts each, according to the previously taken pictures.
Match positive and negative signs on the conductor labels to the signs imprinted on the plastic face of the contactor assembly. Torque to 6.8 Nm (60 in-lb) and mark with a paint pen.

Do not install the contactor lugs with reversed positive/negative polarity. Incorrect polarity could damage the station or the vehicle charging from the station.
Tuck the excess contactor cable down the side of the enclosure to avoid interfering with the cover panel in a later step.

Go to Choose the charging cable to be replaced. Continue with the steps to replace the charging cable.