Replace Charging Cable with a NACS Cable

To replace the charging cable with a NACS North American Charging Standard cable, complete the following steps.

Required Tools and Materials

	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

1. Inspect the new part. 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.

2. 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.

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

Installation Sequence By Station Serial Number

Serial Numbers 2133xxxx and Higher	Serial Numbers Prior to 2132xxxx
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 Reassemble the Station Power On the Station

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

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.

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 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

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

   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

2. Look closely at the upper slot, position 3, on the contactor box (a).

   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.



3. 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.



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

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

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


5. Press the retention tab (d) on the back of the CHAdeMO communication cable and remove it from the contactor assembly.



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



7. Pull both CHAdeMO cables (communication and conductor) so they hang down at the right side of the charging station in a bundle.

8. Remove the DC ferrite from the cable bundle.

   Save the DC ferrite. It must be reinstalled later.

   If you have a 2-relay contactor box (determined in step 2 above), complete the procedure in Update the Contactor Assembly. After updating the contactor assembly, go to Remove and Replace the Cable in the Swing Arm.
   
   If you have a 3-relay contactor box (determined in step 3 above), continue with steps 9 and 10.



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



10. Move the lug landings to position 3.

    1. Align the each lug landing (f) with the correct guide pin (g) on the contactor box. The positive lug landing has a notched corner (h).

    

    2. To seat lug landing on the contactor box, press the base (i) of the lug landing down.

    

    3. Use a T20 Torx screwdriver to secure the lug landings on the contactor box.

       Torque the M4 screws to 1.69 Nm (15 in-lb).

Remove and Replace Cable in Swing Arm

1. Unholster both cables and put them on a padded surface.



2. Swing the top arm out for access. Use the provided foam block (a) to hold the arm in place.



3. 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.

4. 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.


5. 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.



6. If you can see the screws (b) holding the cable clamp to the station, skip to step 9.

   If you cannot see the screws, complete steps 7 and 8.



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



8. Gently lift the cover (c) so you can access the screws in step 9.



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



10. 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.



11. Remove the entire cable from the station.

    Follow recommended product disposal guidelines when discarding the cable.

12. 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.



13. 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.



14. 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).

15. 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 inside the station.

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



17. Gently route the data wire through the tensioner, being careful not to overstress or cut the wire.



18. If you removed the cover to access the cable clamp screws, replace the ten screws that hold the cover in place. Torque to 4.5 Nm (40 in-lb).

19. Check gasket placement to ensure it sits inside the channel all around the arm.

20. 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.

Installation Complete - Power On the Station

Once all cover panels are installed, power on the Express 250. Run a test charge. If you have questions, or if you want to ensure the cable is being detected correctly, contact ChargePoint Support.

Update the Contactor Assembly - Advanced

Remove the Contactor Box

1. Use a 10 mm (3/8 in) nut driver to remove the four CCS Combined Charging System contactor nuts. Save the nuts for later reinstallation.



2. Remove the CCS Combined Charging System contactor cable lugs (a) from the lug landings (b).

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

3. Press the retention tab (c) on the back of the communication cable and remove it from the contactor assembly.



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



5. Remove the remaining three CCS Combined Charging System cables connected to the left side of the contactor assembly: 24 V DC power (e), and CAN connectors (f).

   Each cable is keyed to its corresponding connector except the CAN cables, which are interchangeable.

6. Open the securing latches (g) on the left and right sides of the contactor box assembly by pushing down on the lock tab and lifting the lever.



7. Disengage the contactor assembly from the large bus bar connections at the bottom (h) by holding it with two hands near the bottom and rocking the assembly slightly as you pull outward.

8. Once the bus bar connections release, pull the assembly forward along the support arms (i), then lift it away from the station.

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

Move the Connectors

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



2. Remove the cover.



3. Unplug the 8-pin contactor connector from position 2 (b) and plug it into position 3 (c).



4. Unplug the 8-pin contactor connector from position 1 (d) and plug it into position 2 (b).



5. Replace the cover. Use a T25 Torx screwdriver and three screws to secure the cover.

6. Place the included label on the contactor box indicating the updated slot numbers.

   

Replace the Contactor Assembly

1. Ensure latch clasps are open and not blocking the contactor assembly before installation.

2. Rest the alignment pegs of the contactor assembly on the support arm hooks.

3. 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.

4. Fasten the latches on the right and left sides of the contactor assembly.

5. Reconnect each cable on the left side of the contactor assembly.

   

   (a) DCC Dispenser Charge Controller communication ribbon

   Ensure the key aligns with the notch in the socket.

   (b) 24 V DC power

   (c) 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 automatically click into place.

6. Go to Replace the Swing Arm Assembly. Continue with the steps to replace the charging cable.