Replace the Contractor Assembly

To replace the contractor assembly, complete the following steps.

Required Tools and Materials

• ChargePoint replacement part #CPE250-CONTACTBOX-F

• T20 Torx driver

• T25 Security Torx driver

• Torque wrench capable of 2.8 Nm (25 in-lb)

• Step ladder

• Isopropyl alcohol wipes

• Headlamp

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.

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 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 Contactor Assembly

1. Using a T20 Torx driver, remove the screws (a) that attach the cable tabs to the front of the contactor assembly.

   

2. Remove the cable tabs by moving them slightly back and forth while pulling straight out to release.

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

   There are up to three possible charge connector slots shown as 1, 2, and 3 on the front plastic cover (b). Note the position of each communication connector before removal. Each cable must be reattached to its original connector slot on the contactor assembly. Failure to do so may damage the station or vehicle. If the original connector location is unknown, the cable can be attached to the contactor assembly based on the connector type indicated by the label: CCS1/CCS2: #2 or #3 CHAdeMO: #1 or #3.

3. Remove all cables connected to the left side of the contactor assembly:

   

   (a) Charge cable communications

   (b) DCC Dispenser Charge Controller communication ribbon cable

   (c) 24 V DC power

   (d) CAN connectors

   To remove the horizontal ribbon cable, push the tabs outward. Rock it gently from left to right as you pull out the cable.

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

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

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

6. Once the bus bar connections release, pull the assembly forward along the support arms (g), then lift free from the station.

   

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

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

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.

6. Wipe down the contact surface of each cable tab with isopropyl alcohol wipes.

7. After double-checking the photo of the cable order, push each cable tab into its corresponding slot. Ensure the plastic guide post is fully seated to be level with the surface of the cable tab.

8. Use a T20 Torx driver to re-fasten the screw on each cable tab. Torque to 2.8 Nm (25 in-lb).

9. Tuck the excess contactor cable down the side of the enclosure to avoid interfering with the cover panel in a later step.

   

   (a) Charge cable communications

   (b) DCC Dispenser Charge Controller communication ribbon

   Ensure the key aligns with the notch in the socket.

   (c) 24V DC power

   (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.

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.