Replace the Heat Exchanger Assembly

To replace the heat exchanger assembly, complete the following steps:

Required Tools and Materials

  • ChargePoint replacement part #CPE250-HEATEX-F

  • Coolant (included with replacement part)

  • #2 Phillips screwdriver

  • T10 Torx driver

  • T20 Torx driver

  • T25 Security Torx driver

  • T27 Security Torx driver

  • Lint-free absorbent cloth

  • Step ladder

  • 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.

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

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

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

    Technical illustration depicts the procedural step.

  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.

    Technical illustration depicts the procedural step.

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.

    Technical illustration depicts the procedural step.

  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.

    Technical illustration depicts the procedural step.

    (a) Communications cable (USBClosed 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

Technical illustration depicts the procedural step.

  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.

    3. 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 Ground Screw

  1. From the front of the charging station, look to the left of the contactor assembly. Identify the heat exchanger ground wire.

  2. Using a T10 Torx, remove the heat exchanger ground screw from the radiator and save it for later use.

Remove Top and Middle Rear Panels

  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.

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

    When replacing the panel, squeeze the sides of the panel inward to fit the tabs into place in the C-channel, inside the watertight gasket. Ensure the lower panel’s sign is correctly captured under the middle panel’s edge as you carefully push the panel down.

Small gauge wiring routed on the sides of the frame could be sheared if they are caught by panel tabs. Ensure wiring is cleared from guide holes when installing bottom and middle rear panels.

  1. Determine whether the station has ground straps (a) or EMIClosed Electromagnetic Interference shields (b). An Express 250 only needs one of these protection methods. If you’re servicing a station with ground straps, skip to "Remove the Fan Tray Assemblies".

Remove the Rear Bottom Panel and EMI Shield

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

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

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

  3. Use a T25 Torx to remove the four middle and lower screws and washers from the rear EMIClosed 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.

    When reinstalling, ensure the drain hose and cooling controller cover flap are inside the EMIClosed Electromagnetic Interference shield.

Remove the Fan Tray Assemblies

  1. The system has two fan trays (left and right). On each tray, pull the tab (a) at the top of the fan tray assembly forward to disengage it.

    2. Zip ties on the fan tray must be cut off to remove the fan tray assembly.

  2. Using two hands, slide the tray upward until the mounting tabs (b) on the fan tray assembly are positioned above their corresponding slots.

    3. Check that the power connector at the base of the fan assembly easily disengages as the fan tray is lifted.

  3. Pull the fan tray assembly toward you to remove it.

  4. Repeat for the other fan tray.

  5. When replacing the fan tray:

    • Ensure all four tabs on the fan tray assembly are positioned above their corresponding slots.

    • Press the fan tray assembly against the Express 250, then slide the fan tray downward.

    • Ensure each tab on the fan tray is located under, and not over, its corresponding slot.

    • Ensure the top tabs are engaged into the metal housing behind them.

    • Ensure the fan’s power connector at the bottom seats correctly.

    Fan tray zip ties do not need to be replaced.

Remove the Cooling Controller

  1. Identify the cooling controller, located behind the protective foam edging on the middle frame shelf.

  2. Remove each cable attached to the front of the cooling controller by pressing in on its tab and pulling out by hand (listed left to right):

    The CAN cables are interchangeable.

  3. Remove the small pressure sensor tube (a) from the front of the heat exchanger by hand. Route the tube down through the grommet in the frame shelf. The tube remains attached to the controller.

  4. Use a T20 Torx to remove the two screws attaching the controller to the frame shelf (b). Save the screws for reuse.

Ensure the pressure sensor tube is completely seated and centered on the mount point so that air flow is not constricted. Poor installation can result in a false error alert.

Remove the Heat Exchanger Assembly

Before removing the heat exchanger, hold a clean, lint-free absorbent cloth below the Quick Connect coolant lines to prevent the liquid from spilling onto the Express 250’s other components.

  1. For each of the two coolant lines (a), push the button on the Quick Connect at the bottom of the heat exchanger assembly and pull to disconnect the coolant line from the heat exchanger assembly.

  2. Pull the overflow hose (b) out of its corresponding retaining clip.

  1. Using a T27 Torx driver, remove the five screws from the heat exchanger assembly. Three screws are located along the top edge behind a gasket (a), one is located at the bottom right (b), and one at the bottom left (c).

  2. Pull the overflow hose (b) out of its corresponding retaining clip.

    3. For easy of assembly, the heat exchanger is self-supported with all five screws removed.

    Ensure the gasket is not torn or damaged during removal and replacement of the heat exchanger.

  3. Pull the heat exchanger assembly away from the Express 250.

  4. Drain all coolant from the heat exchanger assembly to prepare for return shipping.

Replace the Heat Exchanger Assembly

  1. Hang the new assembly onto the two pins on the frame to support it.

  2. Slightly move the assembly left to right a few millimeters until the top screw holes align. Fasten the five T27 screws, beginning with the three screws across the top edge.

  3. Fasten the ground wire screw.

  4. Fill the heat exchanger assembly’s reservoir to the marked fill line with coolant.

Ensure that wires are not pinched when reinstalling the heat exchanger assembly.

REVERSE THE ABOVE STEPS TO REPLACE THE COOLING CONTROLLER, FAN TRAY, EMIClosed Electromagnetic Interference SHIELD (IF APPLICABLE), REAR PANELS, 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

(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

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.