Replace a Power Module

To replace a power module, complete the steps in this chapter.

This document describes the complete removal and replacement procedure for a Power Module field replacement. To install a Power Module into a new Express 250 charging station, refer to the Express 250 Installation Guide instead.

Required Tools and Materials

Tools and Materials

Head lamp

T25 Torx security screwdriver

Stepladder

#2 Phillips screwdriver

ChargePoint replacement part #System-PM

Orange and white icon that represents a tool or action.

8 mm (5/16 mm) nut Torque screwdriver
The Express 250 supports one or two Power Modules.

Power Modules are 45 kg (98.5 lbs) each. Installing or replacing Power Modules requires two people.

Always rest a Power Module flat on the ground until it is being installed. Power Modules are not stable in any other position. Images of Power Modules standing up with the handles on top are only to illustrate the proper installation position.

Before you Begin

Complete the following procedures:

  1. Power Off the Station.

  2. Remove the Area Light Bar.

  3. Remove the LED Display.

  4. Remove the Top Front Panel.

  5. Remove the Middle Vent Panel.

  6. Remove the Bottom Front Panel.

  7. Remove the Top Rear Panel.

  8. Remove the Middle Rear Panel.

  9. Remove the Bottom Rear Panel.

  10. Remove the EMI Shield.

  11. Open the Power Module Holders (Ground Straps).

  12. Open the Power Module Holders (EMI Shields).

Remove the Power Module

  1. Tilt both Power Module holders down to the ground and rest them on their kickstands (highlighted).

    2. The kickstands must rest on a surface that is level with the bottom of the station.

  2. To remove a Power Module, slide it partially out of its holder until the handles can be lifted to remove it completely.

Install the Power Module

  1. Install the rear Power Module first. Using two people, lift the Power Module by its top handles and gently slide it into its holder with its connections facing outward (a).

    2. If only one Power Module is being installed, it must be installed in the rear holder (b).

  2. Once the Power Module is positioned partially inside its holder, fold the handles down to slide it in completely.

  3. Repeat the step for the second Power Module if applicable.

  4. Lift each Power Module to the upright position one at a time.

  5. If ground straps are present:

    1. Use a T25 Torx and four M5 screws to attach a ground stud bracket to each side of each Power Module (two brackets and eight screws per Power Module).

    2. Use an 8 mm (5/16 in) nut driver, two M5 nuts, and two M5 washers to reattach each ground strap to the ground studs on the sides of both Power Modules.

  6. If not already done, remove the safety caps from the coolant ports.

  7. At the bottom right of the Express 250, press and hold the yellow release latch while pushing the Power Module tray into the station until it locks into place.

  8. Using two hands, squeeze the Power Module mechanism’s release bar and lower it halfway to check alignment with the ports and guide posts.

  9. Lower the Power Module mechanism until you hear a click as the mechanism locks into place. Ensure the mechanism is fully engaged with all Power Module connectors. The Power Module mechanism should fully cover the ridges on the Power Module’s top edge.

    10. If the mechanism does not engage, raise it again and push the Power Modules to the back of the station to realign, then try again. Do not apply excessive force.

REVERSE THE ABOVE STEPS TO REPLACE THE EMIClosed Electromagnetic Interference SHIELD (IF APPLICABLE), REAR PANELS, FRONT PANELS, LED DISPLAY, AND AREA LIGHT BAR.

Power On the Station.