ClipperCreek HCS series

(up to EV chargers section)

This page provides information to support DIY repair of ClipperCreek HCS series EV charging stations, which include the popular HCS-40 and HCS-60 models. ClipperCreek has famously awesome customer support, including hardware swap if the unit is still under warranty. If out of warranty, well here you go.

Clipper Creek HCS user manual (see page 16 for basic LED codes table)

Fault codes from LED status indicators

LED indicators from top to bottom:

• Power / Yellow
• Charging / Green
• Power Fault / Red
• Charging Fault / Red

Note that the number of blinks of the two bottom red LEDs is important.

No indicators on = No power applied to board.

Solid Amber Power = Power applied to board. Charge not requested.

Solid Amber Power and Solid Green Charging = Power applied to board. Charge requested.

Solid Amber Power and Solid Red Power Fault = No ground connection, or high ground resistance

Solid Amber Power and Blinking Charging Fault = CCID fault, Check CCID coil harness

Solid Amber Power and Solid Charging Fault = Pilot error, pilot signal out of spec

Power Fault and Charging Fault Blinking 2 times = Line 1 relay monitor failure

Power Fault and Charging Fault Blinking 3 times = Line 2 / Neutral relay monitor failure

Power Fault and Charging Fault Blinking 4 times = CCID startup self test failure, check CCID coil harness

Power Fault and Charging Fault Blinking 5 times = Internal fault, component damaged or incorrect component installed

Relay / contactor information

Hongfa contactor seen in actual unit

Two of the fault codes above involve a failed contactor, one of the few mechanical items in the assembly and thus more prone to failure. This part is a 40-Amp, 2-pole contactor with metal mounting plate and screw terminal capability. (Here's a basic intro into what a contactor is and how it works.)

Notes:

• high-current terminals may be label L for Line and T for Terminus (load) but it actually doesn't matter
• When terminating the high-current wires into it, crimp ferrules onto the wire ends.

contactors for HCS series

Make	Model	info / link	info / link	suitability / notes
Hongfa	XMC0-402.IBBD	website	contactors catalog (PDF)	reference, used by OEM 60mm H x ~80mm L x ~50mm W coil terminal tabs are splayed no coil cover
American Zettler	XMC0-402.IBBx (x=C or D, terminal type per data sheet below)	RS Online (out of stock)	DigiKey (high volume only, long lead)	unknown but likely highest quality has manual button override
American Zettler	XMC0-402.ID	data sheet from Zettler	DigiKey ($10 for qty 1)	same as Zettler above but with "standard thermoset frame" instead of "compact thermo plastic frame" visually looks the same 66mm H x 84mm L x 50mm W manual override exposed coil terminal tabs are splayed coil is covered tested with HCS-40 in Aug 2024, worked fine
Appli Parts	APAC-240240		Amazon, $21	65mm H x 82mm L x 55mm W manual override under plastic cover exposed coil testing with HCS-40 in Oct 2024 ...
CGELE	UPC ‎774297736354		Amazon, $12	inspected Aug 2024: 65mm H x 88mm L x 53mm W slightly larger but still fits easily manual override under plastic cover exposed coil L + T terminals not labeled but doesn't matter only 1 vs 2 tabs for each of 4 L+T
BlueStars	LTC-2S-40 / 2P-40A-240V		Amazon, $13	inspected Aug 2024: 65mm H x 82mm L x 53mm W manual override under plastic cover exposed coil L + T terminals not labeled but doesn't matter
Homer	XMC0-402.IBBx (x=C? D?)			unknown
Packard	C240C			unknown

Background / failure modes

Common failure modes on these units:

• inadequate strain relief at J1772 plug handle inlet, leading to broken wire inside
• Corrosion at a terminal causing over heating of the wire inside the factory sealed box
• The one circuit board having a failure
• High ground leakage
• microswitch in the handle getting water in it and freezing, immobilizing the microswitch
• Pin contacts in the handle just wearing out from cycling-- or arcing on pullout, not supposed to work like that...

A common problem with Level 2 EVSEs in general is that the contactor welds itself closed. Typically not an issue with ClipperCreek though. OpenEVSE chargers like to do this later in life. After taking it apart and filing down the welds on the contact faces, you start just banging your fist on it real hard a couple times. Then power cycling it. That fist induced vibration was usually enough to break those welds, power cycle to clear the error, and get it working again for another month. Before it welded itself again. (will move this to OpenEVSE page later)

More product photos

inside view of HCS series EVSe, with back cover removed

lone PCBA inside the HCS series EVSE