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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)
More advanced LED codes come from a table in CC's "HCS Troubleshooting Guide". Note that the number of blinks of the two bottom red LEDs is important. If two blinks, then the line 1 side of the contactor is failing; if three blinks, then line 2.
Relay / contactor information
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. When terminating wires into it, crimp ferrules onto the wire ends.
| Make | Model | link | link | suitability |
|---|---|---|---|---|
| Hongfa | XMC0-402.IBBD | website | contactors catalog (PDF) | used by OEM |
| American Zettler | XMC0-402.IBBx (x=C? D?) | unknown | ||
| Homer | XMC0-402.IBBx (x=C? D?) | unknown | ||
| Packard | C240C | unknown | ||
Background / failure modes
Brain dump from someone experienced with failure modes on these units:
- 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 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
