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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)
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
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.
| 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"
evaluated Aug 2024
|
| Appli Parts | APAC-240240 | Amazon, $21 | evaluated Aug 2024
| |
| CGELE | UPC 774297736354 | Amazon, $12 | evaluated Aug 2024
| |
| BlueStars | LTC-2S-40 / 2P-40A-240V | Amazon, $13 | evaluated Aug 2024
| |
| 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)
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