ChargePoint CT4000-HD Guide

CT4000-HD (Head Assembly)
REPLACEMENT INSTRUCTIONS
Page 1
Ordering Information and Shipping Specifications
Single Output (non-gateway) CT4010-HD 25 lbs 27” x 20” x 11.75”
Single Output (gateway) CT4010-HD-GW 25 lbs 27” x 20” x 11.75”
Dual Output (non-gateway) CT4020-HD 31 lbs 27” x 20” x 11.75”
Dual Output (gateway) CT4020-HD-GW 31 lbs 27” x 20” x 11.75”
Parts Included
Keep the spare activation label. It contains
important information that you must
provide to allow the new head assembly to
be activated on ChargePoint (see page 11).
A duplicate label is attached to the head
assembly.
GATEWAY STATIONS ONLY:
The shipping box also includes an envelope
containing a SIM card. When replacing an existing
gateway head assembly, you will need to destroy
and discard its SIM card and use this new one in the
replacement head.
SIM card
Instructions
Head assembly*
Rubber plugs
(4 - two are spares)
A T25 L-wrench is attached to the side
of the head assembly with a security
tag
*Depending on your ordering option, the head assembly may have only one charging cable.
You Will Need
• Needle Nose Pliers
• #2 Phillips screwdriver
• A ChargePoint card that has been activated on ChargePoint and set up for using
paid charging stations. Go to www.chargepoint.com to create a driver account and
order a ChargePoint card.

Page 3
Page 2
Step 7: Push the black tab on the terminal block
to release the terminal block cover, then
slide the cover up until it locks into the
raised position.
Step 8: Disconnect the blue connector by
pressing the side tabs while rocking
the connector side to side and pulling
downward.
Step 9: Remove the L-wrench you inserted
in Step 6 and lift the existing head
assembly upwards to remove.
Step 10: Place the removed head assembly on
the shipping box to prevent damage
when completing the next step.
Step 11: Using a Phillips screwdriver, remove the
two screws from the back of the top
cap.
Step 12: While using your fingers to release
the top cap’s two retention tabs from
their corresponding nodules (as shown
below), pull the top cap upwards to
remove.
Step 1: Remove the cable clamp(s) by loosening its four screws
using a Phillips screwdriver.
Step 2: With the station powered on, scan your ChargePoint card, then remove the charging
plug(s) from the holster(s).
IMPORTANT! You must scan an activated ChargePoint card to unlock the holster(s)
and remove the charging plug(s).
Step 3: Disconnect the station’s power at the electrical panel.
Step 4: Use pliers to remove the rubber plug(s),
located inside the holster(s).
Step 5: Open the shipping box for the new head
assembly and remove the T25 L-wrench from
the side of the new head assembly (illustrated
on the previous page). Use this L-wrench to
loosen the security set screw(s) located
inside the holster(s).
TIP! After removing the T25 L-wrench from the
new head assembly, close the shipping box—the
top of the box is a place you can support the
removed head assembly, as
described in Step 9.
Step 6: Raise the head assembly high
enough to access the terminal
block. To hold the head assembly
in the raised position, insert the
L-wrench into the thru-hole on
the side of the head assembly.
This hole is located on the right
side of the head assembly and
is marked with the screwdriver
symbol.
Pull the
blue
connector
down to
release
Push tab
and lift
cover
Remove these 2 screws
Lift the tab on
each side of the
top cap to release
it from its
corresponding
nodule on the
head asembly
Tab
Tab
Nodule
Nodule
Remove the Existing Head Assembly Remove the Existing Head Assembly
L-wrench
Insert the
L-wrench
into the
thru-hole

Page 5
Page 4
Step 13: GATEWAY STATIONS ONLY: Remove
and destroy the SIM card.
Lift the rubber flap on the right side of
the old head assembly and push in the
SIM card to unlatch it (use a pointed
object). The card will pop out.
Once removed, use pliers to break the
old SIM card in half.
TIP! You can use the new SIM card’s
carrier to push on the existing SIM
card.
YOU ARE NOW READY TO INSTALL THE NEW HEAD ASSEMBLY.
Step 1: Prepare the head assembly for mounting
a) Re-open the shipping box and stand
the new head assembly upright on
its foam packaging, as shown.
b) GATEWAY STATIONS ONLY: Install
the new SIM card:
• Remove the SIM card, included in
the shipping box, from its carrier
by pushing it firmly.
• Lift the rubber flap located on
the right hand side of the head
assembly, as shown.
• Insert the notched edge of the
SIM card into the slot, with the
notch facing upward. Slide it
into the slot and push it FULLY
into the slot until it “clicks” into
place. Refer to the orientation
instructions printed on the side
of the head assembly.
TIP! To push the SIM card into
the slot, use the corner of the SIM
card’s carrier, as shown.
c) Re-Install the top cap
• Place the top cap over the head
assembly, ensuring correct
alignment.
• Using a Phillips screwdriver, secure the top cap to the head assembly by
inserting its two screws into the back of the top cap and tightening to
20 in-lbs.
Remove the
SIM card
Remove the Existing Head Assembly Install the New Head Assembly

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Step 2: Slide head assembly into the body.
Slide the head assembly into the main body and stop it in its raised position by inserting the
L-wrench into the marked hole on the right side of the head assembly, as shown.
IMPORTANT: Do not insert the charging connectors into the holsters until after you’ve
powered up the station. Doing so causes the holsters to permanently lock.
Step 3: Connect the head assembly.
a) Remove the yellow strap from the blue connector.
b) Connect the blue connector to the
terminal block, ensuring it clicks into
place.
c) Push the cover down over the terminal
block.
Step 4: Power up the station.
At the electrical panel, power up the charging station.
Install the New Head Assembly Install the New Head Assembly
Connect
the blue
connector
to the
terminal
b
l
oc
k
Push the
cover
down over
the terminal
block
Insert the L-wrench
into the marked
thru-hole to keep
the head assembly
raised

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Page 8
Step 5: Verify the station operates correctly.
IMPORTANT:if the station is not operating as described below, see Troubleshooting on
page 13 to resolve the error before continuing.
a) When the station is powered on, you should see:
• The instructional video, and no error messages.
• The status icon for each port displaying a green check mark.
Neither of the two error LEDs light up (for some errors, these LEDs are solid or
blinking red).
NOTE: If the station does not power up, check that the head assembly’s blue
rectangular connector is properly seated onto the terminal block.
For some errors, this top banner
displays an error message instead
of station information
Under
normal
conditions,
the station
displays the
instructional
video
For some errors, one or both error LED(s)
will appear solid or blinking red
The status icon for each port
should display a green check
mark. If these icons appear,
the port (or station) has an
error:
Choose a menu option
by pressing the button
below it
In some cases, a static
error message fills the
entire display
b) Even if the station’s display and LEDs show no indication of an error, always check
the station codes to confirm that no errors exist. To display station codes:
• Activate the Service Menu by simultaneously pressing
and holding the two left most buttons and the right most
button for two seconds.
• Press the station button immediately below the “HELP”
menu option.
• Press the station button immediately below the “DOWN”
menu option to highlight “Station Codes”.
• Press SELECT.
This port is
displaying
a station
code
This port is
not
displaying
a station
code
If you see a station code, you must resolve or report the error before leaving the
installation site. Station codes are described on pages 13 to 17.
Simultaneously press and
hold these three buttons
for two seconds to displa
y
the Service Menu on an
unactivated station
Install the New Head Assembly Install the New Head Assembly
c) Use your ChargePoint card to authorize a charging session. Make sure that both plug
holsters unlock and that the station displays instructions on how to plug into the
vehicle.
d) Ensure the station is receiving an adequate LAN signal to allow it to communicate
with other nearby station(s) in the same radio group. HOW? OR DO THEY JUST
NEED TO MAKE SURE THEY DON’T HAVE AN ERROR 204?
NOTE: Stations must be located within 150 line of sight of a gateway station with no
obstructions.
e) GATEWAY STATIONS only: Ensure the station is receiving an adequate signal
strength from the cellular network:
• Activate the Service Menu as described on the previous page (b).
• Press the station button immediately below the “Basic Mode” menu option.
• Press the station button immediately below the “DOWN” menu option to
highlight “Display last measured RSSI”.
The strength of the signal should be A, B, or C. If the network signal is Grade D and
a better network signal is available on the other type of modem, change modems
by choosing: Basic mode > Change modem technology (CDMA or GSM). If the signal
strength is either weak (D) or not available for both modems, arrange for cellular
repeaters to be installed near the installation site.
If you have performed the above steps, and the station operates as described and no errors
exist, continue with the installation. If any of the above conditions are not met, resolve the
error before continuing (see Troubleshooting on page 13).
Step 6: Install the Cable Clamps.
IMPORTANT:Do not unwrap the retractor’s ropes until they are securely attached to the
charging cable.
a) Locate the bead at the end of the retractor rope.
b) Uncoil the charging cable by removing the plastic wrap, then gently extending it all
the way out, away from the station. Rotate the plug as necessary to remove any
twists or kinks. Locate the tape that marks the position where the clamp attaches to
the cable.
c) Insert the bead inside the clamp, then
snap the opposite side of the clamp into
place.
d) Secure the two sides of the clamp
together by inserting the four screws and
tightening them securely using a Phillips
screwdriver.
e) Pull down on the rope and remove the
rope from its wrapper. When the rope is
unwrapped, it retracts into the top cap.
f) Repeat the above steps for the other charging cable (if applicable). If installing a
single port station, allow the left (unused) rope fully retract into the top cap.
IMPORTANT:Check that the charging cable extends and retracts fully and smoothly. If
it doesn’t, see page 18.

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Page 10
Step 7: Secure the head assembly.
a) Remove the L-wrench from the hole in the right side of the head assembly, then
lower the head assembly. Ensure the head assembly is fully seated and that no gap
exists between the bottom of the head assembly and the main body. The head
assembly fits tightly and may require extra downward force to ensure it is fully
seated.
b) Using the T25 L-wrench, tighten the two
security set screws, located inside the
holsters, to approximately 25 to 30 in-lbs.
c) Cover the screws using the two rubber
plugs.
d) Insert the charging plugs into their
corresponding holsters.
You have now finished the physical installation of the new head assembly and are ready to
prepare the head assembly for activation on ChargePoint.
Record Station InformationInstall the New Head Assembly
Step 1: Record information from the old head assembly.
Write down the following information from the old head
assembly’s activation label. This label is located on the right
side of the head assembly, as shown.
OLD
Head Assembly
Enter Mac Address here:
__________________________
Enter Activation Password here:
__________________________
Step 2: Record information from the new head assembly.
Place the spare activation label for the new head assembly (included in the shipping box)
here:
NEW
Head Assembly
Step 3: The Head Swap Procedure
After completing the checklist on the following page, tear out this page and provide it to the
person responsible for activating ChargePoint stations. This person will need to perform a
logical head swap to activate the new head assembly on ChargePoint. See Appendix A for
instructions on how to perform a logical head swap.

After completing both sides, cut or tear along dotted line and give it to the person responsible for activating the station.

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Before leaving the installation site, complete this checklist. Then tear out this page and give it
to the person responsible for activating the station.
Check each box below to confirm that the task has been completed.
The two security screws inside the holster plugs on the head assembly are
tightened and the rubber plugs are in place (see page 10).
Cable clamp halves are screwed together with no gaps (see page 9). All
charging cables operate smoothly through full extension and retraction.
The station has adequate communications signal(s) (see page 9).
The Service Menu shows no station codes for either port (see page 8).
When starting a charging session using your ChargePoint card, the station
displays no error codes or warning lights (see page 8), and both holsters
unlock and lock.
Station information for both the old head assembly and new head assembly has
been recorded (opposite page).
TroubleshootingComplete the Post-Installation Checklist
Description of Station Codes
If you see a station code (see page 8 for details on how to display station codes), you
must resolve or report the error before leaving the installation site.
Code Symptom Possible cause(s)
Recommended
Action(s)
In most cases, a driver can resolve the following station codes that begin with the digit “1”:
101-
Over Current Detection
n = the number of the applicable port
During charging, the
vehicle attempted to
draw more power than
allowed. The station
stops delivering power to
the vehicle.
Can indicate faulty
wiring in the vehicle.
End the session by
inserting the station’s
plug back into its
holster, then restart
the session.
If the error persists,
call ChargePoint
Customer Support at
1-877-850-4562.
102-
Ventilation Requested
n = the number of the applicable port
Vehicle requires
ventilated charging which
is not supported by the
station. The station stops
delivering power to the
vehicle.
Driver will be unable
to use the station
to charge their type
of vehicle. Call the
vehicle manufacturer.
103-
Soft Ground Fault
n = the number of the applicable port
During charging, the
station detected a ground
fault. The station stops
delivering power to the
vehicle, but continues to
retry every 30 seconds.
End the session by
inserting the station’s
plug back into its
holster, then restart
the session.
If the error persists,
call ChargePoint
Customer Support at
1-877-850-4562.
104-
Immediate Ground
Fault
n = the number of the applicable port
On initial plug-in, the
station detected a
ground fault. The station
stops delivering power to
the vehicle.
End the charging
session by inserting
the station’s plug
back into its holster,
then restart the
session.
If the error persists,
call ChargePoint
Customer Support at
1-877-850-4562.
In most cases, an electrician can resolve the following station codes that begin with the
digit “2”:
201-SIM
SIM Not Detected
The SIM is either not
installed or is incorrectly
installed and the station
can not communicate
with the ChargePoint
network.
Disconnect power
and install (or re-
install) the SIM card
as described on
page 5.
If the error persists,
call ChargePoint
Customer Support at
1-877-850-4562.

After completing both sides, cut or tear along dotted line and give it to the person responsible for activating the station.

Page 15
Page 14
Code Symptom Possible cause(s)
Recommended
Action(s)
202-EF Earth Fault
The station has
detected a poor ground
connection and the
station is not operational.
Disconnect power
and check that the
station is properly
grounded. After
ensuring the station
is properly grounded,
reconnect power.
If the error persists,
try unplugging the
head assembly and
plugging it back in.
If the error continues
to persist, call
ChargePoint
Customer Support at
1-877-850-4562.
203-SNP The banner between the
port icons displays
“STATION NOT
ACTIVATED ON
CHARGEPOINT - GRACE
SESSIONS REMAINING
(N).”
When all grace sessions
have been used:
Station not activated
The station can be
used to charge for the
specified number of
remaining grace sessions.
When all grace sessions
have been used, the
station is not operational.
Arrange for the
station to be
activated on
ChargePoint.
204-NGNP Before activation:
The banner between the
port icons displays
“NO GATEWAY WITHIN
RANGE.”
After activation:
All you will see is the
code listed on Help >
Station Codes.
Non-Gateway Not Paired
The station is set up to
communicate with a
gateway station that is
either not within range,
or is not powered on.
Verify that the
gateway station is
powered on and
located within 150
feet line of sight (no
obstructions).
If the error persists
after these
requirements are
met, call ChargePoint
Customer Support at
1-877-850-4562.
Code Symptom Possible cause(s)
Recommended
Action(s)
205-UNS Before activation:
The banner between the
port icons displays
“NETWORK SIGNAL
NOT DETECTED.”
After activation:
All you will see is the
code listed on Help >
Station Codes.
Unknown Network Signal
The gateway station is
unable to establish a
network connection on
AT&T/Verizon (US) or
Rogers (Canada).
Ensure the station is
receiving an adequate
signal strength from
the cellular network.
To do so, display the
Service menu*, then:
• Check the
network signal
for each type
of modem by
choosing: Basic
mode > Display
last measured
RSSI. The
strength of the
signal should be
A, B, or C.
• If the network
signal is Grade
D, or if a better
network signal
is available on
the other type
of modem,
change modems
by choosing:
Basic mode >
Change modem
technology
(CDMA or GSM).
If the signal strength
is either weak (D)
or not available for
both CDMA and
GSM, arrange for
cellular repeaters to
be installed near the
installation site.
If the error persists
when the station
shows a strong
network signal,
call ChargePoint
Customer Support at
1-877-850-4562.
*To display the
station’s Service
Menu, scan your
ChargePoint Service
card (if the station
is activated) or, if
the station is not
activated, press the
three station buttons
as described on
page 8.
TroubleshootingTroubleshooting

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Code Symptom Possible cause(s)
Recommended
Action(s)
206-FLC Before activation:
After activation:
You will see the code
listed on Help > Station
Codes and the port
status icons will show:
n = the number of the applicable port
or
Floating Line Connection
The voltage of an AC
input line has fallen
below 80 volts AC
relative to ground.
Even if the line to line
voltage measures
nominally 208 or 240
volts, the voltage of each
line must be greater than
80 volts when measured
to ground.
The two most common
causes of a Power Line
Fault are:
• A poor connection in
the wiring supplying
power and the ground
connection to the
station. There could
be a poor connection
between the buss bar
and circuit breaker,
the breaker to the
branch circuit feeding
the station, or at
any splice along the
branch circuit.
• The station is
connected to
an incompatible
improperly grounded
power source. All
power and ground
connections must be
clean and tight and
carry the full rated
current of the station.
Do not connect
the station to an
ungrounded (floating
neutral) system, a
corner grounded
Delta system, or the
high (or “stinger” leg)
of a center grounded
Delta system.
Correct any faulty
connections.
Verify that the
station is connected
to a system with
its neutral properly
grounded according
to NEC Article 250.
Verify the station
is connected to a
compatible and
properly grounded
power source. See
Chapter 1 of the
CT4000 Installation
Guide.
If the error persists,
call ChargePoint
Customer Support at
1-877-850-4562.
Code Symptom Possible cause(s)
Recommended
Action(s)
ChargePoint Support may need to resolve the following station codes that begin with the digit “3”:
301-BA Breakaway Fault
The cable has been
removed from the station
or is damaged. The
station is not operational.
Call ChargePoint
Customer Support at
1-877-850-4562 to
arrange to have the
station replaced.
302-GST
n = the number of the applicable port
or
GFCI Self Test Failed
The station detected
a ground fault during
power up and is not
operational.
End the session by
inserting the station’s
plug back into its
holster, then restart
the session.
If the error persists,
call ChargePoint
Customer Support at
1-877-850-4562.
303-RSC
n = the number of the applicable port
or
Relay Stuck Closed
When attempting to
end a charging session,
the relay stays closed.
Although the driver can
return the station’s plug
to its holster, the station
doesn’t end the session.
Therefore, a new session
can not be started.
Call ChargePoint
Customer Support at
1-877-850-4562 to
arrange to have the
station replaced or
repaired.
305-LCO Pilot Unreachable
The station is out of
service.
Disconnect and
reconnect power.
If the error persists,
call ChargePoint
Customer Support at
1-877-850-4562 to
arrange to have the
station replaced or
repaired.
306-BF Boot Fault
The station is out of
service.
Disconnect and
reconnect power.
If the error persists,
call ChargePoint
Customer Support at
1-877-850-4562 to
arrange to have the
station replaced or
repaired.
307-HE Hardware Error
The station is out of
service.
Disconnect and
reconnect power.
If the error persists,
call ChargePoint
Customer Support at
1-877-850-4562 to
arrange to have the
station replaced or
repaired.
TroubleshootingTroubleshooting

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Page 18
Rotate the
top cap so
the faulty side
faces towards
you
Pull the
center rope
to raise the
weight shelf
Charging Cable Doesn’t Move Freely
If the charging cable does not extend or retract fully and smoothly, it is likely that it’s rope has
come off the pulley and you must re-position it.
TroubleshootingTroubleshooting
Step 1: Using the T25 L-wrench, loosen the set
screws on each side of the retractor below
the top cap.
Step 2: Each rope is attached to a weight that
sits on a shelf. Pull the weight shelf up by
pulling the rope located in the middle of
the top cap.
Step 3: Rotate the top cap so the weight
controlling the rope that doesn’t move
freely is facing towards you.
Step 4: Inspect the rope to ensure it is properly
aligned onto the pulley.
Step 5: Carefully lower the weight back into the
retractor.
Step 6: Rotate the top cap back into position and
re-tighten the set screws to about 10 in-lbs.
Ensure the rope is properly
aligned onto the pulley

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APPENDIX A: Logical Head Swap ProcedureAPPENDIX A: Logical Head Swap Procedure
When a station’s head assembly has been replaced, the new head assembly must be activated
on ChargePoint by following the steps provided in this appendix.
You Will Need
• Laptop or tablet computer
• Installer user name and password for www.chargepoint.com
Follow These Steps
Step 1: Log into www.chargepoint.com using your installer user name and password.
Step 2: Click Manage Stations.
Step 3: In the Table View, find the station associated with the old head assembly.
TIP! You can filter the list of stations by entering its MAC Address (see page 11).
Step 4: Hover the cursor anywhere over the station’s row and click View/Edit Property.
Step 5: On the station properties window, click Status/Actions.
Step 6: Click Swap Head.
Step 7: Enter the new head assembly’s MAC Address and Activation Password. This
information is located on the new head assembly’s spare activation label (see
page 11).
Step 8: Click Swap Head.
The new assembly has now been activated.
Enter the new
head assembly’s
MAC address and
activation password

1692 Dell Ave.
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US toll free: [phone]
www.chargepoint.com