HPC375A Phoenix Strain relief retrofit kit

 

Strain relief retrofit kit is a one-time activity to prevent cables from having damaged the internal wiring inside of the charging cable.

The kit consists of replacing the inner parts which will be automatically replaced by the supplier when we order new charging cables for customers and on stock.

Strain relief does not have a Part Number because of the reasons mentioned above.

 

Only specifically trained and certified ASP Engineers can perform the rework.

 

Link to Training video: 

HPC 375A rework instruction_final.mp4

Measurement form protocol: Attached

Checklist: Attached

Rework instruction in PPT: Attached

 

The service visit consists of following steps:

1. Initial resistance measurements of cable and filling in the protocol

2. The rework process

3. Following the Checklist + Registering the cable`s serial number

4. Repetitive resistance measurements of cable and filling in the protocol 

5. Final checking

 

1. Initial resistance measurements of cable and filling in the protocol

1. CP + (brown) ≈ 0 Ω

2. PP + (grey) ≈ 0 Ω -> This measurement cannot be completed due to the fact that Grey wire is not present in the cable

3. Blue-orange (temp. sensors) ≈ 1100 Ω

4. Purple-white (temp. sensors) ≈ 1100 Ω

5. Fill in the information's to the attached file "Measurement Form"

Figure1. Measurements

 

2. The Rework Process:

1. Loosen 5 screws, 1x in the handle and 4x around the cable, then lift up the plastic parts 

2. Mark the upper position of strain relief and loose the screws on the sides

3. Loosen 6 screws on the bottom of cable (on the housing) in the right order and take it out

4. Cut off the cable tie from the communication wires - be careful not to damage the wires!

5. Install the AC Strain Relief from the kit (white plastic parts) and tighten them up with the black bolts (Strain relief must be installed the right way!!) - use the toque rating 0,5 Nm +/- 0,1 Nm

6. Place the communication wires back to original position and tighten them up with provided set of cable ties

7. Assembly the housing back, screw back in the 6 bolts, follow the order of screws according to the video and use torque rating 0,75Nm

8. Assembly the new metal strain relief and tighten up the screws on the sides - Strain relief must sit under the drawn line!! - use torque rating 4,5Nm 

9. Mark (if not done so) the new strain relief with a marker

10. Assembly End Cap Retainer and use Torque rating 2,4 Nm

11. Screw End Cap with 1,2 Nm

12. Rework is now completed 

 

3. Registering the cable`s serial number

1. Fill in attached Checklist with information's about the Station Description (SN of charger), Cable marking (scan the QR code on the bottom label of cable) 

2. Proceed to Checklist description

3. Fill in the date and name

 

4. Repetitive resistance measurements of cable and filling in the protocol 

1. Same measurements must be done after the rework is completed

2. Measured values must be the same

 

5. Final checking

1. Turn on charger and visually check the HMI if charger does not report any kind of error message

2. Perform the charging test to successfully conclude the service visit