[EXT- H4] HCS Charger Comms Board Upgrade

Purpose of the Upgrade

This upgrade replaces the charger’s GEN1 comms board with a GEN2 model.
The GEN2 board includes:

• Dual SIM support: One internal Verizon SIM and one external multi-carrier SIM for network redundancy.

• Wi-Fi capability, allowing an additional connectivity path.

This upgrade is typically performed when a charger with a GEN1 board has trouble maintaining a reliable cellular connection. Swapping in a GEN2 board often restores full network connectivity and ensures continued communication with ZEFNET.

Tools & Materials Required

• GEN2 comms board (provided)

• Smartphone with functioning camera

• Phillips screwdriver (magnetic tip recommended)

• Flathead screwdriver

• Socket wrench with ratchet

• Headlamp (recommended)

Before starting:

• Power down the charger at the breaker or disconnect.

• Confirm no voltage is present with a multimeter.

• Avoid ESD (electrostatic discharge) — wear a wrist strap if available.

Step-by-Step Instructions

1. Remove the Charger Back Panel

• If necessary, gain access to the back panel by dismounting the charger from the wall
• Remove the screws on the back plate to access the charger interior

2. Disconnect Wiring

• Remove the Red and Black power wires from the charger contactors.

• Remove the green ground wire from the ground bus bar (connected to the comms board).

3. Remove CT (Current Transformer)

• Detach the CT lead from the L1 contactor.

• Carefully slide the CT (black ring) off the L1 wire.
  Note orientation: the green dot should face the grid during reinstallation.

3. Disconnect Serial Cable

• Unplug the gray serial cable (with black boot, RBWG wires at the end).

• Remove the accompanying green ground wire from the bus bar.

4. Remove the GEN1 Board

• Use a Phillips screwdriver to unscrew the board from its mounting posts.

• Gently lift the board out of the enclosure.

5. Install the GEN2 Board

• Position the GEN2 board in place.

• Screw the board down securely with existing fasteners.

• Reconnect:

  • The middle power wires to the board.

  • The green ground wire back to the bus bar.

6. Reinstall the CT

• Slide the CT back onto the L1 conductor, ensuring the green dot faces the grid.

• Reattach the CT lead to the L1 contactor.

7. Reconnect Serial Cable

• Plug in the serial connection.

• Reattach the green grounding wire to the bus bar.

8. Attach Modem

• Align the modem carefully with the connector on the board.

• Caution: It is very common to offset the modem by one or two pins — ensure it's fully seated and aligned on both ends.

9. Connect Antenna

• Attach the antenna to the X1 port on the modem.

10. Power Up the Unit

• Restore power to the charger at the breaker or disconnect.

• Wait for the LED on the new comms board to display breathing cyan — this confirms:

  • Cellular or Wi-Fi connection established

  • Successful communication with ZEFNET

• After taking the photos outlined in the next step, the back panel can be reattached and the charger can be re-mounted. 

Final Tasks

11. Capture and Report Serial Numbers

Use your phone to take clear photos of:

• The old board’s serial number

• The new board’s serial number

Then send an email or ticket to ZEF Support (support@zefenergy.com) with:

• Old Serial Number

• New Serial Number

• Site name or address (if available)

12. Return the Old Board

• Pack the GEN1 board securely, and include notation of 
  - the serial number of the charger from which the board was removed
  - the organization owning the charger

• Return to:
  
  ZEF HQ c/o Jonah Nielsen
  323 N Washington Ave Ste 200, Minneapolis, MN 55401