Prepare for Installation

This topic describes how to prepare for the installation.

Check Site Readiness

The Power Link 1000 can be installed on either a newly poured pad or an existing concrete surface. The Power Link 1000 also supports wiring run above ground for locations where no underground wiring access exists (such as parking garages) or where underground junction boxes are not permitted.

If not installed correctly, the ChargePoint charging station may pose a fall hazard, leading to death, personal injury, or property damage. Always use the provided Concrete Mounting Template or a ChargePoint approved surface mounting solution, to install the ChargePoint charging station. Always install in accordance with applicable codes and standards using licensed professionals. Non approved installation methods are performed at the risk of the contractor and void the Limited One-Year Parts Exchange Warranty.

Before beginning work, check that the site meets these civil and mechanical requirements:

Express Plus Power Link 1000 Pre-Installation Checklist
1.  

The concrete pad for each station must be fully cured and smooth, and must not exceed a slope of approximately 20 mm per meter (0.25 in per ft).

Remove any concrete that is not level with the rest of the surface so you can level the components. Use a grinder or a hammer and chisel to remove any bumps in the concrete.

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2.  
The concrete pad for each station either has a site drawing approved by a structural engineer for this specific site, or is an existing pad that has been approved by a structural engineer for the dimensions and weight of the station. ☐
3.  

The concrete pad for each station must conform to the design requirements listed in the Power Link 1000 Site Design Guide.

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4.  

Walls, fences, or slopes must not prevent water from draining from the pad.

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5.  

You have sufficient space around the installation pad to use a forklift and other lifting equipment, unpack crates, remove packing materials, and allow two people to freely move throughout the area.

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Power Link 1000 Readiness

Ensure that the Power Link 1000 is ready for installation. Refer to the following topics for more information:

Concrete Mounting Template (CMT)

If the Power Link 1000 is pedestal-mounted and using stub-up wiring, ensure the Power Link 1000 Concrete Mounting Template (CMT) is already embedded in the concrete pad.

Space For

Max. Size

Max. Quantity

(a) DC input conductors' conduit entry

Each up to 91 mm (3.5 in) trade size conduit

2

(b) 48 V DC wires' and Cat6 Shielded Twisted Pair (STPClosed Shielded Twisted Pair) Ethernet cable's conduit entry

21 mm (3/4 in) trade size conduit

Check site drawings.

3

(c) M16 anchor bolts entry

76 mm (3 in) above concrete for mounting Power Link 1000

4

Clearances

Image not to scale.

Power Link 1000

Clearance

(a) Front

Minimum open space

610 mm (24 in)

Door swing + width of unit

730 mm (28 3/4 in)

(b) Side

305 mm (12 in) from top corner to top corner

Two Power Link 1000 units can share side clearance provided adequate clearance is allowed for Cable Management Kit (CMKClosed Cable Management Kit) arms.

CMKClosed Cable Management Kit arms cannot share side clearance.

(c) Top

Pedestal mounted:

26 mm (1 in) from top of Cable Management Kit (CMKClosed Cable Management Kit)

Overhead mounted:

305 mm (12 in) from top of Power Link 1000

(d) Rear

203 mm (8 in)

If two Power Link 1000 are positioned back-to-back, there must be at least 610 mm (24 in) of shared clearance.

You will need greater clearance for special methods and accessories.

Special Method Clearance

Surface conduit entry

Rear: 610 mm (24 in)

You must meet additional site requirements for special methods and accessories. See the Power Link 1000 Site Design Guide.

General Estimates for Lifting

Power Link 1000 Configuration

Power Link 1000
(no cables or cable management)

Charging Cable Weight

Cable Management Kit (includes swingarms)

Standard

208 kg (459 lbs)
(120 kg (283 lbs) Power Link 1000 + 80 kg (176 lbs) pedestal)

~3.2–3.5 kg/m

(7 - 8 lbs)

longer lengths vary

20 kg (44 lbs)

Overhead Mounted
(to a wall, gantry, post, or other surface)

120 kg (265 lbs)

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Electrical Readiness

If the site does not meet these basic requirements, contact ChargePoint before continuing.

  • The appropriate circuit protection and metering is in place at the installation site.

  • A grounding conductor that complies with local codes is properly grounded to earth at the service equipment or, when supplied by a separate system, at the supply transformer.

  • Wi-FiClosed Wireless Fidelity and cellular signal strength meet the requirements stated in the Power Link 1000 Site Design Guide.

For questions about site specifications, refer to the Power Link 1000 Datasheet and Power Link 1000 Site Design Guide.

The Power Link 1000 is tested to IEC 61000-4-5, Level 5 (6 kV @ 3000 A) standards. In geographic areas that experience frequent thunderstorms, supplemental surge protection must be installed at the service panel.

Required Tools and Materials

Installing the station requires at least two people. Additionally, the installer must bring the following tools and materials. These are not provided by ChargePoint.

Tools for Installation

Tools

Forklift

  • Rated for ≥ 680 kg (1500 lb)

  • Maximum size of forklift tines:

    • Width = 102–127 mm (4–5 in)

    • Maximum thickness ≤ 57 mm (2.25 in)

  • If your site has height constraints, use alternative equipment

Stepladder

Lock out/tag out equipment

Hard hat

Cut-resistant gloves

Safety glasses

Head lamp

Measuring tape or other tool to measure height, length, and distance

Level

Use hand to tighten

Box cutter

Phillips screwdriver set

  • #2 Phillips screwdriver with long handle

  • #3 Phillips screwdriver

  • #5 Phillips screwdriver

  • Right angle (90°) #5 Phillips screwdriver

Flat head screwdriver

Torx wrench set

  • T20

  • T25

  • T30

Torx security wrench

  • T25

Torque wrenches for 4 to 95 Nm (3 to 70 ft-lb)

Only for Overhead CMKClosed Cable Management Kit: 13 mm spanner wrench.

Adjustable wrench

Socket wrench set including deep sockets, up to 25 mm

Cable puller or fish tape

Hydraulic hole punch tool (to cut 4 inch holes in gland plate)

Conduit cutters (to cut up to 4 inch conduits)

Multimeter with Cat III 1000 V ratings, such as Fluke 87V or similar

Ethernet tester such as a Klein Tools VDV526-052 VDV LANClosed Local Area Network Scout Jr. Tester or similar

Orange and white icon that represents a tool or action.

Wire strippers, including Ethernet (Cat6 STPClosed Shielded Twisted Pair) cable

Ethernet (RJ45) connector crimping tool

  • Wire cutters, including Ethernet (Cat6 STPClosed Shielded Twisted Pair) cable

    		•

    Lug crimping tool

    Dieelectric grease

    Torque paint pen

    Cable ties

    Permanent marker

    Isopropyl wipes and towel roll

    Duct seal compound

    Coolant funnel

    Two gallon coolant

    Padlock provided by station owner if required (for security panel on Power Block)

    Wire brush (to remove concrete from bolts)

    Broom and vacuum

    Smartphone with: Internet connectivity

    ChargePoint installer login credentials

    QRClosed Quick Response code scanner (usually built into the camera app)

    Exact location of stations or units, including parking space

    Ferrule crimp tool (for 16 mm2 or 6 AWGClosed American Wire Gauge wire)

     

     

     

    Tightening Torque

    The tables below provides tightening torque values for installing Power Link 1000.

    Tightening Torque for Power Link 1000

    Component (xFasteners)

    Component Material

    Tool

    Torque

    • Door brackets, upper and lower enclosure (x4)

    Plastic

    T25 Security

    1 Nm (10 in-lb)

    • Top cap, front (x2)

    Plastic

    7 mm socket

    T20 Torx

    T25 Security

    1.7 Nm (15 in-lb)

     

    13 mm socket

    11 Nm (97 in-lb)

    Metal

    8 mm hex

    4.5 Nm (40 in-lb)

    Metal

    T20 Torx

    T25 Security

    2.8 Nm (25 in-lb)

    • Holster (x4 or x8)

    • Top cap, rear (x2)

    • Bottom cap, wall or overhead mount Power Link 1000

    Plastic

    T25 Security

    • Charging cable assembly (x4 or x8)

    • Doors, upper and lower enclosure (x6)

    • Gland plate, wall or overhead mount Power Link 1000

    Metal

    4.5 Nm (40 in-lb)

    10 mm socket

    5.6 Nm (50 in-lb)

    T25 Security

    17 mm socket

    19 Nm (14 ft-lb)

    • Anchor bolt base nuts (x4)

    24 mm deep socket

    54.2 Nm (40 ft-lb)

    • Power Link 1000 mounting nuts (x4)

    94.9 Nm (70 ft-lb)

    Metal

    6 mm hex

    13.5 Nm (120 in-lb)

    -

    Flathead screwdriver

    4 Nm (36 in-lb)

    • Wall or overhead mounting bracket to wall or overhead structure

     

    Per site plan

    Materials

    You will need the following materials for installation:

    • Ground conductors as required by site drawings

    • DC conductors as required by site drawings

    • 48 V DC wiring as required by site drawings

    • Power Link 1000 DC lugs:

      • Copper plated compression lugs (not mechanical)

      • Must fit M12 stud size

      • Must fit 44.5 mm (1.75 in) hole spacing

      • 2-hole specified for North America

      • Maximum tongue width:

        • ≤ 48 mm if 2 conductors per line

          or

        • ≤ 24.5 mm if 3 conductors per line

        Check site drawings for quantity of lugs.

    • Cat6 Shielded Twisted Pair (STPClosed Shielded Twisted Pair) Ethernet wiring

      FTPClosed File Transport Protocol, UTP, and lesser grades of cable do not have the required noise immunity

    • RJ45 shielded connectors

    • Type LB conduit body (for overhead installation only) - maximum 3 inch

    Check Express Plus Shipping Crates

    Each Power Link 1000 ships in the packages listed below. Ensure you have all components at the installation site.

    Always transport and store the charging components in their original packaging. Use appropriate lifting equipment (forklift or crane, lifting straps, and any corresponding attachments and accessories). Ensure the load rating of all lifting equipment is adequate for the weight of the crated components.

    Keep components in original packaging, free of moisture, and protected from damage until you install or service them at the site. Store all shipments of components in a dry covered location and protect from moisture.

    Leave components in the shipping crate until needed. When removing, protect them from damage (such as scratches) by placing them flat on a blanket or tarp, face up. Do not stand up cover panels, as they may be knocked or blown over. Cover charging connectors to prevent damage or ingress.

    Express Plus Shipping Crates

    Power Link 1000

    • Power Link 1000 station(s)

    • Charging cable(s) (1 or 2 per station)

    • Cable Management Kit (CMKClosed Cable Management Kit) or tool balancer

    Installation Kit

    • Duct seal compound

    • Propylene glycol coolant

      The coolant label references its Material Safety Datasheet.

    • T25 Torx security screwdriver

    • Coolant funnel