Connect Wires

(Standard Pedestal)

Risk of shock
  • Before any procedure, disconnect the power.
  • Follow local code and site lockout/tagout procedure to de-energize the station.
  • Wait for energy to dissipate (approximately five minutes).
  • Keep power off until all covers and panels are reinstalled and the work is complete.
Failure to follow these instructions can result in serious injury, loss of life, or property damage.


  • Disconnect power at the site electrical panel.

    Follow standard practice and local code to de-energize the applicable circuit and lock out/tag out the disconnect before proceeding.

    Technical illustration depicts the procedural step.

  • Use a multimeter to test that the unit is de-energized.

    •  

      The upper and lower bus bar plates look similar. Both sets are inscribed (A-, A+ [single] or A-, A+, B-, B+ [dual]) and have lug nuts preinstalled.

    1. Disconnect the Ethernet cable from the Ethernet surge suppressor.

      Take a photo or note to identify which port later.

    2. Access the upper bus bars.

    3. On the power plate cover, loosen the captive screws.

    4. Remove the cover.

    5. Release the tabs on the upper safety cover.

    6. Lift up from the bottom until it locks in the open position.

    Install DC Conductors and Lugs, and Ground Wire

    1. Ensure you have de-energized the applicable circuit and locked out/tagged out the disconnect according to standard practice and local code before proceeding.

    2. Use a multimeter to test that power is off.

    3. Route all conductors into the correct area within the cabinet.

    Measure and cut

    1. Loosely install lugs only (without the conductors) onto bus bars. Hand-tighten.

      Use included bolts, washers, and nuts

    2. Measure the length from each conductor to its corresponding lug.

      Mark each conductor at the point where you will need to trim it.

      DC bus bars are marked in order from left to right:

      Single Input Dual Input
         

      A+

      A-

      		  

       
       

      A+

      A-

      B+

      B-

      		  

    3. Strip and cut the conductors to the desired length.

    Install DC lugs

    1. Uninstall the lugs. Crimp a lug onto each conductor.

      Use compression lugs with the specifications . Use the lug manufacturer’s tool and die. If required, heatshrink or tape the crimp area to meet local code.

    2. Land the DC lugs on the terminals. Torque nuts to 19 Nm (168 in-lb).

      Fasteners are pretreated with dielectric grease.
      If using 500 kcmil conductors, you must use the back set of lugs to avoid interference with the surge suppressor panel.

    3. Mark all torqued power connections.

    Install DC ground wire

    1. Land the ground wire onto a ground stud. Torque to 7 Nm (60 in-lb).

    2. If you are installing the "Overhead" Mounted configuration:

      Tilt down the upper safety cover to close.

    3. Position the power plate cover. Hand tighten the captive screws.

    4. Reconnect Ethernet cable(s) to Ethernet surge suppressor into the same ports as before.

    48 V DC Wiring

    1. Check the 48 V DC wiring requirements in the site drawings:

      48 V DC Wiring

      48 V DC Wire Size

      Conduit Size

      Installation

      16 mm2 (6 AWGClosed American Wire Gauge)

      21 mm (3/4 in)

      Install two 48 V DC wires and one Ethernet cable into one conduit.

      Use only copper conductor wire rated for 90 °C (194 °F).

    2. Strip the 48 V DC wires.

    3. Loosen each terminal tab (upper cabinet, left side).

    4. Seat the 48 V DC wires. Push-pull to test.

    Cat6 STP Ethernet Cable

    1. Trim the Cat6 STPClosed Shielded Twisted Pair Ethernet wires to length and allow for a service loop. Terminate both ends.

    2. Field crimp a shielded connector onto each Cat6 STPClosed Shielded Twisted Pair Ethernet wire. Use a straight-through T568B pattern.

      Do not connect the shield wire here at the Power Link 1000 termination.

    3. Test each Ethernet wire for functionality.

    4. Identify which blue surge suppressors already have cables in the line-out (right) positions. Connect the Ethernet connectors to those surge suppressors at the line-in (left) positions. Push-pull to test.

    Install Ethernet to USB Kit

    If the site plan indicates the Power Link 2000 must be configured with a hardwire Ethernet connection to a network server, follow procedures in this section to install the Ethernet to USBClosed Universal Serial Bus Kit and the hardwire connection.

    Mount Ethernet to USB Module

    1. Unpack the Ethernet to USBClosed Universal Serial Bus Kit. Confirm all parts listed below are present.

      For any missing component, contact chargepoint.com/support.

      Labeled diagram of product, tools or parts.

      1. Ethernet to USBClosed Universal Serial Bus module

      2. M5 star washer nuts (x2)

      3. Zip ties (x5)

      4. USBClosed Universal Serial Bus 3.0 Type B to Type C cable

    2. Locate a grounding stud on the product frame.

      Locate a grounding stud on the pedestal frame

    3. Install one of the provided M5 star washer nuts partially onto the stud. Thread the nut only halfway onto the stud.

      Technical illustration depicts the procedural step.

    4. Mount the Ethernet to USBClosed Universal Serial Bus module onto the stud. Slide the module down to secure the keyhole tab to the stud.

      Technical illustration depicts the procedural step.

    5. Torque the nut to 4.5 Nm (40 in-lb).

      Technical illustration depicts the procedural step.

    6. Plug the USBClosed Universal Serial Bus-B end of the USBClosed Universal Serial Bus cable into the module.

      Technical illustration depicts the procedural step.

    7. Route the cable through the door cable guide and along the main cable harness to the Control and Communication Module (CCOMClosed Control and Communications Module) located on the upper front door.

      Technical illustration depicts the procedural step.

    8. Connect the cable to the CCOMClosed Control and Communications Module.

      Technical illustration depicts the procedural step.

    9. Secure the USBClosed Universal Serial Bus cable to the existing cable tie guides.

      Technical illustration depicts the procedural step.

    10. If needed, use the provided zip ties to secure the USBClosed Universal Serial Bus cable to the main cable harness.

      CAUTION:

    Install Ethernet Cable

    1. Pull the hardwire Ethernet cable into the enclosure and route it through existing cable guides to reach the Ethernet to USBClosed Universal Serial Bus module. Cut to length, allowing for a service loop.

      Technical illustration depicts the procedural step.

    2. Field crimp an RJ45 connector onto the Ethernet cable. Use straight-through T568B pattern.

      IMPORTANT: Do not ground the shield at this end of the Ethernet cable. Ground the shield at the end of the Ethernet cable that connects to the network server.

      Technical illustration depicts the procedural step.

    3. Test the Ethernet cable for functionality.

      If using a Paige OSP Shielded GameChanger cable for a wire run length greater than 100 m (328 ft), follow the test procedure specified by Paige. See Paige GameChanger Resources.

      Technical illustration depicts the procedural step.

    4. Connect the Ethernet cable to the Ethernet to USBClosed Universal Serial Bus module.

      Technical illustration depicts the procedural step.

    5. Route and plug the other end of the Ethernet cable into the network server.

    Secure and Seal Gland Plate

    1. Vacuum all wire ends and metal shavings.

    2. Secure wiring with clips as needed.

    3. Align the gland plate and install screws.

    1. Use duct seal compound to seal inside conduit openings.

    2. Seal the gland plate around and to each conduit.

    Reinstall Lower Safety Panel (if applicable)

    1. Slide in the panel behind the slots on the left.

      Slide in the panel behind the slots on the left.

    2. Install screws (x3) (use T25 security screwdriver) on the right side. Torque to 2.8 Nm (25 in-lb).

      Install three screws using T25 security screwdriver on the right side. Torque to 2.8 Nm or 25 in-lb.