Appendix A: Surface Conduit Entry Kit Installation

The Surface Conduit Entry (SCE Surface Conduit Entry) kit can be used at sites where the wires cannot be laid underground or when the site is not using stub-up entry through Concrete Mounting Template (CMT) embedded in a concrete pad.

Required Tools and Materials

In addition to the tools and materials required for installing Power Link 2000, the installer must bring the following tools and materials for the installation of SCE Surface Conduit Entry kit.

Tools

	Power drill (with level feature recommended)		Sheet metal hole saw with pilot drill bit for conduit sizes listed on site drawings
	Concrete drill bits 20 mm (13/16 in) or per epoxy manufacturer's recommendation for M16 (5/8 in) anchor bolts 6 mm (1/4 in) to drill pilot hole		24 mm hex socket or open ended wrench
	750 ml of epoxy with bonding strength of 11.7 MPa minimum, compressive strength of 82.7 MPa minimum, and tensile strength of 49.3 MPa minimum, such as Hilti HIT-RE 500 V3 (normal cure time), Hilti HIT-HY 200-A (fast curing), or similar. Different epoxy types have different cure times at various temperatures. Check local temperatures for the site in advance to help choose an appropriate epoxy.

Materials

Following are the maximum quantity and size of conduits that can be installed on Power Link 2000 using the SCE Surface Conduit Entry kit:

Conduit Specifications

Conduits For	Conduit Quantity x Trade Size
	North America	Europe
HV DC High Voltage Direct Current wires	2 x 3 inch max.	2 x 78 mm max.
LV Low Voltage DC input wires and Ethernet cable	2 x 1 inch (*)	2 x 27 mm (**)
Optional features (Ethernet to USB Universal Serial Bus or soft shutdown switch)	2 x 3/4 inch max.	2 x 21 mm max.

Kit Components

SCE Kit For LCC Power Link 2000

Check the package for the following components:

(a) Templates for marking and drilling conduit holes.

(b) Surface mount template for marking and drilling holes into concrete surface.

(c) Rear lower cover replacement for SCE Surface Conduit Entry.

(d) M16 anchor bolts (x4) for mounting Power Link 2000.

(e) Mounting bracket for conduits.

(f) Hardware bag, which contains the following components:

• M16 nuts, washers, and protective caps for anchor bolts (d).

• M5 nuts (x4) for mounting bracket (e).

• M5 screws (x2) for gland plate (g).

(g) Gland plate for closing the conduit opening.

SCE Kit For non-LCC Power Link 2000

Check the package for the following components:

1. Template for marking and drilling conduit holes.

2. M16 anchor bolts and nuts with protective caps (x4) for mounting Power Link 2000.

3. Surface mount template for marking and drilling holes into concrete surface.

4. Gland plate for closing the conduit opening.

5. M5 screws (x2) to install gland plate.

Install Anchor Bolts

To install anchor bolts, complete the following steps:

1. Refer to the site drawings and place surface mount template at the proposed location.

   Make sure to leave enough clearance at the rear side (610 mm or 2 ft) for surface conduit entry and servicing.

2. Use a marker to mark the locations for the anchor bolts and remove the surface mount template.

   

3. Use the 6 mm (0.25 in) concrete drill bit to drill a pilot hole about 51 mm (2 in) deep at each marked location. The holes must be parallel to each other and perpendicular to the surface.

4. Use the 25 mm (1 in) concrete drill bit to drill an anchor hole a minimum of 229 mm (9 in) deep. Anchor bolts must have 76 mm +/- 12.7 mm (3 in +/- 0.5 in) above surface.

   

5. Use a vacuum to clean the concrete residue.

   

6. Place surface mount template on the surface again. Verify that the anchor holes align with the holes in the surface mount template.

7. Prepare the epoxy. Ensure the applicator is dispensing correctly mixed epoxy before beginning work (for example, the Hilti epoxy is white when unmixed and gray when mixed).

8. Fill the first anchor hole with epoxy until the epoxy is about 44.5 mm (1.75 in) from the top of the hole.

   Continue immediately to the next step because the epoxy sets within about eight minutes.

   

9. Insert anchor bolt into the hole. Rotate the anchor bolt as you insert it to draw epoxy into the threads. If needed, add more epoxy until it fills hole to surface level. Use paper towels to wipe off any excess.

   

10. Use a level to check that the anchor bolt is plumb. If needed, adjust it while the epoxy is still setting.

    

11. Measure the bolt exposed above the surface and it must be 76 mm (3 in).

    

12. Repeat the above epoxy steps for each of the other three anchor bolts.

13. If product station will not be immediately installed, insert protective caps over the anchor bolts.

    

14. Allow the epoxy to cure for the initial cure time listed on the epoxy usage instructions before beginning to install Power Link 2000.

15. Install Power Link 2000 onto the anchor bolts (see Install Power Link 2000 ).

Install Gland Plate

To install gland plate, complete the following steps:

1. Find the M5 screws (x2) shipped in the SCE kit package.

2. Remove screws (x2) to remove the conduit sleeve.

   

3. Install the gland plate using the M5 screws (x2) and torque the screws to 4.5 Nm (40 in-lb).

   

 

Install Surface Conduits (LCC)

Skip this entire procedure for non-LCC Liquid Cooled Cable variant of Power Link 2000.

Before you Begin

1. If not already removed, remove the following:

   1. Cable cap

   2. Side panels

   3. Rear upper cover

   4. Loosen screws (x6) to remove the rear lower cover.

      

2. Open lower enclosure door.

3. Install gland plate.

Install Conduits

To install conduits, complete the following steps:

1. Align and hold templates against the lower enclosure wall.

   • Ensure that the templates are fully laid on the lower enclosure wall and that their edges are in alignment with the upper and side corners.

   • The pilot holes marked DC IN are for cutting conduit holes for HV DC High Voltage Direct Current input wires, and the ones marked LV Low Voltage are for LV DC Low Voltage Direct Current input wires and Ethernet cable.

   

2. Mark pilot hole locations on the lower enclosure wall and remove the templates.

   • If wires need to enter from rear left or right side of the Power Link 2000, mark LV Low Voltage holes on the upper template.

     

   • If the wires need to enter the rear of the Power Link 2000 from straight on or from above the entry point, mark LV Low Voltage holes on the lower template.

     

3. Using a suitable hole saw, position the hole saw's pilot drill bit on the marked location, and cut a hole into the lower enclosure wall. Repeat for other marked locations.

   To cut holes to correct size, refer to the site drawings for the actual conduit dimensions. For the maximum conduit size supported by the Power Link 2000, refer to the Express Plus Power Link 2000 Site Design Guide, available at ChargePoint Product Reference Documentation.

   The illustrations shown below are for demonstration purposes only. Make sure to cut holes at suitable locations per wire routing proposed in the site drawings.

   

4. Cut corresponding conduit entry locations on the mounting bracket.

   

5. Vacuum all metal shavings.

   

6. Align and install mounting bracket on the back of Power Link 2000. Torque the nuts (x4) to 4.5 Nm (40 in-lb).

   

7. Install the new SCE Surface Conduit Entry rear lower cover.

   1. Align and seat cover onto the alignment pins (x2) on the frame.

      

   2. Torque the screws (x6) to 4.5 Nm (40 in-lb).

      

8. Install LB type conduit bodies and/or conduits into the holes.

   Leave 25 mm (1 in) of clearance between the conduit bodies and the SCE Surface Conduit Entry rear lower cover so that the cover can be removed for service without impacting the conduit bodies.

   

9. Install the remaining components, such as DC input wires, charging cables, cable management kit (CMK Cable Management Kit), and covers, and complete the installation.

Install Surface Conduits (Non-LCC)

Skip this entire procedure for LCC Liquid Cooled Cable variant of Power Link 2000.

1. Open the lower enclosure door.

2. Install the gland plate.

3. Align and hold template against the rear lower cover.

   • Ensure that the template is fully laid and is centered on the rear lower cover.
   • The pilot holes marked DC IN are for cutting conduit holes for HV DC High Voltage Direct Current input wires and the ones marked LV Low Voltage are for LV DC Low Voltage Direct Current input wires and Ethernet cable.

   

4. Mark pilot hole locations on the rear lower cover and remove the template.

   

5. Using a suitable hole saw, position the hole saw's pilot drill bit on the marked location, and cut a hole into the rear lower cover. Repeat for other marked locations.

   To cut holes to correct size, refer to the site drawings for the actual conduit dimensions. For the maximum conduit size supported by the Power Link 2000, refer to the Express Plus Power Link 2000 Site Design Guide, available at ChargePoint Product Reference Documentation.

   

6. Vacuum all metal shavings.

   

7. Install LB type conduit bodies and/or conduits into the holes.

   

8. Install the remaining components, such as DC input wires, charging cables, cable management kit (CMK Cable Management Kit), and covers, and complete the installation .