Appendix: Multiplex Installation

The configuration of Power Link 2000 require an additional sub-assembly called Multiplex. This sub-assembly is a set of input busbars with relays (contactors) added to the bottom part of the Power Link 2000 enclosure. This sub-assembly can be installed in the factory or in the field as a retrofit.

The Power Link 2000 Multiplex Retrofit can be installed in an existing operational site with an existing HV DCClosed High Voltage Direct Current Input cable in place or at a new site.

To successfully complete the Multiplex Kit installation, this section includes cross-references to standard Power Link 2000 installation procedures. Use the images in the referenced procedures for reference only, as they depict a standard Power Link 2000 installation and do not show the Multiplex Kit.

Install Power Link 2000 Multiplex

To install the Multiplex kit on the Power Link 2000 , perform the following steps:

Before you begin, confirm if all the components (Multiplex Kit, tools) are on-site. Start with an empty pedestal and conduit ready for conductor pull.

  1. Use 10 mm wrench to loosen the four M6 nuts and then remove the adapter plate.

  2. Use a 10 mm socket wrench to secure the four M6 nuts and mount the pre-assembled Multiplex unit onto the adapter plate.

    Ensure the large cable already present is routed above the busbar adapter. This prevents contact with busbars or interference with other components.

  3. Connect the power cables, 4 REDClosed Route Enforcement Data (+) wires onto the bus bars' positive (+) pole and 4 BLACK (-) wire onto the bus bars' negative (-) pole.

    • Secure each with M10 nuts.

    • Torque the screws 19 Nm (168 in-lb) and torque mark all high-power connections.

  4. Route and connect two signal wires from the Multiplex Assembly.

    • Thermal Switch Cable - Route and plug into the FDC board.

    • Contactor Harness - Route and connect to the FDC board.

      The contactor harness has a longer pigtail and connects to contactors. Use zip ties to secure the cables to the main cable harness bundle to support the cable weight.

      The cable harness must route behind the mid-height brace and through the door cable guide to prevent the cable from being pinched when closing the door.

      Pull excess cable into the Power Link 2000 pedestal to ensure there is no loose wire hanging from the door. Loose wires may get pinched when closing the door.


  5. Verify all the terminations and ensure large internal cable is routed above busbars.

Plan for HV DC Wire Connect (Multiplex)

The physical locations for landing HV DCClosed High Voltage Direct Current and high power ground wires are shown below. Use this information to plan for the connection of HVClosed High Voltage DC wires.

Labeled diagram of product, tools or parts.

(a1) Path A, upper landing

(a2) Path A, lower landing

(b1) Path B, upper landing

(b2) Path B, lower landing

(c) Ground

Depending on its configuration, a Power Link 2000 will have one or two independent HV DCClosed High Voltage Direct Current power paths, A and B. Power Link 2000s with a single charging cable are configured with Power Path B only.

The Power Block has two HV DCClosed High Voltage Direct Current outputs, also named A and B. Although the Power Link 2000 power paths and Power Block outputs are named alike, it does not mean that Output A of a Power Block must connect to Power Path A of a Power Link 2000. Output A of a Power Block may connect to either Power Path A or B of a Power Link 2000. Likewise, Output B of a Power Block may connect to either Power Path A or B of a Power Link 2000. The A and B designations serve only to identify separate power paths and outputs in each product.

The upper and lower landings may be used to connect a single power path to multiple Express Plus products in an orderly manner. For example:

  • In some Express Plus architectures, a single Power Link 2000 power path receives HV DCClosed High Voltage Direct Current input from two separate Power Blocks. This may be achieved by connecting wires from one Power Block at one landing level and connecting wires from the other Power Block at the other landing level.

  • In some Express Plus architectures, a single Power Link 2000 power path receives HVClosed High Voltage DC input from a Power Block and also provides HV DCClosed High Voltage Direct Current output to another Power Link 2000. This may be achieved by connecting wires from the Power Block at one landing level and connecting wires going to the other Power Link 2000 at the other landing level.

How exactly to make connections within a cluster of Power Block(s) and Power Link 2000(s) is determined by the Express Plus architecture chosen for the site. Use the site plan single line diagram to understand and plan how to land the HV DCClosed High Voltage Direct Current wires on the Power Link 2000 terminals. If you require further assistance in this matter, go to chargepoint.com/support and find your region’s technical support number.

Pull and Cut Wires

In regions that use conduits, wires can be pulled before or after mounting the Power Link 2000 . Skip this procedure if the wires have been pulled before mounting or if the site is using armored cables directly buried and exposed from underground without conduits.

  1. Arrange wires such that the positive wires (REDClosed Route Enforcement Data) arrive on the left side and negative wires (BLACK) arrive on the right side within the Power Link 2000. This arrangement will help you land wires on their respective poles.

  2. If necessary, apply a non-conductive wire pulling lubricant.

  3. Pull wires through the rear conduits to connect them to the bus bars' lower landing locations (see Connect Wires).

    • Do not pull wires through the front conduits first; they may restrict access to the rear conduits, and if connected, also to the bus bars' lower landing locations.

    • Before pulling wires through the front conduits, connect the pulled wires to prevent them from causing interference while pulling another set of wires.

    Technical illustration depicts the procedural step.

  4. Pull wires through the front conduits to connect them to the bus bars' upper landing locations (see Connect Wires).

    Technical illustration depicts the procedural step.

  5. Cut the additional length of wires (if pulled) so that their terminals reach up to the lug's barrel height without having to bend them.

    Technical illustration depicts the procedural step.

  6. Perform insulation resistance test on the HV DCClosed High Voltage Direct Current wires. Refer to the Express Plus High Voltage Wire Insulation Resistance Test Field Guide.

Connect Wires

To connect wires, complete the following steps:

See Wires and Terminations Required for Site for the wire and lug specifications.

Wire entry and landing locations

Links to Connect Wire Procedures

HV DCClosed High Voltage Direct Current input wires (Max. 500 A)

See Connect HV DC Input and Ground Wires

Ground wires (one per Power Block)

LV DCClosed Low Voltage Direct Current input wires

NOTE: Primary LV DCClosed Low Voltage Direct Current input wires land on left terminal. Secondary LV DCClosed Low Voltage Direct Current input wires (optional) land on right terminal

See Connect LV DC Input Wires

Ethernet cable

See Connect Ethernet Cable
If the wire terminals do not appear as pictured here, you are using the wrong installation guide. See About This Guide for more information.

Connect HV DC Input and Ground Wires

To connect HV DCClosed High Voltage Direct Current input and ground wires, complete the steps:

Before you begin, make note of the following:

  • See Connect Wires for the wire landing locations.

  • Make sure no bare conductor is exposed below the lug's barrel. If necessary, heat shrink or tape the exposed area to meet the local code requirements.

  • Wipe off any remains of wire pulling lubricant if applied.

Prepare Wires

Technical illustration depicts the procedural step.

  1. Mark the lug's barrel height on the wire terminal.

  2. Strip the jacket on the marked terminal. Use a suitable wire stripper, such as Klein tool.

  3. If recommended by the wire manufacturer or local code, apply an anti-oxidant joint compound to the stripped wire material to make a gastight joint with the lug.

  4. Insert the stripped terminal into the lug's barrel and crimp it. Use a suitable lug crimping tool and/or die recommended by the lug manufacturer.

  5. Apply dielectric grease to the lug's tongue surface that comes in contact with the bus bars.

Connect HV DC Wires

  1. Identify the location for landing HVClosed High Voltage DC wires , see Plan for HV DC Wire Connect for the wire landing locations.

  2. Use M10 nuts to connect HV DCClosed High Voltage Direct Current Input Conductors from the external conduit (2 per pole).

    • Torque the nuts to 19 Nm (14 ft-lb) and mark each connection.

    • Verify the polarity is aligned all the way up to Proton.

Complete Installation of Multiplex

  1. To complete the installation of Multiplex, perform the following procedures:

    1. Connect LV DC Input Wires

    2. Connect Ethernet Cable

    3. Install Ethernet to USB Kit

    4. Seal Conduit Opening

  2. Use an 8 mm screwdriver to secure the clear safety shield over the entire assembly with four screws, one in each corner.

  3. Proceed to Install Charging Cables.