Install Power Link 2000

To install Power Link 2000, complete the following set of steps:

Do not install or service the charging station in inclement weather. If you work in snow, rain, or wind, you must use a weather-proof shelter that covers all boxes and components.
Warranty Limitation
  • If the charging station is not installed, commissioned, or serviced by a ChargePoint certified technician using a ChargePoint-approved method, it is excluded from all ChargePoint and other warranties and ChargePoint is not responsible.
  • You must be a licensed electrician and complete training at https://www.chargepoint.com/partners/training-certification to become ChargePoint certified and to access ChargePoint's web-based installer tools or ChargePoint Installer app.
Use low torque settings when working with power tools during installation or servicing. Over-torquing can damage the equipment.
While installing fasteners inside a product enclosure, make sure not to drop the fasteners inside conduit openings. You may use conduit caps or covers to temporarily cover the conduit openings.
Ensure that the installation complies with all applicable codes and ordinances.

If the site has height constraints for installation, contact ChargePoint to get instructions and clearances that you will need for the modified process.

Alternatively, you may use a forklift bracket kit, or a crane with lifting shackles and a spreader bar (constraints may differ among sites).

Install Leveling Nuts

To install leveling nuts, complete the following steps:

  1. If applicable, remove protective caps (x4).

    Technical illustration depicts the procedural step.

  2. Clean away residue, if any.

    Technical illustration depicts the procedural step.

  3. Find the M16 hex nuts and washers shipped with the Power Link 2000.

  4. Install M16 washers (x4) and hex nuts (x4) onto the anchor bolts, and flush them against the base. Torque to 54.2 Nm (40 ft-lb).

    Technical illustration depicts the procedural step.

  5. Install another set of M16 hex nuts (x4) and washers (x4) onto the anchor bolts and leave a 6.4 mm (0.25 in) gap between the nuts for leveling the Power Link 2000.

    Technical illustration depicts the procedural step.

  6. Ensure the nuts are level.

    Technical illustration depicts the procedural step.

Install Power Link 2000 Assembly

To install the Power Link 2000 assembly, complete the following steps:

Position Power Link 2000 Assembly over Anchor Bolts

  1. Open and unpack the Power Link 2000 package (see Power Link 2000 with non-LCC or Power Link 2000 with LCC).

  2. Position the forklift to insert strap loops onto the forks. Make sure that the straps are not near the open ends of the forks. Power Link 2000 comes with straps and eye bolts attached for lifting.

    Technical illustration depicts the procedural step.

  3. Gradually lift and position Power Link 2000 over the anchor bolts.

    Technical illustration depicts the procedural step.

 

Open Enclosure Door

To open the enclosure door, complete the following steps:

  1. Quarter turn the door latches (x2 per upper and lower enclosure door).

    Technical illustration depicts the procedural step.

  2. Open the door and engage the door stopper (x1 per upper and lower enclosure door).

    Technical illustration depicts the procedural step.

Install Power Link 2000 onto Anchor Bolts

  1. Align the anchor bolt holes (x4) on the Power Link 2000 with the anchor bolts and slowly move the Power Link 2000 down to rest it on the leveling nuts.

    If the wires have been pulled before mounting the Power Link 2000 or if the site is using armored cables directly buried and exposed from underground without conduits, route wires through conduit opening at the bottom of the Power Link 2000.

    Technical illustration depicts the procedural step.

  2. Make sure that the Power Link 2000 is resting on the leveling nuts and is level and plumb. If not, adjust the leveling nuts.

    Technical illustration depicts the procedural step.

  3. When the Power Link 2000 is level and plumb, install another set of M16 washers (x4) and hex nuts (x4) onto the anchor bolts. Torque to 94.9 Nm (70 ft-lb).

    Technical illustration depicts the procedural step.

  4. Release the lifting straps, and remove the eye bolts (x4) and rubber washers (x4). Use either an adjustable wrench or screwdriver shaft to loosen the eye bolts.

    Technical illustration depicts the procedural step.

Access HV DC Input Bus Bars

To access the HV DCClosed High Voltage Direct Current input bus bars, complete the following steps:

  1. Open the upper door.

  1. Slide the bus bar safety cover up to remove from the hooks (x2) and brackets (x2).

    Technical illustration depicts the procedural step.

Plan for HV DC Wire Connect

To plan for HV DCClosed High Voltage Direct Current wire connect, complete the following steps:

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.

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:

IMPORTANT: 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 Wires

  1. Remove lug nuts (see Connect Wires for the wire landing locations).

    Technical illustration depicts the procedural step.

  2. Install the prepared wire onto the studs (see Prepare Wires).

    When connecting the HV DCClosed High Voltage Direct Current input wires, install the red (+) wire's lug onto the bus bars' positive (+) pole and black (-) wire's lug onto the bus bars' negative (-) pole.

    Technical illustration depicts the procedural step.

  3. Reinstall the lug nuts and torque them.

    Torque the HV DCClosed High Voltage Direct Current input wire lug nuts to 19 Nm (14 ft-lb) (use 17 mm socket) and ground wire lug nuts to 5.6 Nm (50 in-lb) (use 10 mm socket).

    Technical illustration depicts the procedural step.

  4. Repeat for other wires.

  5. Mark all torqued connections to ensure all lug nuts have been tightened. This is also for inspection purposes.

    Technical illustration depicts the procedural step.

  6. Repeat the above steps for ground wires.

Connect LV DC Input Wires

To connect LV DCClosed Low Voltage Direct Current input wires, complete the following steps:

  1. Strip the jacket on the wire terminals (x2).

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

    Technical illustration depicts the procedural step.

  2. Loosen the terminal screws (x2).

  3. Route wires (x2) through the wireway clamps (if necessary use cable ties) and insert them into the LVClosed Low Voltage circuit breaker (red (+) into right and black (-) into left terminal).

    Technical illustration depicts the procedural step.

  4. Torque the screws (x2) to 4 Nm (36 in-lb). Push-pull to test that both (+ and -) wires are secured.

    Technical illustration depicts the procedural step.

  5. Flip the switches (x2) up to turn the LVClosed Low Voltage power supply on.

    Technical illustration depicts the procedural step.

    1. Primary LVClosed Low Voltage circuit breaker

    2. Secondary LVClosed Low Voltage circuit breaker (if present)

Connect Ethernet Cable

To connect the Ethernet cable, complete the following steps:

  1. Trim Ethernet (Cat6 STPClosed Shielded Twisted Pair) cable to length, allowing for a service loop.

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

    Do not ground the shield at this end of the cable. The cable shield must be grounded only at the cable end terminating at the Power Block.

    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. Route the cable through the wireway clamps and connect to the Ethernet surge suppressor. To establish a secure connection, the RJ45 connector's latch must click into the Ethernet surge suppressor.

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

    Technical illustration depicts the procedural step.

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

To mount the Ethernet to USBClosed Universal Serial Bus module, complete the following steps:

  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.

    Technical illustration depicts the procedural step.

    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 Power Link 2000 frame.

    Technical illustration depicts the procedural step.

  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.

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

  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.

Install Ethernet Cable

To install the Ethernet cable, complete the following steps:

  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.

    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.

Seal Conduit Opening

To seal the conduit opening, complete the following steps:

  1. Find the duct seal compound shipped with the Power Link 2000 (see Power Link 2000 Packages).

  2. Vacuum any residue around the conduits.

    Technical illustration depicts the procedural step.

  3. Torque the screws (x2) to 4.5 Nm (40 in-lb). The conduit sleeve must enclose the conduit opening space.

    Technical illustration depicts the procedural step.

  4. Use the duct seal compound and seal the space between the conduit sleeve and the bottom of the Power Link 2000 enclosure.

    Technical illustration depicts the procedural step.