Prepare for Installation

This topic describes how to prepare for the installation.

Check Site Readiness

To check site readiness, complete this checklist before you install Power Link 2000.

Site Readiness Checklist

Express Plus Power Link 2000 Site Readiness Checklist
1.  

Power Blocks are installed at locations proposed in the site drawings.

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2.  

The concrete pad or concrete surface meets the mounting specifications given in the Express Plus Power Link 2000 Site Design Guide and/or is inspected and approved by a structural engineer for the dimensions and weights (as given in the Express Plus Power Link 2000 Site Design Guide) of the Power Link 2000 and its related components such as charging cable(s) and Cable Management Kit (CMKClosed Cable Management Kit).

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3.  

Wires and conduits meet the requirements given in the site drawings.

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4.  

The electrical equipment is installed and labeled in accordance with the National Electrical Code (NECClosed National Electric Code) and all applicable requirements of the serving electric utility company and the authority having jurisdiction.

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5.  

The installation site meets the drainage, ventilation guidelines, and clearances given in the Express PlusPower Link 2000Site Design Guide .

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6.  

The slope at the installation site does not exceed 20 mm per meter (0.25 in per ft). If necessary, use a grinder or a hammer and chisel to remove any concrete that is not level with the rest of the concrete pad or surface.

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7.  

Sufficient space is available to use a forklift or other lifting equipment, unpack, remove packing materials, and allow two people to freely move throughout the site.

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8.  

The anchor bolts, conduits, and concrete pad meet the requirements listed below:

  • The anchor bolts are installed, are 76 mm (3 in) high from the concrete pad, and are plumb.

  • The conduits or armored cables are laid per the conduit layout given in the Express PlusPower Link 2000Site Design Guide.

  • In regions that use conduits, the conduits do not have bell ends, are plumb, and are 102–160 mm (4–6.3 in) high from the concrete pad. Conduits with bell ends may interfere with tolerances inside the Power Link 2000.

  • The concrete pad is fully cured and smooth.

Labeled diagram of product, tools or parts.

  1. Conduits

  2. Anchor bolts with protective caps

  3. Concrete pad
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9.  

In regions that use conduits, wires can be pulled before or after mounting the Power Link 2000. If you want to pull wires before mounting or if the site is using armored cables directly buried and exposed from underground, make sure that the wires reach the bus bars at the following height.

HV DC bus bar height within Power Link 2000 pedetal

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Electrical Readiness

Refer to the Power Link 2000 Datasheet and the Express Plus Power Link 2000 Site Design Guide for electrical input and output specifications.

Bring These Tools and Resources

Installing the Power Link 2000 requires at least two people. Additionally, the installer must bring the following tools and materials. These are not provided by ChargePoint.

Comply with these guidelines to prevent component damage.

  • Use tools suitable to torque metric fasteners. All fasteners used on the Power Link 2000 are in metric sizes.

  • Use the given torque values to tighten the fasteners.

  • Ensure that the tools such as torque tool, multimeter, and Ethernet tester are calibrated.

Required Tools and Materials

Tools and Materials

Orange and white icon that represents a tool or action.

Forklift with anti-slip forks

  • Rated for ≥ 680 kg (1500 lb)

  • Fork specifications:

    • Width = 102–127 mm (4–5 in)

    • Thickness ≤ 57 mm (2.25 in)

  • If your site has height constraints, use alternative equipment

Orange and white icon that represents a tool or action.

Stepladder

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Industrial vacuum cleaner

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Paper towel roll

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Wire brush (to remove any residue on anchor bolts)

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Duct seal compound

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Hard hat

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Cut-resistant gloves

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Safety glasses

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Cable ties

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Cable puller or fish tape

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Measuring tape or other tool to measure linear dimensions

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Level

Lockout/Tagout equipment

Multimeter (meter and probes rated for 1000 V)

Orange and white icon that represents a tool or action.

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.

Conduit cutter (refer to site plans for conduit sizes)

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Box cutter

Orange and white icon that represents a tool or action.

  • Wire cutters

    		•

    Orange and white icon that represents a tool or action.

    Wire strippers

    Orange and white icon that represents a tool or action.

    Lug crimping tool and die

    Orange and white icon that represents a tool or action.

    Ethernet (RJ45) connector crimping tool

    Orange and white icon that represents a tool or action.

    Torque wrench

    Orange and white icon that represents a tool or action.

    Torque screwdriver

    Orange and white icon that represents a tool or action.

    Shallow hex socket set (7 mm, 10 mm, 17 mm) and 24 mm deep socket

    Orange and white icon that represents a tool or action.

    Hex wrench set

    Orange and white icon that represents a tool or action.

    Torx screwdriver (T20, T30)

    Orange and white icon that represents a tool or action.

    T25 Security screwdriver

    Orange and white icon that represents a tool or action.

    Flathead screwdriver set, including 2.5 mm and 3.5 mm tip for terminal blocks

    Orange and white icon that represents a tool or action.

    Phillips head screwdriver set

    Orange and white icon that represents a tool or action.

    Torque paint pen

    Orange and white icon that represents a tool or action.

    Permanent marker

    Orange and white icon that represents a tool or action.

    Anti-oxidant joint compound (to make gastight joint between wire and lug) and wire pulling lubricant

    Orange and white icon that represents a tool or action.

    Dielectric grease

    Orange and white icon that represents a tool or action.

    Smartphone with:

    • Internet connectivity

    Orange and white icon that represents a tool or action.

     

    • ChargePoint installer login credentials

    Orange and white icon that represents a tool or action.

    Orange and white icon that represents a tool or action.

    • ChargePointInstaller app

     

    Wires and Terminations Required for Site

    Following are wire specifications for the Power Link 2000, including the maximum quantity and size that the wire terminals can accommodate. All sizing assumes a maximum ambient temperature of 50 °C (122 °F). Where the maximum wire size is listed, the actual wire quantity and size must be chosen based on site-specific wiring requirements and in accordance with the maximum allowed conduit filling rate per local code.

    The DC output from Power Block is the DC input for Power Link 2000.

    The Power Link 2000 can be installed with two DC power paths (A and B) and each DC power path can accept maximum of 12 HV DCClosed High Voltage Direct Current wires (six per landing, three per pole).

    Power Link 2000 wire entry and landings

    Wire Quantity, Size, and Termination Requirements

    Wire For

    Quantity

    Size

    Lug Size

    Power path

    A and B

    (Max. 500 A per landing)

    Max. 12

    (six per landing, three per pole.)

    Upper landings:

    Max. 150 mm2 (300 MCM)

    Long barrel and tongue with two holes 44.5 mm (1.75 in) apart and must fit M12 studs. Max. lug tongue width for upper landings is 31 mm (1.25 in) and for lower landings is 25.9 mm (1 in)

    Lower landings:

    Max. 120 mm2 (4/0 AWGClosed American Wire Gauge)

    Ground

    Max. 4 (one per Power Block)

    Refer to the local code for size.

    Short barrel and tongue with single hole and must fit M6 stud.

    LV DCClosed Low Voltage Direct Current inputs

    Max 4 (two at left terminal required, two at right terminal are optional)

    16 mm2 (6 AWGClosed American Wire Gauge)

    Not applicable

    Ethernet connection

    Max. 2 outdoor rated Cat6 STPClosed Shielded Twisted Pair cables* terminated with RJ45 connectors

     

    Soft shutdown switch

    2

    2.5 mm2 (14 AWGClosed American Wire Gauge)

    * The required Ethernet cable type depends upon the cable run length. See the Express Plus Power Link 2000 Site Design Guide for details.

    Tightening Torque

    Torque Values
    Component (xFastener Quantity)

    Component Material

    Fastener

    		 Tool Torque

    Plastic

    M4

    T20 Torx

    T25 Security

    1.7 Nm (15 in-lb)

    Metal

    T20 Torx

    2.8 Nm (25 in-lb)

    Plastic

    M5

    T25 Security

    Metal

    4.5 Nm (40 in-lb)

    8 mm socket

    M6

    10 mm socket

    5.6 Nm (50 in-lb)

    T25 Security

    T30 Torx

    T25 Security

    3.4 Nm (30 in-lb)

    M8

    13 mm socket

    11 Nm (97 in-lb)

    M10

    6 mm hex

    13.5 Nm (120 in-lb)

    17 mm socket

    19 Nm (14 ft-lb)

    M16

    24 mm deep socket

    54.2 Nm (40 ft-lb)

    94.9 Nm (70 ft-lb)

     

     

    #2 Phillips screwdriver

    4 Nm (36 in-lb)

    Power Link 2000 Packages

    The crate is heavy and can cause injury or death if dropped. Do not stand or walk beneath the crate while it is being lifted. Take precautions against the crate tipping or sliding.

    Always transport and store 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.
    To protect the charging cables from damage, keep them wrapped throughout the installation process.

    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.

    Keep components out of direct sunlight in a cool area until you install them.

    Package Configurations, Dimensions, and Weights

    Power Link 2000 with non-LCC

    Power Link 2000 with non-LCCClosed Liquid Cooled Cable ship with the charging station enclosure, charging cable, and cable management kit (CMKClosed Cable Management Kit) each placed in separate packages. Also, the cosmetic top cap and covers ship together in a separate package.

    Pedestal-mount Power Link 2000 with Non-LCCClosed Liquid Cooled Cable Packages

    Package

    Variant

    Dimensions (L x W x H)

    Max. Weight

    Power Link 2000 non-LCC configuration

    (enclosure only)

    -

    2.34 x 0.96 x 0.61 m

    (92.25 x 38.13 x 24.13 in)

    173 kg

    (380 lbs)

    Charging cable

    (non-LCCClosed Liquid Cooled Cable)

    Standard length

    (5.8 m or 19 ft)

    0.72 x 0.58 x 0.22 m

    (28.45 x 22.74 x 8.75 in)

    23 kg

    (50 lbs)

    Medium length(7.6 m or 25 ft)

    32 kg

    (70 lbs)

    CMK

    Standard

    1.12 x 0.65 x 0.24 m

    (44.13 x 25.75 x 9.5 in)

    28 kg

    (60 lbs)

    Tall

    1.87 x 0.35 x 0.40 m

    (73.50 x 14.75 x 16.13 in)

    41 kg

    (90 lbs)

    Overhead CMKClosed Cable Management Kit

    0.45 x 0.40 x 0.18 m

    (17.50 x 15.88 x 7 in)

    12 kg

    (25 lbs)

    Cosmetic kit

    (top cap and covers)

    -

    1.11 x 0.53 x 0.64 m

    (44 x 21 x 25 in)

    15 kg

    (34 lbs)

    Power Link 2000 with LCC

    Power Link 2000 with LCCClosed Liquid Cooled Cable ship with the charging station enclosure, charging cables, and standard CMKClosed Cable Management Kit placed in a single package. The charging cables and CMKClosed Cable Management Kit mast are preinstalled on the charging station enclosure. The cosmetic top cap and covers ship together in a separate package.

    Pedestal-Mount Power Link 2000 with LCCClosed Liquid Cooled Cable Packages
    Package Variant Dimensions (L x W x H) Max. Weight

    Power Link 2000 LCC configuration

    (enclosure with dual LCCs and standard CMKClosed Cable Management Kit*)

    -

    2.49 x 1.12 x 0.82 m

    (98 x 44 x 32.38 in)

    318 kg

    (700 lbs)

    Cosmetic kit

    (top cap and covers)

    		 -

    1.11 x 0.53 x 0.64 m

    (44 x 21 x 25 in)

    15 kg

    (34 lbs)

    * The LCCClosed Liquid Cooled Cable(s) and CMKClosed Cable Management Kit mast ship preinstalled on the charging station enclosure.

    Power Link 2000 Non-LCC Configuration Package

    Check the package for the following components:

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

    Labeled diagram of product, tools or parts.

    1. Power Link 2000 assembly

    2. Install kit, which contains the following components:

      1. M16 hex nuts and washers for mounting Power Link 2000 (x12)

      2. T25 Security screwdriver

      3. Sealant for sealing the conduit opening (x5)

    Power Link 2000 LCC Configuration Package

    Check the package for the following components:

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

    Labeled diagram of product, tools or parts.

    1. CMKClosed Cable Management Kit swingarm assembly with one or two swingarms

    2. Power Link 2000 assembly with pre-installed charging cables and CMKClosed Cable Management Kit mast

    3. Install kit, which contains the following components:

      1. M16 hex nuts and washers for mounting Power Link 2000 (x12)

      2. T25 Security screwdriver

      3. Sealant for sealing the conduit opening (x5)

    Cosmetic Kit Package

    Check the cosmetic kit package for the following components:

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

    Labeled diagram of product, tools or parts.

    1. CMKClosed Cable Management Kit mast covers (front and rear)

    2. Power Link 2000 front lower cover

    3. Power Link 2000 top cap

    4. Power Link 2000 front upper cover

     

    Disconnect Power

    To disconnect power, complete the following steps:

    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.

    1. 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.

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

    Do not reconnect the power after completing the installation (after installing the covers). An authorized commissioning partner will commission, power on, pinpoint, and configure Power Link 2000 after installation.