Covers and Panels

This section provides instructions for removing and replacing covers and panels in the Power Link 2000.

Required Tools and Materials

	Stepladder		Cut-resistant gloves
	T25 Security screwdriver, for: Top cap Side panel Rear upper and lower cover Heat sink cap	v	T10 Torx screwdriver (for upper and lower cover trims)
	10 mm hex wrench (for doors)		Isopropyl pads (for upper and lower cover vinyls)
	Vinyl application tool (for upper and lower cover vinyls)

Before You Begin

Before beginning work, complete the following steps:

1. Refer to the site drawings and identify the charging stations to be serviced.

2. End all charging sessions and activity for the stations to be serviced.

3. Use the following sequence to remove a cover:

   Top cap   Front lower cover Removing (b) lets you open the lower door and it can be removed without removing (a).   Front upper cover Removing (a), (b), and (c) lets you open both lower and upper door.   Cable cap   Side panel   Rear upper cover   Rear lower cover

4. If you want to replace ChargePoint branded vinyls with custom branded vinyls, refer to these instructions.

After replacing the components, reverse the above steps to complete the service.

 

Replace the Top Cap

To replace the top cap, complete the steps given below.

Remove the Cap

1. Loosen the screws (x4, two at front and two at rear).

   

2. Lift the top cap.

   

Reinstall the Cap

1. Align the screws (x4) and install the top cap.

   • Front screws (x2)

     

   • Rear screws (x2)

     

2. Make sure that the top cap sides are seated on edges on top of the side panels (x2).

   

3. Torque the rear screws (x2) to 2.8 Nm (25 in-lb) and front screws (x2) to 1.7 Nm (15 in-lb).

   

Replace the Front Lower Cover

To replace the front lower cover, complete the steps given below.

Remove the Cover

1. Remove charging cable connectors from the holster.

2. Pull the cover up by holding upper side of the holster trim.

   

3. Flex any one side of the cover to remove the corresponding edge out of the groove on the side panel.

   

4. Remove the other side edge out of the groove on the other side panel.

Reinstall the Cover

1. Align top edge of the lower cover with the lower edge of the Control and Communication Module (CCOM Control and Communications Module) trim.

   

2. While overlapped with the upper cover, insert any one side of the cover into the groove on the side panel.

   

3. Gently flex the cover to insert its other side into the groove on the other side panel. Make sure that the top and bottom corners of the cover are seated in the groove.

   

4. Press in below the holster trim and lower side of the cover; while pressed in, slide the cover down to engage the hooks (x2) behind the cover. See the previous step for the exact location of the hooks.

   

5. Make sure that the lower edge of the holster bracket and holster trim are aligned.

   

6. Place charging cable connectors into the holsters.

   

Replace the Front Upper Cover

To replace the front upper cover, complete the steps given below.

Remove the Cover

1. Remove top cap.

2. Remove front lower over.

3. Hold and flex lower side of the cover outward to disengage the ball studs (x3) hooked to the bracket on the upper door.

   

4. Flex any one side of the cover to remove the corresponding edge out of the groove on the side panel.

   

5. Remove the other side edge out of the groove on the other side panel.

Reinstall the Cover

1. Insert any one side of the cover into the groove on the side panel.

   

2. Gently flex the cover to insert its other side into the groove on the other side panel. At the same time, align and hook the ball studs (x3) behind the cover into the holes (x3) in a bracket on the upper door.

   

3. Alternatively, you can hold and flex the lower side of the cover slightly outward. While flexed, align the ball studs (x3) behind the cover with the holes (x3) in the bracket on the upper door and press in.

   

4. Make sure that the screws (x2) on the front upper cover are seated in their slots in the area light housing.

   

5. Reinstall front lower over.

6. Reinstall top cap.

Replace the Cable Cap

To replace the cable cap, complete the following steps:

1. Remove top cap.

2. Determine which cable cap you want to remove (the one on the left side lets you remove the left side charging cable and the one on the right side lets you remove the right side charging cable).

3. Pull the cable cap up to remove and keep it aside to reinstall it later.

   

Reverse the above steps to reinstall the cable cap.

Replace the Side Panel

This section provides instructions for replacing a side panel. Before you start, determine which side panel you want to remove (left side panel or right side panel).

Remove the Panel

1. Remove these:

   1. Top cap

   2. Cable cap

   3. Front lower and upper covers

2. Open lower door.

3. If applicable, remove the lower bus bar safety cover.

4. Loosen the screws (x2).

   

5. Slowly push upper side of the side panel up to disengage it from hooks (x2) on the frame.

   

6. Hold the charging cable up and out of the way to slowly lower and remove the side panel.

7. Remove the side panel and keep it aside to reinstall it later.

   

Reinstall the Panel

1. Hold the charging cable up and place it into the cable way on the side panel.

   

2. Align and install the side panel onto the hooks (x2) and alignment pins (x2) on the frame.

   

3. Slowly slide the side panel down to engage the hooks (x2) on the frame.

   

4. Align the screw holes (x2) on the rear side of the side panel with the screws (x2) inside the lower enclosure and torque them to 4.5 Nm (40 in-lb).

   

5. If applicable, reinstall the lower bus bar safety cover.

6. Close lower door.

7. Reinstall front upper and lower covers.

8. Reinstall cable cap.

9. Reinstall top cap.

Replace the Rear Upper Cover (LCC)

This section provides instructions for replacing the rear upper cover, specifically for Power Link 2000 with liquid cooled cable (LCC Liquid Cooled Cable). To replace the rear upper cover, complete the following steps:

1. Remove side panel.

2. Loosen the screws (x6) to remove the cover.

   

   Torque these screws to 4.5 Nm (40 in-lb).

3. If the rear upper cover has a card reader installed on it, disconnect the card reader cable before you remove the cover. Press the latch and pull the connector to disconnect the cable.

   

   To reconnect, plug in. The latch must snap onto the receptacle connector with a click sound to ensure that the connection is secure.

Reverse the above steps to reinstall the rear upper cover.

Replace the Rear Lower Cover (LCC)

This section provides instructions for replacing the rear lower cover specifically for Power Link 2000 with liquid cooled cable (LCC Liquid Cooled Cable). To replace the rear lower cover, complete the following steps:

1. Remove these:

   1. Side panel

   2. Rear upper cover

2. Loosen the screws (x6).

   Torque these screws to 4.5 Nm (40 in-lb).

   

Reverse the above steps to reinstall the rear lower cover.

Replace the Heat Sink Cap (LCC)

This section provides instructions for replacing the heat sink cap, specifically for Power Link 2000 with a liquid cooled cable (LCC Liquid Cooled Cable). To replace the heat sink cap, complete the following steps:

1. Remove top cap.

2. Loosen the screws (x2).

   

   Torque these screws to 4.5 Nm (40 in-lb).

Reverse the above steps to reinstall the heat sink cap.

Replace the ChargePoint Vinyls with Custom Branded Vinyls

To replace ChargePoint vinyls with custom branded vinyls, complete the following steps:

1. Remove front lower and upper covers.

2. Remove the trims (x4) on the upper and lower covers.

   1. Remove the screws (x24).

      • Upper cover screws (x8)

        

      • Lower cover screws (x16)

        

      Torque these screws to 0.57 Nm (5 in-lb).

   2. Remove the trims (x4) and keep them aside to reinstall later.

      • Upper cover trim

        

      • Lower cover trims (x3)

        

3. Peel off the ChargePoint branded vinyls.

   • Upper cover vinyl

     

   • Lower cover vinyl

     

4. Use an isopropyl pad to clean the adhesive residue and dust off the cover surfaces.

5. Affix the new custom branded vinyls.

   Avoid scratching and stretching the vinyls while laying them.

   1. Remove the adhesive strip from the middle of the vinyl's back.

   2. Use the screw and trim cutouts in the middle of the vinyl to align it with the cover.

      • Cutouts on upper cover vinyl (x10)

        

      • Cutouts on lower cover vinyl (x16)

        

   3. Once aligned, gently press down on the adhesive surface to attach it to the cover.

   4. Once the middle of the vinyl is attached, remove the adhesive strip on the left or right side of the vinyl.

   5. Align the vinyl's edges with the cover and check for creases before attaching the adhesive surface to the cover. Repeat for the adhesive strip on the other side.

6. Reinstall the trims (x4) onto the upper and lower covers.

7. Reinstall front upper and lower covers.

Open and Close the Doors

To open and close upper and lower enclosure doors, follow the steps given below.

Open the Doors

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

   

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

   

 

Close the Doors

1. Disengage the door stopper (x1 per upper and lower enclosure door).

   

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