Power Path Lug

This section provides instructions for replacing the power path lug in the Power Link 2000.

This warning applies only to Power Link 2000s certified for Eichrecht. On Power Link 2000 units certified for Eichrecht, the power path lug is not easily replaceable.  As a standard practice, if replacing the power path lug, the Control and Communication Module (CCOM)/Display and Charging Cable (LCC and Non-LCC) must also be replaced.  Removing these components breaks both the digital and physical sealing, which invalidates Eichrecht compliance and disables the station for public charging in affected jurisdictions.  Only ChargePoint or qualified Instandsetzer (a technician certified for Eichrecht work) can replace these parts while preserving Eichrecht validity.  You can identify an Eichrecht-certified Power Link 2000 by the "DE-M" mark on the nameplate.

Assembly Components

The power path lug consists of the following components:

Technical illustration depicts the procedural step.

  1. Contactor switch (Proton) module

  2. Surge arrestor

  3. Bus bars (x2)

Required Tools and Materials

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Stepladder

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Cut-resistant gloves

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Hex socket set

  • 8 mm for backplate nuts

  • 10 mm for ground wire lug nut

  • 17 mm DC power path wire lug nuts

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Dielectric grease

Before You Begin

Before servicing the component, complete the following steps:

  1. Power off.

  2. Remove these:

    1. Top cap

    2. Front lower cover

    3. Front upper cover

  3. Open the upper door.

  4. Determine which power path lug (left or right) you want to replace.

  5. Remove these:

    1. DC power path bus bar safety cover

    2. Charging cable bus bar safety cover

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

 

Replace the Power Path Lug

  1. Disconnect the cables (x3 per power path lug).

    The illustration shows the cable connections for both left-side and right-side power path lugs. If servicing only the right-side unit, you may disconnect cables only from the right-side unit. If servicing the left-side unit, you must disconnect not only the cables at the left-side unit, you must also disconnect P285-1-02 and P285-1-06 from the right-side unit.

    Technical illustration depicts the procedural step.Technical illustration depicts the procedural step.Technical illustration depicts the procedural step.

    • Find the label on each cable to plug its connector back into its correct receptacle connector.

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

    • Ensure that no cable is coming in contact with the bus bars.

  2. Remove the lug nuts to disconnect the DC power path input, charging cable HVClosed High Voltage DC, and ground wires.

    Technical illustration depicts the procedural step.Technical illustration depicts the procedural step.

    • ChargePoint recommends applying dielectric grease to the contact surface of the DC power path wire lugs.

    • Connect the wires back to their original landing location.

    • For 6 mm nuts (M6 HV DCClosed High Voltage Direct Current charging cable and ground wire lug nuts) torque to 5.6 Nm (50 in-lb). For 10 mm nuts (M10 DC power path wire lug nuts) torque to 19 Nm (14 ft-lb).

  3. Loosen the hex nuts (x4) and lift the assembly to remove.

    Hold the assembly backplate with one hand and place the other hand under the surge arrestor to gently push the assembly up to remove it from the studs.

    Technical illustration depicts the procedural step.

    • To prevent wires from being pinched while installing, make sure no wire is between the backplate and the frame.

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

Reverse the above steps to reinstall with replacement FRUClosed Field Replaceable Unit.

 
  • To adhere to ChargePoint best practices, complete the post-service checklist before you leave the site.

  • For assistance or to return a faulty part to ChargePoint, go to chargepoint.com/support and contact technical support using the appropriate region-specific number.