Dual Input Contactor Kit

This section provides information on servicing the dual input contactor kit.

Required Tools and Materials

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T25 security screwdriver

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Hex socket set (17 mm, 10 mm, 8 mm)

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Torque paint pen

    

Kit Components

This kit is for installing on a Power Link 1000 without the dual input contactors or replacing an existing one.

Kit components for a dual input contactor

  1. Dual input contactors assembly

  2. High voltage (HVClosed High Voltage) surge suppressor

Before You Begin

Complete the following steps, before you begin:

  1. Power off the charging station.

  2. Determine if the Power Link 1000 has preassembled covers or unassembled components, remove them as necessary.

  3. Open the upper door.

  4. Remove the DC smart cable bus bar safety cover.

  5. Remove the L shaped bus bar safety cover.

  6. Remove upper bus bar safety cover.

AFTER INSTALLING, REVERSE THE ABOVE STEPS TO COMPLETE THE SERVICE.

Install Dual Input Contactors

To install the dual input contactors, complete the following steps:

  1. If applicable, remove the combiner bus bar assembly.

    1. Remove the M10 hex fasteners (x5) (use 17 mm socket).

      Remove the five M10 hex fasteners using a 17 mm socket

    2. Pull the assembly out of the two bar clips.

      Pull the assembly out of the two bar clips.

  2. Install the dual input contactors assembly.

      1. Press the assembly into the two bar clips. Make sure that the bus bar is installed onto the M10 stud on the left side.

        Press the assembly into the two bar clips. Make sure that the bus bar is installed onto the M10 stud on the left side.

      1. Install the M10 fasteners (x5) (use 17 mm socket).

        IMPORTANT: Torque the fasteners to 19 Nm (168 in-lb) and mark the torqued fasteners using a torque paint pen.

        Install the five M10 fasteners using a 17 mm socket. Torque the fasteners to 19 Nm or 168 in-l) and mark the torqued fasteners using a torque paint pen.

  3. If applicable, install the HVClosed High Voltage surge suppressor.
    1. Hook the upper groove behind the HVClosed High Voltage surge suppressor onto the upper edge of the bracket.

      Hook the upper groove behind the HV surge suppressor onto the upper edge of the bracket.

    1. Rotate in the lower groove and press onto the lower edge of the bracket. Make sure that the clip behind the HVClosed High Voltage surge suppressor clips into place. To remove, press the plunger below the clip and rotate out.

    2. Connect the DC and ground wires.

      1.  Uninstall the M5 nuts (x2) (use 8 mm socket) on the left and right side.

      Uninstall the two M5 nuts using 8 mm socket on the left and right side.

      1. Install the DC wire lugs and M5 nuts onto the studs. Torque to 4.5 Nm (40 in-lb).

      2. Uninstall the M6 nut (use 10 mm socket) on the frame.

        Uninstall the M6 nut using 10 mm socket on the frame.

      3. Install the ground wire lug and M6 nut onto the stud. Torque to 5.6 Nm (50 in-lb).

  1. Connect the HVClosed High Voltage surge feedback wires.

    Connect the HV surge feedback wires.

REVERSE THE ABOVE STEPS TO REMOVE THE DUAL INPUT CONTACTORS AND HVClosed High Voltage SURGE SUPPRESSOR.