Maintenance Switch Kit

This topic provides information on servicing and replacing the maintenance switch kit.

Required Tools and Materials

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T25 security screwdriver

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Hex socket set (17 mm, 8 mm)

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Torque paint pen

    

Kit Components

This kit is for installing on a Power Link 1000 without the maintenance switch or replacing an existing one that has failed.

Kit components for the maintenance switch with the maintenance switch assembly, bus bars, and safety shield

  1. Maintenance switch assembly - single or dual input

  2. Extruded bus bars with two M10 bolts and washers (x2 or x4) - two for single input or four for dual input

  3. Safety shield

Before You Begin

  1. Power off the charging station at the site electrical panel.

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

  3. Open the upper and lower door.

  4. Remove upper bus bar safety cover.

  5. Open the power plate cover.

    1. Release the tabs on the cover.

      Release the tabs on the cover after opening the power plate cover

    2. Lift up from the bottom until it locks in the open position.

      Lift up from the bottom until it locks in the open position.

  6. Remove the M10 nuts (use 17 mm socket) on each lug to uninstall the DC conductor lugs.

    Remove the M10 nuts using 17 mm socket on each lug to uninstall the DC conductor lugs

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

Install Maintenance Switch

To install the maintenance switch, complete the following steps:

  1. To install the maintenance switch assembly:

    1. Partially install the M5 nuts (x4) (use 8 mm socket) onto the four studs on the frame.

      Partially install the four M5 nuts using 8 mm socket onto the four studs on the frame.

    2. Hook the four keyholes on the switch assembly backplate onto the four studs on the frame and torque the M5 nuts to 4.5 Nm (40 in-lb).

  2. To install the extruded bus bars:

    1. Install the extruded bus bars and M10 nuts onto the bus bar studs in the upper cabinet.

      Install the extruded bus bars and M10 nuts onto the bus bar studs in the upper cabinet.

    1. Install the M10 bolts (use 17 mm socket) on the lower side extruded bus bars.

      Install the M10 bolts using 17 mm socket on the lower side extruded bus bars.

    Torque all M10 fasteners to 19 Nm (168 in-lb) and mark them using a torque paint pen.

  3. To connect the auxiliary contact and lug landing thermal switch wires:

    1. Loosen the two screws on the low voltage terminal block and install the auxiliary contact wires (blue and white) at lower side of the terminal block. Tighten the screws with flat head screwdriver.

      Loosen the two screws on the low voltage terminal block and install the auxiliary contact wires (blue and white) at lower side of the terminal block. Tighten the screws with flat head screwdriver.

    2. Connect the lug landing thermal switch wire to its mating plug at the right side.

      Connect the lug landing thermal switch wire to its mating plug at the right side.

REVERSE THE ABOVE STEPS TO REMOVE THE MAINTENANCE SWITCH.