Mount Power Link 2000 and PD Controller

While installing fasteners inside enclosures, make sure not to drop the fasteners inside conduit openings. You may use conduit caps or covers to temporarily cover the conduit openings.

Parts Needed

To prepare for Power Link 2000 and PD Controller mount, find the following parts:

  • Power Link 2000 assembly

  • PD Controller assembly

  • Parts from the Mast Installation Parts Crate:

    • Unistruts (x2)

    • Power Link 2000 mouting base

    • 1/2 in bolts, 1/2 in washers, and 1/2 in nuts (x6 each)

    • M6 x 25 mm screws (x8)

    • 1/2 in bolts, 1/2 in washers, 1/2 in nuts (x4 each)

    • 5/16 in bolts and 5/16 in washers, 5/16 in spring nuts (x4 each)

  • 3-1/2 in strut pipe strap (contractor provided)

Install Power Link 2000 Mounting Base

  1. Open the mast door.

  2. Remove fasteners (x2) to release the HV DCClosed High Voltage Direct Current conduit shipping bracket from the mast.

    Technical illustration depicts the procedural step.

  3. Remove the lock nut to release the HV DCClosed High Voltage Direct Current conduit from the shipping bracket. Slide the nut and shipping bracket off the HV DCClosed High Voltage Direct Current conduit and wires.

    Technical illustration depicts the procedural step.

  4. Remove the remaining fitting from the HV DCClosed High Voltage Direct Current conduit.

    Technical illustration depicts the procedural step.

  5. At the top of the mast, pull the HV DCClosed High Voltage Direct Current wires out the pantograph access opening to fully retract wires into the lower end of the wire conduit. This clears space in the mast for mounting the Power Link 2000.

    Technical illustration depicts the procedural step.

  6. Install the Power Link 2000 mounting base using 1/2 in bolt, 1/2 in washer, and 1/2 in nut (x6 each). Ensure the base is level.

    Technical illustration depicts the procedural step.

  7. Torque fasteners (x6) to 50 Nm (37 ft-lb).

    After mounting the base, double-check the fasteners to ensure they are torqued to the correct value.

Lift Power Link 2000

  1. At the top of the Power Link 2000, locate four preinstalled eye bolts and lifting straps.

    Technical illustration depicts the procedural step.

  2. Lift up the Power Link 2000 by the lifting straps to eye level.

    Use a forklift or service cart with retaining straps.

    Technical illustration depicts the procedural step.

Open Power Link 2000

  1. Quarter turn the door latches (x2) to unlock the door.

    Technical illustration depicts the procedural step.

  2. Open the door and engage the door stopper.

    Technical illustration depicts the procedural step.

  3. Slide the bus bar safety cover up to remove from hooks (x2) and latches (x2).

    Technical illustration depicts the procedural step.

Save Parts

Safely set aside the bus bar safety cover. This part will be reinstalled when completing the Pantograph Down 2000 system install.

Prepare Power Link 2000 Gland Plate

  1. Remove screws (x6) from the Power Link 2000 bottom gland plate. Save screws for later reinstall.

    Technical illustration depicts the procedural step.

  2. Remove the gland plate.

    Technical illustration depicts the procedural step.

  3. Consult the site plan to identify the remaining HV DCClosed High Voltage Direct Current conduits, LV DCClosed Low Voltage Direct Current conduits, and cable gland required for the Power Link 2000. Use a hydraulic hole punch to create the needed openings.

    Technical illustration depicts the procedural step.

    Sample conduit and cable gland hole pattern:

    1. HV DCClosed High Voltage Direct Current input from Power Block

    2. LV DCClosed Low Voltage Direct Current input from Power Block

    3. Ground to mast

    • There is limited space within the Power Link 2000 for bending HV DCClosed High Voltage Direct Current wires. HV DCClosed High Voltage Direct Current conduit holes must be punched at a location that aligns wire entry with their intended bus bar landings. See Wiring Overview for more information.

    • Illustrations in this guide depict a sample conduit configuration. Actual conduit quantity, size, and position at the gland plate will vary by site.

  4. Reinstall the gland plate. Torque screws (x6) to 4.5 Nm (40 in-lb).

    Technical illustration depicts the procedural step.

  5. Disengage the door stopper and close the Power Link 2000 door.

Mount Power Link 2000

  1. Transport the Power Link 2000 to the mast. Align mounting holes on the rear of the Power Link 2000 to the mounting base.

    Technical illustration depicts the procedural step.

  2. Mount the Power Link 2000 to the base with M6 x 25 mm screws (x8).

    Technical illustration depicts the procedural step.

  3. Torque the fasteners to 5.6 Nm (50 in-lb).

    After mounting the enclosure, double-check the fasteners to ensure they are torqued to the correct value.

  4. Release the lifting straps  and remove the eye bolts (x4) and rubber washers (x4). Use either an adjustable wrench or screwdriver's shaft to loosen the eye bolts.

    Technical illustration depicts the procedural step.

Connect Power Link 2000 HV DC Output Conduit

  1. Open the Power Link 2000 door and engage the door stopper.

  2. Connect HV DCClosed High Voltage Direct Current output conduit to the Power Link 2000 top plate.

    Ensure the conduit fitting is installed with no gaps at the top plate. A tight fit is required to prevent moisture and water from entering the enclosure.

    Technical illustration depicts the procedural step.

  3. Use 3-1/2 in strut pipe strap (contractor-supplied) to secure the HV DCClosed High Voltage Direct Current conduit to the strut channel.

    Technical illustration depicts the procedural step.

Install PD Controller Mounting Struts

  1. Install PD Controller mounting unistruts:

    • Position the lower unistrut approximately 143 mm (5.63 in) above the top of the Power Link 2000.

    • Position the upper unistrut such that there is 419 mm (16.5 in) separation between the unistruts.

    • Ensure the struts are level.

    • Fasten the unistruts with 1/2 in bolt, 1/2 in washer, 1/2 in nut (x2 each per unistrut).

    Technical illustration depicts the procedural step.

  2. Torque fasteners to 50 Nm (37 ft-lb).

    After mounting the struts, double-check the fasteners to ensure they are torqued to the correct value.

  3. Slide 5/16 inch spring nuts (x2) into each unistrut.

    Technical illustration depicts the procedural step.

Mount PD Controller

  1. Lift the PD Controller out of its package and stand it vertically on level ground.

    The PD Controller weighs 32.2 kg (71 lb) and can be lifted by two people.

  2. Insert forklift tines into the lifting brackets.

    Technical illustration depicts the procedural step.

  3. Lift and transport the enclosure to the mast. Center the PD Controller in front of the mounting struts.

    Technical illustration depicts the procedural step.

  4. Align the spring nuts with the PD Controller mounting tabs.

    Technical illustration depicts the procedural step.

  5. Fasten the PD Controller to the mounting base with 5/16 in bolt and 5/16 in washer (x4 each).

    Technical illustration depicts the procedural step.

  6. Torque fasteners to 10 Nm (90 in-lb).

    After mounting the enclosure, double-check the fasteners to ensure they are torqued to the correct value.

  7. Remove the forklift.

  8. Remove nuts at lifting brackets (x4 nuts per bracket).

    Technical illustration depicts the procedural step.

  9. Remove lifting brackets.

    Keep lifting brackets for any future removal of the PD Controller (as needed).

    Technical illustration depicts the procedural step.

  10. Remove the eye bolts and washers (optional). Use either an adjustable wrench or screwdriver's shaft to loosen the eye bolts.

    Technical illustration depicts the procedural step.

Connect Remaining Power Link 2000 Conduits

  1. Open the Power Link 2000 door and engage the door stopper.

  2. Connect remaining conduits to the top and bottom gland plates.

    Technical illustration depicts the procedural step.

    Conduit at top plate:

    1. LVClosed Low Voltage output to PD Controller

    Conduits (sample pattern) at bottom plate:

    1. HV DCClosed High Voltage Direct Current input from Power Block

    2. LV DCClosed Low Voltage Direct Current input from Power Block

    • Use suitable fittings to secure and seal conduits to the enclosure. Conduits must be sealed to maintain a Pollution Degree 2 environment.

    • Illustrations in this guide depict a sample conduit configuration at the bottom gland plate. Actual conduit quantity, size, and position at the gland plate will vary by site.

Open PD Controller

  1. Quarter turn the door latch to unlock the door.

    Technical illustration depicts the procedural step.

  2. Open the enclosure.

    Technical illustration depicts the procedural step.

Connect PD Controller Conduits

  1. Connect AC and LVClosed Low Voltage input conduits to the bottom of enclosure.

    Technical illustration depicts the procedural step.

    1. AC input conduit

    2. LVClosed Low Voltage input conduit