Connect Mast Wires

Parts Needed

To prepare for wiring, find the following parts from the Mast Components Kit:

  • M8 bolt and flange nut (x1 each)

  • 3/8 in flange bolt, flange nut, external tooth washer (x5 each)

Wiring Overview

Labeled diagram of product, tools or parts.

The Pantograph Down Mast is equipped with a ground bar (a) located at the base of the pole, on the inside wall of the pole. This location is used to land ground wires connecting to:

  • Grounding rods (if used)

  • Power Link 2000

There is a second grounding point (b) located inside the arm of the mast, which is used to ground the pantograph frame to the mast.

For wire quantities, sizes, and terminations, see Wires and Terminations Required for Site.

Connect Wires at Mast Ground Bar

If grounding rods were installed for the mast, follow the procedure below to prepare the ground rod wires.

  1. If mast grounding rods were installed, follow grounding rod manufacturer's instructions for connecting ground wires to the rods.

  2. Identify the ground wire connecting from the Power Link 2000. See Power Link 2000 Wire Overview.

  3. Cut all ground wires to length for landing on the mast ground bar. See Wiring Overview for landing location. Take into account the length of the lug that will terminate the wire.

  4. Prepare the wires:

    Technical illustration depicts the procedural step.

    1. Mark the lug's barrel height on the wire terminal.

    2. Strip the jacket on the marked terminal. Use a suitable wire stripper, such as Klein tool.

    3. If recommended by the wire manufacturer or local code, apply an anti-oxidant joint compound to the stripped wire material to make a gastight joint with the lug.

    4. Insert the stripped terminal into the lug's barrel and crimp it. Use a suitable lug crimping tool and/or die recommended by the lug manufacturer.

    5. Apply dielectric grease to the lug's tongue surface that comes in contact with the bus bars.

  5. Connect ground wires to the mast ground bar. Use 3/8 in flange bolt, flange nut, and external tooth washer to fasten each wire. Torque fasteners to 19 Nm (14 ft-lb).

    Technical illustration depicts the procedural step.

Connect Wire at Mast Arm

  1. Locate the conduit bracket in the mast arm.

    Technical illustration depicts the procedural step.

  2. Drill a hole into the conduit bracket. The wire will connect at this hole.

    Technical illustration depicts the procedural step.

  3. Find the ground wire connecting from the pantograph frame. See Schunk SLS 201.102 Wiring Overview.

  4. Cut ground wire to length for landing at the conduit bracket.

  5. Install a ring terminal on the wire end.

  6. Connect the wire to the conduit bracket with M8 bolt and flange nut. Torque fasteners to 15 Nm (133 in-lb).

    Technical illustration depicts the procedural step.