Connect Schunk SLS 201.102 Wires

Do not install or service the charging station in inclement weather. If you work in snow, rain, or wind, you must use a weather-proof shelter that covers all boxes and components.
Ensure that the installation complies with all applicable codes and ordinances.
Keep components out of direct sunlight in a cool area until you install them.
Warranty Limitation
  • If the charging station is not installed, commissioned, or serviced by a ChargePoint certified technician using a ChargePoint-approved method, it is excluded from all ChargePoint and other warranties and ChargePoint is not responsible.
  • You must be a licensed electrician and complete training at https://www.chargepoint.com/partners/training-certification to become ChargePoint certified and to access ChargePoint's web-based installer tools or ChargePoint Installer app.
Use low torque settings when working with power tools during installation or servicing. Over-torquing can damage the equipment.

Wiring Overview

Before connecting wires at the pantograph, study and understand the wiring information provided below. For wire quantities, sizes, and terminations, see Wires and Terminations Required for Site and refer to the site drawing.

The Schunk SLS 201.102 is configured with the following wiring:

  • HV DCClosed High Voltage Direct Current and high power ground power wires connecting from Power Link 2000.

  • Three sub-cables within the Controller Interface Cable, connecting from the PD Controller:

    • Control pilot

    • Rest sensor

    • Pantograph control

  • A ground wire connecting between the pantograph frame and the auxiliary mounting frame

The wires land on the pantograph at the locations shown below.

Labeled diagram of product, tools or parts.

  1. High power ground (PE)

  2. HV DCClosed High Voltage Direct Current input, positive (+)

  3. HV DCClosed High Voltage Direct Current input, negative (-)

  4. Control pilot

  5. Rest sensor

  6. Pantograph frame ground

  7. Pantograph control

There are two high power ground wires connecting from Power Link 2000:

  • One ground wire connecting to pantograph PE that lands at terminal (a).

  • One ground wire connecting to the pantograph frame that lands at terminal (f).

The wire that grounds the auxiliary mounting frame to the pantograph frame also lands at terminal (f).

Parts Needed

To prepare for Schunk SLS 201.102 wiring, find the following parts from the Auxiliary Components Kit:

  • M10 bolt and flange nut (x5 each)

  • Ground wire (0.5 m, 1.6 ft)

  • M8 bolt and flange nut (x1 each)

  • Controller interface cable (5 m)

  • Zip ties

Connect HV DC Wires

Prepare Wires

  1. Cut the HV DCClosed High Voltage Direct Current and high power ground wires to length for reaching the bus bars on the pantograph. Account for the length of the lug that will terminate each wire.

    The positive (+) and negative (-) bus bars each have two holes for fastening wire lugs. One bolt at each hole can secure two wires, with one wire on each side of the bus bar.

  2. Install wire lugs.

    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.

Connect Wires

  1. Connect HV DCClosed High Voltage Direct Current wires (positive, negative, and PE). Use provided M10 bolts and flange nuts. Torque to 19 Nm (14 ft-lb).

    Technical illustration depicts the procedural step.

  2. Mark all torqued connections. Torque marks are required to pass post-installation inspection.

Connect Pantograph Frame Ground Wires

Prepare Auxiliary Mounting Frame Ground Wire

  1. Familiarize yourself with the ground cable from the Auxiliary Components Kit. See Pantograph Frame to Auxiliary Frame Ground Wire.

  2. Mark the cable end with the larger ring terminal (sized for M8 (0.31 in) bolt). This is the end that installs at the pantograph.

Prepare Ground Wire from Power Link 2000

  1. Identify the high power ground wire connecting from the Power Link 2000.

  2. Route the wire to the pantograph frame ground landing and cut wire to length. Take into account the length of the lug that will terminate the wire.

  3. Strip the wire end and install a lug.

Connect Ground Wires

  1. Connect the two ground wires to the pantograph frame ground landing. Use M8 bolt and flange nut. Torque to 12.2 Nm (108 in-lb).

    Technical illustration depicts the procedural step.

  2. Use a zip tie to secure the wires so that they are clear of the pantograph during operation. The wires must be kept away from the pantograph arms and charging rails.

Connect LV DC Cables

Route Controller Interface Cable

  1. Familiarize yourself with the controller interface cable. See Controller Interface Cable Schunk SLS 201.102.

  2. If the site plan calls for the controller interface cable to run within conduit, and the 1-1/4 in NPTClosed National Pipe Thread cable gland (provided with PD Controller) is used to seal the end of the conduit nearest to the pantograph, thread the cable gland onto the conduit using a 46 mm hex wrench. Torque to (missing or bad snippet).

  3. Route or pull (through conduit) the controller interface cable from the pantograph to the PD Controller.

    • The cable can be pulled through conduit in only one direction, from the pantograph to the PD Controller.

    • Ensure there is sufficient cable length to land the cable wires inside of the PD Controller. See Connect PD Controller Wires.

Connect Pantograph Control Cable

  1. Route the pantograph control cable to the pantograph electric control unit. Ensure the cable is kept clear of high voltage exposed conductors and the pantograph arms through their full movement range.

  2. Connect the pantograph control cable.

    Technical illustration depicts the procedural step.

  3. Push down on the latch tabs to secure the connector.

    Technical illustration depicts the procedural step.

  4. Use a zip tie to secure the cable so that it is clear of the pantograph during operation. The cable must be kept away from the pantograph arms and charging rails.

Connect Control Pilot Cable

  1. Route the pantograph control pilot cable to reach the pantograph control box. Ensure the cable is kept clear of high voltage exposed conductors and the pantograph arms through the entire movement range.

    Technical illustration depicts the procedural step.

  2. Quarter turn spring latches (x4) to open the pantograph control box.

    The latches are operated with a Phillips head screwdriver but they are not screws. Gently push the latch head inwards with the screwdriver and initiate the turn. Part way through the turn, keep the screwdriver in contact with the latch, but discontinue application of inward pressure. Continue turning until the latch pin pops out.

    Be gentle when operating the latches. The latches can break if the screwdriver applies significant torque.

    Technical illustration depicts the procedural step.

  3. Route the control pilot cable though the cable gland.

    Technical illustration depicts the procedural step.

  4. Strip the wire jackets.

    Technical illustration depicts the procedural step.

  5. Insert the control pilot wire (white/brown) into terminal 4. Use the provided wire terminal operating tool or a flat head screwdriver to open the terminal port. Push-pull to test the wire is secured.

    Technical illustration depicts the procedural step.

  6. Insert the control pilot shield wire (brown/black) into terminal 5. Use the provided wire terminal operating tool or a flat head screwdriver to open the terminal port. Push-pull to test the wire is secured.

    Technical illustration depicts the procedural step.

  7. Close the box. Quarter turn spring latches (x4).

    The latches are operated with a Phillips head screwdriver but they are not screws. Gently push the latch head inwards with the screwdriver and initiate the turn. Part way through the turn, keep the screwdriver in contact with the latch, but discontinue application of inward pressure. Continue turning until the latch pin latches into a locking groove.

    Be gentle when operating the latches. The latches can break if the screwdriver applies significant torque.

    Technical illustration depicts the procedural step.

  8. Tighten the cable gland. Torque to 1.5 Nm (13.3 in-lb).

    Technical illustration depicts the procedural step.

  9. Use a zip tie to secure the cable so that it is clear of the pantograph during operation. The cable must be kept away from the pantograph arms and charging rails.

Connect Rest Sensor Cable

  1. Route the pantograph rest sensor cable to the pantograph control box. Ensure the cable is kept clear of high voltage exposed conductors and the pantograph arms through their full movement range.

    Technical illustration depicts the procedural step.

  2. Connect the rest sensor cable. Hand-tighten.

    Technical illustration depicts the procedural step.

  3. Use a zip tie to secure the cable so that it is clear of the pantograph during operation. The cable must be kept away from the pantograph arms and charging rails.