ChargePoint Power Block Design Manual

Express plus dc fast charging station

Hide thumbs

page of 50

/ 50
Bookmarks

Quick Links

Download this manual

Power Block and Power Link 2000

Express Plus DC Fast Charging Station

Site Design Guide

Need help?

Do you have a question about the Power Block and is the answer not in the manual?

Questions and answers

Summary of Contents for ChargePoint Power Block

Page 1 Power Block and Power Link 2000 Express Plus DC Fast Charging Station Site Design Guide...
Page 2 Read and follow all warnings and instructions before servicing, installing or operating the ChargePoint® charging station. Install and operate it only as instructed. Failure to do so may lead to death, injury or property damage and will void the Limited Warranty.
Page 3 Copyright and Trademarks ©2013 – 2023 ChargePoint, Inc. All rights reserved. This material is protected by the copyright laws of the United States and other countries. It may not be modified, reproduced or distributed without the prior, express written consent of ChargePoint, Inc. CHARGEPOINT is a US, UK and EU registered trademark and service mark of ChargePoint, Inc.
Page 5 Contents Important Safety Instructions 1 Site Design Guidelines Product Components Initial Site Guidelines Plan for Future Charging Capacity Charging Station Placement 2 Civil and Mechanical Design Component Dimensions Mounting Specifications - Concrete Pads Mounting Specifications - Walls Mounting Specifications - Surface Mount Conduit Entry Drainage Clearances Wheel Stops and Bollards...
Page 6 Site Design Guidelines This document describes how to design a project site for the ChargePoint® Express Plus DC fast charging solution. The Express Plus product family is a modular solution for scalable fast charging of electric vehicles. Power Link 2000 charging stations are powered by Power Block AC/DC converters, and the entire system communicates with ChargePoint using the mobile network.
Page 7 Blocks to many Power Link 2000s. The Express Plus solution is highly modular. Each Power Block has two DC outputs. That power can be fed to a single station, or to two different stations, depending on configuration. Low voltage and Ethernet connectivity are also fed to either one or two stations.
Page 8 Power Blocks and Power Links must be installed on a surface rated for the weight of the enclosure (a level concrete base for either Power Block or Power Link or a flat wall or gantry for Power Link). Tarmac cannot support the full weight of the station. Failure to install the enclosure on a suitable surface may cause it to tip over, resulting in death, personal injury or property damage.
Page 9 Charging Station Placement Guidelines for Different Parking Arrangements Choose adjacent parking spaces in an area with adequate lighting. Consider how easily drivers can find the stations they need to access. Check local requirements for accessibility and pathway width, sometimes called “path of travel”, to ensure that station placement does not restrict sidewalk use.
Page 10 Commercial Parking Arrangement Stall parking: For stall parking, ChargePoint recommends using perpendicular parking stalls that allow a vehicle to enter either front-first or rear-first, to better accommodate the varied locations of EV charge ports. Note: While ChargePoint tests charging stations with a...
Page 11 Charging Station Placement Diagonal parking: Centre the station on one parking space to maximise cable reach. Curbside parking: Centre the station between parking spaces to maximise cable reach. Fleet Parking Arrangement Stall parking: If the station will have the same cable type, centre the station between parking spots to allow each cable to be plugged in whenever it is available.
Page 12 Island parking: ChargePoint recommends placing a station in the centre of the island facing away (station front is perpendicular to vehicles) in the same orientation. This allows the station to be accessible from both sides of the island. Diagonal parking: Centre the station between parking spots.
Page 13 Centre enclosure (dry box): A bay for up to five Power Modules and bus bars to land all input and output cables Pedestal: Secures the Power Block and provides access for either stub-up or surface mount installations A fully loaded Power Block weighs approximately 680 kg (1500 lbs). Each Power Module weighs approximately 45 kg (98.5 lbs).
Page 14 Power Link 2000 The Power Link 2000 is a vertical enclosure that can be mounted on a pedestal, wall or overhead. Stations can be configured with one or two charge cables, available in multiple lengths. The Power Link 2000 can have different charging cable types (such as one CCS and one CHAdeMO) to offer flexibility, or it can have the same cable type (in cases such as commercial fleets).
Page 15 Power Link 2000 With Liquid Cooled Cables - Dual Note: Images are not to scale. Measurements appear in metric units (mm), followed by imperial equivalents (inches).
Page 16 Power Link 2000 With Liquid Cooled Cables - Single Note: Images are not to scale. Measurements appear in metric units (mm), followed by imperial equivalents (inches).
Page 17 Power Link 2000 Without Liquid Cooled Cables - Dual Note: Images are not to scale. Measurements appear in metric units (mm), followed by imperial equivalents (inches).
Page 18 Power Link 2000 Without Liquid Cooled Cables - Single Note: Images are not to scale. Measurements appear in metric units (mm), followed by imperial equivalents (inches).
Page 19 Mounting Specifications - Concrete Pads The Power Block and Power Link 2000 (in pedestal configuration) can each be installed on either a newly poured pad or an existing concrete surface. The mounting surface must be smooth and cannot exceed a slope of 20 mm per metre (0.25 inches per foot).
Page 20 The Power Block must be centred within the designed stability area. The concrete pad for the Power Block must either be designed to be site-specific or must meet the specifications above. In some extreme conditions, a larger pad would be required. For sites with less...
Page 21 The Power Block anchor bolt pattern appears below. Power Block input and output cables can either be run under the grade surface in trenches or they can be run along the grade surface and protected by wireways, as described in this section and...
Page 22 Plates (x2) Anchor bolts (x4) with fasteners (x8) Rigid spacers (x9) An overview of Power Block conduit and cable entry locations is shown below. Power Block Concrete Mounting Template (CMT) DC output options: 250, 350 or 500 A (stub-up conduit entry): With two inputs, the Power Link 2000 supports two conduits up to 89 mm (3.5 in trade size)
Page 23 Note: If two pairs of conductors are running to the same Power Link 2000 from a Power Block, conductors must be routed with bus A + and - in one conduit, and Bus B + and - in the other.
Page 24 The concrete pad for the station must either be designed to be site-specific, or must meet the specifications above. In some extreme conditions, a larger pad would be required. For sites with less stringent seismic, soil or wind conditions, a smaller pad might be possible. If the existing pad does not meet the specifications above, it must be inspected and approved by a structural engineer for each component’s dimensions and weight.
Page 25 Mounting Specifications - Concrete Pads Power Link 2000 service wiring enters from the bottom of the enclosure or from the back. In all cases, the maximum required wiring and conduit entries use the maximum conduit sizes listed below. Note: This conduit layout reflects the largest conduit options. See Conduit and WiringRequirements more information.
Page 26 Note: Remove the breakaway tabs to access the DC conduit openings. Note: Low voltage lines can be routed in the same conduit as Ethernet if the wires are routed to the same location. Note: Only round openings in the template are functional.
Page 27 Use wall mount bracket to mark hole locations. Size holes for M8 bolts. WARNING: If not installed correctly, the ChargePoint charging station may pose a crushing hazard, leading to death, personal injury or property damage. Always use the provided Concrete Mounting Template shown pre-installed here, or a ChargePoint-approved surface mounting solution, to install the ChargePoint charging station.
Page 28 The minimum height of the wall must be 1851 mm (72.9 in) above a finished floor. The maximum height of the mounting bracket is 1733.17 mm (68.24 in) above a finished floor.
Page 29 Note: The image shows examples of positioning only. All conduit for a Power Block must enter through a single face. Arranging input and output on opposite sides for rows of Power Blocks is not supported.
Page 30 A pedestal-mount Power Link 2000 also accepts Surface Conduit Entry. The surface conduit can enter from the pedestal back (a), or approach from one side and use a 90 degree elbow to join the pedestal back. Use a ChargePoint approved surface mount template to correctly align anchor bolt locations for drilling and epoxy.
Page 31 (recommended) bottom entry. When units are side by side, wiring for the row cannot pass through one unit into another. Note: A Power Block cannot be positioned more than 100 m (328 ft) from any of its associated stations because of Ethernet communication restrictions.
Page 32 Check local and regional regulations for any additional clearance requirements regarding safety, high voltage equipment and accessibility requirements. CAUTION: Each Power Module weighs 45 kg (98.5 lbs). Service for each Power Block requires a team of at least two people.
Page 33 Clearances Power Link 2000 The Power Link 2000 requires minimum site and service clearances listed below. Power Link 2000 With Liquid Cooled Cables Note: Image not to scale. Power Link 2000 Without Liquid Cooled Cables Note: Image not to scale.
Page 34 Power Link Clearance Front Minimum open space 610 mm (24 in) Door swing + width of unit 730 mm (28 3/4 in) 305 mm (12 in) from top corner to top corner Side Two Power Link units can share side clearance provided adequate clearance is allowed for Cable Management Kit Note: (CMK) arms.
Page 35 Wheel Stops and Bollards Wheel Stops and Bollards Bollards and wheel stops are not explicitly required by ChargePoint. However, ChargePoint recommends these best practices and considerations when designing the site: Permanent bollards or wheel stops must not encroach upon the clearances listed in the clearance diagrams in this section.
Page 36 Intake vents are positioned at the front of the Power Block (blue arrows), and exhaust vents are at the rear (orange arrows). When positioning multiple Power Blocks, orient intake and exhaust to avoid recirculation. Note: Power Block requires 10 kW (34,000 BTU/hr) of heat rejection.
Page 37 Accessibility Power Link Ensure that any installation, especially an indoor installation, has adequate airflow to dissipate heat at maximum operation. The charging location must allow fresh ambient airflow. Do not install a charging component where it is exposed to air that is heated above ambient temperatures.
Page 38 Consult national and local codes or a project engineer to determine the grade, quality and size of the conduit or cable. The Power Block is available in 250, 330, 350 and 500 A versions, each with its own rating labels. Note: All wiring and conduit is supplied by the contractor unless otherwise indicated.
Page 39 Power Link 2000. All charging components must be bonded to one another in sequence: either Power Block to Power Link 2000, or Power Block to Power Hub (if used) to Power Link 2000.
Page 40 If installed, each Power Block must be wired to the shunt trip unit of its own upstream circuit breaker. Upstream AC power must be shut off at the panel to remove shock risk inside the Power Block. All shunt trip behaviour is already hard-coded into the Power Block and has no programmable variables.
Page 41 Notes for all wiring regions: Use one AC input feed per Power Block. The maximum wiring run length is 100 m (328 ft) between a Power Block and each of its Power Link 2000s for DC conductors, 48 VDC wiring and Ethernet.
Page 42 Conduit and Wire Size Requirements Note: The tables provide the largest possible wire sizes in each case. All sizing assumes a maximum ambient temperature of 50°C (122°F). Actual wire sizing and types should be designed to be site-specific. 48 V DC Power Type Wire Insulation Rating Size...
Page 43 The Power Link 2000 can be installed with maximum of 12 HV wires per DC input (six for 500 A and six for 350 A, maximum three per pole). Note: The DC output of Power Block is the DC input for Power Link 2000. Wire Max. Wire Max.
Page 44 North American Wire, Voltage and Current Ratings Inputs to Power Block Power Block to Each Power Link 2000 Shunt Trip / EPO HVDC 48 VDC Ethernet and Gnd Output Output Circuit Voltage 480 < 240 V 100 - 48 V 1000 V...
Page 45 A strong signal is also required for the ChargePoint Assure maintenance and management programmes. ChargePoint stations use mobile data connections to reach ChargePoint cloud services. This allows secure, PCI-compliant data connections without requiring any other form of Internet connectivity at an install site or imposing additional network management responsibilities on a site host.
Page 46 Signal Strength and Quality Use a mobile signal detection device (such as a Siretta Snyper LTE or equivalent) to take signal strength readings at the exact proposed charging station or gateway locations. For stations using LTE, test the location of every gateway and ensure that it meets minimum RSRQ at -12.5 dB or better, for RSRP measured at -90 dBm or better.
Page 47 US: AT&T, T-Mobile, Verizon Canada: Rogers, Telus and Bell For other regions, or if the site does not have strong signal on these bands, contact your ChargePoint representative for additional solutions. ChargePoint strongly recommends a consultation with a mobile connectivity specialist before all installations.
Page 48 Do not rely on readings taken with a mobile phone when conducting site surveys. Many signal boosters and network extenders may not be compatible with ChargePoint hardware, including certain types of distributed antenna systems (DAS), micro/nano/pico/femto-cells, and carrier- or band-specific...
Page 49 The Limited Warranty you received with your charging station is subject to certain exceptions and exclusions. For example, your use of, installation of or modification to the ChargePoint® charging station in a manner in which the ChargePoint® charging station is not intended to be used or modified will void the limited warranty. You should review your limited warranty and become familiar with the terms thereof.
Page 50 75-001574-02 r1...

This manual is also suitable for:

Power link 2000