Related Manuals for ChargePoint Express Plus
Summary of Contents for ChargePoint Express Plus
- Page 1 Power Block and Power Link 2000 Express Plus DC Fast Charging Platform Site Design Guide...
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Page 2: Important Safety Instructions
IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for Express Plus that shall be followed during installation, operation and maintenance of Express Plus modular products. WARNING: 1. Read and follow all warnings and instructions before servicing, installing, or operating the ChargePoint®... - Page 3 United States and other countries. It may not be modified, reproduced, or distributed without the prior, express written consent of ChargePoint, Inc. ChargePoint and the ChargePoint logo are trademarks of ChargePoint, Inc., registered in the United States and other countries, and cannot be used without the prior written consent of ChargePoint.
- Page 4 Illustrations Used in This Document The illustrations used in this document are for demonstration purposes only and may not be an exact representation of the product. However, unless otherwise specified, the underlying instructions are accurate for the product.
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Page 5: Table Of Contents
Contents Important Safety Instructions 1 Introduction Express Plus Components Express Plus System Overview Power Block and Pedestal-Mount Power Link 2000 Configurations Wall and Overhead-Mount Power Link 2000 Configurations Express Plus Guides Questions 2 Site Design Guidelines Initial Site Guidelines... - Page 6 Power Link 2000 Site Considerations Wiring Requirements 4 Connectivity Signal Strength and Quality Repeaters...
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Page 7: Introduction
Introduction Express Plus Components Express Plus is a scalable DC fast charging platform that is based on the modular building blocks outlined below. (a) Power Module: Self-contained AC to DC power conversion system that operates an output of between 100 and 1000 V and delivers up to 40 kW of power. -
Page 8: Express Plus System Overview
Express Plus System Overview Power Block Power Block block diagram: (a) Three phase AC power input (b) Configurable with up to five 40 kW Power Modules for a maximum total output of 200 kW (c) Two available HV DC power outputs (A and B) (d) - Page 9 Express Plus System Overview Power Link 2000 Power Link 2000 block diagram: (a) Single or dual HV DC power paths (A and B) (b) 48 V DC power input (c) Ethernet input (d) Single or dual HV DC charging cable outputs (L and R) (e)
- Page 10 Power Block to Power Link 2000 Architectures Express Plus is a highly modular system wherein Power Blocks and Power Link 2000s can be interconnected in many configurations to meet various charging needs, from simultaneous charging of two vehicles at up to 600 kW by a single station to sequential charging of up to 12 vehicles.
- Page 11 The architectures shown above demonstrate only a few of the many supported by Express Plus. The actual architecture for each site will vary depending on the number of stations, the charging capacity required at each charging station, simultaneous or sequential charging requirements, and other criteria.
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Page 12: Power Block And Pedestal-Mount Power Link 2000 Configurations
Power Block and Pedestal-Mount Power Link 2000 Configurations Charging Cables Depending on the charging speed and connectors required, pedestal-mount Power Link 2000s can be installed with one or two liquid-cooled cables (LCC) or non-liquid-cooled cables (non-LCC). The pedestal- mount Power Link 2000 with LCC comes with a liquid cooling system attached to the back of the enclosure. -
Page 13: Wall And Overhead-Mount Power Link 2000 Configurations
Wall and Overhead-Mount Power Link 2000 Configurations Cable Management Kit (CMK) Depending on the required cable reach, the pedestal-mount Power Link 2000 can be installed with a standard CMK to manage standard length (5.8 m or 19 ft) charging cables, or with a tall CMK or overhead CMK to manage medium length (7.6 m or 25 ft) charging cables. - Page 14 Cable Management Kit (CMK) Wall-Mount: A wall-mount Power Link 2000 can be installed with a standard CMK to manage standard length (5.8 m or 19 ft) charging cables or with a tall CMK to manage medium length (7.6 m or 25 ft) charging cables.
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Page 15: Express Plus Guides
Express Plus Guides Overhead-Mount: An overhead-mount Power Link 2000 can be installed with an overhead CMK to manage medium length (7.6 m or 25 ft) charging cables. Wire Entry The wires enter into wall and overhead-mount Power Link 2000 from the bottom side, through conduits or armored cables laid above ground. -
Page 16: Questions
Service Guide Component replacement procedures, Service technician including optional components Declaration of Conformity Statement of conformity with directives Purchasers and public ChargePoint Product Documents (continued) Questions For assistance, navigate to and contact technical support using the appropriate chargepoint.com/support region-specific number. -
Page 17: Site Design Guidelines
If you have pre-existing infrastructure or are using your own preferred electrical contractor to prepare your site, an Express Plus Construction Signoff Form completed by a ChargePoint Operations and Maintenance (O&M) partner is required to certify compliance with electrical code and to ensure everything was prepared to ChargePoint specifications. -
Page 18: System Placement
The placement of Power Link 2000 and Power Block must meet the following requirements: Do not install Express Plus in a Class 1 hazardous location, as classified by NEC or local codes. Site conditions must be compatible with the following specifications listed in the Express Plus Datasheet: ... - Page 19 System 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 20 EVs. Commercial or Public Station Placement, Single or Dual Cable 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.
- Page 21 System Placement The following three illustrations depict charging stations with single cables. (a) Cable reach radius: 3.76 m (12 ft 4 in) (a) Cable reach radius: 3.76 m (12 ft 4 in)
- Page 22 Fleet Parking Arrangement Stall parking (Dual Charge Cable): For installing dual charge cable Power Link 2000 stations, consider placing the station in front of every other parking space. Additionally, align the overhead CMK tether with the parking stripes on either side of the charging station. ...
- Page 23 System Placement Island parking: ChargePoint recommends placing a station in the center 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.
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Page 24: Civil And Mechanical Design
(35 - 82 lbs) 20 kg Standard CMK - dual (44 lbs) Tall CMK - dual 38.5 kg (85 lbs) Overhead CMK 10 kg (22 lbs) Packaging excluded from weights listed above 45 - 90 kg (100-200 lbs) Express Plus Component Weights ... -
Page 25: Dimensions
Dimensions Dimensions Power Block Note: Images are not to scale. Measurements appear in metric units (mm) followed by imperial equivalents (inches). ... - Page 26 Power Link 2000 Pedestal-Mount Power Link 2000 With LCC, Single or Dual Cable, and Standard Note: Images are not to scale. Measurements appear in metric units (mm) followed by imperial equivalents (inches).
- Page 27 Dimensions Pedestal-Mount Power Link 2000 With Non-LCC, Single or Dual Cable, and Standard CMK Note: Images are not to scale. Measurements appear in metric units (mm) followed by imperial equivalents (inches). ...
- Page 28 Pedestal-Mount Power Link 2000 With Non-LCC, Single or Dual Cable, and Tall Note: Images are not to scale. Measurements appear in metric units (mm) followed by imperial equivalents (inches). ...
- Page 29 Images are not to scale. Measurements appear in metric units (mm) followed by imperial equivalents (inches). Note: The customer must provide the poles at the site for installing pedestal-mount (single or dual cable) Power Link 2000 enclosures with overhead CMK and tether ball extension. These are not provided by ChargePoint.
- Page 30 Wall-Mount Power Link 2000 With Single or Dual Cable and Standard CMK Note: Images are not to scale. Measurements appear in metric units (mm) followed by imperial equivalents (inches). ...
- Page 31 Dimensions Wall-Mount Power Link 2000 With Single or Dual Cable and Tall CMK Note: Images are not to scale. Measurements appear in metric units (mm) followed by imperial equivalents (inches). ...
- Page 32 Overhead-Mount Power Link 2000 With Single or Dual Cable and Overhead CMK The CMK might not fully retract certain charging cables due to their heavier weight. Adding a tether point and a tether hook kit reduces cable weight on the CMK, allowing the cable to retract fully. Note: Images are not to scale.
- Page 33 Dimensions Overhead-Mount Power Link 2000 With Tether Hook Note: Images are not to scale. Measurements appear in metric units (mm) followed by imperial equivalents (inches). Use tether hooks as additional support for overhead CMKs or to enable the use of third party hoist or cable management solutions.
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Page 34: Pedestal-Mount Specifications
Surface entry of wires laid above ground is allowed only at sites where the wires cannot be laid underground such as in a parking garage. Contact ChargePoint for the Surface Conduit Entry (SCE) kit, which includes the hardware needed to install on an existing concrete surface. - Page 35 Always use the Concrete Mounting Template specified in this document section, or a ChargePoint-approved surface mounting solution, to install the ChargePoint charging station. Always install in accordance with applicable codes and standards using licensed professionals. Non approved installation methods are performed at the risk of the contractor and void the Limited One-Year Parts Exchange Warranty.
- Page 36 Design #N1 @ S1” O.C. #N2 @ S2” O.C. Scenarios Width Thickness Top Rebar Bottom Rebar 1524 mm 1524 mm 457 mm #4 @ 305 mm (12 in) O.C. #4 @ 305 mm (12 in) O.C. (60 in) (60 in) (18 in) 1524 mm 1524 mm...
- Page 37 Anchor bolts embedment Anchor bolts placement See Anchor Bolts Placement Express Plus Existing Pad Specifications Anchor Bolts Placement The Power Block and Power Link 2000 enclosures mount over four anchor bolts embedded in the concrete pad. The anchor bolt patterns are shown below.
- Page 38 The Power Block and Power Link 2000 pedestals must each mount onto four M16 anchor bolts exposed 76 mm (3 in) above the concrete pad. The Concrete Mounting Template (CMT) of Power Block and Power Link 2000 is embedded into a newly poured to align anchor bolts and underground run stub-up wiring conduits or concrete pad...
- Page 39 Pedestal-Mount Specifications (e) AC input wires entry. (f) LV DC output, shunt trip wires, and Ethernet cable exit. One for shunt trip (if used). Three for LV wires and Ethernet cable. IMPORTANT: In regions that use conduits, the conduits must be laid per the conduit layout defined by the Concrete Mounting Template (CMT) and the outer diameter of conduits must not exceed the trade sizes listed below.
- Page 40 Power Link 2000 Concrete Mounting Template (CMT) The Power Link 2000 CMT positions the anchor bolts and wire conduits as shown below. (a) M16 anchor bolt (x4) locations for mounting Power Link 2000 (see Anchor Bolts Placement). (b) Breakaway tabs for entry of wires through conduits or armored cables.
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Page 41: Surface Mount
Pedestal-Mount Specifications The following table provides the maximum size and quantity of conduits that can be installed on Power Link 2000 by removing the breakaway tabs (b): Conduits For Conduit Quantity x Trade Size North America Europe HV DC wires 2 x 4 inch max. 2 x 103 mm max. 4 x 3 inch max. 4 x 78 mm max. 6 x 2 inch max. 6 x 53 mm max LV DC ... - Page 42 Note:Power Blocks and Power Link 2000s in a Multiplex architecture cannot be installed on an existing concrete surface because they require stub-up wire entry. Wires Entry - Surface Power Block and Power Link 2000 support wiring that is run above ground in protected wireways for locations where no underground wiring access exists (parking garages, etc.) or where underground junction boxes are not permitted.
- Page 43 Pedestal-Mount Specifications Power Block Surface Conduit Entry (SCE) Surface-run wires must enter Power Block from the rear side through conduits or armored cables. The Power Block kit provides a sturdy pedestal cover panel onto which surface conduits may be fastened at the rear side of the Power Block.
- Page 44 Pedestal-Mount Power Link 2000 Surface Conduit Entry (SCE) The surface-run wires must enter the pedestal-mount Power Link 2000 from the rear side through conduits or armored cables. The Power Link 2000 kit provides a sturdy pedestal cover panel onto which surface conduits may be fastened at the rear side of the Power Link 2000.
- Page 45 To mount the overhead CMK for a pedestal-mount Power Link 2000: You must design and/or purchase the pole. ChargePoint does not sell and/or supply the pole. The pole must have a structural capacity of 1780 N (400 lbf), and it must be designed or verified by a structural engineer per local codes.
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Page 46: Wall Or Overhead-Mount Specifications
The overhead CMK must be mounted using its bracket (supplied by ChargePoint) that attaches to its back. The bracket has four holes sized for M8 bolts to mount the overhead CMK onto the pole. Note: The installer must provide the M8 bolts. These are not provided by ChargePoint. - Page 47 Wall or Overhead-Mount Specifications The wall or overhead structure must have a structural capacity of 1780 N (400 lbf) in addition to the Power Link 2000 weight. The structure must also be designed or verified by a structural engineer per local codes.
- Page 48 Conduits For Conduit Quantity x Trade Size North America Europe HV DC wires 2 x 4 inch max. 2 x 103 mm max. 4 x 3 inch max. 4 x 78 mm max. LV DC w ires and Ethernet cable 2 x 1 inch 2 x 2 7 mm Note: 1 inch size conduit Note: 27 mm size conduit is required. The quantity is required. The quantity of conduit will depend on of conduit will depend on the configuration. the configuration. Optional features 2 x 3/4 inch max. 2 x 21 mm max. (Ethernet-to-USB or s oft shutdown switch) Wall or Overhead-mount Conduit Specifications For surface run wiring to the wall or overhead-mount Power Link 2000: ...
- Page 49 Wall or Overhead-Mount Specifications Overhead mount: IMPORTANT: The height for overhead mount must be calculated based on site specific requirements. For assistance, contact ChargePoint. maximum cable reach Mount the Power Link 2000 at a height of 6096 mm (240 in) above the finished floor.
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Page 50: Drainage
Exposing the Power Block to over 457 mm (18 in) of standing water could create an electrocution, shock, or fire hazard. If the Power Block has been exposed to standing water exceeding this threshold, cut power to the Power Block and contact ChargePoint before powering on the Power Block. -
Page 51: Clearances
The interior of the Power Block is accessed from both the front and rear cover panels, which lift off. No separate door swing clearance is required. Fencing, bollards, or wheel stops must not encroach upon the clearances listed above, if present. These barriers are not explicitly required by ChargePoint. - Page 52 At least 457 mm (18 in) of clearance is available at each end of a row of Power Blocks. Note: For any questions about allowable layouts, contact ChargePoint. CAUTION: Each Power Module weighs 45 kg (98.5 lbs). At least two people are required to replace a Power Module.
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Page 53: Wheel Stops And Bollards
Power Link Clearances (continued) 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 54 (a) Wheel stop, positioned to actively block at least one wheel (b) Cable reach radius: 3.76 m (148 in) (c) Recommended distance for walk-up access: 609 mm (24 in) (d) Recommended distance between wheel stop and station: 1371 mm (54 in) for passenger vehicles Bollards ...
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Page 55: Ventilation
Ventilation Ventilation Power Block 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 56: Accessibility
Accessibility Comply with regional accessibility laws, regulations, and ordinances. The Power Link 2000 charging station must not block ramps or pathways and the height of the interactive display cannot exceed the maximum height as dictated by local laws. Do not install Power Link 2000 on a raised concrete pad for parking spaces reserved for people with limited mobility. -
Page 57: Electrical Design
All wiring and conduit is supplied by the contractor unless otherwise indicated. IMPORTANT: If a site requires surface conduit entry installation, contact ChargePoint before beginning work to obtain an approved installation method. If the station is being fed power by more than two Power Blocks, surface conduit entry installation is not permitted. -
Page 58: Power Block Electrical Supply Requirements
Power Block Electrical Supply Requirements Transformer Configuration Refer to the following table for the transformer configuration. North America Europe Input rating 480 V AC, 3-phase, 260 A, 60 Hz 400 V AC, 3-phase, 310 A, 50 Hz Electrical service 277/480 V AC 3-phase grounded 230/400 V AC, 3-phase grounded configuration WYE (Y) configuration WYE (Y) configuration Product connection Power Block must be connected to L1, L2, and L3 (neutral not required) Transformer Configuration Note: Delta (floating or grounded) is not supported. AC Breaker Size Charging stations are considered continuous load devices (EVs draw maximum load for long durations). -
Page 59: Grounding Requirements
3-phase Power Block AC input Shunt trip diagram Grounding Requirements Express Plus is a metallic accessible enclosure and relies on protective earth or ground connection for protection against electrical shock. Express Plus must be connected to a grounded, metal, permanent wiring system. An equipment-grounding conductor must be run with circuit conductors and connected to an equipment-grounding terminal on the Power Block. -
Page 60: Power Link 2000 Site Considerations
Block can reach up to 200 mA at full power. The RCD must detect and disconnect all power lines. Note: All Express Plus components (Power Block and Power Link 2000) must be bonded to one another in sequence. Power Link 2000 Site Considerations... - Page 61 The Sequential Charging Kit is ordered separately and is field installed. Ethernet-to-USB (ETH2USB) Kit Ethernet to USB is an optional kit that allows an Express Plus cluster (interconnected Power Blocks and Power Link 2000s) to have a hardwired Ethernet connection with an external network server.
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Page 62: Wiring Requirements
Power Link 2000s do not support the Multiplex configuration. Wiring Requirements For full product specifications, refer to the Express Plus Datasheet. Using that data, ensure the installation location is equipped with service wiring that supports the Express Plus site’s power requirements: IMPORTANT: ... -
Page 63: Ethernet Requirements
Wiring Requirements IMPORTANT: All AC and DC high voltage wires must undergo insulation testing as outlined in the Express Plus High Voltage Wire Insulation Resistance Test Field Guide. Notes For All Regions: Wire run lengths The maximum total HV DC wire run length from any Power Block to any connected Power Link 2000 must not exceed 200 m (656 ft). -
Page 64: Conduit Requirements
Conduit requirements The conduits must be sealed to maintain a Pollution Degree 2 environment. See Power Block Concrete Mounting Template (CMT), Power Link 2000 Concrete Mounting Template (CMT), , and for the Power Block Surface Conduit Entry Power Link 2000 Surface Conduit Entry maximum size and quantity of conduits. - Page 65 Wiring Requirements Wire Entry and Landing (a) AC input (b) Ground input (c) HV DC output (d) Ground output (e) LV DC output (f) Ethernet output Power Block wire landings IMPORTANT: Following are wire specifications for the Power Block, including the maximum quantity and size that the wire terminals can accommodate.
- Page 66 Link 2000 provides HV DC output to pantograph(s) and provides LV DC and Ethernet output to PD Controller(s). In some Express Plus architectures, Power Link 2000 also provides DC (HV and LV) and/or Ethernet output to another Power Link 2000.
- Page 67 Wiring Requirements (a1) HV DC Power Path A, upper landing (a2) HV DC Power Path A, lower landing (b1) HV DC Power Path B, upper landing (b2) HV DC Power Path B, lower landing Ground LV DC Ethernet Wire Entry and Landing - Wall and Overhead-Mount Power Link 2000 Note: Depending on configuration, wall and overhead-mount Power Link 2000s have one or two HV DC Power Paths, named A and B.
- Page 68 (a1) HV DC Power Path A, upper landing (a2) HV DC Power Path A, lower landing (b1) HV DC Power Path B, upper landing (b2) HV DC Power Path B, lower landing LV DC Ethernet Ground Wire Quantity, Size, and Termination IMPORTANT: Following are wire specifications for the Power Link 2000, including the maximum quantity and size that the wire terminals can accommodate.
- Page 69 Wiring Requirements Wire Quantity Size Termination Option 1 - Max. 12 wires per Upper landings: Lug: Long barrel and tongue with two HV DC Power Path Max. 150 mm holes spaced 44.5 mm (1.75 in) apart and Power (three wires per (300 MCM)* sized for M12 s tuds. Paths pole on each Max. lug tongue width: 3 1 mm (1.25 in) for A and B landing) upper landings, 25.9 mm (1 in) for lower Lower landings: (max. 500 landings. Max. 120 mm A per Aluminum lug max. tongue thickness: (4/0 AWG) landing) 10 mm (0.4 in) for upper landings, 5 mm (0.2 in) for lower landing. Option 2 - ...
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Page 70: Connectivity
Inputs to Power Block Power Block to Each Power Link 2000 Max. 260 A 6 A 200, 32 A Current 250, 350, or 500 A Notes Rated for Rated for 1000 V Outdoor rated Cat6 STP or Paige 600 V GameChanger* L1, L2, L3, Ground *Note: The required Ethernet cable type depends upon the cable run length. See Ethernet requirements. North American Wire Specifications (continued) UK and European Wire, Voltage, and Current Ratings Inputs to Power Block Power Block to Each Power Link 2000 Shunt Trip HV DC 48 V DC... -
Page 71: Signal Strength And Quality
US: AT&T, T-Mobile, and Verizon Canada: Rogers, Telus, and Bell In Europe, ChargePoint products all support LTE bands 1, 3, 7, 8, and 20. 900 and 1800 MHz are also supported for 2G fallback. Partners vary by country. - Page 72 If the signal strength is weaker than this, take cellular readings at the location where any cellular signal booster antennas will be installed. Ensure enough signal exists for that repeater model. Install repeaters to boost the strength of the cellular signals. Repeaters are often required when installing charging stations in an underground garage or enclosed parking structure.
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Page 73: Repeaters
Repeaters 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 cellular connectivity specialist before all installations. A consultation can verify: ... - Page 74 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.
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