Prepare for Installation

This topic describes how to prepare for the installation.

Check Site Readiness 

Power Block can be installed on either a newly poured pad or an existing concrete surface. Power Block also supports wiring run above ground for locations where no underground wiring access exists (such as parking garages) or where underground junction boxes are not permitted.

If not installed correctly, the ChargePoint charging station may pose a fall hazard, leading to death, personal injury, or property damage. Always use the provided Concrete Mounting Template shown preinstalled here, 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.

Before beginning work, check that the site meets these civil and mechanical requirements:

Power Block Pre-Installation Checklist

Express Plus Power Block Pre-Installation Checklist
1.  

Each concrete pad must be fully cured and smooth, and must not exceed a slope of approximately 20 mm per meter (0.25 in per ft).

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2.  

The concrete pad or concrete surface meets the mounting specifications given in the Express Plus Power Block and Power Link Site Design Guide and/or is inspected and approved by a structural engineer for the dimensions and weights (as given in the Site Design Guide) of the Power Block and its Power Modules.

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3.  

Walls, fences, or slopes must not prevent water from draining from the pad.

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4.  

You have sufficient space around the installation pad to use a forklift and other lifting equipment, unpack crates, remove packing materials, and allow two people to freely move throughout the area.

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Power Block Readiness

Concrete Mounting Template (CMT)

The Power Block Concrete Mounting Template (CMT) should already be embedded in the concrete pad, unless the site is using a surface-conduit entry. Verify the AC and DC conduits are positioned correctly.

Power Block Concrete Mount Template

  1. M16 anchor bolt (x2) locations for mounting SCEClosed Surface Conduit Entry gland plate (applicable only for >surface entry of wires).

  2. M16 anchor bolt (x4) locations 76 mm (3 in) above concrete for mounting Power Block.

  3. HV DCClosed High Voltage Direct Current output B wires exit.

  4. HV DCClosed High Voltage Direct Current output A wires exit.

    The DC output of Power Block is the DC input for the Power Link.

  5. AC input wires entry.

  6. LV DCClosed Low Voltage Direct Current output, shunt trip wires, and Ethernet cable exit.

    • One for shunt trip (if used).

    • Three for LVClosed Low Voltage wires and Ethernet cable.

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. In regions that do not use conduits and/or use armored cables, the cables may be laid per the conduit layout defined by the CMT.


The Concrete Mounting Template CMT must be embedded with its top panel positioned 51 mm (2 in) below the concrete surface.

The following table provides the maximum size and quantity of conduits that can be installed on Power Block:

Power Block Stub-up Conduit Specifications

Conduits For

Conduit Quantity x Trade Size

North America

Europe

HV DCClosed High Voltage Direct Current output wires

2 x 4 inch max.

2 x 110 mm max.

AC input wires

1 x 4 inch max.

1 x 110 mm max.

LVClosed Low Voltage DC, shunt trip, and Ethernet output wires

4 x 1 inch max.

4 x 25 mm max.

The actual conduit size and quantity must be chosen based on site-specific wiring requirements.

For wire specifications, see the Express Plus Power Block and Power Link Site Design Guide.

Clearances

The Power Block requires minimum site and service clearances.

Image not to scale.

Power Block Clearance

  1. Rear

610 mm (24 in) recommended (for rear service access)
457 mm (18 in) required

  1. Front

1000 mm (39.3 in)

  1. Side

51 mm (2 in)
You must meet additional site requirements for special methods and accessories. See the Express Plus Power Block and Power Link Site Design Guide.

General Estimates for Lifting

Estimates for Lifting
Component Dimensions (L x W x H) Max. Weight

Power Block Crate

1.18 x 1.14 x 2.04 m

(46.5 x 45 x 80.25 in)

475 kg

(1048 lbs)

Power Block Pedestal Box

1.12 x 0.978 x 0.762 m

(44 x 38.5 x 30 in)

57 kg

(125 lbs)

Power Block Pallet

1.22 x 1.22 x 1.36 m

(48 x 48 x 53.5 in)

 163 kg
(360 lbs)

Power Link 1000 Box

2.34 x 0.97 x 0.58 m

(92.25 x 38.13 x 22.75 in)

385.6 kg

(850 lbs)

Power Module Box

NOTE: A Power Block can use up to five Power Modules, which ship in separate pallets.

0.902 x 0.572 x 0.375 m

(35.5 x 22.5 x 14.75 in)

41.28 kg

(91 lbs)

Power Block Surface Conduit Entry Kit (Option) Box

1.05 x 0.245 x 0.524 m

(41.38 x 9.63 x 20.63 in)

13.88 kg

(30.6 lbs)

Concrete Mounting Template (CMT) (Option) Box

1.08 x 0.127 x 0.873 m
(42.63 x 5.00 x 34.38 in		 26 kg
(57 lbs)

CMT (Option) Pallet

NOTE:

  • 8 cartons per pallet

  • Single unit can be stacked onto one of the System-PB1000-PDK for shipping.

1.22 x 1.02 x 1.22 m

(48 x 40 x 48 in)

227 kg

(500 lbs)

Electrical Readiness

If the site does not meet these basic requirements, contact ChargePoint before continuing.

  • The appropriate circuit protection and metering is in place at the installation site.

  • A grounding conductor that complies with local codes is properly grounded to earth at the service equipment or, when supplied by a separate system, at the supply transformer.

  • A correctly rated, dedicated breaker is installed for each Power Block:

Power Block Breaker Table

Nominal Voltage

Input Current Rating

Branch Circuit Capacity and Breaker

Breaker Size

Europe: 400 V

315 A

350 A or 400 A

400 A

North America: 480 V

260 A

350 A or 400 A

  • Breakers have shunt trip capability (if specified) to each Power Block.

  • All necessary electrical infrastructure has been completed per local codes and ChargePoint specifications for 3-phase power plus ground, with properly sized wire at the station.
    Neutral is not required for system operation, however Neutral-to-ground bonding is required at the Main Distribution Panel (MDP) supplying the charging station.

    This requirement is applicable to installations carried out within the province of Québec, Canada. Whether using a step-up or step-down autotransformer, refer to the 'Hydro-Québec bulletin - Choosing the right one 600/480 V transformer', that is publicly available, for specific guidance.

For questions about site specifications, refer to the Express Plus Datasheet and Express Plus Power Block and Power Link Site Design Guide.

Required Tools and Materials

Installing the Power Block requires at least two people. Additionally, the installer must bring the following tools and materials. These are not provided by ChargePoint.

Forklift

  • Rated for ≥ 680 kg (1500 lb)

  • Maximum size of forklift tines:

    • Width = 102–127 mm (4–5 in)

    • Maximum thickness ≤ 57 mm (2.25 in)

  • If your site has height constraints, use alternative equipment

Stepladder

Lock out/tag out equipment

Hard hat

Cut-resistant gloves

Safety glasses

Head lamp

Measuring tape or other tool to measure height, length, and distance

Level

Use hand to tighten

Box cutter

Phillips screwdriver set

  • #2 Phillips screwdriver with long handle

  • #3 Phillips screwdriver

  • #5 Phillips screwdriver

  • Right angle (90°) #5 Phillips screwdriver

Flat head screwdriver

Torx wrench set

  • T20

  • T25

  • T30

Torx security wrench

  • T25

Torque wrenches for 4 to 95 Nm (3 to 70 ft-lb)
Only for tool balancer: 3 mm spanner wrench

Adjustable wrench

Socket wrench set including deep sockets, up to 25 mm

Cable puller or fish tape

Hydraulic hole punch tool (to cut 4 inch holes in gland plate)

Conduit cutters (to cut up to 4 inch conduits)

Multimeter with Cat III 1000 V ratings, such as Fluke 87V or similar

Ethernet tester such as a Klein Tools VDV526-052 VDV LANClosed Local Area Network Scout Jr. Tester or similar

Orange and white icon that represents a tool or action.

Wire strippers, including Ethernet (Cat6 STPClosed Shielded Twisted Pair) cable

Ethernet (RJ45) connector crimping tool

  • Wire cutters, including Ethernet (Cat6 STPClosed Shielded Twisted Pair) cable

    		•

    		Lug crimping tool

    		Die electric grease

    		Torque paint pen

    		Cable ties

    Permanent marker

    		Isopropyl wipes and towel roll

    Duct seal compound

    Coolant funnel

    Two gallon coolant

    		Padlock provided by station owner if required (for security panel on Power Block)

    Wire brush (to remove concrete from bolts)

    		Broom and vacuum

    Smartphone with: Internet connectivity

    ChargePoint installer login credentials

    QRClosed Quick Response code scanner (usually built into the camera app)

    Exact location of stations or units, including parking space

    		Ferrule crimp tool (for 16 mm2 or 6 AWGClosed American Wire Gauge wire)    

     

    Tightening Torque

    Tightening Torques
    Component (x Fastener Quantity) Component Material Tool Torque
    Metal 24 mm deep socket

    54 Nm (40 ft-lb)

    Metal

    24 mm deep socket

    95 Nm (70 ft-lb)

    Metal

    15 mm socket

    19 Nm (168 in-lb)

    Metal

    18 mm socket

    21 Nm (15.5 ft-lb)

    Metal

    15 mm socket

    19 Nm (14 ft-lb)

    Metal

    19 mm socket

    21 Nm (15.5 ft-lb)

    Metal

    15 mm

    19 Nm (14 ft-lb)

    Metal

    T30 Torx

    7.0 Nm (62 in-lb)

    Metal T30 Torx 7.0 Nm (62 in-lb)

    Materials

    • AC and ground conductors as required by site drawings

    • DC conductors as required by site drawings

    • 48 V DC wiring as required by site drawings

    • Shunt trip wiring (if on site drawings)

    • Power Block DC and AC lugs:

      • Plated copper compression lugs (not mechanical)

      • Must fit M12 stud size

      • Must fit 44.5 mm (1.75 in) hole spacing

      • 2-hole specified for North America

      • Maximum tongue width ≤ 50.8 mm (2 in)

      Check site drawings for quantity of lugs.

    • RJ45 shielded connectors

    • Type LB conduit body (for overhead installation only) - maximum 3 inch

    Check Express Plus Shipping Crates

    Express Plus ships in multiple crates. Ensure you have all components at the installation site.

    Refer to the Power Link Installation Guide for the list of Power Link crates. This section lists shipping crates for Power Block.

    Always transport and store the charging components in their original packaging. Use appropriate lifting equipment (forklift or crane, lifting straps, and any corresponding attachments and accessories). Ensure the load rating of all lifting equipment is adequate for the weight of the crated components.
    Keep components in original packaging, free of moisture, and protected from damage until you install or service them at the site. Store all shipments of components in a dry covered location and protect from moisture.

    Leave components in the shipping crate until needed. When removing, protect them from damage (such as scratches) by placing them flat on a blanket or tarp, face up. Do not stand up cover panels, as they may be knocked or blown over. Cover charging connectors to prevent damage or ingress.

    Power Block

    • Power Block unit(s)

    • Pedestal

    • Gland plates

    • Enclosure (upper and lower cabinets together)

      • Lower heat exchanger (dry box hex)

        This ships in a box inside the lower cabinet of the enclosure.

    • Fuses

    • Doors and covers

      • Lower door preinstalled

    Power Module

    • Up to five per Power Block

    Installation Kit

    • Duct seal compound

    • Propylene glycol coolant

      The coolant label references its Material Safety Datasheet.

    • T25 Torx security screwdriver

    • Coolant funnel
    Lower heat exchanger and each Power Module are heavy. Two people are needed to install these components.

    Express Plus Guides