Electrical Design

This section provides electrical site design specifications for the Power Block and Power Link 2000.

Conduit and wire size are determined based on current. Service wiring in conduit or armored cable must be run as required to comply with local electrical codes. 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 200, 250, 350, and 500 A versions, each with its own rating labels.

The following illustration shows sample electrical circuit requirements along with optional components for Express Plus with single Power Block and Power Link 2000.

1. Transformer configuration

2. Ground connection

3. Electrical panel

4. Circuit breakers

5. AC disconnect switch (optional)

Power Block Electrical Supply Requirements

Power Block electrical supply requirements are given below.

Transformer Configuration

Refer to the following table for the transformer configuration.

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 configuration	277/480 V AC 3-phase grounded WYE (Y) configuration	230/400 V AC, 3-phase grounded WYE (Y) configuration
Product connection	Power Block must be connected to L1, L2, and L3 (neutral not required)

Neutral is not required for system operation, however Neutral-to-ground bonding is required at the Main Distribution Panel (MDP) supplying the charging station.

AC Breaker Size

Charging stations are considered continuous load devices (EVs draw maximum load for long durations). Therefore, electrical branch circuits to EV Electric Vehicle chargers must be sized at 125% of the load on each leg of a 3‑phase panel for North American installations, in accordance with National Electric Code requirements. For other regions, refer to local code.

When planning multiple EV Electric Vehicle charging stations, it is best practice to segment non-continuous and continuous loads, with all branch circuits for EV Electric Vehicle charging on a dedicated electrical panel assembly with adequate circuit breakers. When sizing new electrical panels dedicated for EV Electric Vehicle charging, all branch circuits must support continuous load.

Each Power Block requires its own circuit breaker as follows:

AC Circuit Breaker Size

Region	Nominal Voltage	Max. AC Input Current	Continuous Load (125%)	Breaker Size
Europe	400 V	315 A	394 A	400 A
North America	480 V	260 A	325 A	350 A and 400 A

AC Disconnect Switch (optional)

A local AC disconnect switch, separate from the shunt trip wiring, is recommended to be installed between each Power Block and the electrical panel. This is especially important if the main electrical panel or utility room is distant, out of line of sight, or has restricted access. For North America installations, refer to disconnect switch requirements per NEC National Electric Code Article 625, “Electric Vehicle Charging and Supply Equipment Systems”. For other regions, refer to local code.

Shunt Trip Wiring (optional)

The Power Block provides a set of unpowered (dry) contacts to connect to an optional shunt trip device. These contacts are rated to 240 V AC and 6 Amps.

Wiring sections to and from the Power Block are deactivated when unsafe conditions are detected, such as unintended cover panel removal. A breaker reset is required any time the shunt trip is activated.

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 behavior is already hard-coded into the Power Block and has no programmable variables.

Emergency stop devices are governed by local and regional codes and may be required in some sites. If one is required by code or by the site, confirm specifications with your ChargePoint representative.

1. Electrical panel

2. Power Block

3. Control voltage supply, maximum 240 V AC

4. Shunt trip circuit breaker

5. Shunt trip coil

6. Auxiliary contacts (closed when main contacts are closed)

7. 3-phase AC main

8. Power Block shunt trip contacts, Normally Open (inside the auxiliary power supply, accessible on field wiring terminal block)

9. 3-phase Power Block AC input

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.

A grounding conductor that complies with applicable codes must be grounded to earth at the service equipment or, when supplied by a separate system, at the supply transformer, or may be grounded to an earth electrode. Ensure the grounding conductor complies with all applicable codes.

• North America: A service ground conductor must be run with circuit conductors and connected to an equipment-grounding terminal on the Power Block.

• Europe: Use TN-S Terra Neutral Separate, TN-C Terra Neutral Combined-S, or TT configurations. Express Plus doesn't have Residual Current Device (RCD Residual Current Device) protection on the AC input side. When RCDs are to be installed, they should be minimum Type A and have leakage current tripping of at least 300 mA. This is because leakage current from Power Block can reach up to 200 mA at full power. The RCD Residual Current Device must detect and disconnect all power lines.

Power Link 2000 Site Considerations

This section provides electrical site design considerations specific to the Power Link 2000.

DC Maintenance Switch (optional)

A maintenance switch is highly recommended when more than one Power Link 2000s are connected to one or multiple Power Blocks to improve system uptime during maintenance. For Power Link 2000s that do not have a maintenance switch, servicing the station requires the Power Block(s) upstream to be powered off. This can affect system uptime and fleet scheduling.

If an external DC disconnect switch is used, then the switch must be configured with Normally Closed (NC) contact feedback wired into each Power Link 2000. The DC Maintenance Switch is an optional part available for the pedestal-mount Power Link 2000. It is ordered and shipped separately and is field installed.

Sequential Charging Kit

Dual output Power Link 2000s may be configured for sequential charging by field installing a Sequential Charging Kit. This kit allows Power Link 2000 to take a single power input and feed the power to either output in a sequential manner. The Sequential Charging Kit is ordered separately and is field installed.

Ethernet-to-USB (ETH2USB) Kit

Ethernet to USB Universal Serial Bus 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.

The Ethernet to USB Universal Serial Bus kit is installed within a single Power Link 2000, providing network connection for every node in the Express Plus cluster. The installation requires a conduit for the Ethernet cable, which must be run from the customer server or network equipment directly to the Power Link 2000.

This kit must be ordered separately and installed in the field.

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:

• For AC and DC high voltage (HV High Voltage), high current wiring, use copper or aluminum wires rated for 90 °C (194 °F).

  • AC high current wires can be THHN Thermoplastic High Heat-Resistant Nylon-Coated/THHW Thermoplastic High Heat-Tesistant, Water-Resistant/THW Thermoplastic Heat-Resistant, Water-Resistant-2/THWN-2 based on site condition (dry or wet) and rated for 600 V.

  • DC HV High Voltage wires can be XHHW/XHHW-2 based on site condition (dry or wet) and rated for 1000 V.

• For low voltage (LV Low Voltage) DC wiring, use only copper wires (XHHW/XHHW-2 based on site condition, dry or wet) rated for 1000 V and 75 °C (167 °F).

• Use copper lugs for copper wires and aluminum lugs for aluminum wires. The lugs must be nickel, tin, or silver plated compression (not mechanical) lugs. Nickel-plated lugs installed with dielectric grease is recommended.

Notes For All Regions:

Wire run lengths

• The maximum total HV DC High Voltage Direct Current wire run length from any Power Block to any connected Power Link 2000 must not exceed 200 m (656 ft). Refer to the cluster configuration provided by ChargePoint for interconnect details.

• LV DC Low Voltage Direct Current wire and Ethernet runs between nodes (Power Block and Power Link 2000):

  • For non-LCC Liquid Cooled Cable cables:

    • Without daisy-chained 48 V, the 48 V and Ethernet wire run length between Power Block and Power Link 2000 can be up to 200 m (656 ft).

    • With Power Link 2000 connected in a chain, the maximum total wire run length from the Power Block to the furthest Power Link 2000 is 160 m (525 ft). Contact ChargePoint for options if greater lengths are needed.

  • For LCC Liquid Cooled Cable cables:

    • The 48 V and Ethernet wire run length between Power Block and Power Link 2000 can be up to 100 m (328 ft). Contact ChargePoint for options if greater lengths are needed.

• The maximum wire run length between a Power Link 2000 and an external network connection is 200 m (656 ft). Refer to the cluster configuration provided by ChargePoint for interconnect details.

Ethernet requirements

• For Ethernet communications between any two nodes (Power Link 2000 or Power Block) or to an external network connection:

  • Distances up to 100 m (328 ft) must use outdoor-rated Cat6 Shielded Twisted Pair (STP Shielded Twisted Pair) cable. Lesser grades of cable do not provide the required noise immunity.

  • Distances between 100 m (328 ft) and 200 m (656 ft) must use Paige OSP Shielded GameChanger cable. See paigedatacom.com/gamechanger.

• An Ethernet cable connecting a Power Block and a Power Link 2000 must have the shield terminated at the Power Block end.

• An Ethernet cable connecting two Power Link 2000s must have the shield terminated at the end nearer to the Power Block.

• An Ethernet cable connecting a Power Block to another Power Block must have the shield terminated at only one end; either end can be terminated.

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), Power Block Surface Conduit Entry, and Power Link 2000 Surface Conduit Entry for the maximum size and quantity of conduits.

Other requirements

• Use one AC input feed per Power Block.

• Make sure to consider the height of bus bars above the concrete pad when determining the wire length required.

  Power Block	Power Link 2000

The following sections provide the maximum wire sizes that can be landed onto the Power Block and Power Link 2000 bus bars. All sizing assumes a maximum ambient temperature of 50 °C (122 °F).

Power Block

Power Block takes AC input from the site and provides DC and Ethernet output to Power Link 2000(s).

Wire Entry and Landing

1. AC input

2. Ground input

3. HV DC High Voltage Direct Current output

4. Ground output

5. LV DC Low Voltage Direct Current output

6. Ethernet output

AC Input Wire Quantity, Size, and Termination

AC Input Wire Specifications

Wire	Quantity	Size	Termination
AC input	Max. 12 wires (four per pole)	Max. 400 mm2 (750 MCM)	Lug: Long barrel and tongue with two holes spaced 44.5 mm (1-3/4 in) apart and sized for M12 studs Max. tongue width: 47.5 mm (1-7/8 in)
Ground	1 wire	Refer to the local code for size	Lug: Short barrel and tongue with single hole sized for M12 stud

DC Output Wire Quantity, Size, and Termination

DC Output Wire Specifications

Wire	Quantity	Size	Termination
HV DC High Voltage Direct Current outputs A and B	Max. 12 wires (six per output, three per pole)	See Power Link 2000 Wire Quantity, Size, and Termination	Lug: Long barrel and tongue with two holes 44.5 mm (1-3/4 in) apart and must fit M12 stud. Max. tongue width is 49 mm (1-15/16 in)
Ground	Max. 4 wires (one per Power Link 2000)	See Power Link 2000 Wire Quantity, Size, and Termination	Lug: Short barrel and tongue with single hole and must fit M12 stud
LV DC Low Voltage Direct Current output	See Power Link 2000 Wire Quantity, Size, and Termination		Stripped wire end
Ethernet	See Power Link 2000 Wire Quantity, Size, and Termination		RJ45 connector, shielded

Power Link 2000

The Power Block DC (HV High Voltage and LV Low Voltage) and Ethernet outputs are the inputs for the Power Link 2000. The Power Link 2000 provides HV DC High Voltage Direct Current output to pantograph(s) and provides LV DC Low Voltage Direct Current and Ethernet output to PD Controller(s). In some Express Plus architectures, Power Link 2000 also provides DC (HV High Voltage and LV Low Voltage) and/or Ethernet output to another Power Link 2000.

Wire Entry and Landing - Pedestal-Mount Power Link 2000

Wire Entry and Landing - Wall and Overhead-Mount Power Link 2000

Wire Quantity, Size, and Termination

North American Wire, Voltage, and Current Ratings

North American Wire Specifications

	Inputs to Power Block		Power Block to Each Power Link 2000
	AC and Ground	Shunt Trip	HV DC High Voltage Direct Current Output	48 V DC Output	Ethernet
Circuit Voltage	480 V AC	≤ 240 V	100 - 1000 V	48 V	--
Max. Current	260 A	6 A	200, 250, 350, or 500 A	32 A	--
Notes	Rated for 600 V L1, L2, L3, Ground		Rated for 1000 V		Outdoor rated Cat6 STP Shielded Twisted Pair or Paige GameChanger*
*The required Ethernet cable type depends upon the cable run length. See Ethernet requirements.

UK and European Wire, Voltage, and Current Ratings

UK and European Wire Specifications

	Inputs to Power Block		Power Block to Each Power Link 2000
	AC and Ground	Shunt Trip	HV DC High Voltage Direct Current Output	48 V DC Output	Ethernet
Circuit Voltage	400 V AC	< 240 V	200- 1000 V	48 V	--
Max. Current	315 A	6 A	200, 250, 350, or 500 A	32 A	--
Notes	3p+E		Rated for 1000 V		Outdoor rated Cat6 STP Shielded Twisted Pair or Paige GameChanger*
* The required Ethernet cable type depends upon the cable run length. See Ethernet requirements.