Concrete Mounting Template

The Express 250 is a DC fast charging station for electric vehicles. The default installation requires service wiring to be installed underground and run to a concrete pad. (If a site requires surface mounting, refer to Install the Surface Mount Plate for instructions on installing the station using a surface mount plate). The ChargePoint Express 250 Concrete Mounting Template (CMT) correctly aligns anchor and conduit openings to ensure the station can be easily installed and connected.

 

Use of a ChargePoint approved mounting method, such as the CMT, is required for safe installation of the Express 250. Failure to use an approved mounting method may result in a risk of tip-over, which can cause death, personal injury, or property damage, and will void the Limited One-Year Parts Exchange Warranty.

The CMT available from ChargePoint includes:

  • 16 mm (5/8 in)-11 thread, 305 mm (12 in) long threaded mounting bolts with plastic caps on one end

  • 16 mm (5/8 in) nuts

  • 16 mm (5/8 in) washers

  • Printed specification detailing how to position an assembled CMT in the concrete

You must order the CMT separately, with sufficient lead time before the site preparation. This kit is not included with the ChargePoint Express 250 charging station.

Required Tools and Materials

In addition to the CMT kit, the site construction team needs:

  • Digging tools (shovel, spade, etc.)

  • Materials to prepare the form for pouring concrete

  • Concrete as specified by site drawings

  • Rebar as specified by site drawings

  • 24 mm (15/16 in) wrench (x2)

  • Pliers to adjust the guide fingers on the CMT conduit openings (if needed)

  • Level

  • Cut-resistant gloves

  • Protective eyewear

  • Conduit, ducting, or armored cable in the amounts and types specified by site drawings, that complies with local code (see the rest of this document for conduit sizes and routing)

CMT Overview

The Express 250 is a DC fast charging station for electric vehicles. It converts three-phase power from its associated building (callout (a) in the image below) to DC power to charge the vehicle. A ground conductor also runs in conduit (a), optional Shunt trip wiring (b) connects the station to the breaker panel, allowing the station to shut down automatically if a fault or hazard ocurs, such as a damaged cover panel or impact from a vehicle.

If two stations are “paired”, they share DC power to allow faster (higher amperage) charging to a vehicle as needed. In this case, DC conduit (e) are run between the stations, as is an Ethernet wire (d) for communication.

Each station communicates with ChargePoint using a cellular network. No communication wiring is needed between the station and the building.

An assembled CMT template is shown below with the positions of all conduit and anchor bolts.

A separate CMT is required for each charging station (two per Paired installation).

  1. AC conduit

  2. Shunt trip conduit

  3. Anchor bolts (x4)

  4. Ethernet conduit (Paired installations only)

  5. DC conduit (Paired installations only)

  1. AC conduit from the left side of each station to the breaker panel (possibly with an AC disconnect switch in the circuit): 50.8 mm (2 in trade size)

  2. Shunt trip conduit from the left side of each station to the breaker panel: 19.1 mm (3/4 in trade size)

  3. Anchor bolts (x4)

  4. Paired installations only: Ethernet conduit between the two stations to be paired, right side to right side: 19.1 mm (3/4 in trade size)

  5. Paired installations only: DC conduit between the two stations to be paired, right side to right side: 76.2 mm (3 in trade size)

  6. Concrete surface

  7. Concrete Mounting Template (embedded in concrete)

Ensure no bell ends are left on any conduit after all wires are pulled. Bell ends can interfere with station placement.

Depth of conduit or armored cable may vary by site. The image above does not dictate conduit depth, as long as the stub-ups are vertical and placed correctly.

Assemble the CMT

The CMT can have sharp edges. Wear cut-resistant gloves.

Before pouring concrete, assemble the CMT with its anchor bolts, washers, and nuts.

To assemble the CMT, perform the steps below:

  1. Holding the mounting bolt by its plastic cap, insert the bare end into a corner bolt hole on the template’s top plate.

  2. Before inserting the bolt through the template’s bottom plate, thread a nut onto the bolt and place a washer as shown.

  3. Make sure the plastic cap is firmly pressed onto the bolt.

  1. Hold the bottom nut and washer flush against the top surface of the bottom plate, then thread the bolt onto the nut until the distance between the plastic cap and the top plate measures 51 mm (2 in).

  2. Repeat Steps 1 to 4 for the remaining three corner bolts.

  1. Secure a second washer and nut onto the bottom of each bolt until it is flush with the bottom surface of the bottom plate. Torque each nut to 5.6 Nm (50 in-lb).

Install the CMT

To install the CMT, perform the steps below:

Failure to install the ChargePoint charging station in accordance with these instructions and all local building practices, climate conditions, safety standards, and all applicable codes and ordinances may lead to risk of death, injury, or property damage, and will void the Limited One-Year Parts Exchange Warranty.

  1. Trench and excavate an opening to accommodate the wiring conduit and the concrete mounting pad that meets local codes and requirements, per site drawings.

  2. Run conduit to each station as needed. If the stations will be Paired, run DC and Ethernet conduit between stations as well.

  3. Build the form and lay rebar for the foundation.

It is critical that the conduits are positioned properly and plumb. The tolerance where the conduits enter the station is 2 mm (1/16 in).

  1. On the CMT, locate the “FRONT” marking and the conduit guide fingers. Position the conduit guide fingers facing up.

  2. Place the assembled CMT so that the “FRONT” marking aligns with the specified front of the station.

  3. Slide the CMT over the conduit stub-ups until the top surface of the template is positioned 50.8 mm (2 in) below where the top surface of the concrete will be when poured. The surface of the concrete must align with the bottom of the plastic caps.

    • Carefully press the CMT down onto the conduit to avoid flexing it.

    • Ensure the conduits are plumb.

    • Use a level to check that the CMT is level from front to back and from side to side.

  4. Tie or shim the CMT to the rebar to prevent movement during concrete pouring.

Before pouring concrete, the CMT and the conduit must be secured in place to prevent them from rising or floating out of position while the concrete is poured and curing.

  1. Pour the concrete.

    2. Make sure the concrete surface between the conduits is completely level and free of any irregularities.

  2. Complete the Construction Signoff Form provided by ChargePoint to verify that the site is correctly completed and ready for product installation.