Introduction

This topic describes how to install a ChargePoint® Express 280 DC fast charging station. An Express 280 can be installed to operate by itself (called Standalone) or to share power with one other Express 280 for higher throughput (called Paired).

ChargePoint Documentation

Access documents at ChargePoint Product Reference Documentation.

ChargePoint Documentation

Document	Content	Primary Audiences
Datasheet	Full station specifications	Site designer, installer, and station owner
Site Design Guide	Civil, mechanical, and electrical guidelines to scope and construct the site	Site designer or engineer of record
Concrete Mounting Template Guide	Instructions to embed the charging station template in a concrete pad with anchor bolts and conduit placement (these may also be included in the Site Design Guide)	Site construction contractor
Surface Conduit Entry Kit Guide	Instructions for sites where conduit cannot be run underground	Installer
Construction Signoff Form	Checklists used by contractors to ensure the site is correctly completed and ready for product installation	Site construction contractor
Installation Guide	Anchoring, wiring, and powering on	Installer
Operation and Maintenance Guide	Operation and preventive maintenance information	Station owner, facility manager, and technician
Service Guide	Component replacement procedures, including optional components	Service technician
Declaration of Conformity	Statement of conformity with directives	Purchasers and public

Installing the Express 280 requires two people and takes approximately 3-4 hours. This time estimate does not include the time needed to pull DC and Ethernet cable for a Paired installation if it is not already done. Paired installation also requires contacting a ChargePoint support technician to perform any required software updates and configuration.

Check Site Readiness

The Express 280 is installed on a concrete pad. For details on how to prepare this pad, see Site Design Guidelines.

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

• The concrete pad is ready and the concrete is fully cured and level.

• The concrete pad either has a site drawing approved by a structural engineer for this specific site, OR conforms to these specifications:

  • At least 305 mm (12 in) deep (or deep enough to be 305 mm (12 in) below the frost line)

  • At least 1296 mm (51 in) on each side

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

• Charging station sites are positioned so that each station is centered on a parking space (unless curbside), with the front of the station facing the vehicle.

• Enough space is available 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.

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

Confirm Anchor Bolt and Conduit Placement

Ensure the following:

• Standalone installations require two conduit stub-ups on the left side for AC wiring and shunt trip wiring.

• Paired installations also require conduit stub-ups on the right side for DC wiring and Ethernet connection.

For information about the Concrete Mounting Template, refer to the Express 280 Site Design Guide.

Check Clearances

The Express 280 requires the following minimum functional and service clearances:

(a) Service clearance of open space (not necessarily at system grade)

(b) Power Module service clearance (at grade, measured from station front): 330.2 mm (1 ft 1 in)

(c) Front service clearance (measured from station front): 609.6 mm (2 ft)

(d) Power Module service clearance (measured from front anchor bolt): 383 mm (1 ft 3.1 in)

(e) Power Module service clearance (measured from station center): 290 mm (11.4 in)

(f) Side service clearance (measured from station center): 1072 mm (3 ft 6 in)

(g) Front service clearance (measured from front anchor bolt): 510 mm (1 ft 8.1 in)

(h) Rear service clearance (measured from front anchor bolt): 663 mm (2 ft 2.1 in)

Allow 26 mm (1 in) clearance above the station if installing a Cable Management Kit (CMK Cable Management Kit).

Confirm Electrical Requirements

Ensure these electrical requirements are in place at the installation site:

• Appropriate circuit protection and metering.

• 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 station, per this table:

Nominal Voltage and Circuit Breaker Size

Nominal Voltage	Max AC Current	Circuit Breaker Size
480 VAC	100 A	125 A (125% continuous load required by National Electrical Code NEC National Electric Code guidelines)

• Breakers have shunt trip capability if the site drawing calls for shunt trip wiring.

• All necessary electrical infrastructure has been completed per local codes and ChargePoint specifications for 3-phase WYE 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.

Maximum Conductor Sizes

	Voltage Rating	Temperature Rating	Maximum Conductor Size for Terminals
Phase conductors	600 V	90 °C	1/0 AWG American Wire Gauge
AC ground conductor	600 V	90 °C	6 AWG American Wire Gauge

• Cellular signal strength is consistently strong to allow installation and station operation. Use a cellular signal detection device (such as a Snyper, Octopus, or similar) to ensure the signal is -85 dBm or better. (Note that these numbers are negative, so -70 dBm is stronger than -85 dBm, and -90 dBm is weaker.) If the signal is below -85 dBm, install multi-carrier, multi-band repeaters to boost signal strength. Repeaters are often required for installations in underground garages or enclosed parking structures.

• Paired only: All four DC copper conductors are installed between stations as follows:

DC Conductor Details

	Voltage Rating	Temperature Rating	Maximum Conductor Size for Terminals	Insulation Type
DC power conductors	1000 V	90 °C	300 Kcmil, 1x per pole	XHHW-2

• Paired only:Outdoor rated Ethernet Cat5e or Cat6 cable, without terminations, is pulled between the two stations with 3 m (10 ft) of service loop at each end.

Refer to the Express 280 Datasheet and Express 280 Site Design for more information about site specifications.

Check Express 280 Shipping Crates

Each Express 280 ships in between five and seven crates. Ensure you have all crates at the installation site.

Shipping Crate Dimensions and Weights

Contents	Max. Shipped Dimensions	Max. Shipped Weight*
Express 280 charging station	2387.6 x 1054.1 x 806.45 mm (94 x 41-1/2 x 31-3/4 in)	310 kg (685 lbs)
Power module crate with 1 power module	901.7 x 571.5 x 368.3 mm (35-1/2 x 22-1/2 x 14-1/2 in)	50 kg (110 lbs)
Power module crate with 2 power modules	901.7 x 571.5 x 676.40 mm (35-1/2 x 22-1/2 x 26-1/2 in)	98 kg (215 lbs)
Cable Management Kit (standard)	1121 x 654 x 241-1/3.3 mm (44 x 25-3/4 x 9-1/2 in)	25 kg (55 lbs)
Cable Management Kit (tall, optional)	1372 x 381 x 407 mm (54 x 15 x 16 in)	45 kg (100 lbs)
Holster and cable 6 m	600 x 600 x 150 mm (23-1/2 x 23-1/2 x 6 in)	24 kg (53 lbs)
Holster and cable 9 m	600 x 600 x 150 mm (23-1/2 x 23-1/2 x 6 in)	33 kg (73 lbs)
Concrete Mounting Template	1117.6 x 838.2 x 914.4 mm (44 x 33 x 36 in)	9.5 kg (21 lbs)
*Includes the weight of the crate; see the Express 280 Datasheet for the weight of the component.

Express 280 Charging Station Box Contents

(a) Front panels and light bar

(b) Rear panels

(c) Top cap

(d) Main body

(e) Touchscreen

(f) Side panels

ChargePoint also provides the following (not shown):

• Coolant funnel

• 2.5 cm x 183 cm (1 in x 6 ft) lifting straps

Power Module Box Contents

Power Module crates can hold one or two Power Modules.

Standard Cable Management Kit (CMK) Box Contents

Check the standard CMK Cable Management Kit package for the following components:

1. Swingarm assembly

2. CMK Cable Management Kit front cover

3. Mast

4. CMK Cable Management Kit rear cover

5. M6 hex screws (5)

 

 

 

 

 

 

 

Tall Cable Management Kit (CMK) Box Contents (Optional)

Check the tall CMK Cable Management Kit package for the following components:

1. Tool balancer assembly

2. Front cover

3. Mast

4. Rear cover

5. M10 hex screws (x4)

 

 

 

 

 

 

Holster and Cable Box Contents

1. Holsters

2. Smart cables

Required Tools and Materials

Installing the Express 280 requires at least two people . Additionally, the certified 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
	Torx wrench set T20 T25 T27		Torx security wrench T25
	Torque wrenches for 4 to 95 Nm (3 to 70 ft-lb)		Adjustable wrench
	Socket wrench set including deep sockets, up to 25 mm		Cable puller or fish tape
	Socket extension, 4 in		Screwdriver, flat blade SL4
	Multimeter with Cat III 1000 V ratings, such as Fluke 87V or similar		Paired stations only - Ethernet tester such as a Klein Tools VDV526-052 VDV LAN Local Area Network Scout Jr. Tester or similar
	Wire strippers, including Ethernet (Cat6 STP Shielded Twisted Pair) cable		Paired stations only - Ethernet (RJ45) connector crimping tool
	Wire cutters, including Ethernet (Cat6 STP Shielded Twisted Pair) cable		Lug crimping tool
	Isopropyl wipes and towel roll		Duct seal compound
	Wire brush (to remove concrete from bolts)		Broom and vacuum
	Conduit cutters (to cut up to 4 inch conduits)		Cable ties
	Smartphone with Internet connectivity		ChargePoint installer login credentials
	QR Quick Response code scanner (usually built into the camera app)		Exact location of stations or units, including parking space

• AC lugs (x3):

• All lugs must be nickel, tin, or silver plated copper compression (not mechanical) lugs

• Holes for an M6 (1/4 in) stud at 19 mm (3/4 in) stud hole spacing

• Maximum width 30 mm (1.18 in)

• AC grounding lug, crimp or mechanical

• If not already installed for this site, and if applicable for local code requirements, shunt trip wiring: size 0.08 to 2.5 mm² (28 to 14 AWG American Wire Gauge), fine stranded or solid

• If not already installed for this site, AC and ground conductors with these specifications:

  AC and Ground Conductor Specifications

  Voltage Rating	Temperature Rating	Maximum Conductor Size for Terminals
  Phase conductors - 600 V	90° C	1/0 AWG American Wire Gauge
  Ground conductor- 600 V	90° C	6 AWG American Wire Gauge

If this is a Paired installation, the certified installer also needs these tools and materials:

• Cable puller or fish tape

• DC conductors (x4):

• 2 positive and 2 negative conductors; 1 positive and 1 negative in each direction

• Copper only, minimum current carrying capacity 200 A and 1000 V rated

• DC cable run must be continuous. Do not splice DC cables

• Consult site drawings for site-specific conductor size and length

• Leave 61 cm (2 ft) of each conductor above grade at each end

DC Conductor Specifications

Voltage Rating	Temperature Rating	Maximum Conductor Size for Terminals	Insulation Type
Phase conductors - 1000 V	90° C	300 kcmil, 1x per pole	XHHW-2

• DC lugs (x4):

• All lugs must be nickel, tin, or silver plated copper compression (not mechanical) lugs

• 2-hole lugs, 1 in spacing, 3/8 in hole size, and 1.23 in max tongue width

• DC cable lug crimper and die that is compatible with lug size and brand

The lug die and crimp tool must match the lug manufacturer. Always review the lug manufacturer’s instructions for compatibility.

• Multimeter with toner attachment, such as Fluke 117 or similar

• Permanent marker

• Torque paint pen

• Ethernet wiring for DC (paired stations only):

  • Minimum of CAT5e or better

  • Outdoor or plenum rated wiring

  • Maximum run length of 100 m (328 ft)

  • Leave 3.2 m (10.5 ft) of wire above grade at each end

  • Field crimp using straight-through pattern T-568B

• Ethernet crimp tester capable of testing for correct T-568B (split pair) pattern, such as a Klein Tools VDV526-052 VDV LAN Local Area Network Scout Jr. Tester or similar

Torque Values

Torque Values

Component	Fastener	Qty	Tool	Torque
Enclosure Body Anchor top nuts	Nut, M16x2.0, 13 mmTHK, Hex, Grade DH, HDG Hot Dipped Galvanized	12	24 mm (15/16 in) socket wrench	94.9 Nm (70 ft-lb)
Rodent Guard Bracket	Screw, M5x0.8, 8 mm length, But Hd, Torx, T-25, SS, Patch	4 (2 per side)	T25 Torx screwdriver	4.5 Nm (40 in-lb)
AC Conductors (L1, L2, L3) Lugs	Nut, KEPS, M6x1.0, 7.5mm thick, Conical Washer, Steel, Zinc	6	10 mm (3/8 in) socket wrench	5.6 Nm (50 in-lb)
DC Conductors	NUT, M8x1.25, 8.8mm thick, KEPS, CONICAL WASHER, Steel, Zinc	8	13 mm (1/2 in) socket wrench	6.8 Nm (60 in-lb)
Holsters	Screw, M6x1.0, 8 mm length, PanHd, Torx, T-25,EXT SEMS 2, SS, Patch	2	T25 Torx screwdriver	2.8 Nm (25 in-lb)
Side Panels	[Use captive screws in Frame]	6	T25 Torx screwdriver	2.8 Nm (25 in-lb)
CMK Cable Management Kit Mast (top 2)	Screw, M6x1.0, 10 mm length, ButWasHd, Torx, T-25, STL, Zinc	2	T25 Torx screwdriver	5.6 Nm (50 in-lb)
CMK Cable Management Kit Mast (bottom 4)	Screw, M6x1.0, 22 mm length, ButHd, Torx, T-30, SS, Patch	4	T30 Torx screwdriver	5.6 Nm (50 in-lb)
CMK Cable Management Kit Swingarm	Screw, M6x1.0, 10 mm length, ButWasHd, Torx, T-25, STL, Zinc	5	T25 Torx screwdriver	5.6 Nm (50 in-lb)
Charge Cable Housing	Screw, M6x1.0, 20 mm length, LowCap, Torx, T-25, SS	4 per charge cable	T25 Torx screwdriver	4.5 Nm (40 in-lb)
Charge Cable Nuts	Nut, KEPS, M6x1.0, 7.5mm thick, Conical Washer, Steel, Zinc	4 per charge cable	10 mm (3/8 in) socket wrench	5.6 Nm (50 in-lb)
Charging Cable	[Use captive screw in tetherball]	1	T25 Torx screwdriver	2.8 Nm (25 in-lb)
Top Cap	M5x0.8, 16mm length, PanHd, Torx, T-25, SS, Patch	4	T25 Torx screwdriver	2.8 Nm (25 in-lb)
Front Lower Panel Screw	M5x0.8, 10 mm length, PanHd, Torx, T-25, SS, Patch	2	T25 Torx screwdriver	2.8 Nm (25 in-lb)
Rear Lower Panel Screw	M5x.08, 14 mm length, PanHd, Torx, T-25, SS, Patch	2	T25 Torx screwdriver	2.8 Nm (25 in-lb)
Front & Rear Upper Panels	Captive screw in sheet metal panel	2	T25 Security Torx Screwdriver	2.8 Nm (25 in-lb)
Area Light Bar	2 Screws, captured (Screw, M4x0.7, 12 length, Captive, TR-Torx, T-25,SS, Patch)	2	T25 Security screwdriver	2.8 Nm (25 in-lb)