Appendix: Wire Specifications (North America)
The requirements and specifications in this section reflect what is supported by Express Solo. When Express Solo is connected to another ChargePoint product, such as a Power Link charging dispenser or battery, conductor characteristics may be further constrained by the connected product. Refer to the site design guide for each connected product and follow the most stringent requirements.
The following table summarizes the conductor requirements for each circuit.
|
Circuit / Application |
Min. Conductor Voltage Rating |
Number of Poles |
Insulation Type |
Conductor Material / Min. Temperature Rating |
|---|---|---|---|---|
|
AC Input |
600 V AC |
3 + PE
|
Must be THHN |
Must be copper or aluminum, rated for 90°C (194°F)
|
|
DC BUS |
1000 V |
2 + PE |
Must be XHHW / XHHW‑2, based on the installation environment (e.g., dry, damp or wet conditions) |
Must be copper or aluminum, rated for 90°C (194°F) |
|
External DC Output |
1000 V |
2 + PE |
||
|
48 V DC Output |
300 V |
2 |
Select type to be suitable for the installation environment (e.g., dry, damp or wet conditions)
|
Copper wire only
|
|
Shunt Trip |
Same voltage rating as AC input conductors (due to routing proximity to power conductors) |
Twisted pair |
||
|
Safety Hub and door interlock |
300 V |
Twisted pair |
IMPORTANT: Following are wire design specifications for Express Solo, including the maximum quantity and size that the wire terminals can accommodate. All sizing assumes a maximum ambient temperature of 50 °C (122 °F). Where the maximum wire size is listed, the actual wire quantity and size must be chosen based on site-specific wiring requirements and in accordance with the maximum allowed conduit filling rate per local code.
|
Wire |
Max. Current |
Quantity |
Size |
|---|---|---|---|
|
AC input (US) |
200 kW unit: 258 A 400 kW unit: 515 A 600 kW unit: 769 A |
Max. 18 wires (six per phase) |
Max. 300 MCM |
| AC input (Canada) |
225 kW unit: 232 A 450 kW unit: 463 A 625 kW unit: 641 A 675 kW unit: 691 A |
||
|
AC ground |
- |
Max. 3 wires (1 per AC conduit) |
Refer to local code for size |
|
DC BUS - intake side |
750 A |
Max. 8 wires (four per pole) |
Max. 300 MCM (*) |
|
DC BUS- exhaust side |
750 A |
Max. 8 wires (four per pole) |
Max. 300 MCM (*) |
|
External DC output - EXT B |
250-600 A, depending on Power Link model and configuration |
Max. 8 wires (four per pole) |
Max. 300 MCM (*) |
|
External DC output - EXT D |
250-600 A, depending on Power Link model and configuration |
Max. 8 wires (four per pole) |
Max. 300 MCM (*) |
|
DC grounding |
- |
Max. 2 wires per interface (1 per interface conduit) |
Refer to local code for size |
|
48 V DC output |
32 A |
Max. 4 wires per connected Power Link (2 wire pairs; each pair has one wire per pole) (**) |
|
|
Ethernet |
- |
Max. 3 cables 1 per Power Link 1 for hardwire Ethernet (if needed) |
Outdoor-rated Cat6 STP |
|
Door interlock sensor |
- |
2 wires |
|
|
Safety Hub |
- |
2 wires per connected Power Link (****) |
|
|
Soft shutdown switch |
- |
2 wires |
|
|
Shunt trip |
6A |
2 wires |
(*) If Aluminum AA8000 conductors are used, max. 400 MCM can be accommodated. (**) The required number of 48 V DC wire pairs depends on the distance between Express Solo and Power Link. See Wire Run Lengths section in the Site Design Guide. (***) The required Ethernet cable type depends upon the cable run length. See Ethernet Cable Type and Configuration section in the Site Design Guide. (****) Safety Hub is not required for all models of Power Link. Refer to the installation guide of the Power Link model specific to your project to determine if Safety Hub twisted wire connection is required.
Plan for lugs and terminations using the following information:
-
Use copper lugs for copper conductors and aluminum lugs for aluminum conductors. The lugs must be nickel-, tin-, or silver-plated compression lugs (not mechanical lugs). Nickel-plated lugs installed with dielectric grease are recommended.
-
When using aluminum lugs, ChargePoint recommends applying an appropriate antioxidant compound to aluminum conductors when terminating into tin-, nickel-, or silver-plated lugs, where required by code or specified by the lug manufacturer.
|
Wire |
Termination |
|---|---|
|
AC input |
Lug: Compression lug; short barrel and tongue with single hole sized for M12 (0.5 in) stud Max. tongue width: 36 mm (1.3 in). |
|
AC PE/ground |
Lug: Short barrel and tongue with single hole sized for M6 (0.25 in) stud |
|
DC BUS |
Lug: Compression lug; short barrel and tongue with single hole sized for M12 (0.5 in) stud. Max. tongue width: 36 mm (1.3 in). |
|
External DC outputs |
Lug: Compression lug; short barrel and tongue with single hole sized for M12 (0.5 in) stud. Max. tongue width: 36 mm (1.3 in). |
|
DC grounding |
Lug: Short barrel and tongue with single hole sized for M6 (0.25 in) stud. |
|
48 V DC output |
Stripped wire end or ferrule |
|
Ethernet |
RJ45 connector, shielded |
|
Door interlock sensor |
Stripped wire end or ferrule |
|
Safety Hub |
Stripped wire end |
|
Soft shutdown switch |
Stripped wire end or ferrule |
|
Shunt trip |
Stripped wire end or ferrule |
