Appendix: Wire Specifications (North America)

The requirements and specifications in this section reflect what is supported by Power Block 2000. When Power Block 2000 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.

Conductor Requirements

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 THHNClosed Thermoplastic High Heat-Resistant Nylon-Coated/THHWClosed Thermoplastic High Heat-Tesistant, Water-Resistant/THWClosed Thermoplastic Heat-Resistant, Water-Resistant-2/THWN-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

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)

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

300 V

Twisted pair

IMPORTANT: Following are wire design specifications for Power Block 2000, 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 Specifications

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 (PE)

 -

Max. 3 wires

(1 per AC conduit)

Refer to local code for size

External DC outputs

(E.g., EXT A, EXT B, EXT C, EXT D)

 250-600 A, depending on Power Link model and configuration

Max. 8 wires per output

(four per pole)

Max. 300 MCM (*)

DC grounding

 -

Max. 2 wires per DC output

(1 per output 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) (**)

6 AWGClosed American Wire Gauge

Ethernet

 -

1 per connected Power Link

1 for hardwire Ethernet (if needed)

Outdoor-rated Cat6 STPClosed Shielded Twisted Pair or Paige OSP Shielded GameChanger (***)

Safety Hub

 -

2 wires per connected Power Link (****)

14 AWGClosed American Wire Gauge

Soft shutdown switch

 -

2 wires

14 AWGClosed American Wire Gauge

Shunt trip

 6A

2 wires

14 AWGClosed American Wire Gauge

(*) 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 Power Block 2000 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. (***) The required Ethernet cable type depends upon the cable run length. See Ethernet Requirements. (****) Safety Hub is required only for certain 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.

Lug Specifications

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

External DC output

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

Safety Hub

Stripped wire end

Soft shutdown switch

Stripped wire end or ferrule

Shunt trip

Stripped wire end or ferrule