Electrical Design

This section provides electrical design guidelines for Power Block 2000.

Electrical Supply Requirements

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 (NA) installations, in accordance with National Electric Code requirements.

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.

Power Block 2000 is available in multiple power ratings:

In the US: 200 kW, 400 kW, 600 kW
In Canada: 225 kW, 450 kW, 625 kW, 675 kW

Each Power Block 2000 requires its own circuit breaker. Recommended breaker sizing is given below. Check with local code for breaker size requirements.

Recommended breaker sizing for the US region (480 V AC):

AC Circuit Breaker Size
Max. Output Power	AC Continuous Input Current Rating	Derating Factor (125% continuous)	Recommended breaker size
Max. output power 200 kW	258 A	323 A	350 A
Max. output power 400 kW	515 A	644 A	700 A
Max. output power 600 kW	769 A	961 A	1000 A

Recommended breaker sizing for the Canada region (600 V AC):

AC Circuit Breaker Size
Max. Output Power	AC Continuous Input Current Rating	Derating Factor (125% continuous)	Recommended breaker size
Max. output power 225 kW	232 A	290 A	300 A
Max. output power 450 kW	463 A	579 A	600 A
Max. output power 625 kW	641 A	801 A	850 A
Max. output power 675 kW	691 A	864 A	900 A

For upstream breakers ≥ 1000 A, provide GFPE in accordance with NEC National Electric Code and CEC (typically implemented via LSIG breakers).
For breakers < 1000 A, GFPE is generally not required; LSI or thermal-magnetic breakers may be used subject to coordination requirements.
Power Block 2000 has a short circuit current rating of 100 kA.

Power Block 2000 is tested to IEC 61000-4-5, Level 5 (6 kV @ 3000 A) standards.

Disconnect and Emergency Shutoff

ChargePoint recommends installing a local AC disconnect switch—separate from the shunt trip wiring—between each cabinet and the electrical panel. A local disconnect is especially important when the main electrical panel or utility room is distant, not within line of sight, or has restricted access.

Power Block 2000 can be ordered with an optional AC disconnect switch. When included, the switch is located on the intake side of the cabinet.

Consult local electrical codes to determine disconnect and emergency shutoff requirements. Recent and upcoming code cycles include significant updates to disconnect and emergency shutoff requirements. Always verify compliance with the latest adopted electrical code.

Transformer Configuration

The table below provides the transformer configuration:

Transformer Configuration
	Transformer Configuration
Parameter	US	Canada
Input rating	480 V AC, 3-phase, 1000 A, 60 Hz	600 V AC, 3-phase, 900 A, 60 Hz
Electrical service configuration	480 V AC 3-phase grounded WYE (Y) configuration 480 V AC 3-phase Delta (D) configuration (corner-grounded Delta transformer) is not acceptable	600 V AC 3-phase grounded WYE (Y) configuration 600 V AC 3-phase Delta (D) configuration (corner-grounded Delta transformer) is not acceptable
Product connection	Power Block 2000 must be connected to L1, L2, and L3 (neutral not required)

Shunt Trip Wiring (optional)

Each cabinet of Power Block 2000 provides a set of unpowered (dry) contacts to connect to an optional shunt trip device. These contacts are rated to 240 VAC and 6 amps.

Wiring sections to and from Power Block 2000 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 cabinet of the Power Block 2000 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 2000. All shunt trip behavior is already hard-coded into the Power Block 2000 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.

Shunt Trip Wiring Diagram

Electrical panel
Power Block 2000
Control voltage supply, maximum 240 VAC
Shunt trip circuit breaker
Shunt trip coil
Auxiliary contacts (closed when main contacts are closed)
3-phase AC main
Power Block 2000 shunt trip contacts, Normally Open (inside the auxiliary power supply, accessible on field wiring terminal block)
3-phase Power Block 2000 AC input

Grounding Requirements

Power Block 2000 grounding requirements are given below:

Power Block 2000 must be connected to a grounded, metal, permanent wiring system.
Ensure 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.
When connecting Power Block 2000 to Power Links, charging components must be ground bonded in sequence from Power Block 2000 to Power Link.
Check local code to ensure compliance to grounding requirements. Some regions also require a grounding rod to be installed adjacent to each component.

The leakage current from Power Block 2000 to the protective earth conductor can reach up to 200 mA.

Soft Shutdown

The soft shutdown function is an optional feature that can be installed as a way to stop a charge session on a Power Block 2000. It is not meant to safely service the Power Block 2000 or take the place of a AC disconnect switch.

Each cabinet of a Power Block 2000 supports connection to a soft shutdown switch.

To use this feature, the installer must select and mount a physical soft shutdown switch (one per Power Block 2000 cabinet) with the following specifications:

THHN Thermoplastic High Heat-Resistant Nylon-Coated insulation building wire rated to 600 V
Normally Open (NO) configuration
Switch current of 2 mA
Switch voltage of 48 V
Gold contacts suggested

When creating the site drawings, consider where any soft shutdown switches should be positioned. If applicable, consider disability and accessibility regulations for your region when choosing switch locations.

Soft shutdown switch requires a dedicated wire conduit. For more information, refer to Conduit Requirements.

When the switch is closed, the Power Block 2000 software ends the current charging session with a normal stop, then opens DC contactors in the Power Block 2000 cabinet. The station stays in this state regardless of station power, not allowing operation. Only a service technician can place the Power Block 2000 cabinet back into service after the switch is reset to Open.

WARNING: The external DC output wires from the Power Block 2000 could still be energized with the switch closed.

Safety Hub

Safety Hub is a Power Block 2000 feature that provides continuous electrical-isolation monitoring to enhance system safety. When required, Safety Hub uses a dedicated twisted-pair connection routed from the Power Block 2000 Safety Hub Board to each associated Power Link. These conductors may share the same conduit as the 48 V DC and Ethernet wires serving the Power Links.

Safety Hub wiring requirements vary by Power Link model. Depending on the specific Power Link used in the installation, one of the following configurations will apply:

Some Power Link models require a direct Safety Hub twisted-pair connection between the Power Block 2000 Safety Hub Board and the Power Link.
Other Power Link models do not require a Safety Hub wire connection. For these models, a jumper wire must be installed on the Power Block 2000 Safety Hub Board instead of running twisted-pair wiring to the Power Link. This jumper is supplied with the Power Link and does not need to be sourced separately. Installation details are provided in the Express Distro Power Block 2000 Installation Guide.

Refer to the site design guide and installation guide of the Power Link model specific to your project to determine whether Safety Hub twisted wire connection is required.

Wiring and Conduit Requirements

Refer to the Express Distro Power Block 2000 Datasheet at ChargePoint Product Reference Documentation for full product specifications.

Ensure that the installation location is equipped with service wiring that support the station's power requirements.

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.

All wiring and conduit is supplied by the contractor unless otherwise indicated.
For V2G and energy storage applications, contact ChargePoint for wire and conduit requirements.

Wire Run Lengths

Wire run length guidelines are given below:

The maximum total external DC output wire run length from a Power Block 2000 to a connected Power Link 2000 must not exceed 200 m (656 ft). Refer to the cluster configuration provided by ChargePoint for interconnect details.
48 V DC wire and Ethernet run length between Power Block 2000 and a Power Link must not exceed 200 m (656 ft).
At minimum, there must be one 48 V DC wire pair connecting from the Power Block 2000 to each Power Link. If the distance between the Power Block 2000 and a Power Link exceeds 100 m (328 ft), contact ChargePoint to determine if an additional 48 V DC wire pair must be run to compensate for voltage drop.

Ethernet Cable Type and Configuration

Specifications for Ethernet cable type and configuration are given below:

For Ethernet communications between any two nodes (for example, between a Power Block 2000 and a Power Link):
- For distances up to 100 m (328 ft): use outdoor-rated Cat6 Shielded Twisted Pair (STP Shielded Twisted Pair) cable. Lesser grades of cable do not provide the required noise immunity.
- For distances between 100 m (328 ft) and 200 m (656 ft): use extended-reach cable rated for 200 m (328 ft).
An Ethernet cable run between a Power Block 2000 and a Power Link must have the shield terminated only at the Power Block 2000 end, not at the Power Link end.

Conduit Requirements

In regions that use conduits, wire conduits may enter Power Block 2000 through a Concrete Mount Template (CMT) or through a skid via conduit stub-ups. In regions that do not use conduits and/or use armored cables, the cables may be laid per the conduit layout defined by the CMT.

If using conduits:

Conduits must be sealed to maintain a Pollution Degree 2 environment.
Conduits must not have bell ends. Conduits with bell ends may interfere with tolerances inside the Power Block 2000.
If using conduit stub-ups (ie., not using surface conduit entry), conduits must stub-up 13–25 mm (0.5–1 in) above the mounting surface.

Below is a sample depiction of wire entry via conduit stub-ups.

IMPORTANT: Conduit and wire size and quantity are shown for illustrative purposes only. The actual quantity and size of conduits and wires for your specific site may vary and shall depend on site specific requirements.

Exterior Parts
Ref	4 DC Output	8 DC Output
(1)	Cabinet front side
(2)	Cabinet intake (right) side
(3)	48 V DC, Ethernet, and Safety Hub
(4)	AC input
(5)	Shunt trip
(6)	EXT A	EXT A
(7)	EXT A	EXT B
(8)	EXT B	EXT C
(9)	EXT B	EXT D
(10)	EXT C	EXT E
(11)	EXT C	EXT F
(12)	EXT D	EXT G
(13)	EXT D	EXT H

IMPORTANT: The following table provides the maximum size and quantity of conduits that can be installed on Power Block 2000 configured for standard wire entry. The actual conduit size and quantity must be chosen based on site specific wiring requirements.

Power Block Stub-up Conduit Specifications
Conduits For	Conduit Quantity x Trade Size
AC input	3 x 4 inch max. or 4 x 2.5 inch max.
Exernal DC output (E.g. EXT A, EXT B, EXT C, EXT D)	1 x 4 inch max. per output or 2 x 3 inch max. per output
48 V DC, Ethernet, and Safety Hub (*)	1 x 1 inch to each Power Link 1 inch size conduit is required. The quantity of conduits will depend on the configuration.
Optional Features (Soft shutdown switch and shunt trip)	1 x 3/4 inch max. per feature

(*) 48 V DC, Ethernet, and Safety Hub wires travel in the same conduit when connecting Power Block 2000 to a Power Link. Safety Hub wires are required for only for certain models of Power Link. Refer to the site design guide and installation guide of the Power Link model specific to your project to determine whether Safety Hub twisted wire connection is required.

Wire Terminal and Bus Bar Locations

This section illustrates terminal and bus bar locations for the Power Block 2000 in a 4 DC output configuration. Illustrations for 8 DC output and 12 DC output configurations will be provided in a future revision.

The following identifies the wire ports, terminals, and bus bars accessible from the intake side (right side) of each Power Block 2000 cabinet. (Safety shields are hidden from view.)

Express Foundation and Cables Entry
Ref	Part
(1)	Safety Hub ports
(2)	Ethernet ports
(3)	Terminal block for 48 V DC and soft shutdown switch wires
(4)	Shunt trip terminals
(5)	EXT A bus bars
(6)	EXT B bus bars

The following identifies the wire ports, terminals, and bus bars accessible from the exhaust side (left side) of each Power Block 2000 cabinet. (Safety shields are hidden from view.)

Express Foundation and Cables Entry
Ref	Part
(1)	Ground/PE bar (with wire landing studs)
(2)	EXT D bus bars
(3)	EXT C bus bars
(4)	AC input (L1, L2, L3) and neutral bus bars

Wire Specifications

IMPORTANT: For AC input and external DC output (EXT A, EXT B, EXT C, EXT D, and so on) high current wiring, use copper or aluminum wires rated for 90 °C (194 °F).

AC input 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 must be rated for 600 V.
External DC output wires can be XHHW/XHHW-2 based on site condition (dry or wet) and must be rated for 1000 V.

Power Block 2000 is available in two factory configurations: with a Neutral landing or without one. A Neutral connection is not required for standard charging applications. However, some Vehicle‑to‑Grid (V2G) systems rely on phase‑to‑neutral voltage measurements for control functions. When planning a V2G deployment, contact ChargePoint to ensure the correct Power Block 2000 configuration is selected.
For 48 V DC, shunt trip, and Safety Hub wiring, use copper wiring only, and ensure the wire type is selected for suitability to the installation environment (e.g., dry, damp, or wet locations).
Use shunt trip wiring that has a voltage rating equal to the voltage rating of the AC input wires selected for the site.
For Safety Hub wires, use twisted wires with voltage rating equal to the voltage rating of the AC input wires selected for the site.
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.
When using aluminum conductors, ChargePoint recommends applying an appropriate antioxidant compound when terminating into tin , nickel , or silver plated lugs, where required by local code or specified by the lug manufacturer.

IMPORTANT:

After pulling of wires, all AC input and external DC output wires must undergo insulation testing as outlined in the High Voltage Wire Insulation Resistance Test Field Guide.

IMPORTANT: Following are wire 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	Quantity	Size	Termination
AC input	Max. 18 wires (six per phase)	Max. 300 MCM	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 ground (PE)	Max. 3 wires (1 per AC conduit)	Refer to local code for size	Lug: Short barrel and tongue with single hole sized for M6 (0.25 in) stud
External DC outputs (E.g. EXT A, EXT B, EXT C, EXT D)	Max. 8 wires per output (four per pole)	Max. 300 MCM(*)	Lug: Compression lug; hort barrel and tongue with single hole sized for M12 (0.5 in) stud. Max. tongue width: 36 mm (1.3 in).
DC grounding	Max. 2 wires per DC output (1 per output conduit)	Refer to local code for size	Lug: Short barrel and tongue with single hole sized for M6 (0.25 in) stud.
48 V DC output	Max 4 wires per connected Power Link (2 wire pairs; each pair has one wire per pole)	6 AWG American Wire Gauge	Stripped wire end or ferrule
Ethernet	1 per connected Power Link 1 for hardwire Ethernet (if needed)	Outdoor-rated Cat6 STP Shielded Twisted Pair(**)	RJ45 connector, shielded
Safety Hub	2 wires per connected Power Link(***)	14 AWG American Wire Gauge	Stripped wire end or ferrule
Soft shutdown switch	2 wires	14 AWG American Wire Gauge	Stripped wire end or ferrule
Shunt trip	2 wires	14 AWG American Wire Gauge	Stripped wire end or ferrule

(*) If Aluminum AA8000 conductors are used, max. 400 MCM can be accommodated. (**)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.

The wire specifications above reflect what is supported by the Power Block 2000. When connecting to a Power Link charging dispenser, the actual wire gauges and quantities may be limited by the Power Link. Refer to the site design guide of the Power Link model specific to your project for details.

For AC input, Power Block 2000 allows a maximum of 18 total current carrying conductors. If utilizing this wiring configuration, install spreader bars at the breaker or transformer to split the outputs across the high number of conductors.