B-Link DCFC-160kW User manual

DC quick charging stations Installation and operating
instructions.
Please read all the instructions before installation and
save them for future reference.
INSTALLATION GUIDE
DCFC – 160kW
BlinkCharging.com

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Dear customer!
Thank you for purchasing this Blink product. Before using or operating this product, please read this
manual carefully and keep it handy. The company is not liable for any accidents caused by breach of
safety precautions or instructions in this manual. This product is live and should only be opened by
instructed service personnel or a qualified electrician for service, maintenance or repair and fault
handling to avoid electric shock.
MANY THANKS!
Our company will not assume any responsibility for power damage, personal injury, property loss
or damage of charger caused by installation not in accordance with the instructions of this manual.
PLEASE NOTE
Blink reserves the right to make change as necessary to comply with change in the industry and due to
errors and omissions to ensure a safe and reliable installation.
Please call our customer support line if there are any questions related to installation or operation of
this equipment.
"Please don't make assumptions, call us!"
ATTENTION

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This manual covers the electrical and mechanical installation procedure for the Blink TP5-160-480/HPC-
160-480 charger. The operations and programming manual are separate. The model hosts
differentvoltage and connector configurations. Below are different product numbers.
The materials contained in this document represent proprietary and confidential information
pertaining to services and methods of Blink. By reading this document you agree that the information
shall not be disclosed outside of and shall not be duplicated, used, or disclosed for any purpose other
than what it was created for.
CONFIDENTIALITY
TP5-160-480-1 Max Voltage: 1000VDC；Connectors: CCS1 and CHAdeMO
TP5-160-480-2 Max Voltage: 1000VDC；Connectors: CCS1 and CCS1
HPC-160-480-1 Max Voltage: 1000VDC；Connectors: Liquid Cooled CCS1 and CHAdeMO
HPC-160-480-2 Max Voltage:1000VDC；Connectors: Dual Liquid Cooled CCS1
HPC-160-480-3 Max Voltage: 1000VDC；Connectors: Liquid Cooled CCS1 and Liquid Cooled NACS
HPC-160-480-4 Max Voltage: 1000VDC；Connectors: Dual Liquid Cooled NACS
TP5-160-480-2-300 Max Voltage:1000VDC；Connectors: Dual CCS1 300A (Nominal) & 350A (Peak)
TP5-160-480-3 Max Voltage:1000VDC；Connectors: CCS1 and NACS
TP5-160-480-4 Max Voltage:1000VDC；Connectors: NACS and NACS

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TABLE OF CONTENTS
TABLE OF CONTENTS 03
CRITICAL SAFETY
SPECIFICATIONS
ADAPTED GRID SYSTEM
INSTALLATION OVERVIEW
ADA CONSIDERATION
RECOMMENDED CABLE GAUGE
BOX CONTENTS
OUTLINE OF DRAWING
MECHANICAL INSTALLATION
STATION ANATOMY
UNPACK
START INSTALLATION
WIRING
05
08
10
11
13
14
15
16
18
21
22
23
26

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TABLE OF CONTENTS
PREPARATIONS BEFORE STARTING
OPERATING INSTRUCTIONS
CHARGER SETTINGS
HOW TO START A CHARGING SESSION
MAINTENANCE AND SERVICE
28
30
31
47
49
51
TROUBLESHOOTING
CUSTOMER RESPONSIBILITIES
WARRANTY AND SERVICE PLAN
WARRANTY TERMS
EXCLUSIONS FROM LIMITED WARRANTY
CONTACT US
54
55
55
56
58

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WARNING
This unit is a high-powered electrical device and can be hazardous if improperly installed, serviced,
or operated. Failure to follow procedures in this manual could result in extreme hazard to
personnel and/or damage to the equipment and related infrastructure. In addition, the installation,
service, and maintenance need to comply with local codes and the Authority Having Jurisdiction
(AHJ).
IMPORTANT SAFETY INSTRUCTIONS
The symbols used are international icons used to depict various levels of caution when
installation, servicing or maintaining the equipment. Same symbols will also appear on the
equipment for identifying caution levels required when accessing certain areas of the charger.
CRITICAL SAFETY READ THE ENTIRE MANUAL BEFORE DESIGNING OR INSTALLING EQUIPMENT
DANGER
WARNING
GENERAL
CAUTION
！
High voltage danger label to keep people safe from electrical
discharge, which could result in injury or potential death.
Warning icon represents hazard, that could result in severe
injury or possibly death.
Caution icon represents a potential hazard or unsafe practice
that could result in injury.

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SERVICE WARNING
There are no serviceable items inside the equipment. There is high voltage inside the equipment which
could cause severe injury or death. Do not attempt to repair the charge station yourself. This can only be
performed by factory qualified personnel.
CHARGING CABLE DAMAGE
Do not operate the charger if the charging cable is damaged or if there are exposed wires in the
charging cord assembly. Shut off power at the electrical disconnect or at the breaker. Then immediately
contact Blink service. If there are any questions, please contact customer service.
SAFETY INSTRUCTIONS
Read the entire installation instructions before designing the installation and prior to installation.
This equipment should be installed by a journeyman level electrician. Local building codes need to be
complied with. In most jurisdictions the installation of this equipment requires plan check, building
and electrical permits. Verify with the local Authority Having Jurisdiction prior to starting construction.
The charging station relies on the grounding system for safety. All grounding instructions should be strictly
adhered to as prescribed in this manual and any applicable electrical safety requirements, all local electrical
safety codes, and NEC.
CRITICAL SAFETY READ THE ENTIRE MANUAL BEFORE DESIGNING OR INSTALLING EQUIPMENT

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HIGH VOLTAGE EQUIPMENT:
This charging system contains both AC and DC high voltage circuitry and devices and should only be
installed by a qualified electrician trained to work on high voltage, high current AC and DC systems.
ADDITIONAL CAUTIONARY NOTES
WARNING
Do not have power on while any of the maintenance doors are open unless proper personnel
protection equipment is worn.
Only trained personnel should be working in this equipment while the doors are open, and the unit
is powered on.
WARNING
There are high voltage and high-capacity energy storage components on this system. There are components
and circuits that remain charged for some time (1 to 2 minutes) with high voltage power, even after main
power is disconnected. Always test with a voltmeter before any maintenance or service is performed.
CRITICAL SAFETY READ THE ENTIRE MANUAL BEFORE DESIGNING OR INSTALLING EQUIPMENT
Only Blink authorized personnel are allowed to perform product repairs.

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(or larger)

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ADAPTED GRID SYSTEM

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INSTALLATION OVERVIEW
Electrical Input
Requirements
Input voltage: 480Y VAC (3 Phase + Neutral + Earth), 60Hz
Full Load Amperage: 215 Amps (At Rated power)
Breaker Capacity: 270 Amps
Location
This charging stations has 4 doors i.e. Front, Rear, Left and Right. Clear
35”distance on the front and rear sides and 24”on left and right side of a
charger to be maintained for air circulation for cooling and opening panel
for maintenance.
Flat Concrete Base with vertical gradient not more than 5% will be provided
and a provision for electrical service wires to exit the concrete pad in the
location as defined in this document.
HPC-160-480 Charger Dimensions (L X D X H): 43.07”x 36.97”x 81.30”
TP5-160-480 Charger Dimensions (L X D X H): 39.96”x 29.52”x 73.42”
Mounting Pad
Mounting pad shall be of concrete cement with approximate dimensions
Length 41.3", Width 41.7", Height 29.6", to accommodate the weight and
dimensions of the base. Place the charger on the concrete mounting pad
with anchor studs using lock washers and nuts.
For ADA requirements, the concrete mounting pad shall not exceed 6
inches above the plane of the parking lot.
For relocation / lifting – Forklift can be used, provision has been made for
this.

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INSTALLATION OVERVIEW
Barricade (Bollards) Suitable bollards should be provisioned to restrict approach of EV to the
charger. EV shall be at in accordance with local code.
Cables
Input Cables must be Copper (3P+N). Flexible copper is preferred. Please
see the table below in next section for the cable gauge.
Depending on the situation and cable type, the cables must be embedded
in the ground with proper cable duct.
Grounding
Reliable protective grounding must be provided. It is recommended to
have separate dedicated ground exclusively for the charger considering
safety aspects. The ground resistance should be less than or equal to 4Ω.
Copper cable in accordance with NEC shall be used to connect charger
housing to external ground.
Breaker
Breaker (3P+N) with suitable current capacity depending up on the charger
rating to be provided. This shall be in accordance with NEC, typically 1.25 X
Full Load Amperage.
Miscellaneous Copper lugs (Flat type) for input cable and earth cable should be provided
based on size of cable.

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Additional
notes
Do not allow flammable or explosive materials, chemicals, flammable vapors, or
other dangerous goods close to charging station.
In the areas of floods, heavy rains, storms, snow, or similar harsh weather
conditions, Blink recommends a canopy for the charger for protection. The
charger is IP54.
Confirm that your installation site has a load capacity sufficient to support this
equipment.
Charge cable length depending on options will be between 13 ft & 16 ft.
This equipment has been designed to meet ADA requirements when installed as prescribed in this
manual and in accordance with the STANDARDS FOR ACCESSIBLE DESIGN for Americans with
Disabilities document, 2010 ADA Standards for Accessible Design:
http://www.ada.gov/2010ADAstandards_index.htm
Parking space, allowances for wheelchair movement, charger, bollards, and parking stops are
defined in several publicly available EV charger installation recommended practices documents
incorporating the ADA requirements. http://www.ada.gov *For information about the ADA, including
the revised 2010 ADA regulations, please visit the Department’s website www.ADA.gov; or, for
answers to specific questions, call the toll-free ADA Information Line at 800- 514-0301 (Voice) or
800-514-0383 (TTY).
INSTALLATION OVERVIEW
ADA CONSIDERATION

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RECOMMENDED CABLE GAUGE
Capacity FLA(Amps) Breaker(Amps) AWG
30kW 40 50 8
60kW 80 100 2
120kW 160 200 3/0
160kW 215 270 300MCM
180kW 240 300 350MCM
200kW 265 335 400MCM
240kW 320 400 600MCM
300kW 400 500 900MCM
360kW 480 600 1500MCM

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BOX CONTENTS
Bolt M14 *100 Matching socket or hex
wrench
Key Forklift damper
Factory Test Report Screws
Certificate
Item Quantity
Charger 1
Bolt M14 *100 6
Key 2
Factory Test Report 1
Matching socket or hex wrench
（Match according to the
molded case circuit breaker
model）
1
Forklift damper 2
Screws M5 *8 8
Certificate 1

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OUTLINE OF DRAWING (HPC-160-480)

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OUTLINE OF DRAWING (HPC-160-480)
Before making the concrete pad, determine the position of the pre-embedded PVC pipe according to the
position shown in the figure to facilitate later wiring.
Location of
embedded PVC pipe
Front
Back

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OUTLINE OF DRAWING (TP5-160-480)

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OUTLINE OF DRAWING (TP5-160-480)
Before making the concrete pad, determine the position of the pre-embedded PVC pipe according to the
position shown in the figure to facilitate later wiring.
Location of
embedded PVC pipe
Front
Back