ChargePoint Express 250 User manual

Express 250
DC Fast Charging Station
Installation Guide
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ii
Copyright and trademarks
©2013-2018 ChargePoint, Inc. All rights reserved. This material is protected by the copyright laws of the United
States and other countries. It may not be modified, reproduced or distributed without the prior, express written
consent of ChargePoint, Inc. CHARGEPOINT is a U.S. and European Union registered trademark and service
mark of ChargePoint, Inc. and cannot be used without the prior written consent of ChargePoint.
No accuracy guarantee
Commercially reasonable efforts were made to ensure that the specifications and other information in this
manual are accurate and complete at the time of its publication. However, the specifications and other
information in this manual are subject to change at any time without prior notice.
Warranty information and disclaimer
The Warranty you received with your Charging Station is subject to certain exceptions and exclusions. For
example, your use of, or modification to, the ChargePoint® Charging Station in a manner in which the
ChargePoint® Charging Station is not intended to be used or modified will void the limited warranty. You should
review your warranty and become familiar with the terms thereof. Other than any such limited warranty, the
ChargePoint products are provided "AS IS," and ChargePoint, Inc. and its distributors expressly disclaim all
implied warranties, including any warranty of design, merchantability, fitness for a particular purposes and non-
infringement, to the maximum extent permitted by law.
Limitation of liability
CHARGEPOINT IS NOT LIABLE FOR ANY INDIRECT, INCIDENTAL, SPECIAL, PUNITIVE OR CONSEQUENTIAL
DAMAGES, INCLUDING WITHOUT LIMITATION LOST PROFITS, LOST BUSINESS, LOST DATA, LOSS OF USE, OR
COST OF COVER INCURRED BY YOU ARISING OUT OF OR RELATED TO YOUR PURCHASE OR USE OF, OR
INABILITY TO USE, THE CHARGING STATION, UNDER ANY THEORY OF LIABILITY, WHETHER IN AN ACTION IN
CONTRACT, STRICT LIABILITY, TORT (INCLUDING NEGLIGENCE) OR OTHER LEGAL OR EQUITABLE THEORY,
EVEN IF CHARGEPOINT KNEW OR SHOULD HAVE KNOWN OF THE POSSIBILITY OF SUCH DAMAGES. IN ANY
EVENT, THE CUMULATIVE LIABILITY OF CHARGEPOINT FOR ALL CLAIMS WHATSOEVER RELATED TO THE
CHARGING STATION WILL NOT EXCEED THE PRICE YOU PAID FOR THE CHARGING STATION. THE
LIMITATIONS SET FORTH HEREIN ARE INTENDED TO LIMIT THE LIABILITY OF CHARGEPOINT AND SHALL
APPLY NOTWITHSTANDING ANY FAILURE OF ESSENTIAL PURPOSE OF ANY LIMITED REMEDY.
ChargePoint, Inc.
254 East Hacienda Avenue
Campbell, CA 95008 USA
US and Canada: +1.877.850.4562
[e-mail]
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Contents
1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Express 250 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Installation Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Concrete Installation Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Before Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Express 250 Shipping Crates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tools and Equipment Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2Installing the Express 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overview of Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Prepare the Express 250 for Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mount and Secure the Express 250. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connect the Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lift the Touchscreen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Install the Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install the Left Extrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Connect the Right Extrusion’s Cable Holsters . . . . . . . . . . . . . . . . . . . 22
Install the Right Extrusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Lower the Power Module Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fill the Coolant Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install the Rear Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Install the Front Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3Completing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
You Will Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Overview of Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Complete the Installation Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Run a Test Charging Session. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Appendix A: Removing the CPE200 Adapter . . . . . . . . . . . . . . . . . . . . 43
Appendix B: Express 250 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 45
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1
1
Introduction
This document describes how to install the ChargePoint Express 250 DC fast charging station.
Before you begin, read this Introduction to familiarize yourself with the Express 250 and to ensure
that you have all the components and tools needed for a successful installation.
Express 250 Overview
Important: The Express 250 must be installed and serviced by a ChargePoint Certified
Installer only. To learn how to become a ChargePoint Certified Installer, go to
chargepoint.com/installers/. If anyone other than a ChargePoint Certified Installer
performs the installation, the warranty is voided and ChargePoint is not responsible for
malfunction and/or damage.
Swing arms
Secondary display
Touchscreen
Charging connectors
Area light bar
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ChargePoint Express 250
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Installation Sequence
Installing the Express 250 requires two people and takes approximately 2-3 hours.
Concrete Installation Pad
The Express 250 is installed on a concrete pad. Details on how to prepare this pad are described in
the Express 250 Site Preparation Guide (Part Number 73-001264-01). Before installing the Express
250, ensure that the concrete installation pad is properly prepared and the concrete is fully cured.
Important: Always check local codes and ensure that the installation complies with all
applicable codes.
Important: Remove any concrete that is not level with the rest of the surface or you will
be unable to level the Express 250. Use a grinder or a hammer or chisel to remove any
bumps in the concrete.
Ensure the installation site is
ready and you have the
required crates and the
equipment and tools
described in this section.
Install the Express 250 as
described in Section 2 of this
document.
Activate the Express 250 and
verify it is fully operational as
described in Section 3 of this
document.
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Introduction
3
Before Installing
Ensure that:
•The concrete pad is ready and the concrete is fully cured (as described on the previous page).
•The appropriate service wiring, circuit protection, and metering is in place at the installation site
(for details, see the Express 250 Site Preparation Guide, Part Number 73-001264-01).
•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.
•The cellular coverage at the installation site is consistently strong. The Express 250
communicates with ChargePoint using the cellular network. A consistently strong cellular signal
is needed before installers can activate the station. Use a cellular signal detection device (such
as a SquidTM) to ensure the signal is -90 dBm or better. If the signal is below -90 dBm, install
repeaters to boost the strength of the cellular signals. Repeaters are often required when
installing the Express 250 in an underground garage or enclosed parking structure.
•Make room in the area. Ensure there is enough space available around the installation pad to
accommodate using a forklift and other lifting equipment, to unpack the large crate and remove
packing materials, and to allow two people to freely move throughout the area.
•You have both shipping crates and all the tools and equipment needed, as described in the
remainder of this section.
•You have read the installation steps that are described in Chapter 2 to familiarize yourself with
the installation process.
Important: The Express 250 charging station is tested to IEC 61000-4-5, Level 5
(6 kV @3000A) standards. In geographic areas that experience frequent
thunderstorms, a supplemental surge protection breaker must be installed at the
service panel.
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ChargePoint Express 250
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Express 250 Shipping Crates
The Express 250 ships in two crates. Check that you have both crates at
the installation site.
Approximate
Dimensions
Approximate
Crated Weight* Contents
48” x 48” x 132”
(122 x 122 x 335 cm)
845 lbs (585 kgs) Express 250 Charging Station
and associated components (see
page 5)
38” x 48” x 15 ¼”*
(97 x 122 x 39 cm)
218 lbs (99 kg)** Power Module(s) (see page 6)
*includes the weight of the crate - for the weight of the component, see Appendix B.
**based on two power modules
Important: Always transport and store the Express 250 in its original packaging in a
horizontal position. Use appropriate lifting equipment (forklift, crane and lifting straps,
etc). Ensure the load rating of all lifting equipment is adequate to accommodate the
weight of the crated Express 250 (as shown above).
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Introduction
5
Express 250 Charging Station Crate
Accessory pouch:
• 1” x 6’ lifting straps
• T25 Torx security driver
• T27 Torx security driver
• Wago tool
• Phillips screwdriver
Plastic bag:
• 5/8-11 nuts (x12)
• 5/8-11 washers (x12)
• M5 x 10 T25 Torx screws with
retained washers (x8)
• M5 x 10 T25 Torx shoulder
screws with retained
washers (x2)
• Plastic caps (x2)
Express 250 main body*
Left
extrusion
Right
extrusion
Rear panels (x3)
Front panels (x3)
Secondary display
Area light bar
Coolant and funnel
*The Express 250 includes forklift ears not shown in this image. These ears are removed (see page 13).
Important: When removing components from the crate, protect them from damage
(such as scratches) by placing them on a blanket or tarp.
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ChargePoint Express 250
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Power Module shipping crate
.
Tools and Equipment Needed
Lifting equipment (forklift or crane) Lifting straps (1 in x 6 ft) (x2)
Level T25 Torx security driver
15/16” wrench (x2) T27 Torx security driver
#2 Phillips screwdriver with long handle WagoTM tool
Step ladder #2 Phillips screwdriver
Head-mounted flashlight Funnel
Standard electrical equipment such as wire
cutter, wire stripper, cable ties, duct seal
You need... ChargePoint provides these tools in the crate....
Power Module (one or two depending on
your order)
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2
Installing the Express 250
Overview of Steps
•Prepare the Express 250 for Mounting (page 8)
•Mount and Secure the Express 250 (page 10)
•Connect the Electrical Power (page 14)
•Lift the Touchscreen (page 18)
•Install the Power Modules (page 19)
•Install the Left Extrusion (page 21)
•Connect the Right Extrusion’s Cable Holsters (page 22)
•Install the Right Extrusion (page 23)
•Lower the Power Module Mechanism (page 25)
•Fill the Coolant Reservoir (page 27)
•Install the Rear Panels (page 28)
•Install the Front Panels (page 31)
Note: The steps in this installation guide assume that you are using a forklift to move and mount the
Express 250. In addition to forklift ears, the Express 250 is equipped with lifting handles and
supplied lifting straps that allow you to use a crane. If using a crane, adjust the first two steps as
appropriate.
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ChargePoint Express 250
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Prepare the Express 250 for Mounting
Step 1 Using appropriately-rated lifting equipment, position the crate vertically on level ground
near the installation pad.
Note: A 1” lifting hole is included in both the left and right skid of the crate to
accommodate lifting straps that can be used to raise the crate to the vertical position.
Step 2 Remove the front panel of the shipping crate and position it as a ramp at the bottom of the
crate.
Note: Position the front panel with the inside facing up.
Step 3 Remove the two wooden braces that secure the Express 250 in the crate.
These braces are labeled “Upper Front” and “Lower Front.”
Step 4 Using two people, one on each side of the Express 250, slowly roll it out of the crate, then
lock the wheels on the dolly.
DO NOT roll the Express 250 on the dolly beyond initial uncrating. Doing so increases the
risk of the Express 250 falling, especially if rolling it on an incline and the surface is slightly
uneven (cracks, rocks, etc.). Any movement of the Express 250 beyond rolling it out of the
crate should be done using a forklift or a crane with lifting straps as described in the next
step.
Note: Align the Express 250 as closely as possible to the mounting bolts on the installation
pad.
Step 5 Remove the wiring cover on the left side of the Express 250 by pressing on its side and
sliding it downward.
Note: The wiring cover on the right side is for future use if DC wiring is installed. There is no
need to remove this before lowering the Express 250 unless it interferes with conduit
installed on the right side of the installation pad.
Step 6 Stabilize the Express 250 by positioning the forklift blades inside the forklift ears.
Forklift blades should be approximately 26.5” apart (inside to inside), and the bottom of
the blades approximately 45” above ground. These measurements vary depending on the
type of forklift used.
You can also stabilize the Express 250 using an overhead crane instead of a forklift. Lifting
ears to accommodate lifting straps are located at the top of the Express 250.
Important: Make sure the ramp is flush against the bottom of the crate to ensure
the dolly can easily roll onto it.
Warning: Due to weight distribution, care should be taken when rolling the
Express 250 to prevent tipping.
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Installing the Express 250
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Note: If a wall is located behind the installation pad, ensure the forklift blades don’t
protrude so far that they can potentially hit the wall when moving the Express 250 onto
the pad.
Step 7 Using a 15/16” wrench, remove the four nuts that secure the Express 250 to its dolly.
Note: For easier access to the rear bolts, slide the power module tray out (see page 19).
Step 8 Slowly raise the Express 250 approximately one foot and slide the dolly out from under it.
.
Important: To protect the charging connectors from damage, keep them
wrapped throughout the installation process.
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ChargePoint Express 250
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Mount and Secure the Express 250
..
Step 1 Remove the plastic cap from each of the six mounting bolts on the concrete installation
pad.
Step 2 Thread a nut, then insert a washer, onto each of the six mounting bolts. Leave
approximately 1/4” between the bottom of the bolt and the concrete to accommodate
leveling.
Step 3 Thread the two center nuts on the mounting bolts downward so they are lower than the
four outer nuts.
Important: If you are replacing a CPE200 you can skip Step 1. The CPE200 adapter must
be removed, as described on page 43, prior to proceeding to Step 2.
Thread nut onto each bolt, then place a washer. Leave
approximately 1/4” to accommodate leveling.
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Installing the Express 250
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Step 4 Slowly lift the Express 250 over the six mounting bolts on the installation pad, ensuring the
bolts align with the corresponding holes in the bottom of the Express 250, then lower the
Express 250 onto the bolts.
Note: You may need to hold the service wiring out of the way to ensure that it doesn’t get
pinched or trapped between the Express 250 and the installation pad.
Note: The Express 250 should rest on the four outer nuts and not on the rails. The purpose
of the rails is to ensure that the Express 250 is installed a minimum height from the surface
of the installation pad, which in turn, allows the front and rear panels to sit flush with the
surface of the concrete.
Step 5 Insert a washer, then thread a nut onto each of the six mounting bolts to secure the
Express 250. To facilitate leveling, do not tighten these upper nuts.
Step 6 Remove the lifting equipment from the installation area.
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ChargePoint Express 250
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Step 7 Using a level on all four sides, adjust the bottom nuts and washers as needed to ensure
that the Express 250 is level, both horizontally and vertically.
Step 8 When level, tighten the four outer four nuts first. Then tighten the center front and back
nuts by hand-turning the lower nuts until they are flush against the Express 250’s frame.
Finally, tighten all top nuts to secure the Express 250.
Adjust the bottom nuts to level
the Express 250
When level, tighten the six top
nuts to secure the Express 250
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Installing the Express 250
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Step 9 Using a level, double-check the vertical and horizontal alignment to ensure the tightening
of the nuts in the previous step did not cause the Express 250 to shift out of its level
position. Make any necessary adjustments to ensure the Express 250 is level while all nuts
are tightly secured.
Step 10 Remove the right and left forklift ears at the top of the Express 250 using the supplied T27
Torx driver.
Note: You may need the step ladder.
Step 11 Remove the plastic covering the Express 250.
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ChargePoint Express 250
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Connect the Electrical Power
Step 1 Pull service wiring through the conduit in the installation pad if not already done so as
described in the Express 250 Site Preparation Guide.
Step 2 Check the length needed to extend the wiring from the conduit opening to the Express
250’s terminal block (approximately 2 ft/61 cm), and trim the excess wire.
Step 3 Strip each wire 1” (25 mm).
Important: The terminal block on the Express 250 accepts 2 AWG wires only. If
using a larger gauge wire to accommodate a long run, reduce the wire size at the
disconnect.
Make sure the wiring can reach the terminal block,
then trim any excess
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Installing the Express 250
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Step 4 Connect the L1, L2, L3 and GND
service wiring to the terminal
block.
Insert the
Wago tool to
open the
corresponding
connector
To connect each wire:
•Fully insert the supplied
Wago tool and rotate the
tool firmly counter-
clockwise 90oto open the
connector.
•Hold the Wago tool in
position, while fully inserting
the wire fully until it hits the
connector’s back stop.
•Release the Wago tool (the
connector is spring-loaded
and releasing the tool closes
the connector onto the
wire).
•Confirm the wire is held
securely inside the
connector by trying to pull
the wire downward.
Note: Although not necessary, you can lock a connector in the open position by firmly
pressing its associated orange button. The orange button locks into its pressed position,
which locks the associated connector in the open position. Then, while holding the wire in
the fully inserted position, insert and rotate the Wago tool counter-clockwise again to
close the connection. You will hear a click as the connector closes onto the wire and the
orange button is released from its pressed state.
Important: Ensure the exposed wires are tightly bundled tightly with no loose
strands.
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ChargePoint Express 250
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Step 5 Use cable ties to bundle the
wires in two or three places.
Bundle
the
wires
Seal the
conduit
opening
Step 6 If the conduit opening was not
sealed as part of the site
preparation process, seal it now
using duct seal.
Important: The
conduit opening must
be sealed to protect
the wiring from the
environment.
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