EV Charging Station Make-Ready

Request for Quotation Date: 06/01/2023 Quotation Number: EV110 Specification/Quotation Documents For: EV Charging Station Make Ready RFQ Due Date: OPTIONAL PRE-BID MEETING 6/15/2023 @ 2:30pm EST Project Location 110 Cherry Street Johnson City, TN 37601 BID DUE 6/22/2023 @ 2:00pm EST To avoid any delay, we encourage you to send responses ahead of the deadline. Responses will not be opened until the stated date and time. Section 1 – Invitation to Bidders Sealed bids will be received by BrightRidge until due date and time, then bids will be opened and publicly read. Bidders may participate in the public bid reading by contacting BrightRidge Purchasing at least two hours prior the bid opening time stated on the specific bid. Bidders making this request will receive a conference call number and a participant code. BrightRidge Purchasing contact information: purchasing@brightridge.com or call 423-952-5161. All bids must be

delivered at the vendor’s sole risk as shown in this request for quotation as per Section 2 Instructions to Bidders. BrightRidge is not obligated to accept quotations received after the date and time stated. Exceptions, if any, will be considered in the quotation evaluation in determining the successful vendor. Vendor must provide supporting documentation with its quotation for any exceptions. BrightRidge reserves the right to reject any or all quotations, to reject any bid that contains prices for individual items or services that are inconsistent or unrealistic when compared to other prices in the same or other bids, to waive any and all informalities and/or irregularities in the quotation, to negotiate and/or renegotiate with any vendor the terms of its quotation, and to accept any quotation which in its opinion may be in the best interest of BrightRidge. This Request does not commit BrightRidge to pay any costs incurred in the preparation of a proposal or to procure or to contract for service. BrightRidge reserves the sole discretion to withdraw this Request in its entirety at any time without prior notice. Information provided in this Request is intended solely to assist the respondent in preparing a Quotation. To the best of BrightRidge’s knowledge, the information provided is accurate, however, there is no warranty expressed or implied. Quotations may be held by BrightRidge for a period not to exceed sixty (60) days from the due date of the quotations for the purpose of evaluating the quotations or investigating the qualifications of the vendors, prior to awarding of the order. All quotations shall remain effective for at least sixty (60) days after the due date. Each vendor’s quotation shall constitute an offer to sell the goods or services sought by this Request for Quotation. The award shall be made by execution of a contract mutually agreed upon by both parties. BrightRidge is a trade name of the Johnson City Energy Authority. Questions about the integrity or fairness of the sealed bid process contact: Purchasing at 423-952-5161 or email purchasing@brightridge.com Specification questions contact: Walter Hopkins (423)952-5135 or email whopkins@brightridge.com Section 2 – Instructions to Bidders Each Bidder shall carefully examine all specifications, drawings, and other contract documents to familiarize themselves with all the requirements, terms and conditions thereof. Any information relating to the work furnished by the Owner or others, or failure to make these examinations shall in no way relieve any Bidder from the responsibility of fulfilling all the terms of the contract, if awarded a contract. No payment will be made for items not set up in the quotation, unless otherwise provided by contract amendment. All Bidders are cautioned that they should include in the prices quoted for the various bid items all necessary allowances for the performance of all work required for the satisfactory completion of the project. REQUIREMENTS FOR A DIGITAL PROPOSAL/BID SUBMISSION  Bids should be clearly identified as: Bid Enclosed and Your Company Name BrightRidge Quotation Number: EV110 Name of the Request: EV Charging Station Make Ready Due: 06/22/2023 at 2PM EST OPTIONAL PRE-BID MEETING 6/15/2023 @ 2:30pm EST Project Location 110 Cherry Street Johnson City, TN 37601 BID DUE 6/22/2023 @ 2:00pm EST  Send an email with an attached PDF of the digital bid including all required documents listed below to: SEALEDBIDS@BRIGHTRIDGE.COM. BrightRidge quotation number should be listed in the email subject line. Documents may be combined and sent as one PDF and cannot exceed 50MB in size. An automatic delivery receipt is sent indicating that the bid email has been delivered to sealedbids@brightridge.com  Digital Proposal/Bids (hereafter called bids) received after the stated due date and time will be disqualified. BrightRidge will not open the bid submission email or any attachment until the due date and time stated for this sealed bid, this is to maintain the integrity of the sealed bid process  Send a SEPARATE EMAIL, indicating that you have submitted a digital bid also include quotation number in the subject to: PURCHASING@BRIGHTRIDGE.COM. DO NOT ATTACH A COPY OF YOUR BID TO THIS EMAIL!  No fax or physically delivered sealed bids will be accepted. Bids must be digital. Bidders from small & minority owned businesses needing to make alternative arrangements for physical delivery may call purchasing at 423-952-5161 or 423-952-5000. CHECKLIST FOR REQUIRED PAGES TO INCLUDE FROM BRIGHTRIDGE BID PACKAGE NOTE: FAILURE TO SUBMIT THESE PAGES WILL RESULT IN DISQUALIFICATION OF BID o BrightRidge Request for Quotation Form o Quote must be in same order and unit of measurement requested or bid may be disqualified o Section 3-Quotation Information Form o Specification Exception Form o No Bid Questionnaire – If applicable o Business and Taxpayer Identification or W9 form – for NEW vendors Contract BrightRidge reserves the right to accept or reject any or all bids or portions thereof. Vendors may bid multiple options, unless otherwise stated. Vendors must complete the BrightRidge Request for Quotation Form, if applicable and included in the request for quotation. As a backup, a vendor may include their company quote form, however, items must be quoted in the same order and in the unit of measure requested on the BrightRidge Request for Quotation form, a no-bid line needs to be included also in the order of our request if not bidding on an item. Delivery The price bid will be FOB Johnson City, Tennessee, at the location specified below. The bid price shown will be the full charge, including all applicable taxes, surcharges and other incidental fees, shipping charges included. Delivery Site: BrightRidge Shipping/Receiving Entrance 2610 Boones Creek Rd Johnson City, TN 37615 Invoicing Unless otherwise stated, submit invoices upon delivery or pickup to ap@brightridge.com. The invoice must include an itemization of all items, supplies, repairs, or labor furnished, including unit list price, net price, extensions, and total amount due. Payment Unless otherwise stated, payment will be made within thirty (30) days of the completion of delivery of all items or services in acceptable condition to BrightRidge and receipt of invoice, whichever is later. Taxes and Fees BrightRidge is exempt from all Sales and Federal Excise Taxes please quote less these taxes. BrightRidge is not responsible for financial or legal obligations of the bidders that may include bond premiums, fees, insurance, licenses, permits, taxes, tariffs, or other costs of compliance, unless agreed to in writing by BrightRidge. Taxes may include federal, state, or local taxes or levies. Particular attention should be given to bids that provide construction, installation, and maintenance services that utilize the materials and supplies purchased by BrightRidge. BrightRidge does not pay Tennessee sales and use tax when materials, supplies, and equipment are purchased. If the Bidder wants information about the value of the items that will be used, contact BrightRidge Purchasing. Make a note of Tennessee Code Annotated 67-6-209 section (b) and (e). If the Bidder wishes to recoup obligations they owe as a result of work performed for BrightRidge, the Bidder must include them in the quotation price. Otherwise, the Bidder should not expect additional payment from BrightRidge for these obligations. Equal Employment Opportunity Clause To the extent not exempt therefrom, the vendor/subcontractor designated herein agrees to in all respects comply with and abide by the provisions of Executive Order 11246, Section 503 of the Rehabilitation Act of 1973, and the Vietnam Era Veterans' Readjustment Assistance Act of 1974, each as amended, and applicable implementing Regulations, including the Equal Employment Opportunity Clause referred to at 41 C.F.R. § 60-1.4, 41 C.F.R. § 60-741.5, and 41 C.F.R. § 60-250.5, as well as those otherwise appearing at 41 C.F.R. § 60-1, et seq., 41 C.F.R. § 60-741.1, et seq., and 41 C.F.R. § 60-250.1, et seq., each as amended. Section 3 – Quotation Information The successful contractor agrees to indemnify, investigate, protect, defend, and save harmless BrightRidge, its officials, officers, agents, and employees from any and all third-party claims and losses accruing or resulting from bodily injury or damage to property caused by the successful contractor in performance of this contract. The successful contractor also agrees to indemnify, investigate, protect, defend, and save harmless BrightRidge, its officials, officers, agents, and employees from any and all third-party claims and losses accruing or resulting from bodily injury or damage to property caused by the successful contractor’s sub- contractors, suppliers, laborers, and any other person, firm, or corporation furnishing or supplying work, services, materials, or supplies to the successful contractor in connection with the performance of this contact. If the successful contractor supplies products it manufactures (in whole or in part), the successful contractor agrees to indemnify BrightRidge, its officials, officers, agents, and employees from any and all third-party claims and losses accruing or resulting from bodily injury or damage to property caused by the failure of such products. If the successful contractor only supplies products manufactured by others, the successful contractor is not obligated to indemnify BrightRidge for a failure of any such products manufactured by others. If the successful contractor only supplies products manufactured by others, the successful contractor agrees to cooperate with BrightRidge and take all reasonable steps to assist BrightRidge in making claims against any such product’s manufacturer for any such product’s failure. In any case, the foregoing provisions concerning indemnification shall not be construed to indemnify BrightRidge from damage arising out of bodily injury to persons or damage to property caused by or resulting from the sole negligence of BrightRidge or its employees. This indemnification shall survive the expiration or early termination of this contract. The undersigned acknowledges: That he/she is an authorized agent of the vendor submitting this quotation. The receipt of the following addenda (if any). The provision of the indemnification agreement. Company Name: _______________________________________________________________________________ Company Address: _______________________________________________________________________________ Taxpayer ID: ___________________________________________________________________ Telephone Number: ________________________ Mobile Number: ______________________ E-mail: __________________________________ Fax Number: _________________________ Primary Point of Contact: ________________________________________________________ Authorized Signature: ___________________________________________________________ Date of Signature: _________________________Title: ________________________________ Printed or Typed Name: __________________________________________________________ FAILURE TO SUBMIT THIS COMPLETED FORM WITH YOUR BID SUBMISSION MAY RESULT IN YOUR BID BEING REJECTED AS UNRESPONSIVE. BrightRidge Specifications Exception Form In the interest of fairness and sound business practice, it is mandatory that you state any exceptions taken by you to our specifications. It should not be the responsibility of BrightRidge to ferret out information concerning the materials which you intend to furnish. If your bid/quotation does not meet all of our specifications, you must so state in the space provided below. Bids on equipment, vehicles, supplies, services, and materials not meeting specifications may be considered by BrightRidge, however, all deviations must be listed below. I do meet specifications. Signature: _________________________________ I do not meet specifications. Exceptions are in the space provided. Signature: _________________________________ FAILURE TO SUBMIT THIS COMPLETED FORM WITH YOUR BID SUBMISSION MAY RESULT IN YOUR BID BEING REJECTED AS UNRESPONSIVE. Exceptions (please list below and specify exceptions) No Bid Questionnaire BrightRidge Attn: Purchasing 2600 Boones Creek Rd Johnson City, TN 37615 Quotation Number: EV110 If you choose not to bid, please complete the questionnaire below and return it with your response by the bid opening date. Your assistance in helping us to analyze no bid rationale is very much appreciated. For the following reason(s) we are submitting a no bid: _____ Item not supplied by our company. _____ Bid specifications (e.g. too restricted, not clear, etc.) Please explain. __________________________________________________________________ _____ Profit margin on municipal bids is too low. _____ Past experience with BrightRidge (e.g. payment delay, bid process, administrative problems, etc.) Please explain. ____________________________________________ _____ Insufficient time allowed to prepare and respond to bid request. _____ Bid requirement Too Large or Too Small for our company. _____ Priority of other business opportunities limit time/other resources available to deliver or perform according to bid specifications. _____ Other reason(s). Please explain. ____________________________________________ Company Name: ___________________________________________ Address: __________________________________________________ Telephone: _____________________ E-mail: _______________________ ____________________________ ______________________________ (Signature) (Printed/Typed Name) Title: _______________________________ Date: ___________________ BrightRidge Business and Taxpayer Identification Information This Business is operating as a: Individual/Sole Proprietor or Single Member LLC Partnership Trust/Estate C Corporation S Corporation Limited Liability Company (Enter the tax classification (C=Corporation, S=S Corporation, P=Partnership) ______________ Other (please describe) _______________________________________ Licensed or otherwise authorize to business by the state of: ________________________ Taxpayer Identification Number: __ __ - __ __ __ __ __ __ __ Or Social Security Number: __ __ __ - __ __ - __ __ __ __ Legal Name: (as shown on your income tax return) ____________________________________________________________ Doing Business as Name: (DBA) ____________________________________________________________ Address: _____________________________________________________ City, State, Zip: _______________________________________________ Note: If applicable, your bid may be rejected if you do not complete and submit this page and/or a W-9 with your bid. Checks in payment of obligations by BrightRidge will be made payable to your legally issued name unless you state a DBA. Federal Tax reporting, if required, will also be in your legal name. ELECTRIC VEHICLE CHARGING STATION MAKE-READY PAGE 1 OF 7 SCOPE OF WORK BID FORM Submit Bid Form with a completed RFQ Information Sheet (Page 1) and a proposed construction schedule detailed per the attached scope of work. Company Name Company Address Contractor's License Number and Classification Item Quantity Unit Cost (USD) per Unit Extended Cost (USD) Project Price 1 Total Rock Removal (Provisional) 1 Hour Total (USD) Authorized Representative Date Print Title ELECTRIC VEHICLE CHARGING STATION MAKE-READY PAGE 2 OF 7 Project Title - Electrical Vehicle Charging Station Make-Ready Project Location – 110 Cherry Street, Johnson City, TN 37601 (36.3161, -82.3499) Project Scope - Project consists of the site work and electrical activities to facilitate the installation of paired ChargePoint Express 250 equipment to provide up to 125-kW of rapid electric vehicle charging capability. The installation and activation of the EV charging equipment is not included in this scope of work; however, the EV charger footprint template will be provided by the owner for anchor bolt and electrical conduit layout and installation by the awarded bidder. A project schedule shall be submitted as part of the offer in conjunction with the provided bid form. Please include a proposed start and completion date, showing any critical path items including equipment lead times and contingency plans. The awarded bidder shall provide the following services. Note: The following items should not be considered an all-inclusive list. All work shall be performed in accordance with the included site drawings and technical specifications. Contractor shall assume full responsibility for complying with all federal, state, and local codes and requirements needed to provide project completion in accordance with the Authority Having Jurisdiction (AHJ), as applicable. SITE PREPARATION  Prior to beginning work, a pre-construction meeting is to be held on site including a representative from the awarded bidder, an owner’s representative, and a representative of the site-host partner (if applicable) to discuss the project’s proposed logistics and schedule.  Provide adequate traffic cones, barricades, and/or fencing to maintain a safe work environment and provide public hazard protection for the duration of the project. ELECTRIC VEHICLE CHARGING STATION MAKE-READY PAGE 3 OF 7  Coordinate with BrightRidge to confirm location, size, and dimensions of the new service transformer pad (if required), required electrical risers, and location of the meter interconnect point.  Perform demolition of the existing curbing, concrete or asphalt pavement, and/or shrubbery to prepare for all necessary site work per the project Site Drawings. No trees larger than 3-inches in diameter shall be removed without prior approval from an owner’s representative. Demoed material shall be removed from the site and disposed of at the awarded bidder’s expense. Project site shall remain in an orderly state and all waste shall be removed daily. ELECTRICAL INSTALLATION  Coordinate with BrightRidge for the new service requirements for the conduit and wiring to facilitate the installation of electric utility service equipment.  Provide all trenching/boring and backfill required for the installation of necessary underground electrical conduit per the project Site Drawings. Please provide rock removal cost per hour if rock is encountered during site excavation activities. Rock removal consists of bedrock encountered at continuous depth, and does not include isolated boulder removal. Rock removal must be approved and documented in order to receive reimbursement.  Install all necessary electrical conduit, fittings, supports, enclosures, panelboards, distribution devices, and wiring to provide electrical service from the utility interconnect to the new Electric Vehicle DC Fast Charge Equipment and lighting structures (if required) per the project Site Drawings and the equipment manufacturers Site Design Guide.  Provide adequate protection to close off and keep free of debris and/or water all installed conduit prior to the installation of final wiring. SITE WORK  Install all necessary formwork, rebar, anchor bolts, concrete foundations, and curbing, concrete or asphalt pavement, railings, signage post, wheel stops and/or bollard protection per the project Site Drawings and the equipment manufacturers Site Design Guide.  Install all necessary signage and parking lot striping per the project Site Drawings. PROJECT CLOSEOUT  Provide damage and/or theft protection to exposed conduit and wiring until the installation of EV charging equipment. Coordination may be required with charging equipment installer to complete electrical installation.  Provide lock out/tag out devices on all energized distribution devices prior to the installation of EV charging equipment.  Complete site remediation to facilitate the installation of the EV charging equipment. This includes, but not limited to, removing temporary protective devices, topsoil grading, establishing vegetative ground cover, sweeping parking lot, and the removal of all construction debris from the site.  Complete and submit the ChargePoint Construction Signoff documentation attached in the project Technical Specifications for Make-Ready validation. ELECTRIC VEHICLE CHARGING STATION MAKE-READY PAGE 4 OF 7 SITE DRAWINGS ELECTRIC VEHICLE CHARGING STATION MAKE-READY PAGE 5 OF 7 ELECTRIC VEHICLE CHARGING STATION MAKE-READY PAGE 6 OF 7 ELECTRIC VEHICLE CHARGING STATION MAKE-READY PAGE 7 OF 7 TECHNICAL SPECIFICATIONS installdispatch@chargepoint.com 75-001384-01 r1 Express 250 Construction Signoff Form This form is required to ensure the site for your ChargePoint EV charging station(s) has been prepared as specified, by you or by your chosen contractor, before beginning your charging station installation. Submit this completed form, and the photos specified at the end, to installdispatch@chargepoint.com. The detailed data sheets, site design guides, and installation guides defining ChargePoint specifications are online at: chargepointuniversity.com. IMPORTANT: All installations must comply with local and regional code. ChargePoint provides concrete pad guidance in the Express 250 Site Design Guide that is applicable for most sites; however, pad size for a given site might be smaller or larger due to site conditions. Ensure site drawings have been completed and approved by a structural engineer for this site. Note: If the station installer arrives to install the charging station and finds these items incomplete, you will incur a separate re-dispatch fee. Site Information Contractor Information Site address: Company name: Site lead name: Number of Express 250 stations to be installed: Site lead job title: Contact name: Site lead email: Contact phone: Site lead phone: Contact email: Date work began: Take the following photos throughout the site construction process. Required Pictures 1. All trenching completed and conduit/ducting laid in place 2. The Concrete Mounting Template (CMT) in place with anchor bolts and conduit stub-ups correctly inserted, and the CMT held at the proper height to prevent movement during the concrete pour 3. Concrete pad completed, showing anchor bolts and conduit stub-ups in place for AC and shunt trip 4. Paired only: Conduit stub-ups (or provision for armored cable) in place for DC conductors and Ethernet 5. Overall space around the concrete pad, showing all service clearances are available 6. The electrical panel‘s specification label, to show total panel capacity 7. The open electrical panel with the dead front panel removed, showing terminations 8. The open electrical panel with the dead front panel on, showing breaker amperage ratings and labels for Express 250 connections 9. Paired only: The front of each AC disconnect (if applicable by region) 10. Charging station sites are positioned so that each station is centered on a parking space (unless curbside), with the front of the station facing the vehicle Sales Order Number (SO#) ______________________ mailto:installdispatch@chargepoint.com http://www.chargepointuniversity.com/ installdispatch@chargepoint.com 75-001384-01 r1 Civil Work 1. The concrete pad was either designed and approved by a structural engineer for this specific site, OR conforms to these specifications: • At least 305 mm (12 in) deep (or deep enough to be 305 mm (12 in) below the frost line) • At least 1296 mm (51 in) on each side • Contains #4 rebar or larger, top and bottom, 305 mm (12 in) on center • Concrete 2500 PSI minimum 2. Walls, fences, or slopes do not prevent water from draining from the pad. 3. The concrete mounting template (CMT) is installed in the concrete pad, 50.8 mm (2 in) below the concrete surface, with anchor bolts in place in the CMT. 4. The AC conduit (max 50.8 mm/ 2 in trade size) and shunt trip conduit (max 19.1 mm/ 3⁄4 in size) are positioned correctly in the CMT and cut down to 76.2 mm (3 in) above grade. 5. Paired only: The DC conduit (max 76.2 mm/ 3 in trade size) and Ethernet conduit (max 19.1 mm/ 3⁄4 in size) are positioned correctly in the CMT and cut down to 76.2 mm (3 in) above grade. 6. The service clearance of open space (not necessarily at system grade) extends a minimum of 610 mm (24 in) beyond the station in front, 1276 mm (50 in) total front to back, 2156 mm (84.8 in) side to side centered on the station, and 305 mm (12 in) above the station (a). 7. The front of the station has 352 mm (14 in) of space at grade from the front right anchor, extending 1700 mm (67 in) to the left, without any permanent obstructions (bollards, wheel stops, etc) (b). 8. Charging station sites are positioned so that each station is centered on a parking space (unless curbside), with the front of the station facing the vehicle. 9. The charging station is at least 305 mm (12 in) from any wall as its rear clearance. Stations positioned back to back are no closer than 610 mm (24 in) shared clearance. 10. All signage, parking spot striping, and “EV” markings are completed per site drawings and local code. a b Sales Order Number (SO#) ______________________ installdispatch@chargepoint.com 75-001384-01 r1 Electrical Work 1. A correctly rated, dedicated breaker is installed for each station, per this table: Nominal Voltage Max AC Current Breaker Size 400 V (EU) 96 A 125 A 480 V (NA) 80 A 100 A (125% continuous load required for N. America) 2. Breakers have shunt trip capability if the site drawing calls for shunt trip wiring. 3. All necessary electrical infrastructure has been completed per local codes and ChargePoint specifications for 3-phase power plus ground, with properly sized wire at the station. (Neutral is not required for system operation.) Voltage Rating Temp Rating Maximum Conductor Size for Terminals EU non-armored: 600/1000 V 90°C 35 mm2 EU armored: 600/1000 V 90°C 35 mm2 multi-core NA: 600 V 90°C 2 AWG Record the AC conductor size and voltage rating: _________________________________________ 4. Paired only: All four DC copper conductors are installed between stations as follows: Voltage Rating Temp Rating Maximum Conductor Size for Terminals Insulation Type EU non-armored: 600/1000 V 90°C 120 mm2 XLPE EU armored: 600/1000 V 90°C 120 mm2 4-core XLPE NA: 1000 V 90°C 4/0 AWG XHHW-2 Record the size, voltage rating, and insulation type for the DC conductors: ___________________________________________________ 5. Paired only: Outdoor rated Ethernet Cat5e or Cat6 cable, without terminations, is pulled between the two stations with 3050 mm (10 ft) of service loop at each end. 6. The station location has been tested for 4G/LTE cellular and meets minimum -85 dBm RSRP or better. I, , hereby certify that the scope of work in this form has been correctly completed. Signature Date Sales Order Number (SO#) ______________________ Express 250 DC Fast Charging Station Site Design Guide for Standalone and Paired Stations ii IMPORTANT SAFETY INSTRUCTIONS: SAVE THESE INSTRUCTIONS Product Disposal To comply with Directive 2012/19/EU of the European Parliament and of the Council of 4 July 2012 on waste electrical and electronic equipment (WEEE), devices marked with this symbol may not be disposed of as part of unsorted domestic waste inside the European Union. Enquire with local authorities regarding proper disposal. Product materials are recyclable as marked. 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. WARNING: 1. Read and follow all warnings and instructions before installing and operating the ChargePoint® Charging Station. Install and operate only as instructed. Failure to do so may lead to death, injury, or property damage, and will void the Limited Warranty. 2. Only use licensed professionals to install your ChargePoint charging station and adhere to all national and local building codes and standards. Before installing the ChargePoint® charging station, consult with a licensed contractor, such as a licensed electrician, and use a trained installation expert to ensure compliance with local building and electrical codes and standards, climate conditions, safety standards, and all applicable codes and ordinances. Inspect the charging station for proper installation before use. 3. Always ground the ChargePoint charging station. Failure to ground the charging station can lead to risk of electrocution or fire. The charging station must be connected to a grounded, metal, permanent wiring system, or an equipment grounding conductor shall be run with circuit conductors and connected to the equipment grounding terminal or lead on the Electric Vehicle Supply Equipment (EVSE). Connections to the EVSE shall comply with all applicable codes and ordinances. 4. Install the ChargePoint charging station on a concrete pad using a ChargePoint approved method. Failure to install on a surface that can support the full weight of the charging station can result in death, personal injury, or property damage. Inspect the charging station for proper installation before use. 5. This charging station is not suitable for use in or around hazardous locations, such as near flammable, explosive, or combustible materials. 6. Do not use this product if the enclosure, EV cable, or the EV connector is broken, cracked, open, or shows any other indication of damage. 7. Do not put fingers into the electric vehicle connector. Important: Under no circumstances will compliance with the information in this manual relieve the user of his/her responsibility to comply with all applicable codes or safety standards. This document describes the most commonly-used installation and mounting scenarios. If situations arise in which it is not possible to perform an installation following the procedures provided in this document, contact ChargePoint, Inc. ChargePoint, Inc. is not responsible for any damages that may result from custom installations that are not described in this document or for any failure to adhere to installation recommendations. iii Copyright and Trademarks ©2013-2019 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. Symbols Used in This Document This guide and product use the following symbols: DANGER: Risk of electric shock. WARNING: Risk of personal harm or death. CAUTION: Risk of equipment or property damage. Important: Crucial step for installation success. Read the manual for instructions. Ground/protective earth. iv v Contents 1 Site Design Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Pairing Two Express 250s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Initial Site Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Plan for Future Charging Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Charging Station Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2 Civil and Mechanical Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Mounting Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Wheel Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Bollards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Pairing Previously Installed Charging Stations . . . . . . . . . . . . . . . . . . 14 Accessibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Signage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3 Electrical Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Upstream Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Transformer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 AC Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 RCD Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Grounding/Earthing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Shunt Trip Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Wiring Requirements for Standalone Stations . . . . . . . . . . . . . . . . . . 22 Additional Wiring Requirements for Paired Stations . . . . . . . . . . . . . 22 Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Cellular Connectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 4 The Express 250 Concrete Mounting Template . . . . . . . . . . . . . . . . 27 Bring Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 vi CPE250-CMT Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Assemble the CPE250-CMT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Install the CPE250-CMT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Appendix A Examples of Express 250 Paired Wire Sizing . . . . . . . . . . 33 1 1Site Design Guidelines This document describes how to design an installation site for the ChargePoint® Express 250 DC fast charging station, and install the Concrete Mounting Template, before station installation. The Express 250 is a DC fast charging station for electric vehicles. Each charging station communicates with ChargePoint using a cellular network. This connectivity is required for diagnostics and reporting, as well as communication with the online dashboard that allows the station owner to control its settings and commands. See the section Cellular Connectivity (page 26) for detailed information. Access ChargePoint documents online at chargepoint.com/guides or chargepoint.com/eu/guides for each phase of the project: Installing the Express 250 requires two people and takes approximately 3-4 hours. This time estimate does not include the time needed to pull DC and Ethernet cable for a Paired installation if it is not already done. Paired installation might also require contacting a ChargePoint support technician to perform any required software updates and configuration if a station is being Important: Always follow all applicable local and national codes and requirements. A site drawing should be engineered for your specific site to reduce installation costs and ensure compliance with local codes. Local authorities might not allow a unit to operate if it is not installed to code. Document Content Audiences Express 250 Data Sheet Full station specifications Site designer, installer, and station owner This document Civil, mechanical, and electrical guidelines to scope and construct the site Site designer or engineer of record Concrete Mounting Template Guide Onsite instructions for installing the CMT with anchor bolts and conduit placement Site construction contractor Express 250 Installation Guide Anchoring, wiring, and powering on Installer Express 250 Operations and Maintenance Guide Operation and preventative maintenance Station owner or facility manager Full set of Field Replacement Guides Component replacement procedures Station owner or third party servicer http://www.chargepoint.com/guides http://www.chargepoint.com/guides 2 retrofitted from Standalone to Paired. Pairing Two Express 250s The Express 250 can be installed either as a standalone system, or paired with another Express 250 using a DC connection to more flexibly share load. The two Power Modules in the base of each charging station can be shared in any combination according to charging need. This allows high power output in sites with space constraints. To pair two Express 250 charging stations, all of the following are required: • Additional conduit, ducting, or armored cable (according to region) correctly installed between the two charging stations for DC conductors and Ethernet wiring • Both Express 250s must have 62.5 kW power enabled (not allowed on stations only enabled for 50 kW) • Both Express 250s must be provisioned for full power back to the panel (not allowed on “power select” stations) Initial Site Guidelines An onsite evaluation is needed to determine conduit and wiring requirements from the panel to the proposed parking spaces, as well as to measure cellular signal levels and identify suitable locations for any necessary cellular signal booster equipment. If you have pre-existing infrastructure or are using your own preferred electrical contractor to prepare your site, a completed Construction Signoff Form is required to certify compliance with electrical specification requirements, and to ensure everything was prepared to ChargePoint specifications. Plan for Future Charging Capacity ChargePoint recommends that you plan to install charging stations for 5-10% of parking spaces, or Important: All installers must be licensed electricians and complete an online training course to become a ChargePoint certified installer. Installers who do not complete installation training cannot access the ChargePoint Network to complete pinpointing and station setup.To complete online training and become a certified installer, refer to ChargePoint University at: chargepoint.com/installers or chargepoint.com/eu/installers Important: Always check local codes or consult an engineer to ensure the site is prepared in compliance with all applicable regulations. Local authorities might not allow a unit to operate if it is not installed to code. http://chargepoint.com/installers http://chargepoint.com/eu/installers 3 10-15% for high EV adoption areas like California. Designing electrical infrastructure to support current and future needs for EV charging helps avoid costly upgrades later as demand for EV charging grows. Consider these methods to prepare a site for future charging stations in a later phase of work: • Add extra capacity if electrical panels are being upgraded now • Use sub-panels as a way to shorten electrical paths • Oversize the conduit between the main electrical panel and future stations • Install pull or junction boxes at the end of an existing row of charging stations, to ease cable pulls for future stations • If a junction box or disconnect will be installed between rows of stations, oversize the wiring between the main panel and the junction box to prevent needing to re-pull wire later Charging Station Placement To help minimize costs, choose station locations that are as close as possible to the available electrical infrastructure. Selecting these types of locations helps minimize long conduit and wire runs, as well as any trenching work. Layout considerations: • Determine appropriate ground anchoring locations where concrete exists or can be installed (no asphalt surfaces). • Consider locations where it will be easy to add future stations. • Determine optimum conduit layout to minimize linear conduit costs to multiple parking spaces. If possible, avoid or minimize trenching requirements, especially more costly trenching to run conduit under asphalt surfaces. • Evaluate existing electrical infrastructure to determine if the existing utility service and electrical panel capacity is sufficient. Identify costs for any necessary upgrades and/or a new dedicated electrical panel. ChargePoint recommends using a certified electrician to evaluate available capacity and identify any upgrades that may be required. • If a dedicated EV electrical panel is required, choose a panel location in close proximity to the existing electrical supply. • Measure cellular signal levels to ensure adequate cellular coverage at the station installation location. To ensure adequate signal strength in underground or enclosed parking structures, cellular repeaters may be required. For more information, see Cellular Connectivity (page 26). • ChargePoint recommends to avoid locations under trees where sap, pollen, or leaves would fall on the charging station and increase the station owner’s site upkeep workload. WARNING: The ChargePoint charging station must be installed on a level concrete base. Asphalt cannot support the full weight of the charging station. Failure to install the ChargePoint charging station on a level concrete base may cause the charging station to tip over, resulting in death, personal injury, or property damage. 4 • For stall parking, ChargePoint recommends using perpendicular parking stalls that allow a vehicle to enter either front-first or rear-first, to better accommodate the varied charge port locations on different EVs. Diagonal stall parking is not advised. Note: While ChargePoint tests charging stations with a majority of upcoming vehicles, ChargePoint cannot guarantee the port locations of future vehicles and cannot warrant the configurations proposed will work for all vehicles. • Choose adjacent parking spaces in an area with adequate lighting. • Consider how easily drivers can find the stations they need to access. • Check local requirements for accessibility and pathway width, sometimes called “path of travel”, to ensure station placement does not restrict sidewalk use. • Building a pad into the head of a parking space (instead of on the sidewalk) is allowed if a) local code allows it compared to the minimum parking space length, and b) the pad meets all pad requirements listed in this document. • Note that the Express 250’s two charge cables are different types of connectors to maximize usability across EV models. The cables cannot both be used at the same time. Therefore, do not position an Express 250 to share two parking spots. • Pull-through parking (gas station model) is not recommended. If pull-through parking is used, ChargePoint recommends placing at least one charging station on each side of the island. This avoids situations where the charging station is on the opposite side of the vehicle from the charge port. Guidance for station placement in island or curbside parking is shown below. Important: Place each charging station centered at the head of its parking space, with the touchscreen facing the vehicle. This placement maximizes cable reach for the varied charge port locations on different EVs. a. 3.76 m (148 in) b. 609 mm (24 in) 5 a. Distance from left space marking: 3048 mm (120 in) maximum b. Distance from right space marking: 4876.8 mm (192 in) c. Distance from curb: 457.2 mm (18 in) d. Cable reach radius: 3.76 m (148 in) e. Example EV length: 4978.4 mm (196 in) f. Recommended parking space length: 7924.8 mm (312 in) g. Recommended parking space width: 2743.2 mm (108 in) 6 7 2Civil and Mechanical Design Use the guidance below to design the civil and mechanical aspects of the site. Component Dimensions and Weights The Express 250 is a vertical enclosure with the dimensions shown here. Component Weight Each Power Module 44 kg (97 lb) Crated Power Module as shipped 49.9 kg (110 lbs) Express 250 with two Power Modules, installed 339 kg (746 lb) Crated Express 250 as shipped 494 kg (1089 lb) 712 mm (28 in) 2230 mm (87.8 in) 420 mm (16.5 in) ~ 1118 mm (44 in) 8 Pad The station can be installed on either a newly poured pad or an existing concrete surface. The mounting surface must be smooth and cannot exceed a slope of 6.35 mm per 304.8 mm (0.25 inches per foot). The concrete pad must either be designed to be site-specific, or must meet these specifications: • At least 305 mm (12 in) deep (or deep enough to be 305 mm (12 in) below the frost line) • At least 1296 mm (51 in) on each side • Contains #4 rebar or larger, top and bottom, 305 mm (12 in) on center • Concrete 2500 PSI minimum The above pad specifications are designed to meet these conditions: • 170 mph wind speed • Wind Risk Category I • Wind Exposure D • Seismic Importance Factor 1.0 • Hayward Fault with mapped spectral response accelerations Ss=2.45 S1=1.019 • Seismic Design Category E • Foundation of Sandy Soil with allowable stress = 1500 psf, Cd = 1.33 In some extreme conditions, a larger pad would be required. For sites with less stringent seismic, soil, or wind conditions, a smaller pad might be possible. If the existing pad does not meet the specifications above, it must be inspected and approved by a structural engineer for the Express 250’s dimensions and weight. If needed, give these structural design specifications to the structural engineer for verification: Product Weight 340 kg (750 lbs) Product Height from Ground 2.230 m (7.317 ft) Product Width 0.71 m (2.33 ft) Product Frontal Area Height * Width CG Height 1.12 m (3.66 ft) Number of Anchor Bolts 4 Bolt Pattern See dimensioned images in this section Anchor Bolt Size M16 (5/8 in) Anchor Bolt Embedment 229 mm (9 in) 9 Drainage Ensure any site slopes, walls, or fencing do not trap water around the charging station installation site. The system is only built to withstand 457.2 mm (18 in) of standing water. Mounting Specifications The Express 250 is installed on a concrete pad. Details on how to prepare this pad are described later in this guide. All installations require four anchor bolts (a). Standalone installations only require the two conduit stub-ups on the left side, for AC wiring and shunt trip wiring (b). Paired installations also require the wiring shown on the right: DC wiring and Ethernet communication (c). For more detail, see Conduit (page 21). WARNING: If not installed correctly, the ChargePoint® charging station may pose a fall hazard, leading to death, personal injury, or property damage. Always use the provided Concrete Mounting Template or a ChargePoint-approved surface mounting solution to install the ChargePoint® charging station and install in accordance with applicable codes and standards using licensed professionals. Non-approved installation methods are performed at the risk of the contractor and void the Limited Warranty. WARNING: Exposing the ChargePoint® charging station to over 18 inches (457 mm) of standing water could create an electrocution, shock, or fire hazard. Cut power to the charging station if it has been exposed to standing water and contact ChargePoint before the charging station is powered on. Important: Although the Concrete Mounting Template was originally designed for six anchor bolts, only the four corner anchor bolts are required for station stability. Newer charging stations are designed to only use the four corner anchor bolts. If older sites were already designed with six anchor bolts, removing the middle bolts is not required. WARNING: If not installed correctly, the ChargePoint® charging station may pose a fall hazard, leading to death, personal injury, or property damage. Always use the provided Concrete Mounting Template shown pre-installed in the Introduction, or a ChargePoint- approved surface mounting solution, to install the ChargePoint® charging station. Always install in accordance with applicable codes and standards using licensed professionals. Non-approved installation methods are performed at the risk of the contractor and void the Limited One-Year Parts Exchange Warranty. 10 Clearances The Express 250 requires minimum functional and service clearances as listed in the table below. * Side clearance is measured from extrusion to extrusion. ** Side clearance can be shared between two charging stations. However, if the charge handles of both stations are facing each other, add an extra 254 mm (10 in). Measurements are provided in millimeters (inches). a. Service clearance of open space (not necessarily at system grade) b. Power Module service clearance at grade from the front right anchor, extending 1700 mm (67 in) to the left, without any permanent obstructions (fencing, bollards, wheel stops, etc.) Note: Listed side clearances are the minimum required for operation and service. For paired charging stations, the bend radius of the DC cable and conduit might require spacing them further apart. Rear clearance, and the front and side clearance for Power Module service, must be at grade level +/- 25 mm (1 in). Refer to the “Ventilation” section, and check local and regional code, for any additional clearance requirements. Front Clearance 330.2 mm (13 in) at grade; 609.6mm (24 in) minimum open space Side Clearance* 711.2 mm (28 in) required; 863.6 mm (34 in) recommended** Rear Clearance 304.8 mm (12 in) required; 609.6 mm (24 in) recommended Top Clearance 304.8 mm (12 in) 280 (11) 352 (14) 1305 (51.4) 610 (24) 63 (2.5) 666 (26) 1700 (67) 851 (33.5) 271 (10.7) 454 (17.9) 11 Ventilation Ensure that any installation, especially an indoor installation, has adequate airflow to dissipate the charging station’s heat at maximum operation. Each Express 250 charging station emits approximately 3.3 kW of waste heat at maximum operation. The charging station location must allow fresh ambient airflow. Restriction of airflow might result in reduced maximum performance. Do not install a station where it is exposed to air that is heated above ambient temperatures. In addition to the service clearances listed in the “Clearances” section, consider these figures for site layout: • If a charging station will have a wall directly behind it, minimum rear clearance is 305 mm (12 in). • If two Express 250 charging stations will be positioned back to back, increase the rear clearance to a shared 610 mm (24 in) for both stations to reduce exhaust recirculation. Wheel Stops Bollards and wheel stops are not explicitly required by ChargePoint. However, ChargePoint recommends these best practices and considerations when designing the site: • Permanent bollards or wheel stops must not encroach upon the Power Module clearance listed in the clearance diagram above. Removable bollards are allowed if service personnel have the ability to move them as needed. • Where permitted by code, wheel stops are preferred over bollards for head-in or back-in spaces. • When using wheel stops, consider the average vehicle overhang distance from tire to bumper (passenger, bus, etc.), as well as leaving space for the driver to walk up and access the touchscreen. General recommended distances are shown in the wheel stop image below. • Position wheel stops to actively block at least one wheel, without presenting a trip hazard to pedestrians walking between vehicles. 12 a. Wheel stop, positioned to actively block at least one wheel b. Cable reach radius: 3.76 m (148 in) c. Recommended distance for walk-up access: 609 mm (24 in) d. Recommended distance between wheel stop and Express 250: 1371 mm (54 in) for passenger vehicles Note: For fleet or commercial use, measure the rear or front overhang of the largest vehicle in use, depending on charge port location. Bollards Bollards and wheel stops are not explicitly required by ChargePoint. However, ChargePoint recommends these best practices and considerations when designing the site: • Permanent bollards or wheel stops must not encroach upon the Power Module clearance listed in the clearance diagram above. Removable bollards are allowed if service personnel have the ability to move them as needed. CAUTION: Shorter wheel stops that are installed in the center of a parking spot can fit between the wheels of a larger vehicle and not prevent forward motion. 13 • Where permitted by code, wheel stops are preferred over bollards for head-in or back-in spaces. • When bollards are required by code, needed for snowy areas, or needed for curbside spaces, ensure bollard placement does not interfere with removing and replacing charge cables in the station’s side holsters. General recommended distances are shown in the bollard images below. • Try to minimize bollard interference with the movement of charge cables between the station and the vehicle. Bollards are recommended to be no taller than 914 mm (36 in) where needed. • No bollard can be placed within 457 mm (18 in) of the station, as measured on-center. Curbside bollard installation: a. Use and service clearance of open space (not necessarily at grade) b. Unobstructed front service clearance at grade 14 Head-in or back-in space bollard installation: Pairing Previously Installed Charging Stations If all site construction for paired charging is completed in advance, Express 250 stations can be initially installed as Standalone and paired at a later date. In that case, follow these additional steps: • During initial site construction, install DC and communication conduit or ducting (as applicable by region) in advance. • Extend side clearance at both DC conduit stub-up locations to 1.2 m (4 ft) to allow space for cable pulling equipment. • Run a pull rope through the larger DC conduit before landing the charging stations. Do not pull DC cable in advance, as it is too thick to hide inside the cover panels without risking damage or unwanted electrical contact. • Install a fishing tape in the smaller communication conduit to assist with routing the Ethernet cable later. If Ethernet is pulled in advance, leave 317.5 cm (125 in) of wire above grade at each end. • Use duct seal compound to seal the ends of the DC and communications conduit stub-ups. Seal the ends of the fishing tape to hang outside the conduit. • Install the cover panels and extrusions on the Express 250 stations over the stub-ups as normal. By only connecting AC wiring (and shunt trip if applicable), each Express 250 can perform as a Standalone station until the station owner is ready to pair them. At a later time, the stations can be paired by installing DC conductors, connecting Ethernet communication, and performing a firmware update if required. Refer to the Express 250 Installation Guide for further details. Once two Express 250s are correctly paired, operation of both stations is inhibited if Ethernet 15 connectivity is lost or one station loses power. This is a safety feature to prevent one Paired station from accidentally powering the other during maintenance. Accessibility The Express 250 touchscreen and charging cables are accessible at a height of less than 1219 mm (48 in) from the ground. This complies with American Disability Act (ADA) requirements, if the station is installed at grade. If your installation must comply with ADA standards, or the disability access regulations for other regions, consider this when designing the height of the pad. Also consider site design factors such as placement of bollards, wheel stops, or other vehicle obstacles when planning charging station access for disabled parking stalls. Check disability access regulations for guidance on the clearances needed for wheelchair access to charging cables and user interfaces. Signage Refer to local and regional code to design the following elements for the site: • Any required re-striping of parking spaces • EV or Accessible EV signs • EV or Accessible EV paint markings on and around the parking spaces WARNING: Do not connect DC power between the charging stations until both stations are ready to complete the full pairing configuration. Station firmware updates are required to enable full Paired behavior. Connecting power before the charging station is properly configured can create a safety risk or can damage equipment. 16 17 3Electrical Design The default Express 250 installation requires service wiring to be installed underground. (If a site requires surface mounting, contact ChargePoint before beginning work, to obtain an approved surface installation method.) Conduit and wire size are determined based on the length of runs from the electrical panel to the station location. Service wiring must be run through conduit or ducting, or use armored cable, 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. The ChargePoint Concrete Mounting Template (CPE250-CMT) accommodates service wiring through the flare, conduit, or locally appropriate wiring method. Note: All wiring and conduit is supplied by the contractor unless otherwise indicated. Note: It is possible to pre-install Express 250 charging stations as Standalone initially and pair them at a later date, if desired. In this case, install the DC and Ethernet conduit per Pairing Previously Installed Charging Stations (page 14), and run a pull rope through the conduit before landing the charging stations. Contact ChargePoint for instructions to pair two charging stations when ready. Upstream Components Charging stations are considered continuous load devices (EVs draw maximum load for long durations). Therefore, electrical branch circuits to EV chargers must be sized at 125% of the load on each leg of a 3-phase panel for North America installations, in accordance with National Electric Code requirements. For other regions, refer to local code. When planning multiple EV charging stations, it is best practice to segment non-continuous and continuous loads, with all branch circuits for EV charging on a dedicated electrical panel assembly with adequate circuit breakers. When sizing new electrical panels dedicated for EV charging, all branch circuits must support continuous load. Each Express 250 requires a service panel breaker as follows: The Express 250 does not contain an internal breaker. Therefore, its KAIC rating (KiloAmps Nominal Voltage Max AC Current Circuit Breaker Size 400 VAC (EU) 96 A 125 A 480 VAC (NA) 80 A 100 A (125% continuous load required for N. America) 18 Interrupt) is related to the station’s upstream breaker. Transformer Configuration Refer to the following tables to configure electrical service. *Delta (floating or grounded) is not supported AC Disconnect Switch A local AC disconnect switch, separate from the shunt trip wiring, is recommended to be installed between each charging station and the electrical panel. This is especially important if the main electrical panel or utility room is distant, out of line of sight, or has restricted access. For North America installations, refer to disconnect switch requirements per NEC Article 625, “Electric Vehicle Charging and Supply Equipment Systems”. Do not install a DC disconnect between Paired charging stations. RCD Use The use of an RCD is not recommended. RCD use can create nuisance tripping, especially during transient conditions such as power restoration, line surge, line dips, or phase loss. To reduce the risk of shock, the Express 250 provides: • Galvanic (reinforced) isolation between the AC input and DC output. Current does not flow to earth ground, even in cases such as charge cable damage. • An output isolation monitor interrupter (IMI). If the isolation level is compromised, charging is halted or prevented from starting, and the output CAUTION: The Express 250 charging station is tested to IEC 61000-4-5, Level 5 (6 kV @ 3000 A) standards. In geographic areas that experience frequent thunderstorms, supplemental surge protection must be installed at the service panel to guard against product damage. North America Europe Input Rating 480 VAC, 3-phase, 80 A, 60 Hz 400 VAC, 3-phase, 96 A, 50 Hz Electrical Service Configuration 277/480 4 wire WYE* 230/400 Y, L1, L2, L3, N, Ground Product Connection 3-phase 480 plus ground (neutral not required) 3-phase 400 plus protective earth (neutral not required) WARNING: If service is performed on either Paired charging station, both stations must be powered off at their AC disconnect switch(es) and locked out/tagged out for safety. 19 de-energized. The isolation monitor operates continuously during charging to ensure the output is always galvanically isolated. UL 2231-1 requires that an isolation monitor interrupter (IMI) is provided in the product and evaluated during operation as part of certification testing. Although RCD/GFCI use is required in mode 1,2,3 AC charger installations, neither UL nor IEC mandate an RCD for a permanently installed mode 4 isolated output DC charger. RCD Settings For Standalone Express 250 installations where the use of an RCD (RCCB or RCBO) cannot be avoided, use the following settings to minimize nuisance trips: • Type: A, F or B (type B and F preferred) • Trip threshold: 500 mA • Trip delay: 150 ms If an RCD must be employed for a Paired installation, contact ChargePoint. Region Specific Notes: UK When discussing DC charging station installations with a UK DNO (utility), include these two considerations: • Where possible, request TN-S earthing from the DNO (distribution network operator) • The Express 250 represents a Class I construction, balanced 3-phase load greater than 500 W Either statement allows UK DNOs to provide a PME earth terminal and avoids the requirement for a TT earthing arrangement and associated (300 mA) RCD. The second statement meets the clause in the IET Code of Practice for EV Charging Equipment Installation, 3rd Edition that allows the DNO to provide a PME connection for “on the street equipment”. Installations at petrol stations are a special case that requires additional site planning. Contact ChargePoint for more information. Grounding/Earthing Requirements • The Express 250 must be connected to a grounded, metal, permanent wiring system. • North America: A grounded service neutral conductor must be run with circuit conductors and connected to an equipment-grounding terminal on the Express 250. • Europe: Use TN-S or TN-C-S configurations. (TT is not recommended because it requires RCDs.) • 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. 20 Shunt Trip Wiring ChargePoint advises against installing an emergency stop (E-stop) button on charging stations. Drivers can unintentionally trip the emergency shutoff, causing inconvenience and downtime to site hosts. However, wiring to enable a remote shunt trip is standard on each Express 250. This shunt trip wiring is activated when unsafe conditions are detected, such as a missing cover panel or a severe impact. All shunt trip behavior is already hard-coded into the charging station and has no programmable variables. The Express 250 provides a set of unpowered (dry pair) contacts near the AC input terminals, to connect to a shunt trip device. These contacts are rated to 440 VAC and 5 ARMS. When a shunt trip is used, select a breaker with a shunt trip that is within the contact rating of the Express 250 shunt trip contacts. Common ratings available for shunt trips are 12, 24, or 48 VDC, or 110-240, 400 VAC depending on the installation region. 480 VAC rated shunt trips may not be used. Follow the installation guide provided by the breaker or shunt trip vendor. Control power is derived at the electrical panel. Note: For Paired charging stations, wire the connections so that a shunt trip activation on either station trips the breakers of both Paired stations. a. Electrical panel b. Express 250 c. Circuit breakers d. Shunt trip e. Control power (fused) f. Express 250 shunt trip terminal block (near AC terminals) 21 Conduit The outer diameter of conduit or armored cable must not exceed the sizes called out in the conduit layout drawing below. Conduit stub-ups cannot extend higher than 76.2 mm (3 in) above the surface of the concrete pad. In regions that do not use conduit, armored cable may be laid in the same configuration to conform to the wire placement as shown in the section, “The Express 250 Concrete Mounting Template (page 27)”. Ensure a length of at least 61 cm (2 ft) is left free above grade at each end to allow the wiring to reach the charging station AC terminals. a. Shunt trip conduit: 19.1 mm (3/4 in trade size) b. AC conduit: 50.8 mm (2 in trade size) c. Anchor bolts d. Paired installations only: Ethernet conduit: 19.1 mm (3/4 in trade size) e. Paired installations only: DC conduit: 76.2 mm (3 in trade size) f. Concrete surface g. Concrete Mounting Template (embedded in concrete) Note: Ensure no bell ends are left on any conduit after all wires are pulled. Bell ends can interfere with station placement. Note: Depth of conduit or armored cable may vary by site. The image above does not dictate conduit depth, as long as the stub-ups are vertical and placed correctly. 22 Wiring Requirements for Standalone Stations For full product specifications, refer to the Express 250 Data Sheet. Using that data, ensure that the installation location is equipped with service wiring that supports the Express 250’s power requirements: • Neutral conductor as required by region (a Neutral connection is not required for equipment operation and the terminal is provided for convenience only) • Shunt trip wiring: size 0.08 to 2.5 mm2 (28 to 14 AWG), fine stranded or solid • AC conductors (L1, L2, L3) and ground per the following specifications: Additional Wiring Requirements for Paired Stations For stations that will be installed as Paired, follow all AC wiring requirements above as well as the following additional wiring. Note: Be sure to acquire, or alert the installer to acquire, lugs in advance of the site visit. Contact ChargePoint in advance if help is required to obtain lugs. • Ethernet wiring for DC: • Minimum of CAT5e or better • Outdoor or plenum rated wiring • Maximum run length of 100 m (328 ft) • Leave 3.2 m (10.5 ft) of wire above grade at each end • Field crimp using straight-through pattern 568B Important: The AC terminal blocks on the Express 250 accept a maximum wire size of 35 mm2 (2 AWG) solid or stranded wires. If using a larger gauge wire to accommodate a long run, reduce the wire size at the local external disconnect. Voltage Rating Temperature Rating Maximum Conductor Size for Terminals EU non-armored: 600/1000 V 90°C 35 mm2 EU armored: 600/1000 V 90°C 35 mm2 multi-core NA: 600 V 90°C 2 AWG Important: The DC terminal blocks on the Express 250 can accept a maximum wire size of 120 mm2 (4/0 AWG). Check site plans and local code for site-specific requirements. 23 • DC conductors (x4): • NOTE: 95 mm2 (3/0 AWG) is sufficient for most sites unless ambient temperatures are >= 40°C per regional code (ASHRAE Table D101 Summer Dry Bulb Temperature for North America or IEC 60364-5-54 in Europe) • 2 positive and 2 negative conductors; 1 positive and 1 negative in each direction • USA/Canada: Copper only, minimum current carrying capacity 160 A • EU/UK: Rated at 1000 V conductor to conductor (+/-500 V conductor to ground, LV), copper only, minimum current carrying capacity 160 A • DC cable run must be continuous, with no joints or splices • Consult site drawings for site-specific conductor size and length (Appendix A provides conductor size calculation examples for reference) • Leave 61 cm (2 ft) of each conductor above grade at each end • DC lugs (x4): • Silver plated copper compression lug (2-hole specified for North America); tin plated is acceptable if used with dielectric grease • Holes for an M6 (1/4 in) stud at 19 mm (3/4 in) stud hole spacing • Maximum width 30 mm (1.18 in) • NOTE: 95 mm2 (3/0 AWG) is sufficient for most sites unless ambient temperatures are >= 40°C per regional code (ASHRAE Table D101 Summer Dry Bulb Temperature for North America or IEC 60364-5-54 in Europe) • North America lug size: 3/0 or 4/0 AWG • Example UK/EU lugs for average conductor size are Weidmuller 1494410000 120 mm2 or similar (always review the lug manufacturer’s instructions for crimper tool and die compatibility) • Contact ChargePoint if the installer requires lugs for 3/0 (kit 99-002644) or 4/0 (kit 99- 002645) conductors Voltage Rating Temperature Rating Maximum Conductor Size for Terminals Insulation Type EU non-armored: 600/1000 V 90°C 120 mm2 XLPE EU armored: 600/1000 V 90°C 120 mm2 4-core and cable gland sized to local code (such as Cablecraft CCG-CW50 or similar) XLPE NA: 1000 V 90°C 4/0 AWG XHHW-2 24 When DC conductors are pulled through conduit, label each end of each DC conductor to aid installation as follows: • “Station 1 A+” on one end and “Station 2 B1+” on the other end • “Station 1 A-” on one end and “Station 2 B1-” on the other end • “Station 1 B1+” on one end and “Station 2 A+” on the other end • “Station 1 B1-” on one end and “Station 2 A-” on the other end CAUTION: Be sure to connect positive to positive, and negative to negative, on the same wire. Do not reverse the polarity. 1 2 25 Wiring Diagram