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Difference between revisions of "Charging Stations"

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(Section for my Open-EVSE)
(copy edit from private wiki)
Line 12: Line 12:
 
=== Ryans Open-EVSE ===
 
=== Ryans Open-EVSE ===
 
{{Clear}}
 
{{Clear}}
 +
All of the OEM Replacement portable units and permanent home installation units appear to cost well over $1000.
 +
So I decided to look into other options such as building my own.
 +
At this point I have built one of three units.
 +
I have yet to add true energy monitoring but intend to add that feature.
 +
Stay tuned as I update this information.
 +
 +
==== Parts List ====
 +
{| class="wikitable sortable"
 +
! Part !! Source !! Cost !! Quantity !! Link
 +
|-
 +
| Open EVSE Plus Board w/ integrated power supply || Open EVSE ||$150.00||1|| http://code.google.com/p/open-evse/wiki/Ordering
 +
|-
 +
| J-1772 cable, 30 amps (A3435-PEV)              || Leviton  ||$133.98||1|| http://store.leviton.com/b/5742800011 +$12.19 shipping
 +
|-
 +
| 30A AC Plug L6-30                              ||Stay Online|| $33.00||1|| http://www.stayonline.com/detail.aspx?ID=15695 ''Good for the plug and an adapter cable''
 +
|-
 +
| RELAY GEN PURPOSE DPST 30A 12V (PB486-ND)      || Digikey  || $13.03||1|| http://www.digikey.com/product-detail/en/T92P7D22-12/PB486-ND/365921
 +
|-
 +
| TRANSFORMER GROUND FAULT WIRE LD (582-1018-ND)  || Digikey  || $10.65||1|| http://www.digikey.com/product-detail/en/CR8420-1000-G/582-1018-ND/1045174
 +
|-
 +
| BOX NEMA ECONOMY 5.9X5.9X3.54 (377-1787-ND)    || Digikey  || $20.62||1e|| http://www.digikey.com/product-detail/en/NBF-32210/377-1787-ND/2328559
 +
|-
 +
| PANEL INTERNAL 4.9" X 4.9" (377-1939-ND)        || Digikey  ||  $4.80||1e|| http://www.digikey.com/product-detail/en/NBX-10984/377-1939-ND/439528
 +
|-
 +
| BOX ABS 7.62X4.47X2.47" TR BL (HM1056-ND)      || Digikey  ||  $9.35||1e|| http://www.digikey.com/product-detail/en/1591XXETBU/HM1056-ND/2094794 ''Alternate Enclosure'' [http://www.digikey.com/product-detail/en/1591XXDTBU/HM1055-ND/2094793 6.0x3.3x2.0 $7.23] [http://www.digikey.com/product-detail/en/1591XXCTBU/HM1053-ND/2094791 4.8x2.6x1.6 $5.40]
 +
|-
 +
| 2" plastic 4-40 M-F standoffs (4813K-ND)        || Digikey  ||  $0.63||8|| http://www.digikey.com/product-detail/en/4813/4813K-ND/255350 [http://www.digikey.com/product-detail/en/4800/4800K-ND/255337 7/16"]
 +
|-
 +
| Terminal Blocks - Barrier Blocks                || Digikey  || ~$5.00||2|| '''[http://www.digikey.com/product-detail/en/39100-1004/WM15910-ND/809417 euro 4x 30A 10-18AWG $1.77]''' [http://www.digikey.com/product-detail/en/0391001104/WM5050-ND/2709057 euro 4x 30A 10-18AWG $1.49] [http://www.digikey.com/product-detail/en/0391001003/WM15908-ND/894440 euro 3x 30A 10-18AWG $1.31] <s>[http://www.digikey.com/product-detail/en/38280-0105/WM5818-ND/362427 Barrier Block 5x 50A 6AWG $12.85]</s>
 +
|-
 +
| FUSEHOLDER 1/4" 30A 250V PNL MNT (283-2850-ND)  || Digikey  ||  $3.69||2f|| http://www.digikey.com/product-detail/en/BK%2FHKP-R/283-2850-ND/1024094
 +
|-
 +
| FUSE BLOCK 3AG 1POS SOLDER (F1497-ND)          || Digikey  ||  $1.13||2f|| http://www.digikey.com/product-detail/en/03540001ZXGY/F1497-ND/553961
 +
|-
 +
| FUSE 250V SLO-BLO 3AB 30A (F1779-ND)            || Digikey  ||  $1.68||2f|| http://www.digikey.com/product-detail/en/0326030.MXP/F1779-ND/778640 
 +
|-
 +
| CIR BRKR THRM 30A PUSH-RESET (302-1268-ND)      || Digikey  ||  $5.37||2f|| http://www.digikey.com/product-detail/en/1658-G21-01-P10-30A/302-1268-ND/659615 ''Replaces Fuses''
 +
|-
 +
| CONN TERMINAL STRIP 4CIRC 10MM (WM15910-ND) 10-18WG||Digikey ||  $1.77||2c || http://www.digikey.com/product-detail/en/39100-1004/WM15910-ND/809417
 +
|-
 +
| CONN TERMINAL STRIP 4CIRC 12MM (WM7725-ND) 8-20AWG||Digikey  ||  $1.94||2c || http://www.digikey.com/product-detail/en/39100-1204/WM7725-ND/1280576
 +
|-
 +
| STANDOFF M/F HEX 4-40 NYL .250"L (4800K-ND)    || Digikey  || $0.397||8(10) || http://www.digikey.com/product-detail/en/4800/4800K-ND/255337
 +
|-
 +
| STANDOFF M/F HEX 4-40 NYL .500"L (4802K-ND)    || Digikey  || $0.442||0 ||
 +
http://www.digikey.com/product-detail/en/4802/4802K-ND/255339
 +
|-
 +
| STANDOFF M/F HEX 4-40 NYL 1.00"L (4806-ND)      || Digikey  || $0.476||0 || http://www.digikey.com/product-detail/en/4806/4806K-ND/255343
 +
|-
 +
| STANDOFF M/F HEX 4-40 NYL 2.00"L (4813K-ND)    || Digikey  || $0.528||4(10) || http://www.digikey.com/product-detail/en/4813/4813K-ND/255350
 +
|-
 +
| HEX NUT 1/4" 4-40 100/PK (H216-ND)              || Digikey  ||$0.0149||100|| http://www.digikey.com/product-detail/en/HNZ%20440/H216-ND/5738
 +
|-
 +
| MACHINE SCREW PAN PHILLIPS 4-40 (H542-ND)      || Digikey  ||$0.0886||100|| http://www.digikey.com/scripts/dksearch/dksus.dll?keywords=NY+PMS+440+0025+PH
 +
|-
 +
| AdaFruit RGB LCD Shield kit                    || AdaFruit  || $24.95||1d|| http://adafruit.com/products/714 or http://adafruit.com/products/716
 +
|-
 +
| Premium Female/Female Jumper Wires - 40 x 6"    || AdaFruit  ||  $6.95||1d|| https://www.adafruit.com/products/266 ''(Handy if adding a display)''
 +
|-
 +
| Liquid Tight Strain Relief                      || Alliedelec||  $3.20||2|| '''[http://www.alliedelec.com/search/productdetail.aspx?SKU=70075265 11-21 mm]''' or [http://www.alliedelec.com/search/productdetail.aspx?SKU=70075264 14-25 mm] or [http://www.alliedelec.com/search/productdetail.aspx?SKU=70074437 14-25 mm black]
 +
|-
 +
| Nut for Strain Reliev                          || Alliedelec||  $0.68||2|| [http://www.alliedelec.com/search/productdetail.aspx?SKU=70075291 PG-29 Nut Grey] or [http://www.alliedelec.com/search/productdetail.aspx?SKU=70074451 PG-29 Nut Black]
 +
|-
 +
| Shipping costs DigiKey, AdaFruit, StayOnline    ||            ||~$25.00||1||
 +
|-
 +
| Crimp Connectors/PCB connectors                || various    ||~$10.00||1||
 +
|-
 +
| Hardware (nuts & bolts)                        || various    || ~$5.00||1||
 +
|-
 +
| USBtinyISP AVR Programmer Kit-USB SpokePOV Dongle || AdaFruit || $22.00||?|| http://www.adafruit.com/products/46 ''(Optional)''
 +
|}
 +
 +
==== Parts Cost ====
 +
Parts for 1 to 3+ builds
 +
* $150.00 - OpenEVSE 1x v4 plus
 +
* $293.42 - leviton.com - 2x 30 Amp J1772 Connector with 25 Ft. Cord
 +
* $ 80.64 - stayonline.com - 2x L6-30 Cord 6 Feet
 +
* $188.00 - digikey.com - Relays, Breakers, Current Sensors, Enclosures
 +
*  $25.00 - adafruit.com - 1x RGB LCD Shield Kit w/ 16x2 Character Display
 +
* $ 36.30 - alliedelec.com - 4x Strain Relief, 10x Nuts
 +
* $ 73.04 - digikey.com - Stand Offs, Screws, Nuts, Terminal Blocks
 +
* $853.96 - Total
 +
----
 +
*  $50.00 - adafruit.com - 2x RGB LCD Shield Kit w/ 16x2 Character Display
 +
* $300.00 - OpenEVSE 2x v4 plus
 +
* $150.00 - leviton.com - 1x 30 Amp J1772 Connector with 25 Ft. Cord
 +
* $ 40.00 - stayonline.com - 1x L6-30 Cord 6 Feet
 +
* $1393.96 - Total including Remaining parts for 3 units '''(464.65 each)'''
 +
 +
==== Assembly ====
 +
[[Image:OpenEVSE Plus board.jpg|thumb|left|600px|Labelled OpenEVSE Board.<table width=100%><tr>
 +
<td>(top left )(6Pins) ISP = ??Unknown?? Programming header
 +
<br>(top right)(4Pins) I2C = Connection for Display    &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp;
 +
<br>
 +
<br>(left) AC Test 2 (Connect to AC Input, after relay) ??Confirm??
 +
<br>(left) AC Test 1
 +
<br>(left) AC Line 2 (Connect to AC Input, after fuse)
 +
<br>(left) AC Line 1
 +
</td>
 +
<td>(right) (2Pins) FTDI ??Unknown??
 +
<br>(right) K1772 Pilot (???? colored wire)
 +
<br>(right) Ground
 +
<br>(right) Relay Coil 12v (To Relay, polarity does not matter)
 +
<br>(right) Relay Coil 12v
 +
<br>(right) (2Pins) CT coil ??Unknown??
 +
<br>(right) (2Pins) CT Self Test (future) ??Unknown??
 +
</td></tr></table>
 +
]]
 +
 +
[[Image:OpenEVSE Plus board bottom.jpg|thumb|Back side of OpenEVSE]]
 +
 +
[[Image:OpenEVSE Display.jpg|thumb|Display Pins near buttons, (Pin3=Yellow, Pin4=Green, Pin5_to_Pin4, 6,Space,7,8,9,10, Pin11=Red, Pin12=Orange)]]
 +
 +
[[Image:OpenEVSE Display Connection.jpg|thumb|Display connects to 4 "IC2" pins. (Red, Orange, Yellow, Green (Corner of Board))]]
 +
 +
{{Clear}}
 +
==== Build Photos ====
 +
<Gallery>
 +
Image:20121220 003836.jpg|1
 +
Image:20121220 005325.jpg|2
 +
Image:20121220 005351.jpg|3
 +
Image:20121220 013540.jpg|4
 +
Image:20121220 013644.jpg|5 strike
 +
Image:20121220 013649.jpg|6
 +
Image:20121220 073516.jpg|7
 +
Image:20121220 074444.jpg|8
 +
Image:20121220 084752.jpg|9
 +
Image:20121220 090424.jpg|10
 +
Image:20121220 092011.jpg|11
 +
Image:20121220 093918.jpg|12
 +
Image:20121220 093931.jpg|13
 +
Image:20121220 094007.jpg|14
 +
Image:20121220 094353.jpg|15
 +
Image:20121220 094421.jpg|16
 +
Image:20121220 094550.jpg|17
 +
</Gallery>
  
 
[[Category:BEV components]]
 
[[Category:BEV components]]

Revision as of 00:43, 31 December 2012

A Charging Station is not a Battery charger which is a component found onboard the vehicle. Rather a Charging Station is a place that can supply electric power to an electric vehicle. This can be as simple as a standard 110v or 220v outlet or a W:SAE_J1772 station.

J1772

SAE J1772-2009 EV connector

SAE J1772 is a North American standard for electrical connectors for electric vehicles maintained by the Society of Automotive Engineers and has the formal title "SAE Surface Vehicle Recommended Practice J1772, SAE Electric Vehicle Conductive Charge Coupler”. It covers the general physical, electrical, communication protocol, and performance requirements for the electric vehicle conductive charge system and coupler. The intent is to define a common electric vehicle conductive charging system architecture including operational requirements and the functional and dimensional requirements for the vehicle inlet and mating connector.

There are many commercially available J1772 options as well as methods to build your own, such as the OpenEVSE Project - Open Source Design for EVSE.

Ryans Open-EVSE

All of the OEM Replacement portable units and permanent home installation units appear to cost well over $1000. So I decided to look into other options such as building my own. At this point I have built one of three units. I have yet to add true energy monitoring but intend to add that feature. Stay tuned as I update this information.

Parts List

Part Source Cost Quantity Link
Open EVSE Plus Board w/ integrated power supply Open EVSE $150.00 1 http://code.google.com/p/open-evse/wiki/Ordering
J-1772 cable, 30 amps (A3435-PEV) Leviton $133.98 1 http://store.leviton.com/b/5742800011 +$12.19 shipping
30A AC Plug L6-30 Stay Online $33.00 1 http://www.stayonline.com/detail.aspx?ID=15695 Good for the plug and an adapter cable
RELAY GEN PURPOSE DPST 30A 12V (PB486-ND) Digikey $13.03 1 http://www.digikey.com/product-detail/en/T92P7D22-12/PB486-ND/365921
TRANSFORMER GROUND FAULT WIRE LD (582-1018-ND) Digikey $10.65 1 http://www.digikey.com/product-detail/en/CR8420-1000-G/582-1018-ND/1045174
BOX NEMA ECONOMY 5.9X5.9X3.54 (377-1787-ND) Digikey $20.62 1e http://www.digikey.com/product-detail/en/NBF-32210/377-1787-ND/2328559
PANEL INTERNAL 4.9" X 4.9" (377-1939-ND) Digikey $4.80 1e http://www.digikey.com/product-detail/en/NBX-10984/377-1939-ND/439528
BOX ABS 7.62X4.47X2.47" TR BL (HM1056-ND) Digikey $9.35 1e http://www.digikey.com/product-detail/en/1591XXETBU/HM1056-ND/2094794 Alternate Enclosure 6.0x3.3x2.0 $7.23 4.8x2.6x1.6 $5.40
2" plastic 4-40 M-F standoffs (4813K-ND) Digikey $0.63 8 http://www.digikey.com/product-detail/en/4813/4813K-ND/255350 7/16"
Terminal Blocks - Barrier Blocks Digikey ~$5.00 2 euro 4x 30A 10-18AWG $1.77 euro 4x 30A 10-18AWG $1.49 euro 3x 30A 10-18AWG $1.31 Barrier Block 5x 50A 6AWG $12.85
FUSEHOLDER 1/4" 30A 250V PNL MNT (283-2850-ND) Digikey $3.69 2f http://www.digikey.com/product-detail/en/BK%2FHKP-R/283-2850-ND/1024094
FUSE BLOCK 3AG 1POS SOLDER (F1497-ND) Digikey $1.13 2f http://www.digikey.com/product-detail/en/03540001ZXGY/F1497-ND/553961
FUSE 250V SLO-BLO 3AB 30A (F1779-ND) Digikey $1.68 2f http://www.digikey.com/product-detail/en/0326030.MXP/F1779-ND/778640
CIR BRKR THRM 30A PUSH-RESET (302-1268-ND) Digikey $5.37 2f http://www.digikey.com/product-detail/en/1658-G21-01-P10-30A/302-1268-ND/659615 Replaces Fuses
CONN TERMINAL STRIP 4CIRC 10MM (WM15910-ND) 10-18WG Digikey $1.77 2c http://www.digikey.com/product-detail/en/39100-1004/WM15910-ND/809417
CONN TERMINAL STRIP 4CIRC 12MM (WM7725-ND) 8-20AWG Digikey $1.94 2c http://www.digikey.com/product-detail/en/39100-1204/WM7725-ND/1280576
STANDOFF M/F HEX 4-40 NYL .250"L (4800K-ND) Digikey $0.397 8(10) http://www.digikey.com/product-detail/en/4800/4800K-ND/255337
STANDOFF M/F HEX 4-40 NYL .500"L (4802K-ND) Digikey $0.442 0

http://www.digikey.com/product-detail/en/4802/4802K-ND/255339

STANDOFF M/F HEX 4-40 NYL 1.00"L (4806-ND) Digikey $0.476 0 http://www.digikey.com/product-detail/en/4806/4806K-ND/255343
STANDOFF M/F HEX 4-40 NYL 2.00"L (4813K-ND) Digikey $0.528 4(10) http://www.digikey.com/product-detail/en/4813/4813K-ND/255350
HEX NUT 1/4" 4-40 100/PK (H216-ND) Digikey $0.0149 100 http://www.digikey.com/product-detail/en/HNZ%20440/H216-ND/5738
MACHINE SCREW PAN PHILLIPS 4-40 (H542-ND) Digikey $0.0886 100 http://www.digikey.com/scripts/dksearch/dksus.dll?keywords=NY+PMS+440+0025+PH
AdaFruit RGB LCD Shield kit AdaFruit $24.95 1d http://adafruit.com/products/714 or http://adafruit.com/products/716
Premium Female/Female Jumper Wires - 40 x 6" AdaFruit $6.95 1d https://www.adafruit.com/products/266 (Handy if adding a display)
Liquid Tight Strain Relief Alliedelec $3.20 2 11-21 mm or 14-25 mm or 14-25 mm black
Nut for Strain Reliev Alliedelec $0.68 2 PG-29 Nut Grey or PG-29 Nut Black
Shipping costs DigiKey, AdaFruit, StayOnline ~$25.00 1
Crimp Connectors/PCB connectors various ~$10.00 1
Hardware (nuts & bolts) various ~$5.00 1
USBtinyISP AVR Programmer Kit-USB SpokePOV Dongle AdaFruit $22.00 ? http://www.adafruit.com/products/46 (Optional)

Parts Cost

Parts for 1 to 3+ builds

  • $150.00 - OpenEVSE 1x v4 plus
  • $293.42 - leviton.com - 2x 30 Amp J1772 Connector with 25 Ft. Cord
  • $ 80.64 - stayonline.com - 2x L6-30 Cord 6 Feet
  • $188.00 - digikey.com - Relays, Breakers, Current Sensors, Enclosures
  • $25.00 - adafruit.com - 1x RGB LCD Shield Kit w/ 16x2 Character Display
  • $ 36.30 - alliedelec.com - 4x Strain Relief, 10x Nuts
  • $ 73.04 - digikey.com - Stand Offs, Screws, Nuts, Terminal Blocks
  • $853.96 - Total
  • $50.00 - adafruit.com - 2x RGB LCD Shield Kit w/ 16x2 Character Display
  • $300.00 - OpenEVSE 2x v4 plus
  • $150.00 - leviton.com - 1x 30 Amp J1772 Connector with 25 Ft. Cord
  • $ 40.00 - stayonline.com - 1x L6-30 Cord 6 Feet
  • $1393.96 - Total including Remaining parts for 3 units (464.65 each)

Assembly

Labelled OpenEVSE Board.
(top left )(6Pins) ISP = ??Unknown?? Programming header
(top right)(4Pins) I2C = Connection for Display            

(left) AC Test 2 (Connect to AC Input, after relay) ??Confirm??
(left) AC Test 1
(left) AC Line 2 (Connect to AC Input, after fuse)
(left) AC Line 1 		(right) (2Pins) FTDI ??Unknown??
(right) K1772 Pilot (???? colored wire)
(right) Ground
(right) Relay Coil 12v (To Relay, polarity does not matter)
(right) Relay Coil 12v
(right) (2Pins) CT coil ??Unknown??
(right) (2Pins) CT Self Test (future) ??Unknown??
Back side of OpenEVSE
Display Pins near buttons, (Pin3=Yellow, Pin4=Green, Pin5_to_Pin4, 6,Space,7,8,9,10, Pin11=Red, Pin12=Orange)
Display connects to 4 "IC2" pins. (Red, Orange, Yellow, Green (Corner of Board))

Build Photos

  • 1

  • 2

  • 3

  • 4

  • 20121220 013644.jpg

    5 strike

  • 6

  • 7

  • 8

  • 9

  • 10

  • 11

  • 12

  • 13

  • 14

  • 15

  • 16

  • 17

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