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Difference between revisions of "User:Rjf/Open-EVSE"

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(→‎Build Photos: descriptions.)
(Move headings out to sub pages for more granular inclusion at external locations.)
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Stay tuned as I update this information.
 
Stay tuned as I update this information.
  
−
==== Parts List ====
+
{{User:Rjf/Open-EVSE/Parts_List}}
−
{| class="wikitable sortable"
+
{{User:Rjf/Open-EVSE/Parts_Cost}}
−
! Part !! Source !! Cost !! Quantity !! Link
+
{{User:Rjf/Open-EVSE/Assembly_Reference}}
−
|-
 
−
| 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}}
 
{{Clear}}
−
==== Build Photos ====
+
{{User:Rjf/Open-EVSE/Build_Photos}}
−
<Gallery>
 
−
Image:20121220 003836.jpg|Components mounted to internal enclosure plate.
 
−
Image:20121220 005325.jpg|AC Line and AC Test wires soldered to relay
 
−
Image:20121220 005351.jpg|Leads to be soldered on to ground fault coil.
 
−
Image:20121220 013649.jpg|Internal AC connected to terminal blocks.
 
−
Image:20121220 013540.jpg|Mock up of Open-EVSE board connections.
 
−
Image:20121220 073516.jpg|Internal Plate mounted inside enclosure.
 
−
Image:20121220 074444.jpg|Open-EVSE mounted and wired.
 
−
Image:20121220 084752.jpg|Created crimp connectors for use with terminal block.
 
−
Image:20121220 090424.jpg|Crimps attached to the J1772 cable for easy installation and removal.
 
−
Image:20121220 092011.jpg|AC input and J1772 output cabled attached.
 
−
Image:20121220 093918.jpg|View of stand offs attached to LCD Display
 
−
Image:20121220 093931.jpg|LCD Display is attached to a piece of scrap plastic.
 
−
Image:20121220 094007.jpg|Closeup of LCD Display standoffs.
 
−
Image:20121220 094353.jpg|LCD Display attached to long standoffs and connected to Open-EVSE.
 
−
Image:20121220 094421.jpg|L6-30 Extension cable converted into adapter cable and plug for EVSE.
 
−
Image:20121220 094550.jpg|Powered up and working!!
 
−
Image:20121222 034723.jpg|220vac 50A plug, plus 220vac L6-30A, plus Xphase 110vac and Yphase 110vac.
 
−
Image:20121222 035812.jpg|Creating a face plate for the 2 gang 110vac 20A + L6-30A outlets.
 
−
</Gallery>
 
−
 
 
 
[[Category:BEV components]]
 
[[Category:BEV components]]

Revision as of 13:10, 13 January 2013

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

Key: Items with letters in the quantity field have multiple options:

  • e = Various enclosures.
  • f = Various fuse/breaker options
  • d = Only needed if adding a display
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 Reference

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 of Enclosure 1

  • Components mounted to internal enclosure plate.

  • AC Line and AC Test wires soldered to relay

  • Leads to be soldered on to ground fault coil.

  • Internal AC connected to terminal blocks.

  • Mock up of Open-EVSE board connections.

  • Internal Plate mounted inside enclosure.

  • Open-EVSE mounted and wired.

  • Created crimp connectors for use with terminal block.

  • Crimps attached to the J1772 cable for easy installation and removal.

  • AC input and J1772 output cabled attached.

  • View of stand offs attached to LCD Display

  • LCD Display is attached to a piece of scrap plastic.

  • Closeup of LCD Display standoffs.

  • LCD Display attached to long standoffs and connected to Open-EVSE.

  • L6-30 Extension cable converted into adapter cable and plug for EVSE.

  • Powered up and working!!

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