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Difference between revisions of "User:Rjf/Open-EVSE"
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Revision as of 13:21, 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 |
| 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
| (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?? |
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!!
