Planning to Build my own EVSE - Any Help is Appreciated

[chris1howell]

I really shoulda bought that Tesla...

Is there any reason not to attach the components right to the back of the box?

If it is indoor install no problem...outdoor its better to have a mounting plate to maintain a watertight seal.

 

[Elephanthead]

I had Glenn do all the work that is my best advice.

 

[Graycenphil]

If it is indoor install no problem...outdoor its better to have a mounting plate to maintain a watertight seal.

Thanks. It will technically be portable, since I am putting a cable and plug on it, but I can't envision ever having it exposed to the elements. It may never leave my garage. Still, perhaps I will search for some sort of mounting board - I like the look of that.


Glenn is too far away, at least until they get a bunch more Level 3's installed. Mitch has offered to help, but I will attempt it on my own first. Fire insurance is paid up.

 

[mitch672]

Here is a case you can use, a baseplate is also availble for it, it's a little less than 6" X 6", you would have to plan carefully to get it all to fit, but I've done it before...

Box: http://www.digikey.com/product-detail/en/NBB-10260/377-1245-ND/428994" onclick="window.open(this.href);return false;
Internal panel: http://www.digikey.com/product-detail/en/NBX-10984/377-1939-ND/439528" onclick="window.open(this.href);return false;

Here is my first 30A OpenEVSE build, in the above enclosure, you can see how tight everything fits, and the planning required: https://code.google.com/p/open-evse/wiki/EVSE_by_mwolrich" onclick="window.open(this.href);return false;

P.S. I've built several 30A OpenEVSE's, the pictures in the above link show 2 different versions, the first was using a Chris's OpenEVSE board with piggyback power supply, the 2nd build shown under "updated", is a build with an external 12V power supply and the DIY through hole OpenEVSE board.

 

[Graycenphil]

You do beautiful work Mitch. I will have those pictures on the bench as I am putting mine together.

I already bought an 8x8 box - I can use the extra room. I may make a plate to go in the back; I like the idea of building everyting outside the box then setting it in.

What is the armor around the cables where they come out of the box?

 

[mitch672]

Those are called "Chinese Fingers", or "kellems" they are used to strain relieve cables, I bought those from an electrical supply house, because I didn't want to wait for the gland nuts, which are a lot less expensive. I think each of those Chinese fingers where in the $15-$20 range (each), now we just use gland nuts, such as these: http://www.stayonline.com/detail.aspx?id=17207" onclick="window.open(this.href);return false;
of course "stayonline" only ships FedEx, so the shipping charges are high, there are other sources for them as well.

Chinese Fingers: http://en.wikipedia.org/wiki/Chinese_finger_trap" onclick="window.open(this.href);return false;

Here's a search on eBay: http://www.ebay.com/bhp/kellems-grip" onclick="window.open(this.href);return false;

 

[Graycenphil]

The kit I bought comes with gland nuts, so I guess I am covered. The Chinese fingers give it a kind of tough, industrial look.

I do remember the Chinese finger party favors from birthday parties many years ago. Haven't seen them in a long time.

 

[Graycenphil]

Moving along nicely - components mounted in the box, half the wiring done, I can finish the rest tomorrow. Except I cannot find the flat connectors to connect the big wires to the relay. Tried Radio Shack, the auto parts store and electrical supply. I couldn't even find them on McMaster-Carr.

Where do you get connectors for 8 gauge wire?

Thanks.

 

[DNAinaGoodWay]

http://www.mouser.com/ProductDetail/Panduit/PV8-10RX-TY/?qs=TJHWRtqmY34v8NgiC0NvRg%3D%3D&gclid=CLDZ9MTW2bwCFY1QOgodXCUAYw" onclick="window.open(this.href);return false;

Google "connector for 8 gauge wire"

 

[Graycenphil]

But I need one that looks like this:

http://www.mouser.com/ProductDetail/Panduit/D14-250-M/?qs=sGAEpiMZZMvz8LftK4jeru%2fp0gfGHh0OgMCzD%252b2ac7k%3d" onclick="window.open(this.href);return false;

but for 8 gauge, to connect the 240 volt lines to the relay.

 

[mitch672]

Here's one that works from DigiKey:
http://www.digikey.com/product-detail/en/62998-2/A29935CT-ND/294470" onclick="window.open(this.href);return false;

 

[chris1howell]

Moving along nicely - components mounted in the box, half the wiring done, I can finish the rest tomorrow. Except I cannot find the flat connectors to connect the big wires to the relay. Tried Radio Shack, the auto parts store and electrical supply. I couldn't even find them on McMaster-Carr.

Where do you get connectors for 8 gauge wire?

Thanks.

For the internal wiring of OpenEVSE 30A Combo kits (24A continuous) you should be using 10 gauge wire. The 1/4" Quick connect Connectors max out at 10 gauge and 30A.

 

[Graycenphil]

Thanks.

 

[Graycenphil]

Finished the wiring, turned on the circuit breaker and nothing smoked. I plugged it into the car and the blue lights started flashing. So I assume it is working!

Many, many thanks to all for your advice, patience and offers of help. Besides saving a little money and understanding a bit more of what is going on, the whole proccess was very rewrding. Thanks also to Jazzy for sending me his graphics and allowing me to use it. Unfortunately, I decide to go with a bigger box (8x8) and I have no LED or readout so it wouldn't really work. I guess I will have to live with the industrial or minimalist look.

If I can figure out how to do it, I'll post some pictures later.

 

[asimba2]

Congrats. Did you go with the DIY combo kit (the some assembly required one)? I was planning to buy an EVSE, but I would rather support the community. Sounds like it's not too incredibly difficult?

Last weekend I installed a NEMA 14-50 outlet in my garage, 6/3 wire (future-proofing for my next EV) and a 40-amp breaker. The kit you built is advertised at 30 amps but I read something about a 24 amp duty cycle. Do you know if it charges at 30 amps and it's safe to do-so?

 

[Graycenphil]

I bought the "OpenEVSE 30A Charge Station Combo - Built - No LCD", which is pretty much all the parts, except the J1772 cable, an enclosure and a few miscellaneous connectors. It really was not difficult at all, as long as you are comfortable with this sort of thing. If you were able to run your own wire and install the outlet, you should not have any difficulty with this. If you are more technically proficient than me, you could buy the unassembled kit for a bit less money. I was kind of afraid of the soldering, fearing I would put something in the wrong spot or fry an IC.

It is called 30 amp, but actually charges at 24 amp. I'm finding the whole current thing a bit imprecise, including the Nissan 6.6 charger that never really gets to 6.6 KW.

If you do decide to build your EVSE, feel free to Pm me, or post on this thread, and I'll give you all my insights as a first timer, relative electronic neophyte.

 

[Graycenphil]

Can't believe I built a working EVSE and figured out how to post images in the same day. Think I'll head out to the racetrack now.

 

[asimba2]

Looks great, you helped me decide to go that route. I have built LED circuits, so I'm comfortable with some soldering. Thanks for the encouragement!

 

[mitch672]

Nice job, I am disappointed I won't get to drive out and help

Have you considered the remote LED status light? (I'm personally a fan of the full LCD display and button, but you don't really need it) It's only $12, and you'd only need to drill 1 small hole in the cover, you could probably just mount it with doubled sided foam tape.

http://openevse-store.myshopify.com/products/copy-of-openevse-rgb-lcd" onclick="window.open(this.href);return false;

 

[Graycenphil]

Thanks Mitch. You're still welcome to come out, and now I can give your car a decent charge while you are here.

I would probably like to have the LED. I just wanted to get everything working a simply as possible first. Is it jus a matter of mounting and plugging in the module? And what does the light tell you?