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Newer

Current - v5.5 OpenEVSE Advanced and Value

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Written By: Christopher Howell (and 4 other contributors)
  • Comments: 5
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  • Completions: 9

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Difficulty

Moderate

Steps

11

Time Required

00:30:00 - 02:00:00

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Introduction

OpenEVSE Store - Purchase this OpenEVSE Kit

Warning Assembly of a Electric Vehicle charging station requires wiring Alternating Current (AC) components that will be exposed to voltages from 100 to 250v. If you do not have the experience and knowledge required to safely work with AC voltages please consult with an experienced electrician for assistance and inspection of your work.

Note Regularly inspect your charging station. Pay special attention to excess heat, components, handles, and wiring will be warm but they should not be HOT...

Always Disconnect your charging station from power before performing an inspection and/or maintenance

  1. These documents will assist with the steps that follow. OpenEVSE Board Pins and Connections Download PDF

    • These documents will assist with the steps that follow.

    • OpenEVSE Board Pins and Connections Download PDF

    • Station Wiring Diagram Download PDF

  2. Position the plate with the FOUR holes for the OpenEVSE controller up top-left. Mount the FOUR 4.5 Hex x 10mm standoffs to the top side of the plate with FOUR M2.5 x 6 mm screws. Tip - use blue LOCTITE on each screw to ensure it remains tight.

    • Position the plate with the FOUR holes for the OpenEVSE controller up top-left.

    • Mount the FOUR 4.5 Hex x 10mm standoffs to the top side of the plate with FOUR M2.5 x 6 mm screws.

    • Tip - use blue LOCTITE on each screw to ensure it remains tight.

    • Mount the Struthers-Dunn relay using TWO 1/2" self threading screws.

    • Mount ground bar to the plate with ONE washer and ONE 1/4" self threading screws.

  3. Attach the relay coil harness. Mount plate in enclosure with SIX coarse threaded 6mm screws. Install the TWO cable glands.

    • Attach the relay coil harness.

    • Mount plate in enclosure with SIX coarse threaded 6mm screws.

    • Install the TWO cable glands.

  4. Insert EV Cable through the Cable Gland on the right and tighten. Connect the ground wire to the ground block. Route the ground, pilot and coil wires low in the enclosure to avoid crossing any high voltage wires or components.

    • Insert EV Cable through the Cable Gland on the right and tighten.

    • Connect the ground wire to the ground block.

    • Route the ground, pilot and coil wires low in the enclosure to avoid crossing any high voltage wires or components.

    • Thread ALL hot and neutral lines through the 4 wire GFCI coil with the orange self test loop.

    • Do not thread the ground wire or pilot wire through.

    • Advanced Series Only - Thread EITHER hot OR neutral through the Current Measurement Coil.

    • Tip - zip tie smaller wires together near the top and bottom to keep them neat and out of the way.

  5. Screw the ring terminals on the EV cable directly to the pads on the relay with the wiring harness on top. Ensure both EV cable ring terminals have good contact directly to the relay pads and the screw is tight.

    • Screw the ring terminals on the EV cable directly to the pads on the relay with the wiring harness on top.

    • Ensure both EV cable ring terminals have good contact directly to the relay pads and the screw is tight.

    • Install the harness wires on top of the EV cable connector to insure the EV cable has the best contact with the relay as possible.

    • Connect the longer lead on the harness to the bottom position and the shorter the top position.

    • Tip - run the top power wire in the middle of the enclosure with the smaller low voltage wires on the bottom. Ensure they is plenty of clearance.

    • Tip - run the bottom power wire high in the enclosure and angled away from the top power wire. Ensure there is plenty of clearance.

  6. Insert the input cable through the left gland. Connect the ground wire to the ground block. Screw the ring terminal on the EV cable power conductor to the top position of relay along with the red wire on the wiring harness.

    • Insert the input cable through the left gland.

    • Connect the ground wire to the ground block.

    • Screw the ring terminal on the EV cable power conductor to the top position of relay along with the red wire on the wiring harness.

    • Ensure both Input cable ring terminals have good contact directly to the relay pads and the screw is tight.

    • Install the harness wires on top of the EV cable connector to insure the EV cable has the best contact with the relay as possible.

    • Screw the ring terminal on the EV cable power conductor to the bottom position of relay along with the black wire on the wiring harness.

    • Tip - run the top power wire in low in the enclosure.

    • Tip - run the bottom power wire high in the enclosure and angled away from the top power wire. Ensure there is plenty of clearance.

  7. Static sensitive - Lift controller by board edges or AC/DC power supply. Do not touch components.

    • Static sensitive - Lift controller by board edges or AC/DC power supply. Do not touch components.

    • Mount OpenEVSE controller to the hex standoffs with FOUR M2.5 x 6mm screws.

    • Connect the pilot wire to the OpenEVSE controller.

  8. View OpenEVSE v5 Diagram in previous step for wires named below. Connect the keyed wiring harnesses to OpenEVSE controller. Wire colors may vary.

    • View OpenEVSE v5 Diagram in previous step for wires named below.

    • Connect the keyed wiring harnesses to OpenEVSE controller.

    • Wire colors may vary.

    • Connect the 6 pin WiFI cable to the controller.

    • Connect the 4 pin Display Cable to the controller.

  9. Static sensitive - Lift WiFi by board edges. Do not touch components.

    • Static sensitive - Lift WiFi by board edges. Do not touch components.

    • Peel the red backing on the 3M VHB industrial mounting tape.

    • Install the WiFi module with the antenna in the top of the enclosure.

    • Connect the WiFi harness.

    • DO NOT PLUG the 6 pin plug into the 8 pin socket (red XXXX) BOTH the WiFi module and OpenEVSE controller will be damaged.

  10. Static sensitive - Lift display by board edges. Do not touch components.

    • Static sensitive - Lift display by board edges. Do not touch components.

    • Attach display with FOUR coarse threaded 6 mm screws.

    • Connect display Cable to EITHER port

Author

with 4 other contributors

Christopher Howell

Member since: 07/05/2014

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