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OpenEVSE 30A Charging Station

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Written By: Christopher Howell (and one other contributor)
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02:00:00 - 03:00:00

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Introduction

  • 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. If you ordered the "Quick Kit" you will need to build the Button, GFCI coil, LCD and OpenEVSE PLUS.

  2. Place 4 foam washers on 4 1/2" wide head screws. Flip lid upside down and stack... Foam seal, then LCD clear window (remove Protective coating from both sides) and finally the LCD Window Brace (remove protective coating).

    • Place 4 foam washers on 4 1/2" wide head screws.

    • Flip lid upside down and stack... Foam seal, then LCD clear window (remove Protective coating from both sides) and finally the LCD Window Brace (remove protective coating).

    • Place the 4 - 1/2" Screw through the lid with the foam washer on the outside. Compress foam and thread the 4- Hex Standoffs. Tighten each one hand tight compressing the foam.

    • Mount the water resistant button switch to the enclosure lid. Do not over tighten seal, if squeezes out of place the button is too tight.

  4. Peel protective coating from the mounting plate. Your Charging station can be built with AC input Left and J1772 Right or opposite. Flip mounting plate to desired position. Fuses will line up with AC input and relays J1772 cable. Mount fuse block with 2 - 3/8" screws from the top and lock nuts on the bottom.

    • Peel protective coating from the mounting plate.

    • Your Charging station can be built with AC input Left and J1772 Right or opposite. Flip mounting plate to desired position. Fuses will line up with AC input and relays J1772 cable.

    • Mount fuse block with 2 - 3/8" screws from the top and lock nuts on the bottom.

    • Position relays so the small tabs are to the outside for easier routing of low voltage wires.

    • Mount Relays with 2 - 3/8" screws from the top and lock nuts on the bottom.

  5. Mount OpenEVSE Plus board with 5/8" screws from the top. Place nylon spacers between OpenEVSE board and mounting plate. Tighten Lock Nuts from the bottom. Do not over tighten. Mount Ground block with 2 - 3/4" screws from the bottom. Tighten Lock nuts from the top.

    • Mount OpenEVSE Plus board with 5/8" screws from the top.

    • Place nylon spacers between OpenEVSE board and mounting plate. Tighten Lock Nuts from the bottom. Do not over tighten.

    • Mount Ground block with 2 - 3/4" screws from the bottom. Tighten Lock nuts from the top.

    • Connect OpenEVSE Ground to the ground Block. Ensure connections are secure.

    • Crimp Yellow connector to 10AWG wire. Screw to the Fuse block. Wire can come from excess from AC cord or J1772 cable.

    • Ensure crimps are secure. Do not solder connectors designed for crimping. Do not connect and disconnect terminal. If loose, discolored, or damaged replace immediately.

  6. Crimp 22AWG wire to larger 1/4" pink QC connectors. Connect to Fuse block QC terminals. Screw the 22AWG wires to the AC line block on the OpenEVSE board. When connecting relay coil tabs. Ensure the QC terminal slides down the tab. It is possible to wedge the QC connector in by bending tab to the side.

    • Crimp 22AWG wire to larger 1/4" pink QC connectors. Connect to Fuse block QC terminals.

    • Screw the 22AWG wires to the AC line block on the OpenEVSE board.

    • When connecting relay coil tabs. Ensure the QC terminal slides down the tab. It is possible to wedge the QC connector in by bending tab to the side.

    • Connect OpenEVSE common relay output (center pin) to 1 relay coil terminal on each relay using small pink QC connectors.

    • Connect OpenEVSE controller Relay 1 output to remaining pin on first Relay.

    • Connect OpenEVSE controller screw terminal Relay output 2 to remaining pin on second relay.

  7. Mount Plate into enclosure base with 3 of the 4 wide head 3/8" screw and lock washer. Do not install screw in the hole closest to the ground block. Crimp spade connector to the Green 10 AWG wire. Secure to enclosure base with the remaining 3/8" wide head screw and lock washer.

    • Mount Plate into enclosure base with 3 of the 4 wide head 3/8" screw and lock washer. Do not install screw in the hole closest to the ground block.

    • Crimp spade connector to the Green 10 AWG wire. Secure to enclosure base with the remaining 3/8" wide head screw and lock washer.

    • Connect Enclosure base ground wire to the ground block.

  8. Prepare J1772 cable. Strip Cable back at least 8". Put Cable Gland on cable, it may take some effort depending on the diameter of the cable. Ground and Pilot conductors should be 7" - 8" long.

    • Prepare J1772 cable. Strip Cable back at least 8". Put Cable Gland on cable, it may take some effort depending on the diameter of the cable.

    • Ground and Pilot conductors should be 7" - 8" long.

    • One Hot conductors should be about 5" long and the other slightly shorter. Crimp Yellow QC connectors to the Hot Conductors AND a 22AWG wire for the AC Test connections.

    • Ensure crimps are secure. Do not solder connectors designed for crimping. Do not connect and disconnect terminal. If loose, discolored, or damaged replace immediately.

  9. Prepare AC cable (if Applicable). Strip back outer insulation 7". Put Cable Gland on cable. Ground conductor should be 6" - 7" long. Hot conductors should be 2" long.

    • Prepare AC cable (if Applicable). Strip back outer insulation 7". Put Cable Gland on cable.

    • Ground conductor should be 6" - 7" long.

    • Hot conductors should be 2" long.

    • Secure AC Cord Cable Gland to enclosure on the side with the fuse block.

    • Connect Hot Wires to the fuse block.

  10. Temporarily tape the 3 wires from the connector to coil leads with about 3/4" overlap. Wrap self test wire through coil 5 times. Secure with shrink wrap tubing as close to the GFCI coil as possible.

    • Temporarily tape the 3 wires from the connector to coil leads with about 3/4" overlap.

    • Wrap self test wire through coil 5 times.

    • Secure with shrink wrap tubing as close to the GFCI coil as possible.

    • Cut wires to length with 1/4" overlap. Solder white wire to 1 lead of the GFCI coil. Shrink tubing over the solder joint.

    • Solder BOTH the Orange self test lead AND the second GFCI coil lead to the black wire (Ground).

    • Shrink tubing over the wires.

  11. Connect J1772 cable gland to the enclosure base. Run both HOT lines through the GFCI coil. Connect J1772 Hot lines to relay outputs.

    • Connect J1772 cable gland to the enclosure base.

    • Run both HOT lines through the GFCI coil.

    • Connect J1772 Hot lines to relay outputs.

    • Connect the 22AWG wires from the QC connectors on the J1772 cable to the AC Test leads to the OpenEVSE board.

    • Connect J1772 Ground to Ground block

    • Connect the Control Pilot from the J1772 cable to the OpenEVSE board.

    • Each manufacture uses different color codes for pilot. IT/Leviton - Orange, Yasaki - Blue, Quick Charge Power - Purple.

  12. Connect 4 pin LCD cable to the OpenEVSE board.

    • Connect 4 pin LCD cable to the OpenEVSE board.

Author

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Christopher Howell

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