Difficulty
Moderate
Steps
13
Time Required
00:45:00 - 02:00:00
- Discontinued May 2018 - v4 Advanced 13 steps
User-Contributed Guide
This guide is not managed by the site's staff.
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
Kit Contents:
1 - Enclosure
1 - Metal Plate
1 - Screw Pack Enclosure Lid
1 - Screw Pack
1 - LCD Seal Kit
1 - Push button
1 - Relay
3 - Red Wires
3 - Black Wires
1 - Ground Bar
2 - Cable Glands Small
1 - OpenEVSE v4 Controller
1 - RGB Liquid Crystal Display
1 - Wifi Kit
Tools
Parts
No parts specified.
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Place the 4 - 10mm M2.5 screws through the top of the enclosure.
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Flip lid upside down and stack... Foam window seal, then LCD clear window (remove Protective coating from both sides) .
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Place the 4 - 10mm M2.5 screw through the lid. Compress window foam and thread into the 4- Hex Standoffs. Tighten each one hand tight compressing the foam fully.
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Mount the water resistant button switch to the enclosure lid, O-ring seal on the outside. Do not over tighten seal, if squeezes out of place the button is too tight.
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Using 4 - 6mm M2.5 screws. Mount LCD module to the lid.
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Connect 4 pin connector to LCD note the color that represents Ground (Green as pictured). Ground pin is labeled (pin closest to board center).
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Mount hex standoffs to the top side of the plate mounting plate with 4 - 6 mm M2.5 screws. Mount the OpenEVSE board to the hex standoffs with the other 4 - 6mm M2.5 screws.
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Mount Ground bar header block to the mounting plate from the top using 2 - 5/8" self threading screws.
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Mount the Struthers - Dunn contactor using 2 - 1/2" self threading screws.
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Review the connection diagram for the board you received in your kit. This guide depicts the latest board OpenEVSE v4.
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Connections are slightly different between board versions. Refer to these diagrams if the image in this guide does not match your board version.
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Struthers & Dunn - Connect DC relay coil (top) with a red wire to OpenEVSE controller Relay 1/2 Common. Connect relay coil (bottom) with a black wire to Relay 2.
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Connect OpenEVSE AC_Line to the incoming AC side of the contactor.
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Connect OpenEVSE AC_Test to the hot line of the contactor output (J1772 side) to both Hot 1 and Hot 2/Neutral.
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Connect the Ground wire from the ground block to the OpenEVSE board.
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Mount plate to Enclosure box using 6 - self tapping screws (2 top, 2 middle 2 bottom).
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Insert the J1772 cable through a Cable Gland and assemble loosely into the RIGHT hole in the box.
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Thread BOTH AC lines through the Ground Fault Coil (4-pin). If you are using the OpenEVSE 40A J1772 Cable, this is both the red pairs AND the black pairs.
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Thread one AC line through the current-measurement CT (2-pin OpenEVSE Current CT) . If you are using the OpenEVSE 40A J1772 Cable, this is either the red pair OR the black pair of wires.
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Organize the low voltage wires (EV Ground, EV Pilot, GFCI coil lead, Current coil lead and the relay coil) and secure with a tie wraps with light tension. Tuck the wires down to the bottom of the enclosure.
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Connect the 4-pin GFCI CT connector to the OpenEVSE board. This coil has two black wires and two orange self-test wires looped through the coil with a 4 pin connector. Orange Self test wires positioned to the inside Black GFCI CT wires to the outside.
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Connect the current measurement CT to the 2 pin connector (either direction is fine).
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Connect the control pilot (CP) line (see below for common colors) to the OpenEVSE pilot screw terminal connection.
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Use a tie wrap to secure the high-voltage low-current wires with light tension. Position so that the wires are pulled away from the center screw post/seal.
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Screw the Power Terminals to the relay with the Quick connect terminal for OpenEVSE AC_Test on top.
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Tighten the J1772 cable gland and check its integrity.
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Insert the AC Input cable through the LEFT Cable Gland and assemble loosely into the hole in the box.
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Run the Ground wire along the bottom of the enclosure and secure the conductor the the ground block.
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Screw Ring Terminals to the contactor with the Quick connect terminal for OpenEVSE AC_Line on top.
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Tighten the cable gland and check its integrity. Check the input wires are secure.
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Connect the LCD cable to the OpenEVSE controller. The pin closest to the board edge is ground (green pictured).
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Adjust LED contrast (VR-1) if text is not visible. Be very careful not to touch any while powered.
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When adjusting, be gentle. Do not force past the stop in either direction. If forced past the stop, the part will no longer function.
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Secure the enclosure lid. Tighten the screws slowly alternating across and top, middle and bottom.
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To Enter the Menu Press and hold the button (long press). Press and release (short press) to scroll through Options.
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Set Current to desired Value (80% of your circuit breaker value). Menu => Setup => Max Current.
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Enable GFCI Self Test. Menu => Setup => GFI Self Test
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Cancel: I did not complete this guide.
7 other people completed this guide.
7 Comments
Can you provide specific details, or perhaps an Add-On Guide section, on how the Deluxe Level1/Level2 50Amp EVSE unit is to be connected to a regular 120V outlet (to provide Level 1 power)? The user probably needs to set a much lower current limit in the menu (How much?) and to plug it in, do we need to build a conversion cable from the regular 120V plug to a NEMA 14-50 socket? In that case, how to connect the 3 pins of the regular plug to the big 4-pin socket? Does this require that we use the previously discarded Neutral (white) wire in the big 4-wire cable that enters the EVSE enclosure (if so: how?)?
The NEMA 14-50 plug is connected Hot 1, Hot 2 and Ground. For 120v you will need to build an adapter that is wired Hot 1, Hot 2, ground on the 14-50 (neutral is not connected) socket to Hot 1, Neutral, ground on the 120v plug.
OpenEVSE will automatically detect just one hot and set the current to 12A. L1 and L2 current is saved independently.
For 120 V use, I built an adapter cable with a 30A "dryer" cable from Menards, and a 14-50R Camco receptacle I bought online, following the above instructions. Hhalf the cost of buying this assembly pre-built is pretty sweet. Works like a charm on both 120V & 240V! It is very nice to have the dual voltage versatility when travelling. Thanks for the details, Chris.
Where are the instructions for the WiFi wiring? Step 2 shows a location for the board, and Step 5 shows connection of the UBEC power supply which I assumes powers the board. How do you connect the power cable to the WiFi board and how do you connect a ?data? cable to the OpenEVSE board?
