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
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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 as follows: Foam seal, then LCD clear window (remove protective coating from both sides).
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Place the (4) - 10mm M2.5 screws 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.
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Mount the water resistant button switch to the enclosure lid, rubber seal on the outside. Do not over-tighten seal. If it 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 the 3-pin cable connector to the LCD module. Strip wires about 1/2", fold in half stripped wire and screw into the switch screw lugs.
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Connect the 4-pin connector to the LCD. Note the color that represents the ground wire (green in picture).
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Mount OpenEVSE board to the mounting plate with hex stand-offs and (8) - M2.5 x 6mm screws.
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Mount ground bar from the top to the mounting plate using (2) - 5/8" self-tapping screws.
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Mount the Packard C240C contactor from the top to the plate with (4) - 1/4" self-tapping 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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v4 After July 2015
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Connect OpenEVSE AC line to the incoming AC side of the contactor. Connect OpenEVSE Ground to Ground Block.
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Connect the red MOV across the AC_Relay terminals on the OpenEVSE board. This shares terminal positions with the AC Relay coil wires.
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Connect OpenEVSE AC Test (v4 top block or V3 middle) to the hot line of the contactor output (J1772 side). V3 Hot only, V4 both Hot and Hot/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 q6 - self tapping screws (2 top, 2 middle 2 bottom).
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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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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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Deluxe kits - Connect the current measurement CT to the 2 pin connector (either direction is fine).
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Connect the EV control pilot (CP) line (see below for common colors) to the OpenEVSE pilot screw terminal connection.
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The OpenEVSE Ultra Flexible Cable ends are factory terminated with sleeve ferrules.
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Insert terminated conductors into the lugs and securely tighten screws.
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Tighten the J1772 cable gland and check its integrity.
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Insert the AC Input cable through a Cable Gland and assemble loosely into the hole in the box.
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Strip the insulation off about 3/4" of insulation, terminate with ends sleeve ferrules.
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Insert terminated wires into lugs and tighten. The 50A kit supports both Split Phase US (Hot, Hot and Ground) and single Phase (Hot, Neutral, Ground) at a voltage of 208 - 240v AC.
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Tighten the cable gland and check its integrity. Check the input wires are secure.
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Connect the ground (Green) from the AC cord to the ground block.
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Connect the Ground from the J1772 cable to the ground block.
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If display text is dim or not present adjust LED contrast (VR-1) located on the right side of the Display Module.
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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 "Service Level" to Level 2. Menu=> Setup => Service Level.
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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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Attached Documents
3 Comments
You must use wire ferrules! (step 10)
Just folding the ends is not sufficient. Screws break the fine copper filaments of flexible wire if they are tightend properly thus decreasing the effective cross section area of the wire. If they are not tightend enough you'll have to little surface area contact. Ether way: Risk a fire or use ferrules!
Jens (electrical engineer)
Very nice! Thank you Christopher Howell!
Jens -
Cables from OpenEVSE come factory terminated with sleeve ferrules. The wording was changed, “should” is now “must” and we made sure it was clear in both EV cable and input cables require ferrules.