Portable OpenEVSE at 40A

[GlennD]

I could not quote since there was too many nested quotes. I edited it and it is somewhat garbled.

I just took my laptop and tape measure out to my garage. Based on these dimensions, the 80 amp chinese relay that Devin posted here http://www.aliexpress.com/item/JQX-62F-2Z-80A-DPDT-DC-12V-Coil-Electromagnetic-Power-Relay/468483981.html, WILL fit but only if you do not use the fuse block and cut out a portion of the mounting plastic included with the kit. You would have to mount the relay to the wall of the case which shouldnt be a problem as long as you use nuts, bolts and silicone.[/quote]
here's a better spec for the same relay courtesy of open source documentation on the EMW (JuiceBox) website. Same part number with the name, "NAIDIAN" on it. I don't think it fits in a JB Basic enclosure with the plastic "dust" cover on the relay, which is probably why it is omitted. I believe relay switching is done under little to no load conditions, so there is no danger of contact arching.

http://emotorwerks.com/JuiceBox_Public/99 - Supporting materials/JQX-62F Power Relay.pdf[/quote]

That relay seems to be a generic Chinese part. My first relays were from Qianji with a clear dust cover. The ones from the link have the same part number but a blue dust cover. They also have Din rail clips. Your link is for yet another mfg. They all seem similar and work well.

 

[jimbo69ny]

Relays and the cable from Tony came in today. Still waiting on the parts from Chris. Once I get those I'll know for sure if I can fit everything into one of his Openevse boxes.

In the past I have used the basic 10-12awg crimp connectors available anywhere. For this 40 amp Evse I'll be dealing with higher amperages and larger cables. Where are you guys getting your connectors? It looks like I'll probably be needing some spade connectors to connect to this Chinese relay.

 

[fooljoe]

I personally like the screw-in type so I don't have to worry about making a good crimp, but using them might make it harder to fit in your enclosure.

 

[jimbo69ny]

Those look good but getting the Chinese relay to fit into Chris' case is already going to be a chore. Those may be my only option though.

Where do you buy those?

 

[DevinL]

Those screw in ones do look pretty skookum. I just used the "heavy duty" metal ones from Home Depot. I was actually able to crimp them well using my cheapo light duty crimper and some gold old fashion Canadian muscle. :lol:

 

[fooljoe]

I found them in 2-packs at Home Depot.

 

[Dsinned]

One thing to be aware of is that the terminals on the relay are somewhat inadequate for most "heavy duty" (commonly available) wire lugs when the wire conductor size gets up to #8 or #6 gauge. The little screws that come with the relay to secure those type of lugs to the terminals seem undersized and the threads may easily strip. An AC relay rated for such high amperage power connections should have much huskier terminals and hold down screws imho. :roll:

 

[fooljoe]

For $15, it's hard to complain.

 

[Dsinned]

I concur, but for UL recognition, which it may not actually have, its hard to believe this relay's current rating is as high as it is with such inadequate power connection terminals!

 

[jimbo69ny]

I thought I would add my parts list to this thread. I too am working on a portable 50 amp, dual voltage charging station. I will post a thread with step by step photos coutisy of photobucket as soon as its done. I have the j1772 and relays but still waiting on the rest of the parts from Chris. I just received an email saying they were shipped so Hopefully by the end of the week I will have one put together.



40 Amp Dual Voltage, Portable EVSE Parts list:
OpenEVSE Plus v2 (Built) – $85.00
http://openevse-store.myshopify.com/pro ... se-plus-v2

J1772 40 Amp Ultra Flexible 25’ Cable - $165.00
http://store.openevse.com/products/water-resistant-led-ring-push-button

JQX-62F 2Z 80A DPDT DC 12V Coil Electromagnetic Power Relay - $7.11
http://www.aliexpress.com/item/Power-Relay-JQX-62F-2Z-80A-DC12V-DC24V-AC220V-high-quality/1983274156.html

OpenEVSE RGB LCD - $29.50
http://store.openevse.com/products/openevse-rgb-lcd

GE WX9X35 4-wire Range Cord (4ft) - $15.45
http://www.amazon.com/General-Electric- ... range+cord

Aluminum Grounding Bar - $4.77
http://www.homedepot.com/p/Blackburn-Al ... YEzaaKyD8I

Cable Gland CG-16 - $7.50
http://store.openevse.com/products/cable-gland-cg-16

Cable Gland CG-17 - $9.50
http://store.openevse.com/products/cable-gland-cg-17

GFCI Current Transformer (Quick Kit) - $27.50
http://store.openevse.com/products/gfci-current-transformer

Chris’ Custom Enclosure (with seal kit, no flanges, with artwork) - $84.50
http://store.openevse.com/products/custom-enclosure

LED Push Button (quick kit) - $16.50
http://store.openevse.com/products/water-resistant-led-ring-push-button

Adapters:
TT-30 to 14-50 Adapter
http://www.amazon.com/dp/B00GX51AFA?psc=1
Alternate TT-30 to 14-50 Adapter
http://www.amazon.com/gp/product/B000BUQOGI/ref=ox_sc_act_title_2?ie=UTF8&psc=1&smid=ATVPDKIKX0DER
Camco TT-30 to 6-15 Adapter
http://www.amazon.com/gp/product/B00192JGA8/ref=ox_sc_act_title_1?ie=UTF8&psc=1&smid=ATVPDKIKX0DER

 

[DevinL]

Adapters:
TT-30 to 14-50 Adapter
http://www.amazon.com/dp/B00GX51AFA?psc=1
Alternate TT-30 to 14-50 Adapter
http://www.amazon.com/gp/product/B000BUQOGI/ref=ox_sc_act_title_2?ie=UTF8&psc=1&smid=ATVPDKIKX0DER
Camco TT-30 to 6-15 Adapter
http://www.amazon.com/gp/product/B00192JGA8/ref=ox_sc_act_title_1?ie=UTF8&psc=1&smid=ATVPDKIKX0DER

Just a heads up, you can't use the ready-made RV TT-30 to 14-50 adapters as they aren't wired correctly for EVSE use. Here's a really great resource for building adapters: http://cosmacelf.net/Home%20Made%20Adapters.pdf

 

[jimbo69ny]

Adapters:
TT-30 to 14-50 Adapter
http://www.amazon.com/dp/B00GX51AFA?psc=1
Alternate TT-30 to 14-50 Adapter
http://www.amazon.com/gp/product/B000BUQOGI/ref=ox_sc_act_title_2?ie=UTF8&psc=1&smid=ATVPDKIKX0DER
Camco TT-30 to 6-15 Adapter
http://www.amazon.com/gp/product/B00192JGA8/ref=ox_sc_act_title_1?ie=UTF8&psc=1&smid=ATVPDKIKX0DER

Just a heads up, you can't use the ready-made RV TT-30 to 14-50 adapters as they aren't wired correctly for EVSE use. Here's a really great resource for building adapters: http://cosmacelf.net/Home%20Made%20Adapters.pdf

Damn, I just bought the short one. Is already on its way. I guess Ill have to be the alternate one, cut it in the middle and rewire it. But before I do any of that, I will test the one that arrives first.

I can tell you that the TT-30 to 6-15 adapter has arrived. I have tested it and that one will work.

 

[DevinL]

Adapters:
TT-30 to 14-50 Adapter
http://www.amazon.com/dp/B00GX51AFA?psc=1
Alternate TT-30 to 14-50 Adapter
http://www.amazon.com/gp/product/B000BUQOGI/ref=ox_sc_act_title_2?ie=UTF8&psc=1&smid=ATVPDKIKX0DER
Camco TT-30 to 6-15 Adapter
http://www.amazon.com/gp/product/B00192JGA8/ref=ox_sc_act_title_1?ie=UTF8&psc=1&smid=ATVPDKIKX0DER

Just a heads up, you can't use the ready-made RV TT-30 to 14-50 adapters as they aren't wired correctly for EVSE use. Here's a really great resource for building adapters: http://cosmacelf.net/Home%20Made%20Adapters.pdf

Damn, I just bought the short one. Is already on its way. I guess Ill have to be the alternate one, cut it in the middle and rewire it. But before I do any of that, I will test the one that arrives first.

For what it's worth, I actually made a 14-50 to 5-20 adapter and then got ready-made 5-20 to TT-30 and 5-20 to 5-15 adapters. The 5-20 adapter is oversized so it can support 20A with a TT-30 if I need it to. I like this approach because the 5-15 and TT-30 adapters are very compact so it minimizes the amount of pigtails I have and 5-20 outlets are fairly common.

 

[jimbo69ny]

I thought of that but if you use your 14-50 to 5-20 adapter and then the tt-30 adapter, you cant go to a full 30 amps because the 14-15 to 5-20 is only built for 20 amps.

My goal was to start with thicker cables and gradually drop lower as the amperage drops. ie 14-50 to tt-30 adapter then a tt30 to 6-15.

 

[fooljoe]

The Rav won't charge faster than 20a @ 120v anyway.

 

[jimbo69ny]

The Rav won't charge faster than 20a @ 120v anyway.

Oh I didnt realize that. Devin is totally right then.

 

[TonyWilliams]

Thanks to Glenn D, my over year old OPENevse project is up and running with a timer. I'll just throw on a Quick Charge Power 40 amp J1772 cable and see what happens.

It actually should NOT charge with the timer once the car goes to sleep, so we may need some modifications.

 

[riderbike37]

It actually should NOT charge with the timer once the car goes to sleep, so we may need some modifications.

I've been using a GlennD OpenEVSE for close to two months now. I haven't had any problem with the car pulling a charge when the RTC timer window opens. How long does the car take to go to sleep? The longest between last drive and charge I've tried is probably about 4-5 hours.

 

[pchilds]

It actually should NOT charge with the timer once the car goes to sleep, so we may need some modifications.

I've been using a GlennD OpenEVSE for close to two months now. I haven't had any problem with the car pulling a charge when the RTC timer window opens. How long does the car take to go to sleep? The longest between last drive and charge I've tried is probably about 4-5 hours.

When I tested, the RAV4 would go to sleep in about 10 minutes. I sounds like they may have fixed that problem. Further testing is required. I am due for my 1.5 year service next week, after that I will retest the CS-60 w/timer and OpenEVSE w/RTC.

 

[dstjohn99]

I just ordered 2 of those Chinese contactors from Aliexpress.

Are you positive they wont fit into one of Chris' OpenEVSE cases?

If you do not use Chris's thick mounting plate It might fit but it will be close. It will comprise the weatherproofing to mount directly to the case.

So far I have received 4 of the relays so it seems to be the real deal. The price is right.

Is the issue the depth? It seems like the length and width leave enough room.

Do you like these relays? Chris says they run hot but I like the idea that I can build a 110 and 220 EVSE in one.

Open EVSE kit with 80 amp relay. Yes it fits. It does run hot, I'll need to keep a close eye on that for a while. I cut the mounting plate to suit, and the relay sits right in the bottom with 1/2 inch to spare on the height. I even kept the cover. I haven't figured out how to make the photos show up yet. I tried to include them below.

I did not hard mount the relay yet. I need a DIN rail (1st choice) or maybe 2 sided tape to the bottom. For now I have foam weatherstrip inserts in a couple of spots to keep it from moving around. The relay coil draws about 160mA at 12 volt. I would like to figure out if there is a 12 volt supply on the board when the relay is off, then it switches off when the relay is on. I have some 12 volt white diodes that I want to install in the J1772 to help see at night (like the JESLA has). They each draw about 18mA at 12 V and I can use the extra wires in the quickchargepower cable.

Thanks to eHelmholtz for the loaner relay and lots of help, programming the firmware, etc. Also thanks to Chris for answering my late night emails and guiding me through a couple of snags. I could not have completed it as well without them.

or try this:

https://plus.google.com/u/0/photos/...6052805035908074754&oid=115954433365048378822