Introduction

This guide is to show the assembly of my OpenEVSE charger using the official OpenEVSE Enclosure and OpenEVSE Plus v2 board. The board was purchased assembled by Chris with RTC and LCD. I chose OpenEVSE becuase I like projects and also I think it looks better and is cheaper then most alternatives out there.

High Voltage Schematic

http://open-evse.googlecode.com/files/EVSEwAdvanced_Power_supply.pdf

Parts List

Part	Source	Cost	Quantity	Link
Open EVSE Plus Board w/ integrated power supply, LCD and RTC (Built)	Open EVSE	$210.00	1	https://code.google.com/p/open-evse/wiki/Ordering
J-1772 cable, 30 amps (A3435-PEV)	Leviton	$173.36 + FS	1	http://store.leviton.com/dp/B00912OT00#.UD18QGjEV68
30A Relay	Digikey	$13.03	1	http://search.digikey.com/us/en/products/T92P7D22-12/PB486-ND/365921
Current Transformer	Digikey	$10.65	1	http://search.digikey.com/us/en/products/CR8420-1000-G/582-1018-ND/1045174
Halex 3/4 in. Strain Relief (2-Pack)	The Home Depot	$6.28	1	http://www.homedepot.com/p/Halex-3-4-in-Strain-Relief-Cord-Connectors-with-Gland-Nut-2-Pack-21694/100126837#.UYEwSaKyD8I
Leviton 30 Amp 2-Pole Single Outlet	The Home Depot	$9.49	1	http://www.homedepot.com/p/Leviton-30-Amp-2-Pole-Flush-Mount-Self-Grounding-Single-Outlet-Black-R60-05372-000/202077690#.UYEywaKyD8I
Leviton 30A Right Angle Plug	The Home Depot	$14.75	1	http://www.homedepot.com/p/Leviton-30-50-Amp-2-Pole-3-Way-Black-Grounded-Angle-Straight-Blade-Plug-R50-00931-000/202077682#.UYEzt6KyD8I
Ground Bar Kit	The Home Depot	$4.67	1	http://www.homedepot.com/p/Blackburn-Aluminum-Ground-Bar-Only-IBT3AB-B1-10/202786635#.UYEzaaKyD8I
OpenEVSE Indoor Enclosure	Diversified Stage, Inc.	$58.00 + $16.85 shipping	1	http://ssl.diversifiedstage.com/estore/index.php?main_page=product_info&products_id=3&zenid=l3sdq75duj52lm2gjlfuavdl71
1/2" Mounting screws and nuts	The Home Depot	$1.18	1	http://www.homedepot.com/p/8-32-x-1-2-in-Zinc-Plated-Round-Head-Combo-Drive-Machine-Screw-8-Pieces-27621/202706065#.UYE5CKKyD8I
1" Mounting screws and nuts	The Home Depot	$1.18	1	http://www.homedepot.com/p/8-32-x-1-in-Zinc-Plated-Round-Head-Combo-Drive-Machine-Screw-8-Pieces-27651/202706068?keyword=27651#.UYE486KyD8I
12-10 AWG Female Spade Piggyback	Ebay	$4.30	1	http://www.ebay.com/itm/130877054917?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649
22-18 AWG Female Spade	Ebay	$4.20	1	http://www.ebay.com/itm/140941993829?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649
Illuminated Momentary Button	Ebay	$8.99 + $4.00 shipping	1	http://www.ebay.com/itm/130563267308?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649
Shipping	Digikey	$5	1

| Total | | $531.18 | |:------|:|:--------|

Build

The first step was gathering all the materials. After I completed this I moved onto mounting the components to the back panel of the enclosure. I used 1/2" screws for the relay and 1" screws for the grounding bar. The enclosure includes mounting hardware for the OpenEVSE Plus v2 board.

The next thing I did was solder on the spade connectors onto the incoming 220 line and the outgoing J-1772 cable. I put heat shrink over the connections.

The next step was to mount the LCD and momentary switch. The enclosure comes pre drilled for the switch but the switch I purchased was slightlty bigger then the hole so I had to drill it out slighlty. Once I did that it fit in perfectly.

The next thing I did was solder the switch connections to the LCD board. I picked up power for the illumination of the switch from the 5v pad on the LCD board. I then wired the normally open contact of the switch between GND and S on the LCD board.

Once that was completed all the soldering was finished and all that remained was to mount the box and connect everything together.

This is what the box looks like internally once mounted and everything is connected.

And this is the finished product.