OpenEVSE DIY 30A - gorawen/open_evse GitHub Wiki
#Build Guide for DIY OpenEVSE PLUS with integrated 30A relays
The DIY OpenEVSE Plus can be built from a starter kit available at the OpenEVSE Store.
The kit is available here: http://openevse-store.myshopify.com/
http://cdn.shopify.com/s/files/1/0249/6207/products/IMG_8956_1024x1024.jpg?187
It is a good idea to print the schematic for reference. The schematic is located here:
https://open-evse.googlecode.com/files/DIY_OpenEVSE_PLUS_30A.zip
Included in Starter Kit
| Part | Value | Type | Quantity | Manufacture | Part Number | Marking |
|---|---|---|---|---|---|---|
| Board | Board | 1 | GoldPheonix | Board | ||
| Power 12V | PS | 1 | MicroPowerDirect | MPM-04D-1205 | ||
| DCDC | D117E | DC/DC converter | 1 | MicroPowerDirect | D117E | |
| IC1 | 328p | Processor | 1 | Atmel | ATMEGA328P-PU-ND | ATMEGA328P-PU |
Required to Complete
| Part | Value | Type | Quantity | Manufacture | Part Number | Marking |
|---|---|---|---|---|---|---|
| Fuse | 1A | Fuse | 2 | Bel | RST 1 | |
| IC3, IC5 | MID400 | AC detect | 2 | Fairchild Semi | MID400 | MID400 |
| IC2 | LF353 | Opamp | 1 | Fairchild Semi | LF353NFS-ND | LF353 |
| IC4 | Lm358 | Opamp | 1 | TI | 296-1395-5-ND | LM368 |
| y1 | 16000 | xtal | 1 | 887-1019-ND | ||
| C1, C2 | 22pf | Capacitor | 2 | Kemet | 399-9721-ND | 220 |
| C3, C5 | 1uf | Capacitor | 2 | TDK | 445-8607-ND | 105 |
| C4, C8 | .1uf | Capacitor | 2 | Kemet | 399-9872-1-ND | 104 |
| C6 | 2.2uf | Capacitor | 1 | TDK | 445-8514-ND | 225 |
| C9 | 10UF | Capacitor | 1 | Panasonic | P5148-ND | |
| TVS | P6KE16CA | TVS Diode | 1 | Littelfuse Inc | P6KE16CA | bi-directional |
| D1, D2, D3, D4 | 1N4148 | Diode | 4 | Diodes Inc | 1N4148DICT-ND | |
| D5,D6 | 1N5231 | Diode | 2 | 1N5231BVSCT-ND | ||
| Q1,Q2 | 2n2222 | NPN Transistor | 2 | STMicroelectronics | 497-2598-ND | |
| R1 (on Google Code) | 649 | Resistor | 1 | vishay | PPC649YCT-ND | Blue - Yellow - White - Black |
| R2 (on Google Code), R3 (on Google Code) | 2.4k | Resistor | 2 | Panasonic | CF14JT2K40CT-ND | Red - Yellow - Red - Gold |
| R4 (on Google Code), R11 (on Google Code), R12 (on Google Code), R17 (on Google Code) | 330 | Resistor | 4 | Panasonic | CF14JT330RCT-ND | Orange - Orange - Brown - Gold |
| R5 (on Google Code) | 56k | Resistor | 1 | Panasonic | CF14JT56K0CT-ND | Green - Blue - Orange - Gold |
| R6 (on Google Code), R8 (on Google Code), R9 (on Google Code), R14 (on Google Code), R16 (on Google Code) | 100k | Resistor | 5 | Panasonic | CF14JT100K0CT-ND | Brown - Black - Yellow - Gold |
| R7 (on Google Code) | 200k | Resistor | 1 | Panasonic | CF14JT200K0CT-ND | Red - Black - Yellow - Gold |
| R10 (on Google Code), R19 (on Google Code) | 10k | Resistor | 2 | Panasonic | CF14JT10K0CT-ND | Brown - Black - Orange - Gold |
| R15 (on Google Code) | 20k | Resistor | 1 | Panasonic | CF14JT20K0CT-ND | Red - Black - Orange - Gold |
| R18 (on Google Code) | 150 | Resistor | 1 | Panasonic | CF14JT150RCT-ND | Brown - Green - Brown - Gold |
| R20 (on Google Code) | 1k | Resistor | 1 | Panasonic | CF14JT1K00CT-ND | Brown - Black - Red - Gold |
| R21 (on Google Code), R22 (on Google Code) | 47k 1w flame | resistor | 2 | Panasonic | P47KW-1BK-ND | 473J |
| PILOT | 2Pos | Term Block | 1 | TE Connectivity | 1776244-2 | |
| Relay | SPST-NO | Relay | 2 | TE Connectivity | T9AS1D22-12 | |
| .1" | Headers | 1 | Misc |
See [How to Solder](How to Solder)
See [Resistor Guide](Resistor Guide)
Resistors can be installed in either direction. To save time a few resistors can be placed, soldered then leads trimmed.
-
Place the 100k ohm resistors (Brown - Black - Yellow - Gold) in positions R6 (on Google Code), R8 (on Google Code), R9 (on Google Code), R14 (on Google Code), and R16 (on Google Code). Solder then trim the excess lead.
-
Place the 330 ohm resistors (Orange - Orange - Brown - Gold) in positions R4 (on Google Code), R11 (on Google Code), R12 (on Google Code), R17 (on Google Code). Solder then trim the excess lead.
-
Place the 2.4k ohm resistors (Red - Yellow - Red - Gold) in position R2 (on Google Code) and R3 (on Google Code) and the 10k ohm resistors (Brown - Black - Orange - Gold) in position R10 (on Google Code) and R19 (on Google Code). Solder then trim the excess lead.
-
Place the 47k ohm 1 watt flame proof resistors (Grey in color - marked 473J) in position R21 (on Google Code) and R22 (on Google Code) and the 649 ohm resistor (Blue - Yellow - White - Black) in position R1 (on Google Code). Solder then trim the excess lead.
-
Place the remaining resistors 56k (Green - Blue - Orange - Gold) - R5 (on Google Code), 200k ohm (Red - Black - Yellow - Gold) - R7 (on Google Code), 20k (Red - Black - Orange - Gold) - R15 (on Google Code), 150ohm (Brown - Green - Brown - Gold) - R18 (on Google Code), and 1k (Brown - Black - Red - Gold) - R20 (on Google Code). Solder then trim the excess lead.
Note: All the diodes in this kit except the TVS diode are directional, note the markings on the board and ensure the dark band on the diode matches the marking.
Caution: Handle diodes with care, take precautions to prevent Electrostatic Discharge.
- Place the 1N4148 diodes in positions D1, D2, D3, D4. Note markings and install in the correct direction. Solder then trim the excess lead.
- Place the 1N5231 diodes in positions D5 and D6. Note markings and install in the correct direction. Solder then trim the excess lead.
- Place the TVS diode, this part is bi-directional. Solder then trim the excess lead.
- Solder the 0.1uf Capacitors (marked 104) in the positions labled C4 and C8. Trim excess lead.
- Solder the 22pf Capacitors (marked 220) in the position labeled C1 and C2. Trim excess lead.
- Solder the 2.2uf Capacitor (marked 225) in the position labeled C6. Trim excess lead.
- Solder the 1uf capacitor (marked 105) in the positions labeled C3 and C5. Trim excess lead.
-
Solder the 2 2N2222 Transistors in positions Q1 and Q2 in the orientation indicated on the board. Trim excess leads.
-
Solder the 16.000Mhz Crystal in the position labeled Y1.
Caution: Handle Integrated Circuits with care, take precautions to prevent Electrostatic Discharge.
- Place MID400 Integrated Circuits in positions IC3 and IC5 in the correct orientation. Solder in place and trim excess leads.
- Place LF353 Integrated Circuit in positions IC2 in the correct orientation. Solder in place and trim excess leads.
- Place LF358 Integrated Circuit in positions IC4 in the correct orientation. Solder in place and trim excess leads.
-
Optional: Install a socket for the Microprocessor. In the event the chip is "bricked" and unable to be programmed by normal means, a new microprocessor can be installed in the place of the "bricked" one.
-
Place ATMEGA328P Microprocessor in positions IC1 in the correct orientation. Solder in place and trim excess leads.
- Solder the .1" header pins into position for FTDI, ISP, I2c and the CT.
- Solder the Screw Terminal in the position labeled Pilot.
- Solder the DC/DC converter labeled D117E into position. Trim excess leads.
- Solder the AC/DC universal switch-mode power supply into position. Trim excess leads.
- Solder Relays into Position.
Follow the Test procedure here: http://code.google.com/p/open-evse/wiki/EVSE_TESTING
This evaluation board/kit is intended for use for ENGINEERING DEVELOPMENT, DEMONSTRATION, OR EVALUATION PURPOSES ONLY and is not considered to be a finished end-product fit for general consumer use.