OpenEVSE Open Source Charging Stations

Chris1howell · Sep 12, 2014

I have not been very active at TMC with OpenEVSE info. There have been a handful of Tesla owners that have built OpenEVSE units at 40A+, however most development has focused on 30A portable units. I have just released a new board and kit that fit the needs of Tesla owners better. I have been using a prototype 40A unit to charge my Model S for several months as has another TMC member. My UMC now is in the car where it should be...

OpenEVSE Plus v3 is now avaliable.
http://store.openevse.com/products/copy-of-openevse-plus-v3 .

It is a board specifically designed for Level 2 charging stations. To the standard OpenEVSE features (basically everything required in SAE J1772) it adds a opto-isolated line voltage AC relay trigger to drive large contactors. It also adds current measurement.

To go along with the new board is a 50A Level 2 Charging station kit.
50A Kit

Build Guide for 50A Charging Station Kit
OpenEVSE 50A Charging Station - OpenEV

http://d17kynu4zpq5hy.cloudfront.net/igi/openevse/uhIhbvIpU14VLu5G.medium

tga · Sep 13, 2014

Chris1howell said:
OpenEVSE Plus v3 is now avaliable.

Sweet...

Cottonwood · Sep 13, 2014

Do you have any good sources for 70-80 Amp J1772 cords and connectors?

lolachampcar · Sep 13, 2014

I used a Leviton cable (rated at 75 amps but the conductor sizes are perfectly fine for 80 amps) when I built my OpenEVSE based HPWC. It worked when it went in and I've not paid a bit of attention to it since (18 months).

http://www.leviton.com/OA_HTML/Home.jsp?minisite=10251&respid=22372

GSP · Sep 13, 2014

ITT Canon has a 75 Amp plug worth looking at. I don't know if they are readily available or not:

http://www.digikey.com/Web%20Export/Supplier%20Content/ITTCannon_1003/PDF/itt-brochure-evc-series-sae-j1772.pdf?redirected=1

GSP

PS. Tesla HPWC replacement plug-cable assemblies are also available. Good for 80 Amp and can open the Model S charge port. Tesla charges over $500 however.

HPWC Replacement Cable now available at Service Center

Cottonwood · Sep 13, 2014

lolachampcar said:
I used a Leviton cable (rated at 75 amps but the conductor sizes are perfectly fine for 80 amps) when I built my OpenEVSE based HPWC. It worked when it went in and I've not paid a bit of attention to it since (18 months).

http://www.leviton.com/OA_HTML/Home.jsp?minisite=10251&respid=22372

If you go to the Leviton site, the biggest they sell is 40 Amps now. http://www.leviton.com/OA_HTML/SectionDisplay.jsp?section=65189&minisite=10251

lolachampcar · Sep 13, 2014

shoot
Sorry about that. I'll count myself lucky to have bought one when I did.

Cottonwood · Sep 13, 2014

GSP said:
ITT Canon has a 75 Amp plug worth looking at. I don't know if they are readily available or not:

http://www.digikey.com/Web%20Export/Supplier%20Content/ITTCannon_1003/PDF/itt-brochure-evc-series-sae-j1772.pdf?redirected=1

GSP

PS. Tesla HPWC replacement plug-cable assemblies are also available. Good for 80 Amp and can open the Model S charge port. Tesla charges over $500 however.

I'll try and remember to call ITT next week.

tga · Sep 13, 2014

25 ft, 75A ITT Cannon cable is listed on Digi-Key:

EVC-C-75A-600-S-25

Bad news - it's $360, not stocked, and has a minimum order quantity of 50 units ($18,049.76)

None of the ITT cables or inlets are stocked.

GSP · Sep 13, 2014

Perhaps clipper creek or Eaton will sell a "replacement cable with plug" for their 80 Amp J1772 EVSEs?

GSP

Cottonwood · Sep 13, 2014

GSP said:
Perhaps clipper creek or Eaton will sell a "replacement cable with plug" for their 80 Amp J1772 EVSEs?

GSP

A 75 Amp J-cable from Clipper Creek for retrofitting a Roadster HPC to J1772 costs $595! The kit does include a holster for the J-Plug, but that still seems like a lot of money.

GSP · Sep 13, 2014

Well, $595 is a lot less than a $18k min order for 50 units! It also is competitive with Tesla's price for the 80 Amp Model S cable.

Sounds like that is the going rate these days. Reminded me of the old racer saying:

"(charging) speed costs money. How fast do you want to go?"

Personally, at these prices, 40 Amps (30 mph) will probably be my answer.

GSP

Cottonwood · Sep 13, 2014

GSP said:
Well, $595 is a lot less than a $18k min order for 50 units! It also is competitive with Tesla's price for the 80 Amp Model S cable.

Sounds like that is the going rate these days. Reminded me of the old racer saying:

"(charging) speed costs money. How fast do you want to go?"

Personally, at these prices, 40 Amps (30 mph) will probably be my answer.

GSP

There is a rumor going around that Tesla is dropping their price for the 80A HPWC from $1,200 to $750. That seems too good to be true, but really makes these a cables seem expensive.

mitch672 · Sep 13, 2014

Here is a link to pictures of the 40A UMC replacement I built with Chris's new HV contactor capable OpenEVSE board, I bought a Tesla UMC connector from Tony Williams, and the EVSE cable from his company as well (It was a challenge to splice them together, used "heat shrink" butt style connectors with solder embedded in them, then taped it all up and then overall shrink on that with a torch)

40A-OpenEVSE Slideshow by mitch672 | Photobucket

I've also built a 75A OpenEVSE with the ITT 75A cable, it's what I use everyday on my Dual charger Model S
OpenEVSE Slideshow by mitch672 | Photobucket
(the 40A OpenEVSE UMC replacement is at another house)

Cosmacelf · Sep 13, 2014

Cottonwood said:
Do you have any good sources for 70-80 Amp J1772 cords and connectors?

I'm selling mine for $149. See

70A J1772 Cord and Plug | eBay

Cottonwood · Sep 14, 2014

Cosmacelf said:
I'm selling mine for $149. See

70A J1772 Cord and Plug | eBay

The listing says Sold. Do you you have any more, or was this a one of a kind?

Cosmacelf · Sep 14, 2014

Cottonwood said:
The listing says Sold. Do you you have any more, or was this a one of a kind?

Damn, this board gets results. No sooner had I posted that link, then it got sold. Sorry, just had the one. I think I had purchased it from tucsonev,com, but they don't seem to sell high power J1772 cables anymore.

tga · Sep 14, 2014

The only place I've seen them listed for sale is at manzanitamicro.com, $345 for 75A. No idea if they are in stock (or even still available):

Manzanita Micro

I did check to see if Kickstarter could be used as "escrow service" for a big order, but their rules prohibit resale; you have to be creating something.

Cosmacelf · Sep 14, 2014

These guys sell a 60A cord set for $219.

Electric Motor Werks, Inc. - J1772 cables for our JuiceBox or DC Charging Systems

wycolo · Sep 15, 2014

They don't spec the plug itself. Also derate the cable to 50/60A, whatever that means. Also, DigiKey omits wire gauge of their 70A plug/cable combo.

Curious, I checked out my still unused CS-60: rated "48A continuous":

Cord - 3x8ga, 1x18ga.
Plug - no name - sticker says "70A at 240/120".

If I upgraded the contactor as well as the circuit board this could make a 70A j1772 (or less if the cable gets too hot).
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OpenEVSE Open Source Charging Stations

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