Build your own EV charger. open-evse Open Electric Vehicle Supply Equipment (EVSE)

pinballlooking · 02-04-14, 12:37 PM

Ok let me start by saying it really is not a charger. All the EV vehicles have the chargers built in you just need to supply power and communication and safety to get it to charge your EV.

There are commercial units available they are expensive and not very flexible. Open EVSE will let you charge with 120 or 240 volts. This will do 3.3KW- 10KW charging. And beyond.

OpenEVSE_Compatibility - open-evse - OpenEVSE is known to be compatible with OpenEVSE Plus: - Open Electric Vehicle Supply Equipment (EVSE) - Google Project Hosting

OpenEVSE - a DIY charge station

I bought OpenEVSE Plus v2
OpenEVSE_boards - open-evse - Comparison OpenEVSE boards. - Open Electric Vehicle Supply Equipment (EVSE) - Google Project Hosting

EV Simulator
EVSimulator - open-evse - Assembly and Operation. - Open Electric Vehicle Supply Equipment (EVSE) - Google Project Hosting

RGB LCD Shield Kit w/ 16x2 Character Display
RGB LCD Shield Kit w/ 16x2 Character Display - Only 2 pins used! [NEGATIVE DISPLAY] ID: 714 - $24.95 : Adafruit Industries, Unique & fun DIY electronics and kits

(he now offers a display that is simpler to build and setup) he now offers a combo kit that will save having you from hunting down the other parts. I bought the kit before he offered this service.
Chris’s store OpenEV Store - OpenEV Store

I now have everything soldered on the boards. I have a few more parts on the way before I can finish this project.

pinballlooking · 02-04-14, 12:55 PM

Here are my boards so far after I soldered them.

pinballlooking · 02-16-14, 06:55 PM

I got my programmer in the mail it was delayed by the snow. I loaded the latest code and I wired the display.

Time to build the rest.

pinballlooking · 02-23-14, 08:23 PM

I finished the putting together the open source EVSE. It is now helping my Chevy Volt get charged up.
One good side benefit is it uses less than 1 watt in standby. This should help in my quest to lower my standby load.

It was a lot of drilling and getting everything to fit in the box. The 10 gauge wire is very stiff to work with. I am happy with the end results.
For the 8 gauge wire I used left over pieces from my solar project.

The second picture shows it actually charging my Volt.

I based my component layout off this build.
http://code.google.com/p/open-evse/wiki/30A_OpenEVSE

A lot of the parts I ordered were based off this build.
http://code.google.com/p/open-evse/wiki/EVSE_by_4Dolio

pinballlooking · 02-24-14, 08:49 AM

Things I would do different.

The fuse holder I bought is working fine but it could be beefier.
This is a better choice.

OpenEV Store - 30A Cooper Bussman Miget Fuse Holder
He did not sell these when I bought the kit. (Other people also sell this fuse holder)

He was out of the displays when I bought my kit. This one is simpler and more compact.

OpenEV Store - DIY - OpenEVSE RGB LCD

Metal enclosure would be stronger and just a little bigger would give more options for mounting things.

Indoor the plastic one is fine.

Things I liked or would do again.

The Leviton cable with J1772 plug is top quality. (Try to get this on sale)
I got this on a black Friday deal and it was a great deal. I got the 25’ version but they don’t sell this one any more. Buy the 30 amp cord even if you don't need it your next EV will need it and you will be all set.

https://store.leviton.com/collection...nt=18215948867

If you use the Leviton cable buy Strain Relief Cord Connectors - PG 21. It is a very tight fit but the next size up will not work at all. I had to send a set back and order these. you will need some soapy water and maybe light sand the cable to get them on. but they need to have a tight fit or they are useless.

I would buy the OpenEVSE Programmer again.
OpenEV Store - OpenEVSE Programmer
This allows up to load the latest software or bug fixes.

The EV simulator kit is a must have.
OpenEV Store - EV Simulator Kit
This allows you to test out the whole thing before plugging in that very expensive car. Then you know you did not mess it up.

Read all directions very carefully. Don’t drill into your work table



Look over other peoples builds to decide how you want yours.
http://code.google.com/p/open-evse/wiki/30A_OpenEVSE

karl0525 · 12-20-14, 07:10 PM

Hello pinballlooking i bought a juice box level 2 charging kit from kickstarter a few months back and after looking at it i think i would need someone to build it for me. It includes all the parts except the charge cable. I to have a chevy volt and would like to be able to level 2 charge.If this is something we could discuss $ or maybe do a trade for 1 of your kits i am open to suggestions thanks.

WyrTwister · 08-16-16, 09:29 AM

Just for information , what would the open Source EVSE do if you feed it 120 VAC in stead of 240 VAC ?

208 VAC ?

God bless
Wyr

pinballlooking · 08-16-16, 09:50 AM

It looks like it depends on what version you are using.

Can I use the 50A deluxe kit with 120V : OpenEVSE Support
Version 4 using 120v relay (not the normal method) : OpenEVSE Support

Mine is hard wired to 240 volt. I moved my old EVSE to my lake place. It used way to much standby power so I just flip off the breaker when we are not there.

pinballlooking · 11-18-19, 07:59 AM

Time for an update.
Almost five years ago I built this EVSE. We used it to charge our car two times a day four years.

This last year we usually only charge once a day my son has his own car and drives himself to school every day.

During this time, I have had the one fuse blow twice. Since this was the second time the fuse blew. I took it off the wall to investigate why it was blowing the fuse.
It turns out the fuse holder that I did not really like had the female spade connector loosen up.
This was on the side the fuse was blowing. I crimped it down and resembled it. I built this in a water proof box.

I could see where some heat was building up so I drilled two 3/8 holes on the top and one on the bottom. This will let the heat out.
It is back to charging my car again.

Daox · 11-18-19, 08:41 AM

Do you recall what was your total cost for this project was? Aren't there EVSEs out there for like $300? That Levition cable alone is nearly $200.

02-04-14, 12:37 PM	#1
pinballlooking Super Moderator Join Date: Jun 2013 Location: SC Posts: 2,923 Thanks: 172 Thanked 564 Times in 463 Posts	Build your own EV charger. open-evse Open Electric Vehicle Supply Equipment (EVSE) Ok let me start by saying it really is not a charger. All the EV vehicles have the chargers built in you just need to supply power and communication and safety to get it to charge your EV. There are commercial units available they are expensive and not very flexible. Open EVSE will let you charge with 120 or 240 volts. This will do 3.3KW- 10KW charging. And beyond. OpenEVSE_Compatibility - open-evse - OpenEVSE is known to be compatible with OpenEVSE Plus: - Open Electric Vehicle Supply Equipment (EVSE) - Google Project Hosting OpenEVSE - a DIY charge station I bought OpenEVSE Plus v2 OpenEVSE_boards - open-evse - Comparison OpenEVSE boards. - Open Electric Vehicle Supply Equipment (EVSE) - Google Project Hosting EV Simulator EVSimulator - open-evse - Assembly and Operation. - Open Electric Vehicle Supply Equipment (EVSE) - Google Project Hosting RGB LCD Shield Kit w/ 16x2 Character Display RGB LCD Shield Kit w/ 16x2 Character Display - Only 2 pins used! [NEGATIVE DISPLAY] ID: 714 - $24.95 : Adafruit Industries, Unique & fun DIY electronics and kits (he now offers a display that is simpler to build and setup) he now offers a combo kit that will save having you from hunting down the other parts. I bought the kit before he offered this service. Chris’s store OpenEV Store - OpenEV Store I now have everything soldered on the boards. I have a few more parts on the way before I can finish this project. Attached Thumbnails Last edited by Daox; 02-04-14 at 02:27 PM..

02-04-14, 12:55 PM	#2
pinballlooking Super Moderator Join Date: Jun 2013 Location: SC Posts: 2,923 Thanks: 172 Thanked 564 Times in 463 Posts	Here are my boards so far after I soldered them. Attached Thumbnails Last edited by Daox; 02-04-14 at 02:27 PM..

02-16-14, 06:55 PM	#3
pinballlooking Super Moderator Join Date: Jun 2013 Location: SC Posts: 2,923 Thanks: 172 Thanked 564 Times in 463 Posts	I got my programmer in the mail it was delayed by the snow. I loaded the latest code and I wired the display. Time to build the rest. Attached Thumbnails Last edited by Daox; 02-17-14 at 10:44 AM..

02-23-14, 08:23 PM	#4
pinballlooking Super Moderator Join Date: Jun 2013 Location: SC Posts: 2,923 Thanks: 172 Thanked 564 Times in 463 Posts	I finished the putting together the open source EVSE. It is now helping my Chevy Volt get charged up. One good side benefit is it uses less than 1 watt in standby. This should help in my quest to lower my standby load. It was a lot of drilling and getting everything to fit in the box. The 10 gauge wire is very stiff to work with. I am happy with the end results. For the 8 gauge wire I used left over pieces from my solar project. The second picture shows it actually charging my Volt. I based my component layout off this build. http://code.google.com/p/open-evse/wiki/30A_OpenEVSE A lot of the parts I ordered were based off this build. http://code.google.com/p/open-evse/wiki/EVSE_by_4Dolio Attached Thumbnails Last edited by pinballlooking; 02-05-17 at 10:43 PM..

02-24-14, 08:49 AM	#5
pinballlooking Super Moderator Join Date: Jun 2013 Location: SC Posts: 2,923 Thanks: 172 Thanked 564 Times in 463 Posts	Things I would do different. The fuse holder I bought is working fine but it could be beefier. This is a better choice. OpenEV Store - 30A Cooper Bussman Miget Fuse Holder He did not sell these when I bought the kit. (Other people also sell this fuse holder) He was out of the displays when I bought my kit. This one is simpler and more compact. OpenEV Store - DIY - OpenEVSE RGB LCD Metal enclosure would be stronger and just a little bigger would give more options for mounting things. Indoor the plastic one is fine. Things I liked or would do again. The Leviton cable with J1772 plug is top quality. (Try to get this on sale) I got this on a black Friday deal and it was a great deal. I got the 25’ version but they don’t sell this one any more. Buy the 30 amp cord even if you don't need it your next EV will need it and you will be all set. https://store.leviton.com/collection...nt=18215948867 If you use the Leviton cable buy Strain Relief Cord Connectors - PG 21. It is a very tight fit but the next size up will not work at all. I had to send a set back and order these. you will need some soapy water and maybe light sand the cable to get them on. but they need to have a tight fit or they are useless. I would buy the OpenEVSE Programmer again. OpenEV Store - OpenEVSE Programmer This allows up to load the latest software or bug fixes. The EV simulator kit is a must have. OpenEV Store - EV Simulator Kit This allows you to test out the whole thing before plugging in that very expensive car. Then you know you did not mess it up. Read all directions very carefully. Don’t drill into your work table  Look over other peoples builds to decide how you want yours. http://code.google.com/p/open-evse/wiki/30A_OpenEVSE Last edited by pinballlooking; 01-16-18 at 05:14 PM..

12-20-14, 07:10 PM	#6
karl0525 Lurking Renovator Join Date: Dec 2014 Location: north texas Posts: 11 Thanks: 1 Thanked 0 Times in 0 Posts	Juice box(base addition) Hello pinballlooking i bought a juice box level 2 charging kit from kickstarter a few months back and after looking at it i think i would need someone to build it for me. It includes all the parts except the charge cable. I to have a chevy volt and would like to be able to level 2 charge.If this is something we could discuss $ or maybe do a trade for 1 of your kits i am open to suggestions thanks.

08-16-16, 09:29 AM	#7
WyrTwister Master EcoRenovator Join Date: Jun 2013 Location: USA Posts: 543 Thanks: 6 Thanked 44 Times in 38 Posts	Just for information , what would the open Source EVSE do if you feed it 120 VAC in stead of 240 VAC ? 208 VAC ? God bless Wyr

08-16-16, 09:50 AM	#8
pinballlooking Super Moderator Join Date: Jun 2013 Location: SC Posts: 2,923 Thanks: 172 Thanked 564 Times in 463 Posts	It looks like it depends on what version you are using. Can I use the 50A deluxe kit with 120V : OpenEVSE Support Version 4 using 120v relay (not the normal method) : OpenEVSE Support Mine is hard wired to 240 volt. I moved my old EVSE to my lake place. It used way to much standby power so I just flip off the breaker when we are not there. __________________ Current project Aquaponics system , Passive Solar Greenhouse build To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Solar Install 12.5 Kwh- To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Mini Split installs - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. EV Chevy Volt - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts.

11-18-19, 07:59 AM	#9
pinballlooking Super Moderator Join Date: Jun 2013 Location: SC Posts: 2,923 Thanks: 172 Thanked 564 Times in 463 Posts	Time for an update. Almost five years ago I built this EVSE. We used it to charge our car two times a day four years. This last year we usually only charge once a day my son has his own car and drives himself to school every day. During this time, I have had the one fuse blow twice. Since this was the second time the fuse blew. I took it off the wall to investigate why it was blowing the fuse. It turns out the fuse holder that I did not really like had the female spade connector loosen up. This was on the side the fuse was blowing. I crimped it down and resembled it. I built this in a water proof box. I could see where some heat was building up so I drilled two 3/8 holes on the top and one on the bottom. This will let the heat out. It is back to charging my car again. __________________ Current project Aquaponics system , Passive Solar Greenhouse build To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Solar Install 12.5 Kwh- To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Mini Split installs - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. EV Chevy Volt - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts.

11-18-19, 08:41 AM	#10
Daox Administrator Join Date: Aug 2008 Location: Germantown, WI Posts: 5,525 Thanks: 1,162 Thanked 374 Times in 305 Posts	Do you recall what was your total cost for this project was? Aren't there EVSEs out there for like $300? That Levition cable alone is nearly $200. __________________ Current project - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. & To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts.