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My Open EVSE Build Thread

Discussion in 'Gen 1 Prius Plug-in 2012-2015' started by trentofdestiny, Nov 1, 2012.

  1. trentofdestiny

    trentofdestiny Master Finagler

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    I decided to undertake building an Open EVSE. This thread will show you what I've done so far, tally the cost, allow you (and me) to ask questions, and so on.

    I'm getting an Open-EVSE v4 through-hole board made, but it comes in a 3-pack. I will have 2 extra ones available (they cost $15 each plus shipping). Also, picked up a relay, enclosure, and (2) 12V pilot lights today (see pic). Cost? $42.

    The boards will be $45 for 3, which means 1 will be $15. I will be getting a Leviton charge cable 25' and plug for ~$135.

    The components to solder on the board cost ~$60. I will see tomorrow if they can be obtained around here more cheaply.
     

    Attached Files:

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  2. trentofdestiny

    trentofdestiny Master Finagler

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    ImageUploadedByTapatalk1351865185.768817.jpg

    Just picked up my "power supply" at the computer store for $10. I would have used one I already had, but didn't have any extra (ie, not tied to a device already). Why pay $30 and have to build it yourself? Lol. I'm debating on whether to install it as-is or take the board out of the unit.
     
  3. Rebound

    Rebound Senior Member

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    I just received the Leviton 30A EVSE cable/plug combo. Here are my observations:
    1) The 30A-rated cable is VERY thick and heavy, as you can see in the photo below. Look where the white Leviton is laid next to the blue Toyota EVSE. If you're building only for PiP, the 15A-rated cable is the way to go.
    2) I plugged it into my PiP and the fit is very tight. It is difficult to remove from the car. I'm not sure where it's too tight, but I might try some fine sandpaper to loosen the fit.
    3) If you look at the close-up photo, note the thin foam o-ring. This doesn't seem very durable.
    4) The reverse side of the EVSE has a twelve screws. Not the most attractive.
    5) It feels solid and well-constructed.

    As long as I can solve the fit issue, I'll use it. Compared to everything else out there, the value is unbeatable, and from what I've heard of other cable/plugs that do-it-yourselfer's have bought, this one's probably the best.

    [​IMG][​IMG][​IMG][​IMG]
     
  4. trentofdestiny

    trentofdestiny Master Finagler

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    Hey thanks for the info! I may try to find a different source for the plug and/or cable. Possibly eBay or if I can get ahold of an OEM unit that died.
     
  5. Rebound

    Rebound Senior Member

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    I edited my post. The Leviton isn't bad, as long as I can correct the fit and loosen it a little.

    I checked your profile to see if you're nearby... but you're in Harrisburg! I grew up there. My mother still lives there. Small world.
     
  6. mitch672

    mitch672 Technology Geek

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    Yep, I just had (3) thruhole V4 boards fabricated by OshPark as well, and bought 3 sets of components for them from DigiKey.
    Also ordered AdaFruit RGB LCD displays for them, 30A DPST relay, GFCI coil and 12V power supplies (actually bought 5 supplies so I have 2 extra availble)

    I'm building an OpenEVSE for a member of the forum, without the case, J-1772 cable and AC input wiring.
    The 2nd one is a spare for myself to work on the current monitoring firmware.
    I'll have the third one availble if anyone is interested, send me a PM
    Not trying to hijack your thread, just going to have 1 availble all built and tested availble.
    Will probably be another week before I can get these together, all parts not in yet
    (Jameco shipped me the wrong power supplies, OshPark PCBs in the US mail as well as the AdaFruit RGB LCD displays)

    Great minds think alike :)
     
  7. trentofdestiny

    trentofdestiny Master Finagler

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    Cool. I wish I had just waited and bought a pre made unit but oh well. It will be fun I guess lol. Is it necessary to program the unit you build yourself? With the USB to FTDI cable?

    Yup, Harrisburg. I actually saw a silver Plug In Advanced at the church/school where I was working. I wasn't aware there was another in the area!
     
  8. bisco

    bisco cookie crumbler

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    i suppose when pip's start hitting the recycling yards, evse's will become available on ebay or wherever.
     
  9. lensovet

    lensovet former BP Brigade 207

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    my god that is hideous. and huge!
     
  10. trentofdestiny

    trentofdestiny Master Finagler

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    I have seen a couple on eBay but they were functional.
     
  11. bisco

    bisco cookie crumbler

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    that's okay, if the price is right.:)
     
  12. mitch672

    mitch672 Technology Geek

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    Yes you need the 6 pin programmer, the PCB also need a jumper added between the RST pin on the 6 pin programming header and the RST line on the Atmel (won't program without it in place)
     
  13. trentofdestiny

    trentofdestiny Master Finagler

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    $5-600 for a 120V Toyota OE unit? Nah.

    Oh I almost forgot! Can I modify the OE unit for 240V?
     
  14. Rebound

    Rebound Senior Member

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    It's no bigger than any 30A, 240V EVSE. But a Prius can't take advantage of 30A.
     
  15. bisco

    bisco cookie crumbler

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    if you know what you're doing. that's what peef does for a couple hundred bucks. you send him your 120v evse, and he sends it back equipped for 240v or 120v with plug adapter.
     
  16. trentofdestiny

    trentofdestiny Master Finagler

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    I thought so, but I can't find out exactly what to replace with something rated for 240V. It would be nice to have two dual voltage chargers 0:)
     
  17. bisco

    bisco cookie crumbler

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    i have not heard of anyone but peef doing it themselves. he built his own phev, seems to be head and shoulders above most everyone.
     
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  18. trentofdestiny

    trentofdestiny Master Finagler

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    Looks like I'm going to have some extra components (from the circuit board) left as well, because of the quantity some of them have to be purchased...
     
  19. trentofdestiny

    trentofdestiny Master Finagler

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    Here's what my night consisted of:
    IMG_0025.jpg

    I managed to get the board 99% completed. Couldn't find any 320 ohm resistors in stock so I had to order another 330 ohm (they are 5% tolerance which is plus or minus 16.5 ohms). Also I forgot the HV resistors (28k ohm) so the board will be out of the housing for a few more days. I did get the cord in/outputs mostly set up though:
    IMG_0026.jpg IMG_0027.jpg
     
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  20. mrbigh

    mrbigh Prius Absolutum Dominium

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    looking nice:)