OpenEVSE International Combo (OpenEVSE v3) with LCD

[Gune]

Hi 

I have finished OpenEVSE International Combo (OpenEVSE v3) with LCD when it power up LCD only Give Blue color but no text I try to adjust the brightness with power off no success. When I press the push button back lit goes and come back in within one or two second I will try to insert a image but white balance is not correct even after manual WB sorry about 

Auto WB

With Manual WB

[Craig Kirkpatrick]

The tiny adjustment VR-1 has a very narrow range where the LCD contrast is viewable. Try adjusting it with power on and I think you will succeed. If you have an ISP programmer cable then it is possible to power the logic with a safe 5V. Powered from AC mains be careful with any tool you use so not to drop it into the high voltage side of the EVSE.

Since it responds to the button press I am confident that you will be smiling very soon. Just adjust that little potentiometer.

[chris1howell .]

To see the text on the display, adjust the contrast labeler "VR-1". Turn counter clock wise to the stop the back about 1/4 turn.  

LCD Build Guide

The backlight should not turn off when the button is pressed. Please ensure the bottom is assembled and connected correctly.

Button Build Guide

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[Gune]

Thank you Craig and Chris for your kind help

I found I have wired push button wrongly +5V and Ground not the select

It was corrected and contrast adjusted now it is working fine but it gives stuck relay I have used following type of 40A relays it operates 3V to 32V DC nothing mentioned about amps

consumed by the relay 

do I need to change the relay or else

[Gune]

Hi Chris

I came to know that my relays are Solid State Relays SSR does Open EVSE support this type?

Internal Diagram is 

Trigger Current is 7.5mA / 12V should it work or do I need any modification to overcome Stuck Relay Test

Thank yo all inadvance

[Craig Kirkpatrick]

Maybe you have reversed the polarity of the 12V wiring to the SSRs. Normal coil relays do not care of the polarity. The diagram of the SSR shows it does care since it actuated a photo diode. On the three terminal really actuation block on the OpenEVSE controller the center terminal is +12V and each side terminal is switched to 0V to actuate the relay or it is left to float like disconnected from 0V. You did no harm to your SSR. I think you just need to reverse the wires leading to the SSRs.

I'm interested to hear from you how you like the SSR when you have your EVSE working. The SSR seems attractive. I wonder if the SSR produces very much heat under high amperage and I wonder how completely off the SSR is when it is switched off. I can look at the specifications for it myself.

[chris1howell .]

Craig intuition is dead on in regards to both heat and mechanics. SSRs should not be used in a charging station. The primary function of the charging station is to isolate the EV end of the plug until all safety checks are verified. A SSR can stop current from flowing but there may be voltage still present on the output. This is likely why the stuck relay test is failing.

Additionally the internal resistance of a SSR will generate considerable heat under load. When an SSR fails they fail they commonly fail closed, relays on the other hand commonly fail safe in the open position.

On Fri, Feb 20, 2015 at 11:36 AM, Craig Kirkpatrick <crai...@comcast.net> wrote:

Maybe you have reversed the polarity of the 12V wiring to the SSRs. Normal coil relays do not care of the polarity. The diagram of the SSR shows it does care since it actuated a photo diode.  On the three terminal really actuation block on the OpenEVSE controller the center terminal is +12V and each side terminal is switched to 0V to actuate the relay or it is left to float like disconnected from 0V. You did no harm to your SSR.  I think you just need to reverse the wires leading to the SSRs.

I'm interested to hear from you how you like the SSR when you have your EVSE working. The SSR seems attractive.  I wonder if the SSR produces very much heat under high amperage and I wonder how completely off the SSR is when it is switched off. I can look at the specifications for it myself.

[Craig Kirkpatrick]

Gune,

I looked at the specifications for the SSR you are using.  It shows a 1.6V Voltage Drop.  If I were to attempt to charge my Ford Focus EV which has a 6.6kW charger with 230V mains voltage then I would expect to see that each SSR needs to dissipate 47W of heat.  With two SSRs you need to get rid of 95W of heat in a small enclosure.  That scares me.  And when the SSR is "off" you have a 3mA leakage current.  So when the SSR is "off" it is not off at all and still the 230V or 240V mains voltage is there at the plug like Chris pointed out.

Regardless of safety at the J1772 plug, I think you will melt your EVSE with the heat generated by the SSRs when a car is attempting to charge. This is a serious safety concern. 

Be safe.  Be careful.

Funny and sad is that after I ordered a 50A Packard C240C contactor from Amazon.com then Amazon was sending me emails teasing me to purchase this same SSR.  I looked at it six months ago and rejected it for the reasons I explain above.

Good Luck and Best Wishes,

Craig

[Gune]

Dear Craig,

Thank you for your kind help again,. I thought center is Zero and other 2 pins are positive I reverse the polarity but it does not work as Chris mentioned SSR's output is not isolated it gives stuck relay 

I have to change the relays I found nearby shop they have 40A ac operated but it switch one wire do I need to isolate both outputs from  the vehicle? 

I just try to test one relay if it works I can go for two.

[Craig Kirkpatrick]

The double pole 40A contactor that is part of the OpenEVSE 50A kit from the OpenEVSE store is the Packard C240C.
http://www.amazon.com/Packard-C240C-Pole-Contactor-Volt/dp/B004Z0RLR6
I suggest using the C240C since it does not cost much money and it is proven to work reliably for the EVSE application with the V3 controller.

In North America our 240V is supplied as two 120V hot lines with 240V measured from hot line to hot line. We must disconnect both hot lines to the EV plug. Therefore we use two relays or we use a double pole contactor like the Packard C240C.

[Gune]

Thank Craig

I check your link relay is cheap but for postage they ask more than 35 USD to my Place. So I have to find someone to pic form USA and hand carry as my OpenEVSE

[Gune]

Hi Craig

I placed the order and it was delivered to my friend today I notice it is available OpenEVSE store I would have order it with my current transformer together but now too late.

[Craig Kirkpatrick]

Gune, Chris just let us know he was adding the contactors to the things he sells in the OpenEV store on Friday last week.  I would have pointed you to the OpenEV store if I knew he was planning to sell them.