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Building a flexible tailless OpenEVSE 40A kit.


I've bought an OpenEVSE Advanced 40A kit, and I'd like a sanity check on my approach to a couple of mods before I commit to assembly. 

I live in NZ where three forms of single phase charging socket are widely available:

1) Home/motel: 3-pin flat 240v, 10A sockets, AS/NZS 3112

2) Caravan parks: Blue commando 3-pin round 240v 16A sockets, IEC 60309

3) Public tailless Type 2 charging stations IEC 62196-1 16A/32A sockets

My current PHEV has a Type 1 on-board socket so I already carry a Type 2 to Type 1 cable.

My plan is to build an OpenEVSE kit with:

1) a Type 2 IEC 62196-1 Socket, for use with the Type 1 to Type 2 cable, to avoid carrying two cables.

2) a Neutrik PowerCon 32A ( locking socket, for use with two alternative patch cables for home 3-pin & blue commando plugs. I would expect one or other of these tails normally to be plugged in for long periods while I'm either at home or on the road .. so don't anticipate unplugging it every time I use it.

So I'm exploring different ways to re-arrange items inside the box to accommodate the two sockets and I think I have a viable and elegant solution, which I'm happy to share once I have settled on 'the answer'. 

So my questions are: (I'm being super cautious in asking each of these just to be sure)

1) which items are most prone to heating up and therefore need some air space round them?

2) is there a risk of electrical interference in having high current cables too near (but obviously not touching) items such as the MINMAX power module, or the walls of the enclosure, or the wifi unit? ie What is a reasonable minimum separation?

3) is the total area of the ground plate critical electrically or for heat dispersion? I'm looking to reduce its length by 20-25% to enlarge the interior volume round the 2x sockets.

4) Given that the ground plate no longer covers the entire base, and that I take suitable precaution to protect insulation a minimise high amp cable curvature, is there any reason why it would be a bad idea to route some cables through new holes in the ground plate?

Finally the Neutrik 32A is the most compact 32A locking socket I have found, but if someone has identified a better alternative, I'm very open to other alternative suggestions.

Many thanks in advance for your help


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