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New Build/Install - Using cables from Juicebox

I received the advanced kit, and just wanted to share my experiences in the build.


I had power/EV cables from my Juicebox Pro, and decided to get the advanced kit due to the issues with the vendor (ie: shutting down, and wifi issues).


I had to use a step bit for the EV cable to make it larger since the Juicebox Pro cable was much larger than others. 


After seeing others having problems with their builds, I put quite a bit of emphasis on ensuring the power wiring was lifted high up in the box and routed over to the left, and the current transformers (x2) and the pilot wire was located low down and kept to the right. And finally, everything zip-tied nicely.


Also, I used 4 large machine screws with nuts for mounting down the relay/contactor as well as the grounding block. I didn't want to use self-tapping screws... which was just a personal preference.. 


With the EV cable conductors being #8, it was a tight fit to get the GFCI CT to slip both of the conductors but, luckily it did work.  The thicker EV conductors made it more of a challenge to get everything bent correctly with both CT's close to one another with different wire.  


Anyways, hopefully this is how we're supposed to do the wiring. In testing, everything works so far

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Looks great. Thank you for posting your experience.


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Got mine up and running today too!   Same deal, step bit, larger hole due to cable.  Other than that, no issues.  


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Thanks for posting.  I just did the same build using Gen 1 (old metal box) JuiceBox input cable and J1772 cable.  My JB cables were terminated with a crimp using a hole in the crimp and screw through terminals, so I had to lop those off for the OpenEVSE build which uses the clamp down terminals.  

As you said, the wiring was very thick compared to other EVSEs I have used at home so it was a challenge to get them through the GFCI (I think...the one with 2 cables through it).  I used a pair of flat pliers to flatten the cables a bit at that spot and it ultimately worked.  

Overall, my unit also works so I'm happy with the build.  

I have another JB that I received as a donation, so I'm hoping there's an easy OpenEVSE upgrade kit that can allow others to simply, say, drop in an OpenEVSE controller and reuse everything else compared to buying a whole OpenEVSE kit.  


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Hmm. I also converted my set of JuiceBox cables. I used a Dremel to expand the hole to install the gland from the JuiceBox. I agree that it was a tight fit getting the #8 wires through the GFCI CT and routing the wires. I cut the ends off those wires and just put the strands into the contactor contact and tightened the screw pretty tight. Is there any reason that may not be acceptable? So far it seems ok. I am happy to now have a setup that does not rely on some server in the cloud to perform its basic operations. I also appreciate that the contactor contacts are not exposed in my unit.

With respond to not using ferrules...  the conductors from the old juicebox have a high number of strands, and with the use of good quality ferrules, they ensure you are able to utilize the entire conductor (all strands) to carry the high current. The terminals on the relay may spread strands apart, and the conductor may not compress properly.  This could also lead to the connecting loosening over time, causing heating (potentially causing excessive heating, fire, and damage to the relay itself or worse)..  I think to get certification in some countries, ferrules are required on stranded wires when being terminated. I would without doubt buy some ferrules and the tool.  I'd also buy them from digikey, or Mouser... and not use cheap chinese ones.


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Thank you for your response. It makes sense. Since the cables are rated for 50A and I flattened the strands as best I could before tightening them and I have set a current maximum of 20A and usually set it down to only 12A, I don't think I will worry about it unless I see an issue. For sure if I was running 40A I would take immediate action on getting ferrules in there. In the event that I see any thermal or other issues, putting in ferrules will be on the top of my list. Thank you again for your response.

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