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SAE J1772:2010 Vehicle Inlet Coupler to NEMA 14-50 receptacle adapter

This is the second design of the adapter with the two connectors inline and a new handle or security ring added on the side.  The ring allows the adapter to be carried on a hooked finger or two while keeping the hand free to carry other needed items.  It also allows for a security cable or chain so the adapter is still  with the car after unattended public charging

In July 2010 the J1772 connector were not available from any source in reasonable quantities.  The distributors had never heard of such a thing.  The representatives were not interested in small quantities.  So we decided to makes some. 

The SAE J1772:2010 standard gives every critical dimension and requirement.  It is obvious the part should be injection molded.  We chose to machine the part from solid materials.  The outer shell is 6061 aircraft aluminum.  The insulator is a electrical grade virgin Delrin.  The pins are nickel plated brass.  The machined parts are all fabricated by small machine shops in South Florida.

We believe this is a well thought out solution while we waited for the J1772 connectors with full UL listings.

When it is in use the cables just plug in.

Remember to always plug the NEMA 14-50 in first and push STOP on the charging station before removing the J1772 commenter for maximum safety and long service life. 

The J1772 parts are safe and robust but not designed to be mated or separated with power on.

There are warnings on the back. 

As with any electrical device there are risks.  Please follow the instructions and only use a full J1772 charging station with ground fault protection.  Having the power coming from the approved J1772 charging station with ground fault protection should reduce risks.

This adapter is not intended for use in a wet area.  If it gets wet or ends up in a puddle STOP the charging at the J1772 charging station before touching the adapter.

This is a side view showing the low profile of the adapter.

Dimensions are :

  • 3.15 inch (80mm) Wide Box
  • 4.44inch (113mm) Wide at handle
  • 1 X 2.7 inch (25 69mm) opening in handle
  • 7.67 inch ( 195mm) Long
  • 3.76 inch (96mm) high

The adapter weights 1.7 pounds, 0.8Kg

We call the adapter a 40Amp device.  There is one J1772 inlet design that covers all current levels to 80 Amps.  The SAE J1772 currents are actual charging amps which are 80% of the supply circuit breaker amps.  So a 40 Amp circuit beaker can charge at 32 Amps.

We selected #8 THHN wire for the power connections.  #8 THHN wire is rated at 45 Amps @ 75 degrees centigrade, which is the maximum temperature the NEMA 14-50 receptacle is rated for.  Since 45 Amps is a odd rating, we have called it 40 Amps, which is the 60 degrees centigrade rating for the wire.  Most charging station old and new charge do not exceed 32 Apps from a 40 amp breaker.

 

 

e-mail: david@modularevpower.com
 

modular EV power LLC, all rights reserved, 2010