Customer Wiring instructions for v8.12

Kris -

*This guide is only for units that are being sent without cables, usually where single phase/240V electrical systems are in use, or Mennekes Type 2 plugs are used in place of Type 1 J1772 (North American Standard)

eMotorWerks, no longer sells kits.

 

If you are building a Pro unit, crimp only the Ground (green) and Line (black) wires to start. If building a Classic unit, crimp all three.

Insert the J-Cable into the cable gland. Inside the unit, run the black and red wires through the Large current sensor with the current sensor’s wires pointed towards the top of the JuiceBox. (top being away from the cable glands.) Run a piece of wire through the large current sensor ensuring it is long enough to later be connected to the top side of the board. If you are building a Pro unit, place the smaller current sensor onto the red wire with it’s wires pointed towards the bottom of the Juicebox. (towards the glands.) You can now crimp the red wire.   

    

 

You are now ready to wire up your Juicebox. When you are connecting cables/wires to the relay, remember to always place the smaller lugs towards the top of the “stack.” This ensures nothing will get hot and burn.

 

Input

Attach the red (neutral hot) input wire to the bottom right lug of the relay with a signal wire on top. Attach the black (line hot) input wire to the bottom left lug of the relay, also with a signal wire on top.

Relay Control

Attach a signal wire onto both of the center connectors on the relay.

J-Cable

Attach the red (neutral hot) J-wire to the top right relay connector with a signal wire on top. Do the same for the black (line hot) J-wire on the other side.

 

Current Sensor Positioning

Classic: Ensure that the large current sensor is far enough away from the bottom of the PCB so that it does not sit under the arduino. That would cause a large bend in the PCB and could cause permanent damage and render the unit non-functional.
Pro: The large current sensor has the same positioning as the Classic unit. The Red (neutral hot) wire should be in an upside down “U.” Slide the small current sensor toward the relay.

 

PCB Wiring

All of the screw terminals on the PCB (blue and black rectangles) are labeled. You will be using those labels throughout the wiring process.

 

Attach the Black input wire’s signal wire to the “AC-In H->” labeled terminal on J7. Attach the Red input wire’s signal wire to the “AC-In N/H->” labeled terminal on J7.

 

Attach the relay control wires to the “Relay->” labeled terminals on J6.

Attach the Black J-wire’s signal wire to the “AC-J H->” labeled terminal on J2. Attach the Red J-wire’s signal wire to the “AC-J N/H->” labeled terminal on J2. Attach the Pilot wire to the “Pilot->” labeled terminal on J6.

 

Attach the wire that runs through the large current sensor to the “GFCI test wire loop” labeled terminals on J8.

 

Attach the large current sensor’s wires to the “GFI Current Sensor” labeled terminals on J10.

 

Attach the small current sensor’s wires to the terminals on J9. The wiring does matter on these 2 - the wires must cross *once* before being connected to the terminals. Think of them making an “X.”

 

That’s it! Make sure your connections are tight, and your unit should start up first time. Feel free to Contact us at JB-support@emotorwerks.com if you have any technical questions.

 

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