Looking for a 240V/100A relay ...

[electron]

I would consider selling it. A J1772 supply is just a contactor anyway with some minor electronics to communicate with the pilot protocol, right? So you are just putting a contactor in front of a contactor. Yes you would be protecting the other minor electronics, but they should be as resistant to failures as any other electronics that is powered by line voltage. The advantages of having live charge/consumption data, scheduling, control, etc. through remote (web/app) and open codebase/API is vastly preferable.

http://www.superbreakers.net/8910dpa93v02.html

https://code.google.com/p/open-evse/

 
I thought about going the OpenEVSE route, but I hadn't seen a good example showing off IP control.  There are other reasons I went with this unit (to avoid being blamed for any car problems, tax credit reasons, got a really good deal on it, etc.).  It really pisses me off that they charge close to $1k for this really simple device, but that's for another thread.
 
I plan on building an OpenEVSE once the cost of the J1772 connector/cable comes down.
 

A contactor is usually mounted in a junction box. I normally use fiberglass JBs, but those are pricy. I'm in Canada so as far as steel enclosures I use Dandy, Ace, and Vancouver electric. Though you can look at Hoffman and Hammond. I didn't notice specs on size but id say an 8x10x6 (wxhxd)is probably large enough. Just give yourself a few inches on each end to form the wire into the terminals.

 
Thanks again!

 

[Del91574]

Have you looked at the Elk 9200?
 
While they specify using an appliance module for HA, it's no different than the elevator shunt relays and contactors we use for elevator recall purposes (and supervise the 120VAC for the shunt breaker).

 

[electron]

Never realized I could switch 240 with that ELK unit, very cool, thanks!