The control box is the primary electrical interface between the controller, motor, and  rest of the vehicle.

• What is it? Converts direct current (DC) from one voltage level to another 

• Take high-voltage power from the battery and convert it to low-voltage power for use by other systems. 

• They connect systems with different voltage levels. 

Can be isolated to help with safety, especially for higher voltages and currents 

Installation: To start, we need four 1/4”-20 x 1” screws with flat washers and nylon insert nuts. The front of the screw goes under the base and the flat washers with the nut go inside the case. The rectangle in front of the front case fan is where the converter sits and the cables exit the converter into the main interior area of ​​the case.

• This install was done earlier to help with clean wiring. 

• Five #10-24 machine screws x 3/4” washers and nylon inserts. The front of the screw goes on the outside and the washers and nuts go on the inside of the bow, but remember that you only want to go halfway up the clamp, meaning the clamp will be open until all the necessary wires are in there before you can close it. The location of this is next to the converter on the frame and it goes 3, another goes to the corner on the same side and the last one goes to the side that would be the back of the frame.

• AUXILIARY BATTERY :

This one requires a  constant  voltage supply .

Supplies power to the control box components to allow the car to start

Recharged  by the high voltage battery pack using the DC to DC converter

• Installation: It goes along to  the Rear of the control box  to the left side of the converter, It has to be one inch of separation between them . After placing it the right spot , place the strap on the top ( half the width of the battery).Then use two 1/4”-20 x 4 bolts with flat washers and nylon nuts. The bolt will go from bottom to inside, which would give the inside of the box, and then place the nuts and washers.

•  The Control Rail ( RCBX)  help to organizes  electrical connections  between  various components  also helping maintain clean and  efficient wires layout 

• Installation :After placing the converter and the battery , the RCBX has to be  in front of the converter and next to it, you will notice two holes on the base. Position in those holes then use two 1/4”-20 x 3/4” bolts with flat washers and nylon insert nuts to attach the rail to the plate. Insert the bolts from the bottom, directing them into the inside of the box.

• The Controller : 

The controller manages the flow of electricity between the battery and the motor. It converts the direct current (DC) from the battery into alternating current (AC) for the motor. 

When you press the accelerator pedal, the controller receives a signal indicating how much power is needed. This input tells the controller how fast to spin the motor. 

The controller adjusts the voltage and frequency of the electricity sent to the motor, controlling its speed and torque. This allows for smooth acceleration and deceleration 

• Installation : One controller is needed per vehicle, and it is typically placed in the same location, located in the rear part of the frame. The plate already has four holes, but to align it properly, check that is in front of the Rear Fan  and the motor cable fittings, and make any necessary adjustments. After positioning it correctly, use four 1/4”-20 x 1-1/2” bolts, each with a nylon insert nut. The bolts should be inserted from the bottom of the plate, passing through the controller (inside the box).

• What it is ?

The main contactor is like a big switch that connects the battery to the rest of the EV.

When you start the car or press the accelerator, the control system sends a signal to close the contactor, allowing electricity to flow from the battery to the motor. 

When you turn off the car or release the accelerator, the contactor opens, cutting off the power and isolating the battery for safety. (or If there is a problem as too much current )

• Installation:The A+1 side of the MC faces the rear side of the box and the -A2 side faces the front of the box (the contactor will operate in either direction, but it is so that the incoming positive voltage goes to the +A1 pole of the contactor). After that use two #10-24 x 1” machine screws with flat washers and nylon insert nuts to hold it to the plate. The screws goes from the outside bottom to inside the control box

• All wires are labeled on both ends. There are three main types of wire terminations inuse: Rail Ferrules for connecting wires to the DIN-rail blocks, Spade Terminations for wire to wire and wire to relay connections, and Ring Terminations for attaching wires to a stud or bolt.

• The DIN-rail is numbered and color coded to match the wires.

• Rails are also set up to have the same number on either side of a terminal block to make wire to wire connections clear. 

• All relays have 12volt DC coils(85,86) with a normally open(87), normally closed(87a), and common(30) spade connections.

• The drive relay powers on the Control Box Rail fuse blocks A through D.

•  The abbreviation used is DRV.RLY followed by the pin #. 

• The drive relay utilizes four connections: Pin 85 is the coil12v source, it triggers on when the key relay is active. Pin 86 is the coil 12v return. Pin 30 is the switched 12 volt power, supplying 12 volts to the control box rail fuses when the relay is on. Pin 87 is the 12 volt source for the switched power, it draws power from the auxiliary battery.

• Connections : 

Pin 85: White 18 AWG, 13”

Pin 86: Black 18 AWG, split

9” and 5”

Pin 87: Red 10 AWG, 8”

Pin 30: Blue 10 AWG, 8”

• The auxiliary battery uses a red 10 AWG wire to connect the positive terminal, and a black 10 AWG wire to connect the negative terminal. The battery terminals each use a M5 x .75 x 15mm bolt, with a washer on either side of the terminal and wire termination, and a lock washer and nut to hold it all together. The red wire(20”) goes into fuse block Y as a source, and the black wire(16”) goes to #24 on the control box rail.

• The control relay is used to control pack voltage to the key on pin of the controller. 

• The control relay utilizes four connections:

 Pin 85 is the coil 12v source, it triggers on when the drive relay is active. 

Pin 86 is the coil 12v return. 

Pin 30 is the switched output of the relay, allowing pack voltage to turn the controller on when the relay is active. 

Pin 87 is the switched voltage source, and gets power from the un-switched side of the main contactor.

• Connections:

Pin 85: 37” Orange 18AWG

Pin 86: 39” Black 18AWG

Pin 87: 8” Yellow 12AWG with inline fuse holder

Pin 30 is Controller Specific and installed later

ASR72: 10” Red 18AWG

H9X1: 25” Blue 20AWG

C1238: 6” Blue 20AWG

• The Hyper 9 motor uses three 1/0 AWG cables with 1/2” motor lugs. The motor cables are fed through the 1-1/4” fitting in the rear of the control box, one at a time, from the outside to the inside of the box. Remove hoods before inserting into fitting. Align the ends of the cables inside the box to match up with the corresponding controller locations. Each termination uses an M10 x 0.75mm x 40mm bolt, flat and split-lock washer. Feed the sensor cable through the conduit fitting before the motor cables.

• The controller cable connects the switched side of the main contactor to the traction pack positive input of the controller. The Main contactor uses 5/16”-18 flange head nuts to secure the terminations.

• The control box is positioned on the rear of the floor behind the seats.

• Place the box in the vehicle with the conduits facing the rear of the vehicle, slightly leaning on the seats.

• The low voltage conduit is fed between the rear passenger side corner of the floor and chassis, and routed forward along the chassis.

• The high voltage conduit If left on, feed it though the driver side corner of the floor and chassis as was done with the low voltage conduit.

•  The flange on the rear of the control box should touch the rear of the floor.

• Remove the Fitting: Unplug the fitting from the high voltage conduit and attach it to the control box.

• Insert the Cables: Push the cables through the fitting until the orange conduit reaches it. Make sure the labels say “CTRL.B-” and “MC+A1.”

Reconnect Everything: Secure the conduit and reconnect the cables to the controller and main contactor.

• Check Cable Length: Ensure there’s not too much excess cable in the control box—about 6 inches for MC+A1 and 20 inches for CTRL.B-.

• Connect the motor cables according to the labels. Both the Hyper 9 and AC35 have three connections: U, V, and W, along with encoder and thermal probe connections. Make sure to connect all motor cables and cover the bolts with the provided hoods. Use zip ties to secure the sensor wires to one of the cables to protect them from wear due to vibration. 

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