Contactor-isolation box prototype

Conversion Process - Electrical - Contactor/isolation box prototype.....

As with the controller, there is a limited amount of space on the firewall in such a small car

I have a usable area of 200mm (h) by 250mm (w) and a depth of 140mm to house the contactor/isolation box hence a two layer design suits best

This page shows the MDF board prototype used to work out the best use of space.....

The first layer has the DC circuit breaker (also used as the emergency off switch) and the main motor contactor

The second layer will accommodate the shunts, KSI relay and solid state heater relay (not shown here)

Two shunts will be mounted to allow some flexibility in the future (a 200A - 200mv shunt and a 600A - 50mv shunt)

A - The circuit breaker "Trip" lever will be used as the emergency shut-off safety switch

B - A modified choke cable will be used to trip the circuit breaker from inside the cabin of the vehicle

C - This bracket will be used to clamp the outside sheath of the choke cable

D - Read the mounting notice! MUST BE MOUNTED ON A VERTICAL SURFACE ONLY

So it will sit upright like this......

And mount roughly in this area......