Thursday, May 18, 2023

Main Battery Pack Connector and Control Box

Purchased from EV Motor Verks Store (573-388-4580, sales@evtv.me) a Rebling 7009-3 Battery Receptacle ($88) and a Rebling 7016 Battery Disconnect Plug Cable Mount ($290).  The 7009 is equivalent to the Rebling 7002 connector and the connector set is rated at up to 750 volts DC, 750 amps continuous, and up to 1500 amps peak.  These connectors are rated for aircraft use and they are positive locking and very robustly manufactured.

Data sheets can be found here:

https://rebling.com/pdf/Rebling___Datasheet-Product___7016%20Avionics%20Cable-Mounted%20Plug%20ver%2020220602.pdf

https://rebling.com/products/two-wire-avionics-plug  

DSC01728 picture of assembled female Rebling Plastics 7016 (right side) and male Rebling Plastics 7009 (left side, equivalent to Rebling 7002).   


DSC01705 view of openings that allow for 2/0 electrical cables.


DSC01726 showing the 7009-3 (Top) and the locking plunger (center) that is rotated into the receptacle using the half-turn handle.  


DSC01703 left side is Rebling 7009-3 (male) and on the right side is the Rebling 7016 (female).


DSC01731 showing the Rebling 7009-3 (terminal studs, 5/16-18, far left as would be viewed from within the control box), middle (male, as would be  seen from outside the control box) and the Rebling 7016 (female) far right top view. 


DSC01723 exploded view of the Rebling 7016 connector.  5/16-18 studs (center) are shown securing a pair of  2/0 terminal lugs.  The far left and far right plastic housings are bolted together with a pair of 10/32 x 1.625" bolts.


DSC01725 showing 7016 after installation of (+) and (-) 2/0 power cables.



DSC01801 showing the installed Rebling connector (left side) on the side of a controller enclosure.  The 7009-3 fits within a 1.50" x 2.90" opening in the controller box.   

The rounded part of the 7009-3 are 1.375" diameter with a center to center distance of 1.54".

A cardboard template of the 7009 was prepared and used to mark the Aluminum of the box before cutting.

The four mounting bolts are 10-32 x 0.5" and Stainless Steel was selected.

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