NetGain HyPer 9-DHV Motor Controller and Kit.

The product description for the HyPer 9-DHV controller is as follows:

Type:  ACX1T50000100
Model:  AC-1X 120/144 V 500 A  112 SWS
SN:  9735730003

The controller can operate in the range of 90 to 180 volts.  This 1992 BMW 325i build will operate at a nominal 144 volts.

DSC06595 Top view of the controller.  Terminal bolts are in the plastic bag.

DSC01163 Detail picture of supplied hardware which includes five M8-1.25x20 hex head bolts (torque to 15Nm max)with washer and lock washers.  These are used for the -B, +B, U1,V1, and W1 terminals.  Also included is a M4-0.7x10 bolt (torque to 2.5Nm max)with both washers.  This is used for the +B pre-charge terminal. The outer diameter of the M8x20 Zinc plated bolts was measured to be 7.82 mm. 

Lock washer ID =  8.29mm, flat washer ID = 8.44mm.     Updated 6-22-2021

DSC06598 side end view of controller.  The black plastic housing is attached to the Aluminum heat sink (base) with four T10 Torx bits (two are shown in the picture).  Updated 9-15-2021

DSC06597 of the 35 pin connector.

Edited 6/8/2023

DSC01891 showing a dust cap that was printed for the K1 port on the SME AC-X1 (or X144) Controller/Inverter.   Ken (a member of the electric auto club FVEAA) made the cap with a Ender Pro 3 and he has posted the file here:

 https://www.printables.com/model/500848-sme-ac-x1-k1-port-cover  

The cap fits perfectly.  We added a few small drops of bathtub Silcone sealer on the inside edges of the cap to further increase the grip of the cap while we are working with the controller.   

DSC06601 showing the mounting holes at the corners of the base of the controller's Aluminum heat sink.  The mounting holes are 6.5 mm diameter and are 197 mm and 147 mm center to center.

The kit purchased from NetGain included the following:

HyPer 9-DHV 3 phase motor  (pictures shown previously in 9/24/19 blog posting)
Hyper-Drive X144 controller  (for up to 144 volts operation) Serial number 9735730003
500 Amps with Standard Ampseal Wire Harness
Gigavac GV200PA-1 contactor
HTS: 8501.32.4500

DSC06593 of the components included in the kit in addition to the motor and controller.  In the center of the picture is the bag of terminal pins for the motor encoder and motor thermistor plugs attached to the motor.  Starting at 12:00, the black plastic 3 phase terminal cover, pre-charge relay, Gigavac main contactor relay, computer cable (bottom right), USB to cable, and wire cable bundle with red Ampseal 35 pin connector.

DSC06596 Picture of the 35 pin Ampseal connector.  Updated 9-18-2021

A full description of how the crimped wires are installed in the AMPSEAL connector can be found here:   https://www.youtube.com/watch?v=uXTkm_XV2OY

It appears that this video (  https://www.youtube.com/watch?v=v157tIIQGEc ) discusses the crimping tool used for the AMPSEAL 16 contacts.  Updated 10-5-2021

                                        (picture of Gigavac to be added)

DSC0   of the Givac 500 amps main contactor relay.

DSC06677 Top view of the pre-charge relay.

DSC06678  Side view of the pre-charge relay.

The HyPer 9-DHV user manual can be found here:

https://www.go-ev.com/PDFs/HyPer_9HV_IS_User_Manual_REV08.pdf