Rincon Power High Voltage Battery Disconnect HVBD4AXR

HVBD4AXR - 400 A Continuous High Voltage Battery Disconnect

A Rincon high voltage battery disconnect was selected for mounting on the controller enclosure as a maintenance switch.  This switch is available in 300A, 400A, and 600A versions.  The 400 amp (continuous) version was selected and it can handle up to 2000 amps for one minute. (EV West sells for  $159).

The disconnect switch data sheet can be found here:

https://uploads-ssl.webflow.com/605a2a14a7fc9726a217b0b2/6261cad9b014d13f844e4d93_HVBD%20SERIES%20DATASHEET_REV_D.pdf 

DSC01741"external view" of the Rincon power switch in the "on" position.  The M8 mounting holes are 100mm center to center. The bolts are torqued to 110-120 IN-LB.  The handle is equipped with a lockout-tag out feature that accommodates a lock whose shank is less than 8.2 mm (0.32").  In this picture the switch is in the ON position.

DSC01744 of the "internal view" of the Rincon power switch. 

DSC01745 side view showing the M10 (316 SS) electrical studs are torqued to 90-100 IN-LBS.  The diameter of the switch body is 68.65 mm  (2.70 ").

DSC01762 after attaching Avery 5165 shipping label stock to the side of the controller enclosure and outlining the required cuts needed to mount both the Rincon HVBD4AXR switch (right) and the Rebling 7009-3 power receptacle (left).

The Avery adhesive on the back of the label is very strong.  If was found that using a propane torch to heat the reverse side of the Aluminum resulted in softening of the adhesive.  It was possible to use a plastic putty knife to scrape off nearly all of the label.  Acetone on a cloth was then used to remove any residual film.

                            

DSC01808 of the Rincon disconnect switch mounted on the side of  the controller enclosure. The switch is in the off position with a lock in place.

Connecting the Master Switch to the Power Receptacle

 updated 5/23/2023

A bus bar was prepared using a 0.125" x 1" x 5.625" copper plate.  

                                      

DSC01836 showing the length dimensions.  

DSC01837 showing bend height. 

DSC01833 after installation of  the bus bar.  The height of the bend was slightly smaller then needed and a 0.125" copper washer was used on the power receptacle (upper right) to compensate.

DSC01834 side view of installed bus bar that connects the master shut off switch (Rincon) and the Rebling 7009-3 power receptacle.  In the foreground is the controller U1 bus bar.