High Voltage Junction Box Install Guide


High voltage Junction Box Install Guide #

The Ampere EV Atom Drive System is designed to work the first time, every time. To maintain this, the Atom Drive System utilizes the custom Atom Drive High Voltage Junction box. This junction box is a compact and feature dense solution for EV power distribution. Incorporating traction pack fusing, fused HV accessory ports, main contactor, HV discharge circuit, and integrated HVIL; this component was designed to flawlessly integrate all components of the Atom Drive System.

Install Considerations #

  • Junction Box can be mounted in any orientation
  • Junction Box is waterproof but should be mounted in a protected location
  • High Voltage Out (to motor) is installed upside down in relation to other cables and must be assembled before mounting of junction box
  • All cable measurements and assembly should be completed before final mounting
  • Junction box is NOT waterproof unless all cables are connected or provided \”dummy plugs\” are installed

Assembly of Amphenol PowerLok High Voltage Connectors #

Note : Before assembly, cut cable to desired length

Note : Each step must be performed twice as there are two cables for each connector

Step 1 : Disassemble Connector #

Alloy Shell x 1
Insulation Housing x 2
R4 Holder x 2
Insulation x 2
Copper Ring x 2
Copper Shield Ring x 2
Rubber Ring x 2
End Cap x 2

Step 2 : Strip Cable #

Strip high voltage cable and cable shielding. Conductor cable must be stripped to 18mm, and shielding must be stripped back to 27mm.

Step 3 : Assemble Cable Side #

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Take 1 of each (8) end cap, (7) rubber ring, (6) copper shield ring, (5) copper ring, and (4) insulation sleeve and assemble them through the cable in the order shown below. 

Note : Ampere EV ships shielded high voltage cables to be used in junction box installation. Shielding must be stripped back and secured by (5) copper ring

Step 4 : Crimp #

Take 1 of (3) R$ holder and crimp it with the cable conductor wire, as shown in the picture above.

Step 5 : Secure Cable Side Assembly #

Take 1 (6) copper shield ring and secure cable shield with (5) copper ring. Secure the braided shield between (5) copper ring and (6) copper shield ring. Trim off any excess braid as shown above.

Note : (6) copper shield ring should hold excess braid in place and fit firmly inside (5) copper ring.

Step 6 : Insulation Sleeve #

Take 1 (4) insulation sleeve and fit into the neck groove of (3) R4 holder, as shown above.

Note : (4) Insulation sleeve should fit comfortably between the neck groove of (3) R4 holder and top of (5) copper ring.

Step 7 : Secure End Cap #

Once all pieces are aligned, push (8) end cap into secure position as shown in the image above.

Note : The (8) end cap is not secured by anything at this moment; however, all parts so far, when pushed together, should align with no gaps between them. If parts are not resting together with no gaps, double check Step 5 was completed correctly before continuing

Step 8 : Seat the Insulation Housing #

Bring (2) insulation housing through (3) R4 holder and rotate until it arrives in stop position. (2) Insulation housing should rotate freely until seated. If properly seated, (2) insulation will not move freely.

Note : Make sure (3) R4 end is visible through the front opening of (2) insulation housing.

Step 9 : Install Alloy Shell #

Put (2) Insulation housing into (1) alloy shell, rotate cable until (2) insulation housing arrives at stop position. Screw (8) end cap into (1) alloy shell, to a torque of 10-12 N.m to finish the assembly.

Note : Steps 1-8 will need to be completed four times for the four high voltage cables included in the kit

NOTE : High Voltage OUT to the motor is upside down in relation to high voltage IN from the battery.

Unless Junction Box is installed on an elevated platform, HV OUT will need to be assembled and connected to the junction box before final mounting in order to achieve a secure connection.

Assembly of HVA-280 High Voltage Connector #

Note : Each plug connector has the same installation process, but each connector will require a different gauge cable for proper installation

Wire Gauges #

Connector OutputItem NumberCable Gauge
Key-F4-2103177-614awg
Heater 24-210377-514awg
Charger-D4-2103177-410awg
Air Conditioning4-2103177-410awg
Heater 14-210377-114awg

Parts #

1Cable Seal Retainer
2Cable Seal
3Inner Ferrule
4Outer Ferrule
5MCP 2.8mm Receptacle Terminal
6Plug Connector Assembly

Assembly #

Step 1 : Assemble Seal #

Assemble (1) cable seal retainer and (2) cable seal in the order and direction shown in the image above.

Note : Circuit numbers are shown on the cable seal retainer. Make sure that the correct cable is inserted into each cavity.

Step 2 : Strip Wire #

With the (1) cable seal retainer and (2) cable seal safely out of the way, strip the outer jacket and braided cable shield off of each cable

Step 3 : Strip Wire Again #

Strip the outer jacket further so that the combined exposed strip length of braided cable shield and conductor insulation matches above

Step 4 : Inner Ferrule #

Insert (3) inner ferrule onto each cable and over the outer jacket as shown in the image above

Step 5 : Fold Braided Cable #

Fold the braided cable shield back over the (3) inner ferrule, taking care to try to keep (3) inner ferrule positioned such that its edge is flush with the stripped edge of the outer jacket as shown in the image above

Step 6 : Strip Wire Again #

Strip the conductor insulation off each cable to the dimension defined by the specific plug connector

Step 7 : Receptacle Terminal #

Apply a (2) receptacle terminal to each cable using the tooling, method, and dimensions necessary for each specific plug connection. The trailing edge of the (2) receptacle terminal box should be located from the stripped edge of the outer jacket to the dimension given (approximately) in the image above

Step 8 : Outer Ferrule #

Insert (4) outer ferrule onto each cable in the orientation shown below and over (3) inner ferrule and folded back braided cable shield

Step 9 : Crimp #

Crimp each (4) outer ferrule using the necessary tool

Recommended Tool : SDE-SA Hand crimping frame assembly : this frame assembly accepts a die assembly designed to crimp the specific outer ferrule. (type 1: 6.80 mm HEX) and (type 2: 7.40 mm HEX) NOT INCLUDED

The distance between the leading edge of the outer ferrule and the trailing edge of the receptacle terminal box must be maintained at the dimension given above

Cable Inspection #

1Samples match examples shown in the images in this document
2Cables are inserted in correct cavity openings in seal retainer
3Seal is not rolled or damaged
4Outer jacket or conductor is not damaged
5No loose or protruding strands from braided cable shield and ferrule crimp
6Terminal crimp meets specified requirements
7Outer ferrule hex crimp is correct and outer ferrule is not damaged

Receptical Terminal Installation #

This section contains steps for installing the receptacle terminal into the plug connector

Step 1 : Orient Cable #

Orient the cable assembly so that the bridge feature on the cable seal retainer is aligned with the plug connector

Step 2 : Click Together #

Inset the receptacle terminals into their respective plug connector circuit cavities until they are fully locked, and an audible and tactile ‘click’ is detected

Note : The installation of the ferrule into the contact springs of the connector shield will cause some resistance, so it is important to verify that the receptacle terminals are fully inserted by pulling back lightly on the cables.

Step 3 : Fully Insert #

Fully insert the cable seal until it stops inside the back of the plug connector

Step 4 : Cable Seal Retainer #

Full install the cable seal retainer over the back of the plug connector, making sure that the bridge feature is correctly aligned with the plug connector latch feature. Verify that both locking features are fully engaged

Mating and Un-Mating #

Mating #

Align the plug connector and header assembly

Push the plug connector and header assembly together fully until they stop (two clicks will be heard). Verify that the plug connector and header assembly are fully locked with a light tug and by visually verifying the location of the indicator slot on the floating latch

Un-Mating #

Fully Depress the thumb actuation pad on the plug connector flexible latch (orange).

Pulll the plug connector back (approx. 4.5mm) into the intermediate position. At this point the HVIL circuit has been opened, but the HVIL terminals are still making contact

DO NOT PULL THE CABLES

Fully depress the thumb actuation pad on the floating latch (red)

Pull the plug connector until it is fully separated from the header assembly

Low Voltage MX150 Data Connector Assembly #

Pin Out #

Input PinDestination
01DC Chg Positive Contactor Feedback
02DC Chg Negative Contactor Feedback
03Positive & Negative DC Contactor 12V
04Voltage Sensor 12V
05HVIL IN
06Can LO
07DC Chg Positive Contactor Feedback
08DC Chg Negative Contactor Feedback
09DC Chg Negative Contactor Ground
10Positive DC Chg Contactor & Voltage Sensor GND
11HVIL OUT
12CAN HI

Assembly Guide #

The images in this section do not match the same data cable contained in the Junction Box installation kit. However, the assembly information is accurate and correct.

Step 1 #

Begin assembly of the crimped male terminals into the plug housing by making sure the Terminal Position Assurance feature (TPA) is in the pre-locked position

Since the TPA is recessed, the most accurate way to determine if it is in pre-lock position is to measure. In pre-lock position, the distance between the housing face and TPA is approximately .50” (12.7mm). If it is not in pre-locked position, insert the tips of needle nose pliers into the two ‘D’ shaped holes in the center of the TPA. Carefully, pull gently on the TPA until it starts moving. Pull to the first stop.

CAUTION: Do not pull TPA completely out of housing. This may break retention features and result in reduced TPA retention in housing.

Step 2 #

Orient the key on the back of the male terminal with the keyway on the rear of the housing. Insert the terminal into the housing until it clicks and a slight pull back on the wire is met with resistance

Repeat step 2 until all terminals are inserted into the housing. If a terminal is inserted into the incorrect housing, use service tool to remove.

Step 3 #

If using a circuit plug to seal an unused terminal, apply the same procedure as the terminal insertion steps above. Inset the circuit plug until it clicks once and a slight pull back on the circuit plug is met with resistance from the terminal retention feature

Step 4 #

When all terminals or circuit plugs are in their proper location, push down on TPA until it clicks into place and sits approximately .700” (17.8mm) from mating edge of outer housing.

Mating Data Cable to Junction Box #

After mating the plug connector to the receptacle, push the Connector Position Assurance (CPA) feature on the receptacle forward until it clicks or is as far forward towards mating end of receptacle as possible

Junction Box Mounting #

NOTE: The high voltage cable being connected to HV OUT needs to be connected prior to mounting the junction box. Connection terminal is upside down in relation to other terminals and a proper connection cannot be made prior to mounting unless the junction box is mounted in an elevated position.

The Atom Drive System High Voltage Junction Box was designed to be Installed anywhere in the vehicle, at the user’s discretion. However, the junction box should ideally be installed in a centrally located, protected area. Because installation will be determined by the user, no mounting hardware will be included in the Atom Drive installation kit. There are four, pre-drilled, mounting holes, sized for 4mm mounting screws

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