[dtbaker]

What is the popular emergency disconnect - something other than an Anderson connector?

you can get double coverage if you use a big circuit breaker (GE, Airpax, etc), and drill a little hole in the switch, and run a choke cable thru the firewall so you can pull manually. typical location would be by your left knee and with a red or yellow sticker or cover identifying it as a 'kill'.

I have a series of a couple pix in my gallery starting at:
http://www.envirokarma.org/ev/gallery/090216_cbcable04.connect.htm

 

[dtbaker]

Thanks for the input. I looked at the Airpax and the largest I found is 250 amps.

I running 144 volts and 500 amps and haven't found any circuit breakers (or switches) that handle that much current at that voltage (DC) that doesn't cost a fortune.

you won't be running 500 amps continuously.... and 'most likely' won't be pulling the circuit breaker while under load anyway. but yes, both the main contacters and circuit breakers get expensive when rated for high voltage and high amp DC.