Good stuff!
Your picture in your post #6 above shows a cable running into the "other box", and a second cable running past it. You must NOT leave both of these cables energized - connected to the 120VAC source. If you cleaned up the one running into the "other box", that's great. But you must disconnect the one running past the "other box" at both ends - both the source and the other end at the air conditioner.
I'll review the thread when I get a chance, and make sure I understand the situation.
Bill
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