Sparkle destroying my Powerpole 45A

[cwah]

Hello,

Tired of doing solding with my bullet connector, I've replaced all of them with Powerpole 45A ones. I thought that crimping is a much neater and time saver option.

However, there is a sparkle everytime I connect them to my battery (60v), and after one month, a chunk of my connector was gone!!

I had a 1h30 walk of shame last night with my bike.

Anyone know what I can do about that?

Have I bought the wrong connectors? With the bullets at least the sparkle wouldn't destroy the connector

Chiwah

 

[Deleted member 4366]

You need a pre-charge resistor. The idea is to connect through a resistor first to charge up the controller's capacitor/s slowly. when it's full you can then connect without the spark. What voltage do you have?

 

[cwah]

I m at 60v. Is there any simple way to do that? I m annoyed to have to connect twice

 

[Deleted member 4366]

If you have separate positive and negative connectors, you inly need to add wires and the resitor to the positive wires, but if the connectors are fixed together so that you have to connect them both at the same time, you need an additional pair in the negative too. Basically, you double up the wires on each side by adding some thin wires with smaller connectors, which you connect first. The resistor sits in the red wire and limits the current . You wait a few seconds until the capacitor is charged, then connect the main connector.

Everything you need is here:
http://scriptasylum.com/rc_speed/nospark.html

The calculator says a 10w 600ohm resistor will take 3 seconds to pre-charge

https://www.ebay.co.uk/itm/WIREWOUND-RESISTOR-600-OHM-10W-5-NWK-PN-CW010600R0JE73/391901584649?hash=item5b3f279d09:g:g~sAAOSw3GtZ16Rb

This one will take 5 secs but is a lot cheaper. 5 secs is still no time at all:
https://www.ebay.co.uk/itm/10-Pcs-Metal-cermet-Power-Resistor-5W-Watts-1K-Ohm-5-W3X1-K3U7/332418698733?epid=2177447336&hash=item4d65b2cded:g:5RsAAOSws6ZZ6W-x

 

[cwah]

Thanks that makes sense. But that also looks like a lot of hassle. Is there a simple way?

For example like this anti spark connector:
https://www.ebay.co.uk/i/192375852124?chn=ps&adgroupid=48658149354&rlsatarget=pla-382031116977&abcId=1128956&adtype=pla&merchantid=114891207&poi=&googleloc=9045901&device=c&campaignid=857333742&crdt=0

But for a crimping plug. Does that exist?

 

[anotherkiwi]

Nope, solder only for XT90. Solder on an XT90 no spark and never look back!

 

[mike killay]

There is always a 'crack' when I connect the 'kettle' plug of my TONARO to the 36 volt battery.
Never seems to have done any damage over 6 years.

 

[malkie0831]

Nope, solder only for XT90. Solder on an XT90 no spark and never look back!

+1 to that:
https://www.ebay.co.uk/itm/XT90-S-Anti-Spark-Connector-Male-Female-rc-lipo-battery-1-Pair/282605935934?epid=2171177624&hash=item41cca05d3e:g:eskAAOSwY99ZjGkI

Only downside is the physical size.

I know the theory that crimped connectors are more reliable than soldered connectors, but I feel much happier with a sound soldered joint.

 

[Charliefox]

There is always a 'crack' when I connect the 'kettle' plug of my TONARO to the 36 volt battery.
Never seems to have done any damage over 6 years.

Even if the battery key is removed?

 

[mike killay]

Even if the battery key is removed?

In effect, yes.
There is no battery key, the terminals (shrouded) are always live.