Sparkle destroying my Powerpole 45A

General Discussion about electric bicycles.
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Re: Sparkle destroying my Powerpole 45A

Post by ClintBX » Dec 25, 2017 12:52 pm

Cwah, I feel your pain. I had Anderson PP45s on my 48v system and they were holding just fine with minimal signs of wear. Then I upgraded my motor from a 500w to a 1200w and it set off a whole slew of new problems I wasn't experiencing before. Amongst them were melting/fusing PPs.

I had an SB50 (that came with a perfectly timed new battery I ordered), and while that lasted for a few months, it eventually started to drop the ball because the pins are pretty much the same concept as the poles. In that case, they were failing to touch.

I tried bullet connectors (the crimping type) and somehow, they were failing me within a week. Even though I had them connected and I heard that sweet sweet spark, it would just lose contact randomly during a ride. At first, I wasn't sure. It was almost ambiguous.

Now, I'm using spade connectors. They're not perfect either but they hold in really well and when they bug out, you're sure it's that and not something else. The only drawback is that you have to mind the gap on the male spade connector with some heat shrink because it eventually tend to leave a little metal exposed.

Hope that helps.

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Re: Sparkle destroying my Powerpole 45A

Post by geoff57 » Jan 17, 2018 10:54 am

I can deal wher you are coming from too.
To calibrate a cycleanalyst I use a bank of 9 50w 12v car lights (3s3p)with a 36v LiPo Battery this gave me a constant draw of approx 450w.for connectors I was using shielded 4mm high power connectors.

When I made the final connection the lights went on immediately and caused on hell of a spark on the joining terminals the terminals started to vaporise.

I finally fixed the problem I fitted a MCB(mini circuit brakes) that you would find in a fuse box, to the Ted wire, I have a similar thing on my ebike with a precharge circuit as well but found I don’t need the precharge circuit.

Ive found on the calibrating circuit the MCB works a treat no more sparks it will work just as well for you with power pole connectors.

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