Anderson plug irritation

Batteries, Chargers, and Battery Management Systems.
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Peter Brigg   10 W

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Posts: 85
Joined: Jan 13 2012 7:20pm

Anderson plug irritation

Post by Peter Brigg » Sep 05 2020 11:13pm

I am using 2 Anderson plugs as a substitute for main switch on my electric bike. When I go over a bump the bike sometimes loses power and pulling the plug out and re-inserting it fixes things until it happens again.

Looking carefully at the plug I can see that the clip that sits under a lip on each contact has failed-in other words the contact pushes further down into the plug rather than making contact with it's matching partner.

Has anyone had a problem like this? Perhaps I am buying a poor quality version of the plug-a cheapie?

99t4   100 W

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Joined: May 10 2020 10:31pm
Location: PNW

Re: Anderson plug irritation

Post by 99t4 » Sep 06 2020 1:00am

Peter Brigg wrote:
Sep 05 2020 11:13pm
Has anyone had a problem like this?
Mine have been working great.
Peter Brigg wrote:
Sep 05 2020 11:13pm
Perhaps I am buying a poor quality version of the plug-a cheapie?
That is a distinct possibility. Counterfeits are all over the place. The plastic is not as good, and the shape is not as crisp. Also, the conductor pins may not be silver coated as the genuines, and not formed properly.
Also, even the genuine can have problems from incorrect assembly. Blobs of excess solder or shoddy crimping can cause the contacts to sit improperly in their housings and make less positive connections.

https://jts12volt.com.au/counterfeit-anderson-plugs/

Balmorhea   1 MW

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Location: Austin

Re: Anderson plug irritation

Post by Balmorhea » Sep 06 2020 2:00am

Peter Brigg wrote:
Sep 05 2020 11:13pm
Looking carefully at the plug I can see that the clip that sits under a lip on each contact has failed-in other words the contact pushes further down into the plug rather than making contact with it's matching partner.
You need a new plug housing at least. The spring in there that maintains tension between the contacts is a necessary component.

If the contact inside isn’t damaged from arcing, then you can simply pop it into a hew housing and you’re back in business. But if the mating surface has been blasted by sparks from separating while under electrical load, then you’ll need to crimp on a new one of those too.
___________
Finish Reconstruction.

pullin-gs   100 W

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Joined: Jul 31 2009 8:26pm

Re: Anderson plug irritation

Post by pullin-gs » Sep 06 2020 6:59pm

Peter Brigg wrote:
Sep 05 2020 11:13pm
I am using 2 Anderson plugs as a substitute for main switch on my electric bike. When I go over a bump the bike sometimes loses power and pulling the plug out and re-inserting it fixes things until it happens again.

Looking carefully at the plug I can see that the clip that sits under a lip on each contact has failed-in other words the contact pushes further down into the plug rather than making contact with it's matching partner.

Has anyone had a problem like this? Perhaps I am buying a poor quality version of the plug-a cheapie?
My off-brand Anderson PP plugs are not reliable. They will pass rated 30 amps, but any vibration will loosen them up requiring a reseat. Also I have had problems with the conductor lip inside connector being pushed back because it slips past stopper spring.

I re-did all my connectors on packs and controllers to XT90 connectors. Zero problems.

Voltron   1 GW

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Joined: May 02 2013 4:53pm
Location: Santa Barbara CA

Re: Anderson plug irritation

Post by Voltron » Sep 07 2020 12:38am

Maybe using the wrong insert for the power levels? The 45 amp ones are noticably thicker. I've had to rebend the tip down on a few after pulling them out of the housing, so they would catch on the spring better. They really don't like it when the wires are trying to twist the contacts in the housing ... Or using the wrong crimper either. That can make the contact too lumpy to fully insert to catch the tip onto the spring.
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s263235063426757404_p56_i1_w400.jpeg (76.95 KiB) Viewed 197 times

john61ct   100 GW

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Joined: Dec 18 2018 2:06pm

Re: Anderson plug irritation

Post by john61ct » Sep 07 2020 7:44am

Step zero is making sure to buy the genuine article.

kcuf   100 W

100 W
Posts: 267
Joined: Sep 29 2018 3:21pm

Re: Anderson plug irritation

Post by kcuf » Sep 07 2020 11:12am

step 1

check for straight tangs

even slight bend downward

this insures solid click over retainer

step 2

avoid current overload

step 3

see step 1
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