AS150 type connectors

[alsmith]

What connectors are the non-spark equivalent of the AS150 anti-spark connectors? I've looked and can only seem to find smaller or larger sized connectors, but have seen them described as 7mm, and even 5.5mm (both described as AS150). Is it XT150 which I assume it would be - but I've seen these described as 6mm. I'd like to get same sized plug and replace sized interchangeable connectors. It's so I don't go and buy other sizes that I don't need.
Thanks

 

[alsmith]

I got some XT150 connectors and as suspected they don't fit- too small for the AS150 connectors. They must be a standard size, it's hard to believe that they would create a new size for the anti-spark that wouldn't cost a lot more because they'd not be making such large quantities. What are they based on- ant ideas?

 

[ddk]

... What are they based on- ant ideas?

user's gullibility?

This topic of 'sparking connections' has previously been addressed in this forum and you could use the search function to learn about the subject, esp. if unfamiliar with electronics and such... but I'll address this slightly for you.

An "anti-spark' connector uses a current limiting device and has to make room for the device(s) one way or another.

If you don't want to weld your connections together when connecting a high current source (B) to the empty capacitor input (C) of most controllers you have to lesson the current flow which is what a so-called switched pre-charge resistor setup does for you.
Clever forum members have invented an "automatic" version of this and some people will source PCB (printed circuit boards) if you inquire. But this is because this started as a DIY board.

Personally, since I build my own battery packs with on/off switches and all my controllers have an on/off switch, I make my connections between the 'B' and 'C' in the OFF positions, then turning the battery ON then the controller ON which alleviates any 'spark'. Other users report differing outcomes using this method but it certainly works for me.

 

[alsmith]

This isn't a question about anti-spark and whether they are needed or not, it's 'what is the standard connector these modified connectors fit (or were constructed from)'.

 

[ddk]

I'll use simpler language:
To accommodate the 'stuff' needed to assure a connector 'spark-less', its' shell or enclosure has to increase in size to include the 'stuff' within. Generally the connector systems I'm familiar with make use of both connector 'genders' to render a spark-less design. However in most cases this also reduces the total 'instantaneous' current-carrying ability of the connector system. I.e mostly useless for an e-vehicle. External methods of spark reduction using way larger stuff is far more effective and can be sized to accommodate any current transfer.
BTW for the last several decades I've found many manufactured connector types that no longer fit together using different manufactured (but the same) types, as I recently experienced with MT90 connectors, TRS connectors and XLR 3-4 pin connectors from various manufacturing plants. The only way to be assured of a correct-fitting connection is using a single manufacturer for both sets of connectors... not good for anyone.

I suspect some of this incompatibility is because many connectors were initially designed using imperial measurements (USA and UK) and are now being made using metric sizings (almost the same but not quite, highly useful playing the game 'horseshoes' but otherwise makes for spectacular near misses)

I assumed you needed info to stop sparking your connections so I included extra info.

 

[alsmith]

With these connectors the difference is not because of the modification- even the unmodified connector from the anti-spark connector doesn't fit the non-spark connectors. The contact diameters are different- see pic:
AS150 spark connector plug diameter is 7mm, the plug is slotted /splayed slightly and the socket is not slotted.
XT standard connector plug diameter is 6mm, the plug is not slotted slightly and the socket is slotted /splayed.