Desperately looking for a waterproof panel mount connector

[schwibsi]

Hi,

I'm going crazy over this.
I'm nearing the end of my build and have almost all equipment in place.

I have a diamond frame with an aluminium triangle frame fitted in there with loads of space, so I'm thinking to put a charger for my 13s Li-Ion battery in there.
If I could find a very light 400W+ charger 230V, i'd install it inside the frame. I have the space.

However, if I don't find one, I'll need a waterproof connector for the charger. It should handle 60V (with safety for 13s) and 10A.
Oh, and it needs to be panel mount, no loose connectors.

I really hope you have suggestions.

 

[bigmoose]

How many pins?

 

[schwibsi]

just 2 pins for the charging leads.

 

[bigmoose]

Take a look at this one at digikey, about 4 bucks for the panel part. I used these on some strobe packs. They have seals. I wouldn't use them for underwater use in submersibles, but it may meet your requirements. The #16 pins are rated 13 amps.
http://www.digikey.com/product-detail/en/EN3P2M16X/SC1572-ND/1289137

 

[spinningmagnets]

You can cut a hole in a panel and epoxy one of the connectors on?

Consider a 4-pin Weatherpack, and parallel two each (4 pins become two pairs). They are made for truck engine compartments, which drive through the rain. The connector is polarised, so you can't plug it in wrong.

http://endless-sphere.com/forums/viewtopic.php?f=16&t=2767#p588505

 

[schwibsi]

Thanks for the suggestions.

I was hoping for something with a cap on so it's weatherproof when not connected. When it's connected, it's in the garage anyways.

In terms of width I'm rather limited, or in length, I'll clarify.
If the connector is wide, I can only connect it from the crankset upwards into the frame. but then the whole connection incl. the straight part of the cable needs to be rather short.
if the connector is flatI can connect it from behind, next to the saddlepost. So there's a bit of a pickle.
I was thinking powercons or speakons, but they're too long and too wide.
If the superseals had a panel mount option, I would have gone that route. One other point. This connector will be used on a daily basis.

The other option is still a small, powerful and affordable charger (400W+ and under a pound (without the case, cooling he fets with the frame), then I'd just use a 230V connector.
Here are a few pictures of the bike frame as it is now, so you can get an impression. There's a flat part 50x53mm just over the crank. That's where the motor wires and PAS-sensor wires will go through I was planning on putting the connector there or into the frame from behind close to the saddle.

 

[dnmun]

use the XLR connector that comes with the charger. it is made to be mounted on the panel and is watertight. with sealer. and it has a cover that flips over.

 

[Toorbough ULL-Zeveigh]

switchcraft EN3 charge conn on my 'wavetrac' ebike uses only 3 of its 5 pins (thermistor pin,+,-).
not the panel ver in my case but comes with the rubber plug cover & never had any water ingress or corrosion problems.

 

[schwibsi]

I think, I'll try the XLR.
- I only need to drill one hole
- small (might just fit from behind next to the saddle post)
- relatively cheap
- 50V 15A without problems
- waterproof design
- caps easily available

Excellent suggestion
I'll keep you guys posted

 

[dnmun]

you should get one in the box with your charger. all the newer kingpan chargers use the XLR and have the charge port in the box.

 

[spinningmagnets]

I was hoping for something with a cap on so it's weatherproof when not connected

If you try Weatherpack connectors, one option is to insert a "dummy" plug to the socket when you are not charging, in order to keep the socket covered and dry. This can be made by potting the wire-side of the dummy plug. Best of luck with whatever you decide.

They call their bulkhead connectors: "Firewall feed-thru bulkhead"- style

 

[_Chris_]

This might be the answer
http://www.ebay.com.au/itm/MERIT-HELLA-PLUG-CHASSIS-PANEL-MOUNT-SOCKET-JACK-SPRING-LOADED-CAP-/221100231134?pt=AU_Car_Parts_Accessories&hash=item337a99c9de

http://www.ebay.com.au/itm/HELLA-SOCKET-SEALED-BULLET-STYLE-FOR-CABLE-END-ABR/390600566481?_trksid=p2045573.m2042&_trkparms=aid%3D111000%26algo%3DREC.CURRENT%26ao%3D1%26asc%3D27%26meid%3D7878897202960382550%26pid%3D100033%26prg%3D1011%26rk%3D1%26sd%3D390600566481%26

I was looking for marine socket in ebay and found those. Something like it might be good if you can find a high current one.

 

[_Chris_]

Maybe this for your higher current chargers a marine trolling motor connector.

http://www.ebay.com.au/itm/3-Wire-Trolling-Motor-Plug-and-Socket-Set-for-Boats-8-Gauge-Wire-/130582523489?pt=Boat_Parts_Accessories_Gear&hash=item1e67532e61

 

[dnmun]

wow, trailer plug, never thought of that. very original.

 

[_Chris_]

wow, trailer plug, never thought of that. very original.

It is a plug and socket for an electric outboard trolling motor. I found them going through the DC marine socket searches I have been doing. There has to be something better than those crappy microphone/speaker plugs they use on chargers.

 

[_Chris_]

Loook in my other hread like this one I bought a hella plug today and its a great solution. They are rated at 16 amps but it looks like it might take more.