electrcal connectors arcing

[al.short]

Hello-
I wasn't sure where to place this, but I'm having repeated failures of my connectors between my battery (in my backpack) and my Lyen 18 FET controller. I am using a 96 v pack and when the connectors are mated the arc due to the caps filling erodes
the connectors to the point where even a 75 A power pole is compromised in a couple of days--the circuit the opens under heavy throttle and must be unplugged and remated to be able to continue. And of course the amount of draw necessary to cause this decreases with each event. Does anyone know of connectors that can withstand this. My only other thought is a current limiting resistor in line while the caps charge, to be removed before proceeding. Has anyone any insights, or has anyone solved this niggling issue?
Al

 

[major]

I suggest you put a switch in the line (either from the battery to the connector or between the controller and the connector. Use a switch rated at your average current. Bypass the switch with a 50 to 100 Ω resistor. With the switch open, when you plug in, the resistor will limit inrush to 1 or 2 Amps and the arc will be small and fast and cause little if any damage. Wait a couple of seconds for the caps to charge and then close the switch and it should not arc either.

Or use a double plug. First connect a small plug rated at like 5 to 10 Amps which has a resistor in line. After a few seconds, plug in the 75A job. The large plug would bypass the small plug and resistor. You can leave the small plug in or unplug it and stash it out of the way while you're riding.

 

[wesnewell]

Precharge resistor.

 

[dnmun]

you can put a switch in the circuit current on the BMS and turn the battery off when you connect it to the controller so there is no spark.

 

[gwhy!1]

This is my solution to a precharge resistor, this will stop the main battery plugs from getting damaged when connecting them up and reduce / stop the arcing.
For reference:..
http://endless-sphere.com/forums/viewtopic.php?f=2&t=50031

 

[MAGICPIE3FOCUSPOWER]

you can put a switch in the circuit current on the BMS and turn the battery off when you connect it to the controller so there is no spark.

Waauww this method looks very reliable!
I am using now 100 ohm resistor, but I don't like it

I don't want to cut both wires of the thermal sensor is there another way to do this mod?