Need some advise on wire and connectors.

A

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100 mW
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Apr 21, 2008
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ok so I'm starting my first project after a couple years of procrastination,need some advise on connectors and wire gauge.BTW i have searched for a few nights and would just like to hear what you guys have to say.I have a Schwinn scooter i bought 4 6s zippy packs for to run it at 50v,the controller is 30a.I bought anderson pp30 connectors and was going to upgrade the wiring from 12 awg to 10 awg thinking i could fit the 10 awg in the pp30 connectors.Cant get the wire in.

My question for you guys is do you think i should just stick with 12 awg wire and the pp30 connectors or get the pp45 ones.I know from searching that the 12 awg and pp30connectors would be alright but would i just be bettor off going bigger anyway?I'm leaning that way now.Or are there maybe better connectors than the andersons?

Thanks!
 
Check this link for wires and plugs..

http://www.hobbyking.com/hobbyking/store/__377__58__Hardware_accessories_-Wires_Plugs.html
 
12ga is plenty for those power levels. Sure, overkill is nice but any "upgrade" is only as good as the execution. Paying attention to proper connector assembly and fitment will do more for reliable operation than any need for 10ga wire.
 
Ok thanks guys,guess i will just stick with 12 ga and the pp30's.I'm going to be using a nice set of ratcheting crimpers so the connection should be pretty good.Those pp30's just look so tiny to me lol.Will post some pics when the lipo packs show up so long as i Don't catch them on fire lol.
 
Nothing wrong with going to 45 amp contacts for 12 guage wire. Contacts are cheap, it's the housings that cost.

If you really want to upgrade your wire to 10, and still use 45 amp housings, there is two ways you can do it. Either way, a short piece will be 12 guage, but the long run of wire will still be 10g.

Either solder or crimp an inch or so of 12g to the end of the 10g wire, or cut a few strands to create a short 12g end to the 10g wire then heat shrink insulate it. You have to have the wire and contact floating around able to move a bit, for andersons to properly make contact.

Jamming a too fat wire into a 45 amp housing means that the contact cannot wiggle into perfect alignment with the other one. a cockeyed contact will only touch at one edge, resulting in heat melting the housing.
 
I would never run any connector at it's rated power level for long. I use plenty of Andersons and various barrel connectors as well and would never use the 30 Amp terminals for anything but charging. Use the 45A ends on everything else. Never had problems with them this way unless I connect up the batts to an already switched on controller then the big spark takes a big chunk out of them. Only takes a few of those sparks at 66V to ruin the 45A connector. Always overbuild then you have fewer repairs/upgrades to do later.
 
Gonna go with the xt60's from hobbyking,seeing i can buy series and parralel connectors pre made it will make life easier for me.Thanks guys!
 
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