Reliable, small and waterproof connectors?

[cwah]

Hello,

I'd like to update my connectors set for my bike to make them more reliable. The one usually shared are big, not waterproof and unreliable.

It would be for brake wiring, display wiring, throttle, Hall sensors...

The closest to something decent is this little connector from BBS:
http://em3ev.com/store/index.php?route=product/product&product_id=198

But they are not easily sourçable and expensive.


I've currently tried this one that is a bit too big for me:
http://www.ebay.co.uk/itm/3-4-5-6-Pins-Assembled-Grade-IP68-Waterproof-Electrical-Connector-Plug-Socket-/381137192857?pt=LH_DefaultDomain_3&var=&hash=item58bd8c0799

And hobbyking JST ones that are unreliable especially with vibration or water:
http://www.hobbyking.com/hobbyking/store/__9738__JST_XH_5S_Wire_Extension_20cm_10pcs_bag_.html

Any view or suggestion?

 

[Nobuo]

For that uses, although is by far not quick to mount and a far approach of what you want, I recommend small spades. They work so close to waterproof are very small and very cheap.
Also let you use them for more amps requirements.
if the space and cost is a must, these can do the job

http://www.aliexpress.com/store/pro...-18-AWG-Free-Shipping/1181135_1741791456.html

 

[Punx0r]

Not overly small, but these are used by the automotive OEMs:

http://www.ebay.co.uk/itm/Econoseal-AMP-Waterproof-Electrical-Wiring-Multi-Connectors-2-3-4-6-Way-Pin-/271674203749?pt=LH_DefaultDomain_3&var=&hash=item3f410b5e65

http://www.ebay.co.uk/itm/Lots-Kits-Electrical-Waterproof-Connector-1-2-3-4-5-6-Pin-Way-seal-Car-Boat-/281668673340?pt=LH_DefaultDomain_3&var=&hash=item4194c2df3c

 

[adriftatsea]

Not overly small, but these are used by the automotive OEMs:

I'm somewhat obsessed with connectors and I'll agree these are a good compromise.

Personally I use Deutsch DTM (Amphenol ATM) connectors for any projects that see the outside world. They are somewhat larger and require specialized tooling (DMC AFM8) - but are the best connectors I've used short of Deutsch Autosports (hundreds of usd per connector). They are IP68+ rated and are found in plenty of heavy equipment, boats, and nascar/alms/etc racecars.

www.amphenol.com.au/catalogue/AT_AHD_Catalog_Web.pdf (available via Mouser and others.... use Octopart.com)

 

[dogman dan]

One thing I like, some of the newer design bike kits are now using a more water resistant plug. I hesitate to call them water proof, because the seal where the plug is molded to the wire sheath can still fail. But they are way better than any hot glue on the back off a white scooter plug, or mini Jst.

With the moderate power bike kits, the whole halls and phases plug fits easily through the washer or torque arm. No more taking apart the plug to put on a TA or stack another washer. Sweet!

You know where you can get one kit like this. We don't sell the whole wiring harness, but you can buy a motor wire, and get both ends of the motor plug that way. At least one less wire that's poorly sealed.

 

[cal3thousand]

I don't think there is a perfect connector out there with respect to size and waterproof-ness (at least not that I have seen).

The best way to get what you want in that case is to take what you consider a small connector and making it as waterproof as possible. You can make connectors that are basically IP65 level with heatshrink and dielectric grease.

For my crucial connectors that are exposed to water or spray, I take a JST-SM connector since they are small and cheap and use 2-3 sizes of heatshrink. I apply a glob of the dielectric grease to the backs of the JST connector after inserting the pins. Before that, I have slid 2 heatshrink tubes into place. One is large enough to cover the whole back of the connector and the other is small enough to grab the cable completely when shrunk but large enough to grab the open end of the larger shrunked heatshrink.

If you are confident in your steps, using a heatshrink that is lined with glue will give even more protection. Also put some dielectric grease between the 2 connectors before you connect them together to keep water out of the joint. AND FINALLY, as even more protection, get a large enough piece of 3:1 or 4:1 heatshrink and slide it up before you connect the 2 ends and shrink it in place after clicking, over the joint. This makes for more work when you need to access the connectors, but doing it this way will keep water out in most cases unless you go swimming with the bike.

 

[tomjasz]

I like the Higo connectors used on my Bafang mid drives. Sadly there doesn't seem to be a retail reseller. I find they are nearly water proof. I also shrink wrap the connections and have ZERO water intrusion.

http://www.ac-solutions.be/files/A&C_folder_E-bikes_A4-low.pdf

 

[dogman dan]

Those are similar to those used now on the E-bikekit motor kits. The motor plugs are not up to much more than 1000w, but they sure are pretty water tight.

 

[tomjasz]

Those are similar to those used now on the E-bikekit motor kits. The motor plugs are not up to much more than 1000w, but they sure are pretty water tight.

I would think someone would make them available. The company, so far, has no interest in responding.

They make some really cool stuff. WANT!

 

[Avitt]

These guys have some options for water tight connectors:

http://www.cycleterminal.com/motorcycle-connectors.html

The Amp Mini Multilock and JST waterproof look nice.

The Molex Mizu-P25 are also very small.

 

[adriftatsea]

Those are similar to those used now on the E-bikekit motor kits. The motor plugs are not up to much more than 1000w, but they sure are pretty water tight.

I would think someone would make them available. The company, so far, has no interest in responding.

They make some really cool stuff. WANT!

I'm pretty sure these are just 'M8'/'M12' connectors. They are an industry standard in industrial/PLC/automation. As such, you'll be able to find them from worldwide suppliers like Amphenol/Tyco/Molex.

See Amphenol's catalog for those and whole lot more: http://www.amphenol-industrial.com/images/catalogs/North%20American%20Product%20Overview.pdf

 

[spinningmagnets]

"Dielectric" means non conductive. You can pack your connectors with dielectric grease. It's messy but seems to work well. Look for synthetic grease so it retains its viscosity over a wide range of temperatures, and something thick, so it doesn't ooze or drip out, something with lots of cling to it.

 

[docnjoj]

I just got a couple of these when I ordered a Cute 100H. 9 bucks apiece and I may need this for my Xiongda where the wire rubbed against the axle. I think Ebikekit sells them too but a bit more money. Maybe not if you just order the wires from China.

https://bmsbattery.com/ebike-parts/439-a-pair-of-9pin-waterproof-male-female-connector-cable-for-motor-parts.html

otherDoc

 

[tomjasz]

"Dielectric" means non conductive. You can pack your connectors with dielectric grease. It's messy but seems to work well. Look for synthetic grease so it retains its viscosity over a wide range of temperatures, and something thick, so it doesn't ooze or drip out, something with lots of cling to it.

I find ACF50 to be an excellent treatment. Far less messy. Good enough for Boeing avionics, good enough for me.

 

[tomjasz]

Well I got a response from a vendor, now to see if I can buy in workable quantities. Maybe another group order from the EU. Fingers crossed!

 

[dogman dan]

Nice find Doc https://bmsbattery.com/55-connectorwire Same page, you can buy 5 wire by the meter, for halls extensions.

The same thing from E-Bike kit is 25 bucks. Buy a motor cable, and cut it in half. Worth it though, to have better water resistant wires to the motor, and the plug near the motor. 20 amps of 48v max though.

Unfortunately, they don't also have the other parts, like the 4 way wire to the handlebars, including the plug to the controller.

 

[tomjasz]

Nice find Doc https://bmsbattery.com/55-connectorwire Same page, you can buy 5 wire by the meter, for halls extensions.

The same thing from E-Bike kit is 25 bucks. Buy a motor cable, and cut it in half. Worth it though, to have better water resistant wires to the motor, and the plug near the motor. 20 amps of 48v max though.

Unfortunately, they don't also have the other parts, like the 4 way wire to the handlebars, including the plug to the controller.

I have a conversation going with the Belgian supplier of Higo. With any luck...
$9 seems a bit steep but I really like the Higo connectors on the BBS0x. I threw a connector shrink wrapped into a pail or water and let it sit for a couple of days. I opened it up and it was bone dry. Adding the tiniest amount of ACF50, in my mind and now experience, makes a perfectly dry connection. Now I need to sort out which are the best sources and which are the best materials for shrink tubing. I'm finding wide differences in quality there too.

 

[adriftatsea]

which are the best materials for shrink tubing. I'm finding wide differences in quality there too.

The 'best' is going to be Tyco/Raychem ATUM heat shrink. It's adhesive lined, has a high 4:1 shrink ratio, flame-retardant, made of crosslinked Polyolefin, resistant to brake fluid, UV, and pretty much every nastyness, and good for >125*C. It's overkill, but you at least want something adhesive lined and a decent shrink ratio.

And as mentioned earlier, these Higo connectors are just 'M8' connectors that can be sourced easily from vendors like Tyco here in the US. As you've found out, they are all waterproof (IP67+) since they are made for washdown in industrial settings.

 

[tomjasz]

I really have no interest in adhesive. I like to not have the sticky mess on a redo or repair. A repellent coating for avionics like ACF50 and an no adhesive takes care of moisture. I looked for the connectors on your referenced site and find the selection and search daunting. Can you point to the "M8" connectors?

 

[Avitt]

The 'best' is going to be Tyco/Raychem ATUM heat shrink. It's adhesive lined, has a high 4:1 shrink ratio, flame-retardant, made of crosslinked Polyolefin, resistant to brake fluid, UV, and pretty much every nastyness, and good for >125*C. It's overkill, but you at least want something adhesive lined and a decent shrink ratio.

Clearly not the best, but an affordable option is this Marine Heat Shrink Tubing from Harbor Freight:

http://www.harborfreight.com/42-piece-marine-heat-shrink-tubing-67598.html

It's adhesive lined, flame retardant, crosslinked Polyolefin, resistant to UV, water, oils, acids, good to about 110degC, and has a 3:1 shrink ratio.

 

[TheBeastie]

Looks like some nice links you folks have posted.

I don't know about waterproof but I started using these for my parallel balance charging, 2 plugs for S12 or S10.., I wanted something more chunky yet compact type connector and more reliable then the JST-XH which are just terrible with frequent use.
I am using these aviation plugs, I figured if there good enough to be used for aviation then they should be good enough for me.
They are available in sets of 5 on ebay (search for "Aviation Plug 7-Pin 16mm GX16-7") in either 6 or 7 pin configurations (maybe more I haven't looked), they also screw together so no accidental pull outs if the wires are tugged on hard, they are really well priced too.
I guess you could spray over them with some water sealer stuff to water proof them up more.
http://www.ebay.com/itm/261583917980?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Only problem I have had is soldering them, I managed to do it so I expect others would find it relatively easy as I don't have a quality soldering gear.

Add/Edit,
I never noticed before but there does appear to be a lot of plugs under the search terms "Aviation Plug waterproof", most higher priced then my url above but definitely look like better quality though.
http://www.ebay.com/sch/i.html?_odkw=Aviation+Plug+water*&_osacat=0&_from=R40&_trksid=p2045573.m570.l1313.TR0.TRC0.H0.XAviation+Plug+waterproof.TRS0&_nkw=Aviation+Plug+waterproof&_sacat=0

 

[cal3thousand]

Looks like some nice links you folks have posted.

I don't know about waterproof but I started using these for my parallel balance charging, 2 plugs for S12 or S10.., I wanted something more chunky and connector reliable then the JST-XH which are just terrible with frequent use.
I am using these aviation plugs, I figured if there good enough to be used for aviation then they should be good enough for me.
They are available in sets of 5 in either 6 or 7 pin configurations (maybe more I haven't looked), they also screw together so no accidental pull outs if the wires are tugged on hard, they are really well priced too.
I guess you could spray over them with some water sealer stuff to water proof them up more.
http://www.ebay.com/itm/261583917980?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Only problem I have had is soldering them, I managed to do it so I expect others will find it repetitively easy as I don't have a quality soldering gear.

These look pretty nice. Same connector as my AOYUE solder iron. Nice share

I also saw Luke mentioned MPX connectors on another thread.

 

[tomjasz]

Lectric Cycles used those crappy eBay connectors. Mine rusted and when I went to replace them they were mounted with stripped screw heads. All those links and catalogues don't produce sources for the parts that eBike builders can access. That is what I am looking for. Retail sources for decent waterproof connectors, so far limited to OEM's and manufacturers buyin wholesale lots. We need sources!

 

[t3sla]

I have an account with Higo, loom MOQs are like 200pcs, not sure about individual connectors.

Would people pay 6 USD for 2-5 pin connectors (male and female) with a MOQ of 3 sets

 

[Avitt]

Lectric Cycles used those crappy eBay connectors. Mine rusted and when I went to replace them they were mounted with stripped screw heads. All those links and catalogues don't produce sources for the parts that eBike builders can access. That is what I am looking for. Retail sources for decent waterproof connectors, so far limited to OEM's and manufacturers buyin wholesale lots. We need sources!

Check my post, above. It has a reference to a retail site, featuring a number of connectors suitable for ebike use.