My Community

Radio => EmComm/Emergency Power => Topic started by: GreekMan on November 18, 2014, 07:47:38 AM

Title: Educate me on DC Connectors (+ suggestions)
Post by: GreekMan on November 18, 2014, 07:47:38 AM
OTHER than Anderson Powerpoles (for a million reasons, especialy local UNavailability/standarization and cost)

I intend on refining the connectors of my backup power system. (low amperage)
And stadarizing on a general system of 2 part cables.
I want to be able to built my cable at whim combining 2 pieces, one for the source and one for the appliance.

Cabling will be around 15-18AWG, usual amp draw 2A for the handhelds, upto -and fused- for 10A just in case (max of car 12V system).
While wire gauge is too much for my power demands, I am trying to minimize voltage drop for the cables connecting batteries and HT.

After reading this http://www.tjinguytech.com/reviews/rc-connectors (http://www.tjinguytech.com/reviews/rc-connectors) I am partial to the EC2 connectors (http://www.e-fliterc.com/Products/Default.aspx?ProdID=EFLAEC201). But i do like some material surrounding the cable at the junction.

I also need a 2A 8V connectors for a case. I am thinking of the lockable 5.5mmx2.5mm DC Connectors (http://www.ebay.com/itm/270953874605?ssPageName=STRK:MESINDXX:IT&_trksid=p3984.m1436.l2649). Though they are spec'ed at 1A 15V. the good think is that being lockable they are handy for connecting power bank and HT.

So specs are:
- Non APP
- less than 10A
- 18-15AWG compatinle
- Solderable
- Field assembled by non-specialized multitool crimper (multitool)
- handy and secure
- avoiding wire break at junction with connector
- plug like (combining the anode and kathode in one plug)
- small

Honestly i am this close to dropping the search for, and going to the electrical insulated spade connectors (http://www.amazon.co.uk/Fully-Insulated-Electrical-Connectors-Female/dp/B00AE4HEEW/ref=pd_sim_diy_3?ie=UTF8&refRID=1BCXKESB4D1JA8MA44AP)
These cover all my criteria, other than the plug like appearence. An they also mate to the 7A SLA batteries.


Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: Tevin on November 18, 2014, 05:38:27 PM
The connectors you already found seem ok to me. I'm not sure how much better than the EC2 connector you could realistically expect. A trip to the auto parts store will give you some good ideas too.

For my purposes I stock pretty much everything. When you're building your own you can be choosy, but when equipment comes with connectors already on it the choice is made for you unless you think it's worth the hassle to change it out. Usually it's not worth it. I do like the spade connectors because they are inexpensive, easy to work with, can be purchased almost anywhere, and are common to a lot of existing equipment.

I occasionally use Anderson Power Poles but they are not my default. I'm baffled by the weird obsession with them in the ham community, emcomm groups in particular.  I understand the value in standardizing equipment, but beyond that, there's nothing about Power Poles that make them better than everything else. There are some groups that won't take an operator seriously unless they have Power Poles, like it's some kind of "look at me I'm a hamsexy emcomm guy!" status symbol. Yeah, whatever.  :-\ 


Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: spacecase0 on November 18, 2014, 08:55:39 PM
the reason I converted to the Anderson Power Pole connectors was that they have no gender,
so I can plug anything into anything else,
I could not find any other connector that could do that.
DC extension cables get really easy to build that way

I was running into having 2 connectors, one of each gender on the power supplies and batteries,
it is not a huge deal, but was kind of annoying
also the cycle life of the Power Poles was up there with a light switch,
many other connectors I was using before would only plug and unplug hundreds to thousands of times,
I had already worn out many connectors that I had to replace, and did not want to do that again

the only other system I would think of using now would be the ring terminal and bolts like I was using at one point,
they never mess up.
Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: Tempstar on November 19, 2014, 05:39:00 AM
Hi Greek!
 I have found the smaller powerpoles to be less than robust, especially in mobile applications. I have gone to an automotive style connector like this:

http://www.amazon.com/CES-Gauge-Quick-Disconnect-Harness/dp/B0057ZQJ12/ref=sr_1_26?ie=UTF8&qid=1416396977&sr=8-26&keywords=Dc+Power+Connectors (http://www.amazon.com/CES-Gauge-Quick-Disconnect-Harness/dp/B0057ZQJ12/ref=sr_1_26?ie=UTF8&qid=1416396977&sr=8-26&keywords=Dc+Power+Connectors)

They are used on a lot of Motorola mobile radios. Never had a failure and they can be found cheap and in different wire guages. Most U.S. auto parts stores carry them as well.
Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: GreekMan on November 19, 2014, 10:30:03 AM
yes i have seen them... And I also have found these:
http://www.ebay.com/itm/311139861979?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT (http://www.ebay.com/itm/311139861979?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT)
Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: unseenone on November 19, 2014, 03:08:45 PM
I've got a full set of Anderson tools and connections I got for projects.  While you might not want to buy all that stuff you can also order pre-made assemblies as well. I use http://powerwerx.com/ (http://powerwerx.com/) put custom cable in the search box.

I'd be happy to build you something or you can send me something to put connectors on, as long as you'll cover my costs for the actual connectors, etc.
Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: DragoSapien on November 19, 2014, 07:34:54 PM
If I may ask,,,, while were talking about connectors, what other connectors could be used to make a distribution hub kinda like the RIGrunner.

http://www.powerwerx.com/powerpole-power-distribution/rigrunner-4005.html (http://www.powerwerx.com/powerpole-power-distribution/rigrunner-4005.html)
Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: GreekMan on November 20, 2014, 01:44:26 PM
I'd be happy to build you something or you can send me something to put connectors on, as long as you'll cover my costs for the actual connectors, etc.

that is very kind of you but i will have to pass.
For reasons of:
Your offer does not solve the problem on the long run.
I sat down and made a list of all the cabling I need to build/rebuild and a significant portion of it will still have to use spade connectors, so I might stay with them for the moment.

thanks anyway!
Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: spacecase0 on November 20, 2014, 09:12:28 PM
spade connectors have been used all over the place for a long time,
and there is a very good reason,
they are going to work, and not cost that much, and every automotive parts store out there will sell them.
Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: unseenone on November 21, 2014, 12:12:02 PM
I've just been buying the powerpoles when I need them. They've got extra circuitry in them to light up a blown fuse, avoid surges on adjacent plugs, etc. 

Spades would probably do fine assuming they are sized correctly. The main reason I went with Anderson is because it's been accepted as a Standardizes connections using the amateur radio ARES & RACES, RSGB, ARRL for interoperability.

I did do the work over time, but I wanted to have it done as well as I could.  I've worked with spades and other such connectors for many years, I really like how the Anderson ones go together, they are much more rugged, and will hold up better in the long run.  The are definitely not the best connection where weather exposure is a factor.  There are clips, pins, etc. that you can use to keep the connectors together.
Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: BTPost on November 21, 2014, 07:39:39 PM
I have used standard old MOLEX Pin/Connectors in Commercial Service for decades, and the Large Versions will easily handle any current up to 10 Amps. Connectors come in M/F and in 2 - 15 Pole, and you can setup the M/F Pins in any arrangement you choose, as they are not Gender Specific, as far as the connectors go.  I usually route the DC Power, Audio IN and Out, and Control, all thru a 15Pin Molex, so that the Radio can be disconnected and removed for servicing, with just one Plug, and one Coax, to take apart. My Shop Bench has a Mating Molex that then feeds Speakers, Mic, and Power, for Service, and can supply the Inputs and Outputs to the Service Monitor, if required.
Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: GreekMan on November 25, 2014, 01:26:44 AM
An update is due.

Yesterday i finished redoing the wiring with the electrical spade connectors. Even took time to paint black the ones on the black wire .
Nice and tidy...

BUT...there is soemthing to be said for the practicality of these conenctors for regular on/off.
There is one that connects the two parts of the wire from the powerbank to the handheld, and this is tough to put on and off.
9afterall they wren't designed for this)
So i slowlycaving in to fate, powerpoles (have evan located dealers in nearby countries)

I would lile to re-pose a question.
"I also need a 2A 8V connectors for a case. I am thinking of the lockable 5.5mmx2.5mm DC Connectors. Though they are spec'ed at 1A 15V. the good thing is that being lockable they are handy for connecting power bank and HT."

many thanks to all that contributed thus far!
Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: TexasRadio on January 05, 2015, 10:40:45 AM
Here is another option for a 12 vdc connection.

http://www.hobbyking.com/hobbyking/store/__9572__Nylon_XT60_Connectors_Male_Female_5_pairs_GENUINE.html (http://www.hobbyking.com/hobbyking/store/__9572__Nylon_XT60_Connectors_Male_Female_5_pairs_GENUINE.html)

73
Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: AD on January 05, 2015, 10:51:22 AM
Interesting.  Thanks TR
Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: Lamewolf on January 08, 2015, 06:27:41 AM
Don't know why anyone wouldn't want to use Anderson Power Poles - wish I had found them 30 years ago !  No need for a special crimper either, just solder them on and you can reuse them by unsoldering.  I do it all the time and they are the best connector I've ever used !
Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: GreekMan on January 12, 2015, 01:48:51 PM
How can the re-use be done?
Don't the connectors lock into the carrier permanently?
Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: spacecase0 on January 12, 2015, 04:01:33 PM
How can the re-use be done?
Don't the connectors lock into the carrier permanently?
I don't know how others do it,
but I just use a tiny flat screw driver pop it out,
from the side I push the flat spring down, then move the screw driver to the front and push the metal connector part back out of the connector,
or just pull on the wire if a wire is still connected
maybe I should make a youtube video showing how
Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: GreekMan on January 13, 2015, 01:46:30 AM
I think I got it....Thanks!

searching for visualizations in google iamges i found this
http://www.w4hso-starc.org/AndersonPowerPoleInstallation.html (http://www.w4hso-starc.org/AndersonPowerPoleInstallation.html)
Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: GreekMan on October 17, 2015, 01:01:05 PM
necroposting...
I finally bit the bullet and capitulated.

major kit power wiring

(http://i176.photobucket.com/albums/w192/greekpreparedness/web-IGP1914_zpsdsd4rjw2.jpg~original)

handheld kit power wiring

(http://i176.photobucket.com/albums/w192/greekpreparedness/web-IGP1927_zpsowgcnt1o.jpg~original)
Title: Re: Educate me on DC Connectors (+ suggestions)
Post by: spacecase0 on October 17, 2015, 05:46:36 PM
your pictures look like what I have set up
it really does end up working well,
once you start you just can't stop...