Help needed for connecting two wires together carrying 250Amps!!!!! - Page 1
Forum section: electronics / beginners

author: Gurpreet
author_rank: Contributor
timestamp: November 09, 2017, 06:19:45 pm
content: Hey everyone,I need some advice on connecting two zero gauge wires which will carry at least 250A through them for a minimum of 30 minutes. I don't have any experience in high current stuff so I need some information on the type of connector and the method to install them on the wires, with the least amount of contact resistance so the connection point does not heat up too much. Are there any industry standard connectors or methods to do this job? What kind of wire(size and material) would be best suited for this job?Any help would be appreciated. thanks

author: grifftech
author_rank: Frequent Contributor
timestamp: November 09, 2017, 06:24:33 pm
content: Dinse plugshttps://www.amazon.com/s/ref=nb_sb_noss_1?url=search-alias%3Dtools&field-keywords=dinse+plug

author: alpher
author_rank: Frequent Contributor
timestamp: November 09, 2017, 06:35:55 pm
content: Standart way is this:https://www.mcmaster.com/#6921k62/=1a6li1g

author: Twoflower
author_rank: Frequent Contributor
timestamp: November 09, 2017, 06:36:06 pm
content: Probably you should also mention voltage and AC or DC as this might have an influence to the selection. Also if the mating or un-mating is done under load (here DC will be very nasty).

author: Gurpreet
author_rank: Contributor
timestamp: November 09, 2017, 06:59:06 pm
content: thanks guys, dinse connectors seems like good option if i need to make and break the connection regularly and Screw-Down Split-Bolt Splice seems cheaper and less bulkier but it wont give the same freedom as dinse connectors . I will have to try both of these options to find out which of these give least resistance because resistance is my main issue.Maximum voltage of the system would be 30V, but I won't mate and un-mate the wires under the load. Thanks for the heads up by the way.

author: dmills
author_rank: Super Contributor
timestamp: November 09, 2017, 07:47:51 pm
content: Camlock or the more modern Powerlock are both popular at this sort of current (and up) in the entertainment power game.Do watch the voltage drop, it can be a bigger factor in cable size at low voltage then you would expect, and is often the determining factor.Regards, Dan.

author: richard.cs
author_rank: Super Contributor
timestamp: November 09, 2017, 11:12:16 pm
content: In the UK we usually call those bolt connectors "line taps" and there is also an insulated version like this:

author: Jwillis
author_rank: Super Contributor
timestamp: November 10, 2017, 02:02:13 am
content: For that amount of amps I would be looking in the direction of welding cable connectors. Google welding cable connector and that will point you in the right direction.

author: MarkL
author_rank: Unknown
timestamp: November 10, 2017, 04:46:43 am
content: Take a look at Anderson SB-175 or SB-350 connectors:http://www.andersonpower.com/us/en/products/sb-sb-boots/sb-175.aspxhttp://www.andersonpower.com/us/en/products/sb-sb-boots/sb-350.aspx

author: rx8pilot
author_rank: Super Contributor
timestamp: November 10, 2017, 05:45:12 am
content: I used Camlok for years up to 400A, but only with AC and mains voltages.Short and misplld from my mobile......

author: forrestc
author_rank: Unknown
timestamp: November 10, 2017, 05:59:52 am
content: Quote from: Psi on November 10, 2017, 05:27:14 amPsi: That isn't the right tool for the job, this is:

author: cs.dk
author_rank: Unknown
timestamp: November 11, 2017, 06:43:38 am
content: If you need to connect both positive and negative, a NATO connector can do it. They are often seen on trucks for charging or starthelp. They can take up to 50 mm^2 cable.

author: stevelup
author_rank: Regular Contributor
timestamp: November 11, 2017, 08:23:27 am
content: Google NATO AN2551 / AN2552 - they are used for charging / jump starting aircraft.Readily available and rated at 28V / 240A continuous / 1500A peak

author: vk6zgo
author_rank: Super Contributor
timestamp: November 11, 2017, 01:40:43 pm
content: Here's how I would do it.A clunky great piece of copper busbar, with a couple of big brass bolts through it.Very large wing nuts to attach equally large terminal lugs.But then, I'm an old fart, what would I know?

author: fcb
author_rank: Super Contributor
timestamp: November 11, 2017, 10:56:24 pm
content: What voltage? AC? (Frequency)? DC?Mate under load? Environmental conditions?

author: Unknown
author_rank: Unknown
timestamp: November 12, 2017, 02:40:41 am
content: Here's a link to some insulated connectors used in mains work.https://commerce.ilsco.com/e2wShoppingCatalog.aspx?parentId=3100012208&parentLink=2100001183:3100012208