Decent DC power connectors that aren't barrel or powerpoles? - Page 1
Forum section: electronics / projects

author: bd139
author_rank: Super Contributor
timestamp: May 28, 2019, 08:04:36 pm
content: Ok so I'm thoroughly done with both powerpoles and DC barrel jacks now. Powerpoles because I've got dicky contacts already on a connector pair plus a number of other issues. Barrel jacks because they're either ridiculously expensive or utter total crap quality and nothing in between.So what can I use for this?1. Needs to withstand regular use (5000 cycle lifetime min)2. 5A current max (normally ~3A)3. 12V4. Cheap5. Reliable6. Available from legitimate non grey market suppliers.7. Casual misuse doesn't result in short across pins (one end will be permanently connected to li-ion pack)8. Doesn't matter if it's gendered or hermaphroditic.9. Relatively small (smaller than powerpole)10. Available in cable or panel mount with strain relief.11. Latched if possible.XT30 is a good starting point apart from points 7, 11

author: bd139
author_rank: Super Contributor
timestamp: May 28, 2019, 08:20:47 pm
content: Have discounted these as they're not latching. Currently looking at Molex mini-fit...

author: Tomorokoshi
author_rank: Super Contributor
timestamp: May 28, 2019, 08:38:32 pm
content: Lots of options in the Phoenix COMBICON series, although I'm not sure what your definition of "cheap" is:https://www.digikey.com/products/en?keywords=277-5816-NDhttps://www.digikey.com/products/en?keywords=277-5710-NDhttps://www.digikey.com/products/en?keywords=277-5928-ND

author: David Hess
author_rank: Super Contributor
timestamp: May 28, 2019, 08:39:24 pm
content: The Molex 1625 series work for this type of application and I have seen them used this way before in commercial equipment.https://www.mouser.com/Search/Refine?FS=TRUE&N=4292887429+4292906361The crimping tool and pin extractor are reasonably priced:https://www.amazon.com/Waldom-Electronics-W-HT-1921-CRIMPING-ELECTRONICS/dp/B0195UWT9Uhttps://www.amazon.com/Extractor-Diameter-Standard-Terminals-11-03-0002/dp/B00IZOD3NE/ref=sr_1_2However they are only rated at 5 amps per pin maximum. There is similar but larger 15 amp version which uses the same crimper above and a larger .093" pin extractor. Besides industrial stuff, I have seen them sometimes used on commercial armature radio equipment:https://www.molex.com/molex/products/family?key=standard_093&channel=products&chanName=family&pageTitle=Introduction&parentKey=power_connectors

author: bd139
author_rank: Super Contributor
timestamp: May 28, 2019, 08:52:02 pm
content: Thanks both for suggestions. Molex standard 093 is looking about right. Trying to find a European source that sells small quantities as I only need about 10 shells male/female each and pins.

author: David Hess
author_rank: Super Contributor
timestamp: May 28, 2019, 09:00:19 pm
content: They lack positive retention and use a friction tab but I actually prefer this for many connections so that tripping on a cord pulls the plug rather than ripping wires or pulling something to fall on the floor.There are some other similar Molex connectors which have positive retention if you want that.

author: bd139
author_rank: Super Contributor
timestamp: May 28, 2019, 09:03:58 pm
content: Positive retention would be good with this. While connected they need to remain reliable.Turns out you can't get .093 molex in anything but crazy numbers in UKWill keep looking.Edit: crazy idea. 9-pin D-sub is an option here. Can get decent quality 5A rated contact units. Option of paralleling pins, screw down and quality connector shells. And bonus, two of the devices already have 9 pin D-sub holes! Downside - if someone plugs one into a PC, kaboom.

author: David Hess
author_rank: Super Contributor
timestamp: May 28, 2019, 09:23:57 pm
content: Quote from: bd139 on May 28, 2019, 09:03:58 pmThat's weird. In the US, I routinely buy the 0.062" ones 10 or 25 at a time.The friction tab is really good. I have never seen one come unplugged due to vibration or rough handling alone unlike say a SATA connector.QuoteThis is usually discouraged because people will plug the damnedest things into D-connectors but paralleling pins will certainly get you where you want to go. The Molex connectors can at least be keyed by arranging male and female pins in the separate housings.

author: soldar
author_rank: Super Contributor
timestamp: May 28, 2019, 11:31:37 pm
content: Quote from: bd139 on May 28, 2019, 09:03:58 pmI can't see how it would be cheap. Or small. Or reliable for higher current except paralleling pins. Sounds crazy.I agree barrel connectors have a very specific use in consumer electronics but are not the best for things like connecting a battery.Molex sounds good. Maybe you can get some big buyer to sell you a few. A few times in my lifetime that has worked for me.

author: MosherIV
author_rank: Super Contributor
timestamp: May 29, 2019, 07:06:23 am
content: Have you looked at round DIN connectors?They are rated upto 2A on each pin.Yes, you can use D Types but check the current rating of the pins, they tend to be limited. You can use multiples pins on same volt to share the current load.Avoid using common ones to stop people 'trying them out to see what happens'

author: bd139
author_rank: Super Contributor
timestamp: May 29, 2019, 07:24:39 am
content: Thanks all again.I looked at DIN a well. In fact I have a whole box of 2 pin DIN connectors (plugs and sockets) but they are terribly unreliable unless you spend spend spend.

author: nali
author_rank: Frequent Contributor
timestamp: May 29, 2019, 08:21:15 am
content: How about speaker connectors e.g. Neutrik? A little bit more expensive but robust, rated for tons of current and uncommon enough that they  won't get plugged into anything else.https://www.neutrik.com/en/product/nl2fx

author: CJay
author_rank: Super Contributor
timestamp: May 29, 2019, 08:51:07 am
content: As Nali said, Neutriks are good but not cheap.Molex are good, it'd be worth having a look at commercial radios to see which ones to use and which to avoid as some of those series are used for features like external ATU or CAT control, it'd be an expensive mistake to plug the wrong one in if you bumped into a radio that uses them.Maybe use the old style hard disk/5.25" floppy connector?FWIW, Tait and (I think) Kenwood use the same Molex for power as Icom use for ATUs, not a great combo if you're plugging stuff in 'blind' under a shelf etc.Curious if you used genuine Anderson powerpoles or knock offs as I've not run into problems with bad contacts (yet) on either?

author: sleemanj
author_rank: Super Contributor
timestamp: May 29, 2019, 09:03:43 am
content: Quote from: bd139 on May 28, 2019, 08:20:47 pmAmass makes latching versions....but even the standard unlatched type fit together very snugly, after all they are used in relatively high vibration models etc. I use XT60 for test leads, love the things, XT60-banana, XT60-alligator, XT60-testhook, XT60-wire, XT60-2xXT60 (parallel), XT60-XT60-XT60 (series), XT60-USB, XT60-Barrel, XT60M-XT60M, XT60F-XT60F.... and so on, so I can just plug together the ends to make up the right cable as needed. The connectors are even marked with a small embossed +/- so you can always be sure you're following the same "standard".

author: bd139
author_rank: Super Contributor
timestamp: May 29, 2019, 09:08:24 am
content: Neutrik ones are rather interesting. Just about in budget. I looked at some Cinch ones that were similar to that but found they were discontinued.I had Molex ones on my FT450D - they were pretty good. Aware of the problems of misconnection. I walked into my local radio shop and someone had blown up their Yaesu thanks to a "polarity incident". I haven't done that yet. In fact I'm so paranoid about it, I tend to DMM check everything before I plug it in several times.They are genuine ones from Torberry (UK distributor). I have been soldering them on as I don't have a crimp tool and I think this has caused some problems with contact alignment. Perhaps I should scrap this idea and stop being a cheap arse and just buy a crimp tool!I notice Torberry do booted ones which might help the strain issue as well:https://www.torberry.co.uk/product/powerpole-pack-red-black-cw-contacts-and-sleeves-1327-1327g6-13312Quote from: sleemanj on May 29, 2019, 09:03:43 amI'm liking that. Thanks for pointing me at these.

author: jfiresto
author_rank: Frequent Contributor
timestamp: May 29, 2019, 09:58:48 am
content: Have you considered Rean Tiny XLR connectors? They are rated to just shy of 5A, with less than 10 mOhms resistance after 5000 mate-unmate cycles. Rean is an alternate for the original Tini Q-G parts from Switchcraft that include mating, male, PCB-mount receptacles.The wired connectors are limited to a maximum wire size of 24 AWG (0.22 mm^2). If you can live with that, they are fairly common, and not expensive for what they offer.

author: AndyC_772
author_rank: Super Contributor
timestamp: May 29, 2019, 10:17:25 am
content: My favourite DC power connectors are these:https://www.toby.co.uk/powertoboard-connectors/75-amp-cable-connectors/

author: soldar
author_rank: Super Contributor
timestamp: May 29, 2019, 10:54:28 am
content: There is a difference on whether the connectors will be included in a fixed panel or only just attached to the cables.These look like they would work:https://www.te.com/usa-en/product-350786-1.html

author: Jeroen3
author_rank: Super Contributor
timestamp: May 29, 2019, 10:58:04 am
content: Those Toby connectors are awful. They are on some laptops and on Synology NAS systems. They extend -a lot- away from the product.And do not offer good tactile feedback. Both correct and incorrect goes tough, and you must look to verify correct insertion depth and orientation.DC connectors are either expensive, or not very good. Or you're getting into very niche crimping products.Also, 5000 mating cycles is a lot.

author: IDEngineer
author_rank: Super Contributor
timestamp: May 29, 2019, 12:50:18 pm
content: Quote from: David Hess on May 28, 2019, 08:39:24 pmYou won't find anything cheaper than the Molex connectors. And while "cheap" and "reliable" are usually mutually exclusive, Molex has these connectors really dialed in. They're ugly but do the job.Another suggestion is the "Deutsch" style connectors, available from both Deutsch themselves as their DT-series and Amphenol as their AT series (and they are physically and electrically compatible). The basic style is rated for 13A per pin and there is a "power" version that goes to 25A. They're also waterproof if that's useful to you. Contacts available in both solder and crimp so you don't have to buy an expensive, dedicated crimping tool. More expensive than the Molex (everything will be) but used throughout the automotive industry so they have tons of history and are well characterized for nasty environments. Available in cable, panel, and PCB mounts though not every pin count is available in every mounting style.Here's a 2 pin example stocked by Mouser:https://www.mouser.com/ProductDetail/TE-Connectivity-DEUTSCH/DT06-2S-C017?qs=sGAEpiMZZMs7eK6h2EBtKo3289hpF6BIKq5aaemO3wo%3D...and here's a 2 pin example stocked by DigiKey:https://www.digikey.com/product-detail/en/amphenol-sine-systems-corp/AT06-2S/889-1012-ND/2125184Both vendors stock the opposite gender mating connector as well.

author: Jeroen3
author_rank: Super Contributor
timestamp: May 29, 2019, 01:13:02 pm
content: This is the kit variant of the two pole mentioned above.https://www.digikey.com/product-detail/en/amphenol-sine-systems-corp/AT2PS-CKIT/889-1234-ND/4415018These are the tools $$$:https://nl.mouser.com/ProductDetail/Amphenol-SINE-Systems/CA-5D12?qs=G1ypbwQO0GwlwsHPbYz8qw%3D%3Dhttps://nl.mouser.com/ProductDetail/Amphenol-SINE-Systems/ATT-20-00?qs=6E8igxPflKewd6RHECuZSw%3D%3DWhich move crimp systems beyond reach for diy use.

author: IDEngineer
author_rank: Super Contributor
timestamp: May 29, 2019, 01:21:07 pm
content: As I mentioned, there are solder versions of the contacts which reduce the cost of the crimping tool to zero.

author: Perfectbaguette
author_rank: Newbie
timestamp: May 29, 2019, 02:26:46 pm
content: Yamaha e-bikes use Hirose HR30 connectors. Solder lips, positive lock and available in wire-wire and wire-panel. Not sure if they are rated for 5k insertions though, that's really a lot. That's several times the rating of a USB Type A socket.

author: NiHaoMike
author_rank: Super Contributor
timestamp: May 29, 2019, 02:34:22 pm
content: What about 4 pin "ATX12V" connectors?

author: David Hess
author_rank: Super Contributor
timestamp: May 29, 2019, 02:43:13 pm
content: Quote from: bd139 on May 29, 2019, 07:24:39 amIf cost is no object, then the various circular LEMO connectors are suitable.

author: mzzj
author_rank: Super Contributor
timestamp: May 29, 2019, 03:10:08 pm
content: Quote from: Perfectbaguette on May 29, 2019, 02:26:46 pm5K insertions rating is going to rule out LOTS of the mentioned connectors. Deutsch DT and Amphenol AT for example are rated for 100 cycles. AMP econoseal same problem.Neutrik: Speakon, Powercon, XLR: bulky but easy to use and decent strain relieve that actually works with multiple cable sizes.And MIL-DTL-5015 connectors are commonly used in industry but not exactly cheap..Chinesium GX12 or GX16 "aviation connectors" are not too bad considering price but not easily available from reputable sources.

author: jfiresto
author_rank: Frequent Contributor
timestamp: May 29, 2019, 04:03:23 pm
content: Quote from: mzzUnless you are a fearless MBA.As far as I can tell, Tiny XLR's will satisfy all of the OP's requirements except one: that they be (9) relatively small (smaller than powerpole). A mated, cable connector pair will be about twice as long.

author: jfiresto
author_rank: Frequent Contributor
timestamp: May 30, 2019, 08:12:57 am
content: Quote from: mzzjHmmmm. I wonder if it wouldn't – with the help of a good contact lubricant. It does wonders to reduce fretting.Imagine getting 5000 cycles out of a pair of tin-plated Mini-Fit Jr. connectors. I think that would be a fun research project.

author: bd139
author_rank: Super Contributor
timestamp: May 30, 2019, 08:18:30 am
content: Big thanks to all the replies. I have sourced some Molex 093 connectors and will try them first.

author: eugenenine
author_rank: Frequent Contributor
timestamp: May 31, 2019, 12:56:01 am
content: 12v says automotive to mefor example:https://www.mouser.com/Aptiv/Connectors/Automotive-Connectors/Metri-Pack-280-Series/_/N-1ehb5?P=1yvsm2aZ1z0zlezZ1yzrh8u

author: ConnWiz
author_rank: Newbie
timestamp: June 06, 2019, 07:23:15 pm
content: I would be very concerned with the 5,000 mating cycles. Most of the connectors mentioned here don't have terminals that withstand that many cycles. Here is my recommendation from Amphenol. They have a terminal that can withstand over 10,000 mating cycles. In comparison, the Mini-ft Jr, even with Molex's special high-cycle terminal is only rated for 1,500 mating cycles. Let me know if you want more information.

author: Kjelt
author_rank: Super Contributor
timestamp: June 07, 2019, 02:18:10 pm
content: Quote from: bd139 on May 28, 2019, 09:03:58 pmHmmm yeah those are for datalines and low voltage low amps connections as you know.But there are special versions called Combo D I believe that will not get you into any compatibility issue and have high amps and pretty high voltagesI don't know which versions exist, these have 5 poles probably smaller ones with less poles do exist.

author: Kjelt
author_rank: Super Contributor
timestamp: June 07, 2019, 02:25:02 pm
content: Ah they are called Combo-D subs and multiple companies like Harting, ITT Cannon and Amphenol makes them.https://nl.farnell.com/amphenol/l17dm53744-1/contact-solder-skt-40a/dp/1849900?MER=bn_level5_5NP_EngagementRecSingleItem_4https://nl.farnell.com/amphenol-icc-commercial-products/l717twb5w5p/connector-d-sub-combo-plug-5-position/dp/1362713?MER=sy-me-pd-mi-altehttps://nl.farnell.com/harting/09-69-181-7423/contact-female-40a/dp/1200480?MER=bn_level5_5NP_EngagementRecSingleItem_2

author: Monkeh
author_rank: Super Contributor
timestamp: June 07, 2019, 03:33:32 pm
content: Quote from: bd139 on May 28, 2019, 09:03:58 pmTry looking for the AMP Mate-n-Lok, better known as the 'four pin molex' of PC fame. It's basically a non-mating copy of the .093", and hilariously common. Don't really need positive retention with something which jams in that tight..