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500 Class Electric Helicopters 500 Class Electric Helicopters manufactured by Align, Tarot, SYMA, Airhog, Chaos, HK and similar. |
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03-01-2015, 08:41 AM | #61 (permalink) | |
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03-01-2015, 10:21 AM | #62 (permalink) |
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The EC5 is simply the wrong connector for the job. Any part used well beyond its rating is at risk.
Rick
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03-01-2015, 01:37 PM | #63 (permalink) | |
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The problem with the APPs is that the connection depends on the plastic keeping its shape. When heating occurs, the plastic can soften and the connection will loosen. A loose connection causes more heating and more loosening. The EC5s connection does not depend on the plastic housing. But they are still 5.5mm bullets which still have limits and issues. As I had mentioned earlier in this very old thread, at some point its much better to raise the operating voltage than replace the connector. 325 amps is a lot for our hobby grade equipment. If the ESC supports it, consider increasing cell count. Also consider a more substantial connector.
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03-01-2015, 01:56 PM | #64 (permalink) |
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Not all EC5's are created equal - the newer - easy connect/disconnect ones - 'straight' males are problematic - especially after many cycles - they loosen their grip - creates a continuity choke point that causes overheating - or total loss of continuity.
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03-01-2015, 01:59 PM | #65 (permalink) | |
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Hi, thanks for the reply. All other connections seem good so far... no heat. Most of the system is 10 Ga wire and only a restricted section takes all of the power of the system. I posted here because I Googled EC5 connectors and landed here. After seeing the questions and comments people had here about the EC5 connector, I thought I would reply to an existing post, and power issues traverse airframe specifics. Thanks Again... Anthony |
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03-01-2015, 02:33 PM | #66 (permalink) | |
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Location: Maryland
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We can discuss generalities with you on electrical stuff, but there are people on the site building large multi-rotors, and they will be able to help you with more specific information (like what electrical connectors they are using.)
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03-01-2015, 03:22 PM | #67 (permalink) | |
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Hey Gregg... Great Info!
I'm committed to the 6S at the moment, but will consider higher voltage in future iterations. The solder melted, but there is no physical signs that the plastic housing or the bullet connectors were effected at all. It could have been that the connector lost its tension and heated up. I am going to eliminate the last connector in the system (other than the ones on my Lipos which are all fitted with EC5s for now) so that I'm getting rid of as many potential fail points as possible. I'm building a Main Bus Connector Bank made from copper and that will connect directly to the main bus (positive going through my 400 amp power switch) with the EC5 Female connectors attached directly to eliminate as much potential resistance as possible. I agree that bolting and crimps are the better way to go but it seems that I must fabricate the necessary equipment because there isn't anything really suitable for my real estate requirements on the market. My Lipos and their connectors never get more than mildly warm so I don't think there will be a problem sticking with these connectors for the battery connection. Right now I'm using various configurations, and one is using 6 X 6000mAh 50C Lipos, another is using 2 X 20000mAh 60C Lipos. I believe, although less convenient, using 6 Lipos may reduce the heat generated at the connectors because less current passes through each one, but I'll test that theory in the next couple of weeks. Thanks to everyone here, every little bit adds to the knowledge pool and helps a lot! Anthony Quote:
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03-01-2015, 03:27 PM | #68 (permalink) | |
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Join Date: Sep 2013
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I've been around the block a few times but am still looking... Thanks! |
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03-01-2015, 03:32 PM | #69 (permalink) | |
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Join Date: Sep 2013
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I think this one connector started to lose it's gripping power, even though it haden;'t gone through that many cycles. I am eliminating all connectors on the rig except the Lipo EC5s and they don't get very warm at all. Thanks Again! Anthony |
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03-01-2015, 03:36 PM | #70 (permalink) | |
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Join Date: Sep 2013
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On another project I'm making my own connectors and I built a 600 amp distribution system, but it's hard to find gear for this kind of power on the market that's also light enough and small enough to fly I can see by your site that you are an innovator... I like that, thanks for the input. Anthony |
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04-26-2015, 04:52 PM | #71 (permalink) |
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Join Date: Apr 2015
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I came across this thread after a google search on failed EC5 connectors. You can see in the picture below that I had a rough afternoon today. I just purchased a DJI S800 used and have been taking my time learning what I can about it as I am very new to the hobby. This was a step up from my Vision 2+ so I am pretty green. This was on about my 3rd flight. fortunately it came apart right as I was landing and about 12" up. Hate to even think what would have happened seconds earlier. The thing that really struck me was how shallow the solder cup was. Doesnt really seem like the best design. I already have the pliers for some 30 amp power pole connectors so I just ordered the 45 amp pieces and will be converting everything over.
I am thinking that this connector was possibly a little worn and not giving a good connection and thus heating up. Add in me tinkering with things and probably moving things around and possibly further stressing the connection and there you go. Very lucky I suppose. |
04-26-2015, 10:13 PM | #72 (permalink) |
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The EC5s will carry a lot more current than APP 45s. But a bad solder job on an EC5 will result in heating even at lower current levels.
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04-26-2015, 11:00 PM | #73 (permalink) |
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Join Date: Sep 2013
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Hi Everyone
Just to make a point... I think that EC5 connectors are some of the best connectors available in their class. In my previous post I mentioned eliminating "most" of them, but for clarification, that was all unnecessary connectors. I had connectors between sub-systems that I just didn't need, so I eliminated them. I still use EC5 connectors on all of my lipos. My monster octocopter can push more than 500 amps if allowed, but normally it runs between 240 amps and 400 amps. With this setup and lifting 45lbs my EC5 connectors aren't much warmer than room temperature, IF that. My engineer is all for crimped connectors, but finding small enough connectors that have high current ratings is harder for a flying vehicle with limited real estate than for industrial settings, which is why I'm sticking to the EC5s (plus they are a standard in this field). I agree that the solder cup should be much deeper (on all of the connectors)... What's Up With That? There is a version of the EC5 that has a deeper cup, I don't recall what it is being called, but it looks promising. Anthony |
05-20-2015, 09:33 AM | #74 (permalink) |
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Anderson PP question
Will the PP45 work with # 8 wire? I'm running a CC130 in a 550L and the connector wires on the 130 are 8 gauge wire. I went to 6.5mm bullets from castle but I don't really like them.
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