Multi pin connectors?

I'm looking for a 16 to 20 pin connector set (male and female) for my home built lithium charger. I want something that is

- User friendly: Safe and easy connection (no chance of incorrect connection)
- Robust: The connection (for charging) is to be made and "unmade" daily
- Capable of handling 3A per pin
- Easy to wire. Crimping is preferred over soldering
- Rectangular or circular? Not sure of the pro and con of either format.

I have never made such a connector set before. I looked at http://www.alliedelec.com/connectors/ for ideas, but the choices are overwhelming and the description "terse" (to me at least).

Recommendation needed based on your experience in building multi pin connectors, please. Thanks.

For now I'm inclined to use this:

http://www.lane-pilot.com/servlet/Detail?no=28

I use a DB25 connector for my home built lithium polymer setup
12 pins for balance taps from the parallel cells and the rest of the pins
divided up for the main leads, has worked flawlessly.

KiM

You could also use 2 of these:

12 circuit/connector, polarized, (male and female) 250v, 7.5 amp.
http://www.mcmelectronics.com/product/WALDOM-ELECTRONICS-1360PRT-/21-3110

Or one of these:

24 circuit/pin connector, polarized, (m + f) 250v, 5.0 amp.
http://www.mcmelectronics.com/product/WALDOM-ELECTRONICS-1625-24PRT-/21-3065


BTW, assembling "multi-pin" connectors is pretty easy. Just think of them as a single pin connector with a bunch of "buddies"...

AussieJester said:

I use a DB25 connector for my home built lithium polymer setup
12 pins for balance taps from the parallel cells and the rest of the pins
divided up for the main leads, has worked flawlessly.

Click to expand...

That's quite innovative. Did you use the flat ribbon type cable? Or did you crimp and insert each pin? Do you have a picture of the back side (where you made the connection) of the connectors?

And which gender did you use for the battery side, male or female? I'm thinking female for the battery side because it lessens the chance of a short. What do you think?

FMB42 said:

24 circuit/pin connector, polarized, (m + f) 250v, 5.0 amp.
http://www.mcmelectronics.com/product/WALDOM-ELECTRONICS-1625-24PRT-/21-3065

BTW, assembling "multi-pin" connectors is pretty easy. Just think of them as a single pin connector with a bunch of "buddies"...

Click to expand...

That's good news for me. I have never assembled a pin connector before. Do you crimp the wire to pin first then insert the pin into the housing? What are the possible ways for me to screw up?

SamTexas said:

That's quite innovative. Did you use the flat ribbon type cable? Or did you crimp and insert each pin? Do you have a picture of the back side (where you made the connection) of the connectors?

Click to expand...

I soldered each wire individually, put heat shrink on each wire/pin join, when all complete i applied
liquid tape over all pins to ensure none would come lose... Some pics of another memebers DB25 setup
in the Hyperion thread GGoodrum started months ago... Only pics i bothered
taking this time-->



No ribbon cable, single strand for each balance wire...

SamTexas said:

And which gender did you use for the battery side, male or female? I'm thinking female for the battery side because it lessens the chance of a short. What do you think?

Click to expand...

Yes, thats how i have gone, female on battery male on charger.

KiM

Thanks KiM. I wish I have the skill to do a decent solder job.

SamTexas said:

That's good news for me. I have never assembled a pin connector before. Do you crimp the wire to pin first then insert the pin into the housing?

Yes, crimp first, then insert into housing.

I usually crimp the wire (conductor) 1st followed by crimping the wire insulation 2nd. I'm not so sure that this matters tho...

Like JussieJ says, always (and I mean always) install the female connector on the battery or "hot" side of any circuit.

SamTexas said:

What are the possible ways for me to screw up?

Click to expand...

Click to expand...

Well, I've screwed up just about every connector you can think of. As such, it is highly recommend that you purchase a number of spare male and female connector pins to "practice" on (with some spare wire).

Just be advised that you will need a crimp tool that is designed for crimping both the conductor and the insulation (for best results). Note: such crimp tools are very inexpensive.

I went with a 24 pin China military plug. It's cool, screws on and off. I've got an extra if someone wants one.





24 pin http://cgi.ebay.com/Military-24-Pin-Voltage-Cylindrical-Circular-Connector-/390332271869?pt=LH_DefaultDomain_0&hash=item5ae19dccfd#ht_2011wt_1393

19 pin http://cgi.ebay.com/Military-Gold-19-Pin-Twist-Male-Female-Connector-F19P-/290571849415?pt=LH_DefaultDomain_0&hash=item43a76e8ec7#ht_1033wt_1160

I've used the 9 pin Molex connectors when I extended my BMS leads and split my 20ah 36 volt Ping into 2 18 volt halves. They are big and easy to crimp but I have had an occasional crimp fail and had to repair it. The removal tool sold by RadioShcak is very effective and I just use my standard HarborFreight cheep crimper. I would not trust this for power connection voltages and amps, only BMS balance wires.
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