DrkAngel
1 GW
Problem
Battery to controller connectors-switches can take considerable abuse from initial "connect".
Often typical is a spark or "snap".
To survive ... the connector, switch or contactor, must be heavier and more durable than is necessary for typical current during use.
Solution
Most common is the use of a Pre-charge resistor circuit.
This involves buffering the millisecond "spark" to a partial~multiple second "charge".
Keeping this circuit simple, reliable and inexpensive is the challenge!
Simple is easy:
View attachment 2
![Temp Pre-charge Resistor.jpg Temp Pre-charge Resistor.jpg](https://endless-sphere.com/sphere/data/attachments/99/99180-869523ffb26e471499444369213628ef.jpg)
Simple Pre-Charge - Switch
A simple, and cheap, on\off\on switch with the 2 positions shorted with a resistor makes an effective pre-charge circuit.
I position to charge, (couple seconds?) II to fully engage.
High V light bulb as replacement for resistor confirms pre-charge complete when bulb dims fully.
Proper resistor with LED would provide similar function. Might need Large resistor parallel with small resistor-LED.
![PC Switch.jpg PC Switch.jpg](https://endless-sphere.com/sphere/data/attachments/99/99181-9d7276e3d44a725f9b34bf3731c90fd3.jpg)
Pictured switch is rated up to 15A in dual (pos and neg) disconnect and 30A as single disconnect (pos or neg).
Personally used at 25.9V and 33.3V w\35A controller on various eZips and survives hundreds of on off cycles before needing replacement.
Adding pre-charge should greatly prolong life even at higher Volts and Amps!
Also liable to prolong controller life. ... ?
Battery to controller connectors-switches can take considerable abuse from initial "connect".
Often typical is a spark or "snap".
To survive ... the connector, switch or contactor, must be heavier and more durable than is necessary for typical current during use.
Solution
Most common is the use of a Pre-charge resistor circuit.
This involves buffering the millisecond "spark" to a partial~multiple second "charge".
Keeping this circuit simple, reliable and inexpensive is the challenge!
Simple is easy:
View attachment 2
![Temp Pre-charge Resistor.jpg Temp Pre-charge Resistor.jpg](https://endless-sphere.com/sphere/data/attachments/99/99180-869523ffb26e471499444369213628ef.jpg)
Simple Pre-Charge - Switch
A simple, and cheap, on\off\on switch with the 2 positions shorted with a resistor makes an effective pre-charge circuit.
I position to charge, (couple seconds?) II to fully engage.
High V light bulb as replacement for resistor confirms pre-charge complete when bulb dims fully.
Proper resistor with LED would provide similar function. Might need Large resistor parallel with small resistor-LED.
![PC Switch.jpg PC Switch.jpg](https://endless-sphere.com/sphere/data/attachments/99/99181-9d7276e3d44a725f9b34bf3731c90fd3.jpg)
Pictured switch is rated up to 15A in dual (pos and neg) disconnect and 30A as single disconnect (pos or neg).
Personally used at 25.9V and 33.3V w\35A controller on various eZips and survives hundreds of on off cycles before needing replacement.
Adding pre-charge should greatly prolong life even at higher Volts and Amps!
Also liable to prolong controller life. ... ?