Electrical Quick release after motor controller?

[Jon Stratis]

Originally Posted by nathan_hui

CHS Robotics used (pretty sure we still are) the Molex .093" series wire to wire connectors for interconnects between the PDB and the Motor Controller, and the Motor Controller and the Motor. These were only for the lower amperage circuits (20 amp max on a connect specc'd for 15 amps). We used a set of Anderson PowerPoles with a 30 amp rating for the 40 amp circuits (but we had some problems with failure of the solder joints. Possibly consider getting the actual crimper for the 45 amp contacts, or switching to a different connector, possibly a Molex).

You should double check what you're using... All connectors must be "appropriately gauged/rated", per R49, previously quoted. To me, that says that if you have a 20A breaker on a given line, any connectors in line with that breaker also need to be rated for a minimum of 20A. For 30A breakers, they should be rated for 30A or above, and for 40A breakers for 40A or above. With what you've suggested above, you are using connectors that are rated less than the breakers - as I read it, that violates the rules.

The crimper for the PowerPoles works really well, and i highly recommend it, although its not necessarily required. For the open PP connectors (shaped like a U), you can bend the tabs over carefully with a pair of pliers. Even with the crimper, though, I recommend everyone solder the terminals as well. So long as it is properly soldered, it'll never be coming apart. The key is to solder it properly... with people new to soldering, its very easy to get a cold solder joint and thus a weak connection that'll break off easily.