Thursday, February 27, 2014

High current wiring

The Hydra v2.2 boards came in today, but I've had trouble in the past with the high-current path of both the OpenEVSEs and Hydras that I've built so far. I've come to the basic conclusion that engineering things that handle 30A of electrical power is a very unforgiving pursuit.

But with help from the OpenEVSE community, I may have finally cracked it.

I had been using crimp on .25" QD terminals I got at Home Depot, but it appears that those just aren't good enough for that kind of high current application. Instead, I've gotten in a supply of Molex Avikrimp terminals (DigiKey WM18256-ND), and with my ratcheting crimping tool, those appear to crimp on much more firmly. It takes a lot more effort to close the tool, and the resulting connector just feels a lot more solid.

The downside is that they don't fit very well in the Cooper Bussmann power distribution block I've been using.

There is the Cooper Bussmann 16220-2 instead of the 11725-2. That has four screw terminals on the load side instead of 4 QD terminals. But it costs $55 instead of $17.

What to do?

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