Connectors are more important than you might think! So which one is the best? (Experiment)
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Date: 2021-10-24
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Comments and reviews: 9
hey_allen
Screw terminals and when are you ever going to run 10 amps through them?
Almost all 3d printers run screw terminals for their main power input to the control board, and most also run them on the heater outputs, both the hot end which is relatively low current, as well as the heat bed output.
Many printer heat beds will run 300-400 watts. Even at 24v that is a good few amps, but the older printers running 12v have burned boards and started fires.
Mine is switched now from being a high current 24v bed to a mains powered and SSR switched bed, but that's taking a few extra steps beyond just using heavy terminal blocks on external switching, as well as bootlace ferrules.
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Screw terminals and when are you ever going to run 10 amps through them?
Almost all 3d printers run screw terminals for their main power input to the control board, and most also run them on the heater outputs, both the hot end which is relatively low current, as well as the heat bed output.
Many printer heat beds will run 300-400 watts. Even at 24v that is a good few amps, but the older printers running 12v have burned boards and started fires.
Mine is switched now from being a high current 24v bed to a mains powered and SSR switched bed, but that's taking a few extra steps beyond just using heavy terminal blocks on external switching, as well as bootlace ferrules.
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Arturs
From my experience, the most worst is old aluminium wires in old houses. They always end up with melted switches, sockets, melted connectors etc. Can cause fire hazard, they can break easily and under big load, they have pretty high voltage drop, causing wires to heat up under load. It's painful to completely change these in concrete walls. By now, there is Wago connector series and special Wago paste, specifically designed for connecting copper and aluminium wires. Great solution if replacement of all cable is not possible.
But I still hate old aluminium wires.
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From my experience, the most worst is old aluminium wires in old houses. They always end up with melted switches, sockets, melted connectors etc. Can cause fire hazard, they can break easily and under big load, they have pretty high voltage drop, causing wires to heat up under load. It's painful to completely change these in concrete walls. By now, there is Wago connector series and special Wago paste, specifically designed for connecting copper and aluminium wires. Great solution if replacement of all cable is not possible.
But I still hate old aluminium wires.
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Mike
7: 45 Fast on are better in real applications. The tests aren't accurate because you use solder metal for the connection of two male, that matel have a higher resistance than copper.
Usually faston are made out of brass and with a strong connection with the copper wire they will perform ad good as the wire itself.
If you want to make scientific test (expecially when a little change in the resistance have a huge impact) do not introduce human error plis.
Wrong information are dangerous.
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7: 45 Fast on are better in real applications. The tests aren't accurate because you use solder metal for the connection of two male, that matel have a higher resistance than copper.
Usually faston are made out of brass and with a strong connection with the copper wire they will perform ad good as the wire itself.
If you want to make scientific test (expecially when a little change in the resistance have a huge impact) do not introduce human error plis.
Wrong information are dangerous.
reply
Alex
Once I soldered the ends of a stranded wire, then inserted this into a butt connector and crimped that. Of course that wire was for a heated bed in a 12V system, so it was pushing about 10A. In this case the connection heated to about 80-100C when I started wondering where the magic smoke is coming from.
Suspect that resistance is increased because the electricity had to go through 3 different materials in a very short section of wire.
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Once I soldered the ends of a stranded wire, then inserted this into a butt connector and crimped that. Of course that wire was for a heated bed in a 12V system, so it was pushing about 10A. In this case the connection heated to about 80-100C when I started wondering where the magic smoke is coming from.
Suspect that resistance is increased because the electricity had to go through 3 different materials in a very short section of wire.
reply
Szab
Solder has a much lower conductivity than copper. I think Scott knows it, but viewers might not, so make sure, when you solder anything together, that there is bare contact between the two pieces of wire or anything you're soldering and you're not just bridging the gap between them with solder. In low current applications the bridging is fine, but in high current applications, that can lead to a bad or dangerous result
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Solder has a much lower conductivity than copper. I think Scott knows it, but viewers might not, so make sure, when you solder anything together, that there is bare contact between the two pieces of wire or anything you're soldering and you're not just bridging the gap between them with solder. In low current applications the bridging is fine, but in high current applications, that can lead to a bad or dangerous result
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logmeindog
For butt connections I care about, I always, rosin the wires, crimp an uninsulated butt connector (Sta-Kon, and then solder the connection. Straight soldering is good but if there are ever high currents or vibration, the connection can fail. A mechanical component is necessary, in my opinion. Soldering protects the copper from oxidation as well. Finish with adhesive lined double-wall heat shrink.
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For butt connections I care about, I always, rosin the wires, crimp an uninsulated butt connector (Sta-Kon, and then solder the connection. Straight soldering is good but if there are ever high currents or vibration, the connection can fail. A mechanical component is necessary, in my opinion. Soldering protects the copper from oxidation as well. Finish with adhesive lined double-wall heat shrink.
reply
Harry
Your parents AC was scary glad you fixed that as far as connectors a good sergeant is always been the best it s just more time consuming but was nice that your test reinforce my experience complete going along as you take current into account a lot of the connectors are very OK I ll be curious about Molex to attend the think not that much current attend think A amp and under
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Your parents AC was scary glad you fixed that as far as connectors a good sergeant is always been the best it s just more time consuming but was nice that your test reinforce my experience complete going along as you take current into account a lot of the connectors are very OK I ll be curious about Molex to attend the think not that much current attend think A amp and under
reply
Jordan
T H A N K Y O U!
I cannot tell you how many times I have to explain to coworkers (AND MY BOSS) that WE DO NOT TIN CABLES THAT ARE GOING INTO CRIMP CONNECTORS!
I spent my first 2 weeks back at work this summer reterminating at least 50 speaker cables, and another 10-15 power cables that went bad due to tinned cable ends (YES THEY TINNED THE POWER CABLES)
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T H A N K Y O U!
I cannot tell you how many times I have to explain to coworkers (AND MY BOSS) that WE DO NOT TIN CABLES THAT ARE GOING INTO CRIMP CONNECTORS!
I spent my first 2 weeks back at work this summer reterminating at least 50 speaker cables, and another 10-15 power cables that went bad due to tinned cable ends (YES THEY TINNED THE POWER CABLES)
reply
Stanley
For your calculations did you consider than several of the connection types had multiple connections as part of their set up? For the cable shoes as well as the wire ferrules you have the wire to shoe/ferrule resistance then the shoe/ ferrule to whatever they connect to. The worst performers have more series resistances as a part of their connection system.
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For your calculations did you consider than several of the connection types had multiple connections as part of their set up? For the cable shoes as well as the wire ferrules you have the wire to shoe/ferrule resistance then the shoe/ ferrule to whatever they connect to. The worst performers have more series resistances as a part of their connection system.
reply
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