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High current DC power connectors?

  1. Aug 23, 2011 #1
    Hi everyone. I'm working on a project that uses 2 high-torque DC motors to move a system. The max current draw from each motor is 50 Amps, so the total current draw for the circuit is 100 Amps. The power for the motors will be coming from a vehicle battery, and will have to be routed to the back of the vehicle. I would like to run a cable from the battery terminals into a flanged receptacle that the system can plug in to. I've been looking for a couple days, and I'm having trouble finding readily available connectors that can handle 100 Amps.

    Does anyone have any recommendations on companies that make (and possibly stock) heavy duty connectors? This is the first time I've had to work with DC motors and DC circuits, so maybe there's a better way to transmit power from the battery to the motors. I've looked at some circular connectors, but I'm having trouble finding anything that will transmit 100 Amps or crimp on to an 8 gauge wire.

    Thanks for any help and advice!
  2. jcsd
  3. Aug 23, 2011 #2
    Use multiple pins of the connector for +V and return. This is very common practice. Say if you have a 10 pins connector and it is spec 30A per pin, you use 5 pins for +V and 5 pins for 0V return. You have yourself a 150A connector. Just remember don't push it. Don't just make 100A for 100A operation.

    If you really cannot find one connector to run both +V and return, Use one connector with multiple pins for +V and one connector for return, that should not be hard to find. You should be able to find one that can take over 100A total per connector.
  4. Aug 23, 2011 #3
    Duh, why didn't I think of that. 4 pins @ 25 amps each will be much easier to find than 1 pin @100 amps.

    Thanks a lot for your help.
  5. Aug 23, 2011 #4
    Try welding supply stores.
  6. Aug 23, 2011 #5
    If each pin @ 25A, use 6 pins to be safe.
  7. Aug 23, 2011 #6
    The 100 Amp estimate is already padded with a decent safety factor, but thanks for making the point.

    How would you connect a large wire into multiple pins? For example I have a 2 gauge wire carrying up to 100 amps, and want to separate it to 4 pins that will carry up to 25 amps each. Most pins I've seen in these connectors will only fit up to a 12 gauge wire. How would I go about connecting the 2 gauge wire into the smaller pins?
  8. Aug 23, 2011 #7
    Same as the connector, put the 2 gauge onto a bus bar and branch out to few of the smaller wires. Actually, it is better to use a few smaller wires in parallel instead of one big wire if you can change it.
  9. Aug 23, 2011 #8
  10. Aug 23, 2011 #9


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    Be sure to check the motor start up and motor stall currents.
  11. May 15, 2013 #10
    DC connectors

    You can Google "Anderson Connectors they have what is needed.
  12. May 15, 2013 #11
    Dc high current connectors

    SB is the same as "Anderson Connectors"
  13. May 15, 2013 #12
  14. May 15, 2013 #13


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    Google for "100a plug and socket". "100a connector" seems to find connector blocks for permanemt wiring, which is not what you want of course.
  15. May 16, 2013 #14

    jim hardy

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    Gold Member

    Here's Amphenol's page for MS 310X connectors, commercial 97 series..
    most #36 inserts have 0 size contacts which oughta do, see pages 16&17 of brochure pdf pages 19&20.

    With those you build the part number by choosing shell, insert and orientation, backshell& strain relief, etc etc etc... that's why the part number is so long. I like them because they're widely available ( but expensive).

    Thanks for the question - I have some surplus 200A army tank alternators and need mating connectors..

    good luck -
    Last edited: May 16, 2013
  16. May 16, 2013 #15
    DC heavy duty connectors

    Anderson Connectors are very cheap they go up to 300 amps and they have different colours,also they have up to 4/O connectors.I have been using them for over 10 years on my Solar array to connect my deep cycle batteries I have 24 batteries.
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