Splitting 12V high current DC wire

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Discussion Overview

The discussion revolves around the wiring and distribution of high current (up to 100 A) 12V DC through a connector with 56 pins, focusing on methods to split the current into multiple 18 AWG paths. Participants explore various construction methods and connector options for achieving a reliable and efficient setup.

Discussion Character

  • Technical explanation
  • Debate/contested
  • Exploratory

Main Points Raised

  • One participant describes the need to rewire groups of pins from a connector into multiple 18 AWG paths and seeks elegant solutions for high current handling.
  • Another participant requests clarification on the initial proposal, indicating a lack of understanding of the intended outcome.
  • A participant outlines a construction method involving a 56 pin input split into two wire conducting paths, leading to multiple 18 AWG paths.
  • Some participants suggest using auto/marine power distribution busbars with crimped ring terminals as a suitable solution for the application.
  • Concerns are raised about the cost of the proposed solutions, with one participant noting that using multiple wires per screw on busbars could be expensive and questioning the reliability of stacked ring terminals.
  • Another participant argues that stacked terminals should perform adequately at the specified current levels and emphasizes the electrical superiority of crimped connections over soldering.
  • A suggestion is made to consider using a golf cart connector as an alternative option.

Areas of Agreement / Disagreement

Participants express differing views on the best method for wiring and the reliability of various connection types, indicating that no consensus has been reached regarding the optimal solution.

Contextual Notes

Participants discuss the potential risks of poor connections, particularly in relation to the cost of equipment that could be damaged by inadequate wiring solutions. The discussion includes considerations of ampacity and contact resistance, but specific assumptions and limitations regarding environmental factors and installation conditions remain unresolved.

MisterX
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A large number (56) of 18 gauge-ish connection pins are presented by the connector. They are wired together in large groups on the "client" side of the connector (4 electrodes). We wish to re wire these groups together and then split them off into 24x 18 AWG a few feet removed from the connector. The current through the connector could approach 100 A at 12 V DC. I am looking for easy and elegant solutions to accomplish this in a sturdy way. One idea is to use a covered bus bar. Let me know if you have any ideas about wiring.
 
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I don't understand what you are trying to accomplish. Can you elaborate?
 
I am looking to construct a cable or series of cables.

56 pin input (28 ground 28 +12V) --> 2 wire conducting path -> split off multiple 18 AWG paths. I am inquiring about what construction methods to use.
 
Auto/marine power distribution Busbars with properly crimped and sized ring terminals would be my choice at 12vdc. For a two wire disconnect (indoors with no special environmental considerations) Anderson Powerpole connectors could be used with PowerMod for individual 18 gauge wires.

http://www.12voltplanet.co.uk/power-distribution-posts-blocks-busbars.html
http://www.andersonpower.com/us/en/products/powerpole/
http://www.andersonpower.com/us/en/products/powermod/index.aspx
 
Last edited:
nsaspook said:
Auto/marine power distribution Busbars with properly crimped and sized ring terminals would be my choice at 12vdc. For a two wire disconnect (indoors with no special environmental considerations) Anderson Powerpole connectors could be used with PowerMod for individual 18 gauge wires.

http://www.12voltplanet.co.uk/power-distribution-posts-blocks-busbars.html
http://www.andersonpower.com/us/en/products/powerpole/
http://www.andersonpower.com/us/en/products/powermod/index.aspx
This is the solution I have been considering. Unfortunately the cost is getting to be too much perhaps. It's over $50 if I use multiple wires per screw on the busbars and more if I don't. This includes the price of two busbars and crimp ring terminals. I am not sure how good the contact would be in that case with the ring terminals stacked on top of each other. I am considering a mere soldering and shrink wrap solution. A bad connection here could cause damage to ~$500 in equipment so perhaps an investment in connectors is warranted. Nonetheless bit by bit things like this add significantly to overall cost.
 
Stacked terminals per screw should not be a problem at your current levels and the results will be far superior electrically than soldering.

The conductor Ampacity for 18 gauge is ~7amps. For 24 equal resistance conductors at 100A that's about 5.5 A per wire.
Typical ring terminal contact resistance should under 1 milliohm for these types of terminals causing minimal losses per terminal connection.

http://www.te.com/usa-en/product-60772-2.html
Contact test data. http://www.te.com/commerce/DocumentDelivery/DDEController?Action=showdoc&DocId=Specification+Or+Standard502-1285ApdfEnglishENG_SS_502-1285_A.pdf61588-1
 
Maybe a golf cart connector ?
 

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