What battery connectors for mtb lights?

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iggs

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As above really :whistle:

Bear with me, I'm new to this game and have no idea of the correct names for some of this stuff.

The battery connector is one of the weak points on any mtb light system. Its often exposed to all the elements so needs to resist the ingress of water and if its not a good solid connection it will get shaken loose.

I've had problems with some of the round style power connectors in the past although my cateye lights seem to be pretty solid and water tight, they have an 'O' ring that makes a pretty good seal.

The RC batteries all come with a tamyia connector. Are these any good, how weather n mud proof for instance? Because the 7.2 volt NiMH RC batteries and chargers are so available I'm probably going to be powering my lights from these in the future. Is it worth changing the connectors for something better if it exists?

I noticed the Min-T is using Deans(?) connectors. What are they like? Better, worse or just different?

Trailhead have some pretty tough looking connectors but these are only available as part of a wire set and I'm looking for an option available in a component form so that I can build up some battery and charger options.

Ideally I'll make a good choice on my connectors and not have to change

Thanks

Ian
 
Search Digi-Key's website. It maytake some time but if you can't find it there you probably won't find it unless you have a company make you an OEM part.
 
Basically, anything that's specified for the kind of abuse you might expect during MTB riding is probably more expensive than the rest of the light. Take a look at LEMO connectors (www.lemo.com) if you want to see what I mean.
The following is strictly my opinion - YMMV, and I'm just a daily commuter (all weather), not an MTB rider:
- Tamyia and spade connectors are kind of ok, if you use enough grease to protect them from the elements, (dis-)connect them only rarely and have the matching crimp tool
- for more frequently used battery connectors, I prefer paired '2mm' connectors (similar to Tamyias but much better quality)
- Since I have now most of our bikes set up for Dynamo operation, I rarely need removable connectors any more ;-). However, installation and maintenance still requires some disconnectable connectors occasionally. Currently, I'm using Hirschmann M8 connectors (industrial connectors for sensor equipment) for those lights that need several poles (multiple LEDs with external drivers)
- SMA connectors are nice and small and sufficiently watertight, but a bugger if you want to install them isolated from the case
- some people swear on RCA/Cinch conectors, some people swear at them
- other people are succesfully using sub-d connectors (multiple redundancy means that even if 8 contacts fail, you still have more than enough left over)

What I haven't seen so far are 110/230V AC mains connectors - probably just because they're too big ;-) [1]

Bye
Markus


[1] This was a joke. Don't try this. One very good reason why you only see these connectors on mains powered equipment is safety! Just imagine you little brother plugging your bike light directly into the AC mains. And it won't be better if you switch the connectors and he plugs the battery pack in...
 
Any connectors that you can hook up with your eyes closed would be good.
The waterproof connectors from Batteryspace might be a bit fiddly -but they lock which could be a good thing.

The mini deans are a pain to connect in the dark -but great as a non-essential small,tight connector.
The big Deans have heaps of surface area and are easy to connect in the dark and you can bend the springs on them if you want a supertight fit.
These are used mainly in RC high amp applications

The main thing you want to waterproof is where the wire joins the plug -so water won't run along inside the wire covers.

The plug itself only needs some silicone grease to keep things nice in there.

Andersons Powerpoles might be another one to look at -though they might be a bit big.

Cheers
Dom
 
Last edited:
dom said:
The main thing you want to waterproof is where the wire joins the plug -so water won't run along inside the wire covers.

Cheers
Dom
Click to expand...

One of the things I've clocked rooting through the various forum posts are the photos of your silkaflex/heatshrink sealing of the wires at plugs etc :thumbsup:
 
dom said:
A
The mini deans are a pain to connect in the dark -but great as a non-essential small,tight connector.
Cheers
Dom
Click to expand...

I have to modify this statement and say that when both the mini deans are on pigtails -it is not too bad to connect.
When one is fixed to something -then it is very hard/impossible to connect in the dark.

Cheers
Dom
 
LEMO and Fischer have some really nice connectors, but you probably get more than 20 pairs of "tamiya-type" connectors with price of one Lemo/Fischer pair. They work like Swiss watch and cost like that also. :)
 
I use AMP Superseal for cable-cable connection. They are sealed and they lock. They are available in kit form so you can build them with the pin count you need. Crimping them is somewhat tricky without an expensive tool. It can be done, though. And they definitely need to be put together with 2 hands. Sometimes the seal needs a little lube.
I usually get mine from Reichelt, but I have seen them at Mouser and once I bought them thru EBAY (good picture of complete kit).
 
I'm simply using standard 3.5mm power jacks for my bike lights, and Molex connectors for my headtorch (the reason for those is that they're the standard connector used for halogen orienteering headlamps, and I want interchangeability). Neither of these are waterproof, but then that doesn't really matter that much, as water only results in a very high impedance short. This would matter for electronics (which is why they need to be sealed), but not for power cables, where you'll get <0.1% loss even if water does bridge across the connectors. The Molex are actually better from this POV due to better physical separation between the conductors, though they are completely unsealed with conductors open to the air (or water)!
 
I've been using anderson powerpole connectors for years. They survive through my frantic 24 houur mtn bike races. They're self cleaning in the mud and grit.

You will find them listed as "sermos connectors" on r/c websites such as towerhobbies.com.

They ARE reusable if you solder the wires. Crimp...... not such a good idea. Not waterproof, but that doesn't matter. Water doesn't affect them.

They are some of the VERY few self-mating. This is useful if you want to get creative on battery pack design.

http://www.srbatteries.com/efwire.htm
 
I just used 4mm plugs, cheap and easy to connect and handle the amps I was expecting to be drawing
 
I've recently found some nice small connectors only 1A rated but it wouldn't be a problem in the most of lightning applications.

Micro Mini Connectors by www.miniatronics.com

2 Pin - 12" flexible leads [ 2 units ], costs 10,95$

miniconnecthomehlp3.jpg

The Miniatronics Micro Mini Connectors are fully assembled. Each has a mated interlock type assembly. All miniature connectors can be used for you lighting, command control, sound, and accessory hookups. Both male and female sides have enough wire attached to give you the ability to extend your power source. Each unit has a firm fit and a trouble free discount. All micro mini connectors, as well as the wires, have polarity markings, for use as an indicator when necessary. The markings help make sure you do not reverse polarity when you reconnect. At time of disconnecting never pull on wires.CAUTION: NOT TO BE USED TO POWER ROLLING STOCK OR OTHER HIGH CURRENT APPLICATIONS.
Click to expand...
 
Has anyone considered using XLR connectors? I know 4-pin XLR is used for 12V power on film equipment, and I've been using them for all my lead-acid 12V kit.

They're built like a tank, relatively waterproof (although not immersible), high-current, and locking (so unlikely to come disconnected mid-ride). The only downside I can think of is that they're physically big.

What do you think?
 
Hi,

did anyone know what type of connector is this. Lupine us it for their Bike lights it is really good and you can't buy it directly from Lupine, because they demand that you send light to them so they can guarantee that the installation of connector is 100% correct and water-resistant.




Thank you
Iztok
 
I was involved in RC racing for a couple years. I've used Deans Ultra connectros and the Anderson Powerpoles. Deans are great because of the tight, secure fit, but sometimes can be difficult to separate (I'm thinking possibly more so with cold, maybe wet fingers) due to the small surface area that you have to grab onto.

The Powerpoles are great in that they interlock as a pair (+/-) and between the two pairs (battery/light), but they were a little big for use in a cramped RC car. When I build up a light I'll likely use the Powerpoles with a bit of dielectric grease.
 
I've spent a fair amount of time looking at many different posts for connectors. I've found that you need to spend some serious money for a setup that is waterproof and small.
I gave up and just ordered the "trailtech" style connectors from Batteryspace.com. They're waterproof and inexpensive, they are small and don't come unlocked easily. They are a little stiff in the cold but I'm told they will work in after a while.I've actually converted all my lights and batteries over to these.
They're not as sexy as some of the other styles available but it didn't cost me $40 per light either.

Eric S
 
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