Electronics > Projects, Designs, and Technical Stuff
Connector sparking and damage due to inrush at "mating" time?
HwAoRrDk:
--- Quote from: bdunham7 on August 31, 2020, 02:16:19 pm ---JST connector and 10K mating cycles? The same JST connectors that I carefully pry out with two plastic picks when I have to repair something and hope I don't hurt them? Yes, they are commonly used for battery packs and the like, but the housings just aren't going to hold up to your long-term expectations.
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I would say probably 50% of JST connectors one encounters in random pieces of equipment are Chinese-made clones, that are markedly different in quality compared to the genuine thing.
In particular I find the plastics are softer and less rigid, which for friction-retention connectors like XH or PH series means they get pretty loose after only a few mating cycles. Also, for some reason the clones have terrible attachment between header pins and the plastic. Half the time when you go to unplug, the receptacle comes with it. :(
So yeah, sometimes you have to treat them delicately simply because they're cheap, crappy clone parts, but the genuine thing are a bit more robust.
wizard69:
--- Quote from: zenerbjt on August 31, 2020, 09:07:25 am ---
--- Quote ---Silly question but why are you plugging in while powered up.
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Thanks but sorry i dont understand...we have a 48V battery which we plug into a circuit to power it, this circuit has an 82uF input capacitor, so we get inrush from the battery, through the JST connector.
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That is all well and good but you didn't answer the question, why are you hot plugging, especially a connector not designed for it. 48 VDC is high enough voltage to present a safety risk to anybody handling such a connector.
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The JST connector has nothing in the datasheet which allows us to absolutely proove that the connector will be damaged by connecting it every day....so we wont get permission to re-do the circuit, as it will mean a PCB re-spin and will cost money.
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I can't possibly imagine any success in a court of law with an attitude like that. If you want to plug something like this daily you need to have a connector that can survive such usage and can also be handled safely by whomever is plugging in daily. As for the JST data sheet there should be some sort of cycle parameter that would specify the number of insertion cycles the connector can handle. JST make a range of connectors so I have no idea what the cycle limit would be on the connector you have but many of these connectors start to have issues after 10-50 cycles.
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