Connector for high current patch panel

[qwaarjet]

Currently in my lab there is patch panel using shrouded 4mm jacks(see attachment) that is used to route power from various power supplies on a 19"rack to various experiments in the lab. These shrouded connector are nice because there is never any exposed high voltages, so it is fairly safe to use them without extensive interlocks. Soon I will be adding some high current supplies and the connector system we currently uses cannot handle the +100A current. Is there a similarly styled but high current connector that could be used. Most of the connector I have found so far have exposed contact so are unsuitable for use.

Requirements:
no exposed contacts
+100A
+600VDC

[NiHaoMike]

If it might get hot plugged, you'll have a hard time overcoming the arcing issue.

[qwaarjet]

Hot plugging is not a common occurrence especially if there is any current flowing. Generally it only happens when there is a need to change biases on floating loads or grids. we use the shrouded connectors to protect against accidental contact in the event the power supply is left on unintentionally.

[Rerouter]

You may be able to use welder connectors, there not as cheap as bnc's by any margin, bu you can get both plug and screw mount sockets in those current ratings, and easily exceed the voltage rating, just not 100% certain myself for how many connections they would be rated for,

[NiHaoMike]

Maybe EV fast charge connectors? Not going to be cheap, however...

[Richard Crowley]

The standard of the industry for decades has been Cam-Lok



http://www.cooperindustries.com/content/public/en/crouse-hinds/brands/camlok.html

[AG6QR]

Have a look at Anderson Power Poles.  I use the 15/30/45 amp versions extensively for various 12VDC applications.  They have no exposed conductors, and they were designed from the outset for DC power connection.   They're relatively "idiot-proof", meaning they can't be connected with wrong polarity, yet they're genderless.

Power Poles come in bigger sizes for higher currents, including 120amp, 175amp, and 350 amp versions.

[alank2]

+1 on the power poles, I use them for all my 12V stuff, stepper motor connections, etc.

[edpalmer42]

Supercon connectors are available up to 250 amps.  They're rather expensive if you buy from official distributors, but Fair Radio Sales has some at a more reasonable price.  Ebay is another source.  YMMV.

http://www.danaherspecialtyproducts.com/Superior-Electric/Products-and-Solutions/SUPERCON-Electrical-Connectors/

Ed

[German_EE]

Add another vote for Power Poles, I get mine from Powerwerx in the USA.

[David Hess]

Anderson Power Poles were my first thought as well but they do not conveniently mount to a front panel like a circular connector.  They do make panel mounting brackets for them though.

[Richard Crowley]

Anderson PowerPoles are hermaphroditic. They have a single contact profile that mates with itself.  So there is no concept of "male" and "female".  This is simultaneously an advantage and a DISadvantage.  So you must consider the use-case and whether a hermaphroditic solution is suitable.  And at least IME, the lack of suitable panel-mounting options is a major disadvantage.

Several techniques are used to sort out various connection requirements.  For example, in big mobile production trucks, they need power connection up to 100s of amps.  So they use Cam-Lok connectors for safety ground, neutral, and each of the hot phases.  For safety reasons, it is common to reverse the ground pin to make it different from the power terminals.

[mikeselectricstuff]

Hot plugging is not a common occurrence especially if there is any current flowing. Generally it only happens when there is a need to change biases on floating loads or grids. we use the shrouded connectors to protect against accidental contact in the event the power supply is left on unintentionally.

You don't want to allow any risk of hot-unplugging 100A at 600V, even less so if it's DC - this would be a serious flash/burn hazard.
You'd want some sort of mechanism to prevent it - e.g. access cover or connector lock with an interlock that prevents access until power is turned off.   

[ajb]

Kleigl SAFPATCH patch bays, commonly installed in North American theaters through the 60s and 70s, had an interesting approach to the hotplugging problem.  They paired each patch receptacle with an adjacent circuit breaker, the handle of which prevented the patch plug from being inserted or removed while in the on position.  It was always a bit disheartening to hear that familiar click while making an adjustment to the mass of spaghetti that was the current patch (a modestly sized theater of that era might have had a hundred 3-12kW dimmers with 300-500 circuits and nearly as many patch receptacles) and knowing you'd have to go back and check every plug until you found the one you'd inadvertantly tugged loose!  (Here's a link to their 1965 catalog for the curious)

A simpler solution may be to put your patch panel behind a lockable door with an interlock that shuts down your power supplies when open.

Cam lock connectors would be up to the current and voltage requirements, but its hard to really say they have no exposed contacts. I suppose if you make sure to never have unutilized receptacles or religiously employ dust caps you could say they qualify.  In any case a big part of the safety and regulatory acceptability of this kind of setup must come from ensuring that it's only accessible to qualified personnel--which, at least in the US, is the only condition under which single pole connectors like camlocks are acceptable anyway.

[qwaarjet]

Right now I'm thinking of using ITT powerlock series they're like the Cam-Lok but seem harder to kill your self with.

[ketil b]

Hi I do like powerlock over camlock. They have spring loaded curves and each color is keyed differently. Just attach a pin removing tool to your pachinko panel.