Battery connectors for electric power equipment need regular maintenance. Dust and grime can build up on the connector power contacts. Connector shells can crack or melt. Contact surfaces should be inspected to ensure they are not pitted or damaged.
While owners should always follow the manufacturer’s recommendations for maintenance, specific connector features can help reduce the amount of maintenance required and improve the connector’s lifespan. Anderson Power innovations such as the Industrial Battery Connector (IBC) deliver unique features like IP68-rated sealing and a modular design that simplify connector inspection and reduce debris buildup, keeping connectors cleaner between service intervals and extending their lifespan.
Top 8 Tips for Extending the Lifespan of Your Battery Connectors
Design engineers for battery-powered material handling equipment, ground support equipment, and more can select connectors with specific design features that extend connector lifespans. Compiled below, the top eight tips from Anderson Power provide an at-a-glance reference of the most important considerations to extend connector lifespans.
1. Regular Connector Maintenance
2. IP68-Rated Sealing
3. Modular Design
4. Flat-Wiping Technology (for Flat-Style Connectors)
5. Avoid Disconnecting Under Load
6. Regular Cleaning with Appropriate Lubrication
7. Visual Inspections
8. Choose Connectors with Durable Materials
By following these tips, engineers can enhance the longevity of their connectors, reduce equipment downtime, and ensure optimal performance. For a deeper explanation of each point, including practical maintenance and connector design insights, keep reading below.
What are Connector Contacts, and What Maintenance Issues are Common?
Before discussing connector design insights, it’s important to first recognize the different types of battery connector contacts and their most common maintenance issues.
Power contacts are the conductive pins that facilitate the flow of electrical current through the connector and enable the equipment to draw power from the battery. Since a large amount of electricity runs through them, power contacts are one of the most common points of failure on a connector. However, their large size makes them easier to visually inspect for damage.
Auxiliary signal contacts are the pins within a battery connector used to transfer data about the battery lifespan, mating cycles, internal temperature, and more. They are smaller than power contacts and buried deeper within the connector housing. Since auxiliary signals handle lower voltages (turning on/off to signal), they are not as prone to wear and tear as power contacts. However, they still can experience damage over time.
There are two primary types of material handling equipment (MHE) and ground support equipment (GSE) connector contacts: pin-and-socket style and flat-wiping style. Euro-DIN connectors feature pin-and-socket contacts with gendered (male and female) ends. They follow the German DIN standard 43589-1, EN 1175-1, and DINVDE 0623-589. On the other hand, flat-wiping connectors or “Anderson connectors” are genderless and self-clean using flat-wiping technology that over-wipes the mating surface when engaged or disengaged. Anderson Power features both types of contacts within its extensive connector catalog.
Whether they are pin-and-socket style or flat-wiping style, all connector contacts require regular maintenance and inspection to avoid maintenance issues such as:
- Dirt/Dust Buildup: Dirt and debris buildup on the connector contacts can lead to poor conductivity or arcing, negatively impacting charging performance.
- Moisture Ingress: Charging outdoors without proper IP-rated sealing can expose contacts to moisture from rain, humidity, and snow. This may cause short circuits or other performance and safety issues.
- Contact Pitting: Pitting can occur when the contacts become dirty or the connector is frequently disconnected under load. This creates dents in the contact surface and can remove the silver plating at the tips of the contacts, impacting charging performance and eventually requiring contact replacement.
Keeping up with proper connector maintenance is essential for safety and optimal charging performance. Owners should always perform regular checks and cleanings that follow the manufacturer’s recommendations for maintenance and inspection intervals.
However, certain connector features can help improve the longevity of these contacts, reduce downtime, and increase the amount of time between servicing. Design engineers can look for connectors with features such as an IP68 rating, modular design, or flat-wiping technology to make servicing and maintenance easier.
How Can IP68 Sealing Help Prolong Connector Contact Life?
Dust buildup on connector contacts is a common issue that increases wear, which can remove plating, expose copper to air, and cause poor conductivity. Contacts can get dirty simply by sitting indoors in a dusty factory or hangar floor. Certain types of dust are worse than others; airborne metal dust will negatively affect connectors more than organic wood dust.
Design engineers can select an IP-rated sealed connector for extra protection from dust. IP68 is one of the highest IP ratings, indicating the connector is fully dust-tight and can withstand complete water submersion for up to 30 minutes at a depth of six feet while mated. By ensuring the connector is protected from dust ingress while mated, an IP68 rating can improve the lifespan of connector contacts and reduce the likelihood of pitting. IP68 sealing is particularly helpful to reduce maintenance requirements in situations where the connector is rarely unmated. For example:
- Material Handling Equipment (MHE): In MHE such as forklifts, the forklift battery connector under the equipment’s hood is not regularly mated and unmated. With IP68 sealing, dust cannot enter and build up on MHE battery connector contacts as long as the connector remains mated. This can increase the amount of time before the next maintenance interval and contact cleaning, reducing equipment downtime.
Outdoor charging locations are even more prone to dust buildup and moisture ingress than indoor locations. When batteries are charged while exposed to the elements, an IP-rated connector is essential for safety and to avoid short circuits. For example:
- Ground Support Equipment (GSE): The GSE industry is increasingly embracing outdoor charging for operational efficiency. On-the-tarmac charging is convenient for getting tugs and belt loaders back into service quickly, but it also leaves their connectors at the mercy of the elements. For an unsealed connector, windblown dust can cause grime to build up on contacts even faster. Exposure to rain, snow, and humidity can lead to safety hazards and corrosion. By ensuring dust and moisture cannot impact the contacts while mated, an IP68-rated GSE battery connector improves safety and the lifespan of an outdoor connector’s contacts.
Which Battery Connectors Offer IP68 Sealing?
For both material handling and ground support equipment, IP-rated sealed connectors provide design engineers with extra protection from dust and moisture. However, not all DIN-style or flat battery connectors on the market offer a sealed option.
The new Industrial Battery Connector (IBC) from Anderson Power is the first DIN-style, high-power battery connector on the market to offer an IP68-rated weatherproof kit accessory. Engineered to withstand harsh environments, the patent-pending IP68 kit seals the IBC against moisture and debris intrusion while mated with a clear voltage cover, two O-rings, and a rubber (EPDM) grommet. The Industrial Battery Connector Series is built for rugged industrial equipment like outdoor GSE and MHE charging, offering up to ten signals and supporting 165A – 450A across three models. It can even be used for marine applications such as outboard motors
An example of flat-wiping-style IP68-rated connectors include the SBS®X Series connectors from Anderson Power. Designed for applications such as commercial lawn and garden equipment, both the SBSX-75A and the SBSXPRO support up to 140A and feature an IP68 weatherproof rating while mated. The SBSX-75A features two power contacts and up to six auxiliary signal pins or ground, while the SBSXPRO delivers three power contacts and up to eight signals.
How to Inspect and Clean Battery Contacts
While IP68 sealing provides extra protection from dust and moisture, all connector contacts should still be regularly inspected and cleaned.
- Inspection should check for contact pitting. Disconnecting the charger while the battery is still charging can create an electrical arc that causes pitting to form. Once present, pitting slowly gets worse over time and the contacts must eventually be replaced. For this reason, operators should always avoid disconnecting a charger under load.
- Cleaning should involve a regular service for contact lubrication. Applying lubrication prevents dust buildup and excessive wear, helping to avoid related issues such as corrosion and poor conductivity. Anderson Power recommends using “white” lithium grease for flat-wiping contacts, which may be obtained from hardware stores and automotive parts suppliers. Avoid over-applying the grease, or the extra grease may end up attracting dirt and debris instead of removing it.
Visually inspecting and cleaning a connector’s power contacts is not overly difficult. The power contacts on battery connectors like the Industrial Battery Connector are large and easily accessible. However, the smaller signaling pins tend to be buried deep within the housing, making accessing them more difficult.
How Can a Modular Design Simplify Connector Servicing and Repair?
To facilitate easier cleaning and/or replacement of a DIN-style connector’s signaling pins, design engineers should look for options that feature a modular design. Modularity makes signal pin inspection and cleaning much easier by permitting tool-less assembly and removal of contact cartridges. For example, the patent-pending modular design of the Industrial Battery Connector means the contacts can be easily and securely installed on the cartridge outside of the crowded housing with a simple click. With another click, the loaded cartridge can then be easily and securely installed into the housing.
The innovative design permits easy access to the signaling pins for maintenance. The pins become much easier to thoroughly clean once freed from the exterior connector housing. The pins, crimps, and wires also become much easier to visually inspect for any damage. The cartridge slides out; no specialized tools are needed to access the interior contacts or wires for repair or replacement.
The Industrial Battery Connector Series includes three models available with different contact holder cartridges. The modular cartridges are color-coded for easy visual identification – white for the air tube cartridge, purple for the four auxiliary signals cartridge, and orange for the six or more auxiliary signals cartridge. The three models of IBC Series connectors and their contact cartridges available are listed below, from smallest to largest:
- 80 Series (70-200A): Available with four auxiliary signals.
- 160 Series (80-270A): Available in configurations that support four auxiliary signals, two auxiliary signals with air tubes, or up to six auxiliary signals.
- 320 Series (165-450A): Available in configurations that support four auxiliary signals, two auxiliary signals with air tubes, or up to ten auxiliary signals.
Flat-Wiping Technology: The Self-Cleaning Advantage
Flat connectors like the SBSX Series use a different method to extend the lifespan of their contacts. Invented by Anderson Power in 1954, flat-wiping contacts over-wipe to self-clean the mating surface when mated or unmated. Their universal, genderless design also includes a sacrificial tip which confines damage to a non-conducting area when mating or breaking under load.
By self-cleaning the contacts to remove dust buildup, flat-wiping contacts help extend the lifespan of connectors in demanding industrial or outdoor environments. This means less maintenance is needed over time and contact pitting is prevented for longer. The Powerpole®, SB®, SBS®, SBSX Sealed Connector Series, and more from Anderson Power feature flat-wiping contacts.
Other Key Considerations to Select the Right Connector
Design engineers should also ensure their connector’s contacts meet industry standards for durability. Contacts should be constructed of professional-grade materials and tested to withstand thousands of mating cycles. For example, the Industrial Battery Connector is rated for 5,000 mating cycles and its contacts are constructed of either silver-plated copper or gold-plated copper (for the ten auxiliary model only).
Selecting the right connector for the type of battery is another consideration. Applications like the Powerpole and SB Connector Series are best suited to lead-acid batteries, as they do not feature the signaling capabilities required for lithium-ion Battery Management Systems (BMS) to communicate data to the charger. This communication helps control and monitor the Li-Ion charging process, making it important for efficiency and safety reasons. In contrast, the new Industrial Battery Connector comes with different auxiliary signal options which makes it perfectly suited to Li-Ion applications.
Ensuring the connector meets key industry standards is also important. The IBC is engineered to meet stringent standards for reliable performance (including DIN VDE 0623-589, RoHS, UL1977, CSA 22.2, IEC 60529, and EN1175:2020), and supports:
- UL94 V0 flammability rating
- Operating temperature range from -20°C to 105°C
- Hot-plug capability (200 to 800A at 96V per EN1175-1)
- Touch-safety (IP20 per IEC 60529)
- IP68 weatherproof rating (with IP68 Kit)
The Industrial Battery Connector also supports contact temperature sensing enablement for enhanced safety, reliability, and performance. This accessory is another first for a high-powered battery connector and helps prevent contacts from overheating during power transfer.
Making Connector Maintenance and Repair Easier than Ever
Dust buildup and contact pitting are common maintenance issues for battery connectors. Anderson Power connectors are designed with maximum quality and durability in mind. With an IP68 sealed rating, the rugged Industrial Battery Connector, SBSX-75A, and SBSXPRO connectors continue to perform in dusty or moisture-prone environments. The modular design of the IBC permits easy access to auxiliary signal pins for their cleaning and inspection. The flat-wiping contacts of the Powerpole, SB, SBS, and SBSX Series connectors provide a self-cleaning function that reduces the amount of maintenance required.
By adopting connectors with such features, design engineers can be confident their connector contacts will withstand dust buildup and maintain peak performance for longer. Enhance the longevity of your contacts, reduce equipment downtime, and make connector maintenance easier than ever with Anderson Power connectors.
Speak with our team of experts to find your best connection: https://www.andersonpower.com/us/en/contact-us/request-a-consult.html
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