heavy duty quick connects for testing?
heavy duty quick connects for testing?
(OP)
Need ideas for a way to quickly connect fairly heavy motor leads (up to ~2 AWG) for test purposes...
I like those little terminal strips for small wires where each one has a little lever you lift up to remove contact pressure. Does anyone know of a vendor who makes these in jumbo sizes?
Maybe I should start a company! :)
I like those little terminal strips for small wires where each one has a little lever you lift up to remove contact pressure. Does anyone know of a vendor who makes these in jumbo sizes?
Maybe I should start a company! :)





RE: heavy duty quick connects for testing?
RE: heavy duty quick connects for testing?
Keith Cress
Flamin Systems, Inc.- http://www.flaminsystems.com
RE: heavy duty quick connects for testing?
The key is they bring the volts and amps up gradually. This would not work well for an accross the line start.
There are other twist lock welding clamps that would work.
RE: heavy duty quick connects for testing?
Do you need to quickly connect plain stranded wire? Wires with crimp lugs already on it? Cable to which you will have or could have permanent plugs and receptacles attached?
Motor test benches, where they will be attaching separate stripped stranded wires, usually use something like a Kearney split bolt connector that has been soldered or welded to a bus bar. That gives you a quick "cage clamp" type of connection that adjusts well to a larger range of wires without the kind of physical damage you would see with more permanent mechanical bolt-on lugs (i.e. Ilsco lugs). For #2 wire as the max size though, I wouldn't worry about that and just use an Ilsco lug, then tighten it with an allen wrench. If you need it insulated, look at a Taylor or Marathon power terminal.
Kearney split bolt
Ilsco lug
Marathon power block
RE: heavy duty quick connects for testing?
You really shouldn't substitute convenience for safety by trying to use a spring loaded connector. I know that what JerryRobinson said is true about the alligator clips, but any safety engineer would have a cow if they actually saw that. The manufacturers specifically warn against using them for that purpose. they are actually called "grounding clips" to avoid being sued when they overheat and lose tension under load, then fall off and start a fire. I'm not saying people don't abuse them that way, it's just not a good idea.
RE: heavy duty quick connects for testing?
We would generally be connecting stranded individual motor leads which do not have lugs on them. It would be nice if the connector were quick to attach, yet safe.
I am trying to avoid spring clips at all costs. Even heavy duty welding type clamps are just ugly. And at 230 or 460 dc or 480 AC, I really don't like the idea of the things coming loose!
The idea of the split bolt connector brazed to busbar is interesting and might work out. A dedicated wrench could be chained nearby to keep it handy. The Marathon style insulated terminal block is probably safer, and I could chain a T-handle allen wrench nearby. We could also install the finger guard covers, and drill small access holes for the allen wrench.
The idea of the air cylinders is pretty clever! Maybe we don't need it THAT convenient :) I think you would still need some sort of mechanical advantage to get adequate clamping force. At hundreds of amps, I think need it tight.
The idea of the "cam over" fasteners is worth investigating... if I could find a cam over that would fit into an Ilsco style lug or Marathon terminal block, or a custom made block, it could eliminate the need for a tool to make the connection.
RE: heavy duty quick connects for testing?
http://www.toolfastclamps.com/toggle4.html
http://destacoclamp.com
RE: heavy duty quick connects for testing?
Mike Halloran
Pembroke Pines, FL, USA
RE: heavy duty quick connects for testing?
This ditches the hazard of chains.
Then you can use the short cable area for clamp ons or shunts. If one side is always connected then you only need one single block per side as no interference will occur 'across block'.
You will have to watch out for wearing out the blocks after a hundred uses. Use lots of the correct grease.
Keith Cress
Flamin Systems, Inc.- http://www.flaminsystems.com
RE: heavy duty quick connects for testing?
JRaef.com
"Engineers like to solve problems. If there are no problems handily available, they will create their own problems." Scott Adams
For the best use of Eng-Tips, please click here -> FAQ731-376
RE: heavy duty quick connects for testing?
Keith Cress
Flamin Systems, Inc.- http://www.flaminsystems.com
RE: heavy duty quick connects for testing?
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Sometimes I only open my mouth to swap feet...
RE: heavy duty quick connects for testing?
Keith Cress
Flamin Systems, Inc.- http://www.flaminsystems.com
RE: heavy duty quick connects for testing?
http
RE: heavy duty quick connects for testing?
RE: heavy duty quick connects for testing?
RE: heavy duty quick connects for testing?
I think the Marathon block with some appropriate safety measures regarding the allen drivers is the way to go. Inexpensive, flexible. Even if I simply got an insulated allen driver, spaced the blocks far apart, and used plastic chain to keep it handy. Risk to personnel would be minimal. I feel far better about a positive connection like that than any type of alligator clip, welding clamp, etc.
PS The "short cable area" between the Marathon blocks (for clamp on meters) is inspired! :)
RE: heavy duty quick connects for testing?
RE: heavy duty quick connects for testing?
Keith Cress
Flamin Systems, Inc.- http://www.flaminsystems.com
RE: heavy duty quick connects for testing?
RE: heavy duty quick connects for testing?
I am not a salesman for Meltric (or anyone else). I used those connectors (series DS, 200A) in design of heavy duty AC dynamometer with quick disconnect requirement, and we had quite positive results. The only tricky issue was to provide a motor cable shield continuity through extensively gasketed parts of the connector.
RE: heavy duty quick connects for testing?
http://www.wago.us/company/397.htm
RE: heavy duty quick connects for testing?
RE: heavy duty quick connects for testing?
Simple, reusable matched male/female insulated high amperage sigle pin connectors..relatively inexpensive.This particular part is rated for up to 300A and is sized for #2AWG-2/0..Simple set screw to attach to your cable.
Similar product is made by others. They are generically referred to as "Cam-lok" connectors.
RE: heavy duty quick connects for testing?
Keith Cress
Flamin Systems, Inc.- http://www.flaminsystems.com
RE: heavy duty quick connects for testing?
RE: heavy duty quick connects for testing?
Sorry, couldn't resist.
RE: heavy duty quick connects for testing?
Phoenix contact
Look at their HDFK series
http://e
We use the HDFK95 for currents up to 210 Amps (up to 4/0 wire I believe)
Simple cage clamp type connector..