Bafang kit connector replacement wiring question.

[learn2eb]

As per the title.
I have received a mid drive Bafang kit which I believe has 12AWG red/black going to a XT60 male connector.
As my battery has an XT90 female connector, my plan is to swap out the drive side XT60 male with a XT90 male.

I ordered a connector that comes with 10AWG wires . My question is can/should I cut off the XT60 then connect the new 10AWG to the 12AWG cable using a butt connector crimp terminal?
I could also return this connector and buy a matching 12AWG XT90 male.

Welcome any other suggestions or tips.

Thanks

 

[saneagle]

You didn't say which Bafang kit!

 

[learn2eb]

You didn't say which Bafang kit!

Sorry, it’s bbs02b 48v 750w

 

[saneagle]

Sorry, it’s bbs02b 48v 750w

BBS02 is 18A max and can go as high as 25A max, IIRC.

XT 30 is rated for 30A continuous and 65A max. I can't understand why anyone would want XT60 or XT90.

I use 14g silicone wire,which is rated for up to 45A. It's easy to solder and handle, and easy to route and conceal on the bike. I don't understand why anyone would want to use anything thicker unless they have a 2 metre length between the battery and the controller.

 

[AGS]

I use these and solder them, then put a couple of layers of heatshrink over them.

I don’t like those cheap crimp butt connectors. I have seen many of them burned.

Copper Tube Butt Connectors

Heavy duty electro tinned copper butt connectors.

www.toolstation.com

 

[guerney]

Upon reading about crimping, there seemed to be a lot that can go wrong, even if you don't scrimp on the crimper. For my lesser "250W"(720W) BBS01B, I decided not to attempt crimping new connectors between my battery mount and controller, after I'd discovered these bullet connectors crimped by purported professionals, had overheated...





I didn't see any such signs of overheating on the controller's phase wire similar bullet connectors.

I wasn't convinced any connector I'd seen would keep water out while submerged for 13 seconds, as happened once to my bike after a sudden thunderstorm left a pond in the road. The water level was above both pedals, and my bike slowed to a stop, then made a bow wave powering through on pedal assist, after I had to stand on the pedals to get it moving to activate pedal assist.

I recall the controller wires being thicker than the ones from the battery mount, but didn't note their guage before fanning the strands out like brushes, pushing the ends together and twisting a bit, pressing tight with pliers, wiping with 99.9% isopropyl alcohol to remove any grease etc, applying acid-free flux, soldering using a 100W Silverline soldering iron and mostly leaded solder, then covering with self-adhesive marine heat shrink and self-amalgamating rubber tape.

 

[learn2eb]

BBS02 is 18A max and can go as high as 25A max, IIRC.

XT 30 is rated for 30A continuous and 65A max. I can't understand why anyone would want XT60 or XT90.

I use 14g silicone wire,which is rated for up to 45A. It's easy to solder and handle, and easy to route and conceal on the bike. I don't understand why anyone would want to use anything thicker unless they have a 2 metre length between the battery and the controller.

Thanks for your reply. It's just because I already have the XT90 on the battery connector and I don't want to mess with it. Similarly, the kit came with XT60. I'm also not familiar with this topic and simply seeking advice to understand the ideal way to make the connection in this scenario. I'm not understanding how the use of 14g is relevant to my question, are you suggesting instead to replace wires from the kit and battery?

 

[Woosh]

I have received the EN15194 certificate of compliance for the TSDZ8.
You can download it from my website:

https://wooshbikes.co.uk/2024/tsdz8/TSDZ8-EN15194-Certificate.pdf

 

[learn2eb]

Upon reading about crimping, there seemed to be a lot that can go wrong, even if you don't scrimp on the crimper. For my lesser "250W"(720W) BBS01B, I decided not to attempt crimping new connectors between my battery mount and controller, after I'd discovered these bullet connectors crimped by purported professionals, had overheated...


View attachment 59054


I didn't see any such signs of overheating on the controller's phase wire similar bullet connectors.

I wasn't convinced any connector I'd seen would keep water out while submerged for 13 seconds, as happened once to my bike after a sudden thunderstorm left a pond in the road. The water level was above both pedals, and my bike slowed to a stop, then made a bow wave powering through on pedal assist, after I had to stand on the pedals to get it moving to activate pedal assist.

I recall the controller wires being thicker than the ones from the battery mount, but didn't note their guage before fanning the strands out like brushes, pushing the ends together and twisting a bit, pressing tight with pliers, wiping with 99.9% isopropyl alcohol to remove any grease etc, applying acid-free flux, soldering using a 100W Silverline soldering iron and mostly leaded solder, then covering with self-adhesive marine heat shrink and self-amalgamating rubber tape.

This sounds like a nice way to do it. Figuring out how to make the connection more waterproof was the next thing on mind. Thanks for sharing your experience!