[SOLVED] Damage to connector due to 82uF input capacitor

[zenerbjt]

Dear Engineers,

We are using the JST connector of Part number = S2B-XH-A. We are using it to connect our 48V battery to our 5Vout DCDC module. (as attached)

This comprises an 82uF capacitor at its input. Considering the inrush and sparking at the connector contacts due to the 82uF input capacitor, how long do you think this connector will last?

Say, after 10000 connections, what would then be the resistance of this connector?

Circuit attached showing where connector is.


S2B-XH-A connector
https://docs.rs-online.com/f25e/0900766b81357f2f.pdf

 

[KlausST]

Hi,

I don't think the connector is suitable for 1000 cycles, surely not 10.000.
Maybe specified for 100 mating cycles or less.
Contact the manufacturer.

Klaus

 

[dick_freebird]

An input filter meant to suppress conducted
emissions would include an inductor (choke)
which ought to slow the current ramp rate.
Whether enough, would want some testing.

Hot-plugging a bare discharged bulk capacitor
could do some damage over time (and maybe
not much time). Connectors tend to have pretty
thin gold plating (if any).

An explicit inrush limiting circuit could be an
option but nobody likes to spend money on a
feature which nobody thinks about.

 

[zenerbjt]

I don't think the connector is suitable for 1000 cycles, surely not 10.000.
Maybe specified for 100 mating cycles or less.
Contact the manufacturer.

Thanks, thats what i thought too...the manufacturer wont get back to us, our volumes are too low.
I am amazed the datasheet of the connector does not allure to the contactor sparking situation, and subsequent lifetime, in any way.

The connector will be connected once per day, every day.