BBS02 Factory wiring and suggestions for parts needed.

[Rodney64]

Guys, this thread is to advise on alternatives to the supplied Bullet Connections on the BBS02 unit.

If you have a soft pack then the best option is to replace the Anderson with a set of xt90 connections. This thread will advise you how to do this. https://electricbike.com/forum/forum...ries-basic-faq


If you have a Shark Pack then the standard connection that these packs come with are Anderson 45 Powerpole Connections. They're rated at 45 amps and are available here: https://www.jaycar.us/45a-anderson-p...r-set/p/PT4406

They're not as water proof as the xt90 and cannot handle as much heat but one advantage is they can be crimped or soldered and replaced quite easy.

When you recieve your BBS02 you will notice that they are supplied with bullets.



Parts Needed

• 1 set of Anderson 45 Powerpoles

Tools that are required to crimp Anderson 45 Powerpoles are as follows:

• 1 pair pliers
• 1 wires stripping tool
• 1 anderson powerpole crimping tool.

The above tools are not required if you decide to solder the Anderson Powerpole or decide to crimp them with a pair of pliers, its not best practice as the crimp may not be as efficient.




Refer to the following procedure to install Anderson 45 Powerpoles

1. Remove both bullets using pliers.
   
2. Using a pair of plier or a wire stripper remove a 1/4 of an inch of plastic from both negative and positive wires.
   
3. Inset powerpole into crimping tool mechanism and insert wires until the plastic is level with the end of the crimp
   
4. Crimp both wires with the tool and test that its firm.
5. Inset both contact pins into the red and black plactic Anderson case the correct colour co-ordination.
6. Slide both the red and black together
   

[Fred]

Here's another article showing in a good bit of detail how to crimp Anderson's without the special Powerpole tools.

https://www.electricbike.com/crimp-anderson/

I personally use Anderson's as a standard for all my connections and for me it was worthwhile to buy the tool. Less frustration; better crimps.

[Rodney64]

Thanks Fred

[funwithbikes]

Pure Gold!

[BubbaJohns]

Good to know. Including the XT90-S pigtailed connectors that Luna sells in my next kit.

[skipbaccus]

In the last picture I noticed the red connector is on the black wire and vice versa. is that really correct? what happens if it's backwards and the user attempts to connect to the battery? is there a polarity safety circuit?

[ncmired]

In the last picture I noticed the red connector is on the black wire and vice versa. is that really correct? what happens if it's backwards and the user attempts to connect to the battery?

Great catch - no, it's not correct!

is there a polarity safety circuit?

No, there's no polarity safety - components melt.

[BMX...ELECTRIC??]

Hey guys, if I have a 52v battery should I be using something other than Anderson 45 Powerpoles?

[AZguy]

Hey guys, if I have a 52v battery should I be using something other than Anderson 45 Powerpoles?

If the battery has an internal power switch it's less a big deal since you can avoid arcing when plugging in by just turning the battery off - if not the andersons can get fried from arcing when plugging in (I've had it happen)

Regardless, the XT90s's are better suited for bicycle application and the "s" version (XT90s) has arc suppression - it doesn't entirely eliminate the arc but definitely reduces it and the XT's hold up better when it arcs... they also are better environmentally and make a more secure connection

[BMX...ELECTRIC??]

Thanks for the quick reply! Yes mine does have an on-off switch. Are you saying it's advisable to plug everything in when the battery is off, then switch it on once I have everything connected? That's pretty smart. I didn't know about XT90's, I will have to look into those.

[AZguy]

Big time... plug it in with the battery on and every time - Pow! You'll get a contact eating arc.... it fried the andersons on my initial install - not pretty

Now I'm talking a switch that's part of the battery not the controller (for bike power) - has to be on the battery side of the connector

It's caused by the controller having large capacitors on their input and since those are at zero volts and the battery is upwards of 50V a very large surge of current charges those capacitors up to the battery voltage and at the time of contact it will make a big arc

With the XT90s's one of the female contacts has a ring with a pre-charge resistor so when you plug it in (do it slowly!) it will pre-charge the controller capacitors to pretty near the battery voltage... there's still an arc once it makes the contact with the recessed part of the female contact but it's diminished orders of magnitude

An internal solid-state switch in the battery forgoes all this arcing nonsense but only as long as the battery is at the same voltage as the controller - pretty darn close to zero volts when the battery is off.. if the battery is on (or like many doesn't have a switch) you'll get the arc...

I'd still use the suppressed XT's even with a battery switch - my mind is old and feeble so I do forget to ensure the battery is off when I plug it in sometimes

Most batteries that go into a cradle can have this issue when plugging the battery into the cradle so if with a battery without a switch better to unplug the XT90s before putting the battery into the mount... some mounts do have pre-charge resistors but most I've seen don't...