IEC C13 versus Anderson connectors

Continuing with the custom trike project, here are the previous three posts:

• Junction box for custom trike part-2 — November 04, 2024
• Junction-box for custom trike — October 17, 2024
• Lensun MPPT has to be isolated from frame — October 11, 2024

Something that has surprised me, is the use of the IEC C13 connector for DC. This connector is intended for mains AC, yet, this is what my lithium battery came with for charging:

To be fair to the vendor, they did offer a choice of other connectors, but I just accepted the default. Looking on Aliexpress at lithium batteries and chargers, it seems this IEC C13 is the usual default choice.

Awhile back, I bought another mains charger, 58.4V, for my LFP battery; they also offered a choice of connectors, but I chose the IEC:

https://www.aliexpress.com/item/1005003269750911.html

But, that really does look "wrong":

...the connector on the left is the 58.4V DC output, on the right is the 240V AC input!

This does not rest comfortably with me. So, decided to replace the DC connectors with 50A Anderson. The choice of Anderson is partly because I have some already, and partly because they have holes for convenient mounting. Of course they are an overkill for the 3-4 amps in this situation.

In the earlier "powerbox" project, I standardized on different colour Anderson connectors; black for the mains charging. So sticking with that. Used the "flood" method of soldering the wires to the Anderson lugs, as explained in my blog a few years ago, here.

The problem that arises from replacing the IEC connector with Anderson, is that with the Anderson connector the wires will flex a lot more and will in time likely break, especially if they have been stiffened by solder having flowed up the wires. So I fabricated a simple brace with a small piece of steel offcut:

...one thing I learnt from the powerbox days, is that the internal lugs need to have some freedom of movement. Back then, was using much heavier guage wire, and if the two wires were pulled together it also twisted the internal lugs and made plugging together of two connectors very difficult. It is not such an issue with these thin wires; however, I splayed them out a bit and wound the electrical tape a bit further back.

Next up, will replace the IEC connector on the lithium battery with an Anderson -- will do that with great care! Branching off from that will be a XT60 connector to which will be plugged charging from the solar MPPT controller -- as discussed in the previous blog post with regard to the DPDT switch.

One interesting detail about the bolt inserted though the Anderson connector; it is 4.0mm, whereas the hole is 3.7mm. I was surprised at such an odd size hole, but perhaps it has heritage from imperial measurements. That got me curious; yes Anderson Power Products is a USA company. Not that most people buy an actual Anderson brand connector, but they are the originator. Anyway, I drilled it out to 4.0mm.   

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