Custom Connector Order Parameter Verification Manual: Guide for Technical Personnel to Confirm Current & Voltage Specifications

Custom high-current anti-spark connectors (QS series) require precise parameter verification—errors cause non-compliance, safety hazards, and production delays. This manual helps technical personnel confirm current/voltage specifications and avoid common mistakes.

Common Parameter Verification Mistakes

Confusing peak current with continuous current (leads to overheating). Ignoring voltage ripple (causes insulation breakdown). Mismatching pre-charge resistor values (triggers severe arcing). Overlooking environmental temperature (reduces current-carrying capacity).

Step-by-Step Parameter Verification (QS Custom Connectors)

Step 1: Confirm Current Specifications

Continuous current: Based on system long-term operating current (add 25% safety margin). For a 200A BMS system, specify 250A continuous current (QS 250A model). Peak current: Account for inrush current (e.g., battery startup, 2x continuous current). QS connectors support 1.5-2x peak current for 10 seconds. Temperature derating: At ≥40℃, derate current by 10% per 10℃ (e.g., 300A connector at 60℃ = 240A continuous current).

Step 2: Verify Voltage Specifications

Rated voltage: Match system nominal voltage (QS connectors support 600V DC, 250V AC; customize for 1000V DC high-voltage systems). Insulation resistance: ≥1000MΩ at 500V DC (QS connectors exceed this, at 2000MΩ+). Dielectric strength: Withstand 2000V AC for 1 minute (no breakdown)—critical for high-voltage battery systems.

Step 3: Cross-Check with Anti-Spark Parameters

Pre-charge resistor value: Confirm based on battery capacity (C = 100Ah → 10Ω resistor; C = 200Ah → 5Ω resistor). Anti-spark activation time: 0.5-1 second (QS connectors’ slow-start module ensures no arcing during plugging).

Step 4: Document & Confirm

List all parameters (current, voltage, temperature, pre-charge resistance) in the order form. Youwei Technology’s technical team will double-check and provide a verification report within 24 hours.

Example Verification Sheet

Parameter: Continuous Current, Value: 300A, Verification Result: Pass (25% margin) Parameter: Peak Current, Value: 600A (10s), Verification Result: Pass Parameter: Rated Voltage, Value: 500V DC, Verification Result: Pass Parameter: Pre-charge Resistance, Value: 8Ω, Verification Result: Pass (200Ah battery)

Conclusion

Precise parameter verification is the foundation of reliable custom QS Antispark connectors. Youwei Technology provides free technical support for parameter confirmation, ensuring orders meet project requirements. If you have any request please contact with my tech team http://www.youweic.com