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Wiring "5590" Connectors

This section teaches you how to acquire and properly wire the connectors for the x90 family of batteries for 12V applications. The parts list is the suggested purchasing list, but other supplies may be substituted. For instance, the two conductor wire chosen is top-notch; but while you could choose something less expensive, why build an inferior product? Also, while any epoxy can be used, the Devcon epoxy gel is really the easiest to work with.

Tools

Supplies

Directions

1. Attach Diodes

To properly wire an x90 connector for 12V applications, you MUST use a diode on each of the positive terminals. A diode serves to prevent reverse current flow (power going back into the battery cell). If you do not use diodes and attach your connector to a BA-5590 with one set of cells partially drained, you run the risk of "venting" (blowing up) the battery. Do it right: Use diodes.

Diode with flow direction indicated	5590 with diodes attached

On the digikey Shotky diodes, current can only flow "towards" the side with the line on the front face. Using an X-Acto blade, pry the metal tabs on the sides of the diodes, and attach one each to poles #4 and #5 on the 5590 connector (with the side WITHOUT the line attached to the pole).

2. Attach Wire

Strip the cable as needed, and attach the ground ("negative") wire to poles 1 and 2. Attach the positive wire to the free ends of the diodes on poles 4 and 5.

Ensure that: + and - wires do not touch + wire only connects to the free ends of the diodes and not to the poles

The image shows the wire coming out to the left, but you can wire it to come out any of the four sides, as long as the wiring is correct and plenty of cable sheath is inserted into the connector body. Not inserting the sheath enough is probably the #1 quality issue observed.

WRONG! This cable jacket was not well inserted, and over time the sheaths of the wires will crack and the connector will short out.

3. Epoxy The Connector

Using a good two part epoxy, fill or "pot" the entire connector insides, then put on the cap. Clamp the connector shut while it cures. The epoxy serves to keep any of the wires moving and weakening the solder joints or diodes during use.

I prefer the "gel" style epoxy as listed above: it doesn't run out like a liquid and is much easier to work with. Don't worry about epoxy squeezing out of the connector when you close it; you can easily remove this extra after the epoxy starts to harden.