XT Charge and QS Discharge Connector
Always connect QS and XT connectors at an angle, ensuring the flat positive (+) side makes contact first.
- Disable the discharge port in the BMS app before connecting a QS discharge connector to the battery.
- There is no need to disable the discharge port when unplugging the battery or the charge port when charging the battery.
ONYX 45AH BATTERY BMS APP
ONYX 41AH BATTERY BMS APP
- ONYX 41AH Overkill Solar BMS App - iOS
- ONYX 41AH Overkill Solar BMS App - Android
- Xiaoxang BMS App - iOS
AMORGE BATTERY BMS APP
Android AMORGE ANT BMS app, follow the instructions below.
- AMORGE ANT BMS App - iOS
- AMORGE ANT BMS App - Android
- Android AMORGE ANT BMS app, follow the instructions on the downloads post.
XLR Charge Connectors
The stock XLR charge connector on ONYX batteries comes in two variations. The older version, found on 23Ah to 41Ah batteries, supports a maximum charge rate of 10 amps, while the newer version supports up to 15 amps. If you’re unsure which version you have, it’s safest to limit your charge amperage to 10 amps or replace the XLR connector with a Neutrik-branded XLR on both the battery and charger. Consider upgrading to an XT60 connector for 12 AWG charge wires or an XT90 for 10 AWG charge wires.
XLR to XT60 Charge Adapter
When using an XLR to XT60 adapter, always follow the maximum amperage rating of the weakest connection. For XLR connectors, this limit is 10 amps.
Avoid QS8, QS9, QS10, QS12 Burnout Snap
The QS8, QS9, QS10, and QS12 connector’s 5-ohm resistance is inadequate for providing effective “anti-spark” protection at higher voltages such as 72V, 84V, or 96V. The “snap” sound from inrush current at these voltages can lead to gradual erosion of the connector. To mitigate this, always connect the QS8, QS9, QS10, and QS12 at an angle, ensuring the flat positive (+) side makes contact first. Alternatively, a custom QS8, QS9, QS10, and QS12 connector with a 15 mΩ pre-charge resistor can be used to address the anti-spark “snap” issue.
QS8-S+, QS8 Blue and QS8 Purple
Variations of the QS8 connector are marketed with different colors and labels, claiming to handle higher amperages, such as peaks of 600 amps. However, these claims are false. All these variations use the same nylon housing and brass connectors as the standard QS8.
QS8 Connector 4 AWG Wire
The back shell cover fits properly with 6 AWG wire but cannot accommodate 4 AWG wire, which 4 AWG wire is unnecessary for an ONYX.
Discharge Connector Cable Configurations
These wire gauge and connector configurations are based on DC line amp ratings for higher-quality aftermarket batteries capable of delivering a minimum of 200 continuous line amps. They take into account factors such as internal 8 AWG or 6 AWG wiring, robust bus bars, and the quality of nickel and copper components. Always consult your battery builder for detailed specifications on your battery’s internal construction.
QS8 And QS8-S Cable Amps Configuration
- 70 amps: 8 AWG wire / SB50 connector
- 100 amps: 8 AWG wire / QS8 or QS8-S connector
- 150 amps: 6 AWG wire / QS8 or QS8-S connector
- 300 amps: Dual 6 AWG wires / Dual QS8 or QS8-S connectors
QS9 Cable Amps Configuration
- 150 amps: 6 AWG wire / QS9 connector
- 300 amps: Dual 6 AWG wires / Dual QS9 connectors
QS10 Cable Amps Configuration
- 150 amps: 6 AWG wire / QS10 connector
- 300 amps: Dual 6 AWG wires / Dual QS10 connectors
QS10 Cable Amps Configuration
- 200 amps: 4 AWG wire / QS12 connector
- 300 amps: Dual 6 AWG wires / Dual QS12 connectors
Amperage Wire Limits
Dual 6 AWG wire becomes a limiting factor beyond 300 amps. While it’s possible to use dual 4 AWG wire with dual QS12 connectors, this setup is bulky, and the internal construction of most batteries likely won’t support such high-capacity discharge. A common misconception about wire and connector configurations is the lack of proper testing for continuous and peak amperage discharge. Often, we rely on hope rather than evidence, but I strongly recommend using a FLIR thermal camera when exceeding 300 line amps. Additionally, ensure your custom battery builder designs a battery capable of sustaining those amperage levels safely and effectively.
Thermal Camera
If you have access to a FLIR thermal camera, use it to monitor how your battery handles temperatures under different loads, including the charge and discharge connectors. Custom batteries are more than just their cell specifications-internal build quality, cell arrangement, wire gauge, and overall design significantly impact temperature control and the prevention of hot spots. Just because a battery fits your compartment doesn’t mean it’s free from compromises in performance or thermal management.
XT60 and XT90 Charge Connectors
XT60 (60-amp) and XT90 (90-amp) connectors are now more commonly used on ONYX charge ports due to their smaller size, greater efficiency, and improved weather resistance.
XT60 Charge Connector Specifications
- Maximum Wire Size: 12 AWG
- Compatible Wire Sizes: 12 AWG to 14 AWG
- Temperature Range: -20°F to +300°F
- Metal Material: Pure Gold-Plated Brass
- Plastic Material: Nylon Reinforced with Fiber
- Flame Retardant Rating: UL94 V0
- Rated Voltage: DC 500V
- Peak Current: 60A (12 AWG)
- Continuous Current: 30A (14 AWG)
- Resistance: 5-ohm
- Recommended Usage: Up to 1,000 cycles
XT90 Charge Connector Specifications
- Maximum Wire Size: 8 AWG
- Compatible Wire Sizes: 8 AWG to 12 AWG
- Temperature Range: -20°F to +300°F
- Metal Material: Pure Gold-Plated Brass
- Plastic Material: Nylon Reinforced with Fiber
- Flame Retardant Rating: UL94 V0
- Rated Voltage: DC 500V
- Peak Current: 90A (8 AWG)
- Continuous Current: 45A (10 AWG)
- Resistance: 5-ohm
- Recommended Usage: Up to 1,000 cycles
SB50 Stock Discharge Connector
The ONYX SB50 discharge connector provided a user-friendly, foolproof experience but has been increasingly phased out due to its large size and limited maximum amperage capacity of 50 amps.
SB50 Discharge Connector Specifications
- Maximum Wire Size: 8 AWG
- Compatible Wire Sizes: 6 AWG to 10 AWG
- Temperature Range: -5°F to +220°F
- Metal Material: Pure Gold-Plated Brass
- Plastic Material: Nylon Reinforced with Fiber
- Flame Retardant Rating: UL94 V0
- Rated Voltage: DC 500V
- Peak Current: 70A
- Continuous Current: 50A
- Resistance: 0.0002-ohm
- Recommended Usage: Up to 1,000 cycles
QS8 Discharge Connector
QS8 connectors are commonly used with 6 AWG wires. They are a popular choice for ONYX’s as a higher-power, more compact alternative to the stock SB50 connector. rewrite: The QS8 connector is officially rated for 110 to 180 amps but is capable of handling peaks of up to 300 amps in short bursts.
QS8 Discharge Connector Specifications
- Maximum Wire Size: 6 AWG
- Compatible Wire Sizes: 8 AWG to 10 AWG
- Temperature Range: -20°F to +300°F
- Metal Material: Pure Gold-Plated Brass
- Plastic Material: Nylon Reinforced with Fiber
- Flame Retardant Rating: UL94 V0
- Rated Voltage: DC 500V
- Peak Current: 180A
- Continuous Current: 130A
- Resistance: 5-ohm
- Recommended Usage: Up to 1,000 cycles
QS9 Discharge Connector Specifications
The QS9 connector is available in four physical variations: “S,” “U,” “D,” and “L.” The configuration best suited for an ONYX is the “QS9-L.”
- Maximum Wire Size: 4 AWG
- Compatible Wire Sizes: 4 AWG to 8 AWG
- Temperature Range: -20°F to +300°F
- Metal Material: Pure Gold-Plated Brass
- Plastic Material: Nylon Reinforced with Fiber
- Flame Retardant Rating: UL94 V0
- Rated Voltage: DC 500V
- Peak Current: 220A
- Continuous Current: 160A
- Resistance: 5-ohm
- Recommended Usage: Up to 1,000 cycles
QS10 Discharge Connector Specifications
The compact variationof the QS10 connector, without the center bus pins, that is best suited for an ONYX is the “QSP10P-L.”
- Maximum Wire Size: 4 AWG
- Compatible Wire Sizes: 4 AWG to 6 AWG
- Temperature Range: -20°F to +300°F
- Metal Material: Pure Gold-Plated Brass
- Plastic Material: Nylon Reinforced with Fiber
- Flame Retardant Rating: UL94 V0
- Rated Voltage: DC 500V
- Peak Current: 270A
- Continuous Current: 210A
- Resistance: 5-ohm
- Recommended Usage: Up to 1,000 cycles
QS12 Discharge Connector Specifications
The QS12 connector variation best suited for an ONYX is the “QS12-M.”
- Maximum Wire Size: 4 AWG
- Compatible Wire Sizes: 4 AWG to 6 AWG
- Temperature Range: -20°F to +300°F
- Metal Material: Pure Gold-Plated Brass
- Plastic Material: Nylon Reinforced with Fiber
- Flame Retardant Rating: UL94 V0
- Rated Voltage: DC 500V
- Peak Current: 320A
- Continuous Current: 250A
- Resistance: 5-ohm
- Recommended Usage: Up to 1,000 cycles
