The ONYX 72V platform uses separate connector systems for charging and high-current discharge, each with different electrical limits, wiring constraints, and failure points.
- XLR, XT60, and XT90 are used for battery charging
- QS8 and SB50 are used for high-current battery discharge
This post covers connector types, pin configuration, wire limits, routing options, discharge port charging behavior, and battery lead performance.
These connectors are used on the following ONYX battery configurations:
- ONYX 72V 45Ah
- ONYX 72V 41Ah
- ONYX 72V 23Ah
The ONYX 80V 45Ah battery and ONYX CTY2 23Ah do not use an XLR charge connector.
Connector performance depends on both electrical and environmental factors:
- Routing impacts durability and accessibility
- Pin alignment is direct between mating connectors
- Environmental exposure is the primary failure cause
- Regular cleaning reduces resistance and charging issues
System Overview
| Component | Category | Type | Function |
|---|---|---|---|
| XLR (Battery) | Charging | Female | Receives charge |
| XLR (Charger) | Charging | Male | Supplies charge |
| XT60 / XT90 | Charging | DC Connector | Charge port upgrade |
| QS8 | Discharge | Anti-Spark | High current discharge |
| QS9 | Discharge | Anti-Spark | Higher capacity discharge |
| QS10 | Discharge | Anti-Spark | High-performance discharge |
| QS12 | Discharge | Anti-Spark | Maximum current discharge |
| SB50 | Discharge | Anderson | Modular discharge |
XLR Charging Connector (72V)
The ONYX 72V charging system uses a 3-pin XLR connector with two active pins for DC charging.
- Battery: female XLR
- Charger: male XLR
- Alignment: direct (1:1, no crossover)
Pin Configuration (Battery & Charger)
- Pin 1: Positive (+)
- Pin 2: Negative (-)
- Pin 3: Not Used
Pins align directly when mating the connectors.
Charger Wire Colors (Stock ONYX 72V 10 Amp)
| XLR Male | XLR Color | 10a Charger Color |
|---|---|---|
| Pin 1 | Red (+) | Brown (+) |
| Pin 2 | Black (-) | Blue (-) |
| Pin 3 | Not Used |
XLR Connector Amps
| Model | Amps | Year |
|---|---|---|
| XLR Stock Black | 10a | 2018-2021 |
| XLR Stock Blue | 13a | 2022-2024 |
| XLR Neutrik | 16a |
Video - How To Solder a XLR Connector
XLR Connector Routing Options
There are multiple ways to position and access the battery’s XLR connector.
- Option 1: Leave inside and slide cover back
- Option 2: Use an XLR extension cable
- Option 3: Route through right-side hole externally
If routing externally, periodically check that the connector is clean and free of dirt or debris. A 3D-printed external dust cap helps keep it protected.
Charge Port Connector Wire
From 2018 to 2021, the stock ONYX RCR 23Ah battery came with a 16 AWG charge port wire, a specification that continued with the ONYX 41Ah battery from 2021 to 2024 and remains unchanged in the ONYX 45Ah battery as of 2025.
| Model | Gauge | Amps Max | Temp |
|---|---|---|---|
| ONYX 23AH | 16 AWG | 15a | 250 °F |
| ONYX 41AH | 16 AWG | 15a | 250 °F |
| ONYX 45AH | 16 AWG | 15a | 250 °F |
| AMORGE | 12 AWG | 25a | 250 °F |
XLR Charge Connector
Stock XLR connectors exist in two main variants:
- Blue XLR: supports up to 13A
- Black XLR: limit to 10A
Upgrades:
- Replace black XLR with Neutrik connectors
- Upgrade to XT60 or XT90 for improved connection quality
XT Charge Connectors
XT60 and XT90 connectors provide improved efficiency, size, and environmental resistance compared to XLR.
- Connect at an angle so positive (+) engages first
XT60 Charge Connector Specifications
- Dimension: 16mm x 8mm x 19mm
- Maximum Wire Size: 12 AWG
- Compatible Wire Sizes: 10 AWG to 14 AWG
- Temperature Range: -20°F to +250°F
- Metal Material: Pure Gold-Plated Brass
- Plastic Material: Nylon Reinforced with Fiber
- Flame Retardant Rating: UL94 V0
- Rated Voltage: DC 500V
- Continuous Current: 60A
- Peak Current: 80A
- Resistance: 5 ohm
- Recommended Usage: Up to 1,000 cycles
XT60 Variations
| Model | Feature | Use |
|---|---|---|
| XT60 | Standard | General power connections |
| XT60E | Panel mount | Fixed installations, enclosures |
| XT60H | Built-in solder covers | Clean and secure wiring |
| XT60S | Anti-spark | High-voltage systems (72V+) |
| XT60I | Inline connector | Custom wiring harnesses |
XT90 Charge Connector Specifications
- Dimension: 21mm x 13mm x 29mm
- Maximum Wire Size: 8 AWG
- Compatible Wire Sizes: 8 AWG to 12 AWG
- Temperature Range: -20°F to +250°F
- Metal Material: Pure Gold-Plated Brass
- Plastic Material: Nylon Reinforced with Fiber
- Flame Retardant Rating: UL94 V0
- Rated Voltage: DC 500V
- Continuous Current: 90A
- Peak Current: 120A
- Resistance: 5 ohm
- Recommended Usage: Up to 1,000 cycles
XT90 Variations
| Model | Feature | Use |
|---|---|---|
| XT90 | Standard | General high-power connections |
| XT90S | Anti-spark | High-voltage (72V+) applications |
| XT90E | Panel mount | Fixed installations, enclosures |
| XT90H | Solder covers | Clean and secure wiring |
| XT90I | Inline connector | Custom wiring harnesses |
XLR to XT60 Charge Adapter
Always follow the lowest-rated component in the chain.
- XLR limit: 10A
Charging Efficiency
An 84V charger draws approximately 11.67A from a 120V AC outlet when outputting 15A at 84V DC with 90% efficiency.
- Voltage drop >6V (5%) can reduce outlet voltage below 114V
- This may cause breaker trips on a 15A circuit
An 84V charger can output approximately 19.3A DC before exceeding a 15A AC breaker, assuming:
- 90% efficiency
- Dedicated circuit
- Proper wiring for distance
Discharge Port Charging
All ONYX batteries since 2018 support charging through the discharge port.
- Requires charger connector modification to SB50 or QS8
- Functions similarly to regenerative braking current flow
Charging behavior:
- 15A-20A is acceptable for larger batteries
- Higher sustained amperage reduces cycle life
Discharge Port BMS Charging Cap
ONYX batteries are limited by their BMS in terms of the maximum amperage they can be charged from the discharge port.
| Model | BMS Amps Cap | Theoretical Amps |
|---|---|---|
| ONYX 23AH | 10a | 24a |
| ONYX 41AH HD | 10a | 45a |
| ONYX 41AH EK | 10a | 37a |
| ONYX 45AH | 10a | 45a |
| AMORGE | 20a | 45a |
Adapter Warning
- Do not convert XLR / XT60 / XT90 to SB50 or QS8 using adapters
XLR Failure
Exposure to water, dirt, or salt can damage XLR connectors and prevent charging.
- Corrosion on pins or sockets
- Increased resistance
- Intermittent charging
- Complete failure
Cleaning XLR Charge Connector
Tools & Materials
- Isopropyl alcohol (90%+)
- Lint-free swabs
- Compressed air (optional)
- Soft brush (optional)
- Contact cleaner (DeoxIT D5)
- Plastic pick (optional)
Male Connector
- Inspect pins
- Clean with alcohol
- Rotate swab around pins
- Blow debris out
- Apply contact cleaner
- Dry completely
Female Connector
- Inspect socket holes
- Clean using wrapped swab or pick
- Rotate gently
- Remove debris
- Apply cleaner
- Dry and blow out
Extra Tips
- Avoid metal tools
- Do not oversaturate
- Replace severely corroded connectors
Video - How To Properly Clean an XLR Connector
Discharge Connectors 72V
See QS8, SB50, and High-Current Battery Discharge Connectors for ONYX for the complete reference.
QS8 Connector (Soldered - 6 AWG)
See QS8, SB50, and High-Current Battery Discharge Connectors for ONYX for the complete reference.
Video - How To Solder a QS8 Connector
See QS8, SB50, and High-Current Battery Discharge Connectors for ONYX for the complete reference.
SB50 Connector Crimp 8 AWG
See QS8, SB50, and High-Current Battery Discharge Connectors for ONYX for the complete reference.
Video - How To Crimp a SB50 Connector
See QS8, SB50, and High-Current Battery Discharge Connectors for ONYX for the complete reference.
Connector Scaling Overview
See QS8, SB50, and High-Current Battery Discharge Connectors for ONYX for the complete reference.
Battery Lead Upgrade
See QS8, SB50, and High-Current Battery Discharge Connectors for ONYX for the complete reference.
QS Connector Burnout and Thermal Behavior
See QS8, SB50, and High-Current Battery Discharge Connectors for ONYX for the complete reference.
Battery Lead Length
See QS8, SB50, and High-Current Battery Discharge Connectors for ONYX for the complete reference.
Battery Lead Amp Limits
See QS8, SB50, and High-Current Battery Discharge Connectors for ONYX for the complete reference.
Battery Lead Bigger Configurations
See QS8, SB50, and High-Current Battery Discharge Connectors for ONYX for the complete reference.
Dual Battery Leads
See QS8, SB50, and High-Current Battery Discharge Connectors for ONYX for the complete reference.
QS8 Discharge Connector
See QS8, SB50, and High-Current Battery Discharge Connectors for ONYX for the complete reference.
QS9 Discharge Connector
See QS8, SB50, and High-Current Battery Discharge Connectors for ONYX for the complete reference.
QS10 Discharge Connector
See QS8, SB50, and High-Current Battery Discharge Connectors for ONYX for the complete reference.
QS12 Discharge Connector
See QS8, SB50, and High-Current Battery Discharge Connectors for ONYX for the complete reference.
Final Advice
Connector reliability depends on installation, cleanliness, and system limits.
- XLR requires regular cleaning and protection
- XT improves charging durability
- QS8 depends on proper soldering
- SB50 depends on correct crimping
- Respect BMS charging limits
- Poor connections increase resistance and heat
- XLR is for charging only