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2025-10-28 5:07 pm
Hey folks,
I’m setting up a new drone power system and using XT60 connectors. They’re rated for 60A, which should be plenty, but I’ve noticed the connectors get a bit warm when the motors pull higher current. I soldered them with 12AWG wires and double-checked polarity, but I’m wondering if my soldering technique or wire length might be causing resistance. Has anyone run into this before? Do you usually add extra strain relief or heat shrink to keep them stable?
Would really appreciate some advice. TIA
2025-10-28 5:54 pm
Hi @jordanm23,
I don't have any experience of drones, or the XT60 connector, but an approach that is generally informative, is to measure the voltage drop ALONG the length of the wiring, whilst it is passing current.
Note, when I refer to a wire (below), I mean the entire path from the power source (e.g. battery terminal), through to the load destination, (e.g. power input pin on the motor controller)
Hopefully the voltage drop will be small (millivolts), but easily measurable with a meter. Mentally divide the wire into segments, and measure the drop across each segment. 1 obvious segment, would be the XT60 connector, itself.
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Remember Power (Watts) = Voltage (drop) * Current
As an example, if the current draw is 60 A, and the voltage drop across the connector is 10 mV, then the connector will dissipate (60 (A) * 10 (mV)) = 600 mW for each pole, which I guess, would make it quite warm after a couple of minutes.
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In addition, Ohm's law states R = V/I
So the same data shows a resistance of 10 (mV) / 60 (A) = 1/6 = 0.17 milliOhm
Then use the data to identify the 'segments' with the largest voltage drop, to consider if and how the resistance of those segments may be reduced.
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I also did a quick Google of XT60 connector, and the first hit was:
https://docs.rs-online.com/4610/A700000008956683.pdf
which includes:
I realise the XT60 is a 'generic' part, with countless different manufacturers, but this datasheet suggests it is only intended to carry 30 A continuously, suggesting it is likely to get very warm when passing 60 A, for a substantial period of time. ("Momentary" in electronics usually means a fraction of a second, not many seconds or longer.)
Whether the time of your usage is sufficient to heat the plastic of the connector to a softening/melting point, I don't know, but please take very great care to avoid an accident that could result from the pins of the connector shorting together, due to the plastic softening. You might consider finding a higher current connector.
Good luck and best wishes, Dave
2026-03-20 8:55 am
Hi @jordanm23,
So sorry I’m only seeing this thread now.
Actually, the XT60 connector you’re using was developed by me, and I’d like to clear up a very common misunderstanding many users have:
The numbers in XT30 / XT60 / XT90 are just series model numbers — they do NOT mean the recommended continuous current is 30A / 60A / 90A.
For the XT60 you’re using now:
- Its max rated continuous current is 35A
- At full 35A load, you must use 12AWG wire
- Temperature rise will be 85°C above ambient (20°C)
If you need, I can send you the full official product manual and detailed specifications for reference.
Yassin
Yassin | Building Compact, High-Current Connections for Drones & Robots