XT60 vs. XT90 Battery Connector Comparison

By Ufine, Updated on April 26, 2024

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XT60 vs. XT90: Which Battery Connector is Right for You? If you’re looking for a reliable battery connector, choosing between XT60 and XT90 depends on your device’s power needs. Here’s a breakdown to help you make the best choice.

Battery connectors link batteries and their power devices, ensuring a stable and reliable connection. When choosing a suitable battery connector, it’s essential to consider factors such as compatibility, current-carrying capacity, and durability.

XT60 vs XT90: Quick Reference

Specification	XT60	XT90
Continuous Current	60-75A	90-120A
Peak Current	120A	180A
Diameter	19.5mm	23.5mm
Weight (per pair)	15g	28g
Anti-Spark Option	Not Available	XT90S Version
Typical Applications	FPV Drones, RC Cars	E-Scooters, Industrial Gear

Selection Tip: Choose XT60 for ≤80A needs, XT90 for ≥100A requirements

Part 1. What are battery connectors?

Battery connectors are electrical components that establish a secure and efficient connection between a battery and an electronic device. They come in various shapes, sizes, and designs to accommodate different applications. The primary purpose of a battery connector is to ensure a reliable flow of electrical current between the battery and the device, minimizing power loss and potential damage.

Importance of choosing the suitable battery connector

Selecting a suitable battery connector is crucial for several reasons.

Firstly, it ensures compatibility between the battery and the device, preventing compatibility issues that could lead to malfunction or damage.
Secondly, the exemplary connector should be able to handle the electrical current required by the device without overheating or causing voltage drops.
Finally, a durable and reliable connector reduces the risk of connection failures, which can lead to power interruptions or even safety hazards.

Part 2. XT60 Battery connector

The XT60 battery connector is popular among hobbyists, drone enthusiasts, and RC (radio-controlled) vehicle enthusiasts. It features a cylindrical design with male and female connectors that securely lock into place, providing a solid connection. The XT60 connector is known for its ease of use, reliability, and wide availability in the market.

Features

Secure Connection: The XT60 connector utilizes a robust locking mechanism that ensures a secure connection, minimizing the risk of accidental disconnections during operation.
High Current Capacity: It can handle high current loads, making it suitable for applications requiring substantial power output. With a continuous current rating of around 60-75 amps, the XT60 connector can safely handle significant power demands.
Heat Resistance: The XT60 connector reliably handles high temperatures without melting or degrading, ensuring performance in demanding conditions.
Ease of Use: The connectors are easy to plug and unplug, providing convenience during setup and maintenance.

Pros

Wide Availability: XT60 connectors are readily available, making them easily accessible for hobbyists and professionals.
Compatibility: They are compatible with various devices, including RC cars, drones, and other high-power applications.
Reliability: The XT60 connector’s solid construction and secure locking mechanism result in a reliable connection that minimizes the risk of power interruptions.

Cons

Size: The XT60 connector is more significant than other battery connectors, which may limit its usability in compact devices or tight spaces.
Limited Current Capacity: While the XT60 connector can handle high current loads, it may only be suitable for moderately power-hungry applications that require even higher current ratings.

Part 3. XT90 Battery connector

The XT90 battery connector is a robust, heavy-duty connector widely used in applications demanding high power output. You can commonly find it in electric vehicles, high-performance drones, and industrial equipment where reliability and durability are paramount.

Features

Heavy-Duty Design: The XT90 connector features a rugged and durable design, capable of withstanding high mechanical stress and vibrations.
High Current Handling: Its design allows it to handle even higher current loads than the XT60 connector, making it ideal for power-hungry applications. With a continuous current rating of around 90-120 amps, the XT90 connector can reliably handle substantial power demands.
Low Resistance: The XT90 connector has low electrical resistance, minimizing power loss and voltage drops during operation.
Anti-Spark Design: Some XT90 connectors feature an anti-spark design, reducing the risk of sparks or arcing during the connection process.

Pros

High-Power Applications: The XT90 connector excels in high-power output applications, such as electric vehicles and heavy-duty industrial equipment.
Durability: Its robust construction ensures long-term durability, withstanding harsh environments and heavy usage.
Low Resistance: The low resistance of the XT90 connector allows for efficient power transmission, minimizing energy loss.

Cons

Size and Weight: The XT90 connector is larger and heavier than the XT60 connector, which can be a disadvantage in applications where space and weight are critical.
Availability: Compared to the XT60 connector, the availability of XT90 connectors may be more limited, making them slightly more challenging to find in some regions.

Part 4. XT60 vs XT90: 7 Critical differences

Performance comparison based on real-world testing:

Heat Resistance: XT90 maintains 22℃ lower temperature than XT60 at 100A load
Durability: XT90 gold-plated contacts withstand 500+ connect cycles (XT60: 300 cycles)
Safety Features: XT90S version includes built-in arc suppression technology
Voltage Efficiency: 0.14V lower drop at 50A compared to XT60
Vibration Resistance: XT90 locking mechanism 40% more secure in high-vibration environments
Wire Compatibility: XT90 accommodates thicker 8AWG cables versus 10AWG for XT60
Connection Security XT90 requires 30% more force to accidentally disconnect

Part 5. Detailed comparison between XT60 and XT90 connectors

Here is a comparison between the XT60 and XT90 connectors to help you understand their differences:

1. Size

The XT60 connector is smaller and lighter than the XT90 connector, making it more suitable for compact devices or applications with limited space constraints. On the other hand, the XT90 connector’s larger size and weight make it better suited for applications where robustness and high power handling are essential.

2. Current Capacity

While both connectors can handle high current loads, the XT90 connector has a higher continuous current rating of around 90-120 amps, surpassing the XT60 connector’s 60-75 amps rating. This makes the XT90 connector more suitable for higher power output applications.

3. Availability

You can easily find XT60 connectors in the market as they are widely available from various sources. However, XT90 connectors may be less standard and require more effort, especially in certain regions.

4. Compatibility

Both connectors are compatible with various devices and applications, including RC vehicles, drones, and other high-power electronics. However, it is essential to ensure the connector’s compatibility with the specific device and its power requirements.

5. Durability

Both connectors offer durability and reliability as part of their design. However, the XT90 connector’s heavy-duty design and construction make it more resilient to mechanical stress, vibrations, and harsh environmental conditions.

6. Resistance

The XT90 connector exhibits lower electrical resistance than the XT60 connector, reducing power loss and voltage drops during operation. This makes the XT90 connector more efficient in power transmission.

7. Locking Mechanism

Both connectors feature a secure locking mechanism that ensures a stable connection. The XT60 connector’s locking mechanism is generally more accessible and user-friendly.

8. Price

The XT60 connector is generally more affordable and budget-friendly than the XT90 connector, which may be pricier due to its heavy-duty design and higher current handling capabilities.

Part 6. XT60 and XT90 battery connector applications

XT60 Battery Connector Applications

RC (radio-controlled) vehicles, including cars, boats, and airplanes
Drones and quadcopters
Robotics projects
Electric skateboards and scooters
Portable power banks and chargers

XT90 Battery Connector Applications

Electric vehicles, including electric cars, scooters, and bikes
Industrial equipment and machinery
High-performance drones and aerial photography platforms
Renewable energy systems, such as solar power installations
Power distribution systems and battery banks

Connector Selection Guide

Choose XT90 if your project requires:

Continuous current ≥80A
Lithium batteries >6S configuration
Operation in high-vibration environments
Industrial or vehicle applications
Spark-free connection requirement

Select XT60 for:

Current needs ≤75A
Hobbyist drones and RC models
Lightweight applications
Compact space installations
Budget-sensitive projects

Part 7. FAQs about xt60 vs xt90

What is the main difference between XT60 and XT90 connectors?

The core difference is current capacity and size. XT60 handles 60-75A continuous current and has a 19.5mm diameter, while XT90 supports 90-120A with a 23.5mm diameter. XT90 also offers optional spark-resistant versions.

Can I use XT60 connectors for 100A applications?

No, it’s dangerous. XT60 connectors overheat at 100A, reaching 98°C within 5 minutes. This causes 400% higher melting risk. Use XT90 or dual parallel XT60 connectors instead.

Are XT90 connectors compatible with XT60 chargers?

Not directly. Their different sizes prevent physical connection. Use adapter cables or replace both ends to match. Never force mismatched connectors.

Which connector is better for electric skateboards?

XT90 is recommended for high-performance boards (1000W+ motors). For boards under 800W, XT60 suffices. Always check your motor’s peak amp draw.

Do XT90 connectors prevent sparks?

Only XT90S (anti-spark) versions reduce sparks. They contain internal resistors that precharge circuits. Standard XT90 lacks this feature.

How many connect/disconnect cycles do these connectors last?

XT60: 300+ cycles. XT90: 500+ cycles due to thicker gold-plated contacts. Lifespan halves in dusty or humid environments.

Can I solder XT60 and XT90 connectors with regular equipment?

Yes, but use 60W+ soldering irons and high-temp solder. Overheating damages plastic housings. Preheat connectors to 150°C before soldering large wires.