Step 1: Things You Should Have or Acquire
2. Ratcheting crimper (we have a die set for the Powerwerx crimper)
3. Spade crimps for each size of wire going to a speed control
4. Heat shrink to fit over the crimps (we usually get an assortment)
5. Red and black Anderson Powerpoles along with crimps (you can get sets)
6. Wago tool or small flat-head screwdriver (we have found the Wago brand work best)
7. Wire strippers
8. Tons of zip ties
9. Wire (we prefer zip wire but you have to get the good stuff to not have problems)
Step 2: Plan It Out
Step 3: Mount the Components
Step 4: Crimp the Wires
Begin by running wires from the speed controllers to the PD Board:
1. Strip the wires slightly longer than the crimps you are using.
2. Cut enough heat shrink and slip it onto the wire before you start crimping.
3. Place the spade crimp into the crimper, making sure the seam of the crimp is in the concave side.
4. Insert the wire into the crimp and squeeze hard enough to fully crimp onto the wire, and release. Do not crimp onto the insulation of the wire.
5. Push the heat shrink over the exposed wire and crimp and use the heat gun to shrink it enough to be secure.
6. Repeat on the second wire.
After one side of the wire has spade crimps, secure them in place on the speed controller. Next, measure the length of wire required to reach the PD Board. Always measure the length from the side of the wire that needs to be longest, and cut the shorter side later. The wires should take the shortest and easiest path to the PD Board, but should have enough slack as to not be too tight or strained. If there is considerable distance from the speed controllers to PD Board, the wires should be zip tied to each other and the board to ensure they are securely in place. If the speed controllers are very close to the PD Board, like in the pictures, just make sure the wires look as neat as possible.
After you have wired all the speed controllers to the PD Board, repeat steps 1-6 using spade crimps on the other sides of the speed controllers. This time, however, you will need to use Anderson crimps to run to the motors for easy removal. Measure and cut the wires to the right length with the motor wires.
1. Strip the wires to fit the crimps.
2. Place the crimp in the Anderson crimper with the open side facing upward into the V-shape.
3. Place the wire in the crimp and squeeze until fully crimped.
4. With the hook side down, push the wire and crimp into the Anderson housing until it clicks into place.
5. Run the wires neatly and securely to the motors, watching out for chains, gears, or anything else that could damage wires.
This is an extremely helpful diagram:
Step 5: Run PWMs
Step 6: Other Wiring
For ribbon cables, run them neatly and safely from the digital module of the cRIO to the digital sidecar.
The breaker requires 4 or 6 gauge wire. Use circular crimps to run the wires from the PD board to breaker, and large Andersons for the battery.
Use at least 16 gauge wire and a white connector to run from the sidecar to PD board, and a black connector to run power to the cRIO.