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Electrical Standards

Version: v2025.0
Owner: Electrical Lead
Last Updated: 2025-11-27
Reviewed: No
Deviations Allowed: Yes (with approval)

Why: reliability, safety, fast inspection fixes. Use this as the canonical wiring checklist.

Wiring rules​

  • Gauge by load, color coding, labeling (polarity, CAN IDs), strain relief.
  • Pull-test every crimp; strain-relief wires on moving parts; insulate with heatshrink/tape.

Layout​

  • Battery/main breaker/PDH/PDP/radio placement; service loops; isolation from sharp edges.
  • Keep metal shavings off electronics; cover during drilling; vacuum/air if needed.

Testing​

  • Tug tests, continuity, CAN health, radio power check, breaker map.
  • Recheck after pit work; retest battery/main/radio power before events.

Visual example​

  • Annotated board layout photo.

Common failure modes​

  • Loose crimps, CAN breaks, brownouts, radio drops, unprotected runs.
  • Shavings causing shorts; uninsulated lugs; buried radio.

Instructions (numbered)​

  1. Size wire gauge by load; set color coding; label polarity and CAN IDs before install.
  2. Crimp/ferrule with correct dies; pull-test every termination before/after install; insulate exposed conductors.
  3. Route power and signal separately; add strain relief, especially near moving parts.
  4. Secure radio with clear line-of-sight; anchor battery and main breaker; avoid sharp edges.
  5. Build breaker map and CAN ID map; keep printed copies in the pit.
  6. Run continuity and CAN health checks; log and fix issues; recheck after any drilling/pit work.

Best practices​

  • Use proper crimpers matched to connector and gauge.
  • Anchor wires before connectors to offload strain; keep service loops.
  • Label everything: polarity, CAN IDs, breaker size, battery dates.
  • Cover electronics when drilling; vacuum shavings; retest critical connections.

Common mistakes​

  • Skipping pull tests; mismatched gauge to connector; uninsulated conductors.
  • Power and CAN bundled with no spacing; sharp bends near lugs.
  • Drilling over open electronics; radio buried/poorly mounted.

Checklist​

  • Gauge/color/labels set; maps printed +- [ ] All crimps/ferrules pull-tested and insulated
  • Strain relief installed; service loops present
  • Radio/battery/main breaker secure and accessible
  • Continuity/CAN checks passed
  • Shavings cleared after drilling
  • Wire strippers (multiple gauges), Anderson/ring/ferrule crimpers, heatshrink, labeler, multimeter, CAN analyzer, vacuum/air.

Sample log (template)​

  • Date:
  • Work done:
  • Pull-test issues/re-crimps:
  • CAN/continuity results:
  • Notes/photos:

Photos/diagrams​

  • [Placeholder: annotated wiring board highlighting labels, strain relief, and maps]

Sources

Deviations​

  • Deviations from wiring standards require EE lead/mentor approval; log any deviations and mitigation.

Version & ownership​

  • Owner: Electrical lead/mentor
  • Review cadence: pre-season and before first event

See also:

��� Reference the Glossary for definitions of common terms and constraints.