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Module 2 — Wiring & Termination

Objective: build robust harnesses and clean routing.

Prereqs: Approved layout and device list.

Steps

  • Crimp/ferrule per spec; strain-relief bundles; separate power and signal where possible.
  • Label polarity, CAN IDs, and breaker sizes; secure radio and antennas.
  • Perform tug tests and continuity checks.
  • Secure battery leads; double-nut main breaker if allowed; route away from sharp edges.
  • Confirm color coding (red/black for power, yellow/green for CAN) and match polarity at devices.
  • Insulate exposed conductors (heatshrink/tape); cover electronics when drilling to avoid shavings.
  • Pull-test every connection (Spectrum method) and log any re-crimps.

Deliverables

  • Wired board with labels, tidy routing, and tug-tested connections.
  • Photos of wiring paths for future service.

Resources

  • WPILib hardware basics: docs.wpilib.org/en/stable/docs/hardware/hardware-basics.html
  • Sensors: playingwithfusion.com, andymark.com/categories/sensors
  • Spectrum wiring guide: Spectrum FRC Electrical Guide.pdf
  • Electrical Bible (legacy fundamentals): UPDATED Electrical Bible.pdf

Instructions (numbered)

  1. Cut/strip wires to length; crimp/ferrule per spec; insulate exposed conductors.
  2. Route power/signal separately; add strain relief, especially near moving parts.
  3. Label polarity, CAN IDs, breaker sizes; secure radio/antennas.
  4. Pull-test every connection (before/after install); perform continuity and CAN health checks.
  5. Secure battery leads; double-nut main breaker if allowed; avoid sharp edges.
  6. Cover electronics when drilling; vacuum/air to remove shavings.

Example

  • CAN daisy chain with labeled IDs 1–8; ferruled sensor wires; 6 AWG battery with heatshrink and pull-tested lugs.

Best practices

  • Use proper crimper for each connector; verify gauge match.
  • Anchor wires before connectors to offload strain.
  • Keep logs of re-crimps and suspect connections.

Common mistakes

  • Skipping pull tests; mixing gauges; leaving uninsulated conductors.
  • Running CAN/power together without spacing; sharp bends near lugs.
  • Drilling near open electronics without protection.

Checklist

  • All crimps/ferrules pull-tested
  • Labels applied (polarity, CAN IDs, breakers)
  • Strain relief installed
  • Continuity/CAN checks passed
  • Battery/main breaker secured
  • Shavings cleared after drilling

Recommended tools

  • Wire strippers (multiple gauges), crimpers (Anderson, ring, ferrule), heatshrink, labeler, multimeter, CAN health tool.

Sample log (template)

  • Date:
  • Wires/crimps done:
  • Pull-test issues/re-crimps:
  • CAN/continuity results:
  • Photos attached:

Photos/diagrams

  • [Placeholder: wiring board photo with labels and strain relief callouts]