Standards & Specifications

This section defines the technical standards, specifications, and requirements that govern all electrical work on FEDS 201 robots.

🔌 Connector Standards

Our standardized connector approach ensures reliability, maintainability, and team efficiency across all robot systems.

📏 Wire and Cable Specifications

Wire Gauge Selection Guide

Our wire gauge selection follows FRC requirements and best engineering practices for safety and performance.

Color Coding Standards

Power Distribution:

• Red: Positive 12V, battery positive
• Black: Ground, battery negative
• White: Neutral (AC applications only)
• Green: Safety ground, chassis ground

Communication Signals:

• Yellow: CAN-H (CAN bus high)
• Green: CAN-L (CAN bus low)
• Blue: Clock signals, SPI CLK
• Purple: Data signals, SPI MOSI/MISO

Control Signals:

• Orange: PWM outputs, servo signals
• Brown: Analog inputs, potentiometer signals
• Gray: Digital I/O, limit switch signals
• Pink: Special functions, custom applications

Insulation and Temperature Ratings

Standard Applications:

• Temperature Rating: 105°C minimum
• Voltage Rating: 600V minimum for power, 300V for control
• Insulation Type: PVC or XLPE
• Flame Rating: VW-1 or better

High-Temperature Applications:

• Temperature Rating: 125°C minimum
• Insulation Type: XLPE or Silicone
• Applications: Motor compartments, engine bay routing
• Color Retention: UV-stable compounds

Flexible Applications:

• Strand Count: 19x30 AWG minimum for 12 AWG
• Flexibility: Greater than 1000 flex cycles at rated current
• Jacket Material: TPE or equivalent
• Applications: Moving mechanisms, service loops

📋 Documentation Requirements

Wiring Diagram Standards

Mandatory Elements:

1. Complete Circuit Representation

   • All power and signal connections
   • Component identification and part numbers
   • Wire gauge and color specifications
   • Connector types and pin assignments

2. Current and Voltage Ratings

   • Fuse/breaker ratings and locations
   • Expected current draw for each circuit
   • Voltage levels at key test points
   • Power consumption calculations

3. Physical Layout Information

   • Approximate wire routing paths
   • Connector locations and orientations
   • Service access requirements
   • Maintenance clearances

Drawing Standards:

• Format: PDF with editable source files
• Scale: Not to scale, schematic representation
• Symbols: IEEE/ANSI standard electrical symbols
• Line Weights: Power (thick), Signal (medium), Reference (thin)

Labeling and Identification

Wire Labeling Format:

[Source Component]-[Destination Component]-[Signal Type]-[Wire Number]

Examples:
PDH-01-MOTOR-FL-PWR    (PDH Channel 1 to Front Left Motor Power)
RIO-PIGEON-CAN-H       (RoboRIO to Pigeon CAN High)  
LIMELIGHT-01-ETH       (Limelight Unit 1 Ethernet)

Component Labeling:

• Unique Identifier: Sequential numbering by type
• QR Code: Links to documentation and specifications
• Maintenance Log: Attachment point for service records
• Emergency Info: Critical safety or operational notes

Cable Management Labels:

• Bundle Identification: Route and destination
• Service Date: Last inspection or modification
• Installer Initials: Responsibility tracking
• Revision Level: Version control for modifications

Revision Control

Document Versioning:

• Major Revisions: Component additions/removals, topology changes
• Minor Revisions: Wire routing changes, connector updates
• Patch Revisions: Corrections, clarifications, cosmetic updates

Change Documentation:

• Change Log: Date, author, description of changes
• Approval Process: Technical review and sign-off required
• Distribution: Updated copies to all team members
• Archive: Previous versions maintained for reference

⚖️ FRC Compliance Requirements

Mandatory Safety Requirements

Robot Signal Light (RSL):

• Device: FRC-approved RSL only
• Wiring: Direct connection to RSL terminals on RoboRIO
• Operation: Steady when enabled, blinking when disabled
• Mounting: Visible from multiple angles, protected from damage

Main Breaker:

• Rating: 120A maximum, appropriate for robot power consumption
• Type: Snap-action circuit breaker (not fuse)
• Mounting: Accessible for emergency disconnect
• Wiring: Proper gauge for full load current

Battery and Power:

• Battery Type: 12V lead-acid, FRC-approved models only
• Connections: SB50 or SB120 connectors as appropriate
• Protection: Main breaker, individual circuit protection
• Mounting: Secure retention, accessible for service

Electrical Safety Standards

Wire Protection:

• All circuits must have appropriate overcurrent protection
• Wire gauge must be appropriate for circuit current and length
• Insulation must be rated for application voltage and temperature
• No exposed conductors in areas of mechanical contact

Grounding Requirements:

• All metallic robot structure must be bonded to electrical ground
• Ground fault protection where required by FRC rules
• Separate signal and power grounds where appropriate
• Ground loop prevention in sensitive circuits

EMI/EMC Compliance:

• Proper shielding of sensitive circuits
• Separation of power and signal cables
• Common-mode choke installation where required
• Compliance with FRC radio frequency restrictions

Inspection and Testing Requirements

Pre-Competition Inspection:

• Complete electrical inspection by qualified inspector
• Documentation review and verification
• Functional testing of all safety systems
• Compliance with current FRC electrical rules

Ongoing Compliance:

• Regular inspection and maintenance schedule
• Documentation of all modifications
• Re-inspection after major changes
• Compliance verification before each competition

🎯 Quality Assurance Standards

Workmanship Standards

Mechanical Assembly:

• All connections must be mechanically secure before electrical connection
• Proper torque specifications for all threaded connections
• No stress on electrical connections from mechanical loading
• Adequate service loops and strain relief

Electrical Assembly:

• Clean, bright electrical connections
• Proper crimp quality per connector manufacturer specifications
• No cold solder joints or poor electrical connections
• Insulation integrity maintained throughout installation

Documentation Quality:

• All modifications documented immediately
• Clear, legible labeling throughout
• Up-to-date wiring diagrams and specifications
• Complete bill of materials and spare parts lists

Testing and Verification

Acceptance Testing:

• Continuity verification of all connections
• Insulation resistance testing where appropriate
• Functional testing under simulated load conditions
• Integration testing with complete robot systems

Periodic Verification:

• Regular inspection schedule based on usage
• Performance monitoring and trending
• Predictive maintenance based on measured parameters
• Proactive replacement of wear items