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Originally Posted by mechanicalbrain
I'm planning our general electrical system and I have two quick questions.
First: Ive been playing with running cable along a frame and I have had great success running cable in our frame (Its non metal and has proper stress releases). So my first question is "realistically what effect does excess wire have?" Ignoring weight gain and assuming you had it properly protected from being yanked, does the excess of cable have any real (not in theory) loss to the entire system and has anyone actually experienced such a negative effect. I want to run cable along our frame or in it because we had trouble with cable getting pulled.
Second: Since i wrap everything in a nylon sleeving i can't easily trace wires (nor do i feel the inclination to). I would like to mark the connectors in a way that i can tell what type of component its powering and a abbreviation for the component (ex mtr1 for motor 1). "What do you recommend and what have you seen that is particularly cool?" Ive already seen all the pictures of various systems on CD and i was thinking a colored power connector (if they make some that are aesthetic and not indicative of gauge). of use some type of tape to connect wrap around the wires. Ive heard something about the Inspectors making you remove such tape though and I want to be sure its ok.
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Well, as resistance is a function of length, among other variables, and voltage drop is a function of resistance, longer wires are not a good thing. However, only take this into consideration when thinking about this, as I wouldn't say it eliminates the possibility of doing this. And yes, this does amount to a measurable (not theoretical) difference, epically on 50-70 A going through 6 ga wire for an extra 2 feet or so. You can do some searches to find actual calculations, or google for wire resistance calculations to do the math yourself.
As far as knowing what wires are what, you can get these books of # stickers for wires. We use them on all our PWM cables.
You can get Anderson PowerPoles with different colored housings as well, which would be a good way to differentiate between circuits, as well as providing a better connection than the standard F disconnects.