HELP: Voltage Drop

[Al Skierkiewicz]

pujan,
Some of the issue you are seeing is also attributable to the natural electrical loss in the wiring and battery. The internal resistance of a fully charged battery is about 11 mohms. Add to that 2 mohms for the #6 wiring between the battery and the PDP and perhaps another 2-4 mohms for the main breaker and terminals and you are now looking at a minimum series resistance of 17mohms. At 400 amps (typical max draw on a four CIM drive at near stall) that resistance will drop ~6.8 volts. That translates to 5.2 volts measured at the input of the PDP. The dedicated outputs at the end of the PDP intended for use with the RoboRio and VRM may drop out when this drop is worse, such as with higher current draw or a less than fully charged battery.
Gaffers Tape is a generic term for a woven cloth tape ~2" wide. It may be called Colored Duct Tape in your area. It is available at big box stores like HomeDepot and Lowes.