Is anyone else having issues with wires falling out of the Rev PDH? I’ve had 10awg motor wire and 4awg power wire fall out while working on the robot. The wire probably had some pressure on it but I wouldn’t expect that to pull it out. I’m using lots of strands flexible silicone wire for the negative power cable (the one that pulled out) and for motor wires. I’ve also had trouble getting the 4awg highly stranded cable to go in to the wago connector without the strands going all over the place. Might be the cause of this issue?
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In my experience I’ve found that the WAGO connecters are fairly reliable if the wire is clamped down properly. Chances are when the wire was put into the connecter it wasn’t pushed in all the way or the connecter wasn’t completely shut. Both of those scenarios have led to unreliable connections on our robot. As for stranded wire control, I’ve found that twisting the strands together helps a lot when trying to insert them into the PDH, but the fact that you’re using stranded gauge wire shouldn’t be the problem.
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We’ve had zero issues, using 6 AWG welding wire for primary loop and 10 AWG for 40A motors. See this post for details.
I have been twisting fairly tightly, seems to work ok for motor wires but 4awg welding cable is still a PITA to get in the holes.
Yea, we have problems with the power wires too. Try stripping them - maybe having fresh ends will help.
@memtech3 has reported to me that the negative power wire (4 AWG) pulled out after I installed it… I need to investigate 
We are having this issue with our supply lines (a large 6AWG) and the Pump power lines (but we may not be using Pneumatics after all). We purchased some non- insulated ferrules for the supply lines and the Pump, and thus far at least the Pump ones are helping.
I know Rev recommends against them, but when you see copper almost shorting, you have to do something.
You will get significantly better clamping if you do not twist the strands.
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Really! We have been twisting all of our wires and they have, for the most part, worked great. I’m intrigued now . . . looks like I know what I’ll be testing this week!
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Why does rev recommend against them?
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So, funny. I think they do recommend them. I cannot find it now (and may be misremembering), but there is another thread on here that talked about wire guage issues, and that came up. However, they do list them in the manual
Power Input Wire Gauge (Stranded, with ferrule) min 18, max 6.
They don’t recommend ferrules for the 4 smaller circuits IIRC.
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