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Wire Use

Wire Gauge

Reasoning

Diameter (Nominal)

Datasheet Image

Datasheet Link

Thermistor

22AWG

  • works with our current microfit crimps

  • getting bulk 22AWG for the rest of the car

1.6mm

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https://www.iewc.com/assets/specsheets/JuddWire%20PCA.pdf

Voltage Monitor

22AWG

  • works with our current microfit crimps

  • getting bulk 22AWG for the rest of the car

1.6mm

Same as above

Same as above

Balance Wires

18AWG

  • To support higher current balancing

  • works with micro-fit crimps

  • Using elsewhere in the car

1.96mm

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https://www.iewc.com/assets/specsheets/Champlain%20EXAR%20150%20UL3266-3398.pdf

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  • Protect the wires from shorts to the underside of the PCB module (the pins for the connectors poke through the board). The pins can be sharp and can rip through the insulation material.

    • Connector pins are highlighted in blue here (this is a view of the underside of the PCB.

      Image RemovedImage Added

  • Provide strain relief - I need to make a confluence page on why this is important

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The area with all 14 wires going through it at the top will be filled with a rubbery glue - to provide some strain relief to the cables.

A note here that probably no one will ever read - For the right angle cable crimps, we should have gone with these ones that support the insulation of the cables as well: https://www.digikey.ca/en/products/detail/te-connectivity-amp-connectors/61481-1/294358. They are $0.10 more expensive each.

Features relevant to Isolation Cover

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