Overview

Each year we have had problems with having the right set of cables to wire up the projects. If we pick a few to standardize for the few different needs (power and data), we can fill a container with them and be able to more easily adapt to the conditions on the playa.

USB

2013 used Teensy boards connected over their MicroUSB connectors. Over short distances with limited dynamics these worked ok, but over longer distances there were frequent protocol errors that caused the USB port to hang.

In 2014 these were reused on the DEX, but the vibration and stress on the connectors caused all of the MicroUSB jacks to rip off the boards. The jacks are not robust against the dust or pluging,

Screw terminals

These are suitable for higher amperage loads and are fairly easy to adapt on the fly, but are not very fast to connect. Sufficient access for tools is important.

XLR

Readily available and highly robust, but very low density. Only three conductors (plus shield). Field termination requires soldering, but the lugs are large and easy to work. Can be used for power transmission and single-ended data, or with extra hardware and phantom power for differential data.

RJ45 / Cat5

Very cheap and available anywhere, ok density (8 conductors). Pre-made cables are available in any length and color, plus field termination is easy without a soldering iron. Ethernet uses it, which is useful for connecting controllers together up to a few hundred meters.

Thus far they have held up quite well in the dust, despite the small contact area of the pins and the recessed nature of the RJ45. A quick blow with compressed air seems to keep them in good shape.

JST

Commonly used in small electronics projects, good density but poor robustness. Limited strain relief makes them subject to stress failures. Available from online sources, but not in stores.

Molex

The 2013 LED panels were wired with 6-pin pre-terminated Molex connectors. They are frustrating to disconnect and not widely available. They filled with dust and were subject to pins bending while being connected. Not commonly available in stores, although some autoparts shops might carry them.

Power Pole

These are really neat hermaphroditic connectors -- instead of male/female ends, they can plug into themselves. Not weather sealed, but fairly rugged and high current. Must be soldered and only available from Anderson.

Amphenol-style

Official Amphenol connectors are incredibly robust, but expensive and not available outside of specific distributors. Adafruit sells a similar hanging inline four-conductor waterproof connector that is much smaller than a XLR.

Recommendations

• Screw terminals for power, up to 30 amps
• Cat5 for communication, both ethernet and custom data
• USB where necessary, inside of boxes over short runs that will not be exposed to the dust.
• Support daisy chainable wiring when possible.
• Get Monoprice quote for 1000 ethernet cables in orange and different lengths.