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Wiring transmitter pots. - 12/6/2012 4:39 PM   
elitheiceman


 

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Status: offline 		I've had two wires to the aileron pot break. Fortunately, I wasn't flying either time. The pot itself moves through the whole range of motion of the right stick, so the wires flex quite a bit. Both wires broke where they are secured, just before the pot. I want to replace the wiring on both the aileron and rudder pots, but don't know if I should use wire with silicon insulation, which is very flexible, or teflon insulation, which is comparatively stiff. I'm leaning toward the latter, but any suggestions would be appreciated. Thanks

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RE: Wiring transmitter pots. - 12/6/2012 7:24 PM   
warbird72


 

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Status: offline 		try to use the same colors.. and same size.. Multi strand works very well. such as antenna wire.. I go after old electronics when I need wire for these.. Or just servo wire. and twist it.. Should be fine..

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RE: Wiring transmitter pots. - 12/6/2012 7:34 PM   
grotto2



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Status: offline 		What a great question!

It's just my opinion, but I don't think the insulation is that big of a factor.

Instead I imagine the wire you want would be more like servo wire, flexible with a lot of strands per conductor.

Some time ago I was searching for the wire Ace used to sell as servo hookup wire for similar (particularly vintage radio) purposes. You'll find that most off-the-shelf wire doesn't have a lot of strands.
I finally found what I wanted, though, and I'm going to reveal my secret source: It's a microphone cable from New Communications Solutions. http://ncsradio.com/Merchant2/merchant.mvc?Screen=PROD&Store_Code=NCS&Product_Code=NCS-3570
I usually buy this wire in ten or twenty foot sections and strip out the individual wires. The wires are 26 AWG nineteen strand and work great for RC applications.



Finally, the pot wires should be strain-relieved in such a way as to maximize any radius (and thus minimize radius changes).

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RE: Wiring transmitter pots. - 12/6/2012 8:37 PM   
Rodney



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Status: offline 		You want it to be flexible so silicon is the way to go. Pay attention to how you route the wires so that the ensuing movement will have minimum effect on fatigue of the new wire.

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RE: Wiring transmitter pots. - 12/7/2012 5:07 AM   
countilaw



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quote:

ORIGINAL: elitheiceman

I've had two wires to the aileron pot break. Fortunately, I wasn't flying either time. The pot itself moves through the whole range of motion of the right stick, so the wires flex quite a bit. Both wires broke where they are secured, just before the pot. I want to replace the wiring on both the aileron and rudder pots, but don't know if I should use wire with silicon insulation, which is very flexible, or teflon insulation, which is comparatively stiff. I'm leaning toward the latter, but any suggestions would be appreciated. Thanks
[/quote

What radio system is this on?   Surely not   JR or Futaba. 

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RE: Wiring transmitter pots. - 12/7/2012 5:55 AM   
chuckk2


 

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Status: offline 		How exactly did the wires break?
Usually, they break at the solder connection.
The wires may have been "annealed" in the insulation strip and solder process.
If there is enough room, two or even three pieces of flexible shrink tubing can be used
to distribute the flexing across a longer length of wire. Failing that, another way is to use
a non acidic form of "RTV" to achieve a similar result. 


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RE: Wiring transmitter pots. - 12/7/2012 4:03 PM   
elitheiceman


 

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Status: offline 		The wires didn't break at the solder joint. They are routed in a big "S" from the main p.c. board to a small one at the pot, where they pass through, and are glued to a plastic ring, so there is no flexing at the pots. They broke where they are glued to the ring. About half way through the "S", they pass through a plastic tube about an inch long. On the other stick, which had no problem, the wires slide easily through the tube as the stick is moved, but on the one with the problem, the clamp was pinching the tube, preventing the wires from moving, and concentrating the flexing to the pot end of the "S". I'm sure that was the major cause of the problem. But my flying, which consists mainly of chasing the airplane around the sky, banging the sticks from one stop to the other in a panicked, and frequently futile attempt to keep from crashing, certainly contributed to the problem.

Frank, rest easy. It isn't a JR or Futaba.

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RE: Wiring transmitter pots. - 12/7/2012 6:09 PM   
Truckracer


 

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Status: offline 		Sounds like a common problem the Airtronics RDS8000 transmitter has. As suggested above, flexible silicone insulated wires work well for replacements and I just use bulk, twisted servo lead material for replacement. Remove every trace of the glue retaining the wires near the pot and replace the wires following the same route the old wires had. Leave a bit larger loop at the pot end to allow for easier flex. Get someone else to do this if you are not well versed in soldering small connections. Re-secure the wires with something like shoe goo or a similar material where they go through the retainer near the pot.

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RE: Wiring transmitter pots. - 12/11/2012 10:14 PM   
elitheiceman


 

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Status: offline 		Thanks for the suggestions. Went with the silicone servo leads, secured to the pot board with a small ty-wrap I was able to snake around the board and a short piece of heat shrink on the wires.

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RE: Wiring transmitter pots. - 12/11/2012 10:39 PM   
A.T.


 

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quote:

ORIGINAL: elitheiceman     Thanks for the suggestions.
Went with the silicone servo leads, secured to the pot board with a small ty-wrap
I was able to snake around the board and a short piece of heat shrink on the wires.     


Repair should last well
A problem seen with all brands of Tx and another reason the Tx should be opened and have
a seasonal check over for black wire (more so if NiMH batteries are being used)
check of antenna wire security, clean metal extension antenna, lubricate gimbals if dry etc.
- see text & photos attached to:
Futaba - 8U FF8 series - Gimbal Wire breakage  
Sanwa Airtronics - RDS8000 faulty wiring repair.
Sanwa Airtronics - RDS8000 Faulty Tx repair.
JR X9303 2.4GHz Aileron Gimbal Wire Breakage Bulletin

more available below
"Radio Systems, Accessories, Alterations and FAQ" at
Alan's Hobby, Model & RC FAQ Web Links
 
Alan T.



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RE: Wiring transmitter pots. - 1/26/2013 3:13 AM   
jrlingrel


 

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Status: offline 		Use at least 24 AWG multi strand wire with the softest insulation you can find.  I have built several kit transmitters and they all use that.  Also, I have repaired a few and the 26 - 24 AWG works very well.  There is almost no current in those wires, so you should never have to worry about smoking anything

John 

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