Compound wires 5 Fitting examples

Wiring - this is probably the most crucial area of ​​work for installation of electrical networks. The higher the load on the site, the higher the requirements for the connection of wires - and therefore need to use the most effective methods, techniques and tools.

We will analyze the most popular ways to connect electrical conductors, paying attention to their advantages and disadvantages. In addition, I will provide examples of the techniques most frequently used in the installation of electricity.

Overview of the main ways to connect

Assembling without additional parts

Wiring the electrical network must comply with a number of requirements:

• reliable mechanical fixation of the two conductors;
• ensuring conduction between the two conductors (The higher the conductivity, the ray);
• Minimization of resistance at the joint portion;
• lack of resistance to growth during continuous operation.

Today, the installation of electric systems use various types of connection cables that allow you to implement the above requirements at different levels. Can classify them in different ways, but for ease of analysis, I will highlight only two large groups: the connection with the use of additional devices and without.

If we need to connect the two wires, and we do not plan to use any other devices (except, of course, insulation), the list of methods will be limited. The wires can be twisted, soldering or welding. This three methods we analyze.

Without the use of special devices mounted conductors as follows:

1. Stranding - the easiest, fastest and cheapest way. The wires are cleaned of isolation, and then twisted together in a spiral, and then re-exposed portions of the conductor are insulated.
   The main disadvantage such a compound is the gradual fall conductivity. contact place eventually oxidized, increasing heat conductor, resulting in reduced reliability of the fixation. The more current in the network, the higher the risk of fire in the place of stranding, the residual current circuit breakers are almost guaranteed not to work.

In today's "Rules for electrical devices" (PUE of 2009, Chapter 2, p. 2.1.21) this method of installation like fixing wires twist absent in principle. If in earlier editions of this method could be applied for joining wires up to 10 mm 2, the increase in the average load on the network by twisting refused. Now it is used only as a stage in the brazed assembly, welding, or other compounds.

1. welding wire - according to the majority of electricians (fully share!), The most reliable method. When welding first twisted conductors to increase the contact area, and then welded together using an alternating current.
   Since copper is very easy to work, but aluminum wires at installation is desirable to use a flux for removing the oxide film from the metal surface. Resistance spot welding is constant and does not increase with time, because land will last a very long time.

1. Soldering - Another very efficient method of mounting connections. When soldering the copper wire is purified by isolation, compounds tinned place, after which the conductors are twisted. Twisted plot propaivaetsya solder and rosin, and the need to try to solder joint without gaps and sagging.

From my point of view, less reliable brazing compared to welding. On the other hand, when installing wiring soldering iron with their hands to find much easier than the welding machine. A margin of safety for domestic use in solder connection is more than enough!

Compound with additional parts

variety of devices may be used to connect wires while maintaining maximum conduction portion. These include both simple sleeve for crimping and complex terminals that let you perform the installation in seconds.

With the help of some parts may be connected wires?

1. Sleeve for crimping. Crimp sleeve - a hollow cylinder made of soft metal. When installing the wires are stripped, are found together, after which they put on the ends of the connecting sleeve. Detail clamped special tool that allows tightly fix the conductors and exclude their displacement relative to each other.

1. Piercing connectors. Taps are used to form the main conductor with the voltage to 660 volts without disturbing its integrity. Contact is provided a clamping platform of galvanized steel, which fits over the stripped portion of the cable and fastened with four screws. Compound wires protected by a dielectric material body (karbolit or analogs).

1. Self-marginalizing (PPE) caps. The popular device that is suitable only for low-voltage circuits. PPE cap - a plastic cone, inside which is a clamping spring. When connecting wires are twisted, and then to twist the cap is screwed. Despite the fact that the spring, in theory, should keep the twist of weakening the contact is not very reliable.

1. Terminal Blocks. Sufficiently sturdy and simple device which consists of a plastic insulating housing, copper contacts with screw fastenings. When connecting wires to the terminal end thereof is trimmed, is inserted into the hole and screw pad is pressed against the contact plate.

The connection quality depends on the state of the terminal block. Some cheap varieties due to thermal expansion of the materials over time weakens the thread, and the contact has to "pull". In other blocks there is a risk of destruction of contact with a strong tightening of the screw.

1. Spring terminals (WAGO and analogues). Used for quick fastening portion: the insulation removed from the wire, the wire inserted in the hole terminals - a spring fixed with its sufficient strength. There are varieties with clamping levers which allow to reliably fix the soft metal conductors - their I use most often.

The main disadvantage in these products - a relatively high price. High-quality self-locking terminal blocks WAGO is from 7 to 25 rubles, depending on the configuration. If these compounds have to do a lot - accumulates decent amount.

A few words of copper and aluminum

Describing techniques electrical installation, it is impossible not to pay attention to such a sensitive issue as the stranding copper and aluminum wires. Probably everyone who has at least remotely related to the field know - joining the material can not be directly.

There are several reasons:

1. Thermal deformation. Aluminum and copper have different coefficients of thermal expansion. This means that when the current they heat in different ways, and different cool down when disconnecting. As a result of periodic on-off lead to loosening of the connection and contact tightness reduction.
2. Oxidation. On eventually formed aluminum surface oxide film, characterized in poor conductivity. As a result, resistance increases and with it the heating.

Yes, both of these factors can be compensated: the first tight clamps, a second application of special lubricants. But let's be honest: who and when to do it when the equipment simple twists?

1. Electroplating. Copper and aluminum - a galvanic pair. This means that when you connect these metals form oxides will disintegrate into ions, though, the higher the humidity in the room, the more the process will go. As a result of the electrolysis of connection reliability will fall - primarily because of the appearance of voids, and later because of the emerging heating.

Flattening into account these arguments, I strongly advise you to connect the copper wire with aluminum without the use of "intermediaries" - terminals, adapters, clamps and other accessories.

Algorithms mounting base compounds

Method 1. Twisting with solder and heat shrink tube

Different ways to connect electrical wires require different approaches. In this section I will provide step by step instructions on the device most commonly used schemes.

Let's start with the simplest - with a twist. Yes, it is not very reliable, but in low-voltage circuits can be successfully applied. And if the solder contact place - use the guides can be just about anywhere.

Illustration	performance technique
	Stripping conductors. Using a special tool or a sharp knife, remove the insulation from the ends of the conductor. We need to expose some 25 mm of wire.
	Preparation of isolation. From the heat-shrinkable tube of the desired diameter is cut off fragment whose length is approximately twice the length of the connected portion. We put on the phone to one of the wires and move in the direction that it did not interfere with us.
	Twisting. Lots conductor, stripped of insulation, are twisted together. When installing single-core conductors, it follows that they are connected spirally, not one wrapped around the other. Stranded wires first "raspushivaem", then weave strands to each other and are twisted in a spiral.
	Soldering. Using the soldering iron on an average heating gently propaivaem compound. When soldering the monitor, so that the solder is uniformly filling the voids between the individual conductors in the twisting.
	Insulation. Thermal insulating tube is shifted by soldered or twisted plot, so that it completely covers it and sets in isolated areas on both sides.
	isolation seal. Using a hair dryer building (better) or an ordinary lighter (worse, but can also be) warm up heat shrinkable tubing as long as its diameter is reduced and it is not obozhmet connection throughout.

Method 2. Installation by pressuring

Conductor connection in the junction box can be made by crimping. To do this we will need a special crimping sleeve and a tool to fix them on the wires.

Installation instructions using crimp sleeves:

Illustration	performance technique
	Removal of total isolation. An incision with a sharp knife on the insulating housing bred in the junction box wires. Remove the insulation and dismantle the wires by color, collecting them in groups. Since work will be much more convenient.
	Stripping conductors. The special tool or a knife remove the insulating layer conductors. It is desirable to remove a little less than it might enter into the crimp sleeve - it will be easier to isolate.
	Donning the liner. Conductors requiring connections to the same group, gather together without twisting. We put on the conductors sleeve, pulling the edge on the island portion.
	Crimping. Using a special tool, perform crimping wires. A sleeve crimped in at least two places, then check the strength of fixing.
	Compound other conductors. Repeat this step for the remaining groups of conductors.
	Insulation. For each group of wires installed crimp sleeve put on heat shrinkable tubing. Warms up for its isolation seal along the entire length.
	Installation of the second isolation circuit. The free ends of heat-shrinkable tubing bends. We put on top of the tube of larger diameter.
	isolation seal. As in the first case, the heat shrink tube warms hairdryer. Shrinking, they will fix the bent ends of the insulation, ensuring maximum tightness.

Method 3. Twisting with welding

The most reliable type of connection without additional parts - welded. It can be used where the contact is exposed place serious stress.

Mount wires in junction boxes by welding can be so:

Illustration	performance technique
	Prepare wires. Lead wire in the junction box, and then remove the outer insulation and dismantle them to the core. We clean the ends of the cores, forming free of insulation sections 50-70 mm. Putting the wires in color, in order to facilitate formation of the twists.
	Formation of twists. All wires of the same color are brought together add up in parallel and bends the edge of approximately 1 cm. Grasp the hook portion, are twisted wire spiral. To improve the reliability and seal stranding the last few turns of doing with a pair of pliers.
	Preparing the welding machine. Welding wire can be virtually any household device - power is enough. Welding is desirable to use graphite (special insert, the brush of the motor, battery rod).
	Welding wire. One clip set on twisting in the upper part, the second jaw with graphite insert perform welding, starting from the bottom of stranding. Thus it is necessary that the compound was not overheated and began to collapse. Carefully boil all connections.

After that, it is sufficient to insulate all the bare portions of the wire. This is done by means of an adhesive tape, heat shrink tubing or special caps.

Method 4. The copper compound and aluminum using screws

Above I noted that joining copper and aluminum can not be directly. Yet sometimes it is necessary to equip a reliable contact of conductors - for example, by "merging" of the old and new wiring.

If we have two single-core wires, then the easiest way to connect them using the clamping screws:

Illustration	performance technique
	Formation of the end rings. We clean the ends of the two conductors of approximately 30-40 mm. Using pliers, do on both wires "ears". The diameter of the ring must advise the diameter of the screw to be used for the connection.
	Installing bolts. In use as a coupling element M4 bolt. On the rod under the bonnet washer put on such a diameter that it completely overlaps the end ring wires. Wire with a ring worn on the bolt so that when tightening the fixing bent part was not disclosed, but on the contrary, even more bent.
	forming compounds. The first wire cover with the second washer of a suitable diameter. Then don on the second wire rod - also with the ring. Cover his third goal, and set top grower (spring washer), which will not spin up the mount.
	Tightening the fastening. Set top nut and tighten fasteners, screws with a screwdriver while holding a hat. When fixing the mount to tighten firmly, but without excessive force, otherwise there is a risk of damaging the soft conductor. This is especially significant for copper stranded wire.
	Insulation. The junction isolate using either tape or shrink tube large diameter. When using the heat-shrinkable tube of its edges is desirable to further secure the left and right of the contact points.

Method 5. Using terminals

The use of different types of terminal blocks can not only attach the wires from copper and aluminum, but also allows you to create collapsible connection.

Apply such details as follows:

Illustration	performance technique
Conventional Terminal Block
	wire stripping. The ends of the wires to be connected we clean. In this case, the insulation should be freed approximately 5-7 mm - this is quite enough for a reliable contact in the terminal block.
	Preparing the terminal block. From the product cut the fragment with the desired number of contacts. Fixing the terminal screws weaken, opening holes for the wires.
	Installation of the first wire. On the one hand in the hole insert the bare ends of the wires, pushing them so that they did not reach the middle. A screwdriver to tighten the fixing screws, clamping the wire inside the shoe.
	Installation of the second wire. Repeat step for the second wire. It follows that within the pads wires do not touch each other.
	Shutdown. Check the reliability of the connection, and then isolate the contact position, protecting it from moisture and dust.
Spring terminal block WAGO 222
	Preparing for installation. Wires intended for mounting, we clean as well as for installation using the terminal block. On the terminal lift lever presser, opening an aperture for installation of the conductor.
	Installing the wire. Conductor inserted into the hole, pushing it until it stops. It follows that the wire is not curled in the device.
	Fixing the conductor. Omit the pressure arm. Wherein the contact plate within the terminal is lifted, clamping the conductor and securely fixing it in the device due to the spring action.

conclusion

Reliable and secure connection of cables can be achieved in different ways. The options listed above, it is enough to perform the most common types of work. If you need additional information - the video will learn in this article or ask a question in the comments!