Wire Splices And ts 6y4l4d

How to Make Electrical Connections Wire Splices, ts and Taps

• Wire must be properly ed or spliced in order that electricity will flow normally in the circuit

ts, Splices, and Taps • t – the tying together of two single wire conductors so that the union will be good both mechanically and electrically • Tap – the connection of the end of one wire to some point along the run of another wire

• Splice – the interlaying of the strands of two stranded conductors so that the union will be good both mechanically and electrically

Mechanically Strong and Electrically Strong • Mechanically Strong means the t must be as strong as a continuous length of wire • The ts will not fall apart easily even if it is not soldered or connected with electrical connectors

• Electrically Strong means it must be as good a conductor as a piece of the same wire with which it is used • Wires are connected (ed or spliced) so you get the electricity either to several locations or to a location a long distance away

Twist VS Turns • Twist - Each wire

is wrapped around the other • Turns - One wire remains straight, the other wire being wrapped around the straight wire

Operations in Making a t, Tap or Splice

1.Removing the insulation 2.Cleaning the conductors 3.Tying, or interlaying 4.Soldering 5.Tape or taping (Insulating)

1. Removing the Insulation • Skinning or Stripping  The first step in making any kind of ts/taps/splices  Wire Stripper  Knife  Side Cutting Pliers • Nick – a small cut in the surface of the conductor when the insulation is removed

 Cut the insulation at an angle of about 30 degrees.  Note: Do not circle the wire with the blade at right angles, because in most cases this produces a groove/nick in the conductor which may: a. cause the latter to break when bent at this point b. Reduce its capacity to carry current .Instead, whittle the insulation away in a manner similar to that of sharpening a pencil

Wire Stripper

Removing the Insulation

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tools mentioned, observe the following precautions: Do not attempt to use a hot-blade stripper on wiring with glass braid or asbestos insulation. These insulators are highly heat resistant. When using the hot-blade stripper, make sure the blades are clean. Clean the blades with a brass wire brush as necessary. Make sure all stripping blades are sharp and free from nicks, dents, and so forth. When using any type of wire stripper, hold the wire perpendicular to the cutting blades. Make sure the insulation is clean-cut with no frayed or ragged edges; trim if necessary. Make sure all insulation is removed from the stripped area. Some types of wire are supplied with a transparent layer between the conductor and the primary

2. Cleaning the Conductors

• The wires must be thoroughly cleaned to insure good electrical between the ends of the wires and so that the solder will adhere properly • The wires maybe cleaned by scraping  Knife - care should be taken to avoid nicking the wire  Sandpaper

3. Tying, or Interlaying

•Depending upon on the types of splices, ts

Types of Wire Splices, ts and Taps

Western Union Short Tie

 Used when the connection must be strong enough to long lengths of heavy, wire. In the past. this splice was used to repair telegraph wires.  If the splice is to be taped,care  should  be   taken  to  eliminate  any  sharp  edges  from the wire ends.

• Western Union Long Tie  The Western Union Long-Tie or telegraph splice, as it is frequently called, is used extensively for outside wiring and is quite similar to the short-tie splice, being used for the same purpose.  The only difference is that a number of long twists are made before wrapping the end turns.  This is claimed to be an advantage because it allows the solder to spread in between the wires more freely.  Five or six long twist and four turns

• Western Union Short Tie  The Western Union t is used more frequently than any other t. It is used in interior wiring in ing two lengths of wire to extend the conductors from outlet to outlet. In outside wiring, it is used extensively.  One twist and four turns

Rat-Tailed t • Used principally in ing conductors in outlet boxes/junction box and for connecting branch circuits • It is satisfactorily if no longitudinal strain is impressed on it • A longitudinal strain would cause to untwist the t • Five or six long twist

Back-Turn t • Used when fixture leads are connected to branch wires at an intermediate point • Useful in connecting two wires that must be drawn taut • Will withstand considerable longitudinal strain.

End Fixture t • Used to connect a smalldiameter wire, such as in a lighting fixture, to a larger diameter wire used in a branch circuit. • Used when a fixture wire, usually No. 18 AWG, is to be ed to a terminating branch conductor, which I most frequently of No. 14 AWG. • Like the rattail t, the fixture t will not stand much strain

Plain Tap or Tee t

• The tap splice is used where you want to a second wire to a conductor • The branch wire is laid behind the main wire. • About three-fourths of the bare portion of the branch wire extends above the main wire. • The branch wire is brought under the main wire, around itself, and then over the main wire to form a knot. • The branch wire is then wrapped around the main conductor in short, tight turns; and the end is trimmed off.

Small Aerial Tap t • Intended for wires subjected to considera ble movemen t • Similar to plain tap except that it has a long easy twist

Knotted Loop Tap t • Used where the splice is subject to strain or slippage. • When there is no strain, the knot may be eliminated.

Ordinary Cross t • The same as plain tap, only it has two tappe d wires

Double-Wrapped Cross-t Used for identically the same reason as the ordinary cross-t, with the advantage of being stronger

Staggering Splices • Also known as Duplex t/Splice • Used in conduit systems where twin wires are used • Could be western union t

Britannia t • Used on overhead lines where considerable tensile strength is required • Also used both for inside and outside wiring where single conductors of sizes No. 6 or larger is used

Scarfed t Used on large wires where appearance and compactness are the main consideration s and where the t is not subject to any heavy tensile stress

Wrapped Tap Used on wires too large to wrap around the round wire

4. Soldering • The act or process of forming ts upon or between metallic surfaces, by means of a fusible alloy or solder, whose melting point is lower than that of the metals to be united • Solder – is a name for any fusible alloy used to unite different metal parts • Flux – is a substance applied to a metal to make solder flow easily • Soldering can be done with the aid of a soldering iron, soldering gun or a torch

Requirements for Good Soldering 1.Absolutely clean conductors 2.Careful use of flux 3.Clean soldering tool 4.Correct temperature of soldering tool 5.Proper solder

• Approximate Soldering Iron Size for Tinning • A B • #20 - #16 65 Watts • #14 & #12 100 Watts • #10 & #8 20 Watts  A. Wire Size (AWG)  B. Soldering Iron Size (Heat Capacity)

5. Reinsulating the t • To complete the various ts, taps and splices, the expose wires must be insulated • Taping  is  required  to  protect  the  splice  from oxidation (formation of rust) and to insulate against electrical shock. Taping should provide at least as much insulation and mechanical protection for the splice as the original covering. • Although one wrap of plastic (vinyl) tape will provide insulation protection up to 600 volts, several wraps may be necessary to provide good mechanical protection. • When plastic tape is used, it should be stretched as it is applied. Stretching will secure the tape more firmly.

Rubber Tape • • • • • • • • • • •

Latex (rubber) tape is a splicing compound. It is used where the original insulation was rubber. The tape is applied to the splice with a light tension so that each layer presses tightly against the one beneath it. This pressure causes the rubber tape to blend into a solid mass. Upon completion, insulation similar to the original is restored. In roll form, there is a layer of paper or treated cloth between each layer of rubber tape. This layer prevents the latex from fusing while still on the roll. The paper or cloth is peeled off and discarded before the tape is applied to the splice. The rubber splicing tape should be applied smoothly and under tension so no air space exists between the layers. Start the first layer near the middle of the t instead of the end. The diameter of the completed insulated t should be somewhat greater than the overall diameter of the original wire,

Rubber Tapes

Friction Tape • • • • • • • • • • •

Putting rubber tape over the splice means that the insulation has been restored to a great degree. It is also necessary to restore the protective covering. Friction tape is used for this purpose. It also provides a minor degree of electrical insulation. Friction tape is a cotton cloth that has been treated with a sticky rubber compound. It comes in rolls similar to rubber tape except that no paper or cloth separator is used. Friction tape is applied like rubber tape; however, it does not stretch. The friction tape should be started slightly back on the original insulation. Wind the tape so that each turn overlaps the one before it. Extend the tape over onto the insulation at the other end of the splice. From this point, a second layer is wound back along the splice until the original starting point is reached.

Friction Tapes

Plastic Electrical Tape • Plastic electrical tape has come into wide use in recent years. • It has certain advantages over rubber and friction tape. • For example, it can withstand higher voltages for a given thickness. • Single thin layers of certain plastic tape will withstand several thousand volts without breaking down. • However, to provide an extra margin of safety, several layers are usually wound over the splice. • The extra layers of thin tape add very little bulk. • The additional layers of plastic tape provide the added protection normally furnished by friction tape. • Plastic electrical tape usually has a certain amount of stretch so that it easily conforms to the contour of the splice.

Plastic Electrical Tape

Steps in Taping

SPLICES

Running Butt Splice • Relates to splices formed by butting together the ends of two cable lengths to extend the run or length of a circuit as distinguished as tap splices • According to the method of wrapping the strands, running butt splices are classified as:  Single Wrapped  Multiple Wrapped

Single Wrapped Splice • Used for large wire (no.6 or larger) because it is easier to wrap a single wire at a turn than to wrapped a them all at once

Single Wrapped Splice

Multiple Wrapped splice • This method is used generally on small cables because the strands are flexible and all can be wrapped in one operation

Tap Splices • These are made when the end of one stranded conductor is to be connected at some point along the run of another stranded conductor  Ordinary Tap Splice  Split Tap Splice  Y Split Splice

Ordinary Tap Splice

Split Tap Splice

Y Split Splice

WIRE CONNECTORS and LUGS

 Electrical Connector • An is an electro-mechanical device for ing  electrical circuits as an interface using a mechanical assembly. • The connection may be temporary, as for portable equipment, require a tool for assembly and removal, or serve as a permanent electrical t between two wires or devices. • There are hundreds of types of electrical connectors. Connectors may two lengths of flexible copper wire  or cable, or connect a wire or cable or optical interface to an electrical terminal. •  Cable glands, known as cable connectors in the U.S., connect wires to devices mechanically rather than electrically and are distinct from quick-disconnects performing the latter.

Electrical Connector • Electrical connectors can be insulated or not insulated and come in various types of insulation. • The non insulated electric connector is usually bare copper that has a tin plating. • Insulated terminals can come in PVC insulated, nylon insulated and heat shrink insulated. The PVC insulated type are usually the cheapest and most common. PVC tends to be a harder insulation and can crack when crimped and for this reason I do non recommend using them. Nylon insulation is a softer insulation and will not crack when the terminal is crimped. The nylon insulation will also withstand higher temperatures. Heat shrink insulated terminals and connectors are great for applications where the terminal is uncovered to outside elements such as high temperatures, rain, snow, and underwater applications.

• A device that s electric conductors mechanically and electrically to other conductors and to the terminals of apparatus and equipment. The term covers a wide range of devices designed, for example, to connect small conductors employed in communication circuits, or at the other extreme, large cables and bus-bars. • Electrical connectors are applied to conductors in a variety of ways. Soldered connectors have a tube or hole of approximately the same diameter as the conductor. The conductor and connector are heated, the conductor inserted, and solder flowed into the t until it is filled. Solderless connectors are applied by clamping the conductor or conductors in a bolted assembly or by staking or crimping under great mechanical force.

Properties of Electrical Connectors • Electrical connectors are characterized by their pinout and physical construction, size, resistance, insulation between pins, ruggedness and resistance to vibration, resistance to entry of water or other contaminants, resistance to pressure, reliability, lifetime (number of connect/disconnect operations before failure), and ease of connecting and disconnecting. • They may be keyed to prevent insertion in the wrong orientation, connecting the wrong pins to each other, and have locking mechanisms to ensure that they are fully inserted and cannot work loose or fall out. Some connectors are designed such that certain pins make before others when inserted, and break first on disconnection; this protects circuits typically in  connectors that apply power , e.g. connecting safety ground first, and sequencing connections properly in hot swapping applications. • It is usually desirable for a connector to be easy to identify visually, rapid to assemble, require only simple tooling, and be inexpensive. In some cases an equipment manufacturer might choose a connector specifically because it is not compatible with those from other sources, allowing control of what may be connected. No single connector has all the ideal properties; the proliferation of types is a reflection of differing requirements.

PEC Definition • Connector is a device that establishes a connection between two or more conductors or between one or more conductors and terminal by means of mechanical pressure and without the use of solder • Solderless Connector • Pressure Connector

Types of Electrical Connectors

Wire Nut • A type of single point connector • Device commonly used to replace the rat-tail t splice. • The wire nut is housed in plastic insulating material. • To use the wire nut, place the two stripped conductors into the wire nut and twist the nut. • In so doing, this will form a splice like the rattail t and insulate itself by drawing the wire insulation into the wire nut insulation. • Twist-on wire connectors are also known as wire nuts or cone or thimble connector

Wire connectors come in different colors. The color indicates the size of the wire that they are capable of holding secure. The following chart will help explain what color wire connector is capable of holding what size wire.

Wire Nut Colors and Wire Sizes Big Blue #10 and Larger Gray #14 and Larger Red #14 and larger Big Tan #14 and larger Yellow #18 and larger Big Orange #18 to #14 Little Orange #22 and to #14 Little Blue #22 to #16

Terminal Blocks • A simple type of electrical connector that connects two or more wires to a single connection point • Also called terminal boards or strips which provide a convenient means of connecting individual electrical wires • They are usually used to connect wiring among various items of equipment within an enclosure or to make connections among individually enclosed items • Since terminal blocks are readily available for a wide range of wire sizes and terminal quantity, they are one of the most flexible types of electrical connector available • Some disadvantages are that connecting wires is more difficult than simply plugging in a cable and the terminals are generally not very well protected from with persons or foreign conducting materials. • One type of terminal block accepts wires that are prepared only by removing (stripping) a short length of insulation from the end. • Another type accepts wires that have ring or spade terminal lugs crimped onto the wires.

Component and Device Connectors • Transistor switch module with large screw connectors and small crimped-on "Fast-on" connectors • Electrical and electronic components and devices sometimes have plug and socket connectors or terminal blocks, but individual screw terminals and fast-on or quick-disconnect terminals are more common. • Small components have bare lead wires for soldering. They are manufactured using casting.

Blade Connector • A type of single wire connection using a flat conductive blade which is inserted into a blade receptacle. • Usually both blade connector and blade receptacle have wires attached to them either through soldering of the wire to the blade or crimping of the blade to the wire • In some cases the blade is an integral manufactured part of a component (such as a switch or a speaker unit), and a blade receptacle is pushed onto the blade to form a connection • A common type of blade connector come in male and female types

Blade connectors (lower half of photo). Ring and spade terminals (upper half).

Ring and Spade Terminals • Ring terminals are used to connect the wire to a stud point like a screw for earthing or similar. • Spade terminals can be used like ring terminals but the nice thing about the spade terminal or fork terminals is that the stud does open to connect to it. The spade can slide around the stud for a connection. • Ring style wire end blade connectors are normally sold in lots. • Electrical is made by ing a screw or bolt through them. • The spade terminal form factor facilitates connections since the screw or bolt can be left partially screwed in as the spade terminal is removed or attached. • Their sizes can be determined by the size of the conducting wire and/or the Screw/Bolt diameter size designation.

Crimp Connectors • Crimp connectors are typically used to terminate stranded wire. • They fulfill numerous uses, including allowing the wires to be easily terminated to screw terminals, fast-on / quickdisconnect / spade-foot type terminals, wire splices, various combinations of these. • Crimp-on terminals are attached by inserting the stripped end of a stranded wire into a portion of the terminal, which is then mechanically deformed / compressed (crimped) tightly around the wire. • The crimping is accomplished with a special  crimping pliers. • A key idea behind crimped connectors is that the finished connection is gas-tight. • Crimped connections fulfill similar roles, and may be thought of similarly to, soldered connections.

Crimp Connectors • Crimp. The physical compression (deformation) of a barrel around a conductor to make an electrical and mechanical connection to the conductor. • Crimping. A method of mechanically compressing or securing a terminal, splice, or to a conductor

Crimp Connectors • There are complex considerations for determining which type is appropriate - crimp connections are sometimes preferred for these reasons:  Easier, cheaper, and/or faster to reproduce reliable connections in large-scale production  Fewer dangerous, toxic and/or harmful processes involved in achieving the connection (soldered connections require aggressive cleaning, high heat, and possibly toxic solders)  Potentially superior mechanical characteristics due to strain relief and lack of solder wicking.

Terminal Lug • A device attached to a conductor to permit connection to a terminal. • A terminal designed to be affixed, usually at one end, to a post, stud, chassis, or the like for mounting. • It has provisions for attachment of wires or similar electrical conductors in order to establish an electrical connection and could require the use of tools for attachment of wire. 

Terminal Lug • A terminal may be attached to a wire by a number of methods including screw-on, press-on or crimp-on [which is shown below]. Selection is based on two main criteria ; the wire size the barrel is designed to accept [ AWG], and the tongue with will fit a particular stud size. The barrel may be insulated [Type 2] or non-insulated [Type 1]. Normally both insulated or noninsulated should have the wire crimped on, but in some cases the non-insulated lugs may be soldered.

Split Bolt Connector • Split-bolt connectors are a compact construction widely used for splices and taps in building wiring. • The bolt-shape casting has a wide and deep slot  lengthwise. The conductors are inserted in the slot and the nut is drawn up, clamping the conductors together inside the bolt

Split Bolt Connector

Multiple Conductor Connector Multiple conductor connectors provide preinsulated connection for various sizes of wire.