How to crimp wires

Wire crimping: choice of tool, advantages and disadvantages of the method, common mistakes

Every homeowner, car owner and garage owner sooner or later is concerned with the issue of connecting wires. There are several methods; the performance and durability of the equipment will depend on the one chosen. One of the simplest reliable methods is wire crimping.

The essence of the method and advantages

Most experts recommend using crimping as the main and only method of connecting wires.

Wire crimping is a method of connecting them using special sleeves. Visually they resemble ordinary tubes. The main task is to play the role of a connecting mechanism.

The wire strands that need to be connected are inserted all the way on both sides of the sleeve and crimped with special press pliers. The result is a reliable and durable electrical assembly.

The tube needs to be compressed in several places, depending on the cross-section of the switched conductors and the length of the cores. The connected sleeve with the conductors is also subject to deformation.

Due to compression, the conductors adhere, which ensures reliable electrical contact. Finally, you must insulate the connection point.

Sleeves for crimping wires

The crimping method is most in demand in the following cases:

• if necessary, connect wires with a large cross-sectional area;
• for connecting multi-core conductors;
• if there is a need to connect wires in power lines with a high current load.

Advantages of the method:

• The tool designed for crimping sleeves is used without electricity. In rooms where there is no voltage, crimping is the only connection method.
• Such a connection does not require maintenance throughout its entire operational life.
• Using sleeves, you can connect conductors made of different metals. One of the most common problems faced by electrical installers is connecting copper and aluminum conductors.
• The quality of the connection is at a high level, the amount of time spent is minimal.
• A special crimping tool allows you to connect wires even in very limited spaces, for example, in a box or electrical outlet.

Even a person without experience and skills in this field can crimp the sleeve, unlike other connection methods. For example, when soldering you need to know how to use a soldering iron and solder.

What is the joining process?

The use of terminals allows you to create reliable contact

Before starting work, you need to purchase couplings that match the diameter of the wire. This figure should be exactly 2 times the diameter together with the insulating layer.

There are two types of couplings - simple and with complicated insulation. The former have a single layer of plastic, the latter are equipped with a layer of heat shrink on the surface and inside with a layer of glue and sealant.

It is worth taking a responsible approach to the choice of tool – press jaws. The best option is a modification equipped with a ratchet for fixation, which greatly simplifies the process of working with bare and insulated conductors.

Work begins by cutting the wire with wire cutters. Next, it is important to clear them of insulation to a length equal to 0.5 times the length of the sleeve. If several wires are connected on one side, first twist them. Next, the sleeve is put on and carefully healed with pliers. If heat shrink was included in the kit, put it on before crimping.

One side of the pliers is equipped with an oval sponge, and the other with the same sponges, only larger sizes. The smaller side is intended for clamping the wire insulation in the sleeve, and the second is for fixing the metal coupling.

The process of crimping wires using press pliers and lugs

To make a reliable connection, the pliers crimp the sleeve first on one side and then on the other. Next, heat shrink is installed and processed by fire from one side to the other. If the wires are connected on one side, heat shrink is applied in advance.

Other connection methods, their advantages and disadvantages

The most common method after crimping wires is soldering. It still occupies a leading position in electronics because it has high mechanical strength. Among the disadvantages, it is worth noting that in a humid environment and places with large temperature differences, this connection method is not suitable.

Another well-known method is twisting. The main advantage of the method lies in its implementation - a minimal set of tools is required. When connected, the conductors remain intact. To twist the wires, you only need to clear small sections of them from the insulating layer. Dismantling the connection should also not raise any questions. The only difficulty that may arise at the work stage is the small contact area, as well as the low reliability of the connection.

The wire crimp connector combines the advantages of all methods.

Typical mistakes when crimping wires

Errors when crimping wires

Despite the fact that crimping wires is not difficult, people make common mistakes during installation.

• The use of a sleeve whose dimensions are the same or smaller than the cross-section of the wire. In this case, you will need to cut off part of the wire, which will negatively affect the durability and reliability of the connection. This also leads to a decrease in the resistance and capacity of the traumatic section of the chain.
• Crimping a sleeve using tools not intended for this purpose. To ensure a high-quality connection, special pliers must be used; other tools will not be able to provide the desired effect. Pliers and a hammer damage the structure of the tips, which again negatively affects the durability and performance of the wire.
• Another common mistake in crimping wires is cutting the sleeve to save money. In such sections of the chain, increased resistance and deformation of the geometry of the tips are observed. The strength and reliability of the connection leaves much to be desired.
• Using oversized sleeves. This approach will also not be successful. Even slight bending will immediately reduce the strength of the connection.

In conclusion, it is definitely worth mentioning the observance of personal safety precautions. Electrical devices and live wires are a potential threat not only to health, but also to human life.

Source: https://StrojDvor.ru/elektrosnabzhenie/kak-obzhimat-provoda-nakonechnikami-vtulkami-i-gidravlicheskimi-kleshhami/

How to crimp an Internet cable with your own hands, video

If the Internet cable connector is broken, there is no need to call a technician to replace it. You can crimp everything yourself, just follow the instructions in this manual. It is suitable for any network equipment that uses twisted pair cable - the most common and cheapest. With proper dexterity, such a connection is made in 5 minutes; even a beginner, with absolute leisureliness, needs no more than 30 minutes.

Materials and tools for work

You will need a twisted pair cable and an 8P8C (RJ-45) connector. An insulating cap can be purchased for each connector. It is advisable to have a tester and special crimping pliers - crimper. However, you can do it without such a tool, only the process will take a little longer, but then you definitely can’t do without a knife and a flat-slotted screwdriver. Its tip should be small - 10-15 millimeters in length.

Twisted pair internet cable

The first modification of twisted pair cable was used in telephone networks; it is designated category CAT1. Any category from the fifth (CAT5) and above is relevant. The name of this wired connection comes from the fact that there are several pairs of wires inside the thick cable, and in each pair 2 cables are intertwined. This reduces signal transmission interference, which allows you to achieve a data transfer rate of at least 100 Mbit/s.

If there is a question of purchasing a new cable, then proceed from the following positions:

1. The higher the category (CAT), the faster and more reliable the data transfer. This is achieved through shielding - covering individual pairs and even wires with a sheath, as well as increasing the number of turns in a pair of wires. All these manipulations are done to protect against electromagnetic interference. In practice, the category CAT5e is most often purchased - the optimal ratio of price and quality.
2. Twisted pair cables have a limited length. This is a key disadvantage of this type of communication. High-quality connection is not guaranteed at a distance of more than 100 meters. Cables of advanced categories in this regard differ from simple fifth category in that they have relatively high speed over a short distance. For example, in CAT7a up to 100 Gbit/s at a distance of up to 15 meters, while in CAT5e up to 1 Gbit/s.
3. A standard wire contains 8 cores. However, there are cheaper options with four cores; they have a lower data transfer speed. The difference between them in the crimping scheme will be discussed in the corresponding block of the article.

Connector

The twisted pair network connector is correctly designated 8P8C, although the much more common name is RJ45. This connector is simple and cheap, so it’s better to immediately buy several pieces in reserve.

In total, it has 8 contacts for a metal core, which are mechanically fixed.

That is, wires are inserted into the contact sockets of the new 8P8C in the correct sequence, and then the connector body is compressed and a stable structure is obtained in which nothing hangs loose. Each groove has its own number.

It is necessary to understand the numbering of contacts if a four-core wire is to be crimped; for the more common eight-core wires, this is not so critical.

Crimping tool

The crimper is a fairly simple tool. The main function is to create equal pressure on the entire connector. In addition, crimping pliers may also contain cutters (built-in blade, press), which quickly cut the wire or strip its outer sheath.

With a crimper everything will be easier, but this does not guarantee the quality of the crimp. The main factor is human hands, because you can even crimp the connector with your teeth.

Instructions for crimping twisted pair cables

First, cut the twisted pair cable at a right angle. All wires should be at the same level so that none of them protrude beyond it. Next, remove the outer shell to a length of 2-3 centimeters (more is possible). It is convenient to do this with a breaking thread - most cables have a nylon thread inside. It is enough to pull it firmly so that the insulation is easily removed and the wires inside are not damaged.

Divide the wires in pairs by color - like to like, one to one. Most likely you will have an eight-core wire, that is, there should be 4 pairs of the same color wires. After this, cut them evenly so that there is 1.3 centimeters from the outer insulation layer to the end of the core. This is important so that when crimping, the outer shell is also fixed and not dangling, which certainly will not add reliability to the structure.

After these preparations, proceed as follows:

• Decide on a crimping scheme - direct is preferable, but for details it’s worth reading the corresponding block of the article, which is just below.
• Carefully insert the wires into the connector according to the selected pattern. One track is intended for only one core, no twisting is allowed, the cores must lie freely in their own groove until they stop.
• Make sure that the outer insulation of the twisted pair is also inside the connector; if not, then shorten the part of the cable without the sheath.
• Carefully insert the connector into the corresponding socket of the crimper and squeeze its handles. There is no need to put in any special effort, the main thing is that the handles reach the stop; squeezing harder is useless.
• Don't forget to put the cap on the connector.

If it doesn't work out the first time, it's okay. A crimped cable becomes uncrimped in a second if you cut off the connector from it.

Network cable crimping diagrams

3 types are used:

• straight;
• cross;
• cantilevered.

Initially, a straight cable was used to connect heterogeneous network devices (router-PC), and the other two for homogeneous devices (router-router, PC-PC). That is, in the past it was necessary to use a suitable scheme.

Today, not only computers, but also simple devices, such as a household router, automatically determine which crimping scheme is used.

Therefore, it is most rational to do crimping for an eight-core wire in a straight line, just follow the color sequence.

If you have a wire with 4 cores, then this does not fundamentally change the circuit, except that the connection is made for the following grooves of the connector: 1, 2, 3, 6.

Crimping a connector without pressing pliers

How to crimp an Internet cable if there is no crimper? This procedure is completely simple and is performed according to the following algorithm:

• Everything is done in the same way as previously described. You should have a cable in your hands, the cores of which are correctly installed in the connector tracks.
• The connector is carefully placed on a flat surface with the latch down, the main thing is that it is fixed.
• On one of its edges you will see yellow latches in the depths - successively push them towards the core so that they touch and the core insulation layer does not interfere.
• Without turning the connector over, press it on the opposite side, where there will be a small slot. As a result, the entire twisted pair should be fixed by pressing the outer sheath of the cable with the plastic latch of the connector.

Let's summarize the instructions and highlight the key nuances:

1. Don't think too much about your cable choice. In most cases, the capabilities of mass-produced products are more than enough. Expensive cables are usually used for specific communication purposes.
2. Follow the color scheme for placing individual cores. You just need to carefully repeat what is indicated in the picture.
3. The connector lock should secure the cable without external insulation. Otherwise, there is a high probability that the crimping will need to be repeated after some time due to damage to the old one.
4. The ends of one cable must be connected in the same way. It is prohibited to use a direct crimping pattern at one end and a cross pattern at the other.
5. It is advisable to check the results of the work with a tester. Both ends of the cable are inserted into this device, after which a signal is passed through it. Of course, if the Internet still works after everything, then OK. However, in case of any problems, the tester will immediately display which core or pair has the problem - this significantly speeds up the repair procedure.
6. If there is no crimper, then perform the procedure slowly. It’s better to carefully do everything with one connector in 20 minutes than in turmoil in 40 minutes, ruining many connectors and even more nerves.

Source: https://CompMastera.net/remont-computer/obzhat-internet-kabel/

How to terminate a wire with a ferrule?

To terminate the cores of wires and cables, a special tool in the form of press pliers is used. It is not difficult to terminate a conductor yourself; it is much more important to choose the right cable lug. Next, we will provide a technique that will allow you to easily cope with crimping both stranded and single-wire wires, both aluminum and copper, and at the same time small and large cross-sections.

It is important to know

The first thing I would like to talk about is the importance of terminating wires and cables with a special tool and why it is generally necessary to crimp conductors with lugs. Surely you paid attention to how the grounding bus is connected to the housing of the distribution panel. The yellow-green wire is attached on both sides with a screw connection through a special tip, as shown in the photo below.

Not so long ago, instead of such a tip, the core was simply bent into a ring using pliers and tightened with a screw. Some would-be electricians simply inserted a core between the screw and the plate and carefully clamped it with a screwdriver. Doing this is strictly prohibited.

Because with this method of terminating the conductors, the transition resistance increases, as a result of which you can see melted cable insulation, which can lead to a short circuit in the wiring or more serious consequences - a fire in the house.

Another very unfavorable consequence of improper fastening of the cores is burnout of the zero at high current loads. You can find out about the consequences of burning out the neutral wire in the corresponding article!

Termination technology

Terminating a wire or cable yourself with a special tool will not present any difficulties. You just need to take a suitable tip, push it onto the core as far as it will go and press it with a press. In this case, the number of crimping points depends on the design of the crimping tool.

If crimping is performed using a matrix with point contact, press the tips in 2 or more places distributed along the length. If the part of the tip being crimped is comparable to the width of the indentation after crimping, then one point is enough. The sleeves are crimped with at least two indentations, one on each side to hold each of the conductors.

In general, the number of crimping points depends on the width of the “jaws” of the crimping tool matrix.

This is necessary for better contact, minimal contact resistance and mechanical strength. In simple words, in this case the conductor will not jump out of the tip or sleeve.

Pay attention to the recommendations given in the instructions or appendix to the crimper (crimp, press tongs) regarding working with tips of different diameters or cross-sections.

The rules and technology for terminating and crimping cores are described in the following documents:

In addition, an important requirement should be noted: to crimp an aluminum conductor, you must additionally use quartz-vaseline lubricant, which prevents the formation of an oxide film that impairs contact.

At home, it is not always wise to buy an expensive crimping tool, so there are alternative options. For example, there is a special tool for removing insulation from wires and cables - a stripper, the design of which may include a press, as shown in the photo.

You can also do without the so-called pliers - manually flatten the sleeve with a hammer or pliers, but in this case there is no guarantee of good contact, so it is better to spend at least on a stripper for reliable termination of the cores, or even better, a crimper (special crimp). We talked about how to use the stripper in a separate article.

Please note that if you decide to terminate a single-core conductor using pliers, you must select the correct crimping die. If selected incorrectly, there is a high probability of damaging the sleeve or tip by simply tearing its metal.

In addition, there are special tips for soldering. In this case, the termination of wire or power cable cores occurs in two stages:

1. The core, stripped to a metallic shine and treated with neutral solder, is inserted into the tip until it stops.
2. Solder is poured through a special hole.

instructions for using the press

Briefly about tips

Well, the last thing I would like to talk about is what kind of lugs you can use to terminate wires and cables at home. Today, the following termination products are popular in industry and everyday life:

• TM – copper, uncoated;
• TML – copper, electrolytic tinned;
• TML (o) – there is additionally a control window that allows you to visually determine whether the core has completely entered the tip;
• TAM – aluminum-copper, allow you to safely attach an aluminum conductor to a copper busbar;
• TA – aluminum;
• PM – copper, for soldering;
• NShP – pin type, used for connecting circuit breakers and other protective automatic equipment of the latest models using a crimped pin;
• NB - tips with shear bolts, allow you to perform crimping by tightening the bolt, as a result of which you tear off its head. After this, it will not be possible to unscrew the bolts, but the termination of the cores will turn out to be of sufficient quality.

So we have listed the most popular types of lugs that allow you to terminate a conductor for safe connection to buses and electrical appliances. It should be noted that connection using crimping is permitted in PUE 2.1.21 (Chapter 2.

1 PUE), as opposed to twists! One of the most important points is the correct choice of tip or sleeve for the cross-section of the conductor. If the tip is too large, you will not be able to achieve good contact; if it is too small, the core simply will not fit into it.

Also, do not crimp large ferrules with significantly smaller dies! And crimping with too large a tool will not ensure reliable contact.

When choosing tips, pay attention to their markings, which look like this:

TM (for example)-XX-YY, where:

• XX – conductor cross-section for crimping;
• YY – diameter of the hole for the clamping bolt.

Also read:

Source: https://samelectrik.ru/kak-okoncevat-provod-nakonechnikom.html

Order of wires when crimping a network cable

Twisted pair cables are used when connecting several computers into a local network. To begin with, the cable is cut into pieces of the required length, after which the ends of the pieces are equipped with RJ-45 connectors, which will be inserted into the sockets of hubs and network adapters.

Soldering is not required to secure the connector to the cable; it is secured by mechanical crimping using a special tool. The connector is fixed when attached and cannot be removed without damaging it.

The cable consists of eight wires, which must be connected in a certain order to the contacts of the RJ-45 connector. You can use the cable to connect two computers together, or to connect a computer to a hub. For each of these cases, there is a different order of connecting wires to the contacts of the connectors.

When crimping a network cable, it is important to know the correct location of the wires by color and understand the crimping principle itself. A twisted pair is eight wires intertwined with each other, enclosed in a dense sheath. Actually, the name “twisted pair” comes from pairs of intertwined wires. This technology is used to minimize interference during the passage of an electrical signal. The cable is crimped with a special tool - pressing pliers.

The cost of these pliers ranges from 500 to 700 rubles, but you shouldn’t buy them for one use - it’s better to ask your friends, and if you’re going to crimp cables all the time, then it’s better to buy an expensive, high-quality model. You will also need connectors; it is better to buy them with a reserve, because it is not always possible to crimp them the first time.

When crimping the cable, proceed in the following sequence:

Strip a centimeter off the end of the cable you are going to crimp.

Then unravel the wires and straighten them. After which the wires are arranged according to color. Remember that if you connect the cable to a switch, hub or router, use the standard RJ45 EIA/TIA-568B pinout. Sort the wires by color, straighten them using wire cutters and insert them into the connector all the way, the colors should be in this order: orange-white, orange, white-green, blue, white-blue, green, brown-white, brown.

Then you insert the connector into the press pliers and squeeze the handles, crimping the cable. This will allow you to push the contacts into the wires and securely fix the wire with plastic fasteners. Repeat the same operations for the other end of the cable.

If you want to connect two computers without a hub, then cross-crimping is necessary, that is, the internal and external pairs must be crossed.

Each wire must be crimped so that it reaches the stop and is firmly fixed with plastic holders.

When you complete all the described operations and insert the connector into the connector of the network card, the LEDs on it will blink. This means that you have a local network and the Internet, and you can download programs and movies.

After this, you should insert the connector into the crimp into the corresponding hole and squeeze the handle. As a result, metal contacts are driven into the wire, and plastic fasteners securely grip the wire. As a result, on one side of the wire it should look like this:

If there is a need to connect another computer to another computer without using hubs, you should use cross crimping. In this case, the color order should look like this:

How to crimp a cable (twisted pair) for the network and the Internet

RJ 45 or “Twisted Pair” is a type of wire consisting of four or eight thin wires twisted in pairs. This type of cable is used to connect computers into a local network or connect to the Internet . In some cases, twisted pair cables can be used to connect some peripheral devices (such as printers) to a computer.

Despite the presence of more advanced and high-quality technologies ( optical fiber, wireless communication channels), twisted pair cables are still used due to the low price of cable and related equipment (network cards, routers), as well as the high ease of deployment of a local network and protection from external interference

How to crimp a cable with an RJ 45 connector

Before you start crimping, you need to prepare all the necessary tools. In addition to the cable, you will need : crimping pliers and special RJ 45 connectors .

to remove from the wire arrange in the correct order (depending on the crimping pattern) . Having positioned all the wires inside the connector, you need to check their correct placement and crimp the cable using pre-prepared pliers.

Crimping schemes

The direct scheme is used to connect different types of network devices (for example, a computer and a router), as well as to combine two hubs or routers into one local network. This crimping scheme is the most commonly used in local networks.

The crimping procedure for an eight-core cable used in gigabit LANs is as follows:

In twisted pair cable used in local networks operating at a speed of 100 Mbit/s . The following direct crimping order is used:

A crossover (reverse) circuit is needed to connect two computers directly . without using hubs or switches. Gigabit crossover twisted pair cable is crimped as follows:

Reverse wire diagram for a local network operating at a speed of 100 Mbit/s .

Determining screen resolution

To connect other devices, such as network printers, IP cameras and other similar devices, the crimping diagram is usually written in the instructions for the connected equipment.

Crimping a two-pair cable

In order to connect two devices a two-pair is used . Those. one cable branches at both ends and is crimped with two connectors.

The diagram below shows the principle of crimping in this way. Two pairs are inserted into one connector (use 1, 2, 3, 6), the remaining pairs are inserted into the second connector (use 4, 5, 7, respectively).

A two-pair RJ 45 cannot be used in gigabit networks or for cross- crimping (they will require all eight cores). In the direct scheme, everything is quite standard.

How to extend the cable

Not in all cases, the available twisted pair is enough to connect the necessary devices. In this case, it may be necessary to extend the wire in some way in order to lengthen it.

The easiest way to extend the cable is to use a special joyner . This device is a regular adapter from one RJ-45 connector to another. To connect, you will need two pre-crimped wires and the joyner itself.

The advantages of this method of wire extension: ease of connecting all elements, low cost . fairly high reliability (there is simply nothing to break).

Flaws . There may be slight losses in connection stability and speed; not all the necessary tools may be at hand.

For the best quality cable extension, it is better to use a router . This will allow you to get the highest quality and stable connection without any signal loss and reduction in network speed. Using this cable extension method, on the contrary, increases signal stability and reduces packet loss.

The disadvantages of this connection method include the fairly high price (you will need to purchase a router). Also, do not forget that to connect you will need an outlet or the use of POE (power supply via twisted pair), in addition, the router may break down at the most inopportune moment.

Netgear router - how to set it up

strictly not recommended to use twisting . Even if you twist the wires perfectly, you will not be able to avoid signal loss and many other problems with this cable extension method.

The only advantage of twisting is its price - it’s practically free . Otherwise, this method of extending the wire is no good.

Twisting can only be used as a temporary option when the necessary tools or equipment for something better are not at hand. In this case, you should adhere to the following recommendations :

• It is advisable not to use twisting with wires made of different metals (for example, connecting aluminum and copper wires in this way). This will lead to strong heating and oxidation of the metal, as well as other undesirable problems;
• It is better to carefully isolate . this will at least slightly protect the connections from external interference and other difficulties.

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Source: https://it-radar.ru/poryadok-provodov-pri-obzhimke-setevogo-kabelya.html

How to crimp an RJ-45 plug onto a UTP twisted pair cable without pliers

Cutting a twisted pair network cable for crimping is the first and most critical step in crimping. The reliability of the connection between the conductors of the twisted pair cable and the RJ45 plug, and as a final result, the stability of access to the Internet, depends on the accuracy and correctness of its implementation.

The main thing when cutting is to avoid notching the twisted pair conductors and to prevent them from overlapping at the point where they are clamped by the clamp in the RJ-45 plug. Crimping pliers for RJ-11 and RJ-45 plugs, as a rule, have special knives for cutting the twisted pair cable to length and trimming its outer sheath. But I never use these functions of pliers, since I have repeatedly had to deal with the consequences of such pruning.

The fact is that a twisted pair cable is far from an ideal circle, since all the pairs are twisted around each other; when cutting in pliers, the copper strands of the conductors are often cut and a few bends are enough for them to break off. Reliability can only be guaranteed by manually preparing the cable end for crimping.

Cutting a network cable begins with removing the outer sheath. To do this, one jaw of the side cutters is inserted inside the cable. Care must be taken to ensure that no conductors come into contact with the cutting edge. Most cables have a split nylon thread running inside them.

After opening a couple of centimeters of the shell, you can grab it and, pulling it away with tension, cut the shell by 4-5 cm. Next, the shell is bent to the side and cut off with side cutters.

Many people recommend removing the sheath by 14 mm, but with such a length it is almost impossible to develop and align the twisted pair conductors well.

Next, the twisted pairs themselves develop counterclockwise; usually they are twisted clockwise when looking at the end of the cable. They must be developed in such a way that the pairs are in the same plane to a shell depth of up to 5-8 mm. This condition must be observed to prevent the conductors from being squeezed by the plug clamp when crimping with pliers. In this case, it is necessary to immediately orient the pairs by color, taking into account the color markings for crimping.

Color scheme for twisted pair crimping according to option B, the most common option.

The twisted pair conductors are developed and straightened until they are in the same plane at the point where the RJ plug clamp is clamped. The twisted pair conductors are shortened to a length of 14 mm and inserted into an RJ-11, RJ-45 plug.

It is imperative to check that all conductors are under the contact teeth and their alternation corresponds to the color marking. Sometimes when the wires are inserted into the plug, they change places. The conductors in color scheme B are arranged one after another, white with colored stripes - colored.

This allows you to quickly check at a glance that the wires are routed correctly.

Crimping of UTP computer twisted pair cables into an RJ-11, RJ-45 plug is performed with a special crimping tool - plug crimping pliers. Professionals call such pliers Crimper . By design, they come in two types: lever and press.

Lever pliers (pictured left) are inexpensive and work accordingly. A lot of force is required and the compression is skewed. The best are the HT-500, in the right photo, they are devoid of the noted disadvantages.

Their design is such that when twisted pairs are compressed, the comb that recesses the contacts in the plug moves strictly perpendicular to the plug.

To crimp a network cable with pliers, you need to cut and thread the twisted pairs into the plug, insert the RJ-11 or RJ-45 plug into the required cell of the pliers and press their handles together with your hands until they stop.

Press the latch of the RJ-11, RJ-45 plug to its body and remove the twisted pair cable, ready for use, crimped with the RJ-45 plug, from the pliers.

How to crimp RJ-11, RJ-45 without pliers

Sometimes you urgently need to crimp a cable with an RJ-11 or RJ-45 plug, but you don’t have pliers at hand. In this case, you can do the crimping manually without a specialized tool. Insert the cut conductors of the twisted pairs into the plug, in accordance with the required color scheme, clamp the RJ in a vice by the latch, and using a screwdriver bit with a small hammer, tapping the bit, deepen the lamellas to the desired depth. Snap the cable clamp onto the plug body.

The thickness of the bit blade should not exceed 0.55 mm, since the thickness of the lamella in RJ forks is 0.56 mm. Otherwise, you can flatten the insulating sides. The spring-loaded contacts of the socket will cling to these places and there will be no contact. If the sides are damaged, you need to use a sharp knife to cut off the overhanging edges at the points of damage.

How to re-crimp RJ-11, RJ-45

There are, at first glance, more dead-end situations. You urgently need to crimp an RJ-11 or RJ-45 plug onto the network cable, but you don’t have a new plug at hand. There is also a simple solution for this problem. It is necessary to hold the fork body in a vice by the latch and pull the lamellas out of their seats by 1 mm, prying them alternately from the ends with an awl.

Use a knife to cut the latch on the near side to the cable, remove it and remove the old twisted pairs. I completely disassembled the RJ-45 plug to demonstrate its components.

Crimp new twisted pairs into an RJ-11 or RJ-45 plug using the technology described above.

Since the UTP cable retainer was removed when disassembling the plug, it is necessary to fix the cable in the plug by dropping a few drops of silicone, glue or sealant into the resulting window from the removed latch. If there is a need to extend or repair damaged twisted pair cables, this can be done by soldering or twisting. The reliability of a soldered connection exceeds any mechanical methods.

Source: https://YDoma.info/kompjuter/seti/kompjuter-kak-obzhat-otpressovat-rj-45.html

Crimping wires Tool for crimping wires crimper

Today we’ll look at the question of how to crimp wires. For this action you need a tool called a crimper. Is it possible to crimp a wire without a tool!? Yes, sure! But if you have a wire crimping tool, then it’s a completely different matter and the feeling and mood that you completed the task as needed!

1.

The tool is as simple as it is ingenious!

Buy: wire crimping tool

more details

Let's start with why I needed this tool in the first place!? It is not always possible to solder the drive in hard-to-reach places. And in general, soldering wires not on a table is always a rather unpleasant task!

Well, I decided to buy myself such a thing!

Crimper front view

Well, here it should be noted that the view from both the front and back is almost identical.

Rear view of the crimper

In order to bring the crimper into the ready position, you just need to press the handles and it will be ready for use.

But when you have a tool, but no sleeves, then such a tool is not needed. Numbering of sleeves 2508. Section 2.5mm

Where to buy sleeves for crimper?

Sleeves

Since I had no idea about the physical parameters of the sleeves regarding the cross-section of the wire, I can say that there is some kind of discrepancy here, the sleeve which is supposedly designed for a cross-section of 2.5 (which is physically 5.kW) in reality, I cannot say for sure, but the wire is clearly not designed for that much, about 2, 2.5 times less

In other words, if it is written that a sleeve is designed for a cross-section of 2.5, but in fact it is a cross-section of 1.5 - 2 kW, keep this in mind when you are planning to buy sleeves!

Or, in another way, look at the power in the column under the letter “W” and feel free to divide by 2. Then you will get a real number and a correspondence between the wire and the sleeve..

2.

Since the size of the sleeves is limited to 5 mm section, you can use the stripper we talked about last time.

Source: http://marrex.ru/Remont/7_objimaem-provoda.html

Wire lug crimping pliers

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Modern electrical engineering is constantly being improved, including in the field of connecting wires and cables for various purposes, power and conductivity. The quality of electrical wiring largely depends on how well the leading conductors and their contacts are prepared.

They must be crimped in a certain way, and this task is completely solved by special pliers for crimping wire lugs. They are widely used among electricians.

The tool is used to crimp not only conventional cables, but also various connectors used in non-standard connectors.

Using crimping pliers

All press jaws, regardless of their size, are designed to perform two main tasks. In the first case, several wires are securely fastened to each other, and in the second, current-carrying conductors are prepared for their subsequent fastening in the terminals of various electrical devices.

First of all, crimping is required when connecting multi-core wires. If they are inserted into the contact terminals unprepared, then gradually, under the influence of microvibrations created by electric current, the individual cores will become compacted.

Free space is formed between them, and therefore the contact will become much weaker. For this reason, power wiring was previously always laid with single-core wires.

However, after press pliers appeared, this recommendation lost its relevance.

Connecting large cross-section cables using the crimping method has been used for a long time, when there were no household tools yet. The quality of such operations was ensured by the use of special powerful presses capable of creating the necessary force. These devices operate on the principle of a jack, and many of them have a separate hydraulic drive. With the help of such presses, even the thickest cables are reliably connected.

The crimping method has proven itself well when connecting two or more wires. For this purpose, pliers are used to crimp lugs and wires. A special sleeve is put on their ends, assembled together, and then crimped. Depending on the type of connection, the wires are inserted from one or both sides of the sleeve. The first option allows you to get reliable twisting, and the second - a high-quality coupling.

Main types and varieties of ticks

Structurally, all crimping pliers - crimpers can be of two types. The former work like pliers, while the latter are diaphragm pliers. The first option is the most widely used. In this case, compression is performed only on both sides. The main difference from pliers is the specially shaped cutouts located in the jaws. They act as guides and ensure high-quality fastening of the lugs to the wire core.

Such crimping pliers are considered to be somewhat universal, since they can grip tips from all sides. The main disadvantage of such pliers is the presence on the jaws of only 3-4 cutouts for different sizes of sleeves.

Therefore, during work you have to use several tools. The best option is to use a universal crimper, which includes replaceable dies mounted on a special cassette.

In order to crimp the wire, the most suitable tip is selected, and the unnecessary one is inserted into the cassette in its place and fixed.

Diaphragm pliers can be used to perform four- or six-sided compression of sleeves, depending on the design of the working mechanism. Full coverage on all sides allows for the tightest possible crimping of the cable ends. During operation, the pliers are automatically adjusted to a specific sleeve diameter. The main disadvantage of such a tool is the possibility of crimping the sleeves on only one side due to the closed head.

A separate category includes crimpers designed for crimping computer cables. They work in the same way as pliers with two jaws, with the exception of the matrices themselves, which have a specific configuration for computer and telephone plugs. In this case, the essence of crimping is to displace the contacts that cut through the insulation of the wire and are pressed tightly against its cores.

Depending on the purpose, all crimping tools are divided into the following categories:

• Removing insulation and sheathing from wires and cables. With the help of these pliers, a section of insulation is cut off without damaging the cores. They can be adjusted to the desired diameter manually or automatically. It is imperative to ensure that the cutting edge is sharp so that the outer insulation is cut in one motion.
• Crimping of end sleeves. The tool for crimping tips has trapezoidal or square shaped sockets. They can be with or without flanges. To ensure reliable and accurate clamping of contacts, pliers must be selected according to color markings that correspond to a specific diameter.
• Crimping pliers for insulated ferrules. The tool has an oval shape, and the matrix contains three press sockets. They are marked in red, blue and yellow. These colors correspond to sleeves, tips and other types of connectors with similar color indications. This marking connects the insulated tips, placing them in the desired socket.
• Crimping of non-insulated terminals. The main working element is a special rod located along the dividing seam and pressing the sleeve in the center.

Crimping with a hydraulic tool

High-quality crimping significantly improves current conductivity at the joints, prevents overheating and emergency situations due to poor contact. At home, for these purposes, ordinary household pliers are used, designed to work with wires with a cross-section of up to 4 mm2.

For continuous or combined crimping of a cable with a cross-section of 4-400 mm2, it is necessary to use more powerful tools that provide high operating pressure. Hydraulic tongs or hydraulic presses fall into this category.

The design uses cylinders of various diameters, interconnected and representing a system of communicating vessels. Each of them contains a piston. The internal cavity of the cylinders is filled with water, oil or other suitable liquid, so this tool is hydraulic.

In accordance with Pascal's law, the force acting on any point of a liquid at rest is uniformly distributed throughout the entire volume. Thus, if a certain force is applied to a piston of a smaller diameter, then when transferred to a large piston, it will increase. The greater the difference between the areas of the pistons, the greater the force generated on the large piston.

Each hydraulic tool of this type has a single, double or triple action. Single-action equipment is equipped with one working element - a movable partition. Double- or triple-action presses have two or three working bodies, respectively. Their work processes are coordinated with each other, and general control is carried out using special switchgear.

Structurally, a hydraulic press can be vertical or horizontal, closed or open. With this tool you can crimp not only metal, but also other materials.

When choosing a hydraulic tool, it is necessary to take into account the presence of a pressure limiting valve. This element provides additional reliability, eliminating overload due to pressure. You should pay attention to the types of pressing heads, which are open or closed, as well as the diameters of the working sections. All hydraulic tools consist of subgroups, each of which performs operations with cables with cross-sections up to 70, 120, 300 and 400 mm2.

How to use crimping pliers correctly

Each pliers is used in accordance with its intended purpose. However, there are general principles that apply to any tool. Each operation requires a wire or cable of a certain cross-section, the pliers themselves, as well as sleeve tubes or other connecting elements.

For example, you can take Internet wires.

1. The ends of the wires are cleared of external insulation. This operation requires pliers with a semicircular notch at the bottom and a cutting edge at the top. The wire is placed in the recess, after which its upper side is pressed with a blade. 1-2 turns are made around the cable, the insulation becomes cut and is removed without any effort. For normal crimping, you will need a cleaned area 3-5 cm long.
2. The cores of the cable conductors are aligned and placed in the required sequence according to the type of connector. They are pressed closely together and cut so that 1-1.5 cm remains for connection.
3. The wires are inserted into the connecting device while maintaining the sequence. In this case, the lower recess of the connector must reach the cable insulation so as not to cause damage when crimping actions are performed.
4. The entire device fits into the pincer seat. After re-checking the correct arrangement of the flowers, crimping is performed.
5. Upon completion, the integrity of the connector and the strength of the connection are checked.

Cable lugs for crimping

Source: https://electric-220.ru/news/kleshhi_dlja_obzhima_nakonechnikov_provodov/2018-01-18-1435

How to crimp a twisted pair cable. Crimping with and without a tool

How to correctly crimp a twisted pair cable is not an idle question, especially for computer beginners¸ and the answer to it is of a purely applied, utilitarian nature. An unprepared person will hardly be able to fully implement this technological event without familiarizing himself with the step-by-step instructions. It contains several key operations from setting the task to successfully testing and launching a new network cable.

First, you need to assemble the correct circuit, and in order for the network to start working normally, you need to carry out step-by-step crimping. To be more specific, you should crimp the cable with RJ-45 connectors at both ends.

What is required to complete the task

From the point of view of assessing the efficiency of the transmitted frequency range in electrical engineering, a number of categories of twisted pair are known, numbered from 1 to 7. A higher category has a larger number of pairs of wires, plus each pair has more turns per unit length. Thus, we are interested in a product of category 5-6.

It is difficult to crimp without a tool at all. Therefore, it is best to stock up on a crimper and stripper (for working with insulation). Convenient “three in one” - crimping tools with the function of simultaneous removal of braiding, insulation, and also performing comprehensive and uniform crimping.

Disposable connectors are cheap, so it's best to have a spare just in case.

The presence of a tester is optional, that is, it is not worth purchasing specifically for one-time use. The device is suitable for frequent use. True, it is easier to find a fault with it by “ringing” each line separately.

Why are we going to crimp the cable and according to what scheme?

• The fundamental question in this situation is for what purpose the crimping is performed. The method of placing the wires in the connector socket will depend on this.

• Using the direct method, a router (modem, laptop switch, hub) is connected to a computer. With it, the wires are arranged according to TIA/EIA-568A and TIA/EIA-568B standards.

• Using the crossover method, devices of the same type are communicated: computer plus computer, computer plus laptop, router plus router, router plus modem, etc. With it, both standards apply to different ends of the wire, but there are discrepancies regarding speeds.

Crimp the cable using a tool

With 8 cores inserted into the connector, there is no need to leave empty grooves - they will all be occupied.

So, the sequence is as follows:

• Wire cutting. This is a simple manipulation that determines the desired length of cable. Initially, it is better to prepare a sufficient length in case of alteration.
• Removing the braid. Removing it with a knife is a thing of the past; special pliers with a hole for removing it to the required length are designed for this. Ideally, you should step back 1 cm from the edge. If you make the workpiece short, the cable will not fit into the connector; if you overdo it, the wires will come out of the device, which will shorten their service life.
• Trimming with scissors. Many people neglect this point, but in vain. The connection does not tolerate negligence, because otherwise the contacts will not fit freely into the connector. The first step is to smooth the wires into a single plane with a pencil. Then they are carefully distributed in order (by color), leveled a second time and lightly trimmed to an even end.
• Shoving. Perhaps the most responsible procedure. We are trying to carefully insert the structure inside the connector. We make sure that each wire is in its place, reaches the stop and nothing sticks out.
• Crimping. Final point. Place the connector in the crimping pliers and squeeze until it clicks.

Crimping process without crimper

This route is taken by those who don’t have a crimper and are not going to buy it (if it’s used one-time, it’s unlikely to be needed later. Moreover, this thing is relatively expensive, and there’s really no point in purchasing it for the sake of crimping two connectors. So everything can be organized with a screwdriver and a knife. Even if it’s handicraft and not on the first try, but it’s economical. In general, in worst case scenario, this option will do.

This is a primitive activity, because... Each channel is pressed separately and there is a real risk of breaking the connector

• Carefully remove the casing by 2 cm.
• We straighten the wires and distribute them by color according to the chosen scheme so that they do not intertwine.
• We trim them, leaving 1 cm. Cable cutters, scissors, and also a knife will do.
• Once again, carefully check whether the wiring is distributed correctly according to the diagram, insert them into the RJ-45 until it stops, while holding the device with the latch away from you. We make sure that the wires go in and rest against the front wall of the connector.
• After a comprehensive examination, we proceed directly to crimping. We take a flat-head screwdriver and slowly press the contacts in successively. Care must be taken to avoid injury.

The contacts must be pressed in with some force. Each of them should not only be aligned with the body of the device, but be somewhat recessed flush.

This is a very painstaking task, and it is not always successful the first time. Sometimes the cable is difficult to insert into the LAN port of the router; the operation will have to be repeated.

After crimping each contact, the cable clamp snaps into place. To do this, you just need to press it inward and press the shell. Now you need to repeat the same at the second end. As a result, the contacts are slightly damaged with a screwdriver, but if you crimp the cable using a crimper, there is no damage.

At one time, at the dawn of the Internet revolution, many users squeezed wire elements with their teeth. Today, such actions look uncivilized, and they are harmful.

The main stages are simple and clear, but you can’t do without them:

• The resulting structure must be fixed motionless. If after a slight twitch nothing falls off, there is no play, that means everything is in order. If it is present, apply pressure (in 90% of cases, secondary pressure helps).
• After turning on the system, the network should begin to function. The normal passage of the signal will be indicated by the declared traffic speed.
• With a LAN tester or a regular multimeter, the interruption will be immediately detected. One of the ways is to also put the squeeze on. Although in most cases you have to start all over again.

However, you should not immediately suspect the cable.

The problem may lie in the connected device, which also needs to be checked.

Afterword

For the sake of completeness, it should be noted that currently there are already so-called in use. tool-free connectors. This is a rather interesting and not yet widespread development. Using the mentioned devices, you can crimp the cable almost effortlessly with your bare hands.

All you need is a paring knife. The connector shows a diagram of where to route which wires. The contacts are stripped and inserted into the socket, then the connector is snapped into place and the cable is crimped in this way. So far, a tool-free connector for a retail network is considered a shortage.

You need to ask and search, like in Soviet times.

Related topics:

Source: https://electrosam.ru/glavnaja/slabotochnye-seti/provoda/kak-obzhat-kabel-vitaia-para/

How to crimp an Internet cable at home without and with a tool

Today it is difficult for even the most conservative person to live without the Internet. On the global network, people work, study and have fun. There is so much information in it that a lifetime would not be enough to study it.

Internet access, as everyone knows, is provided by a provider who lays a cable into an apartment or house that connects to a computer or router. The same type of cable is used to connect a personal computer and a router; it is called a patch cord or connector. To connect the cable and get a connection, it is important to crimp it correctly.

This material describes in detail how to crimp an Internet cable at home, which Internet cable connector is usually used for connection.

What is an internet cable

An Internet cable is a wire with which anyone can access the Internet. It extends from the distribution panel, and there from the provider’s center, which provides network access services. At the moment, the following types of cables are often used:

• Twisted pair;
• Fiber optic wire;
• Coaxial wire.

Patchcord is needed to connect to the local network

In addition, cables differ in shielding method, type of cores, and so on. The most popular among them is twisted pair, which is usually laid for almost any connection. It is also quite easy to crimp on its own.

The cord itself consists of several pairs of wires twisted together. This is done in order to reduce the influence of the electromagnetic field on data transmission. For UTP5 and more categories, an interlacing method with different pitches is used for better signal quality.

Twisted pair cables are used to create LAN (Local area networks) networks of two or more computers, as well as for installation inside stations, outdoors, and even underground.

The wire looks like a regular gray or white cord with markings describing the number of cores and the type of shielding. Inside the insulation are intertwined pairs of veins, which are also insulated from each other. Depending on the type of cable, the cores have a certain color.

They are usually painted in white, brown, green, blue and their “striped” combinations with white.

Specialized tools can perform not only crimping, but also wire stripping

Connecting the cord to network equipment (network card) of a personal computer or laptop uses an 8P8C connector located in the computer. An RJ 45 standard Internet connector placed on a wire is connected to it.

People often confuse the name of the standard with connectors for Internet cable connectors. The 8P8C connector is used, as already mentioned, to create local networks using 10BASE-T, 100BASE-TX, 1000BASE-T and IEEE 802 technologies.

3bz using a four-pair twisted pair cable.

Important! The standards for this communication were developed back in the last century - in 1975 and immediately became widespread for connecting subscribers, first in telephone networks, and then to the global network.

Schematic illustration of the connector

Connector design for network cable

Most often, an Internet connector of the RJ 45 type is used to organize computer networks, although there are also many others - RJ 11 (for telephone lines), RJ 12 and so on, but the first type is the most common. The design of these cords, despite their different purposes, is similar.

The RJ 45 connector consists of a plastic housing in which special contact knives are built-in. The latter are distinguished by a golden coating on the metal, and their number directly depends on the type of cord and the standard of the connector with which it is used in pairs.

Connector design

When assembling the plug, the contact knives are pressed inside the housing, since it is manufactured under pressure by casting. In addition, the connector has elements that securely fix the cord and prevent the contacts from breaking. The appearance resembles a rectangular cap with a latch so that the cable is securely fixed in the outlet or network card slot.

Important! For shielded cable, a different special connector is used. Its difference from the usual one is that it also has additional shielding protection.

RJ socket for RJ 45 type plug

Internet cable crimping methods

The cord is crimped in order to fit into the connector of the network card or socket and be fixed there with all contacts. All 8 contacts of a 4-core twisted pair cable and the outer covering are made in the form of a dense cord, which initially does not contain any connectors.

This is done so that the wire does not cling to other things during storage and transportation. This also allows it to fit into small holes in the walls when installed in an apartment.

If crimping was carried out at the cable manufacturer's plant, pulling would take longer and require more resources.

Direct crimping methods

Direct connection

The direct connection wire is often called a patch cable and is required to replace the wireless connection. Its main feature is that the wire contacts on one side are completely consistent with the contacts on the other. In this case, one standard is used: either T568A or T568B.

It is used to connect:

• Switch and router;
• Computer and switch;
• Computer and hub.

Schematic example of a cross connection

Cross connection

The crossover type is used to connect two computers directly. Its main difference from a straight cable is that it uses different standards for the arrangement of contact groups. The T568A standard may be used at one end, and T568B at the other. It is most often used to combine devices of the same type, namely:

• Switch and Switch;
• Switch and hub;
• Two routers;
• Two computers;
• Computer and router.

Crimping the wire with long-nose pliers

How to crimp an Internet cable yourself

Many people do not know how to crimp an Internet cable without crimping pliers. You can almost always do this at home yourself, without using any special tools. In addition to professional tools such as crimpers and crimpers, you can fix the connector using pliers, pliers, pliers and even a simple screwdriver. Although they are not as effective, they are better suited for a one-time occasion than a tool that costs 2,500 rubles.*

Using press jaws

If there is no other tool, then you can crimp using press pliers or simple pliers. It is not very convenient to perform crimping last, but it is quite possible. The operating procedure is as follows:

1. Take the cord and measure a length sufficient for cutting, stripping and some other aspects;
2. Remove the insulation layer using gentle movements of your hands or a simple knife or tongs. There is no need to touch the insulation of the cores themselves;
3. Determine the scheme according to which the connection and laying of the veins in the connector will take place;
4. Arrange the wires in the connector in accordance with the selected diagram and trim off the excess ends so that the layer without insulation is completely in the connector body;
5. Turn the housing over so that the connector faces down and insert the stripped wires along the contacts until they stop tightly;
6. After this, the contacts should “pierce” all the veins, so using a regular flat-head screwdriver you can direct them deeper into the legs;
7. Carefully tighten the connector clamp using pliers or press pliers;
8. Crimp the second side of the cable, if necessary;
9. Assess the quality of work and fixation, check the cable for functionality.

Crimping twisted pair

Using a screwdriver

If there are no tools at all, then most likely there is at least a screwdriver that can also be used to perform the procedure. The procedure is as follows:

• Straighten the cable and strip part of the outer sheath;
• Measure the distance of the wires along the connector plug;
• Cut the vein so that they are the same length;
• Insert the cable into the end of the tip so that all the wires are fixed along the guide channels until they stop;
• The outer insulation must fit under the connector body;
• Next, using a regular flat-type screwdriver, the housing contacts are recessed towards the veins;
• All that remains is to check the installation for functionality.

Fixing the tip with a screwdriver

Self-crimping connector

There are also special connectors on sale that crimp themselves and require absolutely no tools at hand. To use them, I remove the top insulation of the cable and cut off the wires. After laying the veins into the channels, the housing snaps into place and all the wires are “sinked” into the contacts. All this is possible thanks to two articulated halves.

Corning CAXISS RJ45 Self-Crimp Connector

What is the sequence of wires in the internet cable?

As already mentioned, there are two types of wire arrangement

• Direct, when the network outputs of the device are connected to a router or switch;
• Crossover, when several identical devices are connected directly.

It is the second standard that is most often used. The sequence of wires in which is as follows: white-orange wire, orange, white-green, blue, white-blue, green, white-brown, brown. This type is used when two devices of the same type are connected.

Important! Cross view is used when you need to connect two devices of the same type: computer to computer, switch to switch, etc. Gradually, this type of wire arrangement is losing its popularity, as it is being replaced by interfaces that can independently configure signal transmission and receive them automatically.

Sequence of arrangement of veins in the connector

How to repair or change the plug on a network cable

It also happens that you have to replace the plug on the cable and repair it. You can use a screwdriver. It’s worth saying right away that if the crimping is of poor quality, failures and loss of signal will occur regularly, and the connection will be broken. You can do the installation as follows:

1. Remove the cable insulation and unscrew all the wires located inside it;
2. Measure the distance along the entire body of the plug so that the wires reach the contacts, and the outer layer of insulation ends in the connector itself for greater reliability;
3. Install the cable and fix all the wires along the contact channels;
4. Tighten the lock and “sink” the plug contacts into the veins.
5. Check the cable for functionality.

Pressing out the plug with a special tool

How to check if the Internet cable is working properly If the cable suddenly stops working, then you need to figure out the reasons for this malfunction. There are not many options here:

• The cable cores do not touch the contacts in the plug;
• The plug does not make good contact with the network card slot;
• An internal cable break has occurred.

The second reason does not need to be considered for a long time, since it is not related to a cable malfunction. The first and third cases are of much greater interest. The most important check is with a multimeter or tester, that is, ringing. You can also ring each individual transaction. This is done as follows.

One probe of the device is installed on one part of the cable, and the other on the second. Voltage is applied to each wire in turn. The fault, if it was a break, will be found immediately. If everything is fine with the cable, then most likely the contacts in the plug itself have come loose.

You can reassemble it or buy a new one and clamp it using any of the methods described above.

Advanced crimping pliers

It is now clear how to properly connect the Internet cable and how to fix it in the connector plug. This is quite simple to do, using not even special devices, but simple pliers or a screwdriver. It is better to repair problem wires using a multimeter.

Source: https://rusenergetics.ru/provoda-i-kabeli/kak-obzhat-internet

How to connect wires using crimping sleeves correctly

A large variety of options for connecting wires have been invented - from simple twisting to the most complex welding machines. However, among this variety, there is no ideal method. When operating the electrical network at nominal or peak loads, you can find advantages and disadvantages in each method. Crimping using a sleeve is sometimes the only correct method.

Purpose, types of sleeves and crimping tools

To ensure contact between the connected conductors, special materials are used - sleeves. They are made from copper or aluminum tubes of various diameters according to the wires being fastened, so that electrochemical equality is maintained. Crimping is used in cases where it is necessary to withstand high current loads or when using other methods is problematic.

Table. Types of produced sleeves

Name	Material	Description
Copper	Aluminum
GM	+	–	Without protective coating, looks like pipe scraps
GML	+	–	The surface is subjected to electrochemical sputtering (tinning). This protection protects the surface from corrosion and oxidation.
GA	–	+	For joining cables made of aluminum
GAM	+	+	They are used specifically for connecting cores of various materials. Made from two tubes by friction welding
GSI	+	–	Made from tinned copper tubes with external insulation. During crimping, the protective layer is not damaged and the assembly does not require any more additional manipulations

For your information!

GML are not suitable for aluminum conductors. Metal deformations in the area where pressure is applied by the pliers cause damage to the tin coating; the conductors will come into contact with each other.

To install wiring with a cross-section of up to 120 mm², you will need manual ones, and above that, hydraulic press pliers. The professional tool is equipped with dies and punches designed for different diameters. The size is adjusted by turning the matrix or punch. When working with aluminum conductors, quartz-vaseline paste is used to remove the oxide film from the metal surface.

Features and rules for crimping wires

The crimping procedure is extremely simple: the exposed wires are tightly inserted into the tube and pressed with press pliers. If voids have formed between the wires, they must be filled with the remaining scraps of the appropriate length. Compression is carried out at at least two diametrically opposite points to obtain reliable contact. The conductors must not be twisted.

After the preparatory work, you can begin crimping. Sequencing:

1. Strip the wires of insulation and connect them into a bundle.
2. Place the lug and fill the voids with cable scraps.
3. Clamp at the edges (force is applied while rotating the tool 180°).
4. Trim the protruding edges of the cores.
5. Use heat shrink tubing to insulate exposed parts.
6. Twist the cables tightly and lay them down.

Advantages and disadvantages

Such a connection has high mechanical strength and resistance to tearing. But it is non-separable: if necessary, it cannot be disassembled to replace one of the conductors. During repairs, the old sleeve is cut out and replaced with a new one. Reducing the cable length may require an extension procedure. In general, this is the only drawback when installing electrical wiring using the crimping method.

The crimping method has the following advantages:

1. Performed with hand tools that do not need to be connected to an electrical outlet. If there is no voltage during operation, this is the only way to make a quality connection.
2. Using aluminum-copper lugs, dissimilar conductors are installed in one electrical unit.
3. If welding or soldering requires special equipment and skills to work with it, then even an amateur can do the work with pliers.
4. The crimping tool allows for commutation in confined spaces.
5. Installation is carried out quickly.
6. Operational maintenance is not carried out.

Common Mistakes

For crimp connections, select a sleeve of the appropriate size. If the diameter of the core is larger, then it has to be sharpened. Its thinning leads to an increase in the resistance of the contact area. In this place the wire will heat up and may burn out over time. Mechanical strength is also lost. External influence on the connection can lead to rupture.

An increase in diameter, compared to a wire, similarly leads to a deterioration in contact. The presence of gaps between the cores reduces the reliability and strength of the connection. In order to save money, dividing the sleeve into several parts makes installation inconvenient and reduces the contact length. You should also not use improvised tools when crimping. Pliers, a hammer or a chisel will not bring the desired effect, but can cause irreparable damage.

Connecting wires using crimping will not be a problem. If the sections are consistent, the work is carried out carefully and safety precautions are followed, you can get an excellent result.

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Crimping twisted pair cables without tools

According to experienced networkers, making patch cords using special tools is no more difficult than cracking nuts. With good crimping pliers on hand, even a beginner can feel like a master. But! True mastery lies not so much in the ability to use familiar things, but in the ability to do without them.

Today we’ll talk about how to crimp twisted pair cables without tools, using only what is found in every home - a regular slotted screwdriver, wire cutters, and pliers.

Crimped cable without using pliers

Why do you need crimping using improvised means?

Situations where you have to crimp a twisted pair cable with a screwdriver are usually associated with urgent cable repairs. For example, if someone stepped on the connector or a dog chewed it off, but you don’t have any tools with you and have nothing to replace the damaged patch cord with. Or for one-time network work, when buying crimping pliers is simply impractical.

A connector installed in this way does not look very neat, but the quality can be as good as a traditionally crimped one.

How do they do this kind of crimping?

With ordinary tools from a home craftsman's kit. We are sure you have them too. Here is a list of what you will need:

• A thin slotted (flat-head, “minus”) screwdriver with a strong handle, since you will have to knock on it.

  Screwdriver

• Side cutters. Can be replaced with a sharp knife or small scissors.

  Wire cutters

• Pliers, preferably with a narrow nose.

  Pliers

• The cable itself.

  Network cable

• RJ45 connectors.

  RJ45

After traditional crimping using crimping pliers, it is customary to check the patch cord with a cable tester to determine whether all conductors are connected to the contacts, whether there are crossovers inside the cable or a short circuit. But since we are crimping a twisted pair cable without tools, we will evaluate it “by eye” and test it directly in operation.

Crimping schemes

Before the instructions “how to crimp a twisted pair without a tool,” let us briefly recall the layout of conductors for direct and cross (crossover, cross) crimping. We hope you remember that a direct patch cord connects a PC and network devices, and a cross cord connects two PCs or two switches to each other.

The picture below will remind you of the order in which the conductors should be arranged for both crimping methods.

Crimping schemes

Procedure for crimping a twisted pair cable with a screwdriver

Let's look at the instructions using the example of crimping a twisted pair cable of eight cores.

1. Using any cutting tool, separate the broken connector from the patch cord. The connector cannot be reused, even if it seems to you that it can be glued together;
2. Stepping back 4-6 cm from the end of the cable, use a sharp knife or scissors to make a circular cut into the outer insulation of the cable. Remove the cut part;

   Cutting off the insulation

3. Unravel the twists. Arrange the conductors according to one of the crimping diagrams;
4. Measure 1.1-1.5 mm from the insulation cut line, attaching the connector to the cable;

   Figuring out how long to leave the wires

5. Take side cutters and cut off the ends of the conductors. Make sure that the cut line is perpendicular to the cable axis, otherwise some of the wires will not connect to the contacts. If you use a knife, cut on the table;

   Cutting off the excess

6. Insert the machined end of the cable into the connector. The tips of the conductors should rest against its front wall. When inserting the connector, the side with the contacts is facing you. Place the orange (first) wire at the top;

   We put on the connector

7. If you look at the row of contacts on the connector, you will notice that each of them protrudes slightly above the surface of the case. Our next task is to press them inside. To do this we use pliers;

   We press the veins inside

8. This is not the end of crimping the twisted pair - the next photo shows that we will need a screwdriver next. For what? Then, after pressing with pliers, the contacts are level with the surface of the connector, and we need to “sink” them even deeper - so that the “knives” of the contacts cut through the conductors and form a strong connection with them. Place the tip of the screwdriver on each contact in turn and press firmly inward. Some craftsmen hit the screwdriver with the palm of their hand, while others use a hammer or pliers (as a hammer);

   Press the contacts in with a screwdriver

9. The last step is to secure the cable in the connector so that it does not dangle from side to side. For this purpose, there is a special clamp in the wide part of the connector (pictured). It also needs to be pushed deeper;

   Securing the cable in the connector

10. Place the screwdriver on the recess in the clamp area and press firmly. After all parts of the wire are fixed, the work is finished. All that remains is to check how the patch cord functions.

    Apply pressure in the recess area

Conclusion

So you figured out how to crimp twisted pair cables without tools. More precisely, with a tool, but not the one to which, as it seems to us, you have already become accustomed.

Now that you know almost everything about making patch cords, you can come up with crimping methods yourself and share them with us and our readers.

Source: https://o-vitoipare.ru/vse-stati/obzhimaem-vituyu-paru-bez-instrumenta.html