How to twist wires correctly

How to properly twist copper wires - Metalworker's Handbook

Laying electrical wiring in a house involves connecting wires; from the main network you will need to make branches necessary to provide power to electrical appliances.

How to make a wiring connection correctly

Connecting wires is required everywhere in rooms, in cars, devices and mechanisms, wherever there are wires. Today the following methods are used:

Twisting;
Welding;
Soldering;
Using special blocks, terminal blocks;
Using self-clamping terminal blocks;
Using PPE caps.

Further in the article we will talk about the simplest way to connect wires - twisting; any home craftsman will be able to put it into practice, for example, when installing temporary wiring is required.

What you need to know about twisting

Take a close look at the photo of twisting wires, you will see that it can be done in different ways. You will need to prepare tools: a knife to strip the insulation, pliers to make the connection reliable, and you will also need electrical tape to insulate the twisted area.

Method - twisting wiring with protected ends

Expose the wires by at least 5 cm, cross the ends not protected by insulation, clamp the resulting cross with pliers and twist them together using a rotational movement.

Bend the resulting twist so as to direct it parallel to the wire, and insulate everything.

Twisting method with winding

Strip the wires at the ends and bend them slightly in the middle, hooking the wires together at the bend. Next, alternately wrap the ends of one wire around the other.

To fix the windings and make the connection more reliable, use pliers, tighten everything and carefully insulate it.

Method of connection with the bandage

You need to know how to twist the wires correctly in this case: you will also need to prepare a bare piece of wire.

Before connecting, the wires are stripped and placed side by side so that the stripped ends touch. Use the prepared additional piece for a bandage - use it to wrap the wires.

A common method is groove twisting

First, familiarize yourself with the sequence of steps on how to twist wires with your own hands. Bend the ends of the wire into small hooks, hook them together, and wind one wire around the other.

Insulate the resulting twist to ensure human safety, reliable contact, prevent current leakage and prevent short circuits.

Professionals say that these types of wire twisting can be made more durable by using the following recommendations:

Twisted contacts are additionally connected by soldering or welding, as a result the contact acquires maximum reliability and is almost impossible to break. It is preferable to use soldering when both wires of the connection have a large cross-section.

WAGO terminals greatly facilitate connection, making it more efficient; they are needed when you have to figure out how to twist copper wires with aluminum ones. The whole procedure will take place quite quickly, while the “vags” allow you to connect wires of different cross-sections, the contact will be reliable and durable.

If a home handyman is faced with the task of connecting wires in an electrical outlet or lamp, use WAGO terminal blocks.

Thanks to PPE clamps, the reliability of the connection increases significantly, making it as safe as possible. These products have a low price, so they are available at any electrical store.

Wires twisted together should not be immediately closed using a junction box. It is better to observe how the electrical network works for several hours, after which it is recommended to check the temperature at the mounting location. If the connection gets very hot, you need to do everything again: most likely, the contacts are unreliable.

The twist itself is not waterproof, so it is better to take a box to connect the wires inside the wall; if without it, then the twist wires will need to be insulated using cambrics.

All you have to do is determine for yourself which twisting method is better and consider methods for isolating nodes.

What a DIYer should know about soldering and welding

Soldering is considered simply an improvement on twisting; the wires are first twisted and then soldered using a soldering iron with solder. Advantages of soldering:

Increased twist strength;
Reduced resistance, which means the twisting area will not heat up.

Multi-core copper wiring can be easily soldered, but this method is not suitable for all wires, with the exception of twisting aluminum wires. Since soldering is fragile, you cannot be careless when performing it, otherwise you will end up with a poor-quality connection.

Welding is another method that improves twisting and increases reliability, but is also not suitable for aluminum wires. It is used for multi-core copper cables with a large cross-section; welding reliability is considered higher than soldering.

When using welding, the possibility of weakening of the twist cannot be ruled out; under the influence of high temperatures, the performance characteristics of the metal can change.

Insulation methods

Wire insulation is carried out using various types of electrical tape; it is necessary to insulate the twisted area and a section of insulated wires equal to at least 2 or 3 cm. Then it will be possible to make high-quality insulation that protects against unwanted contact with moisture; also for this purpose, special thermal tubes are additionally used.

Insulation with thermotube

A tube of the required length is put on one core before twisting.

Twisting is performed, after which the thermotube is moved to the junction of the contacts.

It is necessary that the tube adheres to the wiring as tightly as possible, so it is heated a little with a lighter. Under the influence of high temperature, the heat tube will shrink, and it will be possible to ensure a tight grip on the wiring.

The advantages of all kinds of twists lie in the simplicity of their execution; despite the minimal equipment, they have proven themselves to be quite reliable connections.

When high-quality insulation is made, for which good electrical tape is used, the service life of the twist will be quite long. This connection is convenient to use: it is detachable, which means that if necessary, the wires can simply be twisted again.

Twisting is used in loose electrical wiring that sag; this method has been adopted by motorists, since the wiring in the car is constantly exposed to vibration.

Among the disadvantages of twisting, the following should be noted:

It is not possible to connect wires having different cross-sections; in such a connection, as a rule, there is a very high resistance, which causes constant heating of the wires and melting of their insulating layer.

It is difficult to twist together multi-core cables, which are soft and may break under any tension.

When there are several insulated wires in the wiring, due to the fact that each core is insulated separately, the total thickness can be very large.

Twisting is not suitable when it is necessary to connect wires made of different materials - copper and aluminum.

When choosing a method, it is important to take into account all sorts of nuances; only then will you be able to get a high-quality connection with your own hands. Twisting must be done after turning off the power supply for safety reasons.

Photo of wire twisting

Source: https://ssk2121.com/kak-pravilno-delat-skrutku-mednyh-provodov/

How to twist wires correctly?

Very often, twisting wires is used as the main method of connecting them. Not everyone is able to do twists correctly. Even craftsmen sometimes neglect the basic rules for connecting conductors.

It’s worth talking in more detail about what types of twists there are, as well as how to properly do certain types of twists.

Types of cable twists

It is worth immediately noting the fact that GOST states that twisting in a residential apartment is generally unacceptable as a method of connecting conductors. However, some people still take note of it. There are several basic types of twists that are used depending on what type of wire is used.

Parallel twisting is used in cases where we are talking about twisting two single-core wires. This applies mainly to aluminum.

In this case, the contact area is quite large, so this method is considered as the main one when it comes to thin aluminum.

In the event that we are talking about connecting two single-core wires that have a sufficiently large cross-sectional area, it is worth using bandage twisting.

In this case, the bandage is put on the wires. It must be made of the same material as the wire or cable itself. It's also an effective way. When twisting, do not forget about high-quality insulation of the conductors.

If we are talking about copper wires, they are often made multi-core. No additional bandage is needed here, and parallel connection is ineffective.

The pigtail method of connecting conductors is used here. A pigtail is formed by twisting conductors coming from different wires together. The method is the most common.

How to twist wires

twisting wires is used quite often if it is necessary to connect them together. This method is considered very effective, although, according to all rules and standards, it cannot be used in an apartment.

However, many, even professional electricians, do this. Therefore, it is worth talking about twisting in more detail. Most often, stranded copper wiring is used in homes.

This is why the braided twist method is used here. First, the wires need to be stripped, and then a fairly large part of them must be freed from insulation. After this, they are applied perpendicular to each other, and the twisting process itself begins.

In this case, you need to hold the wires with one hand and make circular movements with the other. The result is a kind of braid. An excellent solution to any problem in the house.

After the wires are twisted together, they must be insulated. To do this, you can use the most ordinary electrical tape, as well as use heat shrink. This is a very effective way to insulate conductors.

How to solder twists

You can solder twists, but to do this you need to know how to use a soldering iron. This device can have a wide variety of power. It all depends on which wires are connected with it.

For household needs, a soldering iron with a power of 100 watts will be sufficient. To begin with, you should twist two conductors, then connect the soldering iron to a power outlet. It will heat up. This may take ten minutes.

Then the soldering iron tip is lowered into the rosin, which should begin to boil with one touch. This will mean that the device is warmed up well.

After this, the soldering iron with rosin is placed in the solder. Here you need to take as much tin as necessary so that you can saturate the entire twist, that is, not a single wire should remain sticking out.

Next, you need to bring a soldering iron with tin to the twist and apply solder to it. This must be done extremely carefully, because it can overheat.

In this case, the solder may simply fall off. After this, you should wait until the solder hardens. Then you can check the quality of the connection. If everything is done clearly and correctly, then you can apply insulation and operate the wiring.

Source: http://euroelectrica.ru/kak-pravilno-delat-skrutku-provodov/

How to solder twisted copper wires

Electrical wiring in the room must be safe and convenient to use.

If you strictly follow this rule, then each energy consumer (chandelier, TV, computer, refrigerator) must have its own protection device against short circuits or overheating of the wiring.

You can run a separate cable from the personal circuit breaker for each outlet and switch. Two more criteria oppose this: rationality and economy.

What are distribution boxes for?

Rational wiring looks like this:

That is, the total energy consumption of the facility is evenly distributed among the circuit breakers. In addition, consumers should be divided into groups, for example:

Living room and bedroom lighting
Kitchen lighting
Lighting for bathroom and hallway
Socket group (in each room)
Power socket group (for powerful consumers, such as an air conditioner or an electric oven)

But with such a scheme, there may be many connections on one wiring line.

It is not safe to make overhead connections and hide them in the wall.

At a minimum, this does not make it possible to disable a faulty branch while leaving the rest of the circuit operational.

For normal distribution of lines, there are distribution boxes.

They are an insulated container, inside which switching (permanent) of electrical wiring lines occurs.

The connection of wires in a junction box can be done in various ways, the main thing is to ensure reliable insulation between phases and a contact that can withstand the load.

The wiring diagram in the junction box allows you to save money when purchasing electrical cables, as well as avoid uncontrolled interweaving of wires in the walls. The so-called radial wires diverge from the shield with protective circuit breakers. On each of them there are connecting nodes: those same distribution boxes.

Important: The wire cross-section may be the same or different. The main condition: the power of the main cable cannot be lower than the power of the final wiring to the consumer (socket, light fixture).

In addition, there are certain methods and rules for connecting wires in a junction box. Let's talk about this in more detail.

General rules for switching electrical cables in distribution boxes

Of course, all requirements for energy supply are set out in the PUE.

This is an electrician's reference book. Moreover, there are fines for violating the Electrical Installation Rules. However, in practice, all these strictures apply only to institutions and organizations.

In private households, responsibility ends with the wire coming out of the meter (electricity meter). The rest is up to the homeowner.

To prevent an incorrect connection from leading to a fire or electric shock, you must follow simple rules:

The connection of wires in the junction box is made during a complete power outage. Even if the electrician is wearing dielectric gloves and is familiar with safety rules, accidental contact of the phase wire with structural elements of the building or grounding is possible.
The type of connection must be the same for each line within the same box. This will protect your line from loosening under load.
Physical contact of conductors made of different materials (copper with aluminum) is not allowed. When electric current flows, active electrocorrosion occurs. Metals are coated with an oxide film, which impairs contact. The result is sparking, overheating, and complete burnout of the contact connection. If such a need arises, it is necessary to tin the wires using solder. After twisting, the connection must be soldered for at least 50% of the length. The rest of the strand will not corrode because no current flows through it under load.
It is necessary to exclude the possibility of exposed conductors leaving the box. Even if the cable is completely laid in the wall.
When connecting without contact devices, that is, using soldering, twisting or welding, an insulating cap must be placed on the exposed conductor. The insulator must be firmly fixed; non-combustible materials are used in its manufacture.
The ends of the wires inside the box must have at least a 200% margin along the length of the connecting ends. In the event of a break or burnout, it will be possible to re-install without laying a new wire.

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In addition, inexperienced electricians often make mistakes and break off wires when stripping the insulation. If the wire is inserted into the box under tension, reconnection will be impossible.

Methods for connecting conductors in a box

There is no single possible method. When choosing a way to connect wires in a junction box, an electrician weighs all factors: from the cost of materials to the expected load.

Terminals. There is an opinion that this method is the most reliable, but this is a false statement. Most often, terminals are used on boxes with ready-made contact pads.

This connection of wires in the box allows you to disconnect one of the lines at any time (for example, for repairs) without causing damage to the entire power system.

https://www.youtube.com/watch?v=a2J-6t4Rfb0

There are two ways to connect, directly to the block (by making a ring from a wire core), or using a terminal.

With the ring everything is simple, you just need to ensure that the wire is laid in such a way that when tightening the threaded connection, the contact does not loosen.

But with terminals everything is more complicated.

It is irrational to crimp a single-core wire: you can mechanically damage the conductor, and the core will break off at any moment.

And when laid in a box, a single-core cable with terminals takes up a lot of space, and it is difficult to separate different phases at a sufficient distance.

An excellent result is obtained when crimping a multi-core soft cable; the contact terminal fits comfortably. But stationary installation of multi-core cable is nonsense.

Bottom line: Terminal blocks in the distribution box are convenient, but it is better to make the connection directly to the conductor under the screw, without using crimp terminals.

There are modern boxes with quick-installation contact blocks. This solution is really convenient, but is designed for light load.

Thus, the use of contact blocks is justified only if it is necessary to periodically disconnect one of the lines. And even then, sooner or later the conductor will break off.

For standard wiring in an apartment (or household), the classics are still more suitable:

Welding wires in a junction box has been used since time immemorial. Anyone who repaired their Khrushchev or Brezhnev cars probably noticed a drop of solidified melt at the end of the aluminum strands in the boxes.

Today, the use of aluminum wiring is prohibited by the PUE, and the welding connection method is still popular.

The point is this: after carefully twisting the stripped wires, the contact of the welding machine is briefly applied to the end point.

Usually this is a compact device of low power. It is used by almost all professional electricians. Works on the principle of a spot welding spotter.

It will not be possible to light an arc, but the metal at the point of application melts properly. The figure shows the simplest circuit that can be assembled at home.

The connection quality is more than sufficient.

In addition to the total twist length (40–50 mm), the ball at the end forms a point with minimal resistance.

An additional plus is that this twist will not unwind even when moving the wires inside the box.

If a welding machine is not available, we limit ourselves to ordinary twisting.

Of course, we make the connection not with our fingers, but with the help of pliers.

Twisting is done after the wires are finally secured in the box. If the cable moves, the connection may become weak. The result is sparking, overheating, and contact breakage. It will be good if there is no fire.

As an option, after twisting, the wires are soldered in the junction box.

Important! There is a widespread opinion among amateurs: under load, the twist will heat up and the solder will melt.

Firstly: a load capable of heating a conductor to the melting temperature of solder is unrealistic at home. Of course, provided that the circuit breakers are in working order.

Secondly: heating during twisting occurs due to loose contact, and this can be solved by soldering.

The reliability is not much worse than with welding. In this case, there is no need to purchase (do it yourself) a welding machine, a fairly powerful soldering iron, or even a hair dryer.

Tip: Use the most powerful soldering tool possible. It is better to expose the contacts to high temperatures for a short time than to heat the contacts slowly and for a long time with a weak heater.

During heating, monitor the condition of the insulation. If it starts to melt, take a break until it cools completely. Immediately after soldering, do not move the wire; allow both the solder and the insulation to cool.

Use refractory solders; these alloys have higher strength characteristics.

Crimping. From the point of view of electrical conductivity, the quality of contact is no better than that of conventional twisting. But the strength of the connection increases significantly. If it is not possible to weld or solder the twist, crimp it using a special sleeve.

You can get by with pliers, but a special tool is still more reliable.

There are bushings for parallel splicing of wires, and there are for fixing twists. There is no fundamental difference.

If there are two or three conductors, parallel crimping is suitable. For larger quantities - crimping after twisting.

In fact, the methods discussed above are a modernization of the good old twisting. You should not be skeptical about the issue.

Due to poor contact in the junction box, many fires occurred and damage to household appliances was caused.

Therefore, when repairing electrical wiring in your home, use technical means to improve contact in the twist to the maximum.

Modern methods of connecting wiring in a box

The so-called quick fix pads. These products are widely offered in online stores and building materials markets.

Indeed, such devices make installation quick and convenient. The appearance of the connection is also pleasant. Therefore, such “electric clips” are loved by electricians who perform custom work.

However, this method has serious drawbacks. Let's make a reservation right away: the manufacturer does not promise high connection power: the characteristics are on the case.

For an LED lamp, connecting a computer or TV - just right.

But a refrigerator, electric stove, boiler cannot be connected through such a distribution box.

The contact area in such “quick releases” is small; the pad is connected to the conductor tangentially.

With a light load, the current does not heat the surface too much.

And when a serious consumer is connected, sparking, heating, and burning out of the connection will begin.

Conclusion

With all the variety of ways to connect wires in a box, traditional twisting remains the most reliable. Welding or soldering significantly improves contact.

No serious equipment is required; all work can be completed with basic electrical engineering skills.

on this topic

Source: https://steelfactoryrus.com/kak-payat-skrutku-mednyh-provodov/

How to twist wires correctly? — Metals, equipment, instructions

Wire twisting is one of the methods when it is necessary to make a branch or additional wiring connection. However, according to the PUE it is prohibited to use it. But knowing how to twist wires correctly, you can really avoid unforeseen incidents, especially short circuits, which often lead to fire.

Connecting wires

To ensure full electrical conductivity, the integrity of the wiring is an important point. Damage or poor-quality adhesion is unacceptable. It is important to ensure tight contact contacts and reliable connections in the “electrical node” areas. There are certain methods for eliminating breaks in cables. Among them, welding should be noted. It applies to copper and aluminum wires. This ensures a particularly reliable grip.

Connections can be divided into types:

twist;
welding;
soldering;
pressure testing;
terminal blocks;
self-clamping terminal blocks (WAGO terminals);
PPE caps;
bolt clamp.

Connection methods

The most complete connection for wires made of copper is soldering. It can be easily accomplished using flux (rosin, borax) and tin solder. Terminal blocks are also used - a special device that is made using screw terminals. They are selected separately in accordance with the cross-section of the cores.

Self-clamping terminal blocks are often used to save time on electrical installation work. In order to isolate a twisted or soldered electrical connection, PPE insulating caps are used. Today in the energy sector, WAGO terminals are widely used, which are produced for wires and cables of various diameters.

In addition, WAGO terminals allow you to connect conductors made of different materials (copper and aluminum).

The choice of which connection to use depends on various factors:

material (steel, copper, aluminum);
number of twisted elements;
section;
place of work (house, street, in the ground, etc.).

Types of twists

Reliable and tight twisting protects against unforeseen emergency situations. It is important to do it as correctly as possible. Even the slightest violation of safety regulations can cause a fire.

For this reason, the rules for the design of electrical equipment do not provide for the legal use of this method. Despite the ban, it is relevant both in production and in everyday life.

Existing types of wire twists can be used temporarily when, for some reason, a quick connection using safer methods is not possible.

There are simple methods by which the connection can be made safely and firmly. They are not difficult even for a beginner. When performing, it is possible to use both two wires and several. The following known types of twists are usually used:

bandage;
groove;
simple branching method.

Types of wire twists

The above twisted electrical wires are completely reliable electrical connections. But implementation requires certain skills with hand tools. Self-training is available to every person who practices repairing electrical wires.

Bandage is one of the methods of twisting wires, often used in everyday life. It is characterized by the use of an additional segment, which is superimposed on the connected conductors. This is a good method for serial, parallel and branch connections.

Stranded

Beginners sometimes wonder: “how to connect single-core and stranded copper wire?” In fact, the main requirement is a tight and reliable fit of the cross-sectional area of the cores to each other.

Knowing how many wires can be twisted into one twist, you can quickly complete the task. The number of electrical conductors depends on their cross-section. The larger it is, the fewer wires are allowed to twist.

And vice versa: the smaller the cross-section of the conductive wires, the greater the number of wires that can be twisted.

Connecting stranded wires using the groove method is not difficult. This is an easier way to do the job than the “bandage”. In this connection, it is not necessary to use an additional piece of wiring. In this case, a complete connection of wires by twisting is carried out directly by the wires themselves. They are laid in parallel, in series or in a branch.

Before twisting the three wires together, it is necessary to remove the insulation from the ends of the wires and use a hand tool to twist them. It is permissible to use the “groove” and “bandage” methods, as well as a simple branch.

The maximum number of wires in a twist using the latter method depends on the diameter of the conductor. Even with the smallest diameter of the cores, their number should not be more than six. Novice electricians are wondering: “how to make a twist of 4 wires?”

It is most optimal to perform this action using the “groove” or “simple branch” method.

Twisting of wires according to the PUE

The twisting length of wires according to the PUE ranges from 3 cm to 6 cm, depending on their diameters.

Twisting single-core with stranded is carried out as follows:

The ends are prepared at a distance of 4 cm to 8 cm.
A multi-core current-carrying core is superimposed on a single-core one and wound up to a length of 4 cm.

Wire Twist Tool

This task requires certain tools. Among the mandatory ones:

Hydraulic manual press KVT “PGR-70”

You will also need a twisting attachment and insulation material. When working with these tools, it is imperative to comply with safety regulations. Certain job skills will be required.

Although in some cases it is possible to twist wires protected by insulation by hand, today a wire twister is usually used. It greatly simplifies the work and guarantees high quality results.

A work device such as pneumatic or hydraulic press jaws allows you to terminate conductive wires for further connection.

There are also small devices that allow you to speed up the twisting of the cores. Such a device is inserted into a screwdriver and twists them by rotating them.

Twisting devices

Connection isolation

An important requirement in the connection procedure is their isolation to avoid accidents. Insulating materials include:

PVC tubes;
insulating tape;
heat shrink tubes;
special twist insulator caps.

Wire insulation methods

Methods of insulating wires directly depend on the material used. They are divided into methods such as planting, reeling and heating. In the first case, the material is placed on the twisted segment. In the second, simple winding is performed using insulating tape. In the third, insulation with a heat-shrinkable tube involves placing it on the current-carrying part and then heating it.

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To the question of beginners, “Is it possible to insulate wires with electrical tape?” should be answered unequivocally in the affirmative. This is one of the most common methods. The main requirement is compliance with the shelf life of the material and the absence of visible damage.

Despite the fact that at first glance the procedure for twisting electrically conductive wires seems simple, a responsible approach to the matter is required.

Source: https://spb-metalloobrabotka.com/kak-pravilno-skruchivat-provoda/

How to Twist Wires

Perhaps the most cherished dream of any electrician is electrical wiring without intermediate breaks. So that a separate wire passes from the panel to each switch or socket without connections. But this is a pipe dream - not many people will like the fact that dozens of wires will be connected to the electrical panel. And it gets expensive - you need a lot of wire. That's why the wires branch and connect.

Typical wiring in an apartment can have over a hundred connections. And electrical wiring faults, as a rule, appear precisely in these connections. Therefore, great attention must be paid to the correct connection of wires.

Wire connection methods

methods are used to connect wires :

pressing (crimping);
twist;
PPE clips;
screw terminals;
welding;
soldering;
bolted connections;
WAGO terminals.

What is better to choose for twisting wires?

To begin with, let's turn to the PUE. Paragraph 2.121 says that correct termination, branching and connection of cable cores and wires must be carried out using soldering, welding, pressing or clamping (bolt, screw, etc.). That is, of all the above options, only twisting is illegal. But twists will exist until the day there is electricity. Therefore, we will tell you about all connection options.

Despite the contradiction of the PUE, twisting is considered the most popular type of connecting wires. The main disadvantage of twisting is the gradual weakening of the fastening due to residual elastic deformation of the cable core. Moreover, the transition resistance in the twist increases, the cable begins to overheat and the connection is broken. It's good if there is no fire.

But a properly made twist can last a very long time without any cause for concern. Therefore, if other connection options are not available to you, then twisting can be done at home. But only high quality!

Important! This option should only be used as a last resort. If possible, use other options.

Do not twist when the current in the circuit is more than 2-3 Amps.
Do not twist when laying wires over flammable materials.
Do not accept work from electricians if the connections are made by twisting without welding or soldering.
Do not use twists if you are engaged in electrical work as part of an individual business or official duties - this will entail liability, possibly even criminal liability.

wires made of different materials (aluminum and copper), as well as multi-core and single-core cables in one twist For high-quality twisting, the insulation is removed from two cables to a length of 70–90 mm, the wires are laid perpendicularly crosswise and twisted. If the cable diameter is small (up to one sq. mm), then this can be done manually. But it is advisable to twist it with pliers. The coils must be tight.

The remaining edges of the cable (4-6 mm) are removed with pliers using a screw rotation, while the cable material seems to be smeared together. When attaching three or more wires, the freed ends from the insulation are laid together, parallel to each other, as tightly as possible and twisted by the ends with pliers. After this, the remaining ends are bitten off in the same way. The total twist size must be at least 12–14 diameters of the twisted wires.

Then you need to insulate the twist. To do this, use insulating tape, heat-shrink or polyvinyl chloride tubing, or special caps. It is advisable to thread the heat shrink tube twice, and wind the insulating tape in at least four layers. The insulating material must capture all intact cable insulation - this will protect the twist from moisture and prevent slipping.

This is the most labor-intensive option for connecting wires, which requires some experience. Better quality twisting than poor soldering. Therefore, we will provide general information to those who have sufficient skills.

Before soldering, the cable is cleaned of oxides; if necessary, it is tinned, screwed (maybe not as tightly as when twisted), treated with flux and soldered. You can solder both aluminum and copper wires if you choose the right solder and flux.

There is no need to choose an acidic active flux - it will certainly remain on the wires and will destroy the connection over time. Soldering takes quite a lot of time, but the fastening is one of the most reliable.

The most durable option for twisting wires. Even with little experience, this connection option is relatively quick and simple. Welding is done with a current of any polarity with a voltage of 12-35 V. It is best to have the ability to regulate the welding current. For welding two copper wires with a diameter of 1.5 square meters.

mm 70 Amperes are enough, for 3 wires the voltage increases to 85-95 Amperes, for 3 wires 2.5 kW. mm, 95-110 Amperes are required, and 4-5 of these wires already require 110-130 Amps. With the correct current for welding, the electrode does not stick and the arc is kept quite stable.

Copper-carbon electrodes are used to connect copper conductors.

Insulation 60-70 mm long is removed from the wires and connected “for welding”. It differs from simple twisting in that the ends of the cores are not twisted by 6-7 mm. They are straightened and clamped parallel to each other. If three or more wires are screwed in, then there should still be only two wires at the end, the rest are cut to the length of the twist. This makes it easier for a melt bead to form when the welder is weak.

Important! Welding work must be carried out in compliance with all fire and electrical safety rules with the mandatory use of protective equipment (glasses with a thick filter or a welding mask, gloves, protective clothing).

Then the twist is placed in a welding clamp and the weld is made with an electrode. During welding, you need to melt the ends of the wires until a melt ball appears. For strong mechanical and electrical contact, the melting point must reach the main twisting area. After cooling, the wires are insulated in a way convenient for you.

For welding wires, you can choose different types of welding machines. inverter-type welding devices . Their advantages:

have low electricity consumption;
low weight and dimensions;
large range of welding current regulation;
provide a stable welding arc.

So, with a fairly large number of electrical installation works, purchasing a welding inverter can be considered the best choice; this device will be useful in many other works.

PPE connection

This is a plastic cap . where inside there is a square metal wire installed in a spiral cone. Often its cavity is filled with a special lubricant that protects the wires from moisture and prevents oxidation. When connecting wires using PPE, it is important to choose the size of the clamp correctly, taking into account the number and diameter of the wires being connected. As a rule, this information is located on the packaging.

For fastening, the insulation is removed from the wires to a size slightly smaller than the length of the cap, laid together and the PPE is screwed on top. Moreover, the edges of the square spring remove the layer of oxides from the surface of the core, its cone moves apart and, thanks to its elasticity, reliably clamps the wires together. For reliability, some electricians prefer to first do the usual twisting and then install the PPE.

The advantage of PPE is the simultaneous fastening of wires and insulation of their connection area. Disadvantages include weakening of the spring over time, which leads to increased contact resistance. It is not advisable to install PPE in high-current circuits.

Screw terminals

This fastening is very widely used when connecting switches, electrical sockets, lighting devices and other electrical fittings to wires. Screw terminals are often used when assembling electrical panels . This way they make it possible to carry out a neat and quick installation.

The obvious advantages of clamps include the absence of the need to isolate the fastening. Using these clamps, you can fasten wires made of various metals (copper and aluminum).

Of course, there are also disadvantages. It is not possible to install a multi-core cable into the clamps - it must first be crimped or soldered. In addition, screw terminals require maintenance - they need to be tightened from time to time to prevent the connection from loosening. In general, if there is a free approach to the connection areas, then screw terminals are an inexpensive and reliable solution.

WAGO terminals

This fairly new type of fastening is based on the installation of insulated spring clamps . manufactured by the German company WAGO. These WAGO connectors are manufactured in a large assortment and include connectors of various designs, for various purposes, for a wide variety of cross-sections, types and numbers of wires. Therefore, it is advisable to buy WAGO connectors in a specialized store and always check the certificates.

The main advantages of these connectors include quick and easy installation without any special devices, as well as simultaneous insulation of the connection and fastening of the wires.

WAGO fasteners have all the necessary tests, are certified and are widely used both in our country and around the world. Therefore, there are no serious reasons not to trust them. All cases of any problems are due to the wrong choice of WAGO fastening for a certain load or the installation of fakes. It is these points that you need to pay great attention to when using for connection.

Crimping

This option means connecting the wires using crimping with a lug or tubular sleeve. Tips and sleeves are made for cables and wires with a core diameter of 2.6-250 square meters. mm.

Crimping is quite convenient for “set and forget” fastenings, but requires special equipment and the correct selection of sleeves for the specific diameter and number of wires being fastened.

The tools used are crimping presses, as well as manual hydraulic, electric and mechanical pliers.

For crimping, select the required sleeve; if necessary, adjust or select the working end of the tool. The insulation is removed from the wires, the conductors are cleaned and lubricated with a special paste, the sleeve is put on and clamped. A high-quality tool clamps the entire length of the sleeve in one pass; cheaper ones require several clamps at a certain distance from each other. After this, the sleeves are insulated with heat-shrinkable tubing or insulating tape.

Bolt fastenings

Used in circuits with high voltage . A washer of the required diameter is placed on the bolt, then the wires are wrapped around the bolt, another washer is put on and the whole thing is carefully clamped with a nut. If you install an additional metal washer between the cores, you can connect copper and aluminum wires together. In residential electrical wiring, this option is almost never used due to its bulkiness.

All completed installation connections of any type must be accessible for further maintenance and inspection. Correctly selected connection of wires is the main guarantee of the reliability of electrical wiring in an apartment or private house.

Source: https://electricremont.ru/kak-skruchivat-provoda.html

When starting to install household electrical wiring, you should understand that the standards for electrical work strictly prohibit the connection of wires in the form of twisting. This type of installation is undesirable because at the point of contact of the two wires the cross-sectional area of the connection decreases, which leads to an increase in the transition resistance and local overheating of the wires.

It is believed that most fires occur precisely because of the use of twisting when installing wiring.

For reliable and safe connection of aluminum wires, it is recommended to use special clamps and terminal blocks. In them, the problem of contact and increased resistance is solved by using brass plates. For installation of aluminum conductors that are characterized by ductility, it is preferable to use screw terminal blocks.

The use of such alternative wiring methods slightly increases the cost of the work. But the costs are more than offset by the security of such a connection. In addition, the connection at the terminals or clamps is easy to disassemble to eliminate a possible malfunction, for carrying out maintenance work or measurements.

Twisting of aluminum wires

If you decide to use twisted aluminum wires, you must meet a number of conditions. Such a connection can only be used in low-current circuits, for example, when installing children's games or models of electrical installations, as well as when conducting simple physical experiments with direct current. Using even the most reliable twist when installing apartment electrical wiring is fraught with trouble.

First, you need to carefully remove the ends of the wire from the insulation, trying not to damage the wires themselves. After this, the wires need to be rubbed until shiny with sandpaper, which will help remove harmful oxides that are characteristic of aluminum and worsen the contact.

It is recommended to thoroughly wipe the clean section of the wire with a cloth or cotton wool soaked in acetone.

Bend the prepared ends of the wires at a right angle at a distance of approximately 8-10 wire diameters from the insulation. Tie the wires behind each other. Using pliers with narrow jaws, wind the first core onto the second, making at least seven turns. Try to keep the turns as close to each other as possible, without gaps. All that remains is to carefully wrap the resulting twist with insulating tape.

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Wiring Requirements

If we conduct a retrospective analysis of the processes that took place in the electrical industry, we can highlight several characteristic points.

Half a century ago, twisted connections were used everywhere. The main tools that the installer needed were a special knife, a screwdriver and pliers.

This kit was enough to connect the ends of the wires in the junction box. Electricians have had to do such operations constantly for many years.

Experience has shown that properly performed twisting will serve reliably for many years and even decades.

However, it is necessary to take into account the operating conditions and loads that networks installed in this way can withstand. The load on them was minimal.

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If we compare it with modern values, the growth is in the hundreds of percent. Then the apartment had a minimum of electrical appliances - only light bulbs and a radio.

Today they have added a refrigerator, a computer, a stove, and an air conditioner. The old insulation and cross-section can no longer withstand such a load.

For this reason, the use of aluminum wire is limited by technical conditions, and the use of copper is strongly recommended.

Selecting a connection method

Over time, the tool used to install wiring has changed. If in the recent past it was possible to get by with good pliers, today this is not enough.

Welding wires requires a special machine. Soldering the ends without a minimum set of equipment is also impossible.

The connecting insulating clamp, which is briefly called PPE, was also invented not so long ago. One method is used to connect aluminum wires, and another is used to connect copper wires.

In each specific case, you need to choose the right connection method, and do this according to the rules of electrical equipment - PUE.

Twist

You can make a twist in one of three ways:

simple twist;
bandage;
twisting with a groove.

The first method is most often used in everyday life. The correct choice of tool and the use of PPE caps allows for good contact.

This method is used to connect the ends in the junction box.

Band twisting is used to make connections for large diameter wires. To ensure a strong connection of aluminum cores, groove twisting is used.

If the connection technology in the junction box is carried out accurately, then the contact can serve for a long time and reliably.

All of the listed types of twisting require a certain skill in operation.

Using these methods, it is recommended to connect wires with a cross-section of up to 10 squares. The distribution box of a household circuit uses wires with a cross-section of 1.5 - 2.5 square.

Simple twisting takes up very little space in the distribution box. For better contact, you can “screw on” the PPE cap.

When the wire cross-section is 6 square meters or higher, PPE caps are not used in the junction box.

To strengthen the bandage twist, soldering is used. Technological instructions do not allow simple twisting of aluminum and copper wires.

Such connections can be made after preliminary tinning of the copper.

All of the above methods are used to connect multi-core cables and wires. All operations in the junction box must be done carefully. Especially in the case when there are more than three cores in the cable.

When performing such work, it is recommended to use caps for twisting wires. Before starting, you need to sand the ends of the wire with sandpaper.

If it is necessary to make an additional tap on a certain section of the line, then all actions are performed according to a standard and familiar scheme.

The only difference is that stripping the supply wire must be done in the middle, and not at the end. You will need the same tools - pliers and a knife that removes the insulation.

To reliably twist aluminum wires, an electrician requires theoretical training and practical skills.

With enough experience, he can quickly complete any connection. In this case, the place of twisting must be cleaned. Aluminum oxide has insulating properties.

If the contact at the twisting point gets hot, then most likely the stripping of the aluminum wire was not done properly. It's no secret that all operations need to be done correctly.

This law strictly applies in electrical engineering. The fitter must have good tools and an exam on the rules of operating electrical installations - he must pass it within a certain time frame.

Welding connection

Practice shows that wire welding, as a technology, as a tool for connecting wires, is used in conjunction with other methods.

Most often, welding is used as one of the options for processing twists. A correctly “twisted” contact does not heat up and can serve reliably and for a long time.

However, during operation, there is always the possibility of loosening the twist.

This should not be allowed, especially in a distribution box located in an apartment or private house.

Welding quickly and at minimal cost gives the contact the necessary parameters.

State fire control requires welded joints to be made.

Solder connection

One of the three popular ways to improve twist quality is soldering.

This technology does not require a special transformer or other complex instrument.

Here you need a hundred-watt soldering iron and properly selected solder.

The ends are soldered in the junction box before putting PPE caps on them.

When connecting stranded wires, soldering is used more often than other methods. Rosin is most often used as a flux for soldering.

It should be emphasized that soldering is used to connect copper wires.

Other technologies are used for aluminum products.

Screw terminals and terminal blocks

If connecting copper and aluminum wires by twisting is not allowed, then this problem must be solved in other ways.

Welding cannot help here either. In this case, screw clamps and terminal blocks are used.

When solving any technical issue, it is very important to correctly assess the operating conditions of wires and contacts.

In circuits with a load of more than 100 watts, the contact of the aluminum wire with the copper wire heats up intensely.

To avoid this effect, terminal blocks of various designs are used.

It is advisable to purchase a device of this type from a heat-resistant material that will not react to how the contact heats up.

Self-clamping devices

The main argument that opponents of using twisting give is that the contact obtained in this way heats up.

Which can, and sometimes does, lead to serious incidents.

Connectors with insulated spring clamps do not have this drawback. They started making such a device in Europe several years ago.

If such a clamp is used correctly, the electrical circuit will function without interruption. In practice, welding is still more often used, although over time there are more supporters of the clamping device.

The connection of stranded wires using self-clamping connectors is performed better.

Use of PPE caps

PPE connecting caps are manufactured specifically to improve wire twisting.

Essentially, this is a tool that is designed to perform two functions - to isolate the contact and make it better.

When using a PPE cap, no electrical tape is needed.

The design of this product is not as simple as it might seem. A conical spring is placed inside it.

The correct selection of the number and cross-section of the wires to be connected ensures reliable contact.

Experienced installers recommend first twisting the wires and then screwing the PPE onto it.

The contact with such protection practically does not heat up.

When screwing the PPE cap onto the twisted area, the edges of the spring remove the layer of oxides from the surface of the wire.

The spring, due to its elasticity, presses the wires against one another. This ensures tight and reliable contact.

But if the spring weakens, the contact will also weaken. It is for this reason that these types of connections are not recommended for use in high voltage electrical circuits.

This tool has proven itself in household networks. Including for connecting multi-core wires.

Source: https://remontkvartiri.me/elektrika/kak-pravilno-skruchivat-provoda.html

How to twist wires correctly - Electro City

Almost everyone had to twist wires at least once. You will say that this is a fairly simple procedure. On the one hand, indeed, in order to intertwine several cores with each other and put them in a junction box, you do not need to have any special skills.

But not everything is so simple! After all, twisting wires is one thing, but doing it QUALITY and RELIABLY is a completely different matter.

Unfortunately, homemade twisting of wires often causes electrical fires. That is why such a procedure should be approached very responsibly. So that you can be confident in your work and not worry about the fact that somewhere you have poorly insulated or twisted the wires securely enough, we will tell you how to do everything correctly.

Why can twisting wires be dangerous?

So, let’s confirm: twisting wires is rightfully considered the most dangerous connection method. Why?

This is because the degree of contact between two or several conductors at once depends only on the quality of the work you perform. Moreover, over time, weakly bent veins will gradually become even weaker.

What does this mean? Well, at least because at high electric current loads in this zone there will be too weak contact.

The result is heating of the wires, destruction of the insulating layer and a disastrous ending in the form of a short circuit (we are generally silent about fire and electric shock).

According to the rules of the PUE, this method of connecting wires is completely prohibited. Although, of course, almost all electricians resort to a similar method in ordinary everyday work. And here’s what professional practitioners say: if you twist the wires correctly and carefully insulate them, you won’t have any problems at all. The veins themselves can serve faithfully for another couple of decades.

This begs the question - how to twist wires correctly and “forever”? Let's talk.

Reliable twisting of wires: detailed instructions

For the sake of an example, let’s take the simplest situation - it is necessary to fasten a pair of single-core wires together (let’s assume that both conductors are made of copper). The course of action is as follows:

Carefully strip both wires using a special tool or a simple knife, removing the insulation by about five centimeters;
Degrease bare contacts with acetone;
Take a piece of sandpaper and sand the ends of the conductors to a pronounced metallic color;
We lay the bare wires crosswise and slowly wrap one wire around the other (the procedure is performed using pliers, the number of turns is at least five);
We wind the second core in the same way;
We tightly wrap the twisted area with electrical tape (it would also be a good idea to use a heat-shrinkable cambric - a special tube that will protect the exposed area from the external environment).

You can safely note that there is nothing complicated in the procedure. The main thing is to expose sections of the wires by at least five centimeters and confidently twist them together with pliers, thereby ensuring strong contact.

Options for twisting single-core wires

What about the more complex situation of twisting solid and stranded wires together? Here you need to follow the first two points of the above instructions, after which you need to cross the products together and tightly wind the stranded wire around the single-core wire (at a distance of a couple of centimeters from its end).

Reeled in? Then we take the remaining single-core end and bend it in one smooth movement towards the turns of the stranded conductor. When the task is completed, the wires are insulated and placed in a distribution box. Absolutely the same course of action will help when twisting two stranded wires.

By the way, what is important is that we absolutely do not recommend twisting copper and aluminum wires. Not only professional electricians speak about this, but also regulatory documents - the same GOST.

You should not make such twists because copper and aluminum have different metal resistance indicators.

Also, when they interact, oxidation occurs, and this in turn significantly worsens the contact.

There is also the following nuance: copper and aluminum have different physical properties in the sense that one of the metals is hard and the other is soft. This will also have an extremely negative impact on the quality of contact between the two conductors.

Tips that will be useful to you

If you want to be sure of the quality of the connection you made, we recommend that you familiarize yourself with the following recommendations:

Have you twisted the wires, but the twisting does not seem reliable to you? Use soldering or welding! Such a connection will simply become unbreakable and you definitely won’t have to worry about the quality of contact between the cores. By the way, this option is most acceptable when the wire cores have a large cross-section.
Use terminals, for example - WAGO. They will not only provide a reliable connection, but will also allow you to make it much faster. Which is also very convenient - using terminals it is quite possible to connect several wires, both with different sections, and even made from different metals. The contact will be more reliable than ever. Terminals are also an excellent option for connecting wires in a chandelier or outlet.
Use PPE clamps. Their task is not only to make the connection reliable, but also to increase its security. In addition, such PPE caps are not at all expensive.
Did you twist the wires together? Don't rush to hide the connection in a junction box! Let the new electrical circuit unit operate for some time. After this, you will need to check the temperature of the wires where they are connected. If you feel that the wires are heating up, you should definitely redo the twisting!

Use these tips; they will definitely not interfere with you when performing any electrical work where there is a need to connect wires to each other.

What is important to pay attention to is that the above methods do not make the twist waterproof.

So if you are planning to fasten the conductors in the wall under a layer of plaster (and without a box), be sure to insulate the joints with cambrics.

What's the conclusion?

So we told you about how to twist wires yourself. We advise you to resort to this method only when installing temporary electrical wiring; in other cases, use more modern and safe methods. Also, never forget to turn off the power to your home before starting any electrical work. Good luck!

Source: https://magazin-yar.ru/osveshhenie/kak-pravilno-sdelat-skrutku-provodov.html