How to twist 4 wires correctly

Method of connecting electrical wiring: how to twist wires correctly

When installing electrical wiring, special attention is paid to electrical contacts, since the quality and reliability of the entire electrical network as a whole depends on this. An integral part of such contacts is the connection of wires. For this, both modern technologies and old methods are used. Each method has its own disadvantages and advantages. What type of wire twisting to use depends on the conditions and possibilities.

Requirements for twisting wires

Twisting wires together is the most popular and simplest method, but at the same time it is also the most unreliable. To understand how to twist wires correctly , you need to imagine what processes can take place at the connection point. Over time, as a result of temperature exposure, the clamp weakens.

This is caused by linear expansion of the conductor during the passage of large amounts of current. The contact at the junction weakens, its resistance increases, and accordingly the twisted area heats up. The wires oxidize and overheat, contact is lost or insulation breakdown occurs, which can lead to a short circuit and fire.

Requirements for twisting wires are regulated by the rules for installing electrical equipment (PUE). The basic rules for any method of connecting wires are to ensure contact without additional resistance. That is, this value at the place of twisting should not exceed the minimum value of the resistance of the wires themselves. This is also true for the requirements of mechanical strength; the contact point should not be less strong than the strength value of the wires themselves.

Therefore, according to the PUE, simply made connections in the form of twisting when installing electrical wiring are prohibited. After twisting, additional operations are required to increase its reliability. This can be soldering, welding, crimping, mechanical clamping.

It is important to note that twisting is applicable only if the connected conductors are made of the same material. Otherwise, a chemical compound is formed due to oxidation, which quickly destroys the twist.

There are different types of twists:

• parallel simple;
• sequential simple;
• parallel to the groove;
• consistent groove;
• bandage

Before starting the connection, you need to prepare the wires. To do this, you will need to remove the insulation over a length of at least 50 mm, clean the exposed wire with fine sandpaper, and only then start twisting. Parallel connection is used when there is a need to connect the ends of wires together, for example, in junction boxes. Consistent twisting when making branches.

Parallel connection method

Parallel connection is a simple operation that involves a method in which two wires, stripped to the same length, are applied parallel to each other. Next, the bare ends are crossed so that the edges touch each other. Then, with a rotational movement, they begin to twist. You need to twist in one direction , it doesn’t matter which way.

The insulated parts of the conductors must not be twisted together. First, the conductors are twisted by hand, forming a direction, and then tightened with pliers. In this case, the ends of the wires are taken with pliers to give the twisting uniformity.

The “parallel to the groove” method means that when twisting, one core is motionless, and the second braids it. To do this, starting from the end of the insulation, one wire makes three to four turns around the second.

We lay the first one with a tight touch parallel to the second one and at the end we perform three or four turns again.

Description of the sequential method

A simple serial connection is accomplished in a different way. The stripped ends of the wires are not applied to each other, but are arranged oppositely, overlapping.

The middles of the stripped strands are applied to each other, and then braided in one direction and the other. In this case, it is necessary that the stripped conductors do not come into contact with the insulation of the opposite wire.

When twisting with a groove, each core is braided with the other only at the end of the insulation, and in the middle it passes with a tight touch.

Cable banding

It is performed using both parallel and sequential methods . In the first method, the wires are pressed against each other with an insulating layer, and a third conductor is wound around the stripped conductors in a spiral motion.

To do this, one end of the additional wire is held with your fingers, and the other is wrapped around with pliers, tightly squeezing the connected wires together.

In the second method, the stripped wires are applied in parallel, but opposite each other, not reaching one or two millimeters from the insulation of the opposite wire. Then they are tightly rolled with an additional conductor.

Twisting a multi-core cable

There are some minor nuances with this connection. To increase the contact area, the same methods are used, but with preliminary separation of the cores in each wire.

After removing the insulation, the conductors are separated in each wire, and two to four pigtails are created from them with an equal number of conductors in each. Then they are laid one on top of the other, and the wires are twisted, one pigtail from each wire. At the end, the resulting braids are woven together.

This way you will get the correct twist of the wires with strong mechanical strength and low resistance.

The number of turns that is obtained during operation should be more than six. The types of wire connections do not depend on the material used and are performed in the same way for both aluminum and copper wire. It is important to understand that you cannot twist different types of wires together, and the aluminum wire may break if twisted excessively. If you need to twist more than two wires, the process technology will not change.

Additional technological operations

Since the PUE prohibits twisting alone, and it is impossible to connect different materials, the twisting process must end with a terminal block or soldering. To make the connection reliable, the following technological operations are used:

• soldering;
• welding;
• screw terminals;
• crimping in special spring devices;
• crimping.

Soldering and welding when connecting

The only drawback of this operation is the labor intensity of the work. To perform soldering you will need tin and flux.

When working with copper, rosin is used as a flux, while for aluminum, highly active fluxes containing oleic acid and lithium iodide are used.

If a soldering iron with a power of up to 100 W is enough for soldering copper, then aluminum is welded using a gas heater, the heating temperature should be 400-500 degrees. Solder for copper is lead-tin. And for aluminum containing zinc .

The technology itself is simple, since the thermal conductivity of twisting is greater than that of solder, when melted it transfers to the joint, creating a thin layer. When soldering, large amounts of solder are not allowed; it should be distributed evenly over the entire surface.

Application of screw terminals

Screw clamps, in their operating principle, involve mechanical compression of twisted surfaces using a bolted connection. For this, steel pads are used. The finished twist or individual wire strands are placed under a steel washer and compressed by screwing in a screw. In this case, the clamping is carried out both by the washer itself and only by the screw. The first method is better, since the contact surface is larger.

The terminal block itself looks like a plate on an insulator with a group of contacts. Using terminal blocks, both copper and aluminum wires of different sections are connected.

Using spring devices

Allows for the fastest connections without the use of tools. Wago terminal blocks are widely used. They are produced not only in different sizes, but also for different numbers of connected wires.

With their help, single-core and multi-core wires of different sections and types are connected. The wires are combined both individually and with each other. For this purpose, the terminal blocks have a latch-flag, which allows you to lay the wire and clamp it inside after latching.

Or use a device in the form of clips.

Using the Wago terminal, you can connect aluminum and copper to each other. But for this, a special paste is used to prevent air from entering, and the wire strands are separated into separate cells.

Crimping of connected cords

If it is necessary to connect large cross-section wires, lugs (sleeves) are used. The wires are stripped and inserted into the sleeves, then the sleeve is compressed using press pliers and the wire is crimped. This connection is considered reliable, but requires specialized tools.

Connecting insulating clamps (PPE) are also considered a kind of crimping. After twisting the wire, depending on the diameter, the caps are screwed on top of the connection, pressing the contact and insulating it.

The last final step after making the connection is to carefully isolate it. Dielectric tape or thermal tube is used as an insulator. The insulation should be 2-3 cm larger than the junction itself. The insulation must be carried out efficiently, otherwise there is a possibility of a breakdown between the wires, which will lead to a short circuit.

Source: https://chebo.biz/stroyka-i-remont/pravilnaya-skrutka-elektricheskih-provodov-sposoby-soedineniya.html

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:

1. The ends are prepared at a distance of 4 cm to 8 cm.
2. 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.

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 correctly

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.

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

Wire types

All current-carrying conductors are divided into two main types - single-core and stranded. “Single-core” (aluminum or copper) is most suitable for wall wiring; such wires are laid once and never touched again. Stranded wiring is used everywhere, and it has found wide application in various household appliances and in carrying cases.

Twisting wires

The main mistake that electricians make when working is that they twist short pieces of wire together. Of course, everything will work, but for how long is unknown. To ensure a high-quality connection, the ends of the cores must be stripped to at least 30-40 mm, and for aluminum single-core wires it is better to strip them to 70 mm.

To make contact more reliable, you need to take pliers and use them to tighten the twist more tightly. Aluminum wires twist exactly like copper wires, but their electrical characteristics are worse. When calculating the wiring for a certain load, you need to take a thicker aluminum cable.

If three or more wires are used for twisting, the stripped ends should be made longer. If there are five, six or more ends, you can make a loop from the twist, and install a bolt with a nut and washers at the end of it, thus creating a strong connection.

There are situations when it is necessary to create a fairly thin twist, for example, the wires need to be inserted into a hole of a small diameter. In this case, the two ends are twisted in the connection towards each other.

What not to do

When twisting it is not allowed:

• connect copper and aluminum wire;
• when removing insulation, damage the conductor;
• do a weak twist.

If the situation is hopeless, and it is still necessary to connect the copper and aluminum core, then it is necessary to use additional washers with a nut and bolt for a more durable connection. But if possible, it is better to replace the wires with homogeneous ones in the future.

At Spetssnab-NN LLC, you can select and purchase cable products with the required characteristics for ease of installation.

Source: https://specsnab-nn.ru/kak-pravilno-skruchivat-provoda.html

How to connect wires in a junction box

No electrical wiring diagram can do without some kind of connections, branching wires or cables. There is a special box for this purpose. It is located under the ceiling and is a round or square box made of polymer material.

In this material we will tell you how to make connections correctly, demonstrate diagrams, photos and video instructions.

Why use a junction box

Wiring connection in the junction box

There are cases when, when installing electrical wiring, they neglect the installation of such distributors, considering that this is just a waste of time, since the box must first be installed, then the connections to it must be made, which will lead to additional difficulties. It’s easier to simply twist, insulate and simply plaster the wall. But here you need to think a little ahead, since in this case important points are missed:

• No free access to wires. For example, if the socket in your room does not work or the light has gone out, and after checking it turns out that the problem is a lack of voltage. How to check? Completely remove the trim? Tearing off wallpaper and plaster to get to the twist? This will ruin your renovation.
• If you want to install an additional outlet. It is not always convenient to connect it by laying wires from a previously installed outlet. Thanks to the distribution box, you can easily make new connections.
• The regulatory document PUE states that “places of connections and branches must be accessible for inspection and repair,” therefore the installation of such a distributor cannot be neglected.
• The absence of such distributors is contrary to fire safety standards.

As you can see, the distribution box plays an important role. But installing it is just the beginning. All that remains is to connect all the wires in it. What's the best way to do this? Let's look at some ways.

Types of connections

Types of wire connections

What is the task when connecting wires? Ensure good contact between the cores so that the chain does not break and there is no risk of a short circuit. In order to ensure this, you can act in several ways:

1. Twisting.
2. Crimping.
3. Welding.
4. Soldering with a soldering iron.
5. Use of screw terminals.
6. Bolted connections.
7. Self-clamping terminals.

These are time-tested methods that you can use to ensure reliable contact. Let's take a closer look at each of them. You will learn how to properly connect wires using any of these options.

Crimping with a connecting sleeve

Cross-sectional crimping of copper wires

A fairly reliable method that will require the purchase of a connecting sleeve. You need to select it based on the diameter of the bundle being connected. Depending on the wires you connect, the material of the sleeve itself is selected.

For copper wires the sleeve must be copper, for aluminum wires - aluminum. To ensure a reliable connection, the sleeve is crimped with a special tool called press pliers.

This technology is quite effective and is included, along with other methods, in regulatory documents.

Crimping connection of aluminum wires

To connect this way you need:

1. Remove the insulation, taking into account the length of your sleeve.
2. Twist the wires into a bundle and insert them into the sleeve.
3. Compress the sleeve using press pliers.
4. Insulate the twisting area with heat shrink or insulating tape.

It is not recommended to use pliers in such work, since the connection will not be reliable enough. It is much better to buy press pliers or borrow them from good neighbors.

Welding

Welding wires

This method can be called the most reliable and safe, because the wires are connected using fusion and become one. Due to the fact that the welding will not oxidize, such contact will not weaken over time. But to carry out such work you will need skills in working with welding equipment.

In addition to skills, you must prepare:

• 24 volt welding machine with a power of more than 1 kW;
• welding gloves for skin protection;
• welding glasses or mask;
• sandpaper for stripping wires;
• stationery knife for removing insulation;
• carbon electrode;
• flux, thanks to which the melt will be protected from exposure to air.

Welding copper to aluminum

After all the tools and materials are ready, all that remains is to do the welding, which will not be difficult. The work can be divided into several steps:

1. Remove 60–80 mm of insulation and clean them using sandpaper. The veins should shine.
2. Connect the wires using the twisting method, twisting one onto the other so that the ends are level with each other. It is recommended to make the length at least 50 mm.
3. Pour flux into the recess of your electrode.
4. Place the ground of the device on the bare wire, turn on the welding machine and press the electrode to the top of the twist.
5. Hold the electrode until a ball called a contact point forms. This usually takes 1–3 seconds.
6. All that remains is to clear the point of flux and insulate the welding site with heat-shrinkable tubing or electrical tape.

This type of connection will last a long time. In some old Khrushchev buildings, such welding lasted 50 years and consistently performed its function.

Soldering with a soldering iron

Soldering twists with a soldering iron

The method is very similar to welding, only in this case the wires are connected using solder. For these works you will need a soldering iron. To work you will need:

• soldering iron;
• fine sandpaper;
• rosin (flux);
• brush for applying rosin;
• tin-lead solder.

The operating procedure is the same as for welding:

1. Removing insulation and cleaning with sandpaper.
2. Twisting.
3. Application of flux.
4. Direct soldering. The soldering iron melts the solder, which should flow into the twist itself, reliably connecting the wires to each other.

Soldered wiring in the junction box with a soldering iron

Often copper wires are soldered using this method, but if you purchase special solder for soldering aluminum, you can also solder copper from aluminum.

Soldering is quite reliable, but is not recommended in areas where there may be strong heat. Moreover, under mechanical stress, the connection may weaken.

Using screw terminals

Connection of copper and aluminum wires

This method is fast, simple and effective. And most importantly, such clamps can combine dissimilar metals. For example, if you need to connect aluminum and copper conductors, which in itself, as you know, is contraindicated. These clamps are very simple and compact, and their cost may pleasantly surprise you.

Terminal blocks

To connect wires with clamps you only need to complete 2 steps:

1. Remove 5 mm of insulation.
2. Insert into the clamps and tighten the screw.

Melted terminal block contacts

That's all, as you can see, everything is very simple and fast. It is only important to control the force with which you clamp. If you tighten the screw too tightly, you may damage the wires. You need to be especially careful when working with aluminum wires.

Crimp lugs

The only disadvantage of a screw connection is that when working with a multi-core cable, it must be crimped with a special nozzle to ensure normal contact and integrity of the wire.

Bolted connections

Bolted connection

This connection is quite reliable, but cumbersome. It is not suitable for modern distribution boxes due to its dimensions, but for large old-style boxes it is just right. This method can be used to connect both homogeneous and dissimilar metals. The work is carried out as follows:

1. A steel washer is placed on the bolt.
2. The insulation is removed from the conductors and they are formed into a ring.
3. The first ring is put on the bolt.
4. Then comes another steel washer, which is placed on the bolt after the first.
5. The second connecting wire is put on top.
6. This entire “sandwich” is clamped with a nut.
7. In the end, everything needs to be insulated.

It is this design that makes the contact bulky. If you need to connect several pairs of wires, then this option will not be the best.

Self-clamping terminals

This method can be called the most modern, popular and easy to use. All you need is to buy special terminals at the store. Inside these terminals there is a special paste that prevents metals from oxidizing. Thanks to this, various metals can be inserted into such joints.

The work is as follows:

1. 10 mm of insulation is removed from each wire.
2. The lever, which is located on the clip, rises up.
3. The conductors are inserted into the connector.
4. The lever lowers to its original position.

If your clamps do not have levers, they must be inserted until the terminal snaps into place.

Connecting wires with a terminal block without levers

We have looked at the most reliable methods by which you can combine wires in a junction box. This is a very important stage of electrical installation work, since 70% of errors during the work consist precisely in incorrect connection of conductors.

But if you, even without experience in such work, use the methods given in this article, you can easily do everything in accordance with the requirements of the regulations. But which of these methods to choose depends on your capabilities and desires.

This video shows how to connect wires in a junction box:

You will learn everything about sleeving wires or crimping lugs from the material provided in this video:

Scheme

Box diagram

Switch and socket block diagram

Connection

Junction box connection diagram

Connecting sockets

Switch connection diagram

Junction box

Connecting wires

Wire connection diagram in the box

Source: https://kakpravilnosdelat.ru/kak-soedinit-provoda-v-raspredelitelnoy-korobke/

Twisting wires is a popular and effective method of connecting electrical wiring.

(Last Updated On: 12/08/2017)

Correct twisting of wires

Installation of an electrical network, especially the stage when connecting contacts, involves an operation such as twisting wires - it is twisting that ensures high reliability of connections. the task of twisting is to protect the connection from the occurrence of excess resistance, which will lead to constant heating of the contacts. And this, in turn, will not only reduce the service life of the wiring, but can also become an indirect cause of fire.

Of course, not only twisting wires can relieve an electrical circuit from additional voltage; the following methods can also be used:

• installation of PPE caps;
• welding or soldering joints;
• use of special terminals or clamps.

However, twisting wiring has a long history of use, for example, electricians twisted wires in a variety of circuits back in the middle of the last century; this was the most convenient method, because it required only a screwdriver, pliers and a special knife. With the help of these simple tools, it was possible to quickly and efficiently twist the wires in the junction box, and this operation was carried out almost everywhere, because junction boxes were used at a variety of facilities.

Features of twisting wires

As long-term practice shows, high-quality twisting can retain its qualities for many years - its service life can be tens of years.

However, in modern operating conditions, higher demands are placed on such a connection than in the same last century. After all, back then there were very few electrical appliances in homes, and the load on the home electrical network was minimal. Today, apartments are fully electrified premises in which all life activities are supported by electrical appliances.

Moreover, even an ordinary kettle and or mixer today consumes at least 1 kW of energy, and in total the volume of energy flowing through the electrical network is many times higher than the same volumes that took place 30-35 years ago.

Therefore, increased requirements for quality and reliability are imposed on the wiring, including its connection. For example, it is strongly recommended to replace old aluminum wires with more efficient copper wires, and it is also necessary to replace the wiring if the insulation has worn out.

Selecting the type of wire connection

As mentioned above, in addition to twisting, there are other ways to connect wiring, however, in domestic conditions they cannot always be done:

• welding requires a welding machine;
• soldering requires the use of a soldering iron and suitable solder;
• PPE contacts vary in scope - different types of contacts must be used to connect aluminum and copper wires.

Often, choosing the type of connection confuses a master who does not have much experience working with electrical networks. To help them, special rules for the design of electrical equipment (abbr. PUE ) have been developed.

If experience is very poor or it is not possible to get the necessary equipment, for example, a compact welding machine, then twisting will be the best option.

Types of twisting electrical wiring

First of all, you need to understand the theory of how to make such a connection correctly. Firstly, you can twist the wires in various ways:

• by simple twisting method;
• bandage twist;
• twisting using the “groove” method.

simple twisting is most often used . Its technology is truly elementary - the bare ends of 2 wires are twisted into a single spiral, after which the protruding end of the wire is hidden in the depth of the twist.

With the help of bandage twisting, wires with a large cross-section are most often connected, which cannot be twisted compactly using simple twisting. With this connection, the bare ends of the wires are aligned parallel to each other and twisted on top with a separate piece of thinner wire.

Twisting using the “Groove” is intended for connecting wires with aluminum conductors. This technology has a rather complex geometric shape and is based on the mutual interlocking of wires with ends bent into an open loop. After this engagement, the ends of the wires are wrapped around another wire.

It should be taken into account that the above methods are applicable for connecting wires with a cross-section of up to 10 square meters. This range is quite sufficient for working with a household electrical network, because wires with a cross-section of 1.5-2.5 square meters are most often used here.

PPE caps can be used , but they are only suitable for wires with a cross-section of up to 6 square meters.

PPE caps for twisting wires:

When connecting wires with wires made of different metals using the bandage twist method, they also need to be soldered. The regulations prohibit simple twisting of cores of different compositions. In addition, it is necessary to pre-tin the copper wire.

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

As for connecting stranded wires, it can be done using any convenient method. However, you need to remember that the more cores there are in the wire, the more critical and complex the connection will be. For greater reliability, you need to use connecting caps.

An important point - before twisting, you need to not only remove the insulation from the ends of the wires, but also clean them with fine sandpaper.

The fact is that when metal oxidizes, it acquires insulating properties, which will negatively affect the overall performance of the electrical network.

And one more important point - before working with a functioning electrical network, it is strongly recommended to practice on separate sections of wire.

This will allow the work to be completed both more efficiently and, most importantly, safely. Safety is generally a priority when working with electrical wiring, so if you are not confident in your abilities, it is better to entrust the work to professionals.

Source: http://cassuspro.ru/skrutka-provodov.html

How to properly connect stranded wires to each other

In stranded wires, the cross-section is formed by several, sometimes intertwined, cores. Knowing how to connect stranded wires to each other, you can easily do this work yourself and get a strong contact that is absolutely safe during operation.

Where are stranded wires used?

Any stranded conductor contains at its base a large number of thin wires. The use of a multi-core cable is important in areas that require a large number of bends or, if necessary, to pull the conductor through holes that are too narrow and long enough.

The scope of application of stranded conductors is presented:

• extended tees;
• mobile lighting devices;
• automotive wiring;
• connecting lighting fixtures to the electrical network;
• connecting switches or other types of levers to influence the electrical network.

Flexible stranded conductors can be twisted repeatedly and easily, which does not negatively affect the functionality of the system. Among other things, this particular type of electrical wiring is distinguished by plasticity, and greater flexibility and elasticity is imparted to the wire by weaving a special thread, which in strength and composition is a bit like nylon.

Methods for connecting stranded wires to each other

The methods used today for electrical connections of stranded conductors are distinguished by the ability to obtain not only strong, reliable and durable, but also completely safe contact of the conductors.

Stranding of stranded conductors

This option is the easiest to implement and intuitive, not requiring the use of special equipment or professional tools.

Twisting is the easiest way to connect stranded wires

1. Strip the conductors at the ends of the conductors from the insulating layer and place them on top of each other. Twist the exposed strands overlapping each other.

   Before connecting the wires, the ends must be cleaned

2. Strengthen the twist using pliers. Simple parallel twisting is quite reliable from the point of view of contact between the cores, but vibration and mechanical forces applied to break can easily destroy the strength of such a connection.

   Use pliers to twist the wires together

The second method consists of the following steps:

1. Strip the conductor cores from the insulating layer and place them on top of each other crosswise.

   Peel the insulating layer of the wires and stack the wires on top of each other

2. Wrap one bare wire around the other over the entire surface.

   Wrap one wire around another

   Wrap the wires

3. Visually verify the strength of the winding. Using simple or traditional twisting, the electrical connection of additional conductors to the main, leading electrical wiring line is carried out.

Twisting wires using the third method:

1. Remove insulation from the ends of the conductors. Place the bare ends on top of each other and wind the first core.

   Place the wires on top of each other

2. Wind the second core, then visually verify the reliability of the connection. The sequential twisting method involves “winding” each connected conductor onto another, which ensures optimal contact of the cores.

   Wind one of the cores

   In this method, one wire is “wound” around another

There is also a fourth method, which is as follows:

1. Using a sharp knife, strip the ends of the conductors from insulation and align them along the length.

   Align the wires in length

2. Bend the connected stripped ends and wrap them with a piece of another core.

   Twist the folded strands with a piece of conductor

3. Perform a visual inspection of the connection and make sure it is secure. Band twisting consists of parallel application of the connected cores to each other and subsequent fixation of the resulting connection using a tightly laid soft conductor.

   Bandage twisting ensures a reliable connection of cores

Soldering method

Soldering the conductors using a household soldering iron ensures high-strength contact and good electrical conductivity. Tinning of stranded conductors is carried out using rosin (flux) and standard solder using standard technology.

1. Strip the wires of insulation and remove any resulting oxidation if necessary.

   Remove all oxidation from the wires

2. Heat the wires with a soldering iron tip until the flux melts and immerse the heated wire in a container with rosin.

   Heat the wire with a soldering iron and immerse it in rosin.

3. Apply molten solder to the soldering iron tip and carefully transfer it to the exposed parts of the core. After tinning, the wires should be connected to each other by twisting, which must be “tightened” with pliers.

   Tighten the twist with pliers

Terminal type connections

The use of terminals of different types is the most accessible way to connect multi-core wires in everyday life. In most cases, the terminal blocks used are divided into a couple of main types.

The principle of operation of clamping terminals involves fixing the wire using a built-in spring mechanism.

Terminals are often used to connect wires

The screw-type terminal block involves reliable fixation of all connected stranded wires using a screw. To increase the area of ​​wire contact with a conductive surface, an additional bend of the core is required.

The wires in the terminal block are secured by tightening the screws

Stage-by-stage execution of work:

1. Strip the ends of the conductor and align them in length according to the depth of the terminal block.

   Align the wires in length

2. When connecting more than one conductor to the terminal block at the same time, you must first connect the wires by parallel twisting.

   First you need to twist the wires

3. Check the reliability of the twisting and then fix the wires in the connector hole.

   Fix the wires

Crimping method

The crimping method involves connecting wires or cables using a copper or aluminum sleeve using special crimping pliers of a hydraulic or manual type.

In this case, the connection is made using a special sleeve

The pressing technology involves stripping the insulation according to the length of the sleeve, and conductors that are too thin should be connected by twisting. Then all the cables are folded together and placed inside the sleeve, after which double crimping is performed along the entire length. The method allows for a reliable and safe connection of multi-core wires made of different types of materials.

Bolted connection

The simplest, but not reliable enough way to connect stranded wires is twisting followed by bolting. This detachable connection option is most often used in open wiring conditions.

Bolted connection is the simplest, but not very reliable

To increase the level of reliability of the connection of stranded wires, it is recommended to strip the ends of insulation, then tin the cleaned areas and fasten them with a bolt.

Application of connecting insulating clamps

PPE elements are used when it is necessary to connect multi-core wires with a small cross-section (within 25 mm2). The design feature of this clamp is a plastic body with a built-in cone-shaped spring.

This method is suitable for connecting wires with a small cross-section

Stranded wires are first connected into one bundle using twisting, onto which the clamping part is then screwed. Among other things, the wire connection does not require additional insulation.

Welding method

A permanent connection is the most reliable method when working with multi-core wires. When welding is performed correctly, the general indicators of mechanical strength and contact resistance in terms of reliability do not differ from similar parameters of a solid conductor.

Welding connection of wires is considered the most reliable

Welding can be performed on alternating and direct current. At the preparatory stage, the wires are stripped of insulation, after which they are twisted and straightened by trimming the ends. To ensure that the conductors do not overheat during the welding process, it is necessary to ensure high-quality heat removal.

Security measures

In order to ensure safe operation of connected stranded wires, it is important to insulate all parts of the electrical wiring.

Proper insulation helps prevent dangerous contact of conductive parts with each other or with the human body.

When choosing an insulating material, it is necessary to take into account the operating conditions of the electrical circuit, but in most cases, insulating tape, as well as a special vinyl or heat-shrinkable tube, are used for this purpose.

If the connection area is exposed to the negative effects of high temperatures, it is recommended to use varnished cloth or fabric insulating tape as an insulating material.

Correct execution of all stages of electrical installation is of no small importance.

Only with reliable connection and proper connection of all elements of the electrical network is it possible to minimize the risk of areas with poor contact, and also prevent local overheating and electrical wiring breaks.

Multicore cables are a popular and widespread option, widely used for arranging electrical wiring for various purposes. The general rules for the separate connection of stranded and single-core conductors do not have any differences or features, therefore it is allowed to use twisting, screw clamps, PPE elements, welding and soldering for this purpose.

Source: https://aqua-rmnt.com/ehlektrosnabzhenie/kak-soedinit-mnogozhilnyie-provoda-mezhdu-soboy.html

Connecting wires by twisting - electrician's advice - Electro Genius

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:

1. Carefully strip both wires using a special tool or a simple knife, removing the insulation by about five centimeters;
2. Degrease bare contacts with acetone;
3. Take a piece of sandpaper and sand the ends of the conductors to a pronounced metallic color;
4. 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);
5. We wind the second core in the same way;
6. 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:

1. 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.
2. 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.
3. 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.
4. 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://orenburgelectro.ru/baza-znanij/soedinenie-provodov-skrutkoj-sovety-elektrika.html

Crimping of wires and twists with sleeves

Electric current is no joke, because in the event of a short circuit on any part of the conductive circuit, the owner of the apartment will have a considerable heap of problems at his disposal: from fire of wiring and smoked walls, to a serious fire.

Moreover, the statistics for the country speak for themselves: 250 thousand fires occur throughout Russia every year due to faulty electrical wiring (23%) or due to careless handling of fire (half of the accidents).

The reasons for such critical situations are different, namely:

• The place of a loose connection (contact) will certainly heat up during operation, which will subsequently lead to melted wire insulation and a fire.
• A short circuit in the cable (a matter of chance), and then a fire situation.
• Often the cause of a fire is the person himself, who decides to play dangerous games with the fire element.
• Poor quality cables and wires that are cheap but not safe

Types of connections and advantages of crimping twists

During my work as an electrician in the construction industry, I learned a lot of new things: what types of wires exist, how to calculate the cross-section of cable cores depending on the load, how to twist correctly, and more.

Therefore, I can share my experience with the readers of this article. In the event that one of the experienced and seasoned electricians in installation “battles” does not like something, I do not claim universal recognition; I can limit myself to the role of an adviser to newcomers in this difficult matter.

There are several types of wire connections that are most often used among specialists:

Connecting wires using a terminal block

In this way, I usually connect the wires of light groups where the load is not so great. You take the wire, free it from the outer insulation, strip the wires to the required size and head to the “barricades”. The most important thing is to properly stretch the connecting bolts of the terminal so that in the future the plastic product does not spread, taking on some shapeless shape.

And

Soldering twists

In this matter, some experience is required, since not every electrician is able to irradiate the connection efficiently. I was convinced of this myself when my first twist, connected in a similar way, came apart during testing, making me burn with shame.

However, as they say, everything is for the better! For soldering, they usually use rosin or fat (neutral), the soldering iron itself, tin and a special stand so as not to inadvertently damage, for example, a kitchen table with a hot tool. Having tinned the junction of the wires with rosin, it is necessary to pick up a small amount of solder with the tip of the soldering iron and process the twist with it.

This process must be repeated until the joint is completely and evenly filled with alloy. After this, I usually smooth out the twist with sandpaper to remove any protruding sharp edges and isolate the joint.

Bolted connection of cables and wires using a special clamp (“nut”)

 In my practice, there have been cases when it is necessary to connect wires made of different materials (copper and aluminum). Here you simply cannot do without a bolt with a nut and a washer, with the help of which current flows through the conductor without any problems. The main thing here is to thoroughly tighten the bolted connection with a wrench for better contact.

However, this must be done without fanaticism, otherwise you can ruin the whole thing in the bud by breaking a key or bolt.

Also, in this case, the so-called “walnut” can be very useful, but not a walnut, but a metal one.

This is a clamp that also needs to be pulled through, only with a screwdriver, having previously inserted the exposed wires into special grooves.

Connection using a welding machine

An inconvenient, although very reliable method. Not every electrician will be able to carry such a unit, because the building where the installation is carried out can be quite high. You’ll get tired of running back and forth all day, and you’ll dream of throwing off such a burden.

Moreover, the welded twist is insulated with a special cap or heat shrink. Thus, the connection will serve reliably and for a long time.

 Wire crimping

 For this purpose, I use press pliers, with which I crimp a copper sleeve placed on twisted wires several times. It is important to follow one rule: do not overdo it! After all, a twist cut by a tool can cause a lot of trouble for such a would-be electrician - everything will have to be done again. If the diameter of the connection point is smaller than the diameter of the sleeve, you can always show soldier ingenuity, that is, slip pieces of wires under the copper product - and “Basta”!

The advantages of crimping are obvious: you put a handful of copper sleeves in a small container, took the press pliers with you and that’s it, you don’t need to drag around an extra bulky tool. The crimping process itself is incredibly simple, just calculate your strength.

Wire crimping tool

No matter what anyone says, crimping wires is a simple process. You may not get it right the first time, but over time, after several attempts, you can easily get the hang of it. For example, I, too, was once a completely “green” specialist; I didn’t know how to hold a screwdriver in my hands correctly, but under the strict guidance of my senior fellow electricians, I eventually turned into an experienced craftsman. The main thing is to work.

For crimping there is a special tool - a hand press and copper sleeves. The sleeves are different, just like the wires. Sometimes you need to connect an aluminum wire to a copper wire, but how to do this? After all, different materials have different technical characteristics.

  It is precisely for such cases that there are several main types of sleeves used everywhere by the electrical installation fraternity: Everything is clear here, a sleeve made of the same material is put on the twisted copper wires by an electrician and crimped. However, everything is not so simple. Copper products are also divided into two types: GM and GML. GM means “copper sleeve”. Used in ordinary cases when you just need to fix the twist.

GML - “tinned copper sleeve”. During the tinning process, such a product is covered with a layer of a special solution (tin-bismuth), which protects the sleeve from corrosion. Sleeves made of similar material are used to connect aluminum wires. Although, I have met “masters” who neglected this rule and made hack work: they cleverly put an aluminum sleeve on a copper twist and vice versa.

To be honest, at that moment I wanted to give such craftsmen a slap on the wrist, but they wouldn’t understand why, and they might even give back. These products are used to connect wires made of different materials. On one side (copper), a copper core is inserted, and on the other, an aluminum core. This whole thing is well compressed. GSI sleeve is a product that has undergone a tinning process and is covered with an outer insulated sheath (PVC).

When using these types of sleeves, the electrician only needs to make the press without worrying about the insulation of the twist.

To do this, you will need to strip the wire from the outer insulation, and then use a mounting knife to remove the inner protective sheath. To make it convenient to twist the wires, I personally collect the bare wires into a bundle and bend the ends.

Then, first twisting the wires by hand, I achieve greater contact through the work of the pliers with which I tighten the twist.

Having bitten off the excess wires with the same tool, I get a good connection 3-5 cm long.

Next, the only thing left to do is put copper sleeves of suitable sizes on the twists and crimp them. Moreover, crimps come in different diameters (6 mm, 8 mm, 10 mm and more). Usually, I use 6 mm products to connect strands of light groups, where the cross-section of the wires is not so large (1.5 sq. mm). For socket groups, sleeves with a diameter of 8 mm or more are taken, since here the wires have a cross-section from 2.5 to 4 sq. mm.

After that, I insulate the connections, put them in the junction box and close the lid so that everything is “feng shui”.

How to saw sleeves for crimping

This is the question I asked myself at the beginning of my electrician career. Now, I can easily satisfy the curiosity of any new installer; as they say, you can’t waste your skill. The fact is that standard sleeves are too large for junction boxes, so for convenience and saving material they are cut in half or three times.

To make the required number of sleeves with your own hands, take a copper tube of the required diameter, a hacksaw for metal and some kind of support point (a chair, bench or table).

The tube is placed on a chair and securely fixed with your hand or foot. If you invent another way to fasten a copper product, you hold all the cards. There are no limits to the imagination of the Russian soul!

The other hand grabs a hacksaw for 250 rubles and performs the usual action with a cutting tool: back and forth, like cutting firewood in a country house. It’s better to lay a newspaper on the floor before this, so that the cartridges don’t roll somewhere, but serve every single one of our noble causes.

That's all, it's never too late to learn!

Sergey (c) 2016

Source: http://zakenergo.ru/primeri-rabot/opressovka-provodov.html