Connecting wires in a junction box: learning how to connect wires. Methods for connecting wires to each other How to connect cut wires

Electricity is not an area where you need to save. It is advisable to do everything carefully, select high-quality materials, and take a balanced approach to the choice of sizes/diameters/values. Let's start with the fact that even the conductors must be connected correctly. And choosing ways to connect wires is not as easy as it seems.

There are about a dozen ways to connect wires. In general, they can be divided into two groups: those that require special equipment or specific skills and those that can be successfully used by any home craftsman - they do not require any special skills.

The first group includes:

• Soldering. When connecting wires of small diameter in the amount of 2-3 pieces, this is a very reliable method. True, it requires a soldering iron and some skills in using it.
• Welding. You need a welding machine and special electrodes. But the contact is reliable - the conductors are fused into a monolith.
• Crimping with sleeves. You need sleeves and special pliers. The sleeves are selected according to certain rules that you need to know. The connection is reliable, but it will have to be cut to re-seal.

All these methods of connecting wires are performed mainly by specialists. If you have skills in handling a soldering iron or welding machine, after practicing on unnecessary scraps, you can make them yourself.

Some methods of connecting wires are more popular, others less so.

Methods of connecting wires that do not require any specific skills are becoming increasingly popular. Their advantage is quick installation and reliable connection. Disadvantage - you need “connectors” - terminal blocks, clamps, bolts. Some of them cost quite a lot of money (Wago terminal blocks, for example), although there are also inexpensive options - screw terminal blocks.

So here are ways to connect wires that are easy to implement:

There are two opposing opinions among professionals. Some believe that new methods of connecting wires - clamps - are the best solution, as they speed up installation without compromising the quality of the connection. Others say that the springs will eventually weaken and contact will deteriorate. In this matter, the choice is yours.

Technical nuances of different types of wire connections

All types of wire connections described above are used when laying electrical wiring, but the specific type is selected based on several characteristics:

Let's consider each connection method, the technology for its implementation and the advisability of use in various situations.

Soldering electrical wires

One of the oldest and most widespread types of connection. To work you will need rosin, solder and a soldering iron. The soldering process is as follows:

Actually, this completes the soldering of electrical wires. Not the most difficult process but it requires certain skills. The main thing is to heat the joint enough so that the solder flows between all the wires. In this case, you must not overheat, otherwise the insulation will melt. This is where the art lies - not to burn the insulation, but to ensure reliable contact.

When can soldering be used? This method of connecting wires works well in low-current electrical applications. When connecting wires in a junction box, it is no longer very convenient. Especially if there are a lot of wires and/or they are of large diameter. Soldering such a twist is not a task for beginners. In addition, when trying to make a connection in a junction box, the soldering begins to break down. To the point where some wires fall off. In general, the method is good for connecting conductors of small diameters.

Welding conductors in electrical connections

One of the most reliable methods of connecting wires is welding. During this process, the metal of individual conductors is brought to the melting point, mixed, and after cooling it forms a monolith. This method works very well with large diameters or with a large number of connected conductors. It is distinguished by not just excellent contact, which does not weaken or change its characteristics over time. It is also mechanically very strong - the fused part does not allow the connection to fall apart even under heavy loads.

A drop at the end of the twist is molten aluminum

There are also disadvantages. The first is that the conductors are fused, that is, the connection is absolutely permanent. If you need to re-seal it, you have to remove the fused part and start all over again. To be able to do this, you must always leave a small gap along the length of the wires. The second drawback is that you need a welding machine, skills in handling it, and special electrodes for welding aluminum or copper. The main task in this case is not to burn the insulation, but to melt the conductors. To make this possible, they are stripped of about 10 cm of insulation, tightly twisted into a bundle, and then welded at the very end.

Another disadvantage of welding wires is that it is a labor-intensive process, which also requires pinpoint precision in handling the welding machine. Due to the combination of these qualities, many professional electricians do not like this method. If you do the wiring “for yourself” and know how to handle the equipment, you can spend some time. Just practice first on scraps, select the current strength and welding time. Only after you get everything perfect several times can you start welding wires “in real life”.

Crimping

Another method that requires special equipment is crimping wires with sleeves. There are copper and aluminum sleeves of different diameters. The material is selected depending on the material of the conductor, and the size is selected according to the diameter and number of wires in a particular connection. They should fill almost the entire space inside the sleeve, but there should still be free space. The quality of contact depends on the correct choice of sleeve size. This is the main difficulty with this method of connecting wires: the sleeve should not be too large or too small.

The technology of work is as follows:

• The conductors are stripped of insulation (the length of the stripped section is slightly longer than the length of the sleeve).
• Each conductor is stripped to bare metal (we remove oxides with fine-grain sandpaper).
• The wires are twisted and inserted into the sleeve.
• They are crimped with special pliers.

It seems to be simple, but it is in the selection of the sleeve and the presence of pliers that the whole difficulty lies. You can, of course, try to crimp it with pliers or pliers. But it is impossible to guarantee normal contact in this case.

Twist

In the first section of the article, we deliberately omitted twisting the wires. According to the current standard, it cannot be used, since it does not provide proper contact and reliability of the connection. This method can replace any other methods of connecting wires.

Yes, wiring was done on twists 20-30 years ago and everything worked perfectly. But what were the loads on the networks then, and what are they now... Today, the amount of equipment in an ordinary apartment or private house has increased significantly, and most of the equipment is demanding on power supply. Some types simply will not work at reduced voltage.

Why is twisting so bad? Wires twisted into a bundle do not make good enough contact. At first, everything is fine, but over time the metal becomes covered with an oxide film, which significantly worsens the contact. If there is insufficient contact, the joint begins to heat up; an increase in temperature causes more active formation of an oxide film, which further worsens the contact. At some point, the twist becomes very hot, which can lead to a fire. It is for this reason that it is better to choose any other method. There are some that can be done even faster and easier, but which are more reliable.

Connection insulation

All the methods of connecting wires described above - welding, soldering, crimping with a sleeve - provide for their insulation, since the exposed conductors must be protected. For these purposes, electrical tape or heat-shrinkable tubes are used.

Everyone probably knows how to use electrical tape, but we’ll tell you a little about heat-shrinkable tubes. This is a hollow polymer tube, which, with increasing temperature, significantly reduces its diameter (2-6 times, depending on the type). The size is selected so that the pre-shrink volume is larger than the diameter of the insulated wires, and the post-shrink volume is smaller. In this case, a tight fit of the polymer is ensured, which guarantees a good degree of insulation.

Heat-shrinkable tubes for insulating conductors can be of different diameters and colors

In addition to size, heat shrink tubes are selected according to special characteristics. They are:

• heat resistant;
• light-stabilized (for outdoor use);
• oil-gasoline resistant;
• resistant to chemicals.

The cost of heat-shrinkable tubes is not very high - from $0.5 to $0.75 per 1 meter. Their length should be slightly longer than the length of the bare conductors - so that one edge of the tube stretches over the insulation of the conductors by about 0.5 cm, and the other sticks out by 0.5-1 cm. After the tube is stretched, take a heat source (you can use a lighter) and heat the tube. The heating temperature can be different - from 60°C to +120°C. After the joint is tightened, the heating stops, after which the polymer quickly cools.

Insulating wires with heat-shrinkable tubing takes little time—seconds count—and the quality of the insulation is high. Sometimes, for greater reliability, two tubes can be used - a slightly smaller and a slightly larger diameter. In this case, first one tube is put on and warmed up, then the second. Such connections can be used even in water.

Terminal blocks

This method is also preferred by electricians, but can be easily used by a person who can hold a regular screwdriver. This is one of the first ways to connect electrical wires without soldering. Today, on almost every electrical appliance you can see a version of this connection - this is the output block to which the power cord is connected.

Terminal blocks are a contact plate that is sealed in a plastic (polymer) or carbolite housing. They cost very little and are available in almost any store that sells electrical goods.

Terminal blocks are convenient, inexpensive, allow you to connect copper and aluminum wires, conductors of different diameters, single- and multi-core

The connection occurs literally in seconds. The insulation is removed from the conductor (approximately 0.5-0.7 cm), and the oxide film is removed. Two conductors are inserted into the socket - one opposite the other - and secured with bolts. These bolts press the metal against the contact plate, making the connection.

The advantage of this connection method: you can connect wires of different sections, single-core to multi-core. The disadvantage is that only a pair of wires are connected. To connect three or more, jumpers must be installed.

PPE caps

Another way to connect wires that does not require special skills is to install PPE caps. They are a plastic cone-shaped body with a spring sealed inside. They come in different sizes - from 0 to 5. You can connect wires of different diameters - on each package the minimum and maximum and minimum total cross-section of the wires to be connected is written. In addition, there are cases simply in the form of a cone, and some with stops “ears” that make their installation easier. When choosing, pay attention to the quality of the plastic - it should not bend.

Connecting wires using PPE is very simple: strip the insulation, collect the wires into a bundle, insert them inside the cap and start twisting. A spring inside the cap grips the conductors, helping to twist them. The result is a twist, which is wrapped around the outside with spring wire. That is, the contact turns out to be very high quality and good. This method of connecting wires with PPE caps has been used for a long time in Europe and America; it came to us about 10 years ago.

If you need ways to connect wires without welding, consider PPE

There is another way: first the wires are twisted, then caps are put on them. This method was invented by the Russian company that produces these wire connectors - KZT. But this technique requires more time, and the quality of the connection is no different.

There is one more point: how long to strip the insulation from the wires. Manufacturers give clear instructions on this matter - each size has its own length of exposed conductors. It is designed so that all conductors without insulation are inside the housing. If you do this, the connection does not require additional insulation, which greatly speeds up the process. In addition, the expanded lower part does not interfere with heat dissipation and such a connection heats up less.

Practicing electricians advise stripping the wires by 5-10 cm, and insulating the twist that remains without insulation. This is argued by the fact that the contact area with this option is larger. It is true, but this option heats up more. And the standard solution is reliable. There are no problems with contact (if the quality of PPE is normal).

Wago Clamps

The heated debates flared up specifically about Vago. Some people absolutely love this product, while others don’t. Moreover, no less categorically. Opponents of using the Wago don't like the fact that the contact is based on a spring. They say that it may weaken. This will lead to poor contact and overheating. And they show a photo with melted clamps. Proponents of this method conduct tests and comparisons and say that a properly selected branded clamp lasts for many years without signs of contact deterioration. And manufacturers say that, if the technology is followed, Wago terminal blocks can be used for 25-35 years. It is important to choose the right type and parameters and not buy a fake (there are a lot of them).

There are two types of Vago clamps. The first series is slightly less expensive, called Wago. These clamps are suitable for connecting single-core and stranded wires with a cross-section of 0.5-4 mm2. For conductors of smaller or larger cross-sections there is another series - Cage Clamp. It has a very wide range of use - 0.08-35 mm2, but also high cost. In any case, contact is ensured by a contact plate made of good copper. The special shape of the plate allows for reliable contact.

Detachable

In addition, Vago spring-loaded clamps are detachable (222 series) and permanent (773 and 273 series). Detachable ones are convenient to install in places where changes to the network configuration are possible. For example, in junction boxes. They have levers with which the wires are clamped or released. Wago detachable terminal blocks can connect from 2 to 5 conductors. Moreover, they can be of different sections and types (single-core and multi-core). The order of connecting the wires is as follows:

We repeat the same operation with the other wire(s). All this takes a matter of seconds. Very fast and convenient. It's not surprising that many professional electricians have forgotten other ways to connect wires.

One-piece

One-piece series differ in structure: there is a clamp body and a cap. The cap can be made of transparent polymer (773 series) or opaque plastic (223). The housing has holes into which wires stripped of insulation are inserted.

To ensure normal contact, you just need to remove the insulation correctly - exactly 12-13 mm. These are the requirements set by the manufacturer. After the conductor is inserted, its bare part should be in the terminal block, and the insulation should rest against the housing. Under such conditions, contact will be reliable.

Bolted connection

Another type of connection of electrical wires with solid experience is bolted. It is called so because a bolt, nut and several washers are used to connect the wires. Contact through the use of washers is quite good, but the entire structure takes up a lot of space and is inconvenient to install. It is mainly used if it is necessary to connect conductors made of different metals - aluminum and copper.

The order of assembling the connection is as follows:

• We strip the wires of insulation.
• From the stripped part we form a loop, the diameter of which is equal to the diameter of the bolt.
• We put it on the bolt in this order
  • washer (it rests on the bolt head);
  • one of the conductors;
  • another washer;
  • second conductor;
  • third washer;
• We tighten everything with a nut.

This way you can connect not only two, but also three or more wires. Please note that you must not only tighten the nut by hand. You have to use wrenches and put in a lot of effort.

The best ways to connect wires for different occasions

Since different wires can be connected and they can be used in different conditions, the optimal method must be chosen taking into account all these nuances. Here are the most common situations:

These are the most common options for non-standard connections.

When connecting wires of different diameters in series, the maximum load current will be determined by the cross-section of the wire with a smaller diameter. For example, a connection was made between copper wires with a diameter of 1.6 mm and 2 mm. In this case, the maximum load current on the electrical wiring, which is determined from the table, will be 10 A, and not 16 A, as for a wire with a diameter of 2 mm.

Connecting electrical wires by twisting

Until recently, twisting was the most common method of connecting wires when doing electrical wiring; due to its accessibility, all it took was a knife and pliers. But, according to statistics, twisting is an unreliable way to connect conductors.

According to the electrical installation rules (PUE), twisted connections when installing electrical wiring are prohibited. But, despite the noted disadvantages, the twisting method is currently widely used. Connecting conductors of low-current circuits by twisting, subject to certain rules, is quite justified.

The photo on the left shows how twisting is unacceptable. If one conductor is twisted around another, the mechanical strength of such a connection will be insufficient. When twisting wires, you must make at least three turns of wires around each other. In the middle photo, the twisting is done correctly, but a copper conductor is twisted with an aluminum one, which is not permissible, since when copper comes into contact with aluminum, an emf of more than 0.6 mV occurs.

In the photo on the right, the twisting of copper and aluminum wires is done correctly, since the copper wire is tinned with solder before twisting. You can twist several wires together at once; in a junction box, sometimes up to 6 conductors are twisted, wires of different diameters and from different metals, a stranded wire with a single-core wire. Only the stranded wire needs to be made single-core by first soldering it with solder.

Connecting electrical wires by soldering

The connection of copper wires with high-quality soldering is the most reliable and is practically not inferior to a solid wire. All of the above examples of twisted wires, except for aluminum and tinsel, when tinning the conductors before twisting and then soldering them with solder, will be reliable on a par with solid wires. The only drawback is the extra labor involved, but it's worth it.

If you need to connect a pair of wires and the twisted conductors must be directed in different directions, then a slightly different type of twist is used.

By splicing two pairs of double wires in the manner described below, it is possible to obtain a compact and beautiful connection by twisting both single-core and multi-core pairs of conductors. This twisting method can be successfully used, for example, when splicing broken wires in a wall, extending a wire when moving a socket or switch from one place on the wall to another, when repairing or extending the length of a carrying cable.

To obtain a reliable and beautiful connection, it is necessary to adjust the lengths of the ends of the conductors with a shift of 2-3 cm.

Twist the conductors in pairs. With this type of twisting, two turns are enough for a single-core wire, and five for a multi-core wire.

If you plan to hide the twists under plaster or in another inaccessible place, then the twists must be soldered. After soldering, you need to go over the solder with sandpaper to remove any sharp solder icicles that could pierce the insulation and stick out from it. You can do without soldering if the connection is accessible and the currents flowing through the conductors are not large, but the durability of the connection without soldering will be much lower.

Due to the shift of the twisting points, there is no need to insulate each of the connections separately. We attach a strip of insulating tape on both sides along the conductors. Finally, you need to wind three more layers of insulating tape. According to the requirements of the Electrical Safety Rules, there must be at least three layers.

Wires spliced ​​and soldered in the manner described above can be safely laid in the wall and plastered on top. Before installation, it is advisable to protect the connection with a vinyl chloride tube placed in advance on one of the pairs of wires. I have done this many times, and the reliability has been confirmed by time.

Connecting wires in junction boxes

When I moved into an apartment built in 1958 and began doing renovations, I was immediately confronted with the blinking of the lighting bulbs in rhythm with the hammer blows on the walls. The primary task of repair arose, carrying out an audit of distribution boxes. Opening them revealed the presence of poor contact in the twisted copper wires. To restore contact, it was necessary to disconnect the twists, clean the ends of the wires with sandpaper and twist them again.

When trying to disconnect, I encountered a seemingly insurmountable obstacle. The ends of the wires broke off even without any effort. Over time, copper lost its elasticity and became brittle. When stripping the wire, the insulation was apparently cut in a circle with a knife blade and notches were made. It was in these places that the wire broke off. The copper became hardened due to temperature fluctuations.

You can restore the elasticity of copper, unlike ferrous metals, by heating it to red and quickly cooling it. But for this case, such a technique is unacceptable. The ends of the wires no longer than 4 cm remained. There was no choice for connection. Just solder.

I exposed the wires with a soldering iron, melted the insulation, tinned them with solder, tied them in groups with tinned copper wire and filled them with solder using a 60-watt soldering iron. The question immediately arises: how to solder the wires in the junction box if the electrical wiring is de-energized? The answer is simple, using a soldering iron powered by a battery.

So I updated the connections in all junction boxes, spending no more than 1 hour on each. I am completely confident in the reliability of the connections made, and this has been confirmed by the 18 years that have passed since then. Here's a photo of one of my boxes.

When leveling the walls with Rotband in the hallway and installing a stretch ceiling, the distribution boxes became a hindrance. I had to open them all, and the reliability of the solder connection was confirmed; they were in perfect condition. That's why I boldly hid all the boxes in the wall.

Connections currently practiced using a Wago flat-spring terminal block greatly reduce the time spent on installation work, but are much inferior in reliability to soldered connections. And if there are no spring-loaded contacts in the block, they make connections in high-current circuits completely unreliable.

Mechanical connection of wires

Soldering is the most reliable type of connecting wires and contacts. But it has disadvantages - the inseparability of the resulting connections and the high complexity of the work. Therefore, the most common type of connection of wires to electrical contacts of devices is threaded, screws or nuts. To ensure the reliability of this type of connection, it is necessary to perform it correctly.

Linear expansion due to temperature changes is different for metals. Aluminum changes its linear dimensions especially strongly, then, in descending order, brass, copper, and iron. Therefore, over time, a gap forms between the contact of the connected metals, increasing the contact resistance. As a result, the screws must be tightened periodically to ensure reliable connections.

In order to forget about maintenance, additional slotted washers, called split washers or Grover washers, are installed under the screws. The Grover selects the gaps that arise and thereby ensures high contact reliability.

Often electricians are lazy and do not twist the end of the wire into a ring. In this option, the contact area of ​​the wire with the contact pad of the electrical device will be many times smaller, which reduces the reliability of the contact.

If the formed ring of wire is slightly flattened with a hammer on an anvil, the contact area will increase several times. This is especially true when forming a ring of stranded wire soldered with solder. Instead of a hammer, you can add flatness with a file, grinding off the ring a little at the points of contact with the contacts.

This is how it should be done ideal threaded connection of wires to contact pads of electrical appliances.

Sometimes it is necessary to connect copper and aluminum conductors with each other, or with a diameter of more than 3 mm. In this case, the most accessible is a threaded connection.

The insulation is removed from the wires to a length equal to four screw diameters. If the veins are covered with oxide, then it is removed with sandpaper and rings are formed. A spring washer, a simple washer, a ring of one conductor, a simple washer, a ring of another conductor, a washer and, finally, a nut are put on the screw, screwing the screw into which the entire package is tightened until the spring washer is straightened.

For conductors with a core diameter of up to 2 mm, an M4 screw is sufficient. The connection is ready. If the conductors are made of the same metal or when connecting an aluminum wire to a copper wire whose end is tinned, then there is no need to place a washer between the rings of the conductors. If the copper wire is stranded, then it must first be tinned with solder.

Connecting wires with a terminal block

Connecting wires with low current load can be done using terminal blocks. Structurally, all terminal blocks are constructed identically. Thick-walled brass tubes with two threaded holes on the sides of each are inserted into the housing combs made of plastic or carbolite. The wires to be connected are inserted into the opposite ends of the tube and secured.

The tubes come in different diameters and are selected depending on the diameters of the conductors being connected. You can insert as many wires into one tube as its internal diameter allows.

Although the reliability of connecting wires in terminal blocks is lower than when connecting by soldering, much less time is spent on electrical installation. An undeniable advantage of terminal blocks is the ability to connect copper and aluminum wires in electrical wiring, since brass tubes are coated with chromium or nickel.

When choosing a terminal block, you need to take into account the current that will flow through the switched electrical wiring wires and the required number of terminals in the comb. Long combs can be cut into several short ones.

Connecting wires using a terminal block
with Wago flat spring clamp

Terminal blocks with flat spring clamps Wago (Wago) from a German manufacturer are widely used. Wago terminal blocks come in two designs. Disposable, when the wire is inserted without the possibility of removal, and with a lever that makes it easy to both insert and remove wires.

The photo shows a Wago disposable terminal block. It is designed for connecting any types of single-core wires, including copper and aluminum with a cross-section from 1.5 to 2.5 mm 2. According to the manufacturer, the block is designed to connect electrical wiring in junction and distribution boxes with a current of up to 24 A, but I doubt it. I think it’s not worth loading the Wago terminals with a current of more than 10 A.

Wago spring terminal blocks are very convenient for connecting chandeliers and connecting wires in junction boxes. It is enough just to forcefully insert the wire into the hole of the block, and it will be securely fixed. In order to remove the wire from the block, considerable force will be required. After removing the wires, deformation of the spring contact may occur and a reliable connection of the wires when reconnected is not guaranteed. This is a big disadvantage of a disposable terminal block.

A more convenient Wago terminal block is reusable and has an orange lever. Such terminal blocks allow you to connect and, if necessary, disconnect any electrical wires, single-core, multi-core, aluminum in any combination with a cross-section from 0.08 to 4.0 mm 2. Rated for current up to 34 A.

It is enough to remove 10 mm of insulation from the wire, lift the orange lever up, insert the wire into the terminal and return the lever to its original position. The wire will be securely fixed in the terminal block.

The Wago terminal block is a modern tool-free way to connect wires quickly and reliably, but is more expensive than traditional connection methods.

Permanent connection of wires

In some cases, when it is not intended to connect the wires in the future, they can be connected in a permanent way. This type of connection is highly reliable and is advisable in hard-to-reach places, for example, connecting the ends of a nichrome spiral with copper current-carrying conductors in a soldering iron.

Connecting thin wires by crimping

A simple and reliable way to connect wire cores is crimping. Wire strands are inserted into a piece of copper or aluminum tube, depending on the metal of the wires being connected, and the tube is pressed in the middle with a tool called a press pliers.

Crimping can be used to connect both single-core and stranded wires in any combination. The diameter of the tube must be selected depending on the total cross-section of the conductors. It is desirable that the conductors fit tightly. Then the connection reliability will be high. If in a stranded wire the conductors are twisted together, then it is necessary to develop and straighten them. There is no need to twist the wire strands together. The prepared conductors are inserted into the tube and crimped with press pliers. The connection is ready. All that remains is to insulate the connection.

Crimping tips are available for sale, already equipped with an insulating cap. Crimping is performed by compressing the tube together with the cap. The connection is immediately isolated. Since the cap is made of polyethylene, during crimping it is deformed and held securely, ensuring reliable insulation of the connection.

The disadvantage of joining by crimping is the need for special press jaws. You can make your own pliers using pliers with side cutters. You need to round the side cutter blades and make a groove in the middle. After such modification of the pliers, the edges of the side cutters will become blunt and will no longer be able to bite, but only squeeze.

Connecting wires of larger cross-sections by crimping

To connect electrical wires with a larger cross-section, for example, in power panels of houses, special lugs are used, which are crimped using universal press pliers, for example, the PC, PKG, PMK and PKG types.

To crimp each standard size of tip or sleeve, it requires its own matrix and punch, a set of which is usually included in the set of pliers.

To crimp a tip onto a wire, the insulation is first removed from the wire, the wire is tucked into the hole in the tip and inserted between the matrix and the punch. The long handles of the press pliers are used to squeeze. The tip is deformed, crimping the wire.

In order to correctly select the matrix and punch for the wire, they are usually marked and branded press pliers on the matrix have an engraving for crimping what section of wire the matrix is ​​intended for. The number 95 embossed on the tip means that this matrix is ​​designed for crimping into the tip of a wire with a cross-section of 95 mm 2.

Connecting wires with a rivet

It is made using screw connection technology, only a rivet is used instead of a screw. Disadvantages include the impossibility of disassembly and the need for special tools.

The photo shows an example for connecting copper and aluminum conductors. More details about connecting copper and aluminum conductors are described in the website article “Connection of aluminum wires”. In order to connect the conductors with a rivet, you need to first put an aluminum conductor on the rivet, then a spring washer, then a copper one and a flat washer. Insert a steel rod into the rivet gun and squeeze its handles until it clicks (this cuts off the excess steel rod).

When connecting conductors made of the same metal, there is no need to place a split washer (grower) between them, but put the groover on the rivet first or second to last; the last one must be an ordinary washer.

Connecting broken wires in the wall

Repairs should begin with very careful removal of the plaster in the area of ​​damaged wires. This work is done with a chisel and hammer. As a chisel when laying electrical wiring in the wall, I usually use the rod from a broken screwdriver with a sharpened end of the blade.

Connecting copper wires broken in the wall

Take a piece of copper wire with a cross-section no less than the cross-section of the broken wire. This piece of wire is also covered with a layer of solder. The length of this insert must ensure an overlap of at least 10 mm over the connected ends of the wires.

The insert is soldered to the connecting ends. Solder should not be skimped. Next, the insulating tube is moved so as to completely cover the joint. If a sealed, moisture-resistant connection is required, then before putting on the tube, the soldered joint must be coated with silicone.

Connecting aluminum wires broken in the wall

A prerequisite for obtaining a reliable mechanical connection of aluminum wires is the use of a Grover-type washer. The connection is assembled as follows. A groover is put on the M4 screw, then an ordinary flat washer, rings of connected wires, then a simple washer and a nut.

Step-by-step instructions for connecting broken wires in a wall are outlined in the article “Connecting broken wires in a wall”

Connecting wires with slip-on terminals

Widely used in household appliances and cars is the detachable connection of conductors using slip-on terminals, which are placed on contacts 0.8 mm thick and 6.5 mm wide. Reliability of fixation of the terminal is ensured by the presence of a hole in the center of the contact and a protrusion in the terminal.

Sometimes the conductors break off, and more often the terminal itself burns due to poor contact and then it becomes necessary to replace it. Typically, the terminals are pressed onto the ends of the conductors using special pliers. Crimping can also be done with pliers, but you don’t always have a new replacement terminal on hand. You can successfully use a used one by installing the terminal using the following technology.

First you need to prepare the old terminal for reinstallation. To do this, holding the terminal with pliers at the press-in point, you need to use an awl or a screwdriver with a thin tip to move the tendrils that compress the insulation apart. Next, the wire is bent many times until it breaks off at the point where it exits the press fit. To speed things up, you can trim this area with a knife.

When the wire is separated from the terminal, a needle file prepares a place for soldering it. You can completely grind it off until the remaining wire is free, but this is not necessary. It turns out to be a flat platform.

The resulting area is broken through with solder. The conductor is also stripped and tinned with solder using a soldering iron.

All that remains is to attach the conductor to the prepared terminal area and heat it with a soldering iron. The antennae that fix the wire are bent after soldering the wire to the terminal, since if they are crimped before soldering, the antennae will melt the insulation.

All that remains is to pull on the insulating cap, put the terminal on the desired contact and check the reliability of the fixation by tugging on the wire. If the terminal has come off, then it is necessary to tighten its contacts. A home-made terminal attached to a wire by soldering is much more reliable than one obtained by crimping. Sometimes the cap is put on so tightly that it cannot be removed. Then it needs to be cut and after installing the terminal, cover it with insulating tape. You can also stretch a piece of vinyl chloride or heat-shrinkable tube.

By the way, if you hold a vinyl chloride tube in acetone for about five minutes, it increases in size by one and a half times and becomes plastic, like rubber. After the acetone evaporates from its pores, the tube returns to its original size. About 30 years ago, I insulated the bases of light bulbs in a Christmas tree garland in this way. The insulation is still in excellent condition. I still hang this garland of 120 6.3 V light bulbs on the Christmas tree every year.

Splicing stranded wires without twisting

Stranded wires can be spliced ​​in the same way as single-core wires. But there is a more advanced method, in which the connection is more accurate. First you need to adjust the lengths of the wires with a shift of a couple of centimeters and strip the ends to a length of 5-8 mm.

Fluff the slightly cleaned areas of the pair to be joined and insert the resulting “panicles” into each other. In order for the conductors to take a neat shape, they need to be tied together with a thin wire before soldering. Then lubricate with soldering varnish and solder with solder.

All conductors are soldered. We clean the soldering areas with sandpaper and insulate them. We attach one strip of electrical tape on both sides along the conductors and wind a couple more layers.

This is what the connection looks like after covering it with insulating tape. You can further improve the appearance if you use a file to sharpen the solder joints on the insulation side of adjacent conductors.

The strength of connected stranded wires without twisting by soldering is very high, as the video clearly demonstrates. As you can see, the connection can withstand the weight of the monitor 15 kg without deformation.

Connecting wires with a diameter of less than 1 mm by twisting

Let's consider twisting thin conductors using the example of splicing twisted pair cables for computer networks. For twisting, thin conductors are stripped of insulation for a length of thirty diameters with a shift relative to adjacent conductors and then twisted in the same way as thick ones. The conductors must wrap each other at least 5 times. Then the twists are bent in half with tweezers. This technique increases mechanical strength and reduces the physical size of the twist.

As you can see, all eight conductors are connected by twisting with a shift, which makes it possible to do without isolating each of them separately.

All that remains is to tuck the conductors into the cable sheath. Before refueling, to make it more convenient, you can tighten the conductors with a roll of insulating tape.

All that remains is to secure the cable sheath with insulating tape and the twist connection is complete.

Connecting copper wires in any combination by soldering

When connecting and repairing electrical appliances, you have to lengthen and connect wires with different cross-sections in almost any combination. Let's consider the case of connecting two stranded conductors with different cross-sections and number of cores. One wire has 6 conductors with a diameter of 0.1 mm, and the second has 12 conductors with a diameter of 0.3 mm. Such thin wires cannot be reliably connected with simple twisting.

With the shift, you need to remove the insulation from the conductors. The wires are tinned with solder, and then the smaller gauge wire is wound around the larger gauge wire. It is enough to wind a few turns. The twisting area is soldered with solder. If a direct connection of wires is required, the thinner wire is bent and then the connection is insulated.

Using the same technology, a thin stranded wire is connected to a single-core wire with a larger cross-section.

As is obvious, using the technology described above, you can connect any copper wires of any electrical circuits. At the same time, we must not forget that the permissible current strength will be determined by the cross-section of the thinnest wire.

TV coaxial cable connection

There are three ways to extend or splice a coaxial television cable:
– TV extension cable, commercially available from 2 to 20 meters
– using an adapter TV F socket - F socket;
- soldering with a soldering iron.

Tinsel wire connection
twisted with single-core or stranded conductor

If it is necessary to give the cord very high flexibility and at the same time greater durability, the wires are made using a special technology. Its essence lies in winding very thin copper ribbons onto a cotton thread. This kind of wire is called tinsel.

The name is borrowed from tailors. Gold tinsel is used to embroider the ceremonial uniforms of high-ranking military officers, coats of arms and much more. Copper tinsel wires are currently used in the production of high-quality products - headphones, landline phones, that is, when the cord is subjected to intense bending during use of the product.

In a cord of tinsel conductors, as a rule, there are several and they are twisted together. It is almost impossible to solder such a conductor. To attach tinsel to the contacts of products, the ends of the conductors are crimped into the terminals with a special tool. To make a reliable and mechanically strong twist connection without tools, you can use the following technology.

The insulation is removed from the 10-15 mm tinsel conductors and the conductors with which it is necessary to connect the tinsel to a length of 20-25 mm with a shift using a knife in the manner described in the site article “Preparing wires for installation”. The tinsel thread is not removed.

Then the wires and the cord are applied to each other, the tinsel is bent along the conductor and the wire core is tightly wound onto the tinsel pressed against the insulation. It is enough to make three to five revolutions. Next, the second conductor is twisted. You will get a fairly strong twist with a shift. Several turns of insulating tape are wound and the twisted connection of the tinsel to a single-core wire is ready. Thanks to shear twisting technology, the connections do not need to be separately insulated. If you have a heat-shrinkable or polyvinyl chloride tube of a suitable diameter, you can put on a piece of it instead of insulating tape.

If you want to get a straight connection, you need to rotate the single-core wire 180° before insulating it. The mechanical strength of the twist will be greater. The connection of two cords with tinsel-type conductors to each other is carried out using the technology described above, only for wrapping, a piece of copper wire with a diameter of about 0.3-0.5 mm is taken and at least 8 turns must be made.

Almost every home craftsman faces the need to connect wires. During repairs, new wiring, or simply connecting a new device to the network, similar actions are required. They differ in scale and complexity.

On the way to the consumer, electrical networks have many branches. In these places they are installed connectors for wires. There are many types of them. Every electrician should know how to correctly select and use such elements of electrical networks before starting work.

Evolution of compounds

Previously, electricians never had a question. For this purpose, the same technology was used for all. The wires were stripped, twisted between soda and wrapped with electrical tape.

Previously, wiring in houses was made from copper wire. Today, a copper conductor is simply necessary for the arrangement. In recent decades, new, powerful technology has appeared in our homes and apartments. When using it, durable, high-quality wiring is required.

According to experts, malfunctions most often occur at the junctions of wires. Twisted conductors begin to heat up as the load increases. Electrical tape dries out over time. There is a high probability of a short circuit in this place. To avoid fire, it is necessary to use special wire connectors. Kinds and the features of the use of such products will be discussed further.

Wiring rules

To understand which wire connections are appropriate to make in a particular case, it is necessary to consider the rules for arranging electrical installations. They clearly indicate which methods are acceptable when arranging modern communication systems. Considering rules for connecting wires, conclusions can be drawn about the unacceptability of using twists. The regulatory documentation clearly states that all cores must be connected by welding, crimping, squeezing or soldering.

The wiring must be made from a cable with a copper core. In order for such a network to have high reliability indicators, the connections must be as strong as possible. The cross-section of the cores is selected in accordance with the total expected load. The more equipment is connected to the network, the thicker the conductor needs to be connected to the system.

Caps

Considering how to connect wires together, some unprofessional craftsmen still decide to give preference to twisting wires. This is acceptable if local wiring repairs are being made or a low-power device is being connected to the home network. In this case, the master can somewhat improve such a junction of the cores.

To ensure greater reliability, special caps are used. They are used instead of electrical tape. They are also called (PPE).

It is safer than the duct tape option. The connector looks like a plastic cup. It is built into it. It clamps the contacts and ensures reliable contact. High-quality clamps contain a special lubricant that prevents oxidation processes. When choosing, you must take into account what wires the product is intended for (multi-core or single-core). You should also evaluate the cross-section of the conductor for which the clamp is intended. PPE is not used to connect cores made of different materials.

Terminals

More often cable connector today it looks like terminals. They are made of brass. In this case, the connected ends of the cable do not contact each other directly. Therefore, using such structures, it is possible to switch identical conductors, cores of different cross-sectional sizes, made of different materials.

To be able to create the correct joint, you need to select the appropriate types of terminals. They differ in the nominal current rating, as well as the permissible diameter for the wire. All characteristics of the terminals are indicated on their housing.

Some commercially available terminals may contain a special filler. The gel prevents oxidation processes, increasing the reliability of the connection. Terminals can be knife, spring, or screw.

Spring varieties

Spring type are used for both simple and complex circuits. For several pairs of wires, a special block modification is made.

Fixation occurs due to straightening of the spring mechanism. This mount is considered one of the most reliable. This mechanism includes a special lubricant. It differs from previous materials that are used in fasteners. This is not a gel, but a lubricant of a certain consistency.

When producing a type, manufacturers indicate the scope of application of such products. Clamps are available for stranded and This must be taken into account when choosing. Most often, the presented type of fastening is used for branching zero and phase.

Blade terminals

Today another one is used electrical connector. It is called a knife terminal. This is a reliable, durable connection. These terminals are easy to install and operate. In this case, the wires are connected using a special conductive plate. When clamping wires, this structural element cuts the braid around the core. Therefore, when making such a connection, the wires do not need to be stripped.

Due to its features, the presented type of terminals is considered reliable and durable. When installing, the technician must apply force to secure the ends of the conductors well. This is considered the norm. Sometimes you have to use pliers to clamp.

The presented variety of terminal connectors is produced for permanent and detachable connection types. In the first option, the master must carefully consider all the nuances of organizing the electrical circuit. This process is carried out before installation work begins.

Connecting different materials

As you know, in modern wiring two types of conductors are used. The first category includes conductors made of copper, and the second - made of aluminum. According to fire safety rules, it is recommended to give preference to the first option. However, in some cases the master has to combine copper and aluminum conductors.

The conventional configuration cannot guarantee high quality at the junction. This is due to a number of reasons. With temperature changes, the linear expansion of different metals will not be identical. In this case, a gap may form between the directly joined aluminum and copper.

At the same time, the resistance increases at the point of their contact. The conductors begin to heat up. Also, a film of oxides appears on the stripped conductors. This also contributes to poor contact. This state of the network provokes various malfunctions and can cause a fire. Therefore, only special types of contactors are suitable for such connections.

Screw terminals

Electrical connector may be screw type. Such contactors have been used for a long time. This type of terminals has certain disadvantages and advantages. These are compact, easy-to-install devices. They allow you to connect wires of different diameters. Moreover, they can be used for both single-core and multi-core conductors. In the second option, the end of the cable is stripped and crimped with brass lugs.

The disadvantage of the presented one is the inability of the terminals to connect more than three conductors at the same time. This complicates the work somewhat, forcing you to make more connections. Also, over time, such a connector loses its original characteristics. The wires no longer fit tightly together. Therefore, when using a screw connection, you periodically have to tighten the junction of the wires.

For large diameter wires, connections are used, popularly known as “nut”. Such contactors are most often used when connecting wires from the carrier line to the house.

Modern connectors

Many electricians use male-female connector for wires. This type of connector has been known for a long time. This type of connector is divided into a “male” type with a plug or plug, and a “female” type with a socket or socket. Within the same series, such connectors are compatible with each other.

This is one of the most reliable, modern types of contactors. It will not be possible to connect the wires incorrectly with this connection. The male pins will completely match the internal configuration of the female sockets. In some cases, for accuracy of installation, painting of the connection points is used. This allows you to understand which consumer the connector is intended for and not confuse them.

Female-to-female and male-to-male connectors are available for sale. These are extension cords. Depending on the belonging to each category, contactors with a socket or plug are used.

Spring leads for dissimilar wires

They can be spring-type from different materials. They also help to eliminate direct contact between the cores. They can be detachable or non-detachable. One of the most famous and reliable ways to connect copper and aluminum cables is the Wago universal connector. The cross-section of the cores when using it can also be different.

One-piece wire connectors use the screw terminal principle. You can also use devices in which the metal plate is replaced by a special conductive rod. It is riveted to provide a secure connection. Exposed sections of the cable must be additionally insulated.

Having considered what exist wire connectors, as well as their characteristic differences, everyone will be able to choose the best option for connecting various devices or carrying out repair work.

In this article we will talk about how to connect wires to each other in an apartment. The issue of electrical wiring is very relevant, especially for those who decide to do their own repairs. Mostly people are interested in the possibility and technology of connecting wires of different materials and cross-sections to each other. Let's talk about everything in order.

Is it possible to connect wires by twisting

Very often, especially in old houses, we start removing old wallpaper, unscrewing old sockets, disassembling dilapidated junction boxes and what do we see: a lot of wires twisted together and wrapped in insulation:

I know that many electricians still twist wires this way and consider it the most reliable. However, from a fire safety point of view, no firefighter will approve of electrical connections in an apartment made only by twisting.

The fact is that sometimes you have to connect wires of different sections and different materials, for example, copper and aluminum wires. And it is precisely for such cases that twisting is unacceptable. For example, with the same load on the network, it will act differently on thick and thin wires twisted together, one of which will feel good, and the other will heat up.

How to connect wires of the same material and cross-section

How to connect wires of the same material and cross-section to each other, for example, copper to copper for 2.5 squares? This is the simplest case, and twisting may well be suitable here:

Only instead of regular insulating tape, the store sells caps for twisting:

You need to take the cap and screw it onto the twist:

Is it possible to connect wires of different sections of the same material?

If, for example, you need to connect wires of different cross-sections (they are also suitable for the same cross-section) and the same material (copper or aluminum), then in this case the special connecting blocks presented below are well suited.

They have different numbers of inputs: in the figure, respectively: 2, 4, 6.

That is, this is a “sort of” twist for 2, 3, 4, 5 or 6 wires.

Moreover, if you need to connect 3 wires to each other, then for this you can use a block that has 4 or 6 inputs:

The block is simply pressed tightly onto the wires:

You need to understand that after connecting the wires in this way, they can no longer be removed from the block. Therefore, if you have never tried to work with such devices, buy a few of them in a store with a supply and practice at home. They cost pennies.

How to connect copper and aluminum wires

When you need to connect wires made of different materials (copper and aluminum), and even different sections, in this case you will be helped by pads whose inputs are filled with a special paste that prevents oxidation:

The same pads, of course, are suitable for wires of the same cross-section and the same material. As in the previous case, if you have already put wires on them, then they will no longer be removed from the blocks. Therefore, think through all your connections in advance.

Connecting blocks - latches

There are also jumper blocks that will allow you to connect wires together, but if you make a mistake, you can disconnect any of the connected wires. These are the so-called latches:

For latches, you should definitely check with the seller in the store about the possibility of connecting wires of different materials and cross-sections.

One of the options for connecting wires in a chandelier

If you need to connect a chandelier, then one of the options for connecting the wires coming out of the ceiling with the wires coming from the chandelier would be to use blocks in which the wire connection is secured using screws:

For a chandelier, the option of using wago type terminals, especially if the wires coming from the ceiling are short, will not be very good, since, as already mentioned, in this case the wires cannot be removed (for example, you will need to change the chandelier or wash it) and you will have to cut them off. In the case of terminals with a screw connection, it will be enough to simply unscrew the fastening screws and release the wires.

Important Notes on Wiring Connections

Let us note important points regarding electrical wires.

1. All wires twisted together should not dangle somewhere in the air! They must be placed in a junction box.
2. For all wire connections, ensure that the bare ends of the wires are completely hidden in the connection block. That is, try to make the connection so that after this connection it would be impossible to reach the bare end of the wire with your hand.
3. Do not try to remove the wire from terminals that are not intended for this purpose. For example, there are craftsmen who manage to remove wires from wago terminals. But I do not recommend doing this, since such removal is always associated with deformation of the wire. And this is unacceptable, because the load on the network should be experienced by whole wires, and not half-broken ones, which can lead to short circuits.

This is where the article ends. We have studied in detail the issue of how to connect wires in an apartment. Now, you can easily extend the wires by laying them in the wall and making the correct connection.

Content:

Every person has encountered the problem of connecting wires at least once in their life. Moreover, these products are presented in a fairly wide range: aluminum and copper, single-core and multi-core, computer and telephone, power and heating. They are designed for different loads and require special approaches when working. The question arises: how to connect the wires correctly?

The main requirement is to ensure reliable insulation And long service life.

Features of connecting aluminum and copper wires

Traditional twists are not always able to provide the desired result. Especially in the case of connecting copper and aluminum wire.

Before you connect the wires, you should know that aluminum oxidizes over time. As a result, the surface layer has greater resistance and begins to heat up. The thermal expansion coefficient of aluminum is higher than that of copper. At the same heating temperature, it requires more space.

As a result, after a certain number of heating and cooling cycles, the contact will weaken so much that overheating and breakage of the connection may occur. This situation is unacceptable from a security point of view.

There are several main types of devices for connecting wires:

• Connecting insulating clamps;
• Screw terminal blocks and distribution boxes or blocks;
• Self-clamping terminal blocks and splitters;
• Clamp splitters;
• Electrical connectors with mortise contact;
• Connecting sleeves and tips.

Their practical application requires different approaches and tools.

Connecting insulating clamps

Connecting insulating clamps for connecting wires - Photo

Connecting insulating clamps or just caps PPE provide simultaneous insulation and contact fixation. Exclusively used for single-core wires

Before connecting the wires, their ends are twisted clockwise. There is a coil spring inside the cap that compresses the wires as you put them on. The clamp is screwed onto the contact site also clockwise.

Connecting wires using PPE - Photo

Screw terminal blocks and distribution boxes

How to properly connect wires through the terminal block - Photo

Screw terminal blocks used to connect copper wires. Aluminum is a fairly soft and ductile material. Under constant pressure it deforms. As a result, over time the contact will weaken and begin to heat up.

In addition, screw terminal blocks are not used for multi-core wires. Thin veins break due to uneven load and friction. This is necessary to know in order to understand how to connect the wires correctly.

In practice, the wire is inserted into the brass sleeve of the terminal block and clamped with a screw. For a high-quality connection, it is necessary to select the size of the holes in the device for each section of the wire.

It should be taken into account that if the force is too great, the brass sleeve may burst.

Screw terminal boxes for connecting stranded wires - Photo

IN screw junction box The contact point is also clamped with screws. It is suitable for connection aluminum And stranded wires This is possible due to some design differences between the blocks and terminal blocks. The end of the wire is clamped between two plates. In this case, the upper one has a surface that allows you to increase the contact surface.

How to connect wires - Video

Wago self-clamping terminal blocks for connecting wires - Photo

Self-clamping terminal blocks and splitters designed for connection only single-core wires made of copper or aluminum. They can reliably connect these two materials to each other. These are disposable products. Their design includes a pressure plate that ensures tight contact of the end of the wire with the tinned copper busbar and prevents the connection from loosening over time.

Wago terminal blocks for connecting aluminum wires - Photo

The question arises: how to connect aluminum wires using this device? A mixture of quartz sand and technical petroleum jelly is applied to the surface of the pressure plate.

The first serves as an abrasive to remove the oxide film from the aluminum wire, and the second serves to prevent its re-formation. For reliable and long-term service of products, it is necessary to comply with the requirement for the maximum calculated value of the current passed through it.

Clamp splitters for correct connection of wires

Reusable wire clamp with lever - Photo

Clamp splitters suitable for any type of wires in any combination. The design of the product includes a plate that presses the end of the wire to the tinned copper busbar.

Unlike self-clamping terminal blocks, this connection is reusable. Reliable contact is ensured using a special movable lever. It allows you to change wires and their combinations an unlimited number of times. The product is designed for a maximum current of 35A.

Electrical connectors with a mortise contact for connecting wires - Photo

Electrical connectors with flush contact or Scotch locks can only be used on lightly loaded networks. For example, for phones or LED lamps. This is a disposable product.

The design provides one or two plates, one of the surfaces of which is a cutting-clamping one. The internal space of the connector is filled with hydrophobic gel. Its purpose is to protect the contact point from oxidation, moisture and corrosion.

Connecting thin wires with a special clamp - Photo

When used, the wires are inserted into the holes and the adhesive tape is snapped into place using compressive force. The plate cuts through the wire insulation and provides a tight connection.

Connecting sleeves for high current wires

Connecting sleeves for high current wires - Photo

Connecting sleeves used for high currents. Suitable for aluminum and copper wires or a combination of both. The use is quite simple.

High current crimped wires - Photo

One or more wires are placed inside the sleeve and it is clamped with special pliers. The use of the tool ensures a high-quality connection that does not require additional maintenance. There are several types of product:

1. To connect the wire to the housing when performing grounding, use sleeves with a flat end and a hole in it;
2. For single-core wires use screw clamp sleeves;
3. For any combination of wires use universal tinned copper sleeves.

Tip for crimping stranded wires - Photo

Tip designed for secure connection stranded copper wires On one side it has an extension. Before connecting the copper wires, their ends must be twisted and inserted into the extension. Then the tip is crimped with clamping pliers. In the future, the end of the wire treated in this way can be used in any type of connection.

The main goal pursued when using various means for connecting wires is to ensure their reliable and long-term contact. Knowledge about the purpose and design features of products will help you use them most effectively in practice.