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» Connecting electrical wires is a reliable way. Connecting wires - reliable methods for connecting wires of different types, types and sections (120 photos) Sealed wire connectors

Connecting electrical wires is a reliable way. Connecting wires - reliable methods for connecting wires of different types, types and sections (120 photos) Sealed wire connectors

In the article we will talk about methods for connecting wires in junction boxes, and talk about preparing conductors for connecting household appliances and installation products.

The electrical wiring of residential premises consists of many elements, these are various current-carrying conductors (cables), protective devices, electrical installation products, individual current consumers. In order to assemble all the components of the system into a single circuit and at the same time make the power supply functional and safe, it is necessary to qualitatively connect them together, or, as they say, switch them (switching refers to the processes that occur when electrical circuits are closed or opened).

At first glance, it may seem to an unprepared person that there shouldn’t be anything complicated here. But when working with electricians “on a whim,” it doesn’t matter whether we’re moving a single outlet, connecting a lamp, or assembling a complex control system, we take a serious risk. Experienced electricians know that electrical installation is primarily a “struggle for contact,” since it is an open circuit, and not a short circuit, that is the most common problem encountered. Obviously, the connection points in the circuit (terminals, twists) are the most vulnerable, since at these points the mechanical density of the contact can weaken (the contact area decreases), and an oxide film with a very high resistance forms on the conductors over time. Poor contact causes heating of current-carrying conductors and sparking at switching points - these are the consequences of the occurrence of transient contact resistance. Complete burnout of the wire and loss of power to the area when household appliances do not work or the light goes out is unpleasant, but the problem is solved. It’s worse if the insulation of the wires heats up and is destroyed, which threatens to injure a person. electric shock or the occurrence of a fire.

IN Lately The load on the wiring has seriously increased, so switching is now subject to even more stringent fire and electrical safety requirements. However, if previously there were not many connection options, now reliable modern devices have appeared that make wiring easier. In addition to welding and soldering with subsequent tape insulation of the twist, PPE caps, various terminal screw and spring blocks, all kinds of insulated and open lugs, and branch clamps can be used in a household network. These products will help to qualitatively connect wires in junction boxes, assemble a distribution board, connect household appliances and lighting fixtures, sockets and switches.

There are several key objective factors that influence the choice of switching method, or the use of specific devices. Let's just list the main ones:

  • power and number of consumers (read: total cross-section of conductors);
  • material of current-carrying conductors (copper or aluminum);
  • cable type (flat or round, hard or soft stranded, single or double insulated);
  • purpose of the node (group or single branch, end connection);
  • the presence of movement of wires or vibrations near them;
  • elevated temperature, humidity;
  • indoor or outdoor use.

Connecting wires in junction boxes

According to the provisions of the PUE, branching of household network wires can only be carried out in a distribution (junction) box. During operation of the wiring, junction boxes allow you to quickly get to the ends of any individual branch and, if necessary, detect which of them is broken or has a short circuit. You can also always inspect the condition of the contacts inside the box and carry out their maintenance. Modern PVC boxes are used for open and hidden wiring, they have sufficient reliability and expanded functionality: they are easily installed on various surfaces and are convenient for electrical installation manipulations.

In order to always have access to the connected wires, all distribution boxes are placed on free sections of the walls; it is most rational to install them on the side of the corridors, for example, above the door of the powered room. Naturally, boxes cannot be tightly plastered or sewn inside building frames; the permissible decorative maximum is a thin-layer finish on top of the lid (paint, wallpaper, decorative plaster).

For the arrangement of lighting and power circuits (outputs and sockets), it is recommended to use separate distribution boxes for each room. Such divided power allows you to make the electrical wiring of your home more balanced and safe, since the “lights” and “sockets” differ in workloads and operating conditions, and they are subject to different requirements. Moreover, it is much easier to upgrade or repair the wiring later, and not always all the wires in a room can be properly laid out in one housing.

Switching wires in any distribution box can be carried out according to the same principle. In most cases, “twisting” is initially used, but simply wrapping the conductors with electrical tape is not enough - it must be reinforced with additional operations that are designed to increase the contact area of ​​the connected current-carrying conductors and reduce the oxidation of materials. Clause 2.1.21 of the PUE offers the following options:

  • soldering
  • welding
  • crimping
  • crimping (bolts, screws, etc.)

Wire crimping

The essence this method consists in the fact that twisted wires are inserted into a special sleeve-tip made of metal, which is compressed with hand pliers, mechanical or hydraulic press. Crimping can be done either by local pressing or by continuous compression. This connection of wires is considered one of the most reliable. Crimping allows you to compress the cores very tightly, increasing the contact area; the mechanical strength of such switching is the highest. This method is used for both copper wires, and for aluminum.

The crimping process consists of several operations, each of which has its own nuances:

  1. The wires are freed from insulation 20-40 mm from the edge, depending on the working length of the sleeve.
  2. The veins are cleaned with a brush or emery until shiny.
  3. Using pliers, a tight twist is made.
  4. Based on the total twist section, a GAO sleeve with the required internal diameter is selected, as well as a suitable punch and die.
  5. The inside of the sleeve is treated with quartz vaseline paste (if it comes “dry” from the factory).
  6. The twist is inserted into the sleeve.
  7. The twist is compressed using press pliers. It is necessary that the tool rig is completely closed.
  8. The quality of the connection is checked - the wires should not move in the tip.
  9. The sleeve of the connected conductors is wrapped in three layers of insulating tape; for a tip thickness of up to 9 mm, a polyethylene insulating cap can be used.

Conductor crimping

Crimping of conductors can be done using terminal blocks, PPE caps or WAGO clamps.

The terminal block housing is made of plastic; inside it there are sockets with threads and clamping screws. The wires can be inserted under single screws of the terminal towards each other, or one conductor passes through the entire block and is fixed with two screws. Some distribution boxes are equipped with standard terminal blocks.

A clear advantage of switching on a terminal block is the ability to connect copper and aluminum wires, which in this case have no direct contact. The disadvantage is the need to tighten the bolt clamp if aluminum conductors are used.

PPE caps (connecting insulating clips) are also made of durable non-flammable polymer, which, being an insulator, provides mechanical and fire protection. They are forcefully wound onto the twisted conductors, then the conical metal spring located inside the cap moves apart and compresses the current-carrying conductors. As a rule, the internal cavity of the PPE is treated with a paste that prevents oxidation.

WAGO terminals for junction boxes are screwless, here the compression is performed by a spring, you only need to insert the stripped wire into the terminal. These terminal blocks are designed to connect up to eight wires with a cross-section of 1-2.5 mm 2 or three wires with a cross-section from 2.5 to 6 mm 2, while the spring acts on the conductor with a force suitable for each wire. The clamps function normally at operating currents up to 41 A for 6 squares, 32 A for 4 squares and 25 A for 2.5 squares. Interestingly, WAGO universal clamps allow you to connect wires of different sections (from 0.75 to 4 mm2) in one housing.

These devices can be designed for a hard conductor, or for a soft stranded one. Due to the fact that there is no direct contact of the connected conductors, it is possible to connect copper and aluminum wires, and there is no need to regularly check the compression of aluminum. Inside, WAGO terminal blocks also have a paste that destroys the oxide film and improves contact, however, the clamps for copper conductors are not filled with contact paste. It is very easy to work with such connecting products, they are quickly installed, without the use of additional tools, they are compact and reliable. It must be said that WAGO is not the only company producing screwless spring-loaded terminal blocks.

Whatever type of crimping device is used, it is necessary to accurately select it according to the cross-section of the individual conductor or strand, since a terminal that is too large may not provide normal contact. In this case, you cannot always trust the markings - it is better to check the compliance of fasteners and conductors on site. During installation, we recommend having an assortment of crimp terminal blocks available according to standard sizes. Please note that to work with aluminum it is necessary to use contact gel; copper and aluminum conductors cannot be connected in one twist. After crimping, it is always necessary to check the strength of fixation of the cores in the terminal.

Soldering wires

Due to the technological complexity, this connection method is used quite rarely, mainly when for some reason it is impossible to use crimping, crimping or welding. You can solder wires made of aluminum and copper, you just need to choose the right solder. For branching wires with a cross-section of up to 6-10 mm2, a regular soldering iron is suitable, but larger wires will have to be heated with a portable one. gas burner(propane + oxygen). For soldering, it is necessary to use flux in the form of rosin or its alcohol solution.

The advantages of soldering are the high reliability of the connection compared to crimping (in particular, we have an increased contact area). This method is also quite inexpensive. The disadvantages of switching construction wires by soldering include the duration of the work and the technical complexity of the process.

The soldering of conductors looks like this:

  • the wires are stripped of insulation;
  • the wires are sanded with emery to a metallic shine;
  • a twist is made 50-70 mm long;
  • The core is heated with a torch flame or a soldering iron;
  • the metal is coated with flux;
  • solder is introduced into the working area or the hot twist is immersed in a bath of molten solder for 1-2 seconds;
  • After cooling, the soldered twist is insulated with electrical tape or polymer caps.

Welding

Most often, for reliable switching of wires in a distribution box, electricians use contact heating welding. You can weld twists with a total cross-section of up to 25 mm 2 . Under the influence of an electric arc at the end of the twist, the metal of several cores fuses into a single drop, and then the current during operation of the electrical circuit does not even flow through the body of the twist, but through the formed monolith. If everything is done correctly, the connection is no less reliable than a solid wire. This method does not have technological and operational deficiencies, the only thing is that you need to purchase a suitable welding machine.

Welding of copper conductors is carried out permanently or alternating current with a voltage from 12 to 36 V. If we talk about factory welding units, it is better to use inverter devices with sensitive adjustment of the welding current, which are lightweight and small in size (during operation they are sometimes worn on the shoulder), and can be powered from a household network. In addition, inverters provide good arc stability at low welding currents. Because of high cost inverters, very often electricians use homemade devices for welding, made from a transformer with a power of more than 500 W, with a secondary winding voltage of 12-36 volts. The ground and electrode holder are connected to the secondary winding. The electrode itself for welding copper conductors must be infusible - carbon, this is a factory-coated "pencil" or a home-made element from a similar material.

If a factory inverter is used for welding wires, then for wires of different sections it is recommended to set the following operating current indicators: 70-90 amperes is suitable for connecting two or three wires with a cross-section of 1.5 square, wires with a cross-section of 2.5 mm 2 are welded at 80-120 amperes These indicators are approximate, since the exact composition of the core may vary from one manufacturer to another - it is recommended to test the device and a certain current strength on scraps of conductors. Correctly selected indicators are when the arc is stable and the electrode on the twist does not stick.

The wire welding process includes the following operations:

  • the conductors are cleared of insulation (about 40-50 mm);
  • a tight twist is made with pliers, its end is trimmed so that the ends of the wires have the same length;
  • a ground clamp is connected to the twist;
  • the carbon electrode is brought to the end of the twist for 1-2 seconds (so that the insulation does not melt, but a solid copper ball is formed;
  • after cooling, the welded twist is insulated with electrical tape, heat shrink tube or a plastic tip.

When connecting wires, you should follow safety precautions and take fire precautions, as for any welding work. It is recommended to use a welding mask or special glasses with a light filter; welding gloves or gloves will not be superfluous.

Connecting wires to electrical equipment terminals

Connecting household appliances and various electrical installation products are also important stage wiring switching. From reliability electrical connections These nodes depend on the performance of consumers, as well as user protection and fire safety.

The technology for connecting current-carrying conductors to equipment is regulated by the PUE, current SNiPs, as well as “Instructions for terminating, connecting and branching aluminum and copper conductors of insulated wires and cables and connecting them to the contact terminals of electrical devices.” Just like branching conductors in distribution boxes, soldering, welding, crimping, screw or spring crimping are used for termination and connection. One method or another is selected primarily depending on the design of the equipment, as well as on the properties of the current-carrying conductor.

Screw crimp is used in most types modern equipment. Screw terminals are found in sockets and switches, chandeliers and lamps, in various household appliances(built-in fan, air conditioner, hob). Crimp sockets are used to supply elements of the distribution board: circuit breakers, RCDs, electric meters, and switching busbars with screw terminals are also used here.

It should be noted that convenient spring-loaded terminal blocks can also be used to connect equipment. For example, very often switches are equipped with screwless terminals; WAGO produces a special series of clamps for connecting chandeliers and lamps, as well as for switching in ASUs (terminals mounted on a DIN rail).

Please note that to connect using the crimp method, soft stranded conductors must be terminated with insulated lugs (connectors). For rigid monolithic cores, connectors are not needed. If you do not use lugs, then the soft core should be tightly twisted and tinned with solder before connecting. The size of the tip is selected depending on the cross-section of the conductor, and the geometry of the contact part is selected depending on the type of terminal on the connected device and the operating features. For example, for a clamping tunnel socket, a connector in the form of a pin is used; for fixing with a nut on a bolt, a ring or fork connector is used. In turn, the fork tip is not recommended for use if the device is moving or vibration is possible in the switching area.

If it is necessary to clamp a rigid single-wire conductor (copper or aluminum) with a cross-section of up to 10 mm 2 under the bolt, then it can be bent into a ring of a suitable radius using pliers. Ring with glass sandpaper or sandpaper is cleaned of the oxide film, lubricated with quartz vaseline gel and put on the bolt (the ring should wrap around the bolt clockwise), after which it is covered with an asterisk washer (prevents the conductor from being squeezed out), a groover (springs the connection, prevents it from unwinding during vibrations), and a prefabricated clamp tightened tightly with a nut. If a large cross-section core (from 10 mm2) must be clamped under the bolt, then a metal sleeve with a ring is placed on the conductor using the crimping method.

Switching wires is a very responsible job, and the process of assembling the circuit has a lot of nuances, which for convenience should be combined into one list:

  1. Strip the wires using special pliers, since stripping the insulation with a knife often reduces the cross-section of the wire.
  2. Always remove the oxide film from the conductor. Use glass sandpaper or sandpaper, use special liquids and contact paste.
  3. Make the twist a couple of centimeters longer, and then cut off the excess.
  4. Select the diameter of the sleeve or tip as accurately as possible.
  5. Place the conductor under the terminal or sleeve/tip all the way to the insulation.
  6. Make sure that the wire insulation does not get under the clamp.
  7. If possible, insert and clamp into the tunnel screw terminal not a single soft core, but a double core.
  8. When using electrical tape, wind it with overlapping turns in three layers, be sure to go to the insulating sheath of the conductor. Electrical tape can be replaced with heat shrink or plastic caps.
  9. Be sure to wrap screw terminal blocks with electrical tape.
  10. Always mechanically check the strength of the connection - tug on the conductors.
  11. Never connect copper and aluminum directly.
  12. Securely secure the cable near the patching area so that the wire is not pulled down and there is no mechanical stress on the connection.
  13. Use color coding of conductors, for example, in the entire intra-house network, the brown conductor will be the phase, the blue conductor will be the neutral, and the yellow conductor will be the ground.
  14. For the installation of all devices, adopt a single connection diagram (for example, the phase on the sockets is clamped on the right terminal, and the neutral - not on the left).
  15. Label both ends of all wires yourself - ballpoint pen on the outer shell, at a distance of 100-150 mm from the edge of the conductor, write its purpose (for example, “pink kitchen desk” or “bedroom light”). You can also use tags or pieces of masking tape.
  16. Leave a supply of wires convenient for installation. For distribution boxes, sockets and switches, the normal end length will be 100-200 mm. To switch the switchboard, you may need wires up to one meter long, so that you can run some of them from the bottom of the box, and some from the top.
  17. Bring external cable channels close to the distribution boxes; it is better to insert round corrugation or pipes a few millimeters into the housing.
  18. We connect sockets in parallel, and switches in series. The switch must break a phase, not a zero.
  19. Compress all the wires of one connected twist into a bundle and secure it with electrical tape. Inside the box, route the insulated connections to maximum distance between themselves.
  20. Use only certified materials and specialized tools.

In conclusion, I would like to once again note the importance of high-quality performance of switching work. In fact, the technologies used are quite simple, you just need to make them a habit, and then the “installation culture” will appear by itself, and the wiring will be reliable and durable.

Not only the reliability of the power supply, but also the safety of housing depends on the quality of the wire connection. Damage to the wiring occurs due to poor contact at the connection point, as a result of which it burns out, and in the worst case, causes a fire.

The method of connecting wires is selected depending on:

  • Wire material.
  • Sections of veins.
  • Wiring operating conditions.
  • Number of conductors.

All connections are made according to the diagram in the junction box, which is installed hidden or open method.

Connection with terminal blocks

The terminal block design consists of a plastic housing, inside of which brass tubes with threaded holes on both sides. The diameter of the inlet holes of the tubes varies and is selected depending on the cross-section of the wire.

The process of connecting wires in this way does not cause difficulties even for beginners:

  • Select a block with the required cell size.
  • Cut the required number of sections.
  • Remove 5 mm of insulation from the conductors and clean the surface of the conductors.
  • Insert the ends of the wires inside the cells and secure by tightening the screws.

The last procedure is carried out with force, especially if aluminum conductors are used. If too much force is applied, the screw will crush the aluminum core; the same applies to multi-core wires - thin wires are deformed under the action of the screw, making the connection unreliable.

This problem is solved by special lugs that are placed on the bare ends of the wires, crimped with press jaws or pliers, and then inserted into the cells of the terminal blocks. To connect aluminum or stranded conductors, terminal blocks made of high-strength plastic are also used, in which the conductor is clamped not with a screw, but with a plate, thereby achieving reliable contact. The devices are designed to operate with higher current.

Advantages of terminal blocks:

  • Low cost.
  • Quick installation.
  • Good connection quality.

Flaws:

  1. There are many poor quality products on sale.
  2. You cannot connect more than two conductors.

Terminal blocks are convenient to use for connecting chandeliers, sockets, switches, as well as joining wires broken in the wall, but such a connection cannot be hidden under a layer of plaster, but only in a junction box.

Spring terminals

The design of spring terminals was developed by the German company WAGO. The principle of their operation is that the conductors are clamped not with a screw, as in conventional terminal blocks, but with a lever-type mechanism that fixes the conductors without deforming them.

WAGO terminal housings are made from polymer materials. The contact part consists of two brass plates, one is rigidly fixed, and the second is movable. Simply insert the bare end of the wire into the terminal cell and lower the locking flag.

There are two types of WAGO spring pads:

  • Detachable.
  • One-piece.

Detachable terminals are reusable - the connection can be disassembled and reassembled. Permanent terminals are used only once. To repair the wiring, you will have to cut off the terminal block and install a new one after fixing the problem.

Advantages of spring terminals:

  • Quick installation.
  • Connection of more than two conductors.
  • Reliable contact without deformation of cores.
  • Hole for measuring network parameters.
  • You can connect conductors from different materials.

Flaws:

  • High cost compared to conventional pads.
  • Not recommended for use on heavily loaded networks.

Important. When connected aluminum wires It is recommended to pre-fill the terminal with contact paste to prevent oxidation of the wires. WAGO's product range includes terminals that have already been treated with this product during manufacture.

PPE caps

The design of connecting insulating clamps (PIC) consists of a cap and a cone spring inserted inside it. The cap is made from heat-resistant plastic withstands voltage up to 660 V.

Connecting wires with PPE caps is done in two ways - with and without preliminary twisting of the cores. When connecting two conductors, it is enough to attach their bare ends to each other, put on the cap and twist it with clockwise rotational movements. Connecting three or more wires with a PPE cap is done by twisting their ends with pliers. The insulation from the cables is removed so that the exposed part does not protrude beyond the cap - additional insulation is not required.

Advantages of PPE caps:

  • Low cost connectors.
  • Quick installation.
  • PPE is made of non-flammable material.
  • The caps have different colors, which makes it possible to mark the wiring.

Flaws:

  • Do not connect copper conductors to aluminum conductors.
  • Relatively weak fixation and insulation.

To make the connection reliable, it is important to choose desired type clamp All PPE caps are marked, which first indicates the type of body: 1 - without a protrusion, 2 - with a protrusion for more convenient grip of the cap with your fingers. After the housing type, the minimum and maximum total cross-section of the cores that can be connected in the clamp is indicated.

Crimping with sleeves

The most reliable connection used in lines with high current load. A tube is used as a clamp, into which the bare ends of the conductors are inserted and crimped with mechanical or hydraulic press pliers. Some craftsmen use pliers for this purpose, but in this case the reliability of the connection cannot be guaranteed.

The material of the sleeve must match the material of the conductors. If you need to connect copper cable with aluminum, use a combined copper-aluminum sleeve. The diameter of the tube is selected depending on the total cross-section of the conductors - after inserting the ends, there should be no voids left in it.

The connection of the wires by crimping is done so that their ends are approximately in the middle of the sleeve. The connection is insulated with heat shrink tubing or ordinary electrical tape.

Advantages of crimping with sleeves:

  • Low cost of sleeves.
  • Reliable connection with high mechanical strength.
  • You can combine copper with aluminum.

Flaws:

  • Permanent connection - if necessary, the sleeve will have to be cut off.
  • To work you need a special tool.
  • The work requires more time.

Important. Copper and aluminum are susceptible to oxidation. Before crimping, it is recommended to clean the wires to a shine and treat them with a special lubricant.

Soldering and welding

Soldering is old, but reliable way, still in use today. Its essence is to connect wires with molten solder, which flows into the twist gaps. After it hardens, a monolithic compound is formed. Soldering is used to join copper wires. Fluxes for aluminum are also available for sale, but experts prefer to refrain from soldering it. Soldering process:

  1. Remove the insulation from the ends of the wires and remove any varnish.
  2. Make a twist.
  3. Treat the twist with rosin.
  4. Heat the joint with a soldering iron and solder until it fills all the gaps.
  5. Let cool.
  6. Treat the soldering area with alcohol and insulate it.

This method is well suited for joining conductors of small diameters. The resulting connection does not require maintenance throughout its entire service life.

Advantages of soldering:

  • Excellent connection quality.
  • Low cost of work.

Flaws:

  • Labor intensity.
  • Experience with a soldering iron is required.
  • Permanent connection.
  • Cannot be used in networks with high current load.

To connect cables by welding, a welding machine is used. As in the previous case, the ends of the conductors are pre-twisted, then the end of the twist is fused with a carbon or graphite electrode until a ball is formed. The result is a monolithic connection that is reliable. The disadvantages of this method are the permanent connection and the need for certain welding skills.

Stranding and insulation

The idea is to twist the bare ends of the conductors together with pliers and then insulate them. Until recently, when the load in apartments consisted only of lighting and TV, twisting was used everywhere. Now it is prohibited by PES, especially in wooden buildings and rooms with high humidity.

Advantages of twisting:

  • Ease of operation.
  • No material costs required.

Flaws:

  • Poor connection quality.
  • Copper cannot be combined with aluminum.

Preparatory stage for soldering or welding, when installing temporary wiring.

Connecting wires with walnut clamps

Branch clamp is designed to make branches from the main cable without breaking it. The clamping device consists of a collapsible polycarbonate body; inside there is a steel core of two dies and an intermediate plate. The body halves are connected to each other by retaining rings, and the dies are connected by coupling bolts.

Branch compressor installation:

  1. Disassemble the branch compressor.
  2. Remove the insulation from the main wire to the length of the plate.
  3. Strip the end of the outgoing wire to the length of the plate.
  4. Place the wires in the grooves on the dies.
  5. Tighten the core with bolts, first placing a brass plate between the dies.
  6. Assemble the body.

Important. It is necessary to choose the correct standard size of the “nut”, depending on the cross-section of the cables used. The selection of compressions is carried out in accordance with the range of sections indicated on the core plates.

Benefits of nut compression:

  • Low cost.
  • Easy to install.
  • Possibility of connecting aluminum and copper.
  • Good insulation.

Flaws:

  • Large dimensions of the device.
  • It is necessary to periodically tighten the bolts.

The device can be used in networks with voltages up to 660 V. The body of the “nut” has fairly good insulation, but is not able to provide complete protection from moisture and dust. When using the compressor in unfavorable conditions, it is recommended to wrap the housing with electrical tape.

Bolt connection

All you need for the job is any bolt, washers of the appropriate diameter and a nut.

The ends of the conductors are stripped of insulation. In exposed areas, loops are formed along the diameter of the bolt. To make work easier, the ends of the cables can be wrapped around the bolt and then tightened. The connection elements are put on the bolt in the following order:

  1. Washer.
  2. Conductor.
  3. Washer.
  4. Conductor.
  5. Washer.
  6. Screw.

The nut is tightened by hand, then with a wrench or pliers. The finished connection is carefully insulated.

Advantages of bolted connection:

  • Ease of operation.
  • Reliable contact.
  • Low cost.
  • Demountable connection.
  • Use in networks with high load.

Disadvantages: bulky design, which cannot always fit into a junction box, high consumption of electrical tape.

How to connect multiple wires

The following methods are suitable for combining wires:

  1. Spring terminals.
  2. Twisting with soldering, welding or using PPE caps.
  3. Crimping with sleeves.
  4. Bolted connection.

The first option is less labor-intensive and the fastest. A bolted connection is also suitable - the number of conductors is limited only by the length of the bolt, but the connection has large dimensions.

Connecting wires of different sections

When connecting conductors of different cross-sections, twisting cannot ensure reliable contact, so all methods associated with it are excluded. It is recommended to use terminal blocks, spring terminals or bolt connection.

Combining stranded and solid conductors

Doesn't have any special features. Any of the described methods will do, with the only exception being twisting of conductors from different materials. Otherwise, the choice depends on preferences and financial capabilities. When using screw terminal blocks, it is necessary to have lugs on the stranded wire.

Connecting cables in water and underground

Electricity and moisture are incompatible things, so connections made under water or in the ground have special requirements. The ends of the conductors are connected by soldering or crimping with sleeves. Then they are treated with hot glue and insulated with heat shrink tube. If everything is done correctly, then moisture penetration into the joint is excluded.

You can also use terminal block connections. The connection point is placed in a sealed box and filled silicone sealant. The cable running underground must be placed in a pipe or box to prevent damage by rodents.

You can use one method or several at once - it all depends on the installation. The main thing that should not be forgotten is safety. The area where they are produced electric installation work, it is imperative to disconnect from the network, adhere to the PEU and use a working tool.

Electrical energy has firmly entered our lives. Without it, human existence is unthinkable, electricity will disappear and civilization will collapse. Factories, transport, information networks, in a word, everything is based on it. And one of the most important points all electrical science is the knowledge of how to reliably and correctly connect wires. To an ignorant person it will seem like - well, what nonsense, twist it somehow and it’s done. But no! So we’ll talk about the correct connection of wires for different cases of installation of electrical networks.

About the main types of wire connections

In this article we will try to consider almost all types of wire connections that are encountered when installing an electric lighting network, when creating power and switching networks. All methods of connecting wires have both their advantages and disadvantages. The most important thing is that there is reliable contact at the joints. If it turns out to be bad, then the joint will heat up and burn off over time, but that’s not so bad. It can even cause a fire! So the correct connection of wires must be taken seriously and responsibly.

So, what are the main ways to connect wires:

  • twisted;
  • soldering;
  • slip-on terminal;
  • threaded connection;
  • terminal blocks;
  • crimping;
  • rivets;
  • welding

Let's look at each of them separately.

Connecting wires by twisting

Connecting wires by twisting a few years ago was almost the most important type of installation internal networks buildings, and even now they are not abandoning it.

Features of creating this connection:

  1. A knife and pliers are enough for the job.
  2. It is strictly forbidden to twist a copper wire with an aluminum one, or to twist one wire around the other.
  3. When you still need to twist a copper wire with an aluminum one, you need to tin the copper wire with solder. Use TOC as solder, and rosin as flux. No acid-based fluxes!
  4. When installing internal networks in distribution boxes, it is allowed to connect up to six wires with different cross-sections in one twist.
  5. When you need to twist a stranded wire, the place where it connects also needs to be tinned.
  6. It happens that there is a need to extend the wires, then they do this: they strip each one by two or three centimeters and twist it, wrapping it around one another. Each wire must have at least two turns. If possible, you can solder the twist. And in the end, the whole thing is insulated with three layers of electrical tape.
  7. If you need to twist wires with a cross-section of less than a millimeter (switching wires), then the ends are stripped to two to three centimeters and twisted into five or six turns. After twisting, it is bent in half to reduce dimensions and increase strength.

But at high power, connecting wires by twisting does not support the load. The twist will heat up, because of this the wires will oxidize, and the contact on the twist will disappear.

Connecting wires by soldering

During the soldering process, metals in a solid state are joined by solder, which flows in molten form into the gap between them. Connecting wires by soldering is considered one of the most reliable methods.

Consider soldering single-core copper wires:

  • The insulation is removed from the ends of the wire and the surface is cleaned of varnish, if the wire is covered with it.
  • Next, a simple twist is made, two wires are twisted around one another or a branch is made.
  • Then flux is applied with a soldering iron and the joint is soldered with solder.
  • Use rosin or solder oil as a flux, and TOC lead-tin solder or tertiary as a solder.
  • If you are soldering stranded wires, then after removing the insulation, you need to fluff them up, insert one into the other and wrap them with thin wire, and then everything is exactly the same.
  • After soldering, insulation is applied.

The process for connecting aluminum wires by soldering is as follows:

  1. Soldering of aluminum wires occurs after the ends of the wires are connected by double twisting. There should be a small gap between the wire cores.
  2. The wire connection is heated blowtorch or a gas burner. The heating temperature should be such that the solder begins to melt.
  3. Solder is heated in a flame and rubbed into the wire joint, filling the gap with solder.
  4. Use F-64, FIM or FTBf-A as a flux, and TOS or Braze Tec as a solder.

Connecting wires with snap-on terminals

Connections with slip-on terminals are usually made on wires that have a cross-section of less than one millimeter. This is a very common method. Almost all electrical wiring of vehicles is connected in this way. And there are plenty of similar connections in household appliances. Now there are a lot of different plug terminals on sale, such as “U” 3.7 - 4.75, “P” 2.8 - 6.4, “B” 2.8 - 6.4, “O” 3.7 - 5.

It is easy to attach the terminals to the wire:

  • You need to strip the end of the wire - five to seven millimeters, put the insulator that comes with the terminal on it, and crimp the wire with special tendrils.
  • There are two pairs of antennae on the terminal, the first one crimps the wire core, and the second one crimps the wire with insulation.
  • An insulating cap is placed on the crimped terminal to connect the wires. If there is no special crimping, then you can use pliers.
  • To be on the safe side, you can solder the wire to the terminal, but this is not necessary.

Slip-on terminals only large sizes(1.25 - 3А.О, 1.25 - 3YS.U, etc.), wire connections are made in industrial electrical installations. They are crimped using special crimps. You can’t invent “gags” there, because poor-quality contact can create big troubles.

Wires on threaded connections

Although soldering is a reliable method of connections, it is labor-intensive, so it is better to use threaded connections. Wires in sockets and switches are connected in a similar way. Making a screw connection of wires is simple: you need to remove the insulation from the wire, about a centimeter or one and a half, make a ring if necessary, then tighten the wire to the connection point with a screw with a washer and a screw.

If you need to connect two wires, then perform the following steps:

  1. First, remove the insulation from the ends of the wire and clean the metal core until it shines (you can scrape it with a knife).
  2. Then the rings are rolled up. Their diameter should be slightly larger than the diameter of the bolt that connects them.
  3. We put a washer on the bolt, then two rings and a washer again, then a screwdriver and tighten it with a nut.
  4. This way you can connect wires of different sections.

And if you want to make a connection between copper and aluminum wires, then insert a steel washer between the rings. Copper and aluminum come into contact and oxidize. And if there is no steel washer, the contact on the twist will disappear.

This method also has a drawback. Bolted connections need to be tightened up from time to time. Especially if the twist contains a wire with an aluminum core. Aluminum has a certain fluidity, and no matter how reliable the contact is, it will weaken over time, and if it is not tightened, the twist will heat up, the wire will oxidize and the contact will disappear.

Connection with terminal blocks

Connecting terminal blocks are mainly used in electrical installations, where you need to connect many wires at once. For example, you can connect aluminum and copper wires without any problems.

They are different types and sizes, made from various materials:

  • The base of the carbolite terminal block is made of insulating material- carbolite (does not burn, chars at high temperatures), and brass tires are inserted inside. The wires are fixed with steel bolts, and through the transparent cover you can always observe the quality of the connection.
  • There are terminal blocks with spring contacts; they are used for small cross-section wires, mainly for switching wire connections. When clamping the wires, the spring plate will prevent the thin wire from breaking. The block body is made of non-flammable polyamide material.
  • Terminal blocks for connecting wires, the body of which is made of polyethylene, are convenient for installation; they are easily cut into separate sections. True, they cannot be used where there is even slight heating. Polyethylene begins to melt at low temperatures.

Terminal blocks have two types of fastenings: screw and DIN rail. Connecting wires through the terminal block is very simple:

  1. The insulation is removed from the ends of the wires - about ten millimeters.
  2. Unscrew the screws on the terminal block, insert the wires on both sides and tighten the screws back.
  3. When clamping screws, you must work carefully so as not to crush the wire with the screw and not to break the thread from the screw.

Wire connection by crimping

There are times when it is necessary to connect wires in a permanent way. Then they use pressure testing. The very essence of crimping is that under the action of compression force, simultaneous deformation of the sleeve and the wire that is located in it occurs. There are several types of crimping work - this is either local indentation or complete crimping.

The connection of wires by crimping is carried out as follows:

  • When it is necessary to crimp aluminum wires, due to the fact that they are covered with an oxide film, the wires are cleaned to a shine and treated with a special lubricant. You can use quartz-vaseline lubricant. It will prevent the formation of an oxide film, and the conductivity will be better.
  • Copper wires are lubricated only with technical petroleum jelly. This is done to ensure that the cores are not damaged during operation. During compression, the lubricant will be squeezed out, and there will be no increase in contact resistance due to the lubricant.
  • For crimping, special sleeves are used. The wires are inserted into the sleeve, and the joint should be in the middle. Making two indentations, we crimp the sleeve on both sides.
  • It happens that you need to connect the wires only on one side, then they insert the wires into the sleeve and do everything the same way. After crimping, the connection is isolated.
  • If you need to connect copper and aluminum wires, use a copper-aluminum sleeve.

For proper crimping, it is best to use PMU pliers with manual drive, and for a high-quality connection, use sleeves GA, GM, GAM, GML.

Connecting wires with rivets

Connecting wires with a rivet is very similar to a threaded one. Only if the bolt can be tightened or unscrewed, then in the case of a rivet the connection is disposable. Work with rivet joint is done special tool- riveter. There are different models of riveters: 001, 0050, 0400 reinforced, 004 with a 90-degree rotation, two-handed Master 0710.

A rivet connection is made like this:

  1. Special blind rivets are used for connection.
  2. The insulation is removed from the wire, two or three centimeters, and rings are made.
  3. Then a grommet, a washer and wire rings are put on the rivet, then the washer again.
  4. The whole thing is inserted into the riveter and the riveting process is performed.
  5. If you connect aluminum and copper wires, then you need to put a steel washer between them.
  6. Always leave a supply of wire so that if the connection fails, it can be redone without any problems.

Connecting wires by welding

Every electrician with experience knows that connecting wires by welding has the most reliable contact, or rather not even a contact - a single monolith. Having melted, the wires turn into one whole.

Connecting two wires by welding is not particularly difficult:

  • First you need to remove the insulation from the ends of the wire, optimally - about five to seven centimeters. Then we twist the strands into a twist and bite off the end with side cutters.
  • Direct welding occurs with carbon electrodes. If you were unable to buy original ones, then they can be easily made from carbon-graphite brushes from a commutator motor.
  • Apply the mass to the twist (you can use an alligator clip) and touch the end of the twist with an electrode. From touch there will be electric arc, which will fuse the wires into a single whole.
  • If a ball appears at the end of the twist as a result of melting, then the connection is made qualitatively.
  • The arc burning time should be no more than two seconds, otherwise the heating temperature will damage the wire insulation.
  • When choosing at what currents the welding will take place, take into account the cross-section of the wire and the thickness of the twist. The thicker the twist, the higher the current.
  • When welding wires, use welding machine or an inverter. The latter is preferable, since the inverter has a fairly large range of smooth current adjustment.

Connecting wires with bandages

Connecting wires with banding is used both in combination with other types of connections, and independently. The procedure for connecting the wires is simple. The insulation is removed from them and these sections are connected to each other. Next, the connection is tightly wrapped soft wire made of the same material as the wires being connected.

That's probably all about the basic wire connections. Let everyone choose what they like. Some need to connect faster, others need to connect more reliably. But remember one more thing: before you start working with the wires, make sure that they are disconnected and there is no voltage on them. When working, use proper tools and protective equipment!

Distribution boxes perform very important function. They ensure the distribution of electrical wires between points of consumption, i.e. switches, lighting fixtures and sockets.

Have you decided to install the devices listed above yourself? Then you need to thoroughly understand the features and order of connecting cables, as well as the basic methods of connecting them.

For a better understanding of the process, this event will be considered in several stages: from preparation necessary materials before connecting electrical appliances using the example of a socket, two-key switch and light bulbs. First, you will learn about the basic methods of connecting cables and wiring features

Wire connection methods

There are several methods for connecting electrical wires. You can choose the most convenient and suitable option for your case.

Prices for cables and wires for construction and repair

Cables and wires for construction and repair


The first stage - getting ready for work


First of all, we prepare everything that is needed to connect electrical appliances to the box. Set includes:

  • cables 3x2.5, VVG;
  • cables 2x2.5, AVVG;
  • switch with 2 keys;
  • fastenings;
  • lighting;
  • socket;
  • round nose pliers;
  • roulette;
  • wire cutters;
  • pliers;
  • flat screwdriver;
  • hammer.

Second stage - make the markings


At this stage, we mark the installation locations of electrical appliances and the routes for wires. So we can calculate required quantity materials for system installation.

The third stage - we begin installation

First turn off the electricity supply.

We connect the wires to the junction box. As a rule, cables are laid in grooves. Small nails or special plastic staples are used to secure the cables. If work is performed in wooden house, the wires will be supplied through special mounting boxes.

Important note! You should try to lay the wiring so that the cables do not intersect. If intersections are unavoidable, such places must be isolated especially carefully.

The fourth stage - we connect electrical appliances and connect the wires


We insert approximately 10 cm of wire into a distribution box pre-built into the wall or fixed to the base (depending on the model). We remove the general sheath from the cables. Then we remove approximately 0.5 cm of insulation from each core. At this point, we focus on the situation - we remove enough insulation so that the cores can be connected in the chosen way.

The diagram shows an example of connecting electrical wires using terminal blocks.

In the example under consideration, the connection is made using a two-wire wire, in which one wire is a zero, the second is a phase. We connect the socket to zero and. We connect the phase supply wire to the socket and one core of the switch cable.

In our example, the switch is two-key. Each key is responsible for controlling a separate group lighting fixtures. We connect the second wire of the switch cable to the first button, the third wire is connected to the second button.

The distribution box contains the neutral wires from the socket and light bulb sockets. The power cable is connected: zero is marked in blue, phase is marked in red. Wires are connected to connect each switch button to the light sockets.




Fifth stage - checking the functionality of the system

We turn on the power supply and check the operation of our outlet and. Everything works fine. We did a great job.


Now you know the order of connecting the wires in the junction box and the connection features of each main electrical appliance. Using the information received, you will be able to independently cope with all planned events.

Happy work!

Video - Connecting wires in a junction box