To use electricity safely, it is essential to have proper electrical wiring and equipment. Connections between wires, switches, fuses, lights, motors, and appliances are critical points where current flows. When power is turned on, the current passes through these connections, causing them to heat up. If the connection is well-made, the resistance at the junction remains low, and the temperature stays normal. However, if the connection is poor or loose, the resistance increases, leading to excessive heat generation. This can cause the insulation around the wire to melt, ignite nearby flammable materials like dust, wood, or fabric, and even lead to fires.
Poor connections can also produce sparks when energized, especially if the joint is not properly insulated. If two exposed wires come into contact, a short circuit may occur, resulting in sparks and potential fire hazards. Therefore, ensuring secure and correct wiring connections is crucial for electrical safety.
To connect wires properly, follow these steps:
1. **Strip the Insulation**: Use wire strippers or cutters to remove the outer insulation from the wire. For hard plastic-insulated wires, an electrician’s knife can be used carefully to avoid damaging the core.
2. **Straight and T-Branch Connections**:
- For single-strand copper wires, strip the ends, clean the core, twist them together, and wrap tightly with 6 turns. Trim any excess and clamp the ends.
- For T-branch connections, cross the branch wire over the main wire, wind it clockwise around the main core, and trim the excess.
3. **Multi-Strand Copper Wires (e.g., 7-strand)**:
- For straight connections, spread the strands into an umbrella shape, interleave them, and wrap tightly in multiple layers.
- For T-branches, insert the branch strands into the main wire and wrap them around the trunk.
4. **Soldering**: After making the connection, solder the joint to increase conductivity and mechanical strength. Melt tin in a pot, apply it to the joint, and ensure a smooth finish after cleaning.
5. **Aluminum Wire Connections**: Aluminum oxidizes easily, so direct copper-to-aluminum connections are not recommended. Instead, use crimping tubes and tools to join aluminum wires securely.
6. **Insulation Restoration**: After connecting wires, restore the insulation using materials like black tape or waxed tape. Wrap the insulation starting twice the width of the core, overlapping each turn by half, and ensure a tight seal.
**Wiring Standards**:
- Avoid over-tightening bolts to prevent damage.
- Use the correct screwdriver size and ensure it fits snugly to avoid slipping.
- If bolts are difficult to remove, apply lubricant or gently tap them before attempting to loosen.
- Never use a vise to tighten nuts; adjust the wrench opening to prevent deformation.
- One terminal block should hold no more than two wires of the same type and size.
- Use “U†shaped connectors to increase contact area and reduce loosening.
- Avoid non-conductive gaskets between terminals.
- Clean contact surfaces before applying conductive paste and tightening.
- For temporary wiring, fold soft wires once before connecting, and use “U†shapes for rigid wires.
- For high-power motors (30kW and above), avoid using poor-conductivity washers like galvanized nuts.
- When wrapping insulation, ensure a 1/2 overlap and complete at least one full cycle.
Proper wiring techniques and attention to detail are essential for safe and efficient electrical systems. Always follow best practices and use appropriate tools and materials to minimize risks and ensure long-lasting performance.
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