To use electricity safely, it's essential to have proper electrical wiring and equipment. Whenever wires are connected to other wires or to switches, fuses, lights, motors, or household appliances, connectors are necessary. When the power is on, current flows through the wires, and the connectors and devices may heat up. If the connections are made properly, the contact resistance remains low, and the temperature stays normal. However, if the connection is poor, the resistance increases, leading to excessive heat. 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 generate sparks when energized, especially if the joint is loose. Without proper insulation, the exposed ends of the wires might touch each other, causing a short circuit and potentially starting a fire. Therefore, ensuring correct wiring practices is crucial for safety and reliability.
So, how should you connect wires correctly?
1. First, strip the insulation from the wire using wire strippers or cutters. For hard plastic-insulated wires, an electrician’s knife can be used carefully. Make sure not to damage the core while cutting.
2. For single-strand copper conductors, straight and T-branch connections can be made by twisting the cores together. For a straight connection, the two wire ends are twisted in an X-shape and then wound tightly. For a T-branch, one wire is wrapped around the main conductor in a clockwise direction.
3. For 7-strand copper conductors, the process involves loosening the strands, cleaning them, and arranging them in an umbrella shape before winding them together. Similarly, for 19-strand wires, the same method applies but with more attention to securing the middle of the core.
4. After connecting, soldering improves conductivity and mechanical strength. The joint is cleaned, placed in molten tin, and coated until fully covered. Any residue is removed to ensure a smooth surface.
5. Aluminum wires should never be connected directly to copper because of oxidation issues. Instead, crimping is recommended. A suitable crimping tube is selected, and the wires are inserted and compressed with a crimping tool.
6. Once the wires are connected, their insulation must be restored. Use materials like wax tape, polyester tape, or black tape. Wrap the insulation starting twice the width of the core, maintaining a 1/2 overlap with each turn.
Wiring standards include: tightening bolts moderately, using the right tools, avoiding damage to screws, and ensuring secure connections. Terminal blocks should hold no more than two wires of the same type. Connectors must be properly fastened to prevent looseness, and non-conductive gaskets should not be used. Conductive paste can help improve contact. For temporary lines, soft wires should be folded before connecting, and hard wires should be shaped into a “U†form.
For high-power motors (30kW and above), avoid using poorly conductive washers. When wrapping insulation, ensure at least one full wrap with a 1/2 overlap to maintain safety and durability. Proper wiring techniques are vital for preventing electrical hazards and ensuring long-term performance.
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