How to Make Electrical

Connections
Wire Splices, Joints and Taps

 Wire must be properly joined or

spliced in order that electricity will
flow normally in the circuit

Joints, Splices, and Taps

Joint the tying
together of two single
wire conductors so
that the union will be
good both
mechanically and
electrically
Tap the connection
of the end of one wire
to some point along
the run of another
wire

Splice the
interlaying of
the strands of
two stranded
conductors so
that the union
will be good
both
mechanically
and electrically

Mechanically Strong and Electrically

Strong
Mechanically Strong
means the joint
must be as strong as
a continuous length
of wire
The joints will not
fall apart easily even
if it is not soldered
or connected with
electrical connectors

Electrically Strong
means it must be as
good a conductor as a
piece of the same wire
with which it is used
Wires are connected
(joined or spliced) so
you get the electricity
either to several
locations or to a
location a long
distance away

Twist VS Turns
Twist - Each wire

is wrapped
around the
other
Turns - One
wire remains
straight, the
other wire
being
wrapped
around the
straight wire

Operations in Making a Joint, Tap or

Splice

1.Removing the insulation

2.Cleaning the conductors
3.Tying, or interlaying
4.Soldering
5.Tape or taping (Insulating)

1. Removing the Insulation

Skinning or Stripping
The first step in
making any kind of
joints/taps/splices
Wire Stripper
Knife
Side Cutting Pliers
Nick a small cut in
the surface of the
conductor when the
insulation is removed

Cut the insulation at an

angle of about 30 degrees.
Note: Do not circle the wire
with the blade at right
angles, because in most
cases this produces a
groove/nick in the
conductor which may:
a. cause the latter to break
when bent at this point
b. Reduce its capacity to
carry current
.Instead, whittle the
insulation away in a manner
similar to that of sharpening
a pencil

Wire Stripper

Removing the Insulation

tools mentioned, observe the

following precautions:
Do not attempt to use a hot-blade
stripper on wiring with glass braid
or asbestos insulation. These
insulators are highly heat resistant.
When using the hot-blade stripper,
make sure the blades are clean.
Clean the blades with a brass wire
brush as necessary.
Make sure all stripping blades are
sharp and free from nicks, dents,
and so forth.
When using any type of wire
stripper, hold the wire perpendicular
to the cutting blades.
Make sure the insulation is clean-cut
with no frayed or ragged edges;
trim if necessary.
Make sure all insulation is removed
from the stripped area. Some types
of wire are supplied with a
transparent layer between the
conductor and the primary

2. Cleaning the Conductors

The wires must be thoroughly cleaned

to insure good electrical contact
between the ends of the wires and so
that the solder will adhere properly
The wires maybe cleaned by scraping
Knife - care should be taken to avoid
nicking the wire
Sandpaper

3. Tying, or Interlaying

Depending
upon on the
types of
splices, joints

Types of Wire
Splices, Joints
and Taps

Western Union Short Tie

Used when the

connection must be
strong enough to
support long lengths
of heavy, wire. In the
past. this splice was
used to repair
telegraph wires.
If the splice is to be
taped,care should be
taken to eliminate
any sharp edges
from the wire ends.

 Western Union Long Tie

The Western Union Long-Tie or
telegraph splice, as it is
frequently called, is used
extensively for outside wiring
and is quite similar to the
short-tie splice, being used for
the same purpose.
The only difference is that a
number of long twists are
made before wrapping the
end turns.
This is claimed to be an
advantage because it allows
the solder to spread in
between the wires more
freely.
Five or six long twist and four
turns

 Western Union Short

Tie
The Western Union
joint is used more
frequently than any
other joint. It is used
in interior wiring in
joining two lengths of
wire to extend the
conductors from
outlet to outlet. In
outside wiring, it is
used extensively.
One twist and four
turns

Rat-Tailed Joint
Used principally in
joining conductors in
outlet boxes/junction
box and for
connecting branch
circuits
It is satisfactorily if
no longitudinal strain
is impressed on it
A longitudinal strain
would cause to
untwist the joint
Five or six long twist

Back-Turn Joint
Used when fixture
leads are
connected to
branch wires at an
intermediate point
Useful in
connecting two
wires that must be
drawn taut
Will withstand
considerable
longitudinal strain.

End Fixture Joint

Used to connect a smalldiameter wire, such as in a
lighting fixture, to a larger
diameter wire used in a
branch circuit.
Used when a fixture wire,
usually No. 18 AWG, is to be
joined to a terminating
branch conductor, which I
most frequently of No. 14
AWG.
Like the rattail joint, the
fixture joint will not stand
much strain

Plain Tap or Tee Joint

The tap splice is used where

you want to join a second wire
to a conductor
The branch wire is laid behind
the main wire.
About three-fourths of the bare
portion of the branch wire
extends above the main wire.
The branch wire is brought
under the main wire, around
itself, and then over the main
wire to form a knot.
The branch wire is then
wrapped around the main
conductor in short, tight turns;
and the end is trimmed off.

Small Aerial Tap joint

Intended
for wires
subjected
to
considera
ble
movemen
t
Similar to
plain tap
except
that it has
a long
easy twist

Knotted Loop Tap Joint

Used
where the
splice is
subject to
strain or
slippage.
When
there is no
strain, the
knot may
be
eliminated.

Ordinary Cross Joint

The
same
as
plain
tap,
only it
has
two
tappe
d
wires

Double-Wrapped Cross-Joint
Used for
identically
the same
reason as
the ordinary
cross-joint,
with the
advantage
of being
stronger

Staggering Splices
Also known as Duplex Joint/Splice
Used in conduit systems where twin wires are
used
Could be western union joint

Britannia Joint
Used on overhead
lines where
considerable
tensile strength is
required
Also used both for
inside and outside
wiring where
single conductors
of sizes No. 6 or
larger is used

Scarfed Joint
Used on large
wires where
appearance
and
compactness
are the main
consideration
s and where
the joint is
not subject to
any heavy
tensile stress

Wrapped Tap
Used on
wires
too
large to
wrap
around
the
round
wire

4. Soldering
The act or process of forming joints upon or
between metallic surfaces, by means of a
fusible alloy or solder, whose melting point
is lower than that of the metals to be united
Solder is a name for any fusible alloy used
to unite different metal parts
Flux is a substance applied to a metal to
make solder flow easily
Soldering can be done with the aid of a
soldering iron, soldering gun or a torch

Requirements for Good

Soldering
1.Absolutely clean
conductors
2.Careful use of flux
3.Clean soldering tool
4.Correct temperature of
soldering tool
5.Proper solder

 Approximate
Soldering Iron Size
for Tinning

A
B
#20 - #16
65
Watts
#14 & #12 100 Watts
#10 & #8
20
Watts
A. Wire Size (AWG)
B. Soldering Iron Size
(Heat Capacity)

5. Reinsulating the Joint

To complete the various joints, taps and splices, the
expose wires must be insulated
Taping is required to protect the splice from
oxidation (formation of rust) and to insulate against
electrical shock. Taping should provide at least as
much insulation and mechanical protection for the
splice as the original covering.
Although one wrap of plastic (vinyl) tape will provide
insulation protection up to 600 volts, several wraps
may be necessary to provide good mechanical
protection.
When plastic tape is used, it should be stretched as it
is applied. Stretching will secure the tape more firmly.

Rubber Tape

Latex (rubber) tape is a splicing compound.

It is used where the original insulation was rubber.
The tape is applied to the splice with a light tension so that each
layer presses tightly against the one beneath it.
This pressure causes the rubber tape to blend into a solid mass.
Upon completion, insulation similar to the original is restored.
In roll form, there is a layer of paper or treated cloth between
each layer of rubber tape.
This layer prevents the latex from fusing while still on the roll.
The paper or cloth is peeled off and discarded before the tape is
applied to the splice.
The rubber splicing tape should be applied smoothly and under
tension so no air space exists between the layers.
Start the first layer near the middle of the joint instead of the
end.
The diameter of the completed insulated joint should be
somewhat greater than the overall diameter of the original wire,

Rubber Tapes

Friction Tape

Putting rubber tape over the splice means that the insulation
has been restored to a great degree.
It is also necessary to restore the protective covering.
Friction tape is used for this purpose.
It also provides a minor degree of electrical insulation.
Friction tape is a cotton cloth that has been treated with a sticky
rubber compound.
It comes in rolls similar to rubber tape except that no paper or
cloth separator is used.
Friction tape is applied like rubber tape; however, it does not
stretch.
The friction tape should be started slightly back on the original
insulation.
Wind the tape so that each turn overlaps the one before it.
Extend the tape over onto the insulation at the other end of the
splice.
From this point, a second layer is wound back along the splice
until the original starting point is reached.

Friction Tapes

Plastic Electrical Tape

Plastic electrical tape has come into wide use in recent
years.
It has certain advantages over rubber and friction tape.
For example, it can withstand higher voltages for a
given thickness.
Single thin layers of certain plastic tape will withstand
several thousand volts without breaking down.
However, to provide an extra margin of safety, several
layers are usually wound over the splice.
The extra layers of thin tape add very little bulk.
The additional layers of plastic tape provide the added
protection normally furnished by friction tape.
Plastic electrical tape usually has a certain amount of
stretch so that it easily conforms to the contour of the
splice.

Plastic Electrical Tape

Steps
in Taping

SPLICES

Running Butt Splice

Relates to splices formed by butting
together the ends of two cable
lengths to extend the run or length of
a circuit as distinguished as tap
splices
According to the method of wrapping
the strands, running butt splices are
classified as:
Single Wrapped
Multiple Wrapped

Single Wrapped Splice

Used for
large wire
(no.6 or
larger)
because it is
easier to
wrap a
single wire
at a turn
than to
wrapped a
them all at
once

Single Wrapped Splice

Multiple Wrapped splice

This method
is used
generally on
small cables
because the
strands are
flexible and
all can be
wrapped in
one
operation

Tap Splices
These are made when the end of one
stranded conductor is to be
connected at some point along the
run of another stranded conductor
Ordinary Tap Splice
Split Tap Splice
Y Split Splice

Ordinary Tap Splice

Split Tap Splice

Y Split Splice

WIRE CONNECTORS and

LUGS

Electrical Connector
Anis anelectro-mechanicaldevice for joining
electrical circuitsas aninterfaceusing a mechanical
assembly.
The connection may be temporary, as for portable
equipment, require a tool for assembly and removal, or
serve as a permanent electrical joint between two
wires or devices.
There are hundreds of types of electrical connectors.
Connectors may join two lengths of flexiblecopperwire
or cable, or connect a wire or cable or optical interface
to an electricalterminal.
Cable glands, known ascable connectorsin the U.S.,
connect wires to devices mechanically rather than
electrically and are distinct from quick-disconnects
performing the latter.

Electrical Connector
Electrical connectors can be insulated or not insulated and come
in various types of insulation.
The non insulated electric connector is usually bare copper that
has a tin plating.
Insulated terminals can come in PVC insulated, nylon insulated
and heat shrink insulated. The PVC insulated type are usually
the cheapest and most common. PVC tends to be a harder
insulation and can crack when crimped and for this reason I do
non recommend using them. Nylon insulation is a softer
insulation and will not crack when the terminal is crimped. The
nylon insulation will also withstand higher temperatures. Heat
shrink insulated terminals and connectors are great for
applications where the terminal is uncovered to outside
elements such as high temperatures, rain, snow, and
underwater applications.

 A device that joins electric conductors mechanically and

electrically to other conductors and to the terminals of
apparatus and equipment. The term covers a wide range of
devices designed, for example, to connect small conductors
employed in communication circuits, or at the other extreme,
large cables and bus-bars.
Electrical connectors are applied to conductors in a variety of
ways. Soldered connectors have a tube or hole of
approximately the same diameter as the conductor. The
conductor and connector are heated, the conductor inserted,
andsolderflowed into the joint until it is filled. Solderless
connectors are applied byclampingthe conductor or
conductors in a bolted assembly or by staking or crimping
under great mechanical force.

Properties of Electrical Connectors

Electrical connectors are characterized by theirpinoutand physical
construction, size, contact resistance, insulation between pins, ruggedness and
resistance to vibration, resistance to entry of water or other contaminants,
resistance to pressure, reliability, lifetime (number of connect/disconnect
operations before failure), and ease of connecting and disconnecting.
They may be keyed to prevent insertion in the wrong orientation, connecting
the wrong pins to each other, and have locking mechanisms to ensure that
they are fully inserted and cannot work loose or fall out. Some connectors are
designed such that certain pins make contact before others when inserted, and
break first on disconnection; this protects circuits typically in
connectors that apply power , e.g. connectingsafety groundfirst, and
sequencing connections properly inhot swappingapplications.
It is usually desirable for a connector to be easy to identify visually, rapid to
assemble, require only simple tooling, and be inexpensive. In some cases an
equipment manufacturer might choose a connector specifically because it
isnotcompatible with those from other sources, allowing control of what may
be connected. No single connector has all the ideal properties; the proliferation
of types is a reflection of differing requirements.

PEC Definition
Connector is a device that
establishes a connection between
two or more conductors or between
one or more conductors and terminal
by means of mechanical pressure
and without the use of solder
Solderless Connector
Pressure Connector

Types of Electrical
Connectors

Wire Nut
A type of single point connector
Device commonly used to replace the
rat-tail joint splice.
The wire nut is housed in plastic
insulating material.
To use the wire nut, place the two
stripped conductors into the wire nut
and twist the nut.
In so doing, this will form a splice like
the rattail joint and insulate itself by
drawing the wire insulation into the
wire nut insulation.
Twist-on wire connectors are also
known aswire nutsor cone or
thimble connector

Wire connectors come in different colors. The color indicates the

size of the wire that they are capable of holding secure. The
following chart will help explain what color wire connector is
capable of holding what size wire.

Wire Nut Colors and Wire Sizes

Big Blue
#10 and Larger
Gray
#14 and Larger
Red
#14 and larger
Big Tan
#14 and larger
Yellow
#18 and larger
Big Orange
#18 to #14
Little Orange
#22 and to #14
Little Blue
#22 to #16

Terminal Blocks
A simple type of electrical connector that connects two or more
wires to a single connection point
Also called terminalboardsorstrips which provide a convenient
means of connecting individual electrical wires
They are usually used to connect wiring among various items of
equipment within an enclosure or to make connections among
individually enclosed items
Since terminal blocks are readily available for a wide range of
wire sizes and terminal quantity, they are one of the most flexible
types of electrical connector available
Some disadvantages are that connecting wires is more difficult
than simply plugging in a cable and the terminals are generally
not very well protected from contact with persons or foreign
conducting materials.
One type of terminal block accepts wires that are prepared only
by removing (stripping) a short length ofinsulationfrom the end.
Another type accepts wires that have ring or spade
terminallugscrimped onto the wires.

Component and Device Connectors

Transistor switch module with
large screw connectors and
small crimped-on "Fast-on"
connectors
Electrical and electronic
components and devices
sometimes have plug and socket
connectors or terminal blocks,
but individual screw terminals
and fast-on or quick-disconnect
terminals are more common.
Small components have bare
lead wires for soldering. They
are manufactured using casting.

Blade Connector
A type of single wire connection
using a flat conductive blade which
is inserted into a blade receptacle.
Usually both blade connector and
blade receptacle have wires
attached to them either through
soldering of the wire to the blade
orcrimpingof the blade to the wire
In some cases the blade is an
integral manufactured part of a
component (such as a switch or a
speaker unit), and a blade
receptacle is pushed onto the
blade to form a connection
A common type of blade connector
come in male and female types

Blade connectors (lower

half of photo). Ring and
spade terminals (upper
half).

Ring and Spade Terminals

Ring terminals are used to connect the wire to
a stud point like a screw for earthing or
similar.
Spade terminals can be used like ring
terminals but the nice thing about the spade
terminal or fork terminals is that the stud
does open to connect to it. The spade can
slide around thestud for a connection.
Ring style wire end blade connectors are
normally sold in lots.
Electrical contact is made by passing a screw
or bolt through them.
The spade terminal form factor facilitates
connections since the screw or bolt can be
left partially screwed in as the spade terminal
is removed or attached.
Their sizes can be determined by the size of
the conducting wireand/or theScrew/Bolt
diameter size designation.

Crimp Connectors
Crimp connectors are typically used to terminate
stranded wire.
They fulfill numerous uses, including allowing the wires to
be easily terminated to screw terminals, fast-on / quickdisconnect / spade-foot type terminals, wire splices,
various combinations of these.
Crimp-on terminals are attached by inserting the stripped
end of astranded wireinto a portion of the terminal,
which is then mechanically deformed / compressed
(crimped) tightly around the wire.
The crimping is accomplished with a special
crimping pliers.
A key idea behind crimped connectors is that the finished
connection isgas-tight.
Crimped connections fulfill similar roles, and may be
thought of similarly to, soldered connections.

Crimp Connectors
Crimp. The physical compression
(deformation) of a contact barrel
around a conductor to make an
electrical and mechanical connection
to the conductor.
Crimping. A method of mechanically
compressing or securing a terminal,
splice, or contact to a conductor

Crimp Connectors
There are complex considerations for determining
which type is appropriate - crimp connections are
sometimes preferred for these reasons:
Easier, cheaper, and/or faster to reproduce reliable
connections in large-scale production
Fewer dangerous, toxic and/or harmful processes
involved in achieving the connection (soldered
connections require aggressive cleaning, high
heat, and possibly toxic solders)
Potentially superior mechanical characteristics due
to strain relief and lack of solder wicking.

Terminal Lug
A device attached to a
conductor to permit connection
to a terminal.
A terminal designed to be
affixed, usually at one end, to a
post, stud, chassis, or the like
for mounting.
It has provisions for attachment
of wires or similar electrical
conductors in order to establish
an electrical connection and
could require the use of tools
for attachment of wire.

Terminal Lug
A terminal may be attached to a
wire by a number of methods
including screw-on, press-on or
crimp-on [which is shown
below]. Selection is based on
two main criteria ; the wire size
the barrel is designed to accept [
AWG], and the tongue with will
fit a particular stud size. The
barrel may be insulated [Type 2]
or non-insulated [Type 1].
Normally both insulated or noninsulated should have the wire
crimped on, but in some cases
the non-insulated lugs may be
soldered.

Split Bolt Connector

Split-bolt connectors are a
compact construction
widely used for splices and
taps in building wiring.
The bolt-shape casting
has a wide and deep slot
lengthwise. The
conductors are inserted in
the slot and the nut is
drawn up, clamping the
conductors together inside
the bolt

Split Bolt Connector

Multiple Conductor
Connector
Multiple
conductor
connectors
provide preinsulated
connection
for various
sizes of
wire.