Ways of connecting wires: twisting, soldering, welding, crimping, terminal block. Methods of connecting wires to each other Welding - high reliability in any conditions

Connecting wires is probably the most critical area of work in the installation of electrical networks. The higher the load on the site, the higher the requirements for connecting wires will be - therefore, it is necessary to use the most effective methods, techniques and devices.

We will analyze the most popular ways to connect electrical conductors, paying attention to their advantages and disadvantages. In addition, I will give examples of the implementation of the techniques most commonly used in the installation of electrical networks.

Overview of the main connection methods

Installation without the use of additional parts

The connection of the wires of the electrical network must meet a number of requirements:

reliable mechanical fixation of two conductors;
ensuring conduction between two conductors(the higher the conductivity, the better);
minimization of resistance at the joint;
no increase in resistance during long-term operation.

Today, when installing electrical networks, a variety of types of wire connections are used, which allow you to implement the above requirements at different levels. They can also be classified in different ways, but for the convenience of analysis, I will single out only two large groups: connections with and without additional devices.

If we need to connect two wires, and we do not plan to use any other devices (except, of course, insulation), then the list of methods will be limited. Wires can be twisted, soldered or welded. These are the three methods we will analyze.

Without the use of special devices, the conductors are mounted as follows:

Twisting- the easiest, fastest and cheapest way. The ends of the wires are cleaned of insulation, then twisted together in a spiral, after which the bare sections of the conductor are re-insulated.
Main disadvantage such a connection is a gradual drop in conductivity. The contact point oxidizes over time, the heating of the conductors increases, as a result, the reliability of fixation decreases. The greater the current in the network, the higher the risk of fire at the place of twisting, while the residual current circuit breaker is almost guaranteed not to work.

In the modern "Rules for the installation of electrical installations" (PUE of 2009, chapter 2, clause 2.1.21), such an installation method as fixing wires with a twist is absent in principle. If in earlier editions this method could be used for joining wires with a cross section of up to 10 mm 2, then with an increase in the average load on the network, twisting was abandoned. Now it is used only as one of the stages of mounting soldered, welded or other joints.

wire welding- according to most electricians (I completely agree!) The most reliable method. In welding, the conductors are first twisted to increase the contact area, and then welded using alternating current.
It is very easy to work with copper, but when installing aluminum wires, it is advisable to use a flux to remove the oxide film from the metal surface. The resistance at the welding site remains constant and does not increase over time, so the site will last a very long time.

Soldering- another fairly effective method of mounting connections. When soldering a copper wire, it is cleaned of insulation, the junction is tinned, after which the conductors are twisted. The twisted section is soldered with solder and rosin, while trying to solder the joint without gaps and sagging.

From my point of view, soldering is less reliable than welding. On the other hand, when installing wiring with your own hands, a soldering iron is much easier to find than a welding machine. And the margin of safety for domestic needs at the soldered connection is quite sufficient!

Connection using additional parts

To connect the wires while maintaining the maximum conductivity of the site, a variety of devices can be used. This includes both the simplest crimp sleeves and complex terminals that allow installation in just seconds.

What parts can be used to connect wires?

Sleeves for crimping. The crimp sleeve is a hollow cylinder made of soft metal. During installation, the wires are stripped, driven together, after which a connecting sleeve is put on their ends. The part is clamped with a special tool, which allows you to tightly fix the conductors and prevent their displacement relative to each other.

Branch clamps. They are used to form taps from the main conductor with voltage up to 660 volts without violating its integrity. Contact is provided by an anodized steel clamping platform, which is put on the stripped cable section and secured with four screws. The wire connection is protected by a housing made of dielectric material (carbolite or analogues).

Self-isolating (PPE) caps. A popular fixture that is only suitable for low-current circuits. The PPE cap is a plastic cone with a clamping spring inside. When connecting, the conductors are twisted, after which the cap is screwed onto the twist. Despite the fact that the spring, in theory, should keep the twist from loosening contact, it turns out not very reliable.

Terminal blocks. A fairly reliable and simple device, which consists of a plastic insulating housing, copper contacts with screw fasteners. When connecting the wire to the terminal, its end is stripped, inserted into the hole in the block and pressed against the contact plate with a screw.

The quality of the connection directly depends on the condition of the terminal block itself. In some cheap varieties, due to the thermal expansion of materials, the thread weakens over time, and the contact has to be “tightened”. Other pads have a risk of breaking the contact if the screw is tightened too tightly.

Spring terminals (WAGO and analogues). They are used to secure the section as quickly as possible: they removed the insulation from the wire, inserted the wire into the terminal hole - the spring fixed it with sufficient strength. There are also varieties with clamping levers that allow you to securely fix soft metal conductors - these are the ones I use most often.

The main disadvantage of such products is the relatively high price. A high-quality self-clamping WAGO terminal block costs from 7 to 25 rubles, depending on the configuration. If you need to make a lot of such connections, a decent amount runs up.

A few words about copper and aluminum

Describing the methods of installation of electrical networks, one cannot but pay attention to such a delicate issue as the twisting of copper and aluminum wires. Probably everyone who has at least a distant relation to this area knows that it is impossible to directly connect these materials.

There are several reasons:

temperature deformation. Aluminum and copper have different coefficients of thermal expansion. This means that when the current is turned on, they heat up differently, and cool differently when turned off. As a result, periodic on-off leads to loosening of the connection and a decrease in the contact density.
Oxidation. Over time, an oxide film forms on the surface of aluminum, which is characterized by poor conductivity. As a result, the resistance increases, and with it the heating.

Yes, both of these factors can be compensated: the first with tight clamps, the second with the use of special lubricants. But let's be honest: who and when does this when equipping the simplest twists?

Electroplating. Copper and aluminum are a galvanic pair. This means that when these metals are combined, the resulting oxides will decompose into charged ions, moreover, the higher the humidity in the room, the more actively the process will go. As a result of electrolysis, the reliability of the connection will fall - primarily due to the appearance of voids, and then due to the emerging heating.

Taking into account these arguments, I strongly advise against connecting copper wire to aluminum without the use of "intermediaries" - terminals, adapters, clamps and other devices.

Algorithms for mounting basic connections

Method 1. Twisting with soldering and heat shrink tubing

Different ways of connecting electrical wires require a different approach. In this section, I will provide step-by-step instructions for the construction of the most commonly used circuits.

Let's start with the simplest - twisting. Yes, it is not very reliable, but it can be successfully used in low-current circuits. And if you solder the contact point, then you can use the conductors almost everywhere.

Illustration	Execution technique
	Cleaning conductors. Using a special tool or a sharp knife, remove the insulation from the ends of the conductor. We need to expose about 25mm of wire.
	Insulation preparation. We cut off a fragment from a heat-shrinkable tube of the required diameter, the length of which will be approximately twice the length of the section to be joined. We put the tube on one of the conductors and move it to the side so that it does not interfere with us.
	Twisting. The sections of the conductor, cleared of insulation, are twisted together. When installing single-core conductors, we make sure that they are connected in a spiral, and not one wraps around the other. We first “fluff” stranded wires, then weave the wires together and twist them in a spiral.
	Soldering. Using a soldering iron on medium heat, carefully solder the joint. When soldering, we make sure that the solder evenly fills the voids between the individual cores in the twist.
	Insulation. We shift the heat-insulating tube to the soldered or twisted section, so that it completely overlaps it and enters the insulated sections on both sides.
	Insulation seal. Using a building hair dryer (better) or a regular lighter (worse, but also possible), heat the heat shrink tube until its diameter decreases and it compresses the connection along its entire length.

Method 2. Installation with pressure testing

The connection of conductors in the junction box can be made by crimping. To do this, we will need special crimp sleeves and a tool that allows you to fix them on the wires.

Mounting instructions using crimp sleeves:

Illustration	Execution technique
	Removal of general insulation. With a sharp knife, we cut the insulating casing on the wires brought out into the junction box. We remove the insulation and disassemble the wires by color, collecting them into groups. So it will be much more convenient to work.
	Cleaning conductors. With a special tool or a knife, we remove the insulating layer of conductors. It is advisable to remove a little less than can enter the crimp sleeve - this will make it easier to insulate.
	Putting on a sleeve. Conductors that require connection in one group are assembled together without twisting. We put a sleeve on the conductors, pushing its edge onto the isolated area.
	Crimping. Using a special tool, we crimp the wires. We crimp the sleeve in at least two places, after which we check the strength of the fixation.
	Connection of other conductors. We repeat the operations for the remaining groups of conductors.
	Insulation. We put on a heat shrink tube for each group of wires with an installed crimp sleeve. We heat the insulation to seal it along the entire length.
	Installation of the second isolation circuit. We bend the free ends of the heat shrink tubing. From above we put on pipes of a larger diameter.
	Insulation seal. As in the first case, we warm up the heat shrink tubes with a hair dryer. By contracting, they will fix the bent ends of the insulation, ensuring maximum tightness.

Method 3. Twisting with welding

The most reliable type of connection without additional parts is welded. It can be used where the contact point is subjected to severe stress.

You can mount wires in junction boxes by welding as follows:

Illustration	Execution technique
	Wire preparation. We bring the wires to the junction box, after which we remove the outer insulation and disassemble them into cores. We clean the ends of the veins, forming sections 50–70 mm long that are free from insulation. We collect the wires by color to facilitate the formation of twists.
	Formation of twists. We bring all the wires of the same color together, fold them in parallel and bend the edge by about 1 cm. Holding the bent part, we twist the wires in a spiral. To increase reliability and seal the twist, we make the last few turns with the help of pliers.
	Preparation of the welding machine. You can weld wires with almost any household appliance - there is enough power. For welding, it is desirable to use graphite (special insert, motor brush, battery rod).
	Wire welding. We install one clamp on the twist in the upper part, with the second clamp with a graphite insert, we weld, starting from the bottom of the twist. At the same time, we make sure that the connection is not overheated and does not begin to collapse. Thoroughly weld all connections.

After that, it is enough for us to insulate all the stripped sections of the wire. This is done using insulating tape, heat shrink tubing or special caps.

Method 4. Connecting copper and aluminum using a screw

Above, I noted that it is impossible to directly connect copper and aluminum. And yet, sometimes it is necessary to equip a reliable contact of such conductors - for example, when "splicing" old and new wiring.

If we have two solid wires, then the easiest way is to connect them using a clamp screw:

Illustration	Execution technique
	Formation of end rings. We clean the ends of both wires by about 30–40 mm. Using round-nose pliers, we make “ears” on both wires. The diameter of the ring should advise the diameter of the screw to be used for the connection.
	Bolt installation. We use an M4 bolt as a connecting element. We put a washer of such a diameter on the rod under the hat so that it completely covers the end ring of the wire. We put the wire with the ring on the bolt in such a way that when the fastening is tightened, the bent part does not open, but, on the contrary, bends even more.
	Connection formation. We cover the first wire with a second washer of a suitable diameter. Then we put a second wire on the rod - also with a ring. We cover it with a third washer, and install a grover (spring washer) on top, which will prevent the mount from unwinding.
	Fastening tightening. We install the nut on top and tighten the fasteners, holding the screw head with a screwdriver. When fixing, you need to tighten the mount tightly, but without undue effort, otherwise there is a risk of damaging the soft conductor. This is especially true for copper stranded wires.
	Insulation. We isolate the junction using either tape or large diameter heat shrink tubing. When using a heat shrink tube, it is advisable to additionally fix its edges to the left and right of the contact point.

Method 5. Using terminal blocks

The use of terminal blocks of different types allows not only joining wires made of copper and aluminum, but also makes it possible to create collapsible connections.

The details apply as follows:

Illustration	Execution technique
Conventional terminal block
	Wire stripping. We clean the ends of the connected wires. At the same time, approximately 5–7 mm must be released from the insulation - this is quite enough for reliable contact inside the terminal block.
	Preparing the terminal block. We cut off a fragment from the product with the required number of contacts. We loosen the fixing screws of the terminal block, opening the holes for installing the wires.
	Installation of the first wire. On the one hand, we insert the stripped ends of the wire into the holes, advancing them so that they do not reach the middle. Tighten the mounting screws with a screwdriver, clamping the wire inside the block.
	Installation of the second wire. Repeat the steps for the second wire. We make sure that the wires inside the block do not touch each other.
	Completion of work. We check the reliability of the connection, after which we isolate the contact point, protecting it from moisture and dust.
Spring terminal block WAGO 222
	Preparation for installation. We clean the wires intended for installation in the same way as for installation using the terminal block. Raise the clamping lever on the terminal block, opening a hole for installing the conductor.
	Wire installation. We insert the conductor into the hole, advancing it until it stops. We make sure that the wire does not bend inside the device.
	Conductor fixation. Lower the clamping lever. In this case, the contact plate inside the terminal block rises, clamping the conductor and securely fixing it inside the device due to spring action.

Conclusion

A reliable and safe wire connection can be achieved in many ways. The options listed above are quite enough to perform the most common types of work. If you need more information - watch the video in this article or ask a question in the comments!

Electrical energy has firmly entered our lives. Without it, human existence is unthinkable, electricity will disappear - civilization will collapse. Factories, transport, the information network, in a word, everything rests on it dear. And one of the most important points of all electrical science is knowing how to connect wires reliably and correctly. It will seem to an ignorant person - well, what nonsense, twisted it somehow and it's ready. But no! So we'll talk about the correct connection of wires for different cases of installing 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 during the installation of 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 should be reliable contact at the joints. If it turns out to be bad, then the junction will heat up and burn out over time, but this is not so bad. It can even start a fire! So the correct connection of the wires must be taken with all seriousness and responsibility.

So, what are the main ways of connecting wires:

twist;
soldering;
cap terminal;
threaded connection;
terminal blocks;
crimping;
rivets;
welding.

Let's consider each of them separately.

Twisted wire connection

Connecting wires by twisting a few years ago was almost the most important type when installing internal networks of buildings, and even now it is not abandoned.

Features of creating this connection:

A knife and pliers are enough for the job.
It is strictly forbidden to twist a copper wire with aluminum, as well as wrap one wire around another.
When you still need to twist the copper wire with aluminum, then the copper core needs to be soldered. Use TOC as solder and rosin as flux. No acid-based fluxes!
When installing internal networks in junction boxes, it is allowed to connect up to six wires in one twist and with different cross sections.
When it is required to twist a stranded wire, then the place of its connection must also be tinned.
It happens that there is a need to build up the wires, then they do this: they clean 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, then you can solder the twist. And in the end, the whole thing is insulated with electrical tape in three layers.
If you need to twist wires with a cross section of less than a millimeter (switching), then the ends are stripped by two or three centimeters and five or six turns are made on the twist. After twisting, it is bent in half to reduce dimensions and increase strength.

But at high power, the twisted wire connection does not hold loads. The twist will heat up, because of this, the wires will oxidize, and the contact on the twist will disappear.

Connecting wires by soldering

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

Consider soldering copper single-core 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, they make a simple twist, two wires wrap around one another or make a tap.
Then a flux is applied with a soldering iron and the joint is soldered with solder.
Use rosin or soldering oil as a flux, and TOC lead-tin solder or tretnik as solder.
If you solder stranded wires, then, having removed the insulation, they must be fluffed up, inserted one into the other and wrapped with thin wire, and then everything is exactly the same.
After soldering, insulation is applied.

The process of soldering aluminum wires is as follows:

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

Wire connections with push-on terminals

The connection with ring terminals is usually done on wires that have a cross section of less than one millimeter. This is a very common method. Almost all electrical wiring of transport is connected in this way. Yes, and in household appliances there are enough similar connections. Now on sale there are a lot of different cap clamps, such as "U" 3.7 - 4.75, "P" 2.8 - 6.4, "B" 2.8 - 6.4, "O" 3.7 - 5.

It is not difficult to fix the terminals on the wire:

It is necessary to strip the end of the wire - five to seven millimeters, put on it an insulator that comes with the terminal, and crimp the wire with special antennae.
There are two pairs of antennae on the terminal, the first one crimping the core of the wire, and the second one - the wire with insulation.
An insulating cap is put on the crimped terminal for connecting wires. If there is no special crimping, then pliers can be used.
For reinsurance, connecting the wire to the terminal can be soldered, but this is not necessary.

Ring terminals, only large sizes (1.25 - 3А.О, 1.25 - 3YS.U, etc.), are used to connect wires in industrial electrical installations. They are pressed with the help of 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 connection, it is laborious, so it is better to use threaded connections. In a similar way, wires are connected in sockets and switches. 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, if necessary, make a ring, then twist the wire to the connection point with a screw with a washer and a grover.

If you have to connect two wires, then perform the following actions:

First, remove the insulation from the ends of the wire and clean the metal core to a shine (you can scrape it with a knife).
Then the rings are rolled up. They should be slightly larger in diameter than the diameter of the bolt that connects them.
We put a washer on the bolt, then two rings and again a washer, then a grover and clamp it with a nut.
So you can connect wires of different sizes.

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

This method also has a drawback. Bolted connections must be tightened from time to time. Especially if there is a wire with an aluminum core in the twist. 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 by terminal blocks

Connecting terminal blocks are mainly used in electrical installations where many wires must be connected at once. For example, you can easily connect aluminum and copper wires.

They come in different types and sizes, made of various materials:

The base of the carbolite terminal block is made of insulating material - carbolite (does not burn, charred 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 contact, they are used for wires of small sections, mainly for switching wire connections. When clamping the wires, the spring plate will prevent the thin core from breaking. The pad body is made of non-combustible 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 a slight heating. Polyethylene begins to melt at low temperatures.

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

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

Crimped wire connection

There are cases when it is necessary to connect the wires in an integral way. Then they use pressure. The very essence of crimping lies in the fact that under the action of the compression force, the sleeve and the wire that is in it are simultaneously deformed. There are several types of crimping work - this is either local indentation or continuous compression.

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

When it is required 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 not allow an oxide film to form, and the conductivity will be better.
Copper wires are lubricated only with technical vaseline. This is done so 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. Wires are inserted into the sleeve, and the joint should be in the middle. Making two indentations, we compress the sleeve on both sides.
It happens that it is necessary to connect the wires only on one side, then the wires are inserted into the sleeve and everyone does the same. After crimping, the connection is isolated.
If it is possible to connect copper and aluminum wires, then use a copper-aluminum sleeve.

For proper crimping, it is best to use hand-operated PMU pliers, and for a quality connection, use GA, GM, GAM, GML sleeves.

Connecting wires with rivets

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

The rivet connection is done like this:

Special rivets are used for connection.
The insulation is removed from the wire, two or three centimeters, and rings are made.
Then a grover, a washer and wire rings are put on the rivet, then a washer again.
The whole thing is inserted into the riveter and the riveting process is performed.
If aluminum and copper wires are connected, then a steel washer must be put between them.
Always leave a spare wire so that in the event of a connection failure it can be redone without any problems.

Connection of wires by welding

Every electrician with experience knows that the connection of wires by welding has the most reliable contact, or rather not even a contact - a single monolith. When melted, the wires become one whole.

Making the connection of two wires by welding is not particularly difficult:

First you need to remove the insulation from the ends of the wire, optimally - somewhere around five to seven centimeters. Then we twist the strands into a twist and bite off the end of it with side cutters.
Direct welding takes place with carbon electrodes. If you could not buy the original ones, then it is not difficult to make them from carbon-graphite brushes from a commutator motor.
Feed the mass to the twist (you can use the crocodile clip) and touch the end of the twist with the electrode. From touch, an electric arc will occur, which will fuse the wires into a single whole.
If a ball appears at the end of the twist as a result of reflow, then the connection is made with high quality.
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, consider the cross section of the wire and the thickness of the twist. The thicker the twist, then apply more current.
When welding wires, use a welding machine or an inverter. The latter is preferable, since the inverter has a fairly large range of smooth current adjustment.

Connecting wires by banding

The connection of wires by banding is used both in conjunction 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 with a soft wire of the same material as the wires to be connected.

That, perhaps, is all about the basic wire connections. Let everyone choose what he likes. Some need to connect faster, others need to be more reliable. 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. Use proper tools and protective equipment when working!

Knowledge of modern technologies and methods of working with electrical fittings, is it really necessary? Yes, you need to know how to properly connect electrical wires.

This can be useful during installation, laying of any power supply systems. Whether the wiring burned out, a lighting fixture needs to be replaced or a complete set of new equipment. Such knowledge may not be needed, but it would be better to know all the common ways to connect electrical wires.

Application in terminal block circuits

Terminal blocks are electrical products made of a material that does not conduct electricity, inside which a conductive sleeve is inserted, which has a pair of screws at opposite ends. They serve to fix the wire. An excellent choice for the embodiment of a modern way of connecting wires.

When choosing a reliable wire connection, it is important to remember: terminal blocks are produced with different holes, for many sections.

This method is almost always used for connection in junction boxes of any type, during installation, installation of wall and other fixtures. It's suitable for. It is easy to mount the network using such fittings, you just need to insert the bare ends into the holes and, using moderate force, securely tighten the screws. The wire itself must not be transferred. Having figured out how to properly connect electrical wires using terminals, it is worth exploring other equally reliable methods.

Terminal method evaluation: Excellent mounting quality. Their price is acceptable. Pretty neat and easy to install. A good opportunity to connect different conductors, for example, aluminum and copper.

Blocks are not recommended to connect aluminum and stranded chains. This is due to the high fragility of aluminum wires and the great flexibility of the stranded wire conductors themselves. But overall a decent method.

Spring terminals

Fast installation of electrical networks is sometimes simply necessary. For example, to conduct temporary lighting on a balcony, terrace, gazebo. wago spring terminals are an excellent product for this kind of work. A modern and of course reliable way to connect wires. Although they are new on the market for electrical fittings, installation using spring terminals is quick and, importantly, convenient.

The main difference between the use of the vago terminal blocks themselves: it is more convenient to connect any wires in electrical boxes with them than with twisting. Here, for high-quality installation, a unique clamping mechanism is used, and not a simple screw. Manufacturers produce both disposable and reusable vago systems.

In the usual version, this product is used for one-time use; it cannot be restored during repair work in the future. It is removed and replaced with a new one.
Reusable wago terminals are a little more expensive, but with the help of them you can disconnect the assembled contacts several times, rewiring the circuit to suit your needs. This speeds up the process of repairing or mounting permanent and temporary networks. A simple lever-type mechanism has the advantage that it is possible to carefully, but qualitatively fix any wire without damaging or transferring it.

With the help of vago, fastening yourself is simple, you need to strip the insulation and insert the necessary cores into the mounting hole. Clamp with a lever. It's important to do it right.

wago clamp system rating: A unique possibility of combining any, aluminum, copper and other conductors. There is an option for connecting multi-core cables at the same time (two or more).

wago universal clamps allow you to fix any thin stranded conductor without damaging it. Another plus is the compact size of the pads.

wago self-clamping terminals

Excellent quality and durability. The Vago block has a technological hole that gives access to a screwdriver with a voltage indicator. The operation of any power line can be checked at any time. Perhaps one drawback is the considerable cost of the terminals themselves. But this type of wire connection is the most modern and fastest.

Insulation with PPE caps

Deciphering the product is not difficult, connecting insulating clips (PPE). They are ordinary nylon or plastic caps with an internal lock.

The simplest type of wire connection, it is carried out after twisting the conductors themselves, lived. Caps are often used to connect wires in junction boxes, to mark connections with the desired color.

Evaluation of the use of such products: Relatively low cost of PPE. The use of safe material eliminates the ignition of electrical wiring. Easy installation, put on a twist of wires and you're done. Such caps have a large range of colors, which is convenient. Of course, if the wires are not marked with color, colored PPEs have the ability to determine, or simply mark, zero, phase and other necessary power lines.

There are also disadvantages: Insufficient level of fixation. Stranded type of wires can be mounted only after soldering.

Installation of networks using sleeves

This option claims to be the most reliable connection method. Any on loads and quality of wires.

Crimping wires with sleeves

Conductive wires are inserted into a special tube - a sleeve, and crimped with a certain force. There is one, but. The cross section of the wires must not exceed the cross section of the sleeves to be mounted. After inserting and crimping the clip, the sleeve is carefully insulated with a heat shrink tube, or with the help of other insulating materials.

Overall rating. A great way to securely connect wires. The direction of the conductors can be from different sides of the tube or from one side. Sleeves are quite inexpensive. A good way to securely connect the wires to each other.

There are also disadvantages. Single use sleeves, they are not collapsible. For the production of such work, you will need a tool: pressing tongs, which are also used as a special tool. They remove the insulation. They have a crimping device in their arsenal, and electrical work takes a little more time.

Soldering or welding wires

This method is reliable. Usually, this method of connection in a junction box first involves stripping and twisting the ends, after which they are dipped into heated solder. The connection of aluminum wires to aluminum is preferably carried out by soldering. Then they are isolated with a heat pipe or insulating tape.

Evaluation of the soldering method. It gives strong circuit contacts and excellent quality, not expensive, it is the most reliable with the way of connecting electrical wires in a soldered box.

Technological disadvantage. You can't do without a soldering iron. The speed of work is not high. The connection is naturally not detachable. It follows from this that soldering is done in extreme cases, using more modern methods of connection. Among the masters, he has not been popular for a long time, because it takes more time.

There is also a rare method of connecting electrical wires, by welding. The process is similar, but requires the use of a special welding machine, of course, and certain skills.

Contact twisting method

Not a new, one might say "grandfather" method, it consists of a spiral twisting of the cores among themselves. The essence of all work is to twist the stripped conductors with the help of pliers, and cover the place of twisting with insulation. Here, perhaps, are all the ways of twisting wires.

Evaluation of this connection method. High speed of all installation works. The cost is minimal.

Flaw. It is forbidden to connect together twists of different composition, copper and aluminum wires., oxidation is inevitable. According to the regulatory framework, twisting wires in a junction box is not recommended for use in rooms with combustible materials, high humidity, basements, as well as in any house built of wood. More details about the twisting method. I definitely recommend watching a video about what is better twisting or Vago terminal blocks.

Clamping device for wires "walnut"

Such a device is simply a cable clamp with two plates inside and several tightening screws, usually in the corners. It is enough to fasten the wire to the plate itself. After that, put on a shell of carbolite on top.

Grade. A great way to connect any electrical wires in a junction box, large and medium size. Definitely, these types of products are quite comfortable and have a high degree of protection. It makes it possible to quickly connect a wire to a track with a thick section without breaking it.

Flaws. Dimensions allow installation only in spacious junction boxes, shields. Over time, the screws loosen.

Tip: When choosing fittings and method, remember the following:

It is necessary to work only with an insulated tool, use protective equipment.
Be sure to post a warning sign on the shutdown panel or meter, “do not turn on”.
Connect electrical appliances in accordance with the attached instructions.

Having considered the main types of wire connections, you can easily choose the right option. And having a simple tool and a diagram at hand, you can mount it yourself. In details

In a field such as electricity, all work must be carried out strictly, accurately and without a single mistake. Some wish to understand such work on their own, not trusting third parties to carry out a responsible mission. Today we will talk about how to properly connect the wires in the junction box. The work must be done with high quality, because not only the performance of electrical appliances in the house depends on it, but also the fire safety of the room.

About junction box

In an apartment or house, wires are routed from an electrical panel to different rooms. Usually there are several connection points: a switch, sockets, and so on. In order for all the wires to be collected in one place, junction boxes were created. They start wiring from sockets, switches and are connected in a hollow housing.

In order not to have to look for where the wires are hidden in the walls during the repair, the electrical wiring is laid on the basis of special rules prescribed in the PUE (Electrical Installation Rules).

Distribution boxes are classified according to the type of attachment. So, there are boxes for outdoor installation and indoor installation. For the second option, it is necessary to prepare a hole in the wall into which the box will be inserted. As a result, the lid of the box is flush with the wall. Often the cover during repair is hidden with wallpaper, plastic. In extreme cases, an outer box is used, which is mounted directly on the wall.

There are round or rectangular junction boxes. In any case, there will be at least 4 exits. Each outlet has a fitting or thread to which a corrugated tube is attached. This is done to quickly replace the wire. The old wire is pulled out, the new wiring is laid. It is not recommended to lay the cable in a strobe on the wall. If the electrical wiring burns out, you will have to gouge the wall, break the finish in order to carry out repairs.

What are junction boxes for?

There are many factors that speak in favor of the existence of junction boxes:

the power system can be repaired in a matter of hours. All connections are available, you can easily find the area where the wires are burned out. If the cable was laid in special channels (corrugated tube, for example), then in an hour you can replace the failed cable;
connections can be inspected at any time. As a rule, wiring problems occur at the junctions. If the socket or switch does not work, but there is voltage in the network, check, first of all, the quality of the connection in the junction box;
the highest level of fire safety is created. It is believed that dangerous places are connections. With the use of the box, they will be in one place.
minimum time and financial costs when repairing wiring. No need to look for wires in the walls that are out of order.

Connecting the wires in the box

There are several ways in which conductor connections can be made in junction boxes. Note that there are simple and complex methods, however, if performed correctly, all options will ensure the reliability of the wiring.

Method number 1. Twisting method

It is believed that the twisting method is used by amateurs. At the same time, it is one of the most reliable and proven options. PUE do not recommend the use of twisting, since the contact between the wires is unreliable. As a result, the conductors can overheat, the room is threatened by a fire. However, twisting can be used as a temporary measure, for example when testing an assembled circuit.

Method number 2. Mounting caps - PPE

Very often, special caps are used for twisting conductors. As a result, it is possible to obtain a reliable connection, with good contact. The outer shell of the cap is plastic (the material is not combustible), and inside there is a metal part with a thread in the form of a cone. The insert increases the contact surface, improving the electrical parameters of the twist. Most often, thick conductors are connected using caps (no soldering is required).

It is necessary to remove the insulation from the wire by 2 centimeters, twist the wires slightly. When the cap is on, it must be turned with force. At this point, the connection can be considered ready.

Before making a connection, you need to count the number of wires. Based on the data obtained (by section), a certain type of caps is selected. The advantage of twisting with plastic caps is that you do not need to spend a lot of time, as with conventional twisting. In addition, the connection is compact.

Method number 3. Connection of conductors by soldering

If the household has a soldering iron, and you know how to work with it, then the wires can be connected using soldering. Before connecting the cores, they need to be tinned. Soldering flux or rosin is applied to the conductor. Next, the heated tip of the soldering iron is immersed in rosin, carried out several times along the wire. A reddish coating should appear.

After the rosin dries, the wires are twisted. With the help of a soldering iron, tin is taken, the twist is heated until the tin flows between the turns. The end result is a quality connection with excellent contact. However, electricians are not very fond of using this connection method. The problem is that it takes a lot of time to prepare. However, if you are doing the work for yourself, you should not spare either effort or time.

Method number 4. Core welding

Using an inverter welding machine, you can connect wires. Welding is used over the twist. On the inverter, you need to set the welding current parameters. There are certain standards for different connections:

- conductor with a cross section of 1.5 sq. mm - 30 A;

- conductor with a cross section of 2.5 sq. mm - 50A.

If the conductor is copper, then a graphite electrode is used for welding. Grounding from the welding machine is connected to the upper part of the resulting twist. An electrode is brought from the bottom of the twist, the arc is ignited. The electrode is applied to the twist for a couple of seconds. After a while, the connection will cool down, then it can be isolated.

Read also: Hidden electrical wiring in a wooden house

Method number 5. Terminal blocks

Another option for connecting conductors in a box is using terminal blocks. There are several types of pads: screw, with clamps, but the principle of the device is identical. The most common is a block with a copper plate for attaching wires. By inserting several wires into a special connector, they can be securely connected. Mounting with a clamp terminal connection is very simple.

In screw terminals, the pads are placed in a plastic case. There are open and closed pads. Closed pads are the invention of a new generation. To make the connection, wires are inserted into the socket and clamped with a screw (using a screwdriver).

However, terminal connections have a disadvantage. It lies in the fact that it is inconvenient to connect several conductors together. Contacts are arranged in pairs. And if you need to connect more than three wires, then several branches are squeezed into one socket, which is very difficult. At the same time, such connections make it possible to operate branches with a high current consumption.

Another type of pads is Wago terminals. Today, two types of terminals are in demand:

- terminals with a flat-spring mechanism. Sometimes they are called disposable, since it is impossible to reuse the terminals - the quality of the connection deteriorates. Inside the terminal there is a plate with spring petals. As soon as the conductor is inserted (it must be single-core only), the tab is pressed out and the wire is clamped. The conductor cuts into the metal. If the conductor is pulled out by force, then the petal will not take its previous shape.

Some terminal connections contain wiring paste internally. Such a connection is used if you need to connect a copper and aluminum wire. The paste protects metals from oxidation by protecting conductors;

- universal terminals with a lever mechanism - this is the best type of connector. The wire, stripped of insulation, is inserted into the terminal, a small lever is clamped. At this point, the connection is considered complete. And if you need to re-connect, add contacts, lift the lever, pull out the wire. The pads can be operated at low current (up to 24 A - with a cross section of 1.5 sq. mm) and at high current (32 A - with a conductor cross section of 2.5 sq. mm). If wires are connected through which a current higher than the specified one will flow, then another type of connection must be used.

Method number 6. Crimping

It is possible to connect the wires in the box by crimping only with the help of special pliers, as well as a metal sleeve. A sleeve is put on the twist, after which it is clamped with tongs. Just this method is suitable for connecting conductors with a large load.

Method number 7. Bolted connection

Connecting multiple wires with bolts is a simple and effective connection method. To complete the work, you need to take a bolt and a few washers with a nut.

It is not enough to know how to connect the wires in the junction box. You need to know which conductors are connected to each other. So, a washer is put on the bolt thread. The core is wound, the second washer is put on, and then the next core. At the end, we put on the third washer and press the connection with a nut. The node is closed with insulation.

There are several advantages of bolting conductors:

- ease of work;

- low cost;

- the ability to connect conductors made of different metals (for example, aluminum and copper).

However, there are also disadvantages:

- fixation of wires - not of high quality;

- to hide the bolt you need to use a lot of insulation;

First of all, you must understand that different types of connections can be used in different conditions. And their choice depends on the specific task.

For example, it is much more convenient to connect wires of small cross sections up to 2.5 mm2 in a compact junction box with terminal blocks or clamps. But if we are talking about a strobe or a cable channel, then sleeves come out on top here.

Consider the three most simple and at the same time reliable types of connections.

Let's start with a PPE type connection. It is decoded as:

WITH connecting

AND insulating

W excitement

It looks like a simple cap. There are different colors.

Moreover, each color means belonging to specific sections of the veins.

Cores are inserted into this cap and twisted together.

How to do it right, first twist the cores and then put on a cap or twist them directly with the PPE itself, is discussed in detail in the article “.”

As a result, thanks to PPE, you get the good old twist, only immediately protected and insulated.

On top of that, with a spring-loaded contact that does not allow it to loosen.

In addition, this process can be slightly automated by using a PPE attachment for a screwdriver. This is also covered in the article above.

The next view is the Wago terminal blocks. They also come in different sizes, and for a different number of connected wires - two, three, five, eight.

They can join together both monocores and stranded wires.

Moreover, this can be implemented both in different types of Vago, and in a single one.

For multi-wire, the clamp should have a latch-flag, which, when open, allows you to easily insert the wire and clamp it inside after snapping.

These terminal blocks in home wiring, according to the manufacturer, can easily withstand loads up to 24A (light, sockets).

There are separate compact specimens on 32A-41A.

Here are the most popular types of Wago clamps, their markings, characteristics and for what section they are designed:

Series 2273 Series 221-222 Series 243 Series 773 Series 224

There is also an industrial series for cable sections up to 95mm2. Their terminals are really large, but the principle of operation is almost the same as that of the small ones.

When you measure the load on such clamps, with a current value of more than 200A, and at the same time you see that nothing is burning or heating, many doubts about Wago products disappear.

If your Vago clamps are original, and not a Chinese fake, and at the same time the line is protected by a circuit breaker with a correctly selected setting, then this type of connection can rightfully be called the simplest, most modern and easy to install.

Violate any of the above conditions and the result will be quite natural.

Therefore, you do not need to set wago to 24A and at the same time protect such wiring with an automatic 25A. The contact in this case will burn out during overload.

Always choose the right vago terminal blocks.

Automatic machines, as a rule, you already have, and they protect primarily the electrical wiring, and not the load and the end user.

There is also a fairly old type of connection, such as terminal blocks. ZVI - insulated screw clamp.

In appearance, this is a very simple screw connection of wires to each other. Again, it happens under different sections and various shapes.

Here are their technical characteristics (current, cross section, dimensions, screw torque):

However, ZVI has a number of significant drawbacks, due to which it cannot be called the most successful and reliable connection.

Basically, only two wires can be connected to each other in this way. Unless, of course, you don’t specifically choose large pads and shove several wires there. What to do is not recommended.

Such a screw connection is well suited for solid conductors, but not for stranded flexible wires.

For flexible wires, you will have to press them with NShVI lugs and incur additional costs.

You can find videos on the network where, as an experiment, the transient resistances on different types of connections are measured with a microohmmeter.

Surprisingly, the smallest value is obtained for screw terminals.

But we should not forget that this experiment refers to "fresh contacts". And try to make the same measurements after a year or two of intensive use. The results will be completely different.

Combination of copper and aluminum

Often there is a situation when it is necessary to connect a copper conductor with aluminum. Since the chemical properties of copper and aluminum are different, direct contact between them, with the access of oxygen, leads to oxidation. Often even copper contacts on circuit breakers are subject to this phenomenon.

An oxide film is formed, resistance increases, and heating occurs. Here it is recommended to use 3 options to avoid this:

They remove direct contact between aluminum and copper. Communication occurs through steel.

The contacts are separated from each other in separate cells, plus the paste prevents air from entering and prevents the oxidation process from developing.

The third simple way to connect conductors is crimping with sleeves.

GML sleeves are most often used for joining copper wires. Deciphered as:

G ilza

M single

L narrowed

To connect pure aluminum - GA (aluminum sleeve):

For the transition from copper to aluminum, special GAM transitions:

What is the pressing method? Everything is quite simple. Take two conductors, strip to the required distance.

After that, on each side of the sleeve, the conductors are inserted inside, and the whole thing is crimped with press tongs.

With obvious simplicity, there are several rules and nuances in this procedure, if not followed, you can easily ruin a seemingly reliable contact. Read about these mistakes and rules on how to avoid them in the articles ” ” and ” ”.

To work with conductors of large sections 35mm2-240mm2, a hydraulic press is used.

Up to sections of 35mm2, you can also use a mechanical one with a large span of handles.

The sleeve must be crimped two to four times, depending on the cross section of the wire and the length of the tube.

The most important thing in this work is to choose the right size of the sleeve.

For example, when connecting monofilament, the sleeve is usually taken to the size of a smaller section.

And in this way, you can connect several conductors at the same time at the same point. In this case, only one sleeve will be used.

The main thing is to completely fill its internal space. If you crimp three conductors at the same time, and you still have voids inside, then you need to “fill in” this free space with additional pieces of the same wire, or conductors of a smaller cross section.

Sleeve crimping is one of the most versatile and reliable connections, especially when it is necessary to extend the cable, including the lead one.

In this case, the insulation turns out to be almost equivalent to the main one, while also using the outer tube HERE as a casing.

Of course, you will not use either PPE or Wago for these purposes, but the GML sleeves are the very thing! At the same time, everything comes out compactly and easily decreases even in a strobe, even in a cable channel.

Welding and soldering

In addition to all the above connection methods, there are two more types that experienced electricians rightfully consider the most reliable.

And not always, even with its help, it is possible to connect an aluminum solid wire with a flexible copper stranded wire. In addition, you are forever tied to an outlet or extension cord.

And if there is no voltage or generator nearby at all?

At the same time, elementary press tongs, on the contrary, are present in 90% of electrical installers. It is not necessary to purchase the most expensive and fancy ones for this.

For example, batteries. Convenient of course, go and just press the button.

The Chinese counterparts also cope well with their task of crimping. Moreover, the whole process takes no more than 1 minute.