Different Electrical Wire Splices and Joints

 

 

DIFFERENT ELECTRICAL WIRE SPLICES AND JOINTS

Objectves: 

 Identfy and familiarize dieren elecrical wire splices and is uses.



Undersand he process and procedure in splicing elecrical wires/conducor



Perform acual splicing of dieren ypes of elecrical wire splices and joins.

The National Electrical Code or Philippine Electrical Code requires that the splicing and joining wires must be both mechanical and electrically secure prior to soldering. The joints must then be soldered with a fusible metal or alloy or brazed, a connector or solderless or welded unless some forms of approved splicing are used. Finally, all joints and the free ends of the conductor must be covered with an insulation equal to that of the conductor called electrical tape. In some situations where the wiring system has limited or low power the soldering of joints and splices is not necessary.

1. Rat Tail Joints- This ype of wire splice is commonly used o join wo or more conducors inside he juncton boxes or when xure leads are conneced o hrough conducors. The joins are made by skinning abou 2 inches, he ends of he conducor o be joined. See gure 1 Roman Nos. I and II hen wis he bare conducors abou six tmes, as shown a III. Nex, hey are soldered a he join as a IV. The join is hen insulaed wih elecric ape by applying minimum force o srech he ape and wrap around he join tghly several tmes, owards he end and back jus enough o wihsand or preven he leakage of curren as shown a V.

  Fig.1- Rat-Tail Joint 2.  Western Union Short-e Splice - he mos widely used splice or join in inerior wiring o

exend he lengh of wire from one poin o anoher. To make he splice, he wires are rs skinned for abou 3 inches a he ends as shown in Roman no. I gure 2. They are hen placed in cross positon, abou 1 inch from he insulaton as in II and bes in such a way as o make a long wis or bend as in III bringing i back ino he form of a cross. Four or ve shor urns are hen wrapped on each side of he longes wis, as shown in IV and V, and he free ends cu o and squeezed down close o he sraigh positon of he wire so ha hey will no exend over he surface of he shor urns and permi he sharp ends o cu hrough he ape wih he splice o be wrapped. The splice is hen soldered as shown a VI. The splice is hen insulaed wih elecrical ape, he wrapping begins a one end a leas ¼ inch back on he original insulaton of  he conducor and exending over o he oher side for a similar disance as he insulaed covering.

 

 

Fig.2- Western Union Short-Tie Splice

3. Western Union Long-Tie Splice- used exensively for ouside wiring and is quie like he shor

te splice, being used for inerior wiring. The dierence is ha several long wiss are made before wrapping he end urns. This is done so o wihsand greaer sress of pressure on he wire. The wires for his splice are bared abou 4 ½ inches as shown in No. 1 Figure 3. They are hen placed in he form of an X a a poin midway beween he insulaton and he end of he base wire shown in II. Five or six long wiss wiss are hen made, made, as a III and each side hose four urns are wrapped, as shown in IV. The splice is hen soldered and aped as shown in V and VI.

Fig. 3- Western Union Long-Tie Splice

4. Duplex Wire Splice - I is used only in condui sysems wherein duplex wires are used. These wires have wo conducors wih insulaors. To make he splice, he wires are rs skinned, or being bared abou 3 inches and he oher poin abou 5 inches as shown in Figure 4. The skinning and splicing of he conducors are saggered and no in line wih each oher o preven any possible shor and o presen a nea uniform appearance. The mehod of splicing each conducor is he same as for he Wesern Union Shor-te Splice, as shown in II and III. Each splice is soldered as a IV and he splices are hen insulaed wih elecrical ape as shown in V.

 

 

Fig. 4- Duplex Wire Splice

5. Britannia Splice- I is used in boh inerior and exerior wiring where solid wires of No. 6

AWG gauge or larger sizes are o be joined and where large wire connecors or pliers are no a hand. The wo wires are based for abou 4 inches in a No. 6 wire as shown in No. I Figure 5. Abou ½ inch of he exreme end of each bea o almos a righ angle o he sraigh porton of  he conducors as shown in II. A wrapping wire made of No. 18 bare copper is hen cu o abou 6 . in lengh and prepared by cleaning and bending in half. The large conducors are hen laid ogeher, one ben end pointng upward and he oher downward. The cener of he wrapping wire is hen brough o he cener of he conducors, one half of which is wrapped in one directon and he oher remaining half in he oher as far as he bes porton. The free ends are hen forced hrough he grooves from one end o he oher ends of he large single conducors. The bes ends are hen cu o close o he join, as shown a III. Solder he entre lengh of he splice as shown in IV. Elecric ape is hen wrapped over he splice hick enough as he original insulaor of he conducor as shown in IV.

 

Fig.5- Britannia Splice

6. Scarfed Splice- used only on large solid wires where here is an objecton o he bulkiness of 

he Wesern Union or Briannia Splice. The wires are bared for abou 3 inches, when a No. 6 wire is used as shown in I Fig. 6. The bared wire is hen led o a wedge shape sartng abou ½ inch from he insulatons as II. A piece of No. 18 bare copper wire is cu abou 5 . in lengh and prepared by cleaning and bending in half. The wo le sides of he conducors are hen laid ogeher and he wrapping wire wound around hem, as is similarly done in Briannia Splice. The wrapping is compleed by winding abou six and seven urn of he free ends around he unlled porton of he conducors as shown in III and IV. Soldering and aping is done as shown in V and VI.

 

  Fig. 6- Scarfed Splice 7. Ordinary wrapped cable splice - I is used for joining hrough conducors which is composed of a group of wires (sranded) insead of a solid conducor of a drawn meal. This mehod is

followed because i is impossible o join a large cable or sranded wire and wih he forms of a Wesern Union Splice. This splice is generally used on he large sizes of cable where i is more convenien o handle a single srand a a tme. To make he splice, he ends of he cable are rs skinned, a abou 6 inches. The srands are hen spread apar and each one horoughly cleaned by scrapping wih a knife blade of sandpaper. Nex, he srands are fanned ou a an angle of abou 30 degrees and laced ogeher leng he skinned ends lap over upon he insulaton as shown in I Fig. 7. A wis is hen made by bending a srand going in one directon o a righ angle o he cable and bending and adjacen srand from he opposie directon over he rs srand ino he form of a hook, as shown a II. One of he free ends is wrapped tghly around he main conducor as far as i will go. Anoher srand exending in he same directon is sared sar ed a he poin where he rs srand erminaed erminaed and wrapped similarly similarly o he rs. The remaining ones are wrapped in heir order around he join untl none remains, as shown a III. The oher side is wrapped in a similar manner as a IV. A blow orch is generally used for soldering he splice, he ame being applied in such a manner ha he original insulaton is no injured. The solder is applied in such a manner ha i lls all crevices beween he wrapped srands. Several layers of rubber and fricton ape wrapped o he hickness of he original insulatons o complee he splice as shown in V.

 

  Fig.7- Ordinary Wrapped Cable Splice

8. Mulple wrapped cable splice - I is used more exensively on small sranded wires and cables because hese srands are more pliable and may be wound ogeher wihou much diculy. Large srands are more rigid and require considerable tme in making such a splice. To make he splice, he ends of he conducors are skinned a abou 6 inches. The srands are cleaned and spread abou apar as shown in I, Fig. 8. Nex, he srands are cu abou 3 inches from he insulaton o he righ angles wih he sraigh conducor as a I. The srands of boh conducors are hen laced ogeher, one group of srands wound in he opposie directon as shown in II and in III. Care should be done ha all srands in each group are wrapped simulaneously and parallel o one anoher.

  Fig. 8 – Mulple Wrapped Cable Splice 9. Plain Tap, or Tee Joints - I is used o a grea exen for joining a ap or oher conducor o a

hrough conducor, as for example, a branch or main circui. To make he join, skin he ap wire abou 2 inches and he main wire abou 1 inch as shown in I, Fig.9. Nex, he wires are crossed inersectng abou ¼ inch from he insulaton of he ap wire and he main wire as shown in II. A hook or sharp bend is hen made in he ap wire, as a III, and abou ve or six urns wound around he main wire, as a IV. The join is soldered and aped as shown in V and VI. Care mus be aken ha he solder ows and stcks hrough all he crevices and ha he ape covers all pars of he conducors, beginning and ending on he original insulaton.

 

  Fig. 9- Plain Tap or Tee Joint 10.  Small Aerial Tap Joint - I is used mosly on ouside work, or in locatons where wires are

subjeced o considerable movemen. The wires are skinned and crossed as shown in I and II, Fig. 10. The ap wire is ben over he main wire making a long wis, as a III. Four or ve shor end urns are hen wound around he main wire as a IV. Nex, he joined wires are soldered as shown a V. Care is aken ha he solder will ow only ino he shor urns and no on he long wis. This precauton is necessary insead of he solder will ow a he inersecton of he wo wires wherein he exibiliy of he join would be desroyed and he even of he considerable movemen of he wires, he ap wires would break a he poin where i exends from he main wire. Finally, he joined area aped as shown in VI.

  Fig. 10- Small Aerial Tap Joint

11. Knoed, or loop, Tap Joint- I is a very srong join and will no unwis even hough a srain is placed upon i. I is occasionally used in practce, partcularly for emporary lightng sysems,

 

where tme is no aken o solder joins. To make he poin using No. 12 AWG wire, he ap wire is skinned abou 3 inches and is hen placed over he insulaton of he ap and main wire as a II, Fig. 11. Following his, he ap wire is ben and hooked over he main wire, as a III, brough forward and ben over iself, as a IV. Lasly, he remaining porton is wound inro four or ve shor urns around he main wire as a V. Solder he join, sweaed in and around i which is compleely covered wih rubber and fricton ape as shown a VI.

Fig. 11- Knoed or Loop Tap Joint 12. Wrapped Tap, or Tee Joint - I is used on large solid conducors where i is dicul o wrap

he heavy ap wire around he main wire. When a No. 6 AWG wire is used, boh he main and he ap wire are skinned abou 4 inches as shown in I, Fig. 12. The ap wire is ben ino an L shape abou ½ inch from he insulaton so ha i will res along he side of he main wire, as a II. A wrapping wire is hen prepared using size No. 18 bare conducors erminatng beyond he ben of ap wire and up o he insallaton of he main conducor as shown in III and IV. The  join is soldered and aped aped as shown in V and VI.

 

 

Fig. 12- Wrapped Tap or Tee Joint

13. Ordinary Cable Tap, or Tee Joint- I is used where large sranded wires or cables are apped

o a hrough conducor. To make he join, he main srands should be scraped horoughly wih a knife blade or sandpaper. The ap wire of similar size cable should be skinned abou 6 inches disance and he srands separaed or fanned each srands of he ap ino wo equal groups and forming hem ino he shape of a V as shown in I, Fig. 13. The main cable is placed ino his Vshaped space and forced down o wihin 1 inch from he insulaton of he ap conducor as shown in I. One group of ap wires is hen wound around he main conducor, each srand should be placed parallel o he oher, and all wrapped a he same tme and in one directon as shown in II. The oher group is wound in similar manner bu in he opposie directon as shown a III. Then solder he join by applying ux and hen heatng he join by means of a blow orch. The solder is held a he ap so ha he leas will mel and ow down ino he crevices of he  join. The join is aped wih layer of rubber ape and layers of fricton ape on ap as shown in IV.

 

 

Fig. 13- Ordinary Cable Tap or Tee Joint

14. Split Cable Tap, or Tee Joint- I is used where sranded cables or wires are apped o a

hrough conducor. This join is sronger han he ordinary cable ap and will no unwrap even hough a srain is placed upon i prior o soldering. To make his join, he main wire is skinned 5 inches No. 4 AWG wire size is used and he srands horoughly scraped as for he ordinary cable ap. The srands are nex divided in half by forcing a screwdriver hrough he cener of he bared porton on he main wire. The ap wire is prepared by skinning i abou 6 inches, scrapping each srand untl horoughly cleaned and fanning ou he srands so ha hey can be pushed hrough he space in he main wire as shown in I, Fig. 14. A space of abou 1 1/2 inch should be le beween he main wire and he insulaton of he ap wire. In completng he join, one group is wound around he main conducor, in one directon, and he second group is wound in he opposie directon. In such case he srands are o be wrapped ogeher and parallel o one anoher as shown in II, and as explained he ordinary cable ap.

 

 

 

Fig. 14- Split Cable Tap or Tee Joint

Fig. 15- Ordinary Cross Joint

  Fig. 16- Doble Wrapped Cross Joint

 

17. Terminang Fixture Joint- I is used when xure leads are joined o he end run of a branch

or ap conducor. No. 14 AWG wire is skinned for abou 1 inch, and he xure wire is No. 18 AWG, is skinned for abou 3 inches as a I, Fig. 17. The wires are crossed, allowing a space of  abou ¼ inch beween he inersecton and he insulaton as a II. Abou wo hirds of he xure wire is wound around he heavy wire, one urns only closely aer he oher as a III. The remaining porton of he heavy wire is hen ben over he shor urns of he xure as a IV. Over his bend is wound he remaining one-hirds of he xure wire as a V Solder and ape is done las as shown a VI and VII.

 

Fig. 17- Terminang Fixture Joint

18. The Through Fixture Joint- I is used where xures are conneced o branch wires a an

inermediae poin. In making his join, he end of one conducor is skinned abou 2 inches and he oher abou 4 inches. A a poin ¼ inch away from he insulaton of he shorer wire and 2 inches away from he insulaton of he longer wire, hree or four long wiss are made like he ra-ail join. See Fig. 18, drawing I. The long-bared porton of he long wire is ben over parallel wih he free ends, as a II. Boh free ends are hen placed alongside each oher wrapped ogeher around he sraigh bared porton as a III. Finally, he join is soldered and aped as shown a IV.

 

  Fig. 18- Through Fixture Joint Answer the following quesons:

1. Wha ype ype of join join or splice splice is used where where he skinning skinning and and splicing splicing is saggere saggered? d? Duplex Wire Splice

2. Wha ype ype of splice splice is used o o join srande sranded d large cables cables wherein wherein each each srand srand is inerlaced wih opposie srands? 3. Wha ype ype of joins used used inside boxes boxes or when xure xure leads leads are connec conneced ed hrough hrough conducor? 4. Wha kind kind of insulatng insulatng maerial maerialss are used aer aer splicing splicing and soldering soldering he joins? joins? 5. Wha is he he name of he he join used used in emporar emporary y wiring where where solderi soldering ng is no necessary? 6. Wesern Wesern union union shor-te shor-te splice splice is commonly commonly used in joining joining wo lenghs lenghs of conduc conducors ors in wha partcular locatons? 7.

Wha sp splice lice or join join is used where where large large solid solid wires are are join he he end of which which is made made smaller and wrapped wih smaller size of wire?

8. Wha kind kind of ap is used where where sranded sranded cable cable is apped hroug hrough h anoher anoher cable by spling he cable ino wo and wrapping in opposie directon parallel o each oher? 9. Wha kind kind of splicing splicing connecor connecor is used used on splice no. no. 8 and anoher anoher smaller smaller conducor conducor? ? 10. Name he join where wo plain ap joins are formed formed on he main conducor bu in opposie directons?

Actviy: Draw a projec plan for he Dieren Elecrical Wire Splices and Joins  

Reference: Inerior and Exerior Wiring and Trouble Shootng   By: Feliciano C. Agpaoa

hps://www.academia.edu hps://www. academia.edu/39767874/COMMON /39767874/COMMON_WIRE_SPLICES_AN _WIRE_SPLICES_AND_JOINTS D_JOINTS