UNIT 4

Splicing And Terminating

Rationale

Why is it important to learn about different types of splices?

The purpose of this unit is to make you aware of the importance of

splicing and terminating in the electrical industry. In order for electrical
systems to function properly, the wires and cables must be securely
connected: to each other, to transformers, to ballasts, to switches, LED’s or to
other circuit components. A solid, mechanically secure electrical connection is
one of the most important aspects of any type of electrical installation. If
established procedures are not followed, the system will not perform correctly,
may function intermittently and perhaps become a fire and/or a shock hazard.
Recognizing improper splices will aid in diagnosing problems within signs or
sign components.

Outcome

When you have completed this module you will be able to:

Describe the different types of techniques used for terminating

conductors.
List the basic techniques for soldering components.
State the proper methods for splicing and terminating mechanical
connections.
Describe the proper methods and concerns while splicing aluminum.
Recall the proper methods of splicing high voltage cable.
Describe the proper methods for connecting neon sockets to neon
tubes.

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4-1 TERMINATION TYPES

The sign industry generally uses two common types of terminations or

connections. They are either soldered or mechanical in nature.

Soldered Connections

Soldering is a basic technique used for making connections between

conductors or between conductors and components. Although it is typically
not practical to solder solid conductor connections, it is often useful to solder
or tin (i.e. coat with solder) the ends of flexible conductors before terminating
them.

In the field of electronics, soldering has become a critical skill. Mastery

of this skill requires care, experience, knowledge of the fundamentals, and
high standards of workmanship. Faulty solder joints are a major cause of
equipment failure.

Mechanical Connections

Mechanical terminals or connectors for larger conductors are generally

considered to be of the "nut and bolt" type. That is, wrenches are usually used
to put them together and take them apart. Smaller sizes of wire and cable are
usually joined using twist-on wire connectors. Both types of mechanical
connectors are removable and often reusable. Figure 4-1 shows examples of
split
bolt, lug and twist-on type connectors.

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4-2 SOLDERING

Soldering is the process of joining two metals together by the use of a

solder alloy. Solder is an alloy of tin and lead and is referred to in terms of a
ratio of tin to lead. Tin is always listed first. A solder that is 60/40 is made of
60% tin and 40% lead and this alloy is usually used for electrical soldering.

Much of our present day electrical/electronic technologies depend upon

the reliability of soldered connections. The Canadian Electrical Code (CEC)
requires that an electrical connection be both mechanically and electrically
secure before soldering. The CEC also states that soldered connections can
not be used for grounding or bonding connections.

In order to accomplish reliable soldered connections you must know

something about flux, solder, soldering tools, and basic soldering techniques.

Flux

Reliable solder connections require truly clean surfaces. Scraping the

surface to be soldered is insufficient. When metals are exposed to air, oxide
forms at an extremely rapid rate and the process is accelerated when heated.
This oxide film will prevent proper soldering. Flux is used when soldering to
remove and prevent oxidation. Electrical connections require a flux that is
non-corrosive. Flux used with electrical/electronic connections should be of
the " ROSIN" non-corrosive "R", "RMA", or "RA" type. The flux can be
applied separately, usually in the form of a paste or liquid, or it can be in the
core of the solder. "Acid" fluxes are corrosive and must be completely
avoided when soldering electrical connections.

Soldering Tools

Soldering tools come in a variety of sizes, shapes, and power ratings.

The basic types are:

1. pencil iron
2. soldering iron
3. soldering gun

In basic soldering irons the operating temperature depends on the

capacity of the heating unit, and the mass of the tip. Soldering guns may
incorporate a two stage trigger to vary the temperature of the tip.

Preparation of the soldering tool is required before use. If the tip of the
tool is heavily oxidized (black spots) or pitted it should be filed flat to bare
copper. If the oxidation is light, bring the tool up to temperature before

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preparing the tip. A damp sponge may be used to wipe the tip clean, removing
any oxides that have built up between uses.

After cleaning the tip, apply flux and a thin coat of solder to the entire
tip. This is called tinning the tip and it will reduce the build up of oxides when
soldering. Oxides on the tip will reduce heat transferability, and may cause
contamination of the connection.

There should always be a layer of bright solder on the tip. If not, clean
and re-tin the tip. The tool is now ready for use.

Soldering Techniques

When watching the soldering process it may appear that the solder
simply sticks the two metals together. What actually happens is far different.
When the hot copper comes into contact with a clean copper surface, a metal
solvent action takes place. The solder dissolves and penetrates the copper
surface, and forms a metallic bond between the two parts.

Good soldering only occurs if the surface of the copper is free of any
contaminant or oxide. Also the copper and solder must have reached the
proper temperature.

Although the surface may look shiny and clean before soldering, a thin
film of oxide is still covering it. If solder is applied, it will act like a drop of
water on an oily surface. In fact the oxide film will prevent the solder from
contacting the copper. No solvent action takes place, and the solder can easily
be scraped off. For a good solder bond to take place, surface oxides must be
removed by using flux.

When soldering, it is important to control how fast the work heats up,
how hot it gets, and how long it stays hot. This is affected by factors such as
tip temperature, tip size and connection mass. The heat requirement may vary
over a wide range. If we consider a single, small diameter wire, it heats up
quickly. If wire leads are to be joined, where some of the leads are much
larger than others, then the heat requirement will be much larger.

Each connection has its own particular thermal requirements, therefore

determining the size and power rating of the soldering tool and tip to be used
is important. With large work a small iron will be too slow. If a large tip iron
is used on small work, the temperature rise will be too rapid, even though the
temperature of the tip is the same. This may damage heat sensitive
components.

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 An iron that is too hot will damage electronic components and/or wire
insulation. On the other hand an iron that is too cool will produce a mushy
kind of solder melt and result in what is called a “cold solder joint”. This type
of joint has a dull irregular appearance and usually high resistance. It is
unreliable and unacceptable.

Another factor to remember is the amount of heat being transferred to

the work. Figure 4-2 shows the tip of an iron touching the conductor, and the
actual contact area is very small. The contact area can be increased by
applying a small amount of solder to the contact area. This solder "link"
provides a greatly increased heat transfer area.

You can determine if you have the correct tip Conductor Tip of iron
size and temperature if the solder melts within 2 to 3
seconds after it is applied to the opposite side of the
work piece from the iron. The solder will be drawn
toward the source of heat. If work is properly cleaned,
fluxed, and heated the solder will flow easily onto the
Small contact area
joint.

The following procedure should be used to Figure 4-2

solder a splice or tin the ends of conductors for
termination.

1. Prepare and preheat the soldering tool.

2. Prepare the wire, clean it and shape it as required.
3. Make a tight mechanically secure splice, trim as required.
4. Apply the flux.
5. Apply a small amount of solder between the wire and the tip of the
iron to form a thermal link
6. Apply the solder to the opposite side of the splice from where the tip
of the iron is applied until the solder flows freely. This should take 2
or 3 seconds.
7. Remove the solder.
8. Remove the solder tool with a wiping action. (Slide the tool from the
work )
9. Hold the splice still until it has cooled enough for the solder to
solidify.

Heat sinks

Occasionally, it may be necessary to solder electronic components, such

as timers, flashers and photocells, which are very heat sensitive. In these
instances, a device called a heat sink must be clamped to the lead of the

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component, between the solder point and the component. Excessive and
damaging heat will be drawn away from the component.

De-soldering

When replacing a component which has soldered connections, it may be

required to use a de-soldering process. This may be a copper braid type
material which will draw the solder from the connection when it is heated or
you may also use a de-soldering tool which sucks the solder from the
connection after it has been heated. In either case follow these steps outlined
below.

1. Connect a heat sink if required.

2. Melt the solder joint with a soldering tool.
3. Absorb the solder into a copper braid material or use a de-
soldering tool following the manufacturer’s instructions.
4. Mechanically undo the joint to remove the component.
5. Follow the steps for soldering the replacement component.

4-3 MECHANICAL CONNECTIONS

Stripping of Conductors

Most conductors are covered by insulation which must be removed to

make a connection. Cabled wires, such as non-metallic sheathed cable
(NMSC) and armored cable (AC), must have their outer sheath removed first.
Figure 4-3 shows the removal of the outer coverings.

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 Once the outer covering or sheath is removed, the conductor insulation
must be stripped bare. If a knife is used, it should be held at a 30 degree angle
to the conductor to cut through the insulation. This is known as "penciling".
Never "ring" the conductor by cutting at 90 degrees, as this can nick the
conductor. A nicked conductor may break off when you try to shape it. It
may break off at a later date due to vibration, on some installations. In
addition, a nicked conductor has a reduced cross-sectional area, thereby
increasing the resistance of the conductor at the nick.

A wire stripper may also be used for stripping insulation. Great care
must be taken to adjust the tool correctly so as not to damage the conductor.
Figure 4-4 shows proper hand placements for stripping wires with both a knife
and a wire stripper.

Re-insulation of the conductor is required after a connection has been

completed. First check that no stray conductor strands or sharp edges are
sticking out. Splices with very irregular surfaces may first require filling with
splicing compound such as rubber tape or electrical putty. The splice can now
be covered with a minimum of two layers of half-lapped vinyl plastic
electrical tape, wrapped from opposite directions. The tape should be
stretched slightly when applied.

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 Western Union

The Western Union splice is a strong reliable connection used for any
conductors that are subjected to longitudinal stress. It is also a good style of
splice to use when connecting high-voltage cable to neon tubing since in many
cases this connection is not soldered. To build this type of connection start
with approximately 80 mm of bared conductor on each wire. The splice is
started by making an L-shaped bend on each of the conductors and then
wrapping a minimum of five full turns of each conductor around the opposite
conductor. The turns must be wrapped very tight and the left over ends cut
off. The connection is now ready to be soldered, if required. Figure 4-5
illustrates the procedure.

Pigtail Splice

The pigtail splice, the most common type used, is made by simply
twisting the wires together after they have been bared (see Figure 4-6). A right
hand (clockwise) twisting action is used to match the threading action of
twist-on wire connectors. This splice can be completed by: solder and tape; a
compression connector; or a twist-on wire connector. In some cases, such as a
connection between high-voltage cable and neon tubing, the splice is
sometimes twisted together and left as complete. Since the circuit has low
current and high voltage, this type of splice is considered to be adequate.

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Solid Conductor Terminations

The Canadian Electrical Code limits conductor terminations under screws to a

maximum wire size of # 10 AWG. The conductor should be wrapped around a
screw in a clockwise direction. This will cause the wrapped loop to be drawn
toward the body of the screw when it is tightened. If wrapped in the wrong
direction the conductor may squeeze out from under the screw head when
tightened. Some terminals have a raised shoulder beside the screw head. On
this type of terminal it is not necessary to wrap the copper conductor around
the screw. It can simply be laid under the side of the screw that will draw the
conductor under it when tightened.

Figure 4-7 shows both the proper twisting directing for a wire under a
screw and a wire placed in a raised shoulder termination type.

Figure 4-7

Stranded Conductor Terminations

When terminating stranded conductors some type of lug will usually be

required. To prevent damage to the conductors, the floating bar in the lug
should separate the conductors being spliced. These lugs should be tightened
to manufacturers’ specifications or as specified in the CEC. Figure 4-8 shows
a typical lug used for joining stranded conductors.

Figure 4-8

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Pin style connection

The pin type of connection for attaching conductors to incandescent

sockets involves placing conductors in grooves on the socket itself. The
conductor is then pressured onto sharp pins which pierce the conductor;
contact is now made with the conductors and the socket.

4-5 HIGH-VOLTAGE CABLE CONNECTIONS

In the sign industry the use of neon has created the need for a reliable
high-voltage splice. Presently there are several different methods for
terminating high-voltage cable which provides electrical insulation and
mechanical protection. Figure 4-9 shows a typical high-voltage connector for
terminating high-voltage cable. The cable is mechanically protected by a
flexible metallic conduit (flex). The flex is secured into the connector and the
splice is made inside the plastic portion of the connector. The appropriate
splice to use for the connectors shown would be a pigtail splice.

High-voltage connections can also be made in the type of connector

shown in Figure 4-10. This type of connector is known in the electrical
industry as a "C fitting” As with the other connectors the high voltage cable is
brought into the "C fitting" and a pigtail splice is done inside the device. The
cover of the "C fitting" is detachable for easy maintenance and installation.

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4-5 HIGH-VOLTAGE CONNECTIONS TO NEON

Neon signs operate at high voltages ranging from 7000 to 15000 V,

therefore a secure splice is definitely required to ensure that the sign is safe
from electrical hazard. Figure 4-11 shows a connector used to join the high-
voltage onto the socket that holds the neon tube. Notice that the splice used in
this particular instance is the western union. A pig-tail splice can be used as
well. According to CSA Bulletin #207 when a pig-tail splice is used in for a
field connection between high-voltage cable and an electrode receptacle, the
wires must be twisted together five times.

Similar connectors can also be purchased that have a factory connection

between the high-voltage cable and the socket. This type of connector can be
ordered with enough cable to terminate on the transformer or onto other
portions of a sign installation. The neon tube is then pushed into the socket to
make contact. The neon sign itself is strapped down and these straps provide
the pressure between the neon and the socket. All of the devices listed above
have a mounting bracket to properly secure the housing of the connector. This
is to make sure the splice does not become mechanically damaged due it being
moved or shaken.

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UNIT 4 SUMMARY
• Soldering is a basic technique used for making connections.
• Mechanical connections are of the nut and bolt type, or twist-on.
• Insulation must be removed from conductors before splicing can take
place
• Penciling is the term used to describe a method for removing conductor
insulation.
• Ensure that there are no stray strands or sharp edges on conductors to be
spliced.
• A minimum of two half-lapped wraps of the appropriate electrical tape is
required to insulate splices
• Soldered connections must be both electrically and mechanically secure.
• Flux must be of the non-corrosive type.
• Flux should be of the Rosin type.
• Preparation of the soldering tool is required before use.
• For a good solder joint to take place surface oxides must be removed by
using flux.
• An iron that is too hot will damage electronic components.
• Heat sinks draw excessive heat away from electronic devices.
• The western union splice is used in situations where there is longitudinal
stresses.
• The pigtail splice is made by twisting wires together in a clockwise
direction.
• The CEC limits conductors terminated under a screw to #10 AWG.
• When tightening lug style connectors, refer to the CEC for torque
specifications.
• When joining aluminum conductors we must take into account: cold
flow; oxidation; expansion; and corrosion.
• High-voltage splices for neon tubing are done in connectors designed
specifically for the job.
• Neon tubes can be attached to the socket using factory connectors .
• The western union splice can be used to connect high voltage cable to
a neon socket.

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