Termination and connection of wires of wires and cables by soldering

Soldering is used in cases where there is no possibility to use welding and crimping. Brazing is done using a propane-oxygen torch. Soldering single-wire wires 2.5 — 10 mm2 can also be made with a soldering iron.

Soldering of aluminum and copper wires to wires and cables

Soldering of aluminum wires up to 10 mm2

The connection and the branch are performed with a soldered twist, finishing — by making a ring.

Solid aluminum wires 2.5 — 10 mm². Soldering connections and branches are done by double twisting with a groove. Live remove the insulation, clean to a metallic shine. The joint is then heated with the flame of a propane-oxygen torch until the solder melts.

With soldering iron A placed in the flame, rub the groove with one side. When the connection warms up, the veins begin to tin and the groove fills with solder. In the same way, the wires are tinned and the groove is filled with solder on the other side.

Connecting wires and twist points are also tinned with solder outer surfaces. After cooling, the junction is isolated.

Soldering of solid and stranded copper wires 1.5 — 10 mm2.

Connection and branching of wires with copper wires perform soldered twisting (without groove). The insulation from the end of the core is removed to a length of 20 — 35 mm, clean the core with sandpaper to a metallic shine, twist the wires to be connected and solder with a soldering iron or in a bath of molten solder POSSu 40-0.5 (solders can also be used of other brands, for example POSSu 40-2, POSS 61-0.5). When soldering, a flux is used - rosin or a solution of alcohol rosin. The soldering point is insulated after cooling.

Interruption of stranded copper wires 1 — 2.5 mm2 in the form of a ring, followed by half a day, is carried out. To do this, remove the insulation from the end of the core to a length of 30-35 mm, clean it to a metallic shine with sandpaper, bend the end of the core in the form of a ring with round-nose pliers, cover it with rosin or a solution of rosin in alcohol and immersed for 1-2 s in molten POSSu solder 40 — 0.5. After cooling, insulate the core to the ring.

Soldering of stranded aluminum wires with a cross section of 16 — 150 mm2.

Before soldering connections and branches, remove 50-70 mm of insulation from the end of the core. Before removing the paper insulation in the place where it was cut, apply a thread, then use pliers to loosen the twist of the core wires and with a cloth soaked in gasoline, remove the impregnating composition. Wires with rubber and plastic insulation do not require this operation.

The sector vein is rounded with a press.Stranded wires can be crimped with multi-purpose pliers. The end of the insulated core is cut in steps. A few turns of asbestos with a cable are wound to the edge of the insulation.

Heat the cores with a blowtorch or blowtorch flame. after the beginning of the melting of the soldering rod A, introduced into the flame, it is applied to the entire stepped surface of the twist of the wires and to their ends, when this, for the complete tinning of the wires, the surface of the core is carefully rubbed with a steel brush. This completes the vein maintenance process.

They are then wound onto the core at the intended edge of the form. asbestos cable. The ends of the veins are set in a split shape. Strengthen the form on veins with special locks or wire ties and put the veins protective screens, and for large cross-sections of wires, coolers are installed. We heat the form with a flame, starting from the bottom of the middle part and further along the entire surface, until the beginning of the melting of the solder, the stick of which is introduced into the flame and melted in the grid opening to fill the form with solder to the top.

The molten solder is mixed with a steel hook wire and gently remove the slag from the surface of the molten metal bath, slightly by pressing the mold, the solder is compacted. After the connection has cooled or the branches remove the screens and form and file the place of soldering, then cover it is insulated with moisture-resistant varnishes.

Soldering of aluminum wires

Soldering of aluminum wires is done with lugs.In this case, the size of the tip is taken above the cross section one step higher (for a core of 50 mm2, take a tip of 70 mm2) for better penetration of the solder into the gap between them live and tip.

The inner surface of the sleeve is cleaned with steel brushed and canned, then put the tip on the core so that the central wire (the first step of the core) protrudes from the neck of the tip by 5 — 6 mm. For seals on the core at the top of the tip, roll asbestos cord and repair the core screen.

The flame of the burner is directed to the upper end of the sleeve tip and protruding from it the first stage of twisting the core and heating them before the start of melting the solder. The soldering iron melts at the tip while filling the entire space between the wire and the sleeve.

After cooling and removal of the screen and asbestos winding, the solder joints are covered with moisture-resistant varnish and the wires are insulated to 3/4 of the height of the tip sleeve.

Termination of stranded copper wires 1.5 — 240 mm2

Termination of multi-core copper wires 1.5 — 240 mm2 is carried out using tripped tips. The insulation is removed from the end of the core to a length equal to the length of the tip sleeve plus 10 mm. The core of the sector is rounded pliers. with a cloth soaked in gasoline, remove the impregnating material from the end of the core composition, cover it with flux or soldering grease and tin. They put the vein tip, at the lower end of which a bandage of two or three layers of asbestos is placed.

Heat the tip with the flame of a propane torch or a soldering iron and fill with pre-melted POSS 40-0.5 solder, making sure that the solder penetrates between the strands.Immediately afterwards, with a cloth smeared with solder paste, expel and smooth out any solder spots on the surface of the tip. the asbestos dressing is removed and replaced with insulation.

Soldering aluminum to copper

The connection of aluminum wires 16-240 mm2 with copper wires is done just like soldering two aluminum wires.

The aluminum wire is prepared for step soldering or beveled at an angle of 55 degrees to the horizontal. The copper vein is prepared in the same way as when soldering copper wires.

The ends of aluminum wires must first be tinned with A solder, and then POSS solder, and the ends of copper wires and copper connecting sleeves with POSS solder.

Termination of aluminum wires with copper lugs

Aluminum conductors are terminated with copper lugs as well as aluminum lugs. Copper tip pre-tinned with POSS 40-0.5 solder.

The termination is also carried out by preparing the end of the aluminum veins with a bevel at an angle of 55 degrees. In this case, the end of the prepared aluminum wire is inserted into the sleeve of the tip with a chamfer to its contact parts, so that the core is recessed into the sleeve by 2 mm. Resolutions compacted by directly flashing solder TsO-12 on the beveled surface veins. The oxide film from the end of the core is removed with a scraper under the solder layer.