How to connect wires without soldering: the best methods and their features + installation recommendations

A home electrical network is a complex system of electrical installations and devices connected by electrical conductors. Wires are connected in electrical panels, junction boxes and device housings.

Let's look at how to connect wires without soldering using special clamps and terminals so that the switching is as reliable as possible and meets safety requirements. For this purpose, we provide 4 detailed instructions with the best ways to connect electrical wires.

We will also supplement our material with useful installation tips from experienced electrical installation specialists.

The content of the article:

Briefly about possible switching options
Safe and effective types of connections
Tips from experienced installers
Conclusions and useful video on the topic:

Briefly about possible switching options

Electricians use various methods of connecting conductors - from the simplest insulated twisting to crimping with special sleeves.

Some procedures require additional supplies and special tools, while others are performed manually.

The question of choosing the most reliable connection methods became relevant when the load on the home network increased - many powerful devices appeared, and accordingly, the requirements for the use of conductors and electrical installations became more stringent.

Wire connection points are the most vulnerable points in the circuit.If the contacts are not connected correctly, overheating and sparking will occur over time, the wires may melt, catch fire and cause harm to people and property.

Factors influencing the choice of method:

total cross-section of conductors;
type and method of cable insulation;
the material from which the wires are made;
purpose of the switching node;
external connection conditions;
degree of mobility of the connection, etc.

The installer on site determines how he will make the switching, taking into account the listed factors. Much depends on his skills in using a special tool (soldering iron, welding machine, crimping pliers) and materials that are at hand.

However, professionals always have an installation kit with them and use methods recommended by GOST and PUE standards.

Today you can encounter a variety of wire connection options:

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The oldest method that could be used to assemble light-duty chains. Requires a minimum of time, and the materials are only a roll of electrical tape. Twisting is considered a weak connection

Performed to increase the reliability of twisted conductors. To perform soldering, you need solder, flux and a special power tool - a soldering iron. It is labor-intensive and suitable for all types of connections

Contact heating transforms twisted conductors into a single monolith. Disadvantages – use of an inverter welding machine, labor intensive. Special skills and qualifications required

Plastic products for connecting only a pair of conductor cores. The wires are secured in the box body with screws. The method is popular, economical, but not suitable for all types of wires

To connect two conductors, you will need a bolt with a nut and three washers, which are installed between the conductors and on both sides. Disadvantages - large volume, requires a lot of insulation, connection may become loose over time

Switching occurs not by tightening the screws, but by a spring connection. A well-known example of this type of terminal is Wago products, which provide reliability and the ability to work with several conductors at once.

Multi-colored insulating caps with a spring device are used for quick and economical switching of conductors in distribution boxes and are reliable

A connection crimped with a sleeve is considered one of the most reliable, safe and effective, but requires more time for installation, special tools and skills. Another disadvantage is that it is one-piece and cannot be repaired.

Option #1 – twist

Option #2 - soldering

Option #3 – welding

Option #4 – terminal boxes

Option #5 - bolted connection

Option #6 - spring terminals

Option #7 – plastic caps

Option #8 - crimping with sleeves

According to PUE 2.1.21, simple twisting should in principle not be used for switching. Only welding, soldering, crimping and various types of clamping devices.

To perform soldering or welding, special equipment is not always at hand, especially if the work is performed by an amateur. Therefore, it is advisable to consider methods that are both reliable and affordable.

Safe and effective types of connections

Let's consider 4 options for connecting conductors, suitable for home installation: spring terminal blocks, terminal blocks, PPE caps and crimping with sleeves.

To perform the work, you will need consumables - terminals, clamps, sleeves, selected depending on the type and cross-section of the conductors. We recommend purchasing products only from trusted manufacturers, and not cheap Chinese substitutes.

Method #1 - switching with WAGO terminal blocks

The main advantage of terminal switching is 100% connection reliability. Thanks to the company's developments WAGO screwless connections have received the status of an international standard.

Now other manufacturers are also producing spring clamps. They are used in high-speed cars, airplanes, moving chains - that is, where special responsibility is required.

Spring technology allows you to connect different types of conductors: single-core, multi-core, especially thin. This is in demand in everyday life when it is necessary to connect a lamp or gate control system, pumping equipment or telephone

To install self-clamping terminals, it is enough to strip the ends and insert them into the holes of the terminal block until they stop - the number of conductors may vary depending on the number of holes. The locking mechanism is activated and the cores remain firmly fixed inside the housing

To install the terminal block, you do not need any special preparation. Experienced installers who value quality have also long used only self-clamping terminals.

We offer step-by-step instructions for connecting 2 conductors using a 222 series clamp, representatives of which are successfully used to connect branches of various types of wires:

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We remove the insulation by about 10 mm. There are special marks on the front side of the terminal block to determine the length of the stripped end

We insert the stripped part into the round passage hole until it stops. Check reliability by lightly pulling the wire

Having prepared the conductor, we are preparing to install it in a hole that does not differ in shape, it is similar and is located here. Next to it there is a movable part that provides clamping

We also insert the stripped flexible conductor into the corresponding hole, simultaneously pressing the movable part of the terminal and releasing it

Step 1 - Stripping the End

Step 2 - inserting a rigid conductor

Step 3 - preparing the flexible wire

Step 4 - installation of the branch

After correct execution of the actions, spontaneous opening of the terminal is impossible. The advantage of such a connection is the possibility of disconnection. To open the conductors, you must first press the moving mechanism and then remove the corresponding conductor.

Advantages of terminal connection:

connection of single- and multi-core conductors made of copper or aluminum, as well as mixed connections;
high quality connection;
the conductors are not damaged during installation;
the design provides for reading the circuit parameters without disconnecting;
neatness and order in places of work - distribution boxes, switchboards, electrical installation devices.

This method saves time - it only takes a few seconds. However, it requires caution. If the ends are not inserted all the way, overheating may occur and the terminal block body will melt.

The main disadvantage is the high cost, especially of branded products. For example, a set of 20 Vago three-wire universal terminal blocks costs about 500 rubles.

Even more information about Vago terminals in the following video:

Method #2 - Using Terminal Blocks

Inexpensive plastic products have a clamping mechanism with which the conductors are fixed and connected inside the housing. Each single- or multi-core wire is stripped of its insulation, inserted into a separate socket and secured by tightening a screw.

For installation work, you will need two tools - a construction knife and a screwdriver. Instead of a knife, you can use a special modern device to remove the insulating layer - a stripper

Usage stripper for insulation removal allows even a beginner to cope with this task without much difficulty.

The wires can be wound in two ways - from one side or from both sides, towards each other. This method is often used for wiring in distribution boxes, so manufacturers began to produce distribution boxes with built-in terminals.

Terminal blocks differ in the size of the holes, which depends on the cross-section of the cores, as well as the number of sockets. If you have a box of 12 pairs at hand, but only 2 are needed, then the required segment is simply cut off with a knife

Advantages of connecting with blocks:

efficiency;
quick installation;
aluminum/copper connection;
high quality.

The main disadvantage is that only 2 reins can be connected with one pair of blocks. Experienced installers do not recommend using the block method to connect stranded or aluminum wires, since a screw connection can destroy more fragile material.

And another minus is a large number of low-quality pads.

To better understand this method of connecting wires, we recommend looking at why terminal boxes are good or bad:

Method #3 - use of PPE caps

Non-flammable plastic is used to make spring clip-caps. The housing material is an insulator, suitable for mechanical and fire protection parameters.

To install the cap, you need to prepare the wires, insert them inside, and then forcefully make twisting movements. To protect the exposed parts of the cores from oxidation, the inside of the cap is treated with paste.

Inside the cap there is a conical metal spring, which expands under pressure and then contracts and fixes the conductive wires

The caps are compact and have a simple design, so they are often used for desoldering. One distribution box contains up to ten products.

A practical example of using PPE for wiring in a distribution box:

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To get to the cores, use a construction knife to remove the dense polymer sheath - cut along the entire length of the visible part of the cable, then cut off a piece of separated insulation

We distribute the conductors freed from insulation into groups: neutral (blue) - in one, grounding (green/yellow) - in the second, phase (brown) - in the third

It is inconvenient to connect long wires, and they will not fit into the junction box, so we cut off the long ends with wire cutters. But we leave the pieces necessary for installing the caps

Using a stripper, we strip the ends of all conductors to a length of approximately 10 mm. These parts of the cores will be inserted inside the caps

To ensure a large area and high connection density, it is recommended to twist the caps before installing them. For convenience, we use pliers

The caps come in different sizes, so in the process of preparing the cores, we specify how long the working ends should be, and then remove the excess with wire cutters

We hold the twist with one hand, and with the other forcefully screw the cap on. We perform this procedure 3 times - according to the number of connections (maybe less or more)

When twisting, make sure that the bare parts go completely inside the caps, and only insulated conductors remain outside.

Step 1 - Removing External Insulation

Step 2 - Wire Distribution

Step 3 - adjusting the length

Step 4 – stripping the cores

Step 5 - twisting the conductors

Step 6 – removing excess

Step 7 - installation of PPE

Step 8 – Quality Control

After completing the connection work, carefully place the caps in a circle and close the junction box cover. You can unscrew the spring elements at any time and make reconnection or repairs.

Benefits of PPE:

low cost;
material – non-flammable polymer;
high speed and ease of installation;
variety of colors.

The last point can come in handy when using old, non-color-coded wiring. You can determine the purpose of the cores using caps, selecting them by color. We talked more about color coding of wires In this article.

The main disadvantage is that the connection is considered unreliable. The spring force is not enough to ensure a strong connection, which is why additional twisting is performed.

It is recommended to check the quality of the products before use.

And further - PPE is not intended for switching aluminum/copper wires.

Method #4 - crimping conductors with sleeves

This method is chosen by installers who really care about the quality of the connection.Crimping with a special tool guarantees an increase in the contact area and minimal resistance.

If you cut the crimped sleeve in half, you can see that all the wires have practically merged into one monolith.

It is crimping that is used for communications in junction boxes, which for some reason will be masked from the outside with cladding and will remain without free access

The veins can be wound from one side or from both. In any case, their total cross-section should not be larger than the diameter of the sleeve.

In practice, they often choose a larger sleeve, and the free space inside it is “clogged” with pieces of wiring. The more densely the sleeve is filled, the better the connection.

Step-by-step instructions for crimping:

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To crimp conductors in a distribution box, it is necessary to select the diameter of the sleeve so that all wires fit into it - separately neutral, grounding and phase. The size of the product, as well as the material of manufacture, is indicated on the packaging

There are different types of crimping pliers. For the most part, they use universal ones, designed for crimping sleeves of various diameters. Here is KVT PC, a model for crimping 1-core conductors

We strip the cores, since it is necessary to insert bare conductors without insulation inside the sleeve. To remove insulation we use either a knife or a stripper, which makes the stripping process faster

We alternately insert wires of one purpose, for example, “ground,” into the sleeve so that small ends are visible on the other side. If the volume is small, add small pieces of wire inside for density.

The free space inside the junction box is limited, so all excess must be removed.Here you need to cut off the ends of the copper wires with wire cutters, leaving only 2-3 mm of the part protruding from the sleeve

We take pliers, find a recess of suitable diameter and perform crimping. The first is performed at the edge on the side of the conductors. The ratchet mechanism will not open until you squeeze the pliers handles all the way, with maximum force.

Double pressing guarantees a high quality connection, so we retreat from the place of the first crimp, install the pliers closer to the second end of the sleeve and perform compression again

The pressed sleeve must be insulated, since it is metal and conducts electricity. For protection, either heat-shrinkable material paired with a hairdryer, or regular electrical tape is usually used.

Step 1 - choosing sleeves by size

Step 2 - choosing pliers for crimping

Step 3 – stripping the cores

Step 4 - inserting the wires into the sleeve

Step 5 – removing excess parts

Step 6 - first crimping

Step 7 - second crimping

Step 8 – Heat Shrink Insulation

If there is a shortage of space in the box and compactness comes first, before crimping the sleeve is cut in half and crimped only once. But this should be considered an exception.

This method is considered inexpensive - each sleeve (copper) costs 8-9 rubles, and pliers can be rented.

Advantages of crimping:

excellent connection quality;
efficiency;
high speed.

The disadvantage is that the connection is permanent, and if necessary, you will have to completely replace the switching blocks. If there is a supply of wires left in the box, then the old sleeve is cut off and a new one is installed.

The downside is that without a special tool it will not be possible to perform high-quality crimping.

Tips from experienced installers

There are many controversial issues both in connection methods and in the use of individual mounting products. But a number of rules apply to absolutely all craftsmen who do electrical installations.

For example, Twisting of aluminum conductors with copper is strictly prohibited.. The process of rapid oxidation leads to the destruction of the commutation and the creation of a dangerous point, which can spark or flare up at any time.

A few more important rules:

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Inept use of a knife can lead to thinning of the wire and loss of conductivity qualities. It is better to use a stripper that carefully removes the sheath without harming the conductor

If you use the twisting method - as an independent connection or before crimping - take the wires with a reserve. It is better to twist as tightly as possible, and then trim the ends

Bare conductors must be inserted into clamps, terminals and sleeves until they stop and so that the free part is completely covered with insulation - stripped conductors should not be visible

When arranging your own wiring, be sure to take into account the color and other markings of the wires - this makes it much easier to make connections without the risk of switching wires for different purposes

Pliers instead of a knife

Properly executed twisting

Maximum connection isolation

The importance of marking conductors

If the conductor is covered with an oxide film, it must be carefully removed using either contact paste or fine sandpaper. It is better to select the diameters of sleeves, tips, caps according to size.

When using electrical tape, overlap the wraps.One layer is not enough, it is better to go along the connection 2-3 times, making sure to make the last turn on the insulation

Single conductors in screw terminals are held loosely. Therefore, it is recommended to bend the stripped end in half or make an arbitrary loop out of it.

At the end of the work, be sure to check the reliability of the connections - lightly tug the wires. It happens that the switching is unsuccessful, and the core simply slips out of the terminal block.

If the volume of the distribution box allows, for example, the panels accommodate a lot of wires and devices, then leave the cable with a reserve. Sometimes switching is required and the extra length is useful if the connections are permanent or burnt.

We also have other articles on our website on conductor connectors, methods of connecting wires of different sections, and recommendations for choosing the best connector:

Conclusions and useful video on the topic:

Comparative analysis of various switching methods:

As you can see, when arranging electrical wiring, you can completely do without soldering and welding.

There are enough modern devices on the market to ensure the switching of conductors using safe and efficient technologies. The choice of method depends on personal preferences and financial capabilities..

Are you looking for a safe way to connect electrical wires without soldering, but do you still have questions that we did not address in our article? Feel free to ask your questions to our experts in the comments section.

If you have extensive experience in performing electrical installation work, in particular, connecting conductors without the use of soldering and welding tools, please leave useful recommendations for beginners and additions to our material below under the article.

Sergey

Answer

There are ways to connect wires without soldering, but the main thing is that it is not simple twisting. It is impossible to create a reliable connection through twisting; over time, it will definitely begin to overheat, or even spark. How many ignitions and fires have already occurred and will continue to occur due to disregard for wiring. You need to approach this topic very carefully and responsibly.

Vladimir

I have professional experience in electrical installation work. Based on it, of course, I choose sleeves. You just need to leave the ends of the wire with a margin, that is, about 20 cm. The sleeves are easily crimped with pliers, the main thing is that it is filled. In second place in terms of reliability are clamping blocks. But lighting wiring with many beams and a large number of cores is difficult to make using blocks.

Expert
Vasily Borutsky
Expert
Answer
Good afternoon, Vladimir.
Connecting cables and wires with crimp sleeves is a whole science. Having worked in the electric power industry for a long time, I came across a variety of technologies that take into account all sorts of factors regulating the tool used.
I saw manual, mechanical, hydraulic pliers, I saw how explosive crimping works. In the latter case, special dies and punches are used. The crimping part of the pliers, I note, also has an intricate configuration. The only thing I didn’t see was crimping with pliers.This connection will not pass the tests - read the “Rules for the technical operation of consumer electrical installations” section “p3.0.1”.
You can supplement your experience as an electrician with special literature. Among these is “Instructions for connecting insulated cores of wires and cables” under the number “I 1.09-10”.
About wire stocks and other intricacies of their preparation for connection, you can read GOST 23469.3-79 “Cable connecting copper sleeves, secured by crimping.”

Igor

Professional electricians have this expression: a hot joint is always cold (note: quality), and a cold joint is always hot.

The most reliable connection method is welding. The sleeves are in second place, everything else is for open access only.