Solder joints on solid core cables

Larry48 · 26 Nov 2008

Hi I'm new to this forum so I hope I'm not raising an old question.

Is there an accepted technique for soldering T&E solid core ring-main cable ends? I know I could replace the cable run but that would not be straightforward. I currently have one of the circular 30A connector units joining the two ends under the floor. I've soldered for years on lightweight wires and circuit boards, I just need to know if there is an accepted technique for preparing the cable ends prior to soldering and then covering them wth heat shrink?

Click-Sure · 26 Nov 2008

Never done it myself, personally I have always used staggered compression butt crimps, applied with a proper rachet crimper followed by heatshrink.

Stoday · 26 Nov 2008

The correct way to do it is with a ferrule. I've no idea where you'd buy ferrules from in 2.5mm size. I don't think anyone stocks them because everyone uses a crimp to achieve a joint.

ban-all-sheds · 26 Nov 2008

Some good tips on splicing wires to achieve good mechanical strength before soldering here: http://www.markhellerelectric.com/solder.pdf

Larry48 · 27 Nov 2008

Thanks for the wire splicing web link, really useful.

Thanks too for the replies suggesting crimps. I've often used crimps on car wiring at 12volts but I never see any info on the packs of blue, red and yellow butt-crimps I buy that states that they are OK at 250volts. I have a stack of crimps sold through places like B&Q that are made by TOWER and sold in the mains electrics section; are these OK on mains if I use a decent ratchet crimper? If not whose should I be looking for?

davy_owen_88 · 27 Nov 2008

Insulated butt crimps done with a quality ratchet crimper is an acceptable method of joining mains cable. Just remember that the earth conductor in t&e cables is smaller than that of the live conductors. In the case of 2.5mm² t&e you'll want to use blue crimps for phase/neutral and red for the earth.

Even though the crimps are insulated you will need to reinstate the sheath by covering the whole joint with heatshrink. Try to stagger the joints so that they don't all end up at the same point - this creates a big bulge which is difficult to cover with heatshrink.

Larry48 · 28 Nov 2008

Thanks Davy, sound advice, that may be the way I go for the moment

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Solder joints on solid core cables

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