Shashamane poly Technic College

Terminate and Connect Electrical Wiring

Learning Guide
System

This learning guide is developed to provide you the necessary information

regarding the following content coverage and topics
 Plan and prepare for termination/ connection of electrical wiring/electronics circuits
 Terminate/ connect electrical wiring/electronic circuits
 Test termination/ connections of electrical wiring/ electronics circuits
This guide will also assist you to attain the learning outcome stated in the cover
page. Specifically, upon completion of this Learning Guide, you will be able to:-
 Check Materials according to specifications and tasks
 Select Appropriate tools and equipment according to tasks requirements
 Follow Task is planned to ensure OH & S guidelines and procedures
 Prepare Electrical wiring/electronic circuits correctly for
connecting/termination in accordance with instructions and work site
procedures
 Observe Safety procedures in using tools at all times and appropriate personal
protective equipment are used
 Undertake Work safely in accordance with the workplace and standard
procedures
 Use Appropriate range of methods in termination/connection according to
specifications, manufacturer’s requirements and safety
 Follow Correct sequence of operation according to job specifications
 Adjust Accessories used, if necessary
 Confirm termination/connection undertaken successfully in accordance with
job specification
 Conduct Testing of all completed termination/ connections of electric
wiring/electronic circuits for compliance with specifications and regulations
using appropriate procedures and equipment
 Check Wiring and circuits using specified testing procedures
 Respond Unplanned events or conditions to in accordance with established
procedures

Date: 2012
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BY: Gizaw Tadesse
 Shashamane poly Technic College

Terminate and Connect Electrical Wiring

Information Sheet
System

ELECTRICAL MATERIAL AND DEVICES

CLASSIFICATION OF ELECTRICAL MATERIAL ACCORDING TO FUNCTION
1. Boxes
2. Switches 11. Grounding Devices/Matls.
3. Receptacle/ Convenience outlet 12. Wires/conductors
4. Ceiling Lamp receptacles 13. Lighting Materials
5. Fittings 14. Wiring Methods
6. Supports 15. Adaptors/Connectors
7. Male Plugs 16. Soldering materials
8. Condulets 17. Insulating Materials
9. Electrical Protective Devices 18. Switch plate & covers
10. Metering Devices 19. Safety switches

Boxes are made of galvanized sheet metal or polyvinyl chloride (PVC).

Different Sizes:

SWITCH: -Used to close or open electrical circuit.

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 Shashamane poly Technic College

KINDS OF SWITCHES ACCORDING TO NUMBER OF POLE AND THROW

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Flush type switch

Receptacles/Convenience outlet used to plug in portable devices such as lamps toaster,

radios, refrigerators, washing machines, stove, etc.

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 Shashamane poly Technic College

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 Shashamane poly Technic College

Fitting- An accesory such as locknut, bushing, or other part of a wiring system that is intended
to perform a mechanical rather than an electrical function.

Electrical Wiring Supports

KINDS OF MALE PLUGS

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 Shashamane poly Technic College

ELECTRICAL PROTECTIVE DEVICES

DIN Rail Mounted Circuit breaker

METERING DEVICES

Grounding Materials

WIRES/CONDUCTORS

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 Shashamane poly Technic College

LIGHTING MATERIALS

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 Shashamane poly Technic College

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 Shashamane poly Technic College

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 Shashamane poly Technic College

Adoptors/Connectors

SOLDERING MATERIALS

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 Shashamane poly Technic College

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 Shashamane poly Technic College

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 Shashamane poly Technic College

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BY: Gizaw Tadesse
 Shashamane poly Technic College

TAPS AND JOINTS

Some people are careless and erroneous in using the terms joints and splices. There is a
considerable difference between a joint and a splice.
By definition, a joint is the tying together of two single wire conductors so that the union will be
good both mechanically and electrically.
A splice is the interlaying of the strands of two stranded conductors so that the union will be
good both mechanically and electrically.
Making a joint tap or splice comprises the operations of:
1. Removing the insulation;
2. Cleaning the conductors;
3. Tying or interlaying
4. Soldering;
5. Taping.
The topic of splices will be taken up in the following pages.
REMOVING THE INSULATION - In preparing the insulated conductors for making joints or
splices, the insulation must first be removed from each conductor a proper distance depending
upon the type of joint or splice to be made.

This process is sometimes called skinning or stripping. This operation is usually

performed in a questionable manner by the use of an ordinary knife blade resulting of loss time
and probable nicking of wire. For a single wire conductor, a form of scraper should be used.
The method of using a ripper is shown in the succeeding illustration. The insulation of a
duplex cable should be first ripped with a tool stick; them the insulation from the separate
conductors is removed with a scraper.If a knife must be used, do not cut the insulation crosswise,
but parallel with the wire.
Cleaning the conductors – After removing the insulation the wires must be thoroughly
cleaned to insure good electrical contact between the ends of the wires and so that the solder will
adhere properly. The wires may be cleaned by scraping. If this is done with a knife, care should
be taken to avoid nicking the wire. Sandpaper may be used to clean the wires.

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 Shashamane poly Technic College

Twist and Turns.

Twist and Turns. In making twists, each wire is wrapped around the other, whereas in making
turns, one wire remains straight, the other wire being wrapped around the straight wire.

JOINTS – There is a multiplicity of joints designed to meet the requirements of different kind
of wiring. The duty to be performed by a joint determines the kind to be used.
In some cases, all that is required is that the joint be electrically good as for instance, the
pig tail splice used in junction or fixture outlet boxes; in other cases, the joint must be electrically
good and also mechanically good, as for instance, joints on an overhead line must be made so
that they will withstand considerable tensile stress due to the weight of the suspended conductor.
There are a number of joints extensively used of which the following should be noted:
1. Pig Tail;
2. Bell Hanger’s;
3. Western Union;
4. Turn Back;
5. Brittania;
6. Duplex.
1. Pig tail joint
Pig tail joint 1. Cross the pair of conductors to be connected between the fingers and twist them
together for a distance of 1 inch. For heavy wires, pliers must be used. .

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 Shashamane poly Technic College

Pig tail joint 2. The final twist must be made with a pair of pliers and the excess wire cut off.
The bare joints should now be pulled out of contact with any metal so that the circuit may be
tested.

The Pig Tail Joint as before mentioned is suitable for service where there are no mechanical
stresses as where wires are to be connected in an outlet box, switch, or conduit fitting.

2. Bell Hanger’s Joint

The Bell Hanger’s Joint was, as its name implies, originally intended for bell circuit, however,
on account of its being not only electrically and mechanically strong, but also compact, and it has
numerous other uses where the tensile is not too great.
*Bell Hanger’s Joint 1. Strip off 3 inches of insulation from end of each wire and clean.

Bell Hanger’s Joint 2. Bring wires together and make one turn as shown, then hold first wire
with hand and twist second wire with pliers. Similarly, twist first wire. The twisting may be done
by hand for small wire, but for large wire, pliers are necessary.

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 Shashamane poly Technic College

Bell Hanger’s Joint 3. Appearance of completed joint before soldering and taping.

3. Western Union Joint

The Western Union Joint is a modified form of the bell hanger’s joint. It is made in the same way
as the bell hanger’s joint with the exception that a number of twists are taken instead of one. The
object of the extra twists is to make it more efficient mechanically as the tensile stress brought on
these joints in considerable.

4. Turn Back Joint

The Turn Back Joint is useful in connecting two wires that must be drawn taut.
Turn Back Joint 1. Strip off 3 inches of insulation from one wire and 5 inches from the other
and clean the exposed ends.

Turn Back Joint 2. With the ends of the wires together, twist the wires, using the pliers and
leaving about one inch straight at the end.
Turn Back Joint 3. Turn back the long wire until it be parallel with the twists.

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 Shashamane poly Technic College

Turn Back Joint 4. Turn the two straight ends around the long wire between the twisted portion
and the insulation, thus completing the joint. There should be enough straight wire left after
twisting to make several turns.

5. Brittania Joint
The Brittania Joint is sometimes used on overhead lines where considerable tensile strength is
required. It is also used for both inside and outside wiring where single conductors of size No. 6
or larger are used.
*Brittania Joint 1. Bend up at right angles the end of each wire. Use a hand vise and hammer as
a sharp bend cannot be made by pliers.

Brittania Joint 2. Place the wires together so that they overlap about 3 inches.

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 Shashamane poly Technic College

Brittania Joint 3. Assuming the wires to be joined are a No. 6, use a No. 18 wrapping wire. Take
about 6 ft. of wrapping wire, clean it and bend it half

Brittania Joint 4. Place the center of the wrapping wire at the center of the joint and wrap each
half toward the ends of the joint.

Brittania Joint 5. After wrapping, force the free ends of the wrapping wire through the grooves
formed by the wrap and large wires.

Brittania Joint 6. With the portion of wrapping wire remaining after pulling through, make a few
turns around the large wires at each end of the joint.

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 Shashamane poly Technic College

6. Scarfed Joint
The Scarfed Joint is used on large wires where appearance and compactness are the main
considerations and where the joint is not subjected to any heavy tensile stress.
Scarf Joint 1. The ends of the two wires to be joined are scarfed (file-wedge shape). The scarf
should be about 3 ins. Long, bringing the ends to a file-point making a good fit. When filling, the
ends of the conductors are most conveniently held by laying them in a groove in a block of
wood. The wires, when fitted together, should appear like one continuous wire.

Scarf Joint 2. Tin the ends, then wrap with a No. 18 or No. 20 wire, starting at the middle of the
joint and wrapping towards the ends similarly as with the Brittania joint, except that the ends,
instead of being pulled through, are wrapped s few turns beyond the ends of the joint. Solder the
joint.

7. Duplex Joint
The Duplex Joint is used in conduit systems where twin wires are used, that is, two wire cables.
It will be seen from the illustration that the joint is consisted of 2 bell hanger’s joints spaced so
that they do not come opposite each other.
*Duplex Joint 1. Skin or remove about 3 ins. Of the outer braid from each cable and remove
insulation from each wire, i.e., so that the joints will not come opposite each other.

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 Shashamane poly Technic College

Duplex Joint 2. Make up joints. Note that these joints do not opposite each other, thus giving
better insulation.

TAPS
TAPS – By definition, a tap is the connection of one wire to some point along the run of another
wire. As with joints, there are various taps to meet different conditions. The following should be
noted:
1. Plain;
2. Aerial;
3. Knotted;
4. Cross;
i. Double;
ii. Duplex;
6. Wrapped.
Plain Tap
The Plain Tap is the one most frequently used and is quickly made without difficulty.
*Plain Tap 1. Remove about 1 ¼ in. of insulation a long the run wire and about 3 ins. At the end
of the tap wire. Cross the wire about ¼ in. from insulation and take a hook.

Plain Tap 2. Take 5 or 6 turns of the tap wire around the run wire. Note that the joint should
terminate about ½ in. from the insulation in the run wire. This permits soldering without burning
the insulation and gives better chance for tap (e) ing.

Aerial Tap
The Aerial Tap is intended for wires subjected to considerable movement. It is similar to the
plain tap except that it has a long or easy twist to permit of movement.

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 Shashamane poly Technic College

*Aerial Tap. The long twist is to give flexibility. In making, the joint is soldered on the turns, the
long twist being left free.

Knotted Tap
The Knotted Tap, as must be evident, is designed to take considerable tensile stress.

Double Cross Tap

The Double Cross Tap is simply a combination of two plain taps.
Double Cross Tap. Fir this tap remove about 2 ½ ins. of insulation from the run wire and about
¼ in. from each tap wire. Each tap is made as described for the plain taps; the taps starting at the
middle of the joint and running in opposite directions.

Duplex Cross Tap

The Duplex Cross Tap is used where two wires are to be tapped at the same time, because it can
be made quicker. *Duplex Cross Tap. Remove about 2 ins. of insulation from the run wire and
about 3 ins. From each tap wire. Bring the two tap wires across the run wire at one end of the
joint and double twist the ends of the tap wires.

Wrapped Tap
The Wrapped Tap is used on wires too large to wrap around the run wire.
*Wrapped Tap 1. Using a No. 6 wire remove about 4 ins. of insulation from both wires.

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 Shashamane poly Technic College

Wrapped Tap 2. Bend the tap wire in the shape of an L with bend 1 in. from insulation and place
it along the run wire as shown.

Wrapped Tap 3. Wrap in a similar manner as described for the brittania joint.

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 Shashamane poly Technic College

SPLICES
As pointed out in the preceding chapter there is considerable difference between a joint and a
splice yet the word splice is commonly though incorrectly used for joint. The latter term relates
to single wire conductors and splice to multi-wire or stranded conductors.
According to the method of wrapping the strands, running butt splices are classified as:
1. Single Wrapped
2. Multiple Wrapped

Single Wrapped Splices

Single Wrapped Splices – This kind of splice is used for large (No. 6 or larger) because it is
easier to wrap a single wire at a turn than to wrap them all at once.
*Single Wrapped Splice 1. Remove about 6 ins. of insulation from each cable and clean each
strand.

Single Wrapped Splice 2 Lay up (that is wrap) the strands for a distance of about 2 inch’s. From
the end of the insulation of each cable and fan out the strands to an angle of about 30.

Single Wrapped Splice 3. Interweave the strands by bringing together the laid up sections and in
so doing see, that one strand only of each wire passes between two strands of the other case.
Make a hook by sharply bending say strands 1 and A.

Single Wrapped Splice 4. Wrap tightly one strand as strand around the laid up portion of the
cable.

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 Shashamane poly Technic College

Single Wrapped Splice 5. Wrap tightly each of the remaining strands of each cable around the
laid up portion of the other cable.

Multiple Wrapped Splices

Multiple Wrapped Splices – This method of wrapping is generally used on small cables because
the strands are flexible and all can be wrapped in one operation. A three stands cable is selected
so as clearly show the method of wrapping.
*Multiple Wrapped Splice 1. Remove about 3 ½ ins. of insulation from each cable and clean
each strand.

Multiple Wrapped Splice 2. Lay up the strands for a distance of 1 in. from the insulation. Fan the
free ends and butt together properly intertwining the strands.

Multiple Wrapped Splice 3. Wrap tightly the strands of one cable around the laid up portion of
the other cable. Similarly wrap the strands of the other cable.

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 Shashamane poly Technic College

Tap Splices
Tap Splices – These are made when the end of one stranded conductor is to be conducted at some
point along the run of another stranded conductor.
They may be class as:
1. Ordinary
2. Splice
3. Y-splice

Y-splice
*Y Splice 1. Remove insulation to a distance depending upon the size of wire. Interweave the tap
wire through the run wire strands at one end of the splice and twist up the run wire strands in the
original direction.

Y splice 2. Tightly wrap the strands of the tap wire around the run wire, either by the single or
multiple method, depending upon the size of the wire.

Running Butt Splice – The term running butt relates to splices formed by butting together the
ends if two cable lengths to extend the run or length of circuit as distinguished from tap splices
later described

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 Shashamane poly Technic College

Self-Check Written Test

Name: _________________________ Date: _______________

Directions: Answer all the questions listed below. Illustrations may be necessary to aid some
explanations/answers.

1. Where do we use two way switching? (1 point)

2. When do we use intermediate switching? (1 point)
3. What is DPDT stands for? (1 point)
4. What type of switch is used for staircase lighting? (1 point)

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 Shashamane poly Technic College

LAP Test Practical Demonstration

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________

Instructions:
1. You are required to perform any of the following:
1.1 Request your Store keeper to supply components according to the given
drawing
1.2 Install the following circuit in the installation board provided
 Check continuity test
 Give the supply to the installed wiring

2. Request your teacher for evaluation and feedback

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 Shashamane poly Technic College

Contents
Learning Guide............................................................................................................................................1
Terminate and Connect Electrical Wiring System........................................................................................1
Information Sheet....................................................................................................................................2
Terminate and Connect Electrical Wiring System....................................................................................2
ELECTRICAL MATERIAL AND DEVICES..................................................................................................2
TAPS AND JOINTS...............................................................................................................................17
SPLICES..............................................................................................................................................27
Self-Check..............................................................................................................................................30
Written Test...........................................................................................................................................30
LAP Test.................................................................................................................................................31
Practical Demonstration........................................................................................................................31

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