Wire repairs

Connecting Wires

Very quick but... Will it last? Is this a

professional job? Would you pay a

technician $75 per hour for this?

Crimp connectors Advantages

Disadvantages

Solder connections

A connection that will last.

For important circuits soldering is the preferred methodof joining wires and terminals

Selecting the solder to use

Metal content 40/60 or . . .

Core flux type Rosin or Acid

Solder Composition 40/60

360 – 460 = 100 degree pasty range

60/40 360 – 375 = 15 degree pasty range

Impurities Are a possible problem in lower priced solders

Why is flux needed?

Oxidation Definition:  A common form of chemical

reaction which is the combining of oxygen with various elements and compounds. The corrosion of metals is a form of oxidation, rust on iron for example is iron oxide

The problem Oxidation will occur to a wire while it’s being

heated to solder.

Flux Requirements Remove oxidation Prevent oxidation at soldering temperatures Be easily displaced by molten solder Be easily removed if needed

Flux Types Acid

Strong but always active Rosin

Weak but works well with new wires and terminals. Active only at high temperatures Leaves a protective coating at lower temperatures

Active temperatures of flux Rosin Flux

starts working at 225 degrees

Acid Flux Active even at room temperature

Selecting the right gun for the job

Gun Preparation

Tighten the tips connection to the gun Clean and sand the tip Tin the tip

Joining wires

Careful how you shape the twisted wires

Taping this wire into a harness with others will be difficult Correct method

What is a Cold Joint?

Cold Joint

You want the solder to flow

Let the wire or terminal melt the Solder

Note… The solder wire is not touching the iron

Protecting the wiring connection

Heat Shrink Installation

Demonstration and Assignments