Connecting Wires of Different Gauges (3 Easy Steps)
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In this article, I'll walk you through a few things to keep in mind when connecting wires of different sizes from different sources.
When connecting wires of different cross-sections from different sources, it is necessary to take into account the current strength and length of both wires. Too much current can damage the wire. You can solder or crimp wires together to establish a connection between them. As an experienced electrician, I will cover several methods for splicing different gauge wires in the article below. The skill is very useful, especially if you find yourself in a situation where you need to connect several wires of different sizes.
You should be fine to connect different gauge wires as long as you don't run excessive current through the smaller wires. The process is simple:
- Remove the plastic cover from the end
- Insert wire
- Crimp one side of the wire
- Then crimp the other side over the first wire.
- Solder the wire to the terminal (optional)
I'll go into more detail below.
Can wires of different gauges be connected?
Yes, you can splice wires of different sizes, but parameters such as length and amperage affect practice. Also,
As a rule, the size of the wire is determined by the rated current load for each of them. You should be fine to connect different gauge wires as long as you don't run excessive current through the smaller wires. You should check signal frequencies if your connections are for signals and not power. For high frequency transmissions, stranded wire is generally preferred over solid wire.
In other words, if you're only working with signals, you can probably connect wires of different sizes; however, if any of the lines have high electrical currents, you generally shouldn't do this. The resistance per foot increases as the wire diameter decreases. This affects the maximum length of wiring before significant signal degradation occurs.
A warningA: Please make sure the current load through each of these wires in your application is correct. Depending on how much current the source/load draws, transferring electricity from low to high gauge can heat up a large wire, and sometimes melt the entire wire. So be careful.
Wires of different gauges and interference - reflection of the signal at the junctions
It is not recommended to change the size of the wires for signal transmission, as this will cause interference due to signal reflections at the connection points.
Thinner wire also increases system resistance. As a result, a wire with a smaller cross section will heat up more than a wire with a larger cross section. Verify your account for this in your design. (1)
If you need to connect wires of different gauges, solder the wires to the screw ends of the terminals, such as spade terminals.
- Remove the plastic cap from the end (it also serves as a strain relief)
- Insert wire
- Crimp one side of the wire
- Then crimp the other side over the first wire.
- Solder the wire to the terminal.
An alternative way to connect two wires of different gauge - procedure
The steps below will help you conveniently connect two or more wires of different sizes together.
But if you know how to solder, do it, and then wrap it in heat shrink. Stretching the heat shrink approximately 1/2-1″ past the solder point on both sides. If not, check the following steps:
Step 1. Take a smaller wire and cut about twice as much as you need.
Step 2. Gently twist it (wire) and fold it in half. Use a butt joint or crimp connector. Make sure the wire is fully inserted.
Step 3. Before crimping larger wire into a butt joint, wrap it with heat shrink. Fold both sides and heat shrink.
Tips: Another option is to take a piece of wire, strip both ends, make a loop and run it along with thin wire to fill in the gaps.
If your wire diameter varies greatly from one end to the other, you will almost certainly have to bend the end and join the filler wire. Even this may not be enough. Before crimping, tin the ends of the wires enough to hold the strands together. When you finish tinning or soldering the wire, you should be able to see the strands.
If you can't afford expensive solder sleeves or heat shrink with sealant built in, you can put some clear RTV on the heat shrink and then heat it up. This will give you a good water seal. (2)
Take a look at some of our articles below.
- Is it possible to connect the red and black wires together
- How far can you run wire 10/2
- Which wire to connect two 12V batteries in parallel?
Recommendations
(1) design – https://blog.depositphotos.com/разные-типы-оф-дизайна.html
(2) sealant – https://www.thomasnet.com/articles/adhesives-sealants/best-silicone-sealant/
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