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60 Amp Junction Box.

Zoomup
Mornin' All,

                      I came upon a burnt out terminal on a Crabtree ceiling 50 Amp. shower cord switch yesterday. The cables had become so hot after 3 years of use that the line P.V.C. had completely fallen off the conductor and had left a horrible black smelly sticky mess.


I had to replace the shower cord switch, but the damaged cable was then too short after removing the softened copper and damaged insulation.


So I had to make a trap in the room upstairs, which turned out to be wooden boards over other wooden boards to access the cable below with a view to lengthening one cable. I used a new 60 Amp junction box as it allows two large conductors to overlap and be secured by 4 screws. It is solid and of good quality.


It is this item.....

https://www.toolstation.com/60a-junction-box/p98775?store=N2&utm_source=googleshopping&utm_medium=feed&utm_campaign=googleshoppingfeed&gclid=EAIaIQobChMIufLP1ZD25gIVybTtCh2YWAeiEAQYASABEgJZkvD_BwE


Z.
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    MHRestorations:

    I am surprised nobody has mentioned soldering yet? Is this a dying skill? It really doesn't take very long with a decent setup, and if the joints are well made, it's as good as the original cable.






    Zoomup:

    I like the idea of crimping on lugs and then soldering them as well. The initial crimping holds the lug and the solder fills any voids afterwards and reduces the possibility of corrosion. . A small hole in the lug allows air to escape when soldering. Lugs were soldered on years ago for connection to bus-bars etc. It is not a good idea to solder on fine stranded wires as they can break due to any vibration in vehicles or vibrating machines though.



    I certainly haven't had problems with soldered connexions in motor cars over the years, even battery cables.


    However, we must be mindful of 526.9.

  • 0
    One of my best ever EBay purchases was a brand new Klauke hex crimpers for less than forty quid including delivery, they never fail to impress customers when they come out of the van.


    I still use 60-amp junction boxes to extend 10 and 16 mm twin and earth cables as they are much neater on these cables, despite having a serious pair of crimpers and heat shrink to hand.


    6 mm cables can be joined the using big red Wago connectors  in an enclosure.


    Andy Betteridge
  • 0




    I am surprised nobody has mentioned soldering yet? Is this a dying skill? It really doesn't take very long with a decent setup, and if the joints are well made, it's as good as the original cable.



     

    Please Sir! Please Sir! But Sir I did. I mean I did mention soldering earlier on in this thread. Honest Sir I did, I really did.  Do I get my detention cancelled now Sir?  Sirrrrrrrrrrr?


    Z.

  • 0
    Crimp joint failures danunder.....

    https://www.youtube.com/watch?v=Xl8oPUNc2cc


    I have seen just too may of these failures, especially on 2.5mm2 copper joints to have confidence in them in homes. A circular copper wire in a circular tube exposed to a small torque = a loose joint.


    Z.


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    How much free space is there inside a correctly crimp terminal for solder?


    Andy B
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    I feel happier with the crimp then solder routine.

    I also blame a lot on the single screw mentality of recent years too.

    Screw threads quality and domed shape point of contact are not what they used to be either these days.


    Added - a square peg in a round hole is not near as bad as a round peg in a square hole (actuall two flat plates really). round terminals for round conductors woul be a good start
  • 0

    Sparkingchip:

    How much free space is there inside a correctly crimp terminal for solder?

     




    There should be virtually no space at the lug entrance. Properly crimped  cables do not need to be soldered, the lug/joint should be near as possible to air tight. Indeed,solder may even accelerate the demise of the cable, as it loses some elasticity, so can break easier.

  • 0

    Sparkingchip:

    How much free space is there inside a correctly crimp terminal for solder?


    Andy B 




    The crimp lug can be partially crimped to hold it onto the conductor and the solder wire fed in through the small breather hole found in many lugs near to the ring. Pre-fluxing is possible.


    Z.

  • 0
    It is amazing just how many main installation electricity cut outs and meters use screw terminals with no problems.  Admittedly they do have double screw terminals though.


    Z.
  • 0
    I don't like these efforts. The cable ends are not fluxed and also appear not to be heated sufficiently. One lug does not get filled with sufficient solder. What do others think?

    https://www.youtube.com/watch?v=nXGleTFkb3c


    Z.

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