1st Semeter-Lesson 6

Terminating and Connecting Electrical

Wiring and Electronics Circuit

Topic:
Material Specification
 Assorted wires and cables.

Learning Outcome:
Plan and prepare for terminating connection of electrical wiring/
electronics circuits.

Content:
Oftentimes, wires and cables are being interchanged by definition and use.
But the two are very much different in many aspects. This module will help the
learners identify the difference between wires and cables. Also the different
concepts and underlying principles in terminating and connecting electrical wiring
and electronics circuits will be discussed.

Competency
1.1 Check materials according to specifications and tasks.

Code: TLE_IACSS9-12TCEW-IIIe-f-21
 Directions: Read each statement carefully and rearrange each word below. The
letters in red are already in the correct position. Write your answer in the space
provided.

1. C B A L E
2. X O C A I L A
3. M L U T I C O N T O R D U C
4. T I S W E D T P R A I
5. C N O C U D T S O R
6. S I N U R A L T O
7. I R W E
8. R B O B I N

___________1. Composed of two or more insulated wires bind in one jacket.

___________2. Composed of an inner solid conductor surrounded by a
paralleled outer foil conductor that is protected by an insulating
layer.
___________3. It has two or more conductors that are insulated from each other.
___________4. It has two cables that are twisted across each other.
___________5. Materials that permit the flow of electrons freely.
___________6. Materials that blocks the flow of electrons.
___________7. It is cable composed of a single strand conductor that is either
bare or insulated.
___________8. It is cable made up of multiple insulated wires that run parallel to
each other.
 There are a lot of times where wire and cable are thought to be of the same
thing. But in reality, they are very different in a lot of things. In this module, we will
differentiate the two and we will cite the different type for each. Learners will also
understand the different tools and equipment in terminating and connecting
electrical wiring and electronic circuits. But before we proceed, let us enlighten
ourselves with the difference of conductor and insulator.

CONDUCTORS AND INSULATORS

Conductors are materials that permit the flow of electrons freely.

Example of Conductors are:
Silver Copper Aluminium

Insulators are materials that blocks the flow of electrons.

Example of Insulators are:
 Rubber
 Plastic
 Wood
 Glass
 Increasing conductivity ability

Insulator Semi-conductor Conductor

Rubber

Carbon
Germanium
Wood
Glass

Dry Air

Mercury

Copper
Water

Silver
Aluminium
Iron
Silicon

WIRES AND CABLES

Wires are very much different on cables. A wire is a single strand conductor
while a cable is composed of two or more insulated wires bind in one jacket.

Wire with stranded copper conductor Multi-conductor Cable

TYPES OF ELECTRICAL WIRES

1. Solid wire is composed of a single strand conductor that is either bare or

insulated. It is tougher than a stranded wire but is more prone to breakage if
bend multiple times.

https://learn.sparkfun.com
Moghacableco.com
2. Stranded Wires are composed of many wires twisted together. These wires
are used much more flexible than solid wires and can be used for a much longer
period of time.

www.civicsolar.com www.pvccable.net

TYPES OF ELECTRICAL CABLES

1. Twisted pair cable has two cables that are twisted across each other. Twisted
cables reduce the noise due to its magnetic coupling, so it is suitable in carrying
signals. It is generally used I telecommunication and data communication.

www.nicab.co.uk

2. Multi-conductor cable has two or more conductors that are insulated from each
other. Their purpose is to protect signal integrity by reducing hum. Noise and
crosstalk. Applications include computers, communications, instrumentation
sound, control, audio, and data transmission.

www.readywire.ca
3. Coaxial cable is composed of an inner solid conductor surrounded by a
paralleled outer foil conductor that is protected by an insulating layer. The two
conductors are separated from each other by an insulating dielectric. Coaxial
cables are generally used in TV Cable.

www.en.wikipedia.org

4. Fiber optics cable is a kind of cable that transmits signals by a bundle of glass
threads. Fiber optic cables have a much greater bandwidth than metal cables,
which means they can carry more data. They are also less susceptible to
interference. For these two reasons, fiber optic cables are increasingly being used
instead of traditional copper cables despite that they are very expensive.

www.emaq.com

5. Ribbon cable, also called a multi-wire planar

electrical cable or a flat twin cable, is made up of
multiple insulated wires that run parallel to each
other. The parallel wires allow the simultaneous
transmission of multiple signals of data. The wires
are commonly used to interconnect network
devices. This cable can also connect the
motherboard with other core central processing unit
components. www.digikey.com
Directions: Match the description in Column A with the corresponding object
in Column B. Write the letter of your answer.

Column A Column B
______1. Composed of two or more insulated wires bind A. CONDUCTORS
in one jacket.
B. WIRE
______2. Composed of many wires twisted together.

C. CABLE
_____3. Materials that permit the flow of electrons freely.

D. STRANDED WIRES
_____4. A single strand conductor

E. COAXIAL CABLES
_____5. Materials that block the flow of electrons.

_____6. Composed of an inner solid conductor F. INSULATOR

surrounded by a paralleled outer foil conductor
that is protected by an insulating layer.
_____7. It has two cables that are twisted across each G. RIBBON CABLE
other.
_____8. It is made up of multiple insulated wires that run H. TWISTED PAIR
parallel to each other. CABLE
_____9. It has two or more conductors that are insulated I. SOLID WIRES
from each other.
 J. MULTI
_____10. It is composed of a single strand conductor that
CONDUCTOR
is either bare or insulated.
CABLE

Wires and Cable are two different electrical materials. Wires are
single strand conductor whether insulated or bare whereas Cables are
two or more wires bind together by a jacket. There are two kinds of
wire: stranded and solid wire. Cables have a few types with specific use.
In Computer System Servicing, Unshielded Twisted Pair(UTP) cable will
be used in networking.
 1st Semeter-Lesson 6
Terminating and Connecting Electrical
Wiring and Electronics Circuit

Topics:
 Task requirements;
 Tools and equipment;
• OH&S guidelines and procedures;
 Electrical wiring diagram; and
 Electronics kit.

Learning Outcome:

Plan and prepare for terminating connection of electrical wiring/

electronics circuits.

Content:
In the previous module, we have learned about the difference of wire and
cable and their variations. In this module, learners will be knowledgeable in
terminating connection of electrical wiring and electronic circuits and the
corresponding tools needed to execute the task. The learners will acquire the skills
to solder electronic parts as well as wire splicing procedures.
Competencies:
1.2 Select appropriate tools and equipment according to task
requirements;
1.3 Follow planned task to ensure OHS guidelines and procedures; and
1.4 Prepare electrical wiring/electronics circuits correctly for connecting
/terminating in accordance with instruction and work site procedures.

Code: TLE_IACSS9-12TCEW-IIIe-f-21
Directions: Read the statement carefully and identify what is being described or
defined. Choose your answer from the words inside the box.

Soldering iron Soldering Solder wick

Crimping Plain tap joint Rat Tail or Pig Tail

Aerial tap Electrical termination Tinning

Solder

______________1. An electrical industry term used to describe the specific point

at which a conductive device, such as wire or cable, ends or
starts.
______________2. A process in which two or more metal items are joined
together by melting and then flowing a filler metal into the
joint—the filler metal having a relatively low melting point.
______________3. The process of applying a small amount of solder in the tip of
the soldering iron in preparation of soldering process.
______________4. Used to heat the connections to be soldered.
______________5. Solder has a lower melting point than the metals that are being
connected to.
______________6. Used to remove solder.
______________7. Process of joining 2 pieces of metal or other ductile material
(usually a wire and a metal plate) by deforming one or both of
them to hold the other.
______________8. This kind of joint is commonly used to join two or more
conductors inside the junction box.
______________9. This is used where the tap wire is under considerable tensile
stress circuit.
______________10. This is used as a temporary tap usually done in constructions
sites. The easy twist will facilitate tap wire movement
WIRE TERMINATION
Electrical termination is an electrical industry term used to describe the specific
point at which a conductive device, such as wire or cable, ends or starts. A wire
typically ends, or terminates at the terminal connectors.

SOLDERING Solder

Soldering is a process in which two

or more metal items are joined
together by melting and then flowing
a filler metal into the joint—the filler
metal having a relatively low melting
point. Soldering is a process to
permanently connect electrical
components together. Tinning is
the process of applying a small
amount of solder in the tip of the
soldering iron in preparation of
soldering process.

Tools and Materials needed for Soldering

Soldering iron
A soldering iron is used to heat the connections to
be soldered. For electronic circuits, you should use a 25-
to 40-watt (W) soldering iron. Higher wattage soldering
irons are not necessarily hotter; they are just able to heat
larger components. A 40-W soldering iron makes joints
faster than a 25-W soldering iron does. Circuitspecialist.com

Solder
Solder has a lower melting point than the metals that
are being connected to. The solder melts when it is heated by
the soldering iron, but the metals being joined will not melt.

en.wifipedia.com
 An alloy of 60/40 (60% tin, 40% lead) is used for most electronics work,
but lead-free solders are available as well.

Solder stand with sponge

Solder Stand
There are a variety of stands available. It is important to
always keep the hot iron in its stand when not in use.
thetoolbar.net

Sponge
The damp sponge is used to clean the tip of the iron.

Solder wick
This is used to remove solder. To use the wick, place it
over the solder to be removed and heat it from above with the
iron. The solder will flow into the braid. It is also used to reduce
the amount of solder on a connection.
archive.fabacademy.org
Printed Circuit Board (PCB)
A printed circuit board is used to assemble the circuit.
Prototype boards have copper tracks or pads for connecting
components.

futurlec.com

Steel wool or fine sandpaper

This is used to clean connections prior to soldering. Dirty
connections are harder to solder so use steel wool for fine
sandpaper to clean the surface.
walmart.com
Occupational Health and Safety in Soldering
1. The average heat that a soldering iron produce is around 400°C, so be
carefull in using it because it can burn you.
2. When the iron in not in use, unplug it.
3. Don’t use the iron where the power cord can be tripped over.
4. Take great care to avoid touching the tip of the soldering iron on a power
line. If a power cord is touched by a hot iron, there is a serious risk of
burns and electric shock.
5. If the soldering iron is not in use, insert it in the soldering stand.
6. Never put the soldering iron down on your work bench, even for a
moment!
7. Work in a well-ventilated area.
8. The smoke that will form as you melt solder is mostly from the flux and
can be quite irritating. Avoid breathing it by keeping your head to the side
of, not above, your work.
9. Solder contains lead, which is a poisonous metal. Wash your hands after
using solder.

Common Soldering Problems

The Ideal Solder Joint

The ideal solder joint for through-hole components should resemble the
diagram below.

Crimping
Crimping is joining 2 pieces of metal or other ductile material (usually a
wire and a metal plate) by deforming one or both of them to hold the other.

CRIMPPING TOOL
WIRE JOINTING/SPLICING
The following are the Common Electrical Wire Splices and Joints.

Rat Tail or Pig Tail. This kind of joint is Y-splice. This method of wrapping is
commonly used to join two or more generally used on small cables because
conductors inside the junction box. It is the strands are flexible and all can be
suitable for service where there is no wrapped in one operation.
mechanical stress when wires are to be
connected in an outlet box, switch, or
conduit fitting

Plain tap joint. This is used where the

Knotted tap. This is used where the tap tap wire is under considerable tensile
wire is under heavy tensile stress. stress circuit.

Aerial tap. This is used as a temporary tap Duplex cross joint. This is a two-tap
usually done in constructions sites. The wire turned simultaneously and is used
easy twist will facilitate tap wire movement where the two tap wire is under heavy
tensile stress.

Western Union Short-tie Splice. This is Western Union Long Tie. This is used
the most widely used splice or joint in extensively for outside wiring to extend
interior wiring installation to extend the the length of wire from one end to
length of wire from one point to another. another.
Cross joint. The same application is done Wrapped Tap or Tee Joint. This is
as in plain tap and the only difference is used on large solid conductors where it
that this tap is a combination of two plain is difficult to wrap the heavy tap wire
taps place side by side with each other. around the main wire.

Tools in performing wire splicing

Long nose Pliers – use for cutting and holding
small electronic parts.

en.wikipedia.com

Wire Stripper – use to strip the insulator of a wire

licenseelectician.com
 SOLDERING ACTIVITY
DIRECTION. Given are sets of task, practice soldering using appropriate tools
and materials. Your performance will be evaluated using the following criteria:

PERFORMANCE RUBRICS:
CRITERIA 1 2 3 4
Safety
Accuracy
Workmanship
Proper handling of tools
Speed

Legend:
1- Poor 2- Fair 3- Good 4- Excellent
SCALE DESCRIPTION POINTS
4 Excellent 93-100
3 Good 86-92
2 Fair 79-85
1 Poor 78 and below
o Safety – adherence to follow OHS in soldering electronic components.
o Accuracy- the ability to follow the procedures/directions with precision.
o Workmanship- the art, skill and finality of work.
o Proper handling of tools- the ability to apply proper handling of tools for a
given task.
o Speed- efficiency of work.
Tools:
 Soldering iron  Extension Wires
 Solder wick  Wire stripper
 Diagonal Pliers  Steel wool/fine sand paper
 Long nose pliers  Sponge
 Safety goggles
Materials
 Small piece of prototype printed circuit board about 3x3 inches
 AWG #22 solid wire 2 meters.
 Rosin core solder

Procedures:
1. Cut the AWG #22 wire into 4 inches long.
2. Strip each end of the 4-inch wire at least ½ inch per end.
3. Put on your safety glasses.
4. Plug in soldering iron. Allow to heat up, enough to melt the rosin core
solder. Apply sufficient amount of solder in the tip of the soldering iron and
then clean with the sponge.
5. Put the 4-inch wire into the Printed Circuit Board (PCB).
6. Begin soldering the wire on both ends. Secure the wire using long nose
pliers.
7. Inspect each solder. Make sure that the output has the quality of a good
solder.
8. Cut the excess wire below the PCB.
9. Repeat procedure #6 until the whole PCB is covered with soldered wires.
10. Present the final output to your teacher for critiquing and grading.
 SPLICING OF WIRES
DIRECTIONS: Below are pictures of common wire splices and joints used in
electrical wiring installations. Practice doing the task by following the steps given.
Your performance will be evaluated using the rubric:

Materials:
AWG wire #14

Tools:
Long nose Plier
Diagonal Cutter
Wire stripper

Procedures:
I. Prepare all the tools and materials needed.
II. Refer to the procedure below to perform each splicing joint.
Steps in splicing a rat tail joint
1. Strip the wire insulator at the ends of the
conductor to be joined at about 50 mm. Clean both
wires to be joined.
2. Place the two ends of bare wire in crossed
position.
3. Then, twist the bare conductors about five to seven
times.

Steps in Splicing Western Union Long-Tie Joint

1. Strip the wire ends for about 75mm.
2. Place the wires in crossed position about mid halfway
rom the insulation.
3. Make four to six long twists of wires.
4. Wrap each side of the wire for about four to five turns.
 Steps in Splicing Western Union Short-tie Joint
1. Strip the wire ends for about 75mm.
2. Place the wires in crossed position about mid halfway
rom the insulation.
3. Make four to 3 short twists of wires.
4. Wrap each side of the wire for about four to five turns.

Steps in Splicing Plain Tap or Tee Joint

1. Prepare a solid wire about 3 inches long.
2. Stripped the main wire of about 1 inch from both
ends.
3. Prepare a solid wire as our Tap wire of about 3
inches’ long
4. Stripped the Tap wire of about 2 inches from one end.
5. The wire is cross intersecting for about ¼ inches from the insulation of the
tap wire and main wire.
6. Sharp bend is then made in the tap wire at about five to six turns wound
around the main wire.

Steps in Splicing Aerial Tap Joint

1. Strip the tap wire end about 75 mm and the main wire end about 25 mm.
2. Place the wires in crossed position intersecting about 5 mm from the
insulation of the tap wire and the main wire.
3. Place the wires in crossed position intersecting about 5 mm from the
insulation of the tap wire and the main wire.
4. Bend the tap wire over the main wire making a long twist.
5. Turn the tap wire around the main wire making four to five turns.

III. Present your final output to your teacher for critiquing.

IV. Attach your final output in an illustration board with cover.
 Electrical termination is an electrical industry term used to describe
the specific point at which a conductive device, such as wire or cable, ends
or starts. A wire typically ends, or terminates at the terminal connectors.
Some of the terminating procedures are soldering and crimping. When
performing soldering activities, one should strictly follow the OHS to refrain
accidents from happening.