How to Safely Splice Low Voltage Wiring without Proper Connectors

Introduction

Splicing low voltage wiring is often necessary when installing new devices or making repairs. However, it can be unsafe if not done properly, especially without the right connectors. This article will provide an in-depth guide on how to safely splice low voltage wiring of 12V or 24V systems without proper connectors.

Understanding Low Voltage Wiring

Low voltage refers to electrical systems that operate at less than 50 volts. Common examples are 12V or 24V DC systems found in landscape lighting, automotive applications, RV/boating, alarm systems, etc.

Low voltage wiring is thinner and more flexible compared to standard 120V household wiring. It uses less insulation since the voltage is lower. Common types of low voltage wiring include:

• 16 AWG multi-stranded copper - Used for lighting and other low power applications
• 12 AWG multi-stranded copper - Used for higher power up to 20A
• 18-22 AWG stranded copper - Used for alarm systems and thermostats

Proper connectors like crimp connectors, wago connectors, or solder are ideal for splicing low voltage wires. But in an emergency, it is possible to splice without connectors safely.

Dangers of Improper Splicing

Splicing without proper connectors is less reliable and can lead to:

• Loose connections - Wires can pull apart easily leading to open circuits
• Corrosion - Exposed copper can oxidize leading to resistance
• Short circuits - Bare wires touching can short circuit the system
• Fire hazard - Heat build up in poor connections can ignite materials
• Shocks/electrocution - Exposed conductors increase risk of shocks

So proper precautions must be taken when splicing low voltage wiring without connectors.

Precautions When Splicing without Connectors

Here are some safety precautions to follow:

• Disconnect power source - Cut power to wires before splicing to prevent shocks
• Use wire strippers - Strip just enough insulation, avoid nicking conductors
• Keep wires untwisted - Untwist stranded wires before joining, improves contact
• Overlap 1/2 to 3/4 inch - Longer overlap creates better mechanical joint
• Twist wires together - Twist stripped ends tightly to join conductors
• Use electrical tape - Tape joint tightly with >= 2 layers for insulation
• Keep joints loose - Avoid tight bends/kinks which can break conductors
• Test connections - Check for continuity and excessive resistance
• Protect splices - Keep joints inside boxes away from damage

Following these methods will produce safe and fairly reliable temporary splice joints.

Step-by-Step Process for Splicing Wires

Here is a step-by-step process to safely splice low voltage wires without connectors:

1. Shut Off Power

• Use circuit breakers or disconnect switch to cut power to wires
• Verify power is off with a multimeter or test light
• Failure to do so risks dangerous shocks!

2. Prepare Wires

• Strip away 3/4 to 1 inch of insulation from each wire using strippers
• Untwist any stranded conductors so strands are separated
• Trim strands flush and twist conductor lightly between fingers
• Ensure no strands stick out and no copper is nicked

: Damaged strands and nicked copper will lead to poor connections.

3. Twist Wires Together

• Take stripped ends and overlap aligned 1/2 to 3/4 inches
• Twist stripped ends tightly together between fingers
• More twists and longer overlap lead to better conductivity

4. Apply Electrical Tape

• Take electrical tape and tightly tape over twisted wire joint
• Start 1-inch back from joint and tape towards joint
• Tighten tape over joint and continue past for 1-inch
• Cover entire joint with >= 2 tight layers of tape

5. Test Connection

• Restore power and use DMM to measure resistance through splice
• Resistance should be very low, similar to unspliced wire
• No continuity or high resistance indicates poor connection

6. Protect Connection

• Coil extra wire length to avoid tight bends at joint
• Place splice inside a protective box if possible
• Position splice to avoid stress, snagging, or damage

With proper technique, these emergency splices can last surprisingly long. But use connectorized splices as soon as possible.

Example Low Voltage Splice Applications

Splicing low voltage wiring without connectors may be necessary in:

• Automotive - When tapping power for accessories or repairs
• Lighting - Extending wires for landscape lighting or holiday lights
• Boats/RVs - Adding new accessories or making repairs
• Alarm systems - Lengthening sensor wires or adding accessories
• Low voltage repairs - Any repair or extension of 12V/24V wiring

In these cases, use the splicing method above to safely connect and insulate wires for a temporary repair.

Long Term Reliability of Splices

Splicing low voltage wiring without connectors is considered temporary:

• Use <24 hours - For emergency repairs to restore operation
• Replace <1 month - Improper splices prone to long term failure
• Critical systems - Use proper connectors for reliability

Exposed copper and lack of mechanical strength limits life expectancy. Eventually oxidation, vibration, and stress will cause splice failure.

For long term reliability, always use proper connectors like:

• Crimp connectors - Requires special crimping tool for tight seal
• Wago connectors - Has spring clamping mechanism for solid joint
• Solder joints - When done properly, solder creates reliable joint

So only use splice method above for temporary emergency repairs until proper connectors can be installed.

Safety Tips

Here are some additional electrical safety tips when working with low voltage wiring:

• Use caution around live circuits - Assume wires are live until tested
• Wear eye protection - Protect eyes from debris when stripping wires
• Keep work area dry - Avoid moisture which can lead to electrocution risk
• Learn electrical techniques - Study before attempting electrical work
• Hire an electrician when needed - If uncomfortable doing electrical repairs

Conclusion

While splicing low voltage wiring without proper connectors is not ideal, it can be done safely. The key is taking precautions like disconnecting power, making solid mechanical joints, insulating with tape, and testing connections. This can provide temporary repairs until proper connectors are installed for reliability. Only trained individuals should attempt electrical repairs.