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Effective Solutions for Wire Connections That Burn Out Easily
If a wire connection burns out easily, it indicates that there is an underlying issue with the circuit—either excessive heating or a wire that is too thin.
Causes of Burned-Out Connections
When a wire is connected, it naturally generates some localized heat. However, if the wire gauge is thick enough, this heat will never be sufficient to burn out the connection, regardless of the joint's size. Therefore, it is crucial to identify the root cause of the burnout.
1. Overcurrent (Overload)
If you have a clamp meter, you can measure the current flowing through the wire to see if it exceeds the rated current of the electrical equipment. If there is an overcurrent, the load itself may have an issue, either due to old age or partial internal structural degradation.
Repair the load as appropriate. If replacement parts are unavailable, the best solution is to upgrade to a thicker wire.
2. Wire Aging
Wire aging is another major cause of excessive heating. As wires age, their insulation degrades. (Note: Aging typically increases resistance, leading to more heat generation at joints under the same current.)
If the wire is severely aged, any type of connection will eventually fail. The simplest and most effective solution is to replace it with a new wire of a larger diameter.
What Are the Most Reliable Wiring Methods?
If the load is functioning properly (no overcurrent) and the wire is not aged, but connection issues persist due to poor joint handling, you should consider alternative connection methods:
1. Soldering with a Soldering Iron
Soldering is both convenient and safe. It doesn't require a massive contact area; simply bring the two wires together, apply solder, and insulate the joint. There is no need to twist them together multiple times as you would with traditional splicing. If conditions permit, this method is highly recommended.
2. Using Wire Connectors (Terminal Blocks)
Another excellent option is using wire connectors. You simply insert both ends into the connector and tighten the screws with a screwdriver. This is a highly convenient tool to have, and insulating the joint becomes much easier.
Other connection methods are not recommended, as improper splicing increases electrical resistance, which inevitably leads to overheating.
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