Inline connectors often seem like one of the simplest components in an electrical wiring system, but they play a huge role in ensuring that connections are safe and reliable.
They are also quite versatile and necessary whether you are doing simple splicing of wires at home, repairing the electrical system in a car, or working with an industrial control panel.
But while they are simple, overlooked details like voltage rating can result in huge problems and compromise an entire electrical installation – or even cause fires.
We’ll look at various pitfalls that you should know to help you create safer and more durable connections, whether you’re a professional electrician, an automotive technician, or a DIY enthusiast.
Using the Wrong Connector Type
While most easy-to-install inline cable connectors are straightforward to use, not all of them are interchangeable.
In fact, using the wrong one can easily lead to poor conductivity, mechanical failure, and even safety hazards.
Before buying one, consider the voltage rating, the load you want to support, and the environmental conditions.
If it’s rated lower, it won’t work well. If it’s a standard connector, it may not be suitable for outdoor connections with exposure to high levels of moisture or heat.
Besides that, match the connector type to the application. For example, if you want to move the connected items frequently, you need one that can be pushed in or crimped.
If you are looking for a more permanent connection, you can opt for inline connectors that support soldering.
Using a 2-Pin Connector When a 3-Pin Is Required
Besides the connector’s voltage and connection type, you’ll also need to choose between a 2-pin connector and a 3-pin one. Using the former in a 3-pin setup can easily introduce a safety hazard.
The difference between the two is that the 3-pin connector has a grounding pin. The pin is meant to reduce the risk of electrical shocks by connecting the electrical installation to the ground, and it’s the most common on bigger appliances like washing machines.
The 2-pin connector doesn’t have the grounding pin as it’s mostly used with low-voltage home appliances like LED fittings. While most will fit into 3-pin connections, ensure you avoid the mistake.
Insufficient Crimping or Soldering
If you are using an inline connector that needs crimping or soldering, it’s good to ensure that the connection is intact.
These types of connectors can easily become loose when not done well, which increases resistance and can cause them to overheat.
Ultimately, this then results in voltage dips, erratic performance, and even complete circuit failure.
When creating a crimping connection, ensure it’s tight enough so that no wire can slip out. However, don’t apply too much pressure, as it can crush the wires or break the connector.
Ensure that you also use the correct crimping pliers, depending on the connection you are creating.
When soldering, the heat should be sufficient, and you should also avoid using too much solder. Then, after it dries up, test the connection with a light pull to ensure everything is in place.
Overloading the Connector’s Current Capacity
Every inline connector has its own current capacity. This is the amount of current it’s designed to handle, and exceeding it can have dangerous consequences – it will generate a lot of heat, the insulation may degrade, and it may even cause a fire.
When creating a connection, ensure you look at the demands of the wiring system. You can then select the inline connectors with this in mind to ensure they match.
Note that some connectors will handle high voltage connections, but they may not handle high current ones, and vice versa.
While at this, you should also consider the wire gauge. In most cases, these range from 9mm to 13mm.
The connector’s gauge should match the connection to ensure there are no resistance issues that could lead to overheating.
Failing to Consider Environmental Factors
While they may seem like simple components that can fit anywhere, these connectors need to be chosen with the environment in mind.
This means considering factors such as moisture, temperature, and exposure to chemicals to ensure you don’t end up with corrosion, poor conductivity, or even complete failure.
Most connectors are meant to be used indoors, so exposing them to high levels of UV will make them degrade quickly.
These can also be easily destroyed by industrial solvents, so ensure you choose a hard material if working in such environments. This will help prevent performance issues and ensure a reliable, long-lasting connection.
