Every cable termination should be meticulously completed and thoroughly inspected, adhering to the following guidelines:
Solid Conductors:
Double back solid conductors whenever feasible.
Stranded and Flexible Conductors:
Ensure all strands are neatly twisted together in the correct direction.
Double back the strands whenever possible to enhance clamping.
Confirm the presence of all strands and ensure they are securely clamped.
Conductor Damage:
Avoid any damage to conductors during insulation stripping.
Prevent conductor damage while pulling in cables.
Insulation:
Insulate conductors up to the metal terminal without any gaps.
A maximum of 2mm exposed bare copper is allowed.
Slack and Neat Arrangement:
Provide sufficient slack in the cable for flexibility.
Arrange cables neatly to prevent interference with moving parts or covers.
No Makeshift Terminals:
Utilize proper terminals, avoiding makeshift solutions.
Terminal Screw Tightening:
Ensure terminal screws are adequately tightened to establish a secure connection.
Maximum Conductors per Terminal:
Limit the number of conductors per terminal to a maximum of three (3).
Conductor Doubled Back:
Whenever feasible, double back conductors within the terminal to share stress.
This practice prevents conductor indentations and potential movement under the screw.
Stranded Conductor Termination:
For stranded conductors, twist all strands in the direction of the cable lay.
Double back strands neatly to ensure proper clamping under the screw.
Conductor Integrity:
Avoid nicks or cuts on conductors or strands, as these reduce the cross-sectional area, leading to increased resistance and overheating.
Insulation Protection:
Maintain intact insulation up to the metal terminal.
Preserve the insulation to prevent accidental contact and maintain safety.
Shrouded Terminals:
Preserve insulation integrity during termination to uphold the purpose of shrouding terminals.
Avoid excessive insulation removal that exposes bare copper.
Sufficient slack must be present on each conductor, neatly arranged to avoid interference with moving parts or hindering proper cover/lid fitting.
The use of makeshift terminals is especially pertinent when grounding equipment. It is unacceptable to find an earth conductor terminated under a woodscrew meant for securing a metallic enclosure. This practice is entirely incorrect and should always be avoided.
Terminal screws must be adequately tightened—striking a balance between being too loose or too tight. Achieving this balance involves using an appropriately sized screwdriver. The size of the screwdriver's tip affects the handle size and consequently, the torque applied. A smaller handle applies less torque, while a larger one generates greater torque.
Competence in creating sound terminations is developed through consistent practice and meticulous self-assessment.
Adhering to these comprehensive criteria for cable terminations ensures reliable and secure electrical connections, minimizes risks of damage or overheating, and upholds safety standards.
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