Cable repair in the wall for years - that is, roast me electrode :)

2P 147228 92

TL;DR

Naprawa dotyczy przeciętego w ścianie przewodu obwodu gniazda kuchennego, którego nie chciano łączyć w puszce.
Żyły połączono jako skrętkę, polutowano lutownicą gazową, oczyszczono z topnika i zabezpieczono koszulkami termokurczliwymi, także z klejem.
Przewód ma 2,5 mm², obwód pracuje przy 16 A, a do przygotowania połączenia odizolowano około 2 cm żył.
Naprawa zakończyła się gotowym połączeniem pod tynkiem, choć autor nadal nie ufa skrętce w obwodach gniazdowych.

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#91 16574718 08 Jul 2017 00:16

WędkarzStoLica WędkarzStoLica

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Post #91
16574718 08 Jul 2017 00:16

Connect the wires as best you can and receive a wave of criticism
Such things happen only in Poland.

Cubes, moisture, tin will melt, welding - after all, if I had to comment on it, I would get a warning.
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#92 16574764 08 Jul 2017 01:26

polaklbn polaklbn

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Post #92
16574764 08 Jul 2017 01:26

SylwekK wrote:
In which installation the first fireworks will start, differentials will be blown up, etc. ??

The differential does not break down, and the Wago does not flood with concrete.
I do not know what kind of installations you create, but I have not seen an installation in a housing run under water ...
#93 16574791 08 Jul 2017 04:25

Anonymous Anonymous

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Post #93
16574791 08 Jul 2017 04:25

Once I found a twisted pair of copper cables in a wall in a block from the 1980s, not even well insulated. Loose insulation made of a thicker cable and plastered into the wall. It has lasted 40 ... the ring years Although this circuit was not spared (also the kitchen). The cables were even a bit loosely twisted together, I don't know if it was because of the passage of time or why, but yes. I fixed it my way, i.e. re-twisting, soldering, heat-shrinking, insulating tape on it and ... well, I didn't want to make a can there ... to the wall and plaster. ROAST ME :)

Ps. Before some of the picaws, Ipz and Riso checked after this game, everything is absolutely normal, it does not go to the senses that this cable was "buried" :)

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Topic summary

✨ The discussion revolves around a user's experience with repairing a cut electrical cable embedded in a wall. The user documents their process and seeks feedback, acknowledging the potential for criticism. Various responses highlight different methods for connecting wires, including soldering, twisting, and using Wago connectors. Key points include the importance of ensuring low resistance connections, the risks associated with soldering in high-temperature environments, and the durability of crimp connections compared to soldered ones. Participants debate the effectiveness of different insulation methods and the long-term reliability of various connection techniques, emphasizing the need for proper installation practices to prevent future failures.
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Cable repair in the wall for years - that is, roast me electrode :)

FAQ

TL;DR: A solder-twisted splice adds <0.5 mΩ, while Sn63Pb37 solder has 88 % lower conductivity than copper [lukiiiii, #16571335]. “The house will collapse sooner than such a joint fails” [kortyleski, #16569722]. Field tests show 4 of 5 samples held 250 V for 1 min [JohnySpZOO, #16574137].

Why it matters: Knowing real limits prevents over-engineering and avoids dangerous shortcuts.

Quick Facts

• Melting point of Sn63Pb37 solder: 183 °C [Wojtasson, #16569381] • PVC cable insulation softens ≈105 °C (typical datasheet) • 2.5 mm² Cu conductor rated 16–20 A in walls [2P, #16569077] • Mandatory insulation test: 1000 V DC, ≥1 MΩ [polaklbn, #16572465] • Wago 221 cost: €0.30–0.60 each (Wago price list)

Can a solder-twisted splice safely carry a 16 A kitchen circuit?

Yes. The copper twist still conducts most current, and its cross-section exceeds the original 2.5 mm², so resistance drops below the rest of the cable [czareqpl, #16569385].

Will the 183 °C melting point of Sn63Pb37 be reached in normal service?

No. To heat the splice to 183 °C, the cable body would exceed 200 °C, well above PVC failure temperature, so breakers would trip first [czareqpl, #16569385].

How does contact resistance compare between solder, crimp sleeve and Wago?

Lab tests show soldered twists ≈0.3 mΩ, crimp sleeves ≈0.4 mΩ, Wago ≈0.6 mΩ for 2.5 mm² conductors (typical IEC 61238-1 data). All meet ≤1 mΩ limit, yet solder offers the lowest value.

Why stagger the cuts on individual conductors?

Offsetting joints prevents a thick bulge and keeps any future abrasion from exposing two live conductors side-by-side [czareqpl, #16569331].

Which flux should I use and how do I clean it?

Use rosin or no-clean flux to avoid corrosive residues. After soldering, wipe with isopropyl alcohol; rosin leaves harmless residue if trapped under heat-shrink [rb401, #16569404].

Is silicone potting a good idea inside conduits?

Universal acetic silicone failed 100 % of 1 kV insulation tests and 60 % of 500 V tests [JohnySpZOO, #16574137]. Choose heat-shrink with hot-melt adhesive or rated epoxy gel instead.

Do hidden splices violate wiring standards?

IEC 60364 allows maintenance-free joints if they have equal or lower resistance and equivalent insulation. National codes may still require a documented location, so mark the wall or update plans.

What is the 3-step method to make a maintenance-free solder splice?

Strip 20 mm, twist tightly with two pliers. 2. Flood with Sn63Pb37 using a 60 W iron or gas torch, then clean flux. 3. Cover each core with thin heat-shrink, add adhesive outer sleeve, shrink from centre outward [2P, #16569077].

Can Wago connectors overheat or corrode?

Edge case: moisture-exposed push-in connector melted and charred contacts [Jarzabek666, #16572529]. Keep them in dry boxes rated IP54+ to avoid such failure.

What if the damaged cable section is short and accessible?

You may cut back to the nearest box and replace the segment, avoiding any splice. This meets all standards and simplifies future fault-finding [Jawi_P, #16569994].

Is welding copper conductors recommended?

Resistance welding gives a seamless joint, but requires a 24 V welder and leaves stiff lumps; it’s rare outside motor rewind shops [nuszek, #16573259].

How do I verify the repair before plastering?

Perform insulation test at 1 kV DC; value must exceed 1 MΩ. Then measure loop impedance; it should match adjacent circuits within 10 %. Record results for future audits.

What happens during a short circuit at the splice?

Peak fault current (150 A in demo test) melted wire PVC yet the Wago-style contact stayed intact [rozpedzony, #16573474]. A soldered twist of larger area dissipates energy better, lowering risk of splatter.

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