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Soldering wires to deans-T connectors is a very important process.

There are two best methods of the soldering 'at home'. Both are characterized by a very low resistance.

 

First method

Second method

lutowanie1 lutowanie2

 

Suggested tools:

  • Soldering iron
  • Solder, rosin
  • Pliers
  • Tweezers
  • Small vice
  • Sandpaper 600 (or finer)
  • Paper knife
  • Pincers
  • Scissors
  • Lighter

ATTENTION

  • Electrical resistance of solder is six times higher than resistance of copper. In general, solder serves as mechanical and electrical connection.
  • Always use flux or rosin when soldering. This is necessary to achieve the correct connection.
  • The 0.5 mm diameter wire can be made out of 8-conductor cable UTP (unshielded twisted pair).
  • It is suggested to use a copper wire, as an aluminum wire is prone to breaking.

 


 

FIRST METHOD

1. Deans-t connectors preparation:

  • Clean out with fine sandpaper the part that is going to be soldered
1-1a 1-1b
  • Cover it with a thin layer of solder (always use flux or rosin during soldering, especially when solder melts. This is necessary to achieve the correct connection).
  • Remove excess solder
1-2a 1-2b

 2. Wire preparation:

  • Put 2 cm of heat shrink tube on a wire
  • Take off the wire’s insulation to the desired length - about 6mm (using a knife, score carefully the external part of the silicone insulation. Then use your nail to pull it away)
  • Never twist subcables in a wire (twisting increases space between the subcables, which is going to be filled with solder)

3. Wire fitting and soldering

  • Attach the stripped wire to the contact
  • Pulling strongly, coil the contact around with the additional 0.5 mm diameter wire
  • Pour over the wires with solder. The tightly twisted wires should  perfectly fit the contact
1-3a 1-3b

 4. Connection verification

  • Have a look at the connection and check if it is done properly. Pay attention to solder – it should fill soldered space correctly and solder should not be oxidised
  • Try to pull out the wire
1-4a 1-4b

5. Protection of the soldered connection

  • Remove excess rosin from the connection
  • Prepare heat shrink tubes and close them
  • Heat  the heat shrink tube carefully from all sides. Do it over the flame of a gas range or lighter
1-5a 1-5b

 


SECOND METHOD

Second method is easier than the first one, but the connection parameters are a bit worse than in the previous method.

 1. Deans-T connectors’ preparation:

  • Clean out with fine sandpaper the part that is going to be soldered
  • Cover it with a thin layer of solder (always use flux or rosin during soldering, especially when solder melts. This is necessary to achieve the correct connection). 
  • Remove excess solder
2-1a 2-1b

 2. Wire preparation:

  • Put 2 cm of heat shrink tube on a wire
  • Take off the wire’s insulation to the desired length of about 6mm (using a knife, score carefully the external part of the silicone insulation, your nail should pull it away)
  • Twist the subcables at a slight angle
  • Apply solder to the wire ends
2-2a 2-2b

 3. Soldering wire to the contact

  • Attach an end of wire to the contact, and hold it firmly with tweezers (using great force ensures the right connection)
  • Heat it and pour over with solder
2-3a 2-3b

 4. Connection verification

  • Have a look at the connection and check if it is done properly. Pay attention to solder – it should fill soldered space correctly and solder should not be oxidised
  • Try to pull out the wire

2-4a

 5. Protection of the soldered connection

  • Remove excess rosin from the connection
  • Prepare heat shrink tubes and close them
  • Heat  the heat shrink tube carefully from all sides. Do it over the flame of a gas range or lighter