STEP 1
Use side cutting pliers to cut the motor leads and pump cable to proper length in a
staggered pattern. Ensure that the connections are not all in one short section which would result in a very bulky connection that will increase the risk of excessive abrasion against the well casing as the pump is lowered down the well.
Staggered Splicing
It is best practice to stagger the splice connections to reduce the risk of bulky wire connections which are more prone to damage during pump installation.
When making splices with 3” heat shrink tubes, cut the motor leads / pump cable at a minimum of 4” intervals for each color of conductor to provide a small gap between the heat shrink tubes as shown in the 3” tube staggered pattern diagram below.
For installations using the Deluxe -XLS Extra Long Stakon heat shrink kits with 6” heat shrink tubes, cut the motor leads / pump cable at a minimum of 7” intervals for each color of conductor to provide a small gap between the heat shrink tubes as shown in the 6” tube staggered pattern diagram below.
STEP 2
Clean the insulation for a minimum of 4 inches on all cable & motor lead wires to ensure any
dirt, grease or other foreign debris is removed. This will provide a dry, clean surface for the adhesive lining of the heat shrink tube to adhere and provide a watertight seal for the submersed connections.
STEP 3
Remove insulation from the pump cable & motor lead wires. To make a secure connection,
the wires must be inserted all the way to the stop in the center of the stakon connector. Do not force the wires past the stop!
With the copper wires against the stop, the insulation should be very close to or touching the connector. Do not leave a wide gap between the insulation and the stakon connector.
STEP 4
Scrape copper to a “bright” finish to remove any oxidization and to ensure the wires are clean and free of any foreign debris to optimize conductivity between the wires and the stakon connector.
STEP 5
Insert the 1/4" stripped motor lead wires into the stakon connector and crimp the stakon to the motor lead using a proper crimping tool. Repeat for each motor lead. Three connections (BRG) for 2 wire pumps and four connections (BRYG) for 3 wire pumps. Short stakon connectors only have room to make a single crimp on each end of the connector.
X-Long Stakon Crimping Tip:
On the Extra-Long connectors, you can fit a second crimp on each end (total of four crimps per connector).
Crimp the wire in in two places, equally spaced between the center wire stop and the end of the stakon connector. Make the first crimp at the top and the second crimp at 180° degrees (Bottom). The opposing crimps press the wire firmly against the interior wall on the opposite side of the connector, creating a secure, pull-out resistant connection when done correctly.
STEP 6
Slide the shrink tubes over one end of the pump cable or motor lead. Do not forget to do this before making your second crimp connection on the stakon.
TIP: If you want to provide additional abrasion resistance by shrinking a long length of large diameter heat shrink tube over all the connections at the end of the splicing procedure rather than using electrical tape, you must install it at this time sliding it up the pump cable, out of the way for the time being.
STEP 7
Insert the stripped pump cable into the opposite end of the stakon connector, making sure to match the color-coded wires and crimp the stakon securely to the pump cable.
STEP 8
Make sure to pull lightly on each connection to test the crimp connections.
PULL-OUT PREVENTION TIP – Soldering the wires into the connector provides maximum
conductivity, ensuring consistent electrical connections that maintain their integrity over time, ensuring the longevity and reliability. In addition, soldering eliminates the risk of the wires pulling out of the stakon connector due to a poor crimp.
This step provides cheap insurance against unnecessary call backs in the event a poor or failed crimp connection.
STEP 9
Slide the heat shrink tube over the stakon connector. It is very important to center the heat shrink tube over the connector to ensure equal sealing area on each side of the splice. Clear heat shrink tubing allows for a quick and easy visual inspection.
STEP 10-A Apply low heat with a heat gun (preferable) or a torch to the shrink tube. It is critical to start in the center of the tube, applying the heat evenly around the circumference of the tube, until it is fully shrunk to the fully recovered diameter and starts forcing the adhesive to flow from the center towards both ends.
STEP 10-B Continue applying heat from the center, out towards one end, rotating the wire to apply heat around the entire diameter. Move at a slow steady pace, making sure that you do not get trapped air bubbles. It is crucial that the shrinking tube and melted adhesive forces all the air out of the tube as the heat is applied to the tubing.
STEP 10-C Repeat the process again, applying heat from the center, out towards the opposite end.
This will ensure a watertight seal that is free from any trapped air bubbles, which could potentially cause moisture to creep in and cause a short. Again, clear heat shrink tubing allows for a visual inspection during the shrink procedure to ensure that no air bubbles are getting trapped.
STEP 11
Inspect each connection. When completely sealed, a small bead of adhesive glue will be forced out and should be visible around the wire at each end of the heat shrink tube. Allow connections to cool a few minutes before installing the pump.
STEP 12
To provide additional abrasion protection to the splice connections, the application of multiple layers of electrical tape around the entire length of the splices can be highly effective.
TIP #1 HALF WRAP - Proper application of electrical tape is to half-lap, as shown in the diagram below, which results in a double layer of tape. The rule of thumb is to do a minimum of two half-lapped layers or one and a half times the thickness of the insulation of the wire that you are wrapping, whichever is greater. The tape should be thicker than the insulation, for added protection.
TIP#2 STRETCH TAPE AS YOU WRAP - Electrical tape works the best when it adapts to the object it is being applied to. When you go to apply your electrical tape to a cord or piece of wire, you should stretch the tape as you wrap. When the tape is stretched as it's being applied, it will provide more insulation protection than when it is applied loosely. To create an effective insulation, you should wrap the tape between 75% of it's width to right before the breaking point. Doing this will ensure the tape will be able to withstand the elements. The last wrap should be applied with no tension to prevent flagging.
