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Installation 5
Cable Splicing
Splice cable to motor leads. Use one of the
three methods outlined below. Use only copper
wire for all connections. Use only UL
®
-approved
water-submersion-grade electrical tape.
Taped splice - For wire sizes AWG 8 (8.4mm²)
and larger:
1. Cut off motor leads. Stagger lead and wire
length so that 2nd lead is 2” (50mm) longer
than 1st lead and 3rd lead is 2” (50mm) longer
than second.
2. Cut off cable ends. Be sure to match colors
and lengths of wires in drop cable to colors
and lengths of motor leads.
3. Trim insulation back 1/2” (13mm) from cable
ends and motor lead ends.
4. Insert motor lead ends and cable ends into
butt connectors (see Figure 2). Be sure to
match wire colors between drop cable and
motor leads.
5. Using crimping pliers, indent butt connector
lugs (see Figure 3) to secure wires.
6. Cut electrical insulation putty into 3 equal
parts and form tightly around butt connectors.
Be sure electrical insulation putty overlaps
insulated part of wire.
7. Wrap each joint tightly with electrical tape -
cover wire for about 1-1/2” (40mm) on each
side of joint. Make four passes with the tape
- when finished you should have four layers
of tape tightly wrapped around the wire. Press
edges of tape firmly down against the wire (see
Figure 5).
NOTICE Since the tightly wound tape is the
only means of keeping water out of the splice,
the efficiency of the splice will depend on the
care used in wrapping the tape.
NOTICE For wire sizes larger than AWG 8
(8.4mm²), use a soldered joint rather than a
butt connector (see Figure 4).
Heat-shrink splice - For wire sizes AWG 14, 12
and 10 (2, 3, and 5.5mm²):
1. Remove 3/8” (10mm) insulation from ends of
motor leads and drop cable wires.
2. Put plastic heat shrink tubing over motor leads.
3. Match wire colors and lengths in drop cable to
wire colors and lengths of motor leads.
4. Insert cable and motor wire ends into butt
connectors and crimp (See Figures 2 and
3). BE SURE to match wire colors between
drop cable and motor leads. Pull leads to
check connections.
5. Center tubing over butt connector and apply
heat evenly with a torch (a match or lighter
will not supply enough heat).
NOTICE Keep torch moving. Too much
concentrated heat may damage tubing (see
Figure 6).
1/2”
(12.7mm)
Butt Connector
Indent Here
Alternate Method
Twist and Solder
Completed Splice
6468 1111
Connector
Heat Shrink Tubing
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6