Non-automotive electrical question

Part of the problem with that connection is that the two wires are touching each other. Nichrome wire is designed to heat up so the copper conductor will erode rather quickly. Use of a crimp butt splice will isolate the two wires.

 

So if I get what you are saying is to keep from trying to compress the 2 wires onto each other and rather crimp them next to each other within
the same ferrule?

 

This is what you want. It is a 600 degree but splice, crimp style.
https://www.grainger.com/product/PO.../rp/s/is/image/Grainger/24C815_AW01?$smthumb$

 

One wire goes into each end. They don't touch each other.

 

Sometimes somebody just has to grab me by the hand and spell it out. You said butt splice enough times and it did not register with me.
Seems I could crimp each side of the splice to fit the different wires properly too. It there anything I could use in addition to help protect
the connection or is clean and tight enough?

 

The nichrome wire gets very hot glowing hot.
So you need the butt splice to act as a heat sink to protect the other wire which will not hold up to the heat it will cause the wire to melt or get brittle and crack.
I use nichrome alot for sealing plastic bags. This is why you don't want them to touch.

 

A high temperature sleeve to reduce air flow and keep contaminants away for the splice should also be used. You should be able to find a small quantity on Amazon or Ebay.
https://www.delcity.net/store/High-...MI6_6ykNSs1QIVFIZ-Ch0XogmpEAEYAyAAEgIslPD_BwE

 

The picture is coming into focus (slowly ). Thanks for all the input.

 

So I found a couple of things. Braided silica tubing to use as a jacket. Seems to have a tighter weave than fiberglass for less air intrusion and is good to 1200F. Nickle plated steel butt connectors , good for 900F. We have a crimper at work so I have to see if it is up to the job and have to figure out what die it needs to close the butt connectors. I don't know how it translates but the panels never glow visibly and the chamber temp does not go over 500F so I have to guess that the nichrome does not get much hotter than 600-700F. Hopefully this will be a better way to keep these connections in good order. We use the heck out of that oven every day and it can not afford much downtime.
One more question. Would be harmful or helpful to add more nichrome strands into the connector with the panels nichrome lead to give the connector more bite or would it be best to just crimp to the lead as-is is?

 

If the gauge of the wire is smaller than the minimum listed on the connector you can fold the wire and insert it. Loose wires should not be use as they will move into voids during the crimp.

 

OK, gotcha.

 

Following up, we had a ratchet style crimper in the shop, so I ordered SS butt connectors and a die to fit that connector. Here is what I came up with.




Sorry about the crappy images, but you get the idea. The nichrome is doubled over and the die is leaving an impression/mark on the splice barrel.
I also have some ceramic fiber tube/sheath to cover it with when I install it into the oven.

 

That's the way to do it!

 

Thanks, appreciate the help. Now I'm ready for the next burned wire. Hopefully that is no time soon.

 

A follow up from a long-ish time ago. John, since we changed over to the crimp style barrel connectors, none have failed. Little oven is running 10 hours a day, 4 days a week and we have had only
needed to make 2 repairs to old connections since. Thanks for the advice, it helped us out a lot.

Jeff

 

Glad I could be of help and that you ended up with a reliable installation.