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      Welding is the traditional and most economical method of wire termination. The soldering process involves melting and cooling a lead or tin alloy into a solder cup to bond a wire (solid core or stranded) to the contact. Solder termination connectors are recommended for all general and industrial applications that require reliable signaling and power connections. The main benefit of welding is that it is affordable. Unlike crimp terminations, which require specialized tools, wires and welding contacts of almost any size can be terminated using basic soldering kits.

Basic connector soldering instructions

Step 1
Step 1: Clean the solder cup
To ensure the cleanest and strongest bonding of solder, gently brush or wipe the solder cup with alcohol to remove impurities before connecting any wires.

Step 2
Step 2: Prepare the wires
Prepare the wires, cut them to a certain length and peel off the right amount of insulation from the ends. Stranded wires are twisted together to form a single piece for welding. Make sure to label each wire based on contact location (color-coded is best) and string the rear connector attachment along the wire.

Step 3.

Step 3: Tin plate the tip of the soldering iron

Lightly tinned on the tip of the soldering iron. Tin plating involves melting a thin layer of solder on the soldering iron tip to enhance thermal conductivity. Gently shake off excess solder or wipe with a wet sponge as only a thin layer is required. Be sure to stay away from your body and face.

Step 4
Step 4: Tin plating of the wire ends
After tinning the soldering iron tip, tinn the tip of the stripping thread. This is done by touching the tip of the soldering iron and the solder on the stripped wire to heat it. Soldering irons and solder should be close to each other, but should not touch. Solder should be quickly and easily diffused over the metal by core suction. Rotate the wires to ensure even coverage.

Step 5
Step 5: Clean the tin plating wire
After cooling, gently wipe the tin plating thread with alcohol to remove flux residue or other impurities. Wipe off the tip of the soldering iron with a wet sponge. Then give the soldering iron head tin again (see step 3)

Step 6
Step 6: Cut the solder
Cut a piece of rosin-cored solder over the inner length of the solder cup. The easiest way to measure is to put the uncut solder wire into the cup and bend slightly backwards at the edges and cut at the bends. It is optional to pre-cut all solder before performing any actual welding.

Step 7
Step 7: Melt the electrode
Insert one or more pieces of pre-cut solder into the solder cup. Holding the pre-tinned wire in one hand and the soldering iron in the other, touch the tip of the soldering iron to the outside of the cup to melt the welding rod. Do not contact the soldering iron directly with the solder. Instead, it heats the solder cup. It is recommended to use a third-hand tool or vise to help fix the material.

Step 8
Step 8: Insert the wire into the solder cup
When the solder melts, quickly insert the wire into the cup so that the tip of the wire touches the bottom and the rest of the wire is flat on the side. Hold the wire in place and remove the soldering iron to allow the solder to cool. Gently pull the wire to test the solder joints.

Step 9
Step 9: Wipe the terminal
Wipe the terminal with alcohol to remove flux residues and other contaminants. Repeat steps 1-9 above for the remaining necessary terminations. When you are done, double-check all terminations, connect the rear shell attachments and test the connection.

Welding tips and tricks

Don't weld yourself into corners

Welding tips and tricks: start at the bottom
For high-density inserts, it is recommended to start soldering from the bottom and work upwards while working from left to right. This ensures good visibility when welding.

Avoid cold solder joints

Cold solder joints are brittle and prone to physical failure. It may also have very high resistance, which may affect the operation of the circuit or cause it to fail completely. When the temperature of the solder cup is different from the temperature of the molten solder, a cold solder joint will appear. Another common cause of them is to move the wires before the solder has completely cooled. For this reason, the operation of heating the solder cup and allowing heat transfer to melt the solder ensures that the cup and solder are heated and cooled evenly, forming a perfect solder joint. Remember not to melt the solder directly with a soldering tip.