Otis Singleton
Electrical connectors are prone to corrosion, especially in environments with high exposure to water and salt. Corrosion can be identified by the presence of a powdery green or white substance on the connectors, which are usually made of copper. To prevent corrosion, it is important to keep the connectors dry and free from moisture. This can be achieved through regular inspections and cleaning, using a toothbrush and a mild solvent like WD-40, as well as applying dielectric grease to seal out moisture. Additionally, electrical contact cleaner can be used to dissolve and remove any dirt, oil, and oxidation build-up.
| Characteristics | Values |
|---|---|
| Priority | Keep moisture out |
| Inspection | Regularly check for water leaks and damage |
| Cleaning | Use a toothbrush and mild solvent like WD-40 |
| Protection | Use dialectic grease to seal out moisture |
| Cleaning products | Electrical contact cleaner |
| Protection | Use adhesive-lined heat shrink tubing |
| Protection | Coat connections with dielectric grease |
| Protection | Use copper-based anti-seize |
| Protection | Spray with CRC Marine Corrosion Inhibitor |
| Maintenance | Use a multimeter to troubleshoot wiring |
| Maintenance | Regularly clean and re-apply dielectric grease |
| Cleaning | Use electrical cleaner |
| Protection | Use heat shrink terminals or tubing with adhesive |
| Protection | Use STA-DRY modular sealed harness |
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What You'll Learn
Keep moisture out
Keeping moisture out is the first step in preventing electrical corrosion. Water is usually the culprit behind electrical corrosion, so it's crucial to keep water away from electrical panels and both indoor and outdoor connections. Indoors, regularly inspect your space for any damaged pipes, leaks, or cracks in the foundation or walls. For outdoor wiring, ensure that there are no spots where rainwater or garden water can collect.
It's also important to be vigilant about keeping water away from electrical connections. Inspect your wiring and electrical panel regularly to ensure nothing is deteriorating, rusting, or oxidizing. Pay close attention to outdoor lighting and your garage area, as they are more susceptible to the elements.
To protect electrical connections from moisture, you can use mechanical or chemical methods. A mechanical approach involves installing a sealed electrical box with a gasketed lid. On the other hand, chemical protection involves using products like dielectric grease, which seals and prevents moisture from collecting around wiring.
When it comes to chemical protection, start by sealing terminals and connectors with adhesive-lined heat shrink tubing to prevent water from travelling up the wire into the connector. Then, carefully take apart each connection and apply dielectric grease to the connecting surfaces. Alternatively, you can use a copper-based anti-seize product, but use it sparingly to avoid messiness. Finally, spray the area with a corrosion inhibitor to displace water and provide a protective barrier.
Remember, before cleaning or applying any products, always disconnect the power source to stay safe and avoid electric shock.
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Regular inspections
During your inspections, be on the lookout for any signs of corrosion. For example, copper, which is commonly used as a conductor in wires and connectors, corrodes into a powdery green or white substance. Iron-based components, on the other hand, form brown or red rust as they deteriorate. If you notice any green or white powder on your copper connectors or any rust on your iron-based components, take immediate action to clean and treat the affected areas.
Additionally, inspect areas where dissimilar metals come into contact, as a galvanic reaction can occur, increasing the rate of corrosion. Lighting connections, such as pigtails, are often the first places where corrosion becomes visible, so be sure to check these regularly. If you notice any corrosion, clean the connections with a mild solvent like WD-40, and consider using a toothbrush for a gentle but effective clean. Avoid using wire brushes, as they can cause scratches and damage to the soft metals used in electrical connectors.
For vehicles, it is recommended to perform inspections and maintenance every six months or more frequently in highly corrosive environments. Use a plug and socket brush with electrical cleaner to clean connectors, and re-apply dielectric grease to keep corrosion at bay. During your inspections, also look for road hazard damage such as cracks, cuts, or excessive wear on connectors from old repairs. Replace or repair any damaged cables or wires to prevent moisture ingress and potential corrosion.
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Use dialectic grease
Dielectric grease is a viscous, non-conductive, waterproof substance used to protect electrical connections from corrosion and dirt. It is a popular product used in garages across the country, though it is not an automotive necessity like oil or coolant. Dielectric grease is often found around electrical systems, where it can be used to lubricate connectors, seal gaps, and prevent corrosion by sealing out moisture.
Dielectric grease is also used to insulate metal and wiring from external invaders, thwarting corrosion by preventing moisture ingress. It can be used liberally to ensure the tops of the posts and fastener heads/threads are well covered. However, it is important to note that you do not need to use large amounts of dielectric grease in your connectors. The grease can also be used to keep rubber parts from drying out and to coat dissimilar metals to prevent seizing.
Dielectric grease is most commonly applied to spark plug boots, lightbulbs, and battery terminals. It can also be used on electrical connectors to prevent corrosion. Before applying any product, it is important to disconnect the power source to avoid electric shock.
Overall, dielectric grease is a useful product for preventing electrical corrosion by sealing out moisture and insulating electrical connections. It is important to note that it should be used in appropriate amounts and is not a substitute for other automotive necessities such as oil or coolant.
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Avoid wire brushes
When it comes to electrical connectors, it is important to avoid using wire brushes for cleaning. While keeping electrical connectors free from corrosion is essential, the wrong cleaning method can cause more harm than good.
Most electrical contacts are made with copper connectors or copper plated with tin or silver. A wire brush, typically made of stiff steel wires, will cause scratches on these softer metals. The goal when cleaning electrical contacts is to reduce surface variations at the point of contact between the conductors. Any scratches, pockets, or openings at the point of contact will reduce the surface area, which is undesirable.
Instead of a wire brush, a toothbrush and a mild solvent like WD-40 can be used. WD-40 is not harmful to copper, tin, or silver, and will help remove corrosion and other deposits. This method will effectively clean the electrical connections without causing scratches or other damage.
It is also important to note that electrical connectors should be disconnected from the power source before any cleaning is attempted, to avoid electric shock. Additionally, regular inspections of electrical connectors should be conducted to check for any signs of deterioration, rust, or corrosion. By avoiding wire brushes and adopting a careful approach to cleaning and maintenance, you can effectively prevent electrical corrosion and ensure the longevity of your electrical systems.
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Mechanical or chemical protection
Mechanical protection involves installing a sealed electrical box with a gasketed lid to enclose the electrical connections and protect them from external elements. This method provides a physical barrier that prevents water and other contaminants from coming into contact with the connectors. It is important to ensure that the electrical box is properly sealed and gasketed to avoid any gaps or openings that could allow moisture intrusion.
Chemical protection, on the other hand, involves the use of various substances to prevent corrosion. One option is to seal the terminals and connectors with adhesive-lined heat shrink tubing. This creates a waterproof barrier that prevents water from wicking up the wire into the connector. After sealing, a coating of dielectric grease can be applied to the connecting surfaces. Dielectric grease is a type of sealant that repels moisture and prevents corrosion. It is important to disconnect the power source before applying any chemical protection products to avoid electric shock.
Another chemical protection method is to use a copper-based anti-seize product, such as Permatex. This involves carefully applying a small amount of the product to the connection surfaces, as too much can create a mess. Copper-based anti-seize products provide long-lasting protection against corrosion. After application, the connection can be closed, and the area can be sprayed with a corrosion inhibitor, such as CRC Marine Corrosion Inhibitor. This spray dries to form a waxy film that displaces water and prevents corrosion.
In addition to these methods, regular inspections and maintenance are crucial to prevent electrical connector corrosion. This includes checking for any signs of deterioration, rust, or oxidation, as well as inspecting for damage such as cracks, cuts, or rubbing that could expose connectors to moisture. It is also important to be cautious when cleaning electrical connections, as harsh abrasions, such as wire brushes, can damage soft metals like copper and create scratches that increase the risk of corrosion. Instead, a soft-bristled toothbrush and a mild solvent like WD-40 can be used for cleaning without causing harm to the connectors.
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