Kimball Midwest Blog

Preventing Electrical Failures: Best Practices and Product Selection

Written by Kimball Midwest | February 13, 2025

When it comes to electrical systems, the last thing you want is an unexpected failure, especially when it can lead to costly downtime, safety risks or the need for unplanned maintenance. In fact, estimates suggest that over 60% of unplanned maintenance is electrical-related, with nearly 80% of electrical failures happening at the point of termination. That's why it's crucial to understand the role of proper materials, tools and techniques to ensure a reliable and long-lasting electrical connection.

Choosing the Right Product for Reliable Connections

One of the most important decisions you’ll make is selecting the right product for your connections. Pro-Tech™ Nytrex Heat Shrink Terminals are an excellent choice for preventing failures. Here’s why:

  • Abrasion Resistance: Pro-Tech™ Nytrex’s material is designed to resist wear and tear, ensuring your connections stay intact even in harsh environments.
  • Sealant for Strain Relief: The sealant provides strain relief, which helps prevent wire pull-out and protects your electrical system from stress-related damage.
  • Corrosion Protection: The built-in sealant locks out moisture, preventing corrosion, which can weaken connections and lead to failures over time.
  • Lower Shrink Temperature: The tubing shrinks at a lower temperature, allowing for quicker installation. Plus, the transparent design lets you visually inspect connections to ensure a job well done.

Using high-quality materials like Pro-Tech™ Nytrex can make a world of difference in the longevity and reliability of your electrical connections.

The Right Tools for a Secure Crimp

In addition to choosing the best materials, it's essential to have the right tools to make secure, durable crimps. Proper crimping ensures that your electrical connections are both tight and reliable, reducing the chances of failure.

One tool that stands out for its ease of use and effective crimping is the Ratcheting Crimp Tool. These tools ensure that the crimp is applied evenly and securely, providing a consistent, high-quality termination each time.

Using ratcheting crimpers like these ensures:

  • Proper force application: The ratchet mechanism ensures you apply the right amount of force to get a reliable crimp.
  • Consistent, high-quality results: Even novice users can achieve professional-level crimps, reducing the chance of human error.
  • Faster installation: With the right tool, the crimping process becomes quicker and more efficient, improving your productivity.

If you're not using the proper tools or techniques, you're setting yourself up for avoidable electrical failures.

Wire Selection

Another key consideration is your choice of wire. Cross-Link Primary Wire offers several advantages over traditional PVC Primary Wire that contribute to the long-term reliability of electrical systems:

  • Heat Resistance: Cross-link wire can withstand higher temperatures, reducing the risk of insulation breakdown due to heat exposure.
  • Abrasion Resistance: It's also more resistant to abrasion, making it a great option for installations where wires are subject to friction or movement.
  • Flexibility: Cross-link wire is more flexible, which helps prevent wire fatigue over time. This increased flexibility is particularly useful in tight spaces or areas where the wiring may be subjected to bending or twisting.

In combination with the right terminals and tools, cross-link wire significantly reduces the risk of electrical failures and enhances overall system durability.

Preventing electrical failures starts with making informed choices about the products and tools you use. By selecting high-quality terminals like Pro-Tech™ Nytrex, using the right crimping tools like Ratcheting Crimpers and choosing more durable wire options like Cross-Link Wire, you can dramatically reduce the risk of electrical issues.

Take these simple yet effective steps to ensure that your electrical systems are safe, reliable and long-lasting. If you want to learn more about the proper selection of electrical products, contact your sales rep today. If you do not already have a rep, we can help you