One of the most common weak points in an irrigation system is the wire join at the solenoid. It is also one of the most common causes of faults later on.
Most of the time, cable joins fail because they were not joined tightly, were not waterproofed properly, or were left exposed to moisture in the valve box.
When joining irrigation cable to a solenoid, there are three main steps to get right.
1. Prepare the cable properly
Strip the cable back so you have clean copper to work with.
If the copper is dirty, corroded, green, black, or oxidised, cut it back until you get to clean copper. A poor connection at this point can cause the solenoid to work sometimes, fail completely, or create frustrating intermittent faults.
The copper should be clean, tight and ready to make a solid connection.
2. Join the wires securely
For most standard 24V AC irrigation solenoids, the two solenoid wires are not polarity sensitive, which means either solenoid wire can connect to the common or active wire.
To make the join, line the two stripped copper ends up, slightly bend them together, then twist them firmly so the copper wraps tightly around itself. A good join should not feel loose or pull apart easily.
Once the wires are twisted together, trim the end neatly so there are no sharp strands sticking out.
3. Waterproof the join
This is the most important step.
If moisture gets into the copper join, the connection can corrode, short out, or go to earth. That can stop the valve from working and can also create faults at the controller.
The best options are:
Gel joiners
Gel joiners are quick and easy to use. The gel surrounds the copper connection and helps keep moisture out. They are a good option for most residential irrigation systems.
Resin Filled Heat shrinks
Heat shrink can create a very secure waterproof seal when installed properly. It takes a little more care to install, but it is one of the best ways to protect a join. A handy tip is to bend the join back on itself before shrinking it down, so the join forms a small hook. As the resin heats and seals, the hook helps stop the join from pulling apart.
Electrical tape
Electrical tape should not be used as the main waterproofing method for underground or valve box joins. Over time, tape can loosen, let moisture in and leave the copper exposed. This is usually where problems start.
For a long-lasting solenoid connection, always use a proper waterproof cable joiner, gel connector, or adhesive-lined heat shrink. A few extra minutes spent protecting the join can save a lot of fault-finding later.
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