Posi-Install

Posi Product Installation

The following instructions show how to install a Posi-Tap.

Note: Regular Posi-Lock Products install the same way as the small cap of the Posi-Tap. Click here to see how to install a regular Posi-Lock.

Note: Larger Posi-Locks require about 3/8” (9 mm) of stripped wire, and smaller ones require 1/4” (6 mm) of wire to be stripped. These photos show a Posi-Tap 1824, which requires 1/4” stripped on the tapping wire only. The tapped wire is not stripped.


	Note: Always attach this part of a Posi-Tap first so you can turn the body to tighten it. If you install the tapping wire first, you’ll end up twisting that wire, so attach the tapping wire after attaching the tapped wire. Here is a side view showing the point that pierces the wire for the tap. Remove this large cap and the smaller cap. Start by inserting fully the wire to be tapped as shown in the next photo below.

	Slide the large cap over the wire as far as it will go. Here, the wire to be tapped is inserted and ready to tap.

	Here the tap is started carefully onto the threads of the large cap. Make sure the pin is centred on the wire when the pin contacts the wire. Keep the Posi-Tap body straight to do this. If the wire being tapped is a bit small, look through the opening from the side and align the tapping pin with the centre of the wire.

	Continue to thread by hand and snug up by hand to finish the tap.


	Now, complete the Posi-Tap install, by stripping and installing the tapping wire, as shown below.


	Regular Posi-Lock Install - Posi-Tap Tapping Wire

First, carefully strip the wire the proper amount depending on the Posi-Product. Be careful not to nick or cut any strands!

Tip: Even on a decent wire stripper as shown here, it’s easy to break or nick a wire if you’re not careful. I usually choose the next larger size to strip, which avoids nicking a wire. You might want to practise stripping if you haven’t done it before. Many kinds of low cost strippers will do a job if you are careful.

I use a Patco Thermal Wire Stripper, which makes it easier and faster to get perfect stripping every time. You should inspect your stripping with a magnifier to make sure you’re not cutting any strands. If you cut a wire strand, you should cut the wire off and strip it again.


	Unscrew the cap and insert the wire end with a gentle twisting motion. Be careful to get all the strands through the cap.


		Tweak the strands to one side with your thumbnail.

	Note: On larger Posilocks with very heavy wire, I recommend instead to splay the strands evenly around the perimeter.


	Insert the wire strands into one side of the metal core. Hold the wire from sliding back out.


	Completed Posi-Tap Install


		Tapped wire after removal.


	Push and turn until the threads catch, then screw in tightly by hand - make sure the wire does not slip back in the cap.

Note - on large Posi-Locks I finish tightening with a pair of pliers. Be careful not to strip the threads. On the small Posi-locks, tighten firmly by hand, but if you are strong, you can strip the threads by hand too, so don’t over-tighten the small Posi-Locks either. You want a good snug fit in all cases. The PL1824 is more delicate since it’s made for smaller wires, but the PL1416 is extremely tough and you can hand tighten it very tightly on wires up to 12 AWG. The larger PL1012 can be tightened with pliers.

		Backside of tapped wire.

Posi-Locks install the same way as the small cap of the Posi-Tap.




Pushing The Limits Of Posi-Locks

I did some testing and found out you can use larger than the rated wires in most Posi-Products. When doing this, I recommend you strip the wires just enough to slightly protrude from the Posi-Lock when the wire is pushed into it as far as possible. You don’t want too much of the strands of wire in the Posi-Lock, as there isn’t enough room for them. Also, you must spread the strands evenly around the perimeter of the Posi-Lock. Examples: PL1824 - this little Posi-Lock can work with up to 16 AWG wire. Note, this Posi-Lock should not be tightened too much or the threads will strip. Snug the cap up by hand only. PL1416 - this Posi-Lock is amazing and can actually work on 12 AWG wire. This Posi-Lock is very tough and you can tighten the cap up by hand as tight as possible. Ok, some gorillas out there might strip the threads, but I found I could tighten this little guy up really really tight. I’m sure others such as the PL1012 can also work with larger wires. If the wire insulation will physically fit into the cap opening, you can likely use that wire in the Posi-Lock. The PL1012 can be tightened with pliers to really lock a wire into it. It’s tough and of course has larger threads. Here’s some photos of a PL1416 joining two large 12 AWG wires. I tested this connection by pulling apart as hard as I could and it held. As a bonus, the wire practically seals in the cap because its insulation size fills the opening. If your wire has extremely stiff strands this may not work.



		When you use a wire beyond a Posi-Lock’s rated limit you MUST spread the strands evenly around the cap. Also the strands should not protrude much above the cap edge.