What should be ensured when soldering high voltage connections?

When soldering high voltage connections, it is crucial to leave the terminal with a smooth and rounded covering of solder. This practice ensures that the solder joint is mechanically strong and creates a low-resistance electrical connection. A well-formed solder joint can handle the thermal and electrical demands of high voltage applications, minimizing the risk of failure due to stress or thermal expansion.

Additionally, a smooth and rounded solder joint helps prevent the accumulation of flux or debris that can cause unwanted conductivity or arcing, which is particularly important in high voltage applications where even small gaps or irregularities can lead to hazardous situations.

A cold soldering iron is ineffective because it doesn't provide the necessary heat to properly melt the solder and create a reliable joint. Avoiding soldering altogether is impractical since reliable connections are vital in electronics. Using excess solder can create issues such as bridges between terminals or components, leading to short circuits rather than enhancing conductivity. Therefore, ensuring a smooth and rounded solder joint is the best practice in high voltage soldering.