10 Things to Consider When Buying Wire to Wire Connector Types

Wire connectors are available in a variety of sizes and shapes. While their exterior covering is typically made from insulating plastic, their means of connection is a tapered coiled metal spring or interior grooves that thread onto the wires and holds them securely.

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When a connector is twisted onto the stripped and twisted-together ends of wires, the wires are drawn into the connector's metal spring and squeezed together inside it. Electrical continuity is maintained by both the direct twisted wire-to-wire contact and by contact with the metal spring or insert.

There are seven main types of wire connectors, each tailored to a specific purpose. Usually, the product name is directly related to how to use the wire connector. This can help you select the correct connector for your job.

Tip: Some electricians prefer crimp-on wire connectors for joining ground conductors in an electrical box.

Twist-on wire connectors are typically installed by hand. They may have external grooves to make them easier to handle and apply. Wing-like extensions are commonly molded into higher quality connectors to make attachment easier. Such extensions also allow these connectors to be installed with a common nut driver or a specialized tool.

Twist-on wire connectors are:

• Commonly color-coded to indicate the connector size/capacity.
• Frequently used as an alternative to terminal blocks or the soldering of conductors together, since they are quicker to install and, unlike soldered connections, allow easy subsequent removal for future modifications.
• Not often used on wire gauges thicker than AWG #10 (5.26 mm²), because such solid wires are too stiff to be reliably connected with this method. Instead, set screw connectors, clamps or crimp connectors are used.
• Typically used in electrical wiring systems for light switches, receptacles, ceiling fans, can lights, thermostat controls, HVAC, smoke/CO detectors, garage doors, doorbells, security systems, recessed lighting, signage and more.

Crimp-on wire connectors are typically made of steel or copper, and require a crimping tool to attach correctly. They are designed for making permanent, pressure-type connections and are therefore not reusable. Crimp-on connectors afford a very secure connection. Plastic cap insulators can be used after the connection is made.

Both underground and waterproof wire connectors are typically filled with 100 percent silicone sealant and serve to protect against moisture and corrosion.
They are easy to apply and are typically not reusable. Underground wire connectors are usually used for buried electrical cables and are slightly more durable.

Underground connectors or waterproof connectors are often found in sprinkler systems, outdoor pet containment systems, low-voltage outdoor lighting and similar applications.

As an alternative to twisting wires together, some electrical work can be completed with push-in wire connectors. The push-in design eliminates twisting, reducing repetitive motion fatigue, particularly on jobs that require numerous connections.

The wires push into the connector securely and the clear shell gives visual verification of the connection. It can also make it easier to spot a loose connection when undertaking a repair. The compact size of the connector typically takes up less space in an electrical box. Most connectors can easily be removed by pulling or twisting conductors, and the connectors generally can be re-used.

Whether you're rewiring a receptacle, installing a new light fixture, or updating your sprinkler system, chances are, you'll need to connect multiple wires together securely to make your new device or outlet work.

The easiest way to make these circuit wire connections is with a little piece of plastic or ceramic called a wire connector, or wire nut— and knowing the right wire nut sizes to use for each type of project is key in making your DIY wiring last and preventing loose connections.

Wire Nut Sizes by Color

Standard wire nuts come in five main sizes, which are usually color-coded to show the ranges of wire gauges— or wire thicknesses, measured in AWG— that they can be used for. Bigger wire nuts can also be used for wires that carry higher voltages, or more power.

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The colors can vary, but as a general rule:

• Gray wire nuts can accommodate wires between 22-16 AWG, up to 300 volts.
• Blue wire nuts can accommodate wires between 22-14 AWG, up to 300 volts.
• Orange wire nuts can also accommodate wires between 22-14 AWG, but of higher voltages up to 600 volts.
• Yellow wire nuts can accommodate wires between 18-12 AWG, and up to 600 volts.
• Red wire nuts can accommodate wires between 18-6 AWG, and up to 600 volts.

You may also come across green wire nuts, which are used to join copper grounding wires, or purple wire nuts, which can be used to join aluminum and copper wires.

Types of Wire Nuts

There are a few main types of wire nuts and connectors you can use for different electrical wiring projects in and around your home.

Standard

Standard, or twist-on wire nuts, are color-coded by the wire sizes they can fit. Twist-on wire nuts can be round, square, or have built-in wings to make twisting easier to do by hand. They're usually made from a durable plastic that acts as insulation for the wires, and can withstand the heat generated by regular household electrical connections.

Deep Skirt

Deep skirt wire nuts are similar to standard ones, but they have a longer skirt, or body, to cover longer lengths of exposed wire and provide more insulation and protection to the connection.

Weatherproof

Underground and waterproof wire connectors are designed with a silicone sealant filling to protect the wires from any moisture present in outdoor wiring situations. Underground wire nuts in particular will be rated for direct burial.

High-Temperature

Made of ceramic or thermaplastic to prevent melting, high-temperature wire nuts are used in heaters and lighting fixtures. Just keep in mind that ceramic is much more fragile than plastic, so connections will need to be made with care and pre-twisting your wires is best to avoid any excessive force.

Push-In

Push-in wire connectors are flatter than the standard variation, and involve pushing the wires through allocated transparent slots instead of twisting them together. They accommodate a smaller range of wire gauges than standard nuts— typically 22 to 12 AWG.

Special Connections

There are also wire nuts that look similar to the standard varieties, but are designed for special connections, such as creating one point for grounding when rewiring an outlet, or joining aluminum and copper wires together in older homes. These are usually green and purple, respectively.

Wire Nut Sizes by Fixture

Standard wire nuts can be used for a majority of wiring projects in the home, ranging from outlet receptacles and control panels to fans, garage doors, and doorbells. However, there are some fixtures around the house that will require a special type of connector.

For example, it's best to use high-temperature or ceramic wire nuts when working on connections within light fixtures and heaters, and you'll need waterproof or underground wire nuts for outdoor lights, sprinklers, and pool pumps.

If you're ever unsure what your project calls for, it's always safest to call a professional to help.

How to Use Wire Nuts

Always follow manufacturer instructions, as they can vary by product. But here's the standard procedure:

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