Aluminum Pigtails – Purple Wirenuts vs. AlumiConn
Aluminum Wire Pigtailing Connectors
When it comes to pigtailing aluminum wiring to copper wire, there are still several options available to use. For this particular blog I am focusing on the easily available solutions which are Purple Wirenuts (Model 65) and AlumiConn Lugs. This means I’m leaving out the CopAlum Crimp because it’s not easily available.
For many, many years the style of pigtailing involved pouring some No-Lox liquid into whichever wirenut you needed to install. Purple wirenuts then became the accepted UL solution for Aluminum/Copper connections having antioxidant liquid pre-installed and a flap-style system at the base to prevent run-out. AlumiConn Lugs are now become the standard solution for Aluminum/Copper connections.
The U.S Consumer Product Safety Commission only recognize CopAlum and AlumiConn as meeting the agency’s standards regarding preventing fire hazards as of March 15, 2011.
AlumiConn vs. Purple Wirenuts : Specs
Max Voltage – 300v AlumiConn : 600v Purples
Wire Size Range – Minimum #18/Maximum #10 for both
Temperature Rating – 105 degrees C for both
UL Listed – Both
Flammability Rating : V-2 for both
Maximum Wires per Connector – 3 for both
AlumiConn vs Purple Wirenuts Pros and Cons – Installer
Manufacturing Location:
King Innovation AlumiConn Lugs and Ideal Purple Wirenuts are Made in the USA
Installation Time:
Purple Wirenuts twist on quick and installation is easy. AlumiConn Lugs are a bit more time consuming with having to unscrew each port and then tighten each port. Plan on spending up-front time prepping the lugs, it will speed up installation.
Size:
Both Wirenuts and Lugs take up considerable space. Purple wirenuts take up slightly less than AlumiConn Lugs. Considering that most homes with aluminum wire also have smaller metal boxes, this can become an issue. Standard switches and outlets aren’t usually an issue but GFCI outlets and dimmers will often not fit when using aluminum/copper connectors. Plan on installing a GFCI breaker for bathrooms/kitchens or removing the old metal boxes and installing a new plastic remodel box for space when bringing those areas up to code.
Quality:
Purple wirenuts will occasionally not grab your wires but for the most part are reliable. AlumiConn lugs are solid and the only complaint is the occasional lug port is pre-set just a bit too tight.
Application:
A main reason for using AlumiConn lugs over Purple Wirenuts AND CopAlum Crimps is the fact that the copper and aluminum wires DO NOT make direct contact. AlumiConn keeps the dissimilar metals from ever directly contacting one another.
Installation:
We prep AlumiConn lugs up-front with a variety of leads and loosening the ports for improved installation time. As with any installation, make sure not to strip the wire too much or have any exposed metal remaining on connections. Wirenuts can be stripped longer for wirenut installation, AlumiConn lugs have a smaller strip size to keep leads from being exposed. Keep in mind your amp rating and sizing for aluminum and copper to help your installation time.
20amp Circuit = #10 Aluminum and #12 Copper THHN
15amp Circuit = #12 Aluminum and #14 Copper THHN
Wire Charts : Allowable Connections and Sizes
AlumiConn Lugs
One wire per port/three total
#12-#10 Solid Aluminum
#18-#10 Solid or Stranded Copper
Purple Wirenuts
1 #10 AL sol. w/1 or 2 #10 CU sol.
1 #10 AL w/1 or 2 #12 CU
1 #10 AL w/1 or 2 #14 CU
1 #10 AL w/1 or 2 #16 CU
2 #10 AL sol. w/1 #12 CU
2 #10 AL sol. w/1 #14 CU
2 #12 AL sol. w/1 #10 CU sol.
2 #12 AL sol. w/1 #10 CU str.
1 #12 AL sol. w/1 or 2 #10 CU sol or str
1 #12 AL str. w/1 or 2 #10 CU sol.
1 #12 AL w/1 or 2 #12 CU
2 #12 AL sol. w/1 #12 CU
1 #12 AL w/1 or 2 #14 CU
2 #12 AL sol. w/1 #14 CU
1 #10 AL w/1 or 2 #18 CU
2 #10 AL sol. w/1 #16 CU
2 #10 AL sol. w/1 #18 CU
1 #12 AL w/1 or 2 #16 CU
1 #12 AL w/1 or 2 #18 CU
2 #12 AL sol. w/1 #16 CU
2 #12 AL sol. w/1 #18 CU
Visit our Aluminum Wire Repair Page for more pictures
