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Independent Test Lab Results - Ideal 65 Twister

• Splices made with the Ideal-65 Twister™ connector are not capable of long-term safe performance as part as part of the permanent wiring of existing aluminum wired homes. The results of independent testing were presented at the IEEE Holm Conference on Electric Contact Phenomena in Philadelphia Oct.20. Copies are available from the IEEE library (908-562-3974). Title of paper is "Evaluation of a Twist-on Connector for Aluminum Wire," by J. Aronstein.
• Note also that field failures (overheating, burnouts) of these connectors in actual service as pigtailing "repair" in existing aluminum wired residential structures have now been reported.
• Documents provided under the Freedom of Information Act, describe independent testing of the Ideal 65 "Twister" purple twist-on connector marketed for certain retrofit repairs of aluminum electrical wiring.

Here are photos of failed Ideal-65™ twist-on connectors currently sold for aluminum wire "repair," submitted by Dr. Jess Aronstein on 1-10-01.

Available Documents on the Ideal 65 Purple Twister Connector for Aluminum Wiring Repairs

Documents (listed below) indicate that notwithstanding it's UL Listing, the purple Ideal #65 "does not meet the UL486C heat-cycle test performance requirements when tested with splices representative of the common "pigtailing" combination used in aluminum-wired homes, even though the connector is UL listed for those wire combinations."

The UL response refers-to but does not address Aronstein's findings.

• "Evaluation of a Twist-on Connector for Aluminum Wire," J. Aronstein, IEEE Holm Conference on Electric Contact Phenomena in Philadelphia Oct.20, 1997 IEEE library 908-562-3974
• Letter, 1/4/96, Aronstein to Castino at Underwriters Labs
• Letter, 3/29/96, Aronstein to Castino at Underwriters Labs
• Letter, 3/29/96, Aronstein to King at US Consumer Product Safety Commission
• Letter, 4/22/96, Castino to Aronstein (independent tester)

More Information - Detection, Repair, Advice for Aluminum Wiring in Buildings

"Evaluation of a Twist-on Connector for Aluminum Wire", J. Aronstein, Forty-Third IEEE Holm Conference on Electrical Contacts, Jan 1997, 0-7803-3968-1/97.
[This article describes the Ideal Industries Ideal#65 purple "Twister" twist-on connector marketed as a repair/retrofit for residential aluminum wiring.--DJF]

Abstract: A new type of twist-on splicing component for use with aluminum and copper wire combinations is tested to determine initial resistance, performance in a zero-current environment test, performance in a heat-cycle test, and portion of current carried by the connector's steel spring. The splices tested consist of two aluminum wires and one copper wire.

The aluminum wire samples used for the test are of the types actually installed in aluminum-wired homes. Initial resistance is found to be relatively high, and there is a significant sample-to-sample variation. This reflects failure to consistently establish low-resistance wire-to-wire contact Through the insulating oxide film on the wire.

Results of the environmental and heat-cycle tests show deterioration of a significant portion of the samples.

The splices made with this connector are also found to be sensitive to mechanical disturbance, such as applied in normal installation when the completed splice is pushed back in to the junction box.

Based on the test results, it is concluded that this connector has not overcome the fundamental deficiency of twist-on connectors for use with aluminum wire applications. Keywords: aluminum wire, connectors, twist-on connectors, environmental test, heat-cycle test.

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History of and Links to CPSC Documents about the Ideal #65 Twister Purple Twist-on connector debate

More Information on Building Diagnostic Inspections and Repairs

• History of and Links to CPSC Documents about the Ideal #65 Twister Purple Twist-on connector debate
• The Aluminum Wiring Information Website Aluminum Wiring Hazards and Repairs: in-depth info, photos, documents.

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