Beatrice Lang
Electrical connectors are used to join subsections of circuits together. They can be divided into four basic categories: inline or cable connectors, chassis or panel connectors, PCB mount connectors, and splice or butt connectors. There are many different types of electrical connectors, including wire connectors, PCB connectors, USB connectors, and audio-visual connectors. Some common types of wire connectors include twist-on wire connectors, push-in wire connectors, and underground or waterproof connectors. Standard wire connectors come in five main sizes, which are usually color-coded to indicate the connector size and capacity. The size of an electrical connector is important because it needs to fit the wires or devices it is connecting and accommodate the appropriate amount of current.
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What You'll Learn
Wire connectors for electrical boxes
Electrical connectors are used to join subsections of circuits together. They are typically used when it is desirable to disconnect the subsections in the future, such as for power inputs, peripheral connections, or replaceable boards.
Wire connectors, specifically, are UL Listed fasteners used to make a tight connection with little interference between two or more electrical wires in an electrical box. They are made of flame-retardant materials and prevent wires from contacting other wires or exposed metal surfaces, which could cause a dangerous fault or short circuit.
There are several types of wire connectors for electrical boxes, including twist-on, crimp-on, push-in, and underground or waterproof connectors. Twist-on wire connectors are typically installed by hand and may have external grooves to make them easier to handle and apply. They are frequently used as an alternative to terminal blocks or soldering conductors together, as they are quicker to install and allow for easy subsequent removal. Crimp-on connectors are preferred by some electricians for joining ground conductors in an electrical box. Push-in wire connectors are another alternative to twisting wires together and can be used for applications such as sprinkler systems, outdoor lighting, and similar low-voltage systems. Underground or waterproof connectors are often used in sprinkler systems, outdoor pet containment systems, and other similar applications.
In addition to the connector type, it is important to select the appropriate size and capacity for the electrical box. Connectors are available in a variety of sizes and are often colour-coded to indicate their size and capacity. They are also designed to accommodate different wire gauges, with some connectors being more suitable for thicker wire gauges.
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Audio-visual connectors
RCA connectors are defined by both composite and component video interfaces. They are used for analog or digital audio or analog video. The 1/8" version of this connector is commonly found as the plug on the end of a pair of headphones. These connectors come in three common sizes: 1/4" (6.35mm), 1/8" (3.5mm), and 2.5mm. The 1/4" size connectors are often used in professional audio and music, with most electric guitars and amplifiers featuring 1/4" tip-sleeve (TS) jacks. The 1/8" tip-ring-sleeve (TRS) is often used as the connector for headphones or audio output signals on MP3 players or computers.
Other audio-visual connectors include TOSLINK, DVI, VGA, DFP, S-Video, DisplayPort, HDMI, Thunderbolt, coaxial TV, F connector, and MIDI. DVI, or Digital Visual Interface, is a hybrid analog/digital connector commonly found on PC graphics cards and LCD monitors. The DVI specification is compatible with the VGA interface, which is a digital display interface standard.
DisplayPort is a competitor to the HDMI connector, which is the standard digital connection for high-definition consumer electronics devices. There are three types of HDMI connectors: Type A, Type B, and Type C. Type A is electrically compatible with single-link DVI-D, while Type B is electrically compatible with dual-link DVI-D but has not been used in any products.
Finally, barrel connectors are commonly found on low-cost consumer electronics, such as wall power adaptors. They are used to connect power to small projects.
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Power connectors
One of the most common power connectors is the barrel connector, also known as a coaxial power connector or concentric barrel connector. These connectors are typically used in low-cost consumer electronics and can be plugged into wall power using AC wall adapters. Barrel connectors are defined in terms of “plugs” and “receptacles”, with the female barrel connector being referred to as a “jack”. They come in various sizes, with the most common being 5.5 mm outer diameter (OD) plugs, followed by 3.5 mm OD plugs. The size and shape of connectors can vary across manufacturers and models.
Another type of power connector is the USB connector, which is known for its power delivery and data transfer capabilities. The USB Type-C connector, in particular, has a current rating of up to 5 A and a maximum voltage rating of 20 V, making it suitable for power-only applications.
In addition to these, there are also power connectors specific to computers and their components, such as SATA power connectors for hard drives and optical drives, and PCI Express power connectors for graphics cards. These connectors have different pin configurations, such as 4-pin and 8-pin (6 + 2) connectors, depending on the power requirements of the connected device.
Other power connectors include Anderson Powerpole connectors, which come in various sizes and are capable of transferring substantial electrical loads. Japanese Solderless Terminal (JST) connectors are also used to bridge electrical connections or carry electrical signals. Registered jack connectors are commonly used in telecommunications equipment.
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Industrial connectors
Board-to-Board Connectors
These connectors are used to connect printed circuit boards (PCBs) without using wires. They are suitable for systems with limited space as they reduce wire clutter. Board-to-board connectors can be arranged in a parallel or perpendicular layout when connecting PCBs.
Cable-to-Cable Connectors
Cable-to-cable connectors are used to connect cables directly to each other.
Wire-to-Board Connectors
Wire-to-board connectors are simple, dependable, and cost-effective solutions for electrical transmission to PCBs. They are used in various sectors, including telecommunications, automotive, commercial, and industrial. These connectors do not have standard designs, so the type selected will depend on specific requirements and applications. Wire-to-board connectors are also used in home appliances, where PCB terminals fasten a wire to a board without solder, allowing for quick replacement or repair.
Panel Feedthrough Connectors
Panel feedthrough connectors are suitable for managing large cables in industrial environments, including factory automation, process control, and medical technology applications.
In addition to these four main types, there are various other industrial connectors, such as the RJ45 connector, commonly used in computers, routers, and communications equipment. The RJ45 connector is designed to make safe and reliable input/output connections. Other connectors include the XT60, a high-temperature connector that prevents reverse polarity, and the Anderson Powerpole Connector, which is used for transferring substantial electrical loads.
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Household connectors
Electrical connectors are used to join subsections of circuits together, usually when it is desirable to disconnect the subsections in the future. They are also used to convert between two connection methods. Connectors are differentiated by their function, pinout, method of connection, materials, size, contact resistance, insulation, and mechanical durability.
There are four basic categories of electrical connectors:
- Inline or cable connectors: These are permanently attached to a cable so that it can be plugged into another terminal, such as a stationary instrument or another cable. An example is the barrel connector, which is commonly found on low-cost consumer electronics.
- Chassis or panel connectors: These are permanently attached to a piece of equipment so that users can connect a cable to a stationary device.
- PCB mount connectors: These are soldered to a printed circuit board (PCB), providing a point for cable or wire attachment. Examples include pin headers, screw terminals, and board-to-board connectors.
- Splice or butt connectors: These permanently join two lengths of wire or cable.
There are also various types of wire connectors used in household electrical wiring projects. These include:
- Standard wire nuts: These are the most common type of wire connectors used for a majority of wiring projects in the home, ranging from outlet receptacles and control panels to fans, garage doors, and doorbells. They are usually colour-coded by wire size and can be round, square, or have built-in wings to make twisting easier.
- High-temperature or ceramic wire nuts: These are used for connections within light fixtures and heaters.
- Waterproof or underground wire nuts: These are used for outdoor lights, sprinklers, and pool pumps. They are designed with a silicone sealant filling to protect the wires from moisture.
- Deep skirt wire nuts: These are similar to standard wire nuts but have a longer body to cover longer lengths of exposed wire and provide more insulation and protection to the connection.
- Push-in wire connectors: These are an alternative to twisting wires together and can be used in sprinkler systems, outdoor pet containment systems, and low-voltage outdoor lighting. They reduce repetitive motion fatigue and allow for easy visual verification and repair of connections.
- Twist-on wire connectors: These are typically installed by hand and may have external grooves to make them easier to handle and apply. They are commonly colour-coded to indicate the connector size and capacity.
- Winged connectors: These speed up the attachment process and allow for a better grip, making them ideal for large projects requiring multiple connections.
- Set screw connectors, clamps, or crimp connectors: These are typically used in electrical wiring systems for light switches, ceiling fans, thermostat controls, HVAC, smoke/CO detectors, garage doors, and security systems.
- Crimp-on wire connectors: These are made of steel or copper and require a crimping tool to attach correctly. They are designed for permanent, pressure-type connections and are not reusable.
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