splicing aluminum conductors

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JES2727

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Last week I was troubleshooting a circuit that was giving the homeowner some headaches. The house was built in the 70's, with aluminum wire. There were several trouble spots in the circuit, as the previous homeowner was one of those dangerous do-it-yourselfers. You know, the kind of guy that thinks he knows more than he really does. Anyway, at one point I found a j-box that contained only aluminum wires, no copper. The splice was pretty sloppy so I decided to do it over. And here's my dilemma: Looking at the labeling for the Ideal Purple wirenuts, I see that they are for "aluminum to copper connections". The labeling for the regular red wirenuts says "copper-to-copper connections, do not use on aluminum wire". Nothing is specifically identified for aluminum to aluminum connections. So, what is the proper, approved way to make this splice? I used the purple wirenuts since they do not specifically say that I can't.

John
 
Re: splicing aluminum conductors

Ideal's Chart shows two al #12 or #10 wires with a pigtailed #16 or #18 copper wire. Call them up and see if you can splice just two al wires with their product. 1-800-435-0705. Or throw a short #16 or #18 pigtail in there with a wirenut on the end of it. Cheesy, but hell...it meets their approval.

Or do what was done for years before their purple wirenut came out. Carefully strip the wires back a bit more than usual, pretwist with your linesman pliers, dip them in de-ox and put a wirenut on it.

[ October 18, 2005, 12:24 AM: Message edited by: paul ]
 
Re: splicing aluminum conductors

Split bolts in a lets say 18 cu.in box,on an in and out there would be 3 hots 3 neutrals and 3 grounds.That includes the pigtails. :eek: + the 3 splitbolts and tape.
 
Re: splicing aluminum conductors

I haven't wired in a bit and it may not be applicable to this specific situation, but i was using insulated connectors for aluminum to copper (or Al to Al). They came in multiple configs for each wire size, had screw driver head or hex head (brand variations), some were small enough (for smallest conductors) to fit a couple in a outlet box, probably three in a deep box. They were expensive but passed the inspector's "you-can't-do-that" test.

They looked sort of like a small split bolt when the bolt is taped, but all they are is tubed body with tapped holes to set the conductors, pre-dipped in some plastic insulating material, and insulating caps for the screw tubes. Some were pretty small. I still have a few in a bucket somewhere.

They are listed for al to cu, require no goop (i used anyway), are really small in some cases, can be made up deep in a box to allow for twisting of wires. May not be applicable but i thought they were a possible code compliant situation for some one. can't remember the name, but someone should be able to provide that, assuming they still are around (4-5 years ago).

paul
 
Re: splicing aluminum conductors

I ever even considered the polaris blocks for this application. Not sure if I've even seen them that small. But it's a good tip, and I thank you for suggesting it. I'm going to get some of those to keep on my truck.
I did consider the split-bolts, but I felt they would be pretty cumbersome.
Maybe I'll contact Ideal and ask them why they don't offer a wirenut that's listed for al to al connections.
Thanks for the input.

John
 
Re: splicing aluminum conductors

i would think polaris connectors are good. at the absolute least a rated parallel clamp or split bolt wrapped up but thats ghetto.


personally i would imagine anything rated for a copper to aluminum termination would be suitable for a copper to copper or aluminum to aluminum connection. i mean it is sorta rated for both.
 
Re: splicing aluminum conductors

Originally posted by JES2727:
I ever even considered the polaris blocks for
this application. Not sure if I've even seen them
that small. But it's a good tip, and I thank you
for suggesting it. I'm going to get some of those
to keep on my truck.
I did consider the split-bolts, but I felt they
would be pretty cumbersome.
Maybe I'll contact Ideal and ask them why they
don't offer a wirenut that's listed for al to al
connections.
Thanks for the input.

John
Click to expand...
They make them that small. It's rather tough to get your
smallest screwdriver in to turn the setscrews, though.
 
Re: splicing aluminum conductors

Originally posted by PlnOldRick:
personally i would imagine anything rated for a copper to aluminum termination would be suitable for a copper to copper or aluminum to aluminum connection. i mean it is sorta rated for both.
Click to expand...
I agree with Rick
 
Re: splicing aluminum conductors

yup: polaris is one of them. The inspector thought he had me, but they came stamped some where al/cu, with a ul reference somewhere in the paperwork. There is a hex variety (or was).

paul
 
Re: splicing aluminum conductors

In all the articles I read the concensus was the same.There were some twist on wire nuts manufactured for this application but they failed to hold up under field usage.
CPSC only lists the crimp sleeve as the established means of terminating AL conductors and CU pigtails.
Polaris lugs might be a little tough to terminate in a small 1 gang box.Maybe a single pigtail to a single AL conductor X 3 if grnd. is done.But if there are 2 or 3 cable assys. in the box well that could get pretty tight as well as expensive / Box ;)
 
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