Splicing aluminum wire to copper within a breaker panel

[lanel]

Wondering if the following is ever done to use copper conductors on large breakers within a subpanel, then splice within that panel to aluminum prior to its exit? For those wondering what the purpose would be, it's to have the flexibiliy of the copper conductor where it connects to the breaker versus the stiffness of an aluminum conductor. Has anyone done this and would it meet code? Large aluminum can be difficult to work with in small spaces.

Thanks,

 

[qcroanoke]

Wondering if the following is ever done to use copper conductors on large breakers within a subpanel, then splice within that panel to aluminum prior to its exit? For those wondering what the purpose would be, it's to have the flexibiliy of the copper conductor where it connects to the breaker versus the stiffness of an aluminum conductor. Has anyone done this and would it meet code? Large aluminum can be difficult to work with in small spaces.

Thanks,

What type of copper conductor are you using? Seems to me copper can be stiffer in lrger sizes and stranding

 

[lanel]

THHN 2 gauge stranded

 

[LarryFine]

It is often done, and for any of several reasons, such as:

To use a larger aluminum wire with a smaller terminal.

To connect to terminals not compatible with aluminum.

 

[electrofelon]

What type of copper conductor are you using? Seems to me copper can be stiffer in lrger sizes and stranding

Yeah my thoughts too. Last year I put a 1000A PB in where there were 4 existing 3/0 CU and two new 250AL feeders. It had been so long since I had worked with CU that size as I nearly always use AL. Def found the AL ones much easier and more cooperative.

 

[marmathsen]

Aside from the reasons Larry mentioned, no I don't do it. Mainly because I prefer to avoid unnecessary splices.

I use these for uncooperative wire:

"Wire & Conduit Bending Archives - Rack-A-Tiers with Category Wire Bending" https://www.rack-a-tiers.com/produc...it-bending/?filters=product_cat[wire-bending]

Rob G

 

[LarryFine]

. . . I prefer to avoid unnecessary splices.

Absolutely agree.

I use these for uncooperative wire:

I used to carry a 1/2" and a 3/4" copper pipe, each about 8" long, with well-rounded ends, for bending short ends.

 

[marmathsen]

I used to carry a 1/2" and a 3/4" copper pipe, each about 8" long, with well-rounded ends, for bending short ends.

Sounds like my rebar bender, a piece of RMC. It worked for all the footings for my deck but it was good and worn out by the end of it. If you're doing a large project just buy a rebar bender.

Rob G

 

[lanel]

Last year I put a 1000A PB

When I said large breaker, I was thinking 125A. So I guess it's all relative.

The breaker is installed with 1/0 alum without the use of any bending tools. For this application, I just prefer the copper attachment at the breaker but also agree with Marmathsen about eliminating unnecessary splices.

 

[ggunn]

It is often done, and for any of several reasons, such as:

To use a larger aluminum wire with a smaller terminal.

To connect to terminals not compatible with aluminum.

Another is to reduce the conductor size or count when conductor runs are upsized for voltage drop.