How to repair aluminum wiring: recommended methods
How to Reduce the Risk of Aluminum Wiring
Fires
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This article describes the immediate safety steps needed in a building where solid conductor aluminum electrical wiring is installed. This article describes the acceptable methods to repair aluminum wiring, including which aluminum wire connectors to use for safest results. We describe how to make aluminum to copper pigtail connections using the COPALUM connector or the AlumiConn™ connector as well as how to make aluminum-to-aluminum wire connections and aluminum ground wire connections. How to reduce the risks associated with aluminum electrical wiring - a practical guide shows which aluminum wiring connectors can be used successfully to connect aluminum conductor wires to copper-wired devices (such as lighting fixtures or fans) and to electrical receptacles ("plugs") or to light switches. Notes on using the COPALUM connector for aluminum wire repairs - aluminum to copper pigtailing. Notes on using the AlumiConn™ connector for aluminum wire repairs - aluminum to copper pigtailing & aluminum to aluminum wire splices - where to buy and how to install and torque the AlumiConn aluminum wire repair connector. How to splice aluminum-to-aluminum electrical wires.
Green links show where you are. © Copyright 2013 InspectAPedia.com, All Rights Reserved. Author Daniel Friedman.
HOW TO REDUCE THE RISK of Fire and Electrical Circuit Connector Overheating in buildings with Aluminum Electrical Wiring
The page top photograph shows an infra-red photo of an overheating aluminum wiring
connection at an improper aluminum-to-copper "pigtail" splice (courtesy of G. Cohen). Aluminum wire connections can overheat enough to
start a fire without ever drawing enough current to trip a circuit breaker, and improper repairs can increase the hazard.
Immediate Actions for Safety of Aluminum Wiring
- See if you have aluminum wiring (solid conductor branch circuit) installed in your home. Aluminum wiring identification tips are
provided at ALUMINUM WIRING, HOW TO RECOGNIZE
- Look for signs of aluminum wiring failure, such as flickering lights, turn off the circuit involved and call a licensed electrician. See U.S. CPSC 516 (linked-to below) for other trouble signs.
- Install smoke detectors at locations recommended by your local building officials or fire department. Sample smoke detector locations are also provided on instructions that come with the smoke detector.
How to Repair Aluminum Electrical Wiring to Reduce the Hazards - Repair Alternatives & Choices
Once the initial steps above have been addressed here are the US CPSC recommended choices for safe repair of aluminum wiring:
Aluminum Wiring Repair Method No. 1: Re-wire the Building, Replacing All Aluminum with Copper Wire
Re-wire the Building replacing all aluminum branch circuit wiring with copper, as a "best repair method" for aluminum wiring. However this approach will be the most costly method for aluminum wire repair, requiring snaking new wires throughout the building.
New copper wires are run throughout the building, from the electrical panel to junction boxes, receptacle boxes and to connected devices such as electrical switches, receptacles (outlets or "wall plugs"), etc.
The old aluminum electrical conductors can be left in place in building walls and ceilings, and will be harmless once those wires are completely disconnected from the electrical system.
The re-wire approach to aluminum wiring repair is used principally when other building renovations that require opening building walls, ceilings, floors, make this method practical.
Aluminum Wiring Repair Method No. 2: Copper Pigtailing using the COPALUM Connector
COPALUM Copper-to-Aluminum Pigtailing Use the special AMP (now TYCO) COPALUM connector and special tool to
connect short copper wires to every aluminum wire end in the Building, reconnecting the copper to the
various devices (outlets, switches, lights) and splices.
This "copper pigtailing" procedure is performed by an electrician trained
and licensed by AMP or TYCO to use this COPALUM procedure.
The TYCO COPALUM connector method and its pro's and con's are discussed here (below). The installation procedure for this connector is given in TYCO's instructions and is illustrated in precise detail by Aronstein at PIGTAILING USING AMP "COPALUM" CONNECTORS.
Typically this approach costs about half that of completely re-wiring a home with copper.
A brief US CPSC article COPALUM ALUMINUM WIRE CONNECTORS discusses how
to get these aluminum wire connectors.
TYCO currently leases the crimp tool necessary for making COPALUM repairs, and training is needed to use it properly. For photos of the TYCO COPALUM "Retermination Kit" - the crimping tool used to install COPALUM connectors on aluminum wiring, see this TYCO COPALUM Tool document. (PDF)
You'll see that the tool is large, making work in tight quarters a challenge, especially if the original lengths of wire to be pigtailed are short.
You'll also read in Tyco's draft contract for electricians that TYCO considers "old technology" aluminum wire to be unsafe, but in fact later-installed "new technology wire" performs about the same. Both "old technology" and "new technology" solid conductor aluminum wire alloys varied from manufacturer to manufacturer, some performing better or worse than others. |
How to Become a Certified COPALUM Installer for Aluminum Wiring Repairs
The following material is based on information from Tyco Electronics, supplier of the COPALUM connector and crimping tool used for aluminum wiring repair:
Becoming a Certified COPALUM Installer - Certification Procedure
- Review, sign and return the contract for the COPALUM Retermination Program.*
- Contact a participating local Electrical Distributor for availability and delivery of the COPALUM Retermination Tool.
- Contact Tyco Electronics to set up a training date for certification training.
- Certification Card is provided after completion of training for the purchase of product.
*Refer to Terms & Conditions Document concerning contract specifics
Tool Leasing:
Pricing and availability only through a participating Electrical Distributor
- Tooling: Lease only option (Tool is NOT available for sale)
- 3 month minimum lease — Contact a participating Electrical Distributor for pricing.
- Monthly Fee — Contact Electrical Distributor for pricing.
- Certification Training is provided by Tyco Electronics Field Service Specialist.
- Training consists of 2 to 4 hour instruction for tool use & connector application.
- Training Cost - $ 750.00 plus travel & expense (Limited to 6 participants).
Once contractor has tool availability date from distributor, contact Tyco Electronics to schedule training date.
Contact Tyco Electronics customer service for additional information at 800.468.2023.
Contractors can identify distributors in their area by contacting 1-800-527-6686.
See Tyco Electronics for details about COPALUM certification, crimping tool leasing, supplies, training. Terms and conditions of leasing the COPALUM retermination tool (crimping tool) for aluminum wire repairs includes requiring that the contractor be properly trained in use of the equipment.
Tyco COPALUM Part Numbers
- The Tyco part number for the Tyco COPALUM retermination tool (crimping tool) is 1976330-1.
- The Tyco part numbers for the COPALUM crimp connector itself are 608501-1(Red) & 608502-1(Blue) (two sizes).
Shortcomings of the COPALUM Aluminum Wiring Repair Method
Space limitations in the junction box or receptacle box: These connectors and the copper pigtail wires take up more space in a junction box or receptacle box than the original wires and connectors. At MAKE SPACE FOR ALUMINUM CONNECTORS we discuss options for fitting the COPALUM connector and pigtail wires into electrical boxes where space is tight.
OPINION: Problem for Large Electrical Contractors repairing aluminum wiring: Tyco should make the COPALUM crimping tool available for sale: Unfortunately, Tyco's "rent-only" option for the COPALUM connector makes aluminum wiring repair service prohibitively expensive for large electrical repair companies who are performing extensive aluminum repair work in large urban areas.
Placing multiple repair tools in multiple repair service trucks with aluminum-wire repair-trained experts, and keeping them there year in and year out in order to be responsive to consumer needs prices this service right out of that market place and has tempted some aluminum repair electricians to make use of alternative repair methods that appear to work (the AlumiConn discussed below) and other aluminum repair methods that have been shown to be ineffective and dangerous.
OPINION: Problem for Small Electrical Contractors repairing aluminum wiring:Tyco should make the COPALUM crimping tool available for short term rental: A small electrical contractor wanting to become trained, certified, and qualified to perform a small number of aluminum wire repairs faces a different problem. Tyco rents the COPALUM crimping tool for a three-month minimum, converting to a month-to-month lease thereafter. This will not be economical for a small contractor performing only occasional aluminum wiring repairs.
Aluminum Wiring Repair Method #3 - the AlumiConn™ Alternative has U.L. Listing & Approval
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AlumiConn TM aluminum to copper lug connectors[1]
[New in 2006, U.L. Listed, 2007 completed independent testing, CPSC recommended 2011]
available from King Innovation.
Results of independent
testing indicate that this product "... is predicted to have a high probability of failure-free long-term safe performance,
PROVIDED THAT THE SETSCREWS ARE CAREFULLY TIGHTENED TO THE MANUFACTURER'S RECOMMENDATION".
AlumiConn TM Purple #95135 aluminum to copper lug connectors [New in 2006, now U.L. Listed, 2007 completed independent testing] available from King Innovation. The AlumiConn connector is now recommended for aluminum wiring repairs - US CPSC.
The AlumiConn™ connector shown here is used to splice a copper "pigtail" wire together with one or two aluminum wires as a step in reducing the fire hazard associated with aluminum electrical wiring. This connector performs well provided that the wires are properly secured in the connector, and it has been included in the US CPSC recommendations for aluminum wiring repair.
Reference: details of the study and recommendations are on page #6 (the 9th page in the .pdf file) in Dr. J.A. Aronstein's .pdf document version of
"Reducing the Fire Hazards in Aluminum Wired Homes" May 21, 2007.
The test results are completed and will be published in September 2007.
(100 connectors cost $285. Lower prices for larger quantities.)
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Where to Buy the AlumiConn connector
How to Install the AlumiConn aluminum wiring repair connector
Installation instructions for AlumiConn™ for aluminum wiring repair
Technical notes on Installing or Wiring the AlumiConn™ for aluminum wiring repair
- Aluminum ground wires: don't forget that not only original solid aluminum the hot and neutral conductors but also the aluminum ground conductor need to be treated. See ALUMINUM GROUND WIRES for additional wiring details and an example using the AlumiConn™.
- Aluminum Wire Repair Connector Space Problems in junction boxes and receptacle boxes: at MAKE SPACE FOR ALUMINUM CONNECTORS we discuss options for fitting the AlumiConn™ connector and/or COPALUM and the necessary copper pigtail wires into electrical boxes where space is tight. The NEC makes an exception to connector count and wire count and space limitations to permit the use of these connectors for aluminum wiring repairs.
- Torque settings for the AlumiConn™: torque specifications (discussed below) for the AlumiConn are particularly important for this particular connector as it involves tightening a screw in a terminal block to secure the aluminum or copper wire being spliced.
Aronstein emphasized that the connector's acceptable performance relied on using the proper torque settings.[3] King Innovations provides two installation methods, depending on whether or not you own a torque-screwdriver.
Watch out: the manufacturer makes clear that their installation instructions for the AlumiConn without using a torque-setting screwdriver are not included in the CPSC recommendations, but the " manufacturer (King Innovation) stands firmly behind this installation method." [1]
The AlumiConn Torque settings specified by King are
Technical note on binding and poor wire connections in aluminum terminal blocks & aluminum wire repairs
In larger-sized electrical wire connector applications such as electrical panel buses (not this product),
we have saw (prior to 2011) aluminum-block connection
failures occur when the steel screw bound in the aluminum block,
appearing to be a tight connection before proper contact with the wire has been made.
Mr. King informed us that they have addressed this concern by plating the screws in nickel and plating the lug block in tin,
thus eliminating the galling found in other lugs. Also there is a very small gap at the back of the
wire terminal block where the installer can see the wire (coated in sealant) coming through. This
provides visual confirmation that the wires came all the way through.
Junction box/receptacle box space limitations & aluminum wire repairs
As we introduced in discussing the COPALUM, the AlumiConn™ connectors and the copper pigtail wires also take up more space in a junction box or receptacle box than the original wires and connectors. The manufacturer informs us that the AlumiConn™ and the COPALUM are similar in the space these devices require.
At MAKE SPACE FOR ALUMINUM CONNECTORS we discuss options for fitting the COPALUM connector or the AlumiConn™ connector along with copper pigtail wires into electrical boxes where space is tight.
AlumiConnTM Status Update - CPSC Recommended
Question: Is it OK to Use the AlumiConn™ by King Innovation for Aluminum Wiring Repair
In the section regarding aluminum wiring repair it is not clear to me if the product called Alumiconn by King Innovation is a safe and acceptable alternative to Copalum. I have not been able to find anywhere in the internet any further references to how safe is this product beyond the publication by J. Aronstein last update July 6, 2007. Can you clarify this for me?
- J. C., Orlando, FL
[Note: this question and answer was posed in 2009 but has been updated to reflect the 2011 US CPSC recommendations concerning the AlumiConn connector - Ed.]
Answer: Safety/Usability of the AlumiConn™: 4 Points of Discussion
1. Independent tests showed that IF the Alumiconn connector is properly installed (including torquing to the proper torque setting) it performs as well as COPALUM. We have absolute confidence in Dr. Aronstein in this matter - he is fully qualified, experienced, and is an unbiased independent party with no financial connection to the company selling Alumiconn (nor to any one else selling other products).
Here is Aronstein's paper on the topic: Reducing the Fire Hazards in Aluminum-Wired Homes - 5/21/07, (AlumiConn™ info is on p. 9)
The Alumiconn™ is UL listed (UL 486C) as a "pressure type screw connector" (USA) and CSA approved (Canada) for aluminum wiring repairs.
For general information about that listing type, see this UL connector information on the UL listing for wire connectors.
2. U.S. CPSC: This connector performs well provided that the wires are properly secured in the connector, and it has been included in the US CPSC recommendations for aluminum wiring repair as of approximately June 2011.[2][3]
3. Torque settings for the AlumiConn™: Reading the UL document we see no mention whatsoever of torque specifications - those are particularly important for this particular connector as it involves tightening a screw in a terminal block to secure the aluminum or copper wire being spliced. Aronstein emphasized that the connector's acceptable performance relied on using the proper torque settings.
Torque settings are described above in this article and are also found at the AlumiConn site - you'd need the $100. SK torque screwdriver to install these connectors - costly, but much less so than renting the COPALUM crimping tool and becoming certified to use it.
The "alternative method" described by the manufacturer for tightening the screws produces torque close to or exceeding the actual torque specified numbers (according to some preliminary tests we have done in our lab) - photo at left.
But we are not confident that that approach would be adequate for general field use where individual human performance may vary considerably.
For example, you may not be exactly sure just when the setscrew "... comes into contact with the solid conductor". King is confident of this approach but is careful to point out that it is not associated with the UL listing for the product. |
4. UL listing vs CPSC Recommended: So if you were working for someone else and wanted to install only the CPSC-recommended connectors, you'd use only the AMP/TYCO COPALUM™ method or the AlumiConn™.
In March 2010, prior to the CPSC recommendation of AlumiConn™ connectors for aluminum wiring repairs, we (DJF) presented this information for a group of 50 licensed electricians at an Aluminum Wiring Repair Methods Update - class in Dallas TX. These were trained licensed electricians who are informed and conservative in their practice. The company's position was that they would not use an connector that was not CPSC-recommended, notwithstanding its UL listing.
Indeed, some products carrying a UL listing for aluminum wiring repair have been shown to perform very poorly in the field, such as CU/AL devices and the Ideal65 purple "Twister" connector sold for that purpose.
How to Repair Aluminum-to-Aluminum Wire Splice Connections
Aluminum to aluminum wire splices also need to be repaired in an aluminum-wired home. These splice connections are typically found in junction boxes (shown below) but may also occur in some receptacle boxes where a device such as a light or electrical receptacle are also wired.
Traditionally these splices were made with twist-on connectors - an approach shown below (left) and one that is unsafe (below right) because of the risk of overheating and a potential for fire.
Our photograph at above left shows aluminum wire spliced to aluminum wire at a connection which had not overheated when we took this photo. The photograph at above right shows severe overheating and burn-up of an aluminum to copper splice made using a conventional twist-on connector.
Avoid Using Copper Pigtails When Splicing Multiple Aluminum Wires Together
The various "copper pigtailing" methods
discussed in articles on aluminum wire repairs (at aluminum-wired devices such as electrical receptacles, switches, and lights)
are not the best approach when repairing aluminum-to-aluminum wire splices such as at a
junction box in a building (where several aluminum-wire circuits or wires are joined together).
Which Connectors Are Used for Splicing Aluminum Branch Circuit Wires
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For the aluminum wire to aluminum wire connector case, use of a splicing connector whose manufacturer specifies that the connector must be used with a combination of copper and aluminum wires together (the COPALUM) makes little sense.
Our photo left shows three aluminum wires connected together (spliced) into an AlumiConnTM device.
For the small aluminum wire sizes such as found in building branch circuit wiring for lighting and receptacles, the AlumiConnTM is probably the best choice if the COPALUM connectors and special crimping tool are not readily available.
The installation instructions for the AlumiConnTM (see AlumiConn ALUMINUM WIRE CONNECTORS) indicate that the connector can be used for splicing solid conductor aluminum branch circuit wires in sizes #12 - #10. |
For larger aluminum wire sizes sizes (stranded aluminum wiring such as found at air conditioning compressor circuits, electric
range circuits, clothes dryer circuits and other high-amp devices), any of the (UL listed for Aluminum) setscrew type connectors
in combination with the inhibitor/abrasion installation technique should suffice.
Since we've seen frequent field reports of overheating at multi-strand high-amp aluminum wired devices such as air conditioning compressors, it is important
to address these cases by proper repair methods.
[Note: some air conditioning equipment manufacturers currently recommend use of only
copper wiring to feed their equipment - DJF June 2007]
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Other Approaches to the Repair of Aluminum Electrical Wiring
Other aluminum wiring repair connector products
have been sold by various manufacturers, some with good performance and some unacceptable. Descriptions are below. Emergency temporary repairs necessary to keep an essential circuit in service might be possible following other procedures described by the CPSC or by industry experts.
Details about other aluminum wire repair methods that are not recommended are found at
ALUMINUM WIRING REPAIR NOT-Recommended.
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Other methods - not recommended: Warnings regarding other "repair" methods which are not recommended
are discussed at ALUMINUM WIRING REPAIR, Other Products, such as the
Ideal 65 purple "Twister" aluminum wire splice connector shown in the photo at left (12 connectors cost $49. to $79.)
Note: The instructions for this connector require that it always include a copper pigtail when making aluminum wiring connections - a condition impractical for splicing aluminum-to-aluminum wires. |
Other methods - also not recommended: include attempts to repair aluminum wiring using
receptacles and outlets marked "COALR" (even if these worked, which has not been
demonstrated, what about all of the other electrical connections and splices in the building?). COALR and CU/AL devices
as a "repair" for aluminum wiring is discussed at ALUMINUM WIRING REPAIR, Other Products.
Photographs for recognizing aluminum electrical wiring hazards are provided at
How to Recognize or Identify Aluminum Electrical Wiring in buildings
Reducing the Fire Hazards in Aluminum-Wired Homes - 2007 Update, [large .pdf document], Jess Aronstein, Ph.D., 21 May 2007. This document answers most technical questions about the hazards and remedies of aluminum electrical wiring and includes
a report on independent test results of alternative products and methods for repairing aluminum wiring.
MAKE SPACE FOR ALUMINUM CONNECTORS discusses how to fit aluminum-to-copper connectors and copper pigtail wires into electrical boxes where space is limited.
ALUMINUM GROUND WIRES discusses the importance of including the aluminum electrical ground wire in the aluminum wiring repair procedure.
Frequently Asked Questions (FAQs) about the recommended ways to repair aluminum wiring: COPALUM or AlumiConn or rewiring
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Technical Reviewers & References
Related Topics, found near the top of this page suggest articles closely related to this one.
- AlumiConn website - http://www.kinginnovation.com/products/alumiconn/ has installation videos, Wire combinations, specification sheets, and other information and assistance in purchasing or using this product.
- [1] AlumiConn™ AlCopStore.com
223 Salt Lick Road, #279,
St. Peters, MO 63376
Tel: 866-826-2256, Fax: 636-754-0500, Email Sales: pking@AlCopStore.com, Email General Inquiry: info@AlCopStore.com
- [2] "Repairing Aluminum Wiring," [As updated 2011] U.S. Consumer Product Safety Commission Publication CPSC#516 available online
- [3] "Record of Commission Action, Commissioners Voting by Ballot", CPSC Publication No. 516, Repairing Aluminum Wiring (original version op.cit.), (Briefing package dated March 15, 2011), Quoting:
The Commission voted unanimously (5-0)·to approve republication of CPSC Publication No. 516, Repairing Aluminum Wiring, with the explicit recognition that the COPALUM and AlumiConn connectors currently are the only products that meet the agency's standards to prevent aluminum wire fire hazards
Copy on file as /aluminum/Pub516_Alumi_Conn.pdf
- [4] Dr. Jess Aronstein, protune@aol.com is a research consultant and an electrical engineer in Poughkeepsie, NY. Dr. Aronstein provides forensic engineering services and independent laboratory testing for various agencies. Dr. Aronstein has published widely on and has designed and conducted tests on aluminum wiring failures, Federal Pacific Stab-Lok electrical equipment, and numerous electrical products and hazards. See Aluminum Wiring Bibliography and see FPE HAZARD ARTICLES, STUDIES for examples.
- [5] "The Influence of Corrosion Inhibitor and Surface Abrasion on the Failure of Aluminum-Wired Twist-on Connections",
Aronstein, J.; Campbell, W.,
Components, Hybrids, and Manufacturing Technology, IEEE Transactions on
Volume 7, Issue 1, Mar 1984 Page(s): 20 - 24
- "Aluminum Wiring: Understanding the Problem and Its Solutions", Hartford Insurance Company - NOTICE: this information contains technical errors and some obsolete information. We include the document reference as an indication of insurance companies who are aware of aluminum electrical wiring hazards and costs. Local copy.
- 05/21/2007 Reducing the Fire Hazards in Aluminum-Wired Homes, [.pdf document], Jess Aronstein, Ph.D., 21 May 2007. This document answers most technical questions about the hazards and remedies of aluminum electrical wiring and includes
a report on independent test results of alternative products and methods for repairing aluminum wiring. Some of the sections of this very thorough document are listed below:
- 02/09/2006Reducing the Fire Hazards in Aluminum-Wired Homes, Jess Aronstein, Ph.D., This older version of the above document also answers most technical questions about the hazards and remedies of aluminum electrical wiring
but lacks latest repair product testing such as the AlumiConn connector discussed above. Some of the sections of this very thorough document are listed below:
[UPDATED-DF 03/08/2003, Edits-df 02/09/2006]
Pigtailing using COPALUM - CPSC recommended,
Pigtailing using Scotchlok 3M - superceded by new alternate repair as of June 2007 - a tested, useable aluminum wiring connector method, with a link to step-by-step "how to" photos,
Pigtailing using Ideal 65 - NOT RECOMMENDED, aluminum wiring failures research, field and lab experience, expert sources.
- WANTED: Aluminum Wiring Field Reports, Photographs, Samples, & Failure Cases & Data for ongoing study on frequency and severity of occurrence of problems.
If you have experienced any problem, or symptom of possible problem with aluminum electrical wiring, or have repaired or replaced it, please contact Daniel Friedman. All information is confidential.
Study results will be provided to the U.S. Consumer Product
Safety Commission and to the electrical industry. Real life aluminum wiring field failure reports can be seen at Aluminum Wiring Failures in Residential Properties: Field Reports & Pictures.
Books & Articles on Building & Environmental Inspection, Testing, Diagnosis, & Repair
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