Slide 1 Aluminum Wire Repair by Copper Pigtailing: Instructions and Illustrations

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Aluminum Wiring Repair Procedure - Page 1 Color photos and descriptive captions from CPSC Meeting 9/28/95. In this document aluminum wire twist-on connector failures and repair procedures are described, including aluminum wire repair methods which work and methods which do not work and are unsafe.

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A Description of Alumnum Electrical Wiring Repair Procedures, Which Repairs Work & Which Aluminum Wire Repairs Fail - US CPSC Presentation

Color photos of aluminum wire repair procedures, and photos of failed connectors are included. This document series describes hazards with existing aluminum wiring repair products, explains the aluminum wiring failure mechanism, and reviews recommended retrofit procedures including use of readily-available materials. This information was presented to the US Consumer Product Safety Commission by Dr. J. Aronstein, 9/28/95. The minutes of that meeting were obtained under the Freedom of Information Act and posted by Daniel Friedman January 1996.

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Slide 1 1. Commonly used instruction for pigtailing using twist-on connector. This instruction has been widely published and distributed by UL, by trade journals and instruction books, and in the National Electric Code Handbook. Since about 1985, until now, no twist-on connectors were listed by UL for this purpose.

Slide 2 2. Prior to 1985 most twist on connectors on the market were listed by UL as suitable for the purpose. The actual performance in this application varied widely, however, depending on the construction and installation method.

Slide 3 3. The pigtailing application works this way. A short copper wire is spliced to the aluminum circuit wire. The copper wire is connected to the device terminal. The pigtail splices carry full circuit current to downstream loads. With the best connector and method of installation, this could be a safe technique.


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