Aluminum Wire: "Special Service" connector failures (similar standard)
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Failures in twist-on connectors used for aluminum wiring repairs: This article continues the discussion of the inadequacy of UL Standard 486C for twist on connectors
if used for splicing aluminum to copper wires and adds that certain "special service" connectors
sold for this purpose, such as the Purple twist-on connector shown do not perform well in this
application.
Green links show where you are. © Copyright 2013 InspectAPedia.com, All Rights Reserved. Author Daniel Friedman.
Aluminum Wiring repairs using twist on connectors supported by UL486C & that Standard are Inadequate
This is the Aluminum Wiring Repair Procedure - Page 10 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.
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 aluminum wiring safety 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.
30. That testing of the type applied by UL486C is inadequate has previously been demonstrated by the Canadian "Special Service" twist-on connector.
These were qualified by tests essentially the same
as UL486C, but performed poorly in long-term tests within rated conditions. This one is starting to overheat.
31. This special service connector splice has overheated to the point of softening the wire insulation.
32. This special service twist-on splice between aluminum wire and stranded copper wire burned up.
Details are at IDEAL-65 Purple Twister and at ALUMINUM WIRING REPAIR NOT-Recommended
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Technical Reviewers & References
Related Topics, found near the top of this page suggest articles closely related to this one.
- [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
- [6] Thanks to reader Thomas Kremer
for suggesting clarification to this topic 08/09
- [7] Personal communication, Email, P. King to D Friedman, 3/10/2012 [copy on file AlumiConn_PK120310.pdf].
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