ECN Forum Forums General Topics of the Trade General Discussion Area Aluminum to Copper Connectors

Who says you can't make splices in the panel? Some times you have to and I don't know of a specific code prohiting splices in a panel.

We use the CU/AL wire nuts for temp repairs only, and recommend the customer rewire. The AMP tooling is the only approved method of permanent repairs; however try to get this tool in the box to make a proper splice and you will qualify for doing brain surgery. The use of pigtails can make more problems occur. Just moving the existing alum wire can damage it. You may want to check some of the back issues of news papers there are some real horror stories out there.
We had one here in North Jersey last year.
The home was a total loss and the family never made it out. They said the wiring was mixed copper and alum. So be cautious when you take these jobs.
LK

Electric Eagle,

As far as I know panels are not to be used as junction boxes, which includes splicing wires.

Some good points were made, I may have to just pass this one up.

There is no problem with splicing in panels as long as you don't fill the panel with splices. (Not very technical but it's early) As far as replacing the wiring read the link that Bill has up there and you may think differently. To me only options are replace wiring or use the COPALUM repair system. I wouldn't do anything else. I have to trust the CPSC and as they would likely have more info on this application than any of us. Again try to convince them of the hazard, if they can't see it tell them you are not comfortable with a band aid approach and walk away!

According to the U.S. Consumer Oroducts Safety Commission (CPSC), Tyco Electronics' COPALUM crimp connector repair system, which uses a cold weld to attach a copper wire to the old aluminum wires, is the only system that has been recognized to provide a complete and permanent repair.

To insure that repairs are properly made, the system's connector repair materials and power crimpimg tools are available only to electricians who receive training from the manufacturer.

Without the Tyco system, the only way to safely upgrade aluminum wiring systems is to install new copper circuits.

Rowdy

Splicing in, and using a panel as a raceway is permitted.

In the 2002 NEC you can find this at 312.8 but this is not a new code, just relocated.

You can also look at 404.3(A) and 404.3(B) this ends up pointing you back to 312.8

[This message has been edited by iwire (edited 05-03-2003).]

FOR IMMEDIATE RELEASE
May 1, 2003
Release # 03-120 CPSC Consumer Hotline: (800) 638-2772
CPSC Media Contact: Scott Wolfson, (301) 504-7051
Tyco Electronics Media Contact: Paul Lavenberg, (717) 592-2409

May Is National Electrical Safety Month: Good News for Homeowners - Aluminum Wiring Fix Still Available
WASHINGTON, D.C. - The U.S. Consumer Product Safety Commission (CPSC) announced today that Tyco Electronics Corp., of Harrisburg, Pa., has agreed to continue offering the COPALUM connector repair system until at least 2005 for homes with aluminum wiring. The COPALUM repair system has benefited tens of thousands of consumers by reducing the risks of dangerous overheating and fire that can be caused by failing aluminum wiring connections. It is estimated that 2 million homes were built with aluminum wire between 1965 and 1973.

Warning signs, such as warm-to-the-touch face plates on outlets or switches, flickering lights, circuits that don't work, or the smell of burning plastics, can indicate a fire hazard within 15- and 20-ampere aluminum wiring circuits. A failure in the circuits can lead to electrical arcing and a serious fire, which can spread within the walls of a home before being detected.

The COPALUM crimp connector, which has been available for more than 20 years, is the only system recognized by CPSC that provides a complete and permanent repair and reduces the fire hazard in aluminum wire circuits. The COPALUM connector system attaches a copper wire to the old aluminum wires and is then crimped together with a power tool, achieving a "cold weld" between the conductors. The "cold weld" creates a permanent bond that eliminates electrical arcing or glowing connections and creates a safer electrical connection at outlets, switches, lights, circuit breakers, and panelboard terminals. The COPALUM connector repair materials and power crimping tools are only available to electricians who receive training from the manufacturer, to ensure that repairs are properly made.

"CPSC appreciates Tyco's commitment to protecting the safety of consumers by continuing to offer COPALUM connectors," said CPSC Chairman Hal Stratton. "Without the Tyco Electronics system, the only method for safely upgrading aluminum wiring systems would be to install new copper circuits, which is often impractical for consumers."

CPSC believes that "twist-on" connectors, receptacles and switches and other devices that connect directly to aluminum wires, are an inadequate solution. The COPALUM crimp connector system provides a safe, permanent fix.

If homeowners are not certain whether their home has aluminum branch circuit wiring, they can look at the markings on the surface of the electric cables which may be visible in unfinished basements, attics or garages. Aluminum wiring will have "Al" or "Aluminum" marked every few feet along the cable. A home inspector or qualified electrician also can assist in identifying aluminum wiring. CPSC advises that consumers should not open the interior of the panelboard or circuit breaker compartment - this can expose live wires and pose an electrocution hazard.

COPALUM connectors are available from Tyco Electronics under the AMP brand. Consumers can check to see if the COPALUM connector system is available in their area by calling the company at (800) 522-6752. To order a list of authorized electricians in their area, consumers can write to: Tyco Electronics Corp., Attn: Aluminum Wire Repair Program, P.O. Box 3608, Harrisburg, PA 17105-3608. If no authorized electrician is currently located nearby, consumers can have an electrician interested in repairing their home contact the nearest supplier of AMP- brand COPALUM connectors for training and other repair information.

For more information about aluminum wiring and the crimp connector system, see "Repairing Aluminum Wiring" (pdf). Consumers can also obtain a free copy of this booklet by writing to CPSC, Washington, DC 20207.

Any estimates or ideas on rewiring with copper? Looks to be a lot of fishing through the walls.

aldav53:
I have only done 2 home rewires, not because of aluminum wiring though, we replaced bx and knob and tube. We charged T&M for both jobs because of the variables involved-possible cats in the walls, low attic space, and lots of wall fishes, etc...


[This message has been edited by fla sparkey (edited 05-03-2003).]