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Other Products Sold for Repairing Aluminum Wiring InspectAPedia®  -     Other products sold for repair of aluminum wiring connections: Caution - some of these products are not recommended or have been superceded by newer listed products This website answers nearly all questions about aluminum wiring inspection, hazards, repairs

Our site offers impartial, unbiased advice without conflicts of interest. We will block advertisements which we discover or readers inform us are associated with bad business practices, false-advertising, or junk science. Our contact info is at InspectAPedia.com/appointment.htm. Aluminum wire connections can overheat enough to start a fire without ever drawing enough current to trip a circuit breaker. © Copyright 2009 Daniel Friedman, All Rights Reserved. Information Accuracy & Bias Pledge is at below-left. Use links at the left of each page to navigate this document or to view other topics at this website. Green links show where you are in our document or website.

OTHER ALUMINUM WIRING REPAIR PRODUCTS: for Aluminum Electrical Wiring - Ideal 65 Purple Twister and Other Aluminum Wire Products/Articles

Currently-recommended aluminum wiring repair products & methods such as the AMP/TYCO COPALUM ^TM crimp connector and the AlumiConn ^TM connector, as well as other aluminum wire repair methods can be read-about at How to Reduce the Risk of Aluminum Wiring.

Aluminum Wiring Connectors or "repair methods" which are obsolete or which are not recommended, such as the Scotchlok ^TM 3M Special Method, and aluminum wiring connectors and repair methods such as the Ideal-65 ^TM Purple Twist On Connector, electrical switches and receptacles marked "COALR" or "CU/AL", or conventional twist-on wire connectors are described just below.

• Dr. Jesse Aronstein, "Evaluation of a Twist-on Connector for Aluminum Wire", Forty-Third IEEE Holm Conference on Electrical Contacts, Jan 1997, 0-7803-3968-1/97.
  [This article describes the Ideal Industries Ideal#65 purple "Twister" twist-on connector marketed as a repair/retrofit for residential aluminum wiring.--DJF]
  
  Abstract: A new type of twist-on splicing component for use with aluminum and copper wire combinations is tested to determine initial resistance, performance in a zero-current environment test, performance in a heat-cycle test, and portion of current carried by the connector's steel spring. The splices tested consist of two aluminum wires and one copper wire.
  
  The aluminum wire samples used for the test are of the types actually installed in aluminum-wired homes. Initial resistance is found to be relatively high, and there is a significant sample-to-sample variation. This reflects failure to consistently establish low-resistance wire-to-wire contact through the insulating oxide film on the wire. Results of the environmental and heat-cycle tests show deterioration of a significant portion of the samples.
  
  The splices made with this connector are also found to be sensitive to mechanical disturbance, such as applied in normal installation when the completed splice is pushed back in to the junction box. Based on the test results, it is concluded that this connector has not overcome the fundamental deficiency of twist-on connectors for use with aluminum wire applications. Keywords: aluminum wire, connectors, twist-on connectors, environmental test, heat-cycle test.

Harbor Freight's Aluminum to Copper Crimping Tool

Harbor Freight offers a hydraulic crimping tool advertised as usable for aluminum wiring repairs. The tool is displayed and sold only by Harbor Freight as the Hydraulic Wire Crimping Tool Model 66150. Harbor Freight is a large, long-established tool retailer (since 1978) retailing a wide variety of tools and equipment.

We recommend that you read the instruction manual for this tool (large PDF).

As of 7 Feb 2009 we don't know the approval status of this tool for aluminum wiring repairs.

We took a preliminary look at the Harbor Freight Hydraulic Wire Crimping Tool Model 66150 and also at the instruction manual, and we saw that HF advertises that this tool intended for connecting copper and aluminum wires. The text does not say that the tool is approved for joining copper to aluminum wires as is performed in the standard aluminum wiring repair procedure. But we may be interpreting the manufacturer's text more carefully than did their ad copy writer.

What we don't yet know about this aluminum or copper wire crimping tool:

• Who actually makes this tool - it is distributed exclusively by Harbor Freight http://www.harborfreight.com/ who sell a wide range of tools
• How much force the crimping tool exerts on the crimp connector, whether it is capable of performing the same connection cold weld as provided by the AMP TYCO COPALUM crimping tool
• Which crimp connectors this tool is designed to use - the manual does not specify any specific connectors.
• If TYCO has approved its use with the COPALUM connector or if there is another crimp connector that has been tested and found to perform acceptably with this tool
• If tool has been listed by UL or approved by CPSC for use for aluminum wiring repairs.
• If there are independent certifying tests of this tool and the performance of the connections it produces

What we have learned so far about this copper to aluminum wire crimping tool

The Harbor Freight Hydraulic Wire Crimping Tool Model 66150 instruction manual has some interesting paragraphs like

6. Refer to the wire manufacturer's instructions for specific crimping instructions prior to using this product.

That paragraph alone might exclude the use of this tool for aluminum-copper pigtailing repairs. There are no such instructions. The manual also, quite understandably, includes a general disclaimer:

We shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special or consequential damages arising from the use of our product.

Currently the only repairs that we recommend for aluminum wiring are those recommended by the US CPSC

• the AMP TYCO COPALUM™ connector- which requires use of their (costly or rented) crimping tool
• the AlumiConn™

both of which are described at HOW TO REDUCE THE RISK of ALUMINUM WIRING

Is this hydraulic crimping tool for copper and aluminum wires recommended for repairing aluminum wiring?

No.

But given the difficulty people in some areas have finding qualified aluminum wiring repair electricians, connectors, and tools, here some

IFs

• If this tool is or has been independently tested and demonstrated as capable of producing the same quality of connection as the two currently recommended connectors
• If this tool accepts the AMP TYCO COPALUM crimp connectors or another connector that is tested and recommended by the US CPSC (there are no others as of this writing)
• If this tool and the connections it makes have been or are tested independently and are then recommended by the US CPSC

THEN having another aluminum wire repair method would be a boon for the AL wire repair topic.

This tool is Distributed exclusively by Harbor Freight Tools®. 3491 Mission Oaks Blvd., Camarillo, CA 93011
800-444-3353. We recommend that before using it for aluminum electrical wiring repairs you call the company to ask the questions listed above.

Until those safety conditions are met we do not recommend any aluminum wire repair method other than those described at HOW TO REDUCE THE RISK of ALUMINUM WIRING. Using a non-recommended tool for repairing aluminum electrical wiring might be unsafe and might also create fire insurance issues with your carrier.

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• Dr. Jess Aronstein, Poughkeepsie, NY
• Hankey and Brown home inspectors, Eden Prairie, MN, technical review by Roger Hankey, prior chairman, Standards Committee, American Society of Home Inspectors - ASHI. 952 829-0044 - hankeyandbrown.com
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Use links just below or at the left of each page to navigate this document or to view other topics at this website. Green links show where you are in our document or website.

ALUMINUM WIRING HAZARDS & REPAIRS
ALUMINUM WIRE FAILURE REPORTS
ALUMINUM WIRE RISK
  Aluminum Wiring Safety
  Aluminum Wiring - CPSC Publication #516
HOW TO RECOGNIZE ALUMINUM WIRING
HOW TO REDUCE THE RISK of ALUMINUM WIRING
  HOW TO REDUCE THE AL WIRE RISK: DETAILS
  COPALUM ALUMINUM WIRE CONNECTORS
  ALUMI-CCONN ALUMINUM WIRE CONNECTORS
  ALUMINUM GROUND WIRES
  MAKING SPACE FOR ALUMINUM WIRE CONNECTORS
NOT-Recommended Repair Products
  CPSC Against Twist-On Aluminum Wire Connectors
  CPSC Letter Aluminum Wiring Connectors
  CPSC Twist-On Wiring Connectors Meeting Log
  Ideal 65 Connector for Aluminum Wire Repair?
  COALR & CU-AL Devices?
  Scotchlok 3M connector
  Aluminum Wiring Repair Methods - CPSC Meeting 9/28/95
BOOKSTORE - ELECTRICAL
DIRECTORY OF ELECTRICIANS - Aluminum Wiring
DIRECTORY OF ELECTRICIANS - FPE Zinsco
Aluminum Wiring Bibliography
Aluminum Wiring Notes for Home Inspectors

Books & Articles on Building & Environmental Inspection, Testing, Diagnosis, & Repair

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More Information on Building Diagnostic Inspections and Repairs

• The Aluminum Wiring Information Website Aluminum Wiring Hazards and Repairs: in-depth info, photos, documents. Main Page.
• The Aluminum Electrical Wiring Hazard Explained (in the document you are presently viewing)
• How to Reduce the Risk in Buildings with Aluminum Electrical Wiring - Overview of Acceptable Repair Practices (in the document you are presently viewing)
• Aluminum Electrical Repair Method Details - "How to" details, how to identify, COPALUM repair, alternative repairs, history, products, research, source of special AMP TYCO COPALUM connectors & COPALUM Electricians (in the document you are presently viewing)
• COPALUM Electricians: Sources of TYCO COPALUM -Certified/Trained Aluminum Wire Repair Services (in the document you are presently viewing)
• Other Products, Ideal 65 Purple Twister (not recommended), & other Aluminum Wire Products/Articles (in the document you are presently viewing)
• The Aluminum Wiring Bibliography: extensive resources on Aluminum Wiring
• Aluminum Wire Failure Reports & Photos: Real life aluminum wiring field failure reports
• Reducing the Fire Hazards in Aluminum-Wired Homes, Jess Aronstein, Ph.D., This document answers most technical questions about the hazards and remedies of aluminum electrical wiring. Some of the sections of this very thorough document are listed below:
• Fire Hazards With Aluminum to Copper Twist-on Connectors & Acceptable Aluminum Wiring Repair Practices Color Photos, Current Issues. 9/28/95 CPSC Meeting Minutes
• "Is YOUR Aluminum Wiring Safe?" article discussing safety claims made by some people without looking at the wiring, J. Aronstein, 11/21/95
• "Repairing Aluminum Wiring," U.S. Consumer Product Safety Commission Publication CPSC#516 available online
• * Safety Hazards and Safe Inspection Procedures for Electrical and Home Inspectors at Residential Electric Panels
• Electrical Panels, How to Inspect in Buildings, safety for electrical inspectors, electrical panel, fusing, wiring defects, defective products. Inspection Class Presentation
• Electrical System & Wiring Hazard Inspection, Detection, Cause, Remedy, Prevention - Main Electrical Page
• Directory of Home Inspectors accessible via Internet

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