Aluminum Wire: Equivalent circuits, general case and newly made InspectAPedia® -
Why twist-on connectors for aluminum wire repair overheat and lead to failures when used for
copper to aluminum pigtailing as an attempt at aluminum wiring repair.
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Aluminum Wiring Repair Procedure - Page 6 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 describes hazards with existing 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.
Click on the thumbnail sketches below to see each full-sized illustration.
20. Here are the current paths in this type of connection. Each of the paths from wire to wire has some associated resistance. The direct wire to wire path has only contact resistance, while paths
through the spring sections have contact resistance as well as bulk resistance of the steel wire.
21. Here is the most general equivalent circuit for the twist-on connector
22. Because the spring scrapes and digs into the wires, the spring-to-wire contact resistance in the newly-made connections is extremely low. The equivalent circuit is then simplified to this form.
23. Combining the bulk resistance of the sections of the spring that are in parallel in the current path further simplifies the equivalent circuit for newly-made connections.
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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)
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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:
Electrical Panels, How to Inspect in Buildings, safety for electrical inspectors, electrical panel, fusing, wiring defects, defective products. Inspection Class Presentation
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