Mike Dolt Enterprises
Mike Dolt Enterprises
User: Marty Funkhauser, Location: The other side of aluminum
Asked on: Sunday, May 30, 2021 at 11:20 am EDT
Answered on: Thursday, June 20, 2024 at 11:16 am EDT
Question: If you come across an aluminum splice of lets say 5 #12s that you need to take apart for troubleshooting. The connection has an old wire nut on it currently that was probably installed in 1970s when the splice was made. You take the connector off separate the wires and do your testing. Now its time to put the splice back together what do you do?? The Ideal purple wire nuts say on the packaging not to use on aluminum to aluminum connections. Split bolts are usually rated for 2 or 3 wires. The standard wire nut in your pouch is for copper only. Multi tap connectors take up a lot of space in lets say a two gang plastic box. Now what
Recommended Method
Use a Listed Aluminum Splice Connector
Look for a connector specifically designed for aluminum-to-aluminum connections, such as: Ideal 45-840 Aluminum Split Bolt Connector Burndy YAAL Series Split Bolt Connector Ensure the connector is rated for the number of wires and wire size involved.
Alternative Methods
1. Soldered Connection
Clean the wire ends thoroughly. Tin the wire ends with solder. Twist the wires together and solder the connection. Insulate the connection with heat shrink tubing or electrical tape.
2. Mechanical Crimp Connector
Use a crimp connector designed for aluminum wires. Insert the wire ends into the connector and crimp it securely using a dedicated crimping tool. Insulate the connection with heat shrink tubing or electrical tape.
3. Insulated Butt Connector with Heat Shrink Housing
Insert the bare wire ends into an insulated butt connector. Crimp the connector securely. Slide the heat shrink tubing over the connector and heat it with a heat gun to seal the connection.
Note: Do not use wire nuts on aluminum-to-aluminum connections. Always refer to the manufacturer's instructions for proper installation and safety precautions.* When troubleshooting aluminum splices, use caution as they can become loose and corroded over time. Flag for review