Splicing Aluminum Power and Control Wiring in an Industrial Plant
Splicing Aluminum Power and Control Wiring in an Industrial Plant
(OP)
We are replacing some Motor Control Centers at a plant that was wired with aluminum wiring for both the power and control. Some of the wires will be too short by 2 or 3 feet. They range in size from #12 to #350. Re-wiring the entire circuit with copper conductors is the last option.
We have considered butt splicing. Someone else suggested soldering, which I had not heard of. Any suggestions on the best way to make such a splice, or testimony to the reliability of a butt splice?
We have considered butt splicing. Someone else suggested soldering, which I had not heard of. Any suggestions on the best way to make such a splice, or testimony to the reliability of a butt splice?






RE: Splicing Aluminum Power and Control Wiring in an Industrial Plant
RE: Splicing Aluminum Power and Control Wiring in an Industrial Plant
RE: Splicing Aluminum Power and Control Wiring in an Industrial Plant
After a few years, almost any bending of the wire caused the conductor to break inside the insulation. During troubleshooting, we would lift a wire off a terminal strip to check for control voltage at the terminal and then replace the wire. That little bending action of lifting and replacing the wire would break the conductor enough to stop the circuit. Drove us crazy. Troubleshooting efforts created more problems until we did a 100% replacement with copper control wiring.
IMHO - Compression splices are the best way to go for the power cables.
RE: Splicing Aluminum Power and Control Wiring in an Industrial Plant
Was this stranded wiring?
RE: Splicing Aluminum Power and Control Wiring in an Industrial Plant
BTW - the plant was built in the late '50's and used aluminum as much as possible. In the mid '60's the company switched to using aluminum wire only in #6 awg and larger and later went to #1/0 awg and larger to avoid termination problems.
RE: Splicing Aluminum Power and Control Wiring in an Industrial Plant
Mechanical connectors are available for the #12. #10 and up have more compression choices.
RE: Splicing Aluminum Power and Control Wiring in an Industrial Plant
respectfuly