DIY Wiring Upgrade

COPALUM Crimps

• 1

  Head to the main breaker box. Turn off the breaker controlling the circuit of the outlet or switch you are upgrading.

• 2

  Unscrew the screw or screws holding the cover plate over the switch or outlet. Pull the cover plate off, exposing the inside of the junction box.

• 3

  Unscrew the two screws holding the switch or outlet in the junction box. Pull the switch or outlet from the junction box.

• 4

  Unscrew the black and white aluminum AC cables from the corresponding screws on the switch or outlet.

• 5

  Cut a 4-inch length of copper wire with the wire snips. Strip 1/2 inch from the outer insulation with the stripper tool.

• 6

  Place the crimp over the exposed copper and aluminum wires. Place the crimp inside the COPALUM tool. Squeeze the trigger to meld the two wires together. Repeat for the other lead in the box.

• 7

  Cut a section of heat shrink tubing for both leads inside the junction box. Make sure the tubing extends over each crimp by at least 1/4 inch.

• 8

  Turn on the heat gun. Shrink the tubing over each COPALUM crimp until it tightens over the surface of the compressed crimp.

• 9

  Screw the new copper pigtail to the screws on the switch or outlet. Screw the outlet or switch to the junction box. Screw the plate back on.

• 10

  Repeat the process for every switch and/or outlet that requires upgrading.

AlumiConn

• 11

  Turn off the breaker at the main electrical panel that powers the outlet or switch you are upgrading.

• 12

  Remove the wall plate and securing screws to expose the switch or outlet. Pull the outlet or switch from the wall.

• 13

  Unscrew the two screws securing the white, black and ground wire (if present) from the outlet or switch.

• 14

  Strip 5/16 inch of outer insulation from the white and black wires. Cut a 4-inch copper pigtail for the hot, neutral and ground wires. Strip 5/16 inch of insulation from one end of these wires.

• 15

  Unsnap the protective cover concealing the set screws in the AlumiConn connector. Loosen the screws sufficiently to accommodate the aluminum wiring protruding from the junction box. You will have a separate AlumiConn connector for the hot, neutral, and ground wires.

• 16

  Insert the black aluminum wire coming from the junction box into the first slot on one of the AlumiConn connectors. Repeat for the white and ground wires into the second and third connectors. Tighten the set screws in the connector until they come in contact with the aluminum wiring.

• 17

  Inspect the aluminum wires' labeling to determine the gauge. If the wires indicate "12AWG" or "10AWG," tighten each screw holding the aluminum wire in the connector one full turn in addition to the turns made to contact the screw with the wire. If the wires indicate "18AWG," turn the set screw a half turn more.

• 18

  Slide the copper hot (black), neutral (white) and ground (bare or green) pigtail wires into the second slot on the AlumiConn connectors. Observe carefully which aluminum wires are in which connector. Tighten the set screws as before. Snap the protective covers back down over the set screws.

• 19

  Reconnect the black wire to the brass colored screw on the outlet or switch. Screw the white wire to the silver-tone screw, and the ground to the smaller green ground screw.

• 20

  Reinsert the outlet or switch and install the protective cover plate. Turn on the breaker to test the circuit.