Electrical – How to handle 4 wires using 3-port AlumiConn connectors

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I'm rewiring outlets and switches in our 1960's California home using AlumiConn connectors to connect the aluminum wiring to copper pigtails. Most cases are straightforward, but I've run into a case where a box (a double-sized box, thankfully) includes a joint of the neutrals of 4 aluminum wires (10 gauge each). AlumiConn's only come with a max of 3 ports.

What is the correct way to handle 4-wire connections? Is it correct to daisy chain the AlumiConns?

Lacking any other instructions, my instinct would be to wire them like this, but I don't know if this is acceptable, safe or correct:

  AL  AL      CU      AL     AL
  |    |   ,------.    |     |
  |    |   |      |    |     |
,--._,--._,--.   ,--._,--._,--.
|  AlumiConn |   |  AlumiConn |
`------------'   `------------'

Best Answer

You have two options here

You have two options here. Either you can daisy-chain AlumiConns as you describe, using 12AWG copper THHN for the jumper wire, or you can use a single Al/Cu rated mechanical tap connector (often called "Polaris connector") rated for the wire sizes in question (the smallest size you'll find can take anywhere from 14 to 4 AWG), provided the latter will fit into the box. An ILSCO PBTS-4-4, for instance, takes up about 2" by 1.3" by 1.4" (LxWxH) and requires a torque setting of 20 in-lbs for 14-10AWG wire. Either way, you'll need to torque these connections correctly, as you are already doing with your existing AlumiConns.

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