Copper Clad Aluminum Wire Question | DIY Solar Power Forum

So, being that new guy, I've messed up and now I am wondering how much work I need to do to fix it. I'm building a simple camping trailer with a small solar setup. I bought and ran some 12 gauge wire behind the walls so that when I got to the electrical part I would have wire ready to go. I didn't know about the issues of copper clad aluminum until today and when I checked the wire I bought that is what it is. The wires I ran are only for led lighting and a ceiling fan so they won't be running many amps. What I'm wondering is- for that sort of usage do I need to replace that wire or can I get away with using it in that application? Any help is appreciated. Thanks!

Thanks for bringing up the considerations on the devices and the noalox. I wish I had known more when I started...

Noalox isn't needed much anymore. A newer aluminum alloy is used now when making wire, that prevents corrosion at connections. They guy in the video talks about it, and I've heard it at work before as well.


I accidentally used some mis-marketed copper-clad aluminum ( 10awg, 200c silicone, InstallGear brand) for my solar panels, and my "solar box" internal wiring. It worked perfectly fine, no corrosion on charge controller or terminal contacts, no loose crimps or screw connections, and because it still met spec for my amp ratings, it never even got warm.

Aluminum wire is fantastic (light and cheap), as long as you keep it within it's rated limits. The electric companies use it for good reason. From personal experience with 45 year old aluminum house wiring, just say no. I rented, but before you buy a house 40 to 50 years old, always verify that copper wiring was used. I see this "stop using noalox" video every time the subject comes up. Certainly there are electricians that use too much, but if you want the connection to last, make your own choice. Daly uses it to attach the high current cables, obviously they haven't watched the video.

Of course most of us aren't wiring houses, even if we were, we hopefully aren't using aluminum wiring. Battery terminals are not made of the special aluminum alloy, so a $3 tube seems prudent, others obviously feel different. The problem is real, it's well documented, there is actual scientific research, and just because someone makes a YouTube video doesn't mean they are an expert. Will recently did a video on wiring materials, and he points out the big reason why not to use it.
Thermal expansion.
Aluminum expands at a different rate than brass or copper, and it expands MORE... so, when heat, either from the load, or environment, the aluminum will expand more than the connections, it will loosen the connections over time, and it WILL cause resistance issues.
In a climate controlled home, the issue is small, but still many houses burned down because of it.
In a mobile situation... no way would I allow aluminum wiring to remain.

when it comes to wiring one thing to watch out for is that many outlets/devices/etc. are actually labeled "copper only"!!
CCA is defineitely not copper so do you need to use noalox on each connection?
This is why I avoid the stuff as it just seems to cause questions that lead you down a rabbit hole.

I think the purpose behind cladding it in copper is to make it unnecessary to take the same precautions as with pure aluminum. From the Amazon and Ebay sellers perspective, it makes it easier to sell since many people won't notice or know to look for it.

So, being that new guy, I've messed up and now I am wondering how much work I need to do to fix it. I'm building a simple camping trailer with a small solar setup. I bought and ran some 12 gauge wire behind the walls so that when I got to the electrical part I would have wire ready to go. I didn't know about the issues of copper clad aluminum until today and when I checked the wire I bought that is what it is. The wires I ran are only for led lighting and a ceiling fan so they won't be running many amps. What I'm wondering is- for that sort of usage do I need to replace that wire or can I get away with using it in that application? Any help is appreciated. Thanks!

If access is still easy then by all means replace. Otherwise the hazard is extremely small for low power lights etc. Long term effect will be the light does not come on and you tighten the connection. If this is 12v wire, no concern.

I have a home that was built in the late '60s with aluminum wire (thanks to the copper shortage during Vietnam war) and it has been fine. Home has been in the family since new. Maybe two connections have had to get attention and the rest still works. Have a condo with aluminum to the range and dryer and both have had no issues in 40 years. OK mobile environment is a bit different but not that much for the wires.

So, being that new guy, I've messed up and now I am wondering how much work I need to do to fix it. I'm building a simple camping trailer with a small solar setup. I bought and ran some 12 gauge wire behind the walls so that when I got to the electrical part I would have wire ready to go. I didn't know about the issues of copper clad aluminum until today and when I checked the wire I bought that is what it is. The wires I ran are only for led lighting and a ceiling fan so they won't be running many amps. What I'm wondering is- for that sort of usage do I need to replace that wire or can I get away with using it in that application? Any help is appreciated. Thanks!

I also made the same mistake when running 12g cca. wire for my trailer conversions led lighting. Didn’t take notice until things were all buttoned up? Low power usage so I wasn’t going to take things all apart to replace them with pure copper.
I did replace a couple of them that will be using higher power (Bpap assy outlets and dc compressor fridge) with 10g pure copper wire though.
I don’t turn on all of the low wattage led lights at the same time, no need so I’m not real concerned about the 12g cca wiring.

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THERMOPLASTIC INSULATION

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THERMOSET INSULATION

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