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How to install a subpanel / How to install main lug |
| Indoor subpanels are not
weathertight. They are generally
mounted between 2x4 studs. Install
1/2"-5/8" from wall so final
install will be flush with sheetrock. Outdoor subpanels can be used indoors or outdoors. Rated Nema 3R water-tight, outdoor panels are 'weather resistant' but not 'waterproof.' Locate 12" above anticipated snowfall. Best in sheltered, shaded area when possible. Never locate panel where equipment (forklift, lawn mower) can impact panel. Outdoor panels should be bonded to ground wire that is connected to nearby ground rod when required by code. Never touch or work on outdoor electric while standing on bare soil or wet surface... stand on dry 2x4s or plywood. Wear dry clothes. Turn off power to subpanel. Use non-contact voltage tester to determine if power is present. Outlets installed outdoor must have gfci protection. Basic installation Attach subpanel and wiring firmly to structure. Subpanel must have cover. Cover must fit flat against the panel, and door remain shut to avoid fire hazard. Attach wires to subpanel with wire clamp or conduit so wires cannot move ... wires and conduit must be attached to structure so they cannot pull loose. 240 volt breakers must be double-pole breaker with connected switches, and cannot be 2 separate single-pole breakers, unless the breaker switches are connected together. Each side of 30 amp double breaker is 30 amp (not 15 amp each). 3-phase panels are made for 3-pole breakers and 3-phase commercial application. Single phase 120-240 volt breakers, single-pole and double-pole, will fit into 3-phase panels. How to wire 3-phase |
 Buy indoor 120-240 volt: 100 amp 6 space 100 amp 8-space 125 amp 8-space 125 amp 8-space 125 amp 8-space 200 amp 20 space Subpanels at Amazon Main lug Up to 100 amps |
 Buy outdoor/ from my affiliate links: 120-240 Volt 70 amp 2-space 60-100-200 amp 2-space 125 amp 8-space Subpanels at Amazon Up to 125 amps |
 120-240 Volt with breakers Buy main load center: 200 amp 30 space HOM 125 amp 12 space |
 Outdoor subpanels with space for breaker, timer, switches, outlets/ 120-240 Volt. Flush mount, widths vary. Resources: 60-125 amp panels w/o timer 60-125 amp with timers With freeze protection |
 3-phase subpanel Not residential Buy: 24 space 125 amp 24 space 125 amp NOT residential 3-pole breakers Resource: 3-phase Wiring |
 QP-type 1" wide Push down breaker Plug-in breakers Buy single-pole: Siemens 15-60 amp Single-pole tandem breaker Tandem breakers Buy QO breaker 20 amp Square D |
 QP type 2" wide Push down breaker Plug-in breakers Fits residential panels Fits subpanels above Buy double-pole: Siemens 15-125 amp Square D 30 amp breaker Double pole GFCI |
 Breaker base 60 amp 4 breaker 125 amp 8 breaker Buy: 124TP2608A 4 breaker spaces 124T2530A 8 breaker spaces |
| Use only 600 volt wire. Lamp cord, extension cords are not rated 600 volt. Use copper wire only. Aluminum wire is fire risk and should be avoided or installed by professional. 30 amp breaker use 10 gauge /  Buy: 10-2 gauge/ 30 amp 10-3/ 30 amp Southwire electric tools |
Yellow
12 gauge 20 amp Yellow/ #12 gauge wire for 20 amp with ground Buy: 12-2 gauge/ 20 amp 12-3/ 20 amp NMB is house wiring UF is underground Rolls of stranded wire |
White
14 gauge 15 amp White/ #14 gauge wire for 15 amp with ground Buy: 14-2 gauge/ 15 amp 14-3/ 15 amp NMB is house wiring UF is underground |
 Buy: Armored cable |
 Southwire armored cable cutter Buy: Rolls of stranded wire |
Stranded wire  Buy: Rolls of stranded wire |
50-60
amp breaker use 6 gauge /  Buy: 6-2 wire Southwire electric tools NMB is house wiring UF is underground |
40-50
amp breaker use 8 gauge / Buy: 8-2 wire Southwire electric tools NMB is house wiring UF is underground |
  Copper ground wire Use same size as other wire in circuit Buy: 12 gauge copper ground wire Ground wire Green ground wire Ground pigtails Ground rods/ ground clamps at Amazon |
 Buy End cutting nippers at Amazon |
  When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistances on wire and creates weak point. Buy tools: Wire strippers at Amazon Linesman pliers Utility knife at Amazon |
 Buy: Multimeter Electrical testers |
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Wire size and motors/
120-240 volt The longer the wire must travel, the larger the wire must be to handle same amp load. This is especially important when calculating wire and breaker size for shop tools used inside a detached structure. Resources: Motor wire size and distance Figure volts amps watts |
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60
amp Subpanel / with 240Volt and 120Volt Use with both 240Volt and 120Volt breakers 1) 60-150 Amp breaker replaces any 240 breaker in main box near top of box 2) Two Hot wires connect to 60-150 Amp breaker in main breaker box. Either hot wire can connect to either hot busbar inside subpanel. 3) Neutral connects to Neutral busbar so subpanel can power 120 and 240 breakers. 4) Ground wire connects to Ground busbar. Ground busbar can be purchased separately. If Subpanel located at another structure, for example garage several hundred feet away, might be cheaper to use ground rod located outside other structure. If structure is farther than 140', then wire gauge increases from #6 to #4. Consult local electrician for correct gauge. Resources: See wire size chart Electrical formulas |
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Main
breaker wires are HOT when main breaker is OFF Main breaker wires are HOT when main breaker is OFF unless meter is pulled How to pull meter |
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150
amp subpanel/ with 240Volt and 120Volt 150 amp breaker uses #2/0 wire Neutral wire needed only if subpanel has 120Volt breakers/ or GFCI Ground wire required for all installations If panel will not have 120Volt circuits, then neutral wire not needed. Separate ground busbar not needed since ground wires can connect to neutral busbar Resource: Subpanel shown here is for installing while-house tankless electric water heater How to wire Tankless water heater |
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240
Volt
subpanel does not need Neutral wire
Neutral wire needed for 120Volt breakers, but not 240Volt 2 Hot wires arrive from breaker, and connect to Hot lugs This will energize both hot busbars Connect ground wire to silver busbar. Wires going to Load connect to 240Volt breakers When connecting ground wires to ground busbar, keep wires along edge of box. Wires cannot be put over the top of breakers or busbars Wires cannot lay over the breakers or busbars. Wires can lay over top of other wires, but not at point where wires connect to busbars. Lay all wires to sides of box |
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Neutral
wire needed in 240Volt subpanel when installing 2-pole GFCI breaker 240V GFCI has white wire. This wire must be connected to neutral busbar Wires going to Load connect to breaker in usual way, except there are 3 connection screws on 240 Volt GFCI Connect neutral going to Load to center screw on breaker... if Load has neutral wire available Connect Hot leads going to Load to other two screws on breaker (either wire to either screw) General rule/ Load neutral not required: The Load Neutral does not have to be connected to center pole on breaker. Buy from my affiliate links: Single pole GFCI at Amazon GFCI breakers at Amazon Double pole GFCI/ choose 15 to 60 amp/ at Amazon Resources: Wiring-GFCI.pdf How to wire GFCI |
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120Volt
subpanel illustration/ ...
install jumper over top of neutral busbar 1 Hot wire arrives from breaker Add jumper wire between Hot lugs This will energize both hot busbars so each breaker slot will work. Ground bar must be installed so Neutrals and grounds are separate Buy: Terminal ground bar at Amazon Ground bar with attachment screws Resource: How to change 120 volt subpanel into 240 volt subpanel |
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120Volt
subpanel with GFCI breaker
Neutral wire required for GFCI breaker Neutral wire required for GFCI outlet Do not put 2 GFCI on same circuit Buy: Single pole GFCI/ choose 15 to 30 amp/ at Amazon Resources: How to wire GFCI |
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Install
separate ground bar Main lugs and subpanel etc often do not have separate ground bar. Good electric practice requires separate busbars for ground wires and neutral wires. Install ground bar If subpanel is 240volt then separate ground busbar not needed. And ground wires can attach to busbar where neutral wires attach Buy: Terminal ground bar at Amazon Ground bar with attachment screws Ground bars at Amazon |
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| Do not bond (connect) Neutral and
ground together inside main lug, or subpanel. Why? Answer: Resistance on the ground wire. The purpose of the ground wire is to offer a continuous resistance-free route for electricity to reach ground (earth). Inside main breaker box, the Neutral and ground are bonded together because the ground busbar is directly connected to the ground rod. If you bond the ground and Neutral together inside a subpanel, it would be same as connecting the ground wire and Neutral wire at each light fixture or using ground wire for the Neutral. It would function of course, but add resistance to the ground. It would increase risk of fire and electrocution in event of a short. Overview: Grid transformers that supply power to each home have a neutral that is connected to ground. Every pole in the grid has a neutral that is connected to ground. Every main breaker box should have a neutral bonded to ground busbar that is connected to ground rod. Some older main breaker boxes use same busbar for both Neutral and ground, but codes have changed to help avoid hazards. So whenever there is a ground rod nearby, the neutral and ground are connected together. This mean if your subpanel is located outside or in a separate building where local codes require the box to be bonded to ground wire that is connected to ground rod, then you can bond the ground and Neutral busbars together. So proximity of the ground rod is the guideline for bonding neutral and ground. |
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Put electric meter on Subpanel Resource: New and used electric meters How to install electric meter on water heater How to get electric service |
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Square
D
60 amp/ 6-space/ Subpanel with 6 gauge wire Replace any 240V breaker with new breaker Or remove two 120V breakers to make room for new breaker. Normally, each 240V breaker serves 1 appliance. For example stove has 240V breaker. Water heater has separate 240V breaker. Air conditioner another 240V breaker. 240V appliances cannot be 'doubled-up' on a single 240 breaker. Each needs separate breaker. If there are no extra slots in breaker box, add a Tandem breaker. Also you can double-up two lightly used 120Volt circuits. Buy: Terminal ground bar at Amazon Main lugs (subpanels) at Amazon Resource: How to replace circuit breaker |
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Wire
size chart for distances up to 50 feet Resources: See rating chart with more sizes Rating chart with temperature, long length Select correct breaker and wire size Wire diameter, weight, resistance |
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Wire
color Black-black or Red-black is preferred for Hot wires White wire should be used for neutral wire only. If white wire carries power, then wrap black tape around wire to indicate that it carries voltage, and is not a neutral wire. Green or bare copper for ground. Green or bare copper for ground can never be used to carry voltage |
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Choosing
subpanel /or main lug Consider: Amp rating of panel Number of breaker spaces With Door / No door Weathertight or indoor (example shows indoor panel) Availability of breakers: Square D uses Square D breakers, etc Siemens uses Siemens breakers Buy: Main lugs at Amazon Siemens 125 amp/ 8 space at Amazon Siemens 125 amp/ 12 space at Amazon 100 amp 6-8 space/ indoor and outdoor 125 amp 8-12 space/ indoor and outdoor Terminal ground bar at Amazon Copper ground rod Ground rod clamp |
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Example
subpanel with 6 breaker slots See larger Subpanel with 6 slots. This panel accommodates three 240Volt breakers -or- six 120Volt breakers Resources: See amp - wire rating chart Color-code for household wires |
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 Subpanels available with or without timer(s) 4-8 spaces to mount circuit breakers 2-5 spaces to mount switches and GFCI outlets |
Outdoor
Subpanels with timers Can be used for any subpanel purpose located outdoor Subpanels available with or without timer(s)
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4 or 8
space breaker busbar Can be used for any subpanel Intermatic breaker bases: 124TP2608A 4 breaker spaces 124T2530A 8 breaker spaces at Amazon |
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Service
disconnect Buy disconnect from my affiliate links: 200 amp Circuit Breaker Enclosures 60-100-200 Amp outdoor service disconnect at Amazon 200 amp outdoor breaker enclosure 60 amp indoor flush mount breaker enclosure Buy: Meter box to install meter Once meter box is installed, the electric company installs their meter. Or if you are installing a meter for rental property attached through your house voltage, you can install your own meter Buy: Ground busbars at Amazon Copper ground rod Ground rod clamp Ground rod driver |
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 Bond solar panel to ground wire that is connected to ground rod |
Bond outdoor
panels to ground rod All phone, satellite, pool equipment, solar systems and electric panels must be grounded. Check local electric codes. What does this mean? Bonding is the connection of metal to a ground wire that is in turn connected to a ground rod driven into the earth to a depth that meets local codes for grounding. Drive ground rod 8-10 feet into soil as per local code. Bond #6-8 bare copper wire to ground rod and to solar panels and pipes on roof. Do NOT ground electric system to water pipes. Ground must be connected to ground rod. Stray current corrosion can cause pipes to deteriorate. Uncertain bond to ground because of plastic pipes. Subpanels installed outdoors or in distant buildings should have a separate ground rod ... local codes vary. For example, outdoor pool equipment should have a separate ground rod. Satellite dish or antenna should have ground rod. All ground rods should be wired together if possible to give best protection from lightning and power surge. Buy: Ground rod and clamps at Amazon Bonding lugs Resources: Why you need ground Ground loop |
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Safety
switch Install safety switch next to any electric appliance HVAC requires safety switch or pull-out so service technician knows power is OFF Tankless electric requires safety switch when breaker box is not in clear sight line Machine tools generally require safety switch. Use fused or non-fused safety switches. Having two fuses, or fuse and breaker, or 2 breakers on same line is not a problem... as shown in illustrations above for wiring subpanels Note: having 2 GFCI on same line will cause GFCI to trip Buy: Safety switch Resources How to wire safety switch Related How to save hot water with mixing valve/ applies to any tank-type water heater Pro and con with mixing valve 9-ways to save with water heater |
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Installation
illustrations Buy tapered drill/ step drill bit for any size hole Step drill bits at Amazon Neiko tapered drill bit 1/4"-1-3/8 holes  |
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Electric
tools Buy: Linesman pliers Buy: Wire strippers at Amazon Buy: Crescent-brand end cutting nipper at Amazon End cutting nippers at Amazon Buy: Utility knife at Amazon< |
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 Photo shows typical residential breaker-types |
Example
circuit breakers Tandem circuit breakers give 2 separate circuits for 1 slot Tandem is for two-120Volt circuits because it pulls power from one of the how busbars. Tandem is not for 240V. Best practice: Use tandem breaker for two circuits that do not pull high amperage. For example, choose hallway lights and a bedroom for the two circuits, but not higher amp loads like dedicated microwave circuit and a 1/2+ Hp attic fan. Single-pole 20 amp breakers Double-pole 208-240Volt breakers Buy single-pole: Siemens 15-60 amp single-pole tandem breaker Buy double-pole: Siemens 15-60 amp |
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 Push-down type breaker |
Attach
wires very tight Only copper wire under screw No wire insulation under screw Double-pole breakers Double-pole 208-240Volt breakers must have connected switches so both legs are turned on-off at same time. It is not code to use two separate single-pole breakers for 208-240 volt circuits |
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Push-down breaker Notch on breaker sits against rail or cleat Rotate breaker down to busbar Push breaker down over vertical busbar BR type 1" wide breakers are usually used for residential applications Available local box store Buy circuit breakers: Siemens circuit breakers at Amazon Siemens single-pole 15-60 amp Single-pole tandem breaker Siemens two-pole 15-125 amp |
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Hook on breaker Either hooks or snaps over round rod Rotate breaker down to busbar Snap breaker down over bar Instructions for replacing circuit breaker: Turn off electricity > > remove wire from breaker > pull old breaker off busbar > grab switch and rock breaker back-forth > if needed, use screwdriver between breakers to gently pry up breaker > rotate out > remove other end of breaker off cleat or bar or metal rod > buy matching brand breaker > check busbar for damage > install new breaker onto cleat or bar > rotate breaker down to busbar > push new breaker firmly onto busbar > re-attach wire > tighten screw very tight against copper wire Resource: How to replace circuit breaker |
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 Review
basic 120Volt and 240VoltOrdinary Main panel for home has 120 volt and 240 volt circuits. This is called single-phase electric power. Phasing is determined by the power company. Each 120 volt circuit can include up to 12 outlets, and supply power to lights inside a room. - Generally each 120 volt circuit sends power to one area of home. The Hot and neutral and ground wires leave breaker box and travel to first junction box inside a room. From junction box, the wires split off and travel to each individual box, jumping from box to box until the final box is reached. So each box will have 1 black hot wire, 1 white neutral wire, and 1 ground wire that connect back to main breaker box. - Some circuit breakers are dedicated to 1 specific appliance. For example the kitchen microwave is usually wired to 1 circuit breaker and no other outlets or lights are connected to that breaker. This is because microwave draws so much amperage. That is called dedicated circuit, and dedicated breaker. Each 240 volt circuit is usually dedicated to one appliance. For example electric water heater is connected to 1 240 volt breaker. The electric dryer is connected to another 240 volt breaker. The heat/AC is connected to another 240 volt circuit breaker, and so on. Resources: See inside main breaker box How to replace circuit breaker Basic water heater circuit Figure volts amps watts for electric water heater |
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What is 3-phase electric: power plant to end
user Basic house wiring |
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Buy Industrial electric Industrial supplies Tools and home improvement Home and garden Hayward pool Pentair pool Southwire electric |
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Buy
Tools DEWALT Black and Decker Stanley SKIL Makita Porter-Cable Bosch Irwin Hand tools Klein hand tools Fluke electrical testing Dremel hobby tools Campbell Hausfeld air powered Tekton automotive Powerbuilt automotive Saws and saw blades |
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Resource: Compare box timers DPDT timers Intermatic Control water heater w/ Z-wave |
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Resource: Intermatic control centers: and parts Digital control centers and parts Tork control centers and parts Subpanels All control centers and parts Enclosures |
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Resource: Programmable timers Countdown timers Off delay timers On delay timers Timer modules Din rail Twin & one-shot Woods Intermatic Tork |
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Recirculation systems |
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