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How to change 120 Volt subpanel to 240 Volt subpanel |
 Multimeter Connect multimeter leads to wood sticks. Keep hands away from power. Test for breaks in wire or Test for voltage, amperage, resistance etc. Voltage is tested across two separate wires. Ohms is tested across both ends of same wire. Amperage is tested along two points on same wire. Typical appliance and electronics require 80% rated voltage to function correctly. Buy Analog multimeter Multimeters at Amazon Klein multimeter Electric testers at Amazon Clampmeter for testing amp flow on line Resource: How to test and replace element How to test thermocouple Element tests for 120 volts How to test wire |
Safety
when testing wires:
Never touch wet or previously flooded appliance. Never stand on wet surface when working on electric. Never stand on bare soil, put down dry boards. Tape tester leads to wood sticks to keep hands away from power. Use non-contact voltage tester before touching wires. Never touch or lean into any made of metal. Remove metal objects from pockets. Do not use oxygen or fuel accelerants in same room as electrical repairs Resource: Basic house wiring   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 Pro linesman plier Needle nose pliers End cutting nippers at Amazon |
 Non-contact voltage tester Test for power without touching connectors NEVER assume power is OFF Buy: Non-contact voltage tester Amazon Electric testers at Amazon Resource: How to test electric power is off  Insulated
lever switch on outdoor lightsOperate outdoor toggle switch safely ... and easily Replaces outdoor cover. Install over top of ordinary toggle switch. Works with single-pole, double-pole, 3PST, 3-way, 4-way switches etc. Buy: Best choice: Cantex lever switch Outdoor lever switches at Amazon |
 Indoor: Install between 2x4 studs or surface mount. Must be attached to structure, and grounded.. Keep enclosure door closed. Buy Indoor 120-240 volt: 100 amp 6 space 125 amp 8-space 125 amp 20 space 125 amp 24 space Main lugs/ subpanels |
 Outdoor: Install above anticipated snowfall ... away from direct sun and exposure to physical damage. Must be grounded. Must be attached to structure. 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 |
 Load centers with main breaker 120-240 Volt with breakers. Install between 2x4 studs, flush with finished surface. Must be attached to structure and grounded. Buy main load center: 200 amp INDOOR 30 space HOM 125 amp outdoor 12 space |
 Outdoor subpanels with space for breakers, timer, switches, outlets, GFCI, low voltage transformer etc/ 120-240 Volt. Flush mount, widths vary. Must be attached to structure and grounded. Resources: 60-125 amp with & without timers With freeze protection panels for pools How to wire control centers |
 3-phase subpanel W and w/o main breaker Not for residential installation Commercial 3-phase panels are made for 3-pole, 2-pole and 1-pole breakers. Rated for any service up to 600 volt. Buy: Siemens 3 phase load centers 24 space 125 amp 24 space 125 amp 3-pole breakers Resources: 3-phase Wiring Difference between single-phase and 3-phase |
 QP-type 1" wide Push down breaker Plug-in breakers Breakers can get warm, but should never be hot. If breaker is installed on damaged busbar, it will arc and overheat, causing breaker to trip and eventually melt the busbar. Do not install a breaker that is rated for fewer (less) amps than Load. Look at rating plate on each Load that is on the circuit, divide total wattage on circuit by voltage to find amps. 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 subpanels above Fits residential/ commercial panels Attach screws very tight against solid copper wire. Do not use stranded wire. Attach short jumper of solid wire to stranded wire and then put solid under screw terminals. Match breaker amp rating with wire size. Note: each side of a double 20 amp breaker is 20 amp. Buy double-pole: Siemens 15-125 amp Square D 30 amp breaker Double pole GFCI |
 Breaker base/ repair existing subpanel ... or building a control box 60 amp 4 breaker 125 amp 8 breaker Buy: 124TP2608A 4 breaker spaces 124T2530A 8 breaker spaces Din rail mounted circuit breakers Din rail fuseholders  |
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How
to install 1" wide push-down breaker Push-down breaker Attach wire to breaker first. Make sure no insulation is under the screw plate. Solid copper wire only. Never use stranded wire. Do not attach more than one wire under screw terminal. Match wire and breaker size. Notch on breaker sits against rail or cleat Rotate breaker down to busbar Push breaker down over vertical busbar Buy single-pole: Siemens 15-60 amp Buy double-pole: Siemens 15-60 amp Resources: How to replace circuit breaker Match breaker and wire size |
 Household NM-B Wires are color-coded so inspectors/ electricians can easily identify which wire is used during construction |
Use
only 600 volt electric cable
Never use extension cord for permanent in-wall wiring. Do not use aluminum wire, unless breaker, subpanels and all devices are rated for AL. Best to avoid altogether. Do not splice aluminum and copper together. Aluminum is a fire hazard. Match wire size and breaker amp rating If your home was wired by professional electrician who pulled permits, then circuit breaker and wire size will match. If manufactured home or travel trailer has not been altered by homeowner then breaker and wire size will match. If breaker is oversized for wire... fire danger Breaker can let too much amperage onto the wire. Wire will overheat and can cause fire. Call electrician if you suspect wiring is not correct, Buy: Southwire Romex® wire at Amazon Resource: Match breaker and wire size |
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 Absolute
electrocution danger..Main breaker terminals are still Hot when main breaker is turned off. ... unless meter is pulled How to pull meter If you are not familiar with safe electric practice, best not attempt conversion. |
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Check wiring and circuit for 120 volt panel Step 1) Basic 120 Volt subpanel can supply power for 120 volt single pole breakers but not 240 volt double pole. Step 2) Inside the main circuit breaker box, identify single pole breaker supplying power to 120V subpanel. Note the amperage of breaker and wire size. Example illustration shows 30 amp 120 volt single pole breaker. Step 3) Important: Identify if other 120Volt outlets and switches are on same circuit ... does the 30 amp single breaker inside main panel supply power to anything other than the subpanel? Turn breaker OFF, and check which outlets and switches are on that breaker. It is against code if 20 amp switches, outlets etc are connected to 30 amp breaker. A 30 amp breaker can only be used for 30 amp outlets, switches, and other 30 amp loads like the subpanel, water heater etc. This means that single-pole breakers inside subpanel must be 20 amp, if they serve 20 amp outlets, switches etc Step 4) The change-over to 240Volt will NOT work if other 120 volt outlets and switches are on same breaker ... why? Because the circuit is going to be changed from 120 to 240 volt ... and those other 120 volt outlets and switches will be energized with wrong voltage. Step 5) If the breaker serves more than the subpanel, then a dedicated wire must be installed for the subpanel. |
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 Move wires inside subpanel
 Step 6) Move wires inside the subpanel to start the conversion to 240 volt. Add black tape to White wire that will be carrying voltage. This is a convention to notify that the white wire is not a Neutral. Step 7) The new 240 volt subpanel will not have a Neutral wire. Why? because the white wire is going to be converted from a Neutral to a Hot. No Neutral means No 120 volt inside the new 240 volt subpanel, and means that a 120 or 240 volt GFCI breaker cannot be installed inside the subpanel. However a new 240 volt breaker is going to be added inside the main breaker panel, and that breaker can be a GFCI. Resource: How to wire GFCI breaker Buy: 240 volt GFCI breaker GFCI circuit breakers Step 8) Tighten wires very tight using allen wrench or screwdriver as required. Use screwdriver that matches width of slot on screws so wires are thoroughly tightened. |
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 Larger image Change wiring inside main breaker box for 240 volt Step 9) If the new subpanel is going to be strictly 240 volt without 120 volt, then all that's needed is to move the white wire and add a double breaker. Step 10) Install 240V breaker. The changeover requires a new double breaker installed close to where the old single-pole was located. By code, the 240V breaker must be a single connected breaker, and not two independent 120V breakers, unless those breakers are connected by a bar. Why? Because a 240 volt breaker must trip both legs off during an insulation failure or overamperage event. If one leg trips, and other leg doesn't, it causes serious safety risk. Not enough space? Step 11) Make space for new double breaker. If the main breaker box or panel has no extra spaces for new breakers, then double up two lightly-used 120 volt onto a tandem breaker. The tandem uses 1 space for 2 circuits. Buy: Tandem breakers  Step 12)
Remove old single breaker and install double pole breaker. New breaker
must have same amp rating as single breaker ... and is required by code
to have properly sized wire to match breaker ... and that breaker and
wire match expected load. Resource: Breaker, wire, motor charts Note if the the breaker is 30 amps, then both sides of breaker are 30 amp. Step 14) Move black wire from the old single-pole breaker to new 240V breaker. Move white Neutral to new 240V breaker. Add black tape to any white wire that carries voltage ... this is a convention to notify when white is not used as a Neutral. Step 15) Review: 240V Subpanel will NOT work for 120Volt breakers since ground wire cannot be used as Neutral. It is against code, and dangerous to use ground wire as Neutral. (Or use Neutral as a ground) 120 Volt is NOT available in the subpanel using this diagram. Step 16) Safety: Wires cannot run over the top of breakers or busbars in either main panel or subpanel. If wires are too short, then add a length of wire and join with twist on wire connector. Wires can be over top of other wires, but not at the point where wires connect to busbars or breaker. Push all wires to sides of box. |
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Do you want both 120 volt and 240 volt inside subpanel? If both 120 and 240 volt breakers are needed inside subpanel, then a new cable with red, black, white and ground wires is required. The new cable would have 3 wires plus ground wire running between subpanel and main breaker box. This diagram on left has 10-3 wire from main breaker box to subpanel ... and carries 2 Hots, Neutral and ground wires for both 120 and 240 volt breakers inside subpanel. NOTE: Code requires Ground and Neutral wires to be connected to separate busbars inside both main panel and subpanel. Buy: Southwire 600 volt cable Ground bar with attachment screws Ground bars at Amazon |
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Add 240 volt GFCI breaker inside
main breaker box Outdoor circuits are always safer with GFCI protection, and GFCI installation might be required to meet local codes. Caution, only 1 GFCI per circuit. Illustration shows overview of main breaker panel and 2-pole 240Volt GFCI. Adding a GFCI inside main breaker panel will protect subpanel and every circuit connected to subpanel. The GFCI 240Volt breaker has white wire that connects to neutral busbar. Buy: 240 volt GFCI breaker GFCI circuit breakers  |
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More subpanel wiring |
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Pull
120 volt from 240 volt ... Siemens industrial transformers Inexpensive .... reliable ... requires enclosure 5.1 x 5.6 x 3.6 inches ; 3 pounds Different models have input for 120 with 24 volt AC output, input for 240 with 120 volt output ... or input 480 volt with 240 volt output. Outputs are AC. When ordering: "If the dual voltage is separated by an “X” (120 x 240), the transformer can be connected only for 120 volts or 240 volts. But, if it is separated by a “slash” (120/240), an additional Neutral connection is possible since the mid-point becomes available for 240/120 3-wire operation." Resource pdf pg 4 Buy: Buy: Siemens industrial transformers Choose enclosure that is large enough Bud industries hinged box 6x8x4 Metal outdoor Enclosure/ with 1/2-3/4" knockouts Polycarbonate enclosures drill for knockouts Thomas and Betts 6x6x4 plastic with cover at Amazon Bud industries 11x7x5 box no knockouts Tapered drill bit 1/4"-1-3/8 holes  Example Nema 3R indoor outdoor enclosures   Resources: Siemens control transformers Siemens transformers |
  Example
wiring diagram for transformerIf the input voltage is 220-230-240 volt, then connect one wire to terminals H1 and H3, connect other wire to H2 and H4. Output on X1 X2. Optional fuse clip. If input voltage is commercial 440-460-480 volt (480 for Americas), then connect one wire to H1 and other wire to H4, then jumper a wire between H2 and H3. Larger image of transformer Buy: Siemens MT0050 industrial transformer Note: 60 Hz Hot to Hot 240 volt is for power grid in Americas, 50 Hz Hot to Neutral 230 for Europe, and 50 Hz Hot to Neutral 220 for Australia etc. |
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| 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 / 120-240 volt 30 amp outlet can be installed on 30 amp breaker only/ use 10 gauge wire ... cannot be connected to 15-20-40 amp breaker.  Orange/ #10 gauge wire, with ground ... 30 amp capacity. Safe maximum: 30 x 80% = 24 amps. Buy: 10-2 gauge/ 30 amp 10-3/ 30 amp Southwire electric tools |
Yellow
12 gauge 20 amp 120 volt 20 amp outlet can be installed on 20 amp breaker, but not 15 amp breaker/ use 12 ga wire. ... cannot be connected to 30-40 amp breaker.  Yellow/ #12 gauge wire, with ground ... 20 amp capacity. Safe maximum 16 amps. 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 120 volt 15 amp outlet, AFCI, GFCI, timer, switch etc can be installed on 15 or 20 amp breaker. Never connect 15 gauge wire to 20-30-40 amp breaker.  White/ #14 gauge wire, with ground ... 15 amp capacity. Safe maximum 12 amps. Buy: 14-2 gauge/ 15 amp 14-3/ 15 amp NMB is house wiring UF is underground |
| 50-60
amp breaker use 6 gauge / 240 volt 50 outlet can be installed on 50 amp breaker only  Buy: 6-2 wire Southwire electric tools NMB is house wiring UF is underground |
40-50
amp breaker use 8 gauge / 240 volt 40 amp outlet can be installed on 40 or 50 amp breaker only  Buy: 8-2 wire Southwire electric tools NMB is house wiring UF is underground |
  Copper ground wire. Every device, load, metal enclosure etc must be grounded. Ground wire must be continuous throughout installation, never switched on-off, never used as a Neutral wire. Generally ... 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 |
 Armored cable can be used as a grounded connection, and will protect wires from damage. Metal can be energized from an insulation failure. Non metallic flexible cables must carry ground wire, but does not have hazard of short circuit causing injury from shock. All conduit ...metal, plastic ... flexible and rigid ... must be attached to structure, and attached to enclosures, boxes. Movement, damage and deterioration are major cause of electrical failure. Buy: Armored cable Southwire armored cable cutter Non-metallic flexible conduit Power whip Pull boxes |
 Electrical tools must be insulated. Always best to disconnect power, but issues of insulation failure, lack of proper grounding, lack of GFCI, out-of-code wiring, generator operating without transfer switch, and other problems pose a risk to anyone working on electric power. Buy: Electrician tools kits Klein tools Tools kits |
 12 ga Stranded wire is good for conduit with multiple wires ... but stranded cannot be installed under screw terminals on outlets, switches, timers etc without risk ... of heat causing splayed strands ....that come loose ... and begin to arc. Connect stranded to short piece of solid copper wire, and attach solid to screw terminal. Do not solder residential or commercial wiring. Buy: Rolls of stranded wire |
 Protect wiring from damage Use nipper instead of pliers or screwdriver for removing staples (and nails). Do not damage cable or wires inside cable. -Code says: Cable SHALL BE secured without damage to the outer covering. NEC sec. 336-15 Buy End cutting nippers at Amazon |
 Electrically insulated tools When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistances and heat on wire and creates possible weak point. Buy tools: Wire strippers at Amazon Linesman pliers Utility knife at Amazon |
 Multimeters Voltage is tested across two separate wires. Ohms or resistance is tested across both ends of same wire. Amperage is tested along one or two points on same wire. Buy: Analog multimeter Multimeters at Amazon Klein multimeter Electric testers at Amazon Clampmeter for testing amp flow on line |
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Convert 240 volt to 120 volt
using step down
power transformers Reliable ... efficient ... no moving parts ... years of service ..... requires enclosure 5.1 x 5.6 x 3.6 inches ; 3 pounds Connect 240 volt incoming voltage to Primary side, connect 120 volt output wires to secondary side. Inputs and outputs are AC. How to wire power transformer: Incoming 240 volt, one hot wire to H1-H3 and other hot wire to H2-H4. 120 volt output comes from X1 and X2 terminals. Cartridge fuse installed for N/A-X1. "If the dual voltage is separated by an “X” (120 x 240), the transformer can be connected only for 120 volts or 240 volts. But, if it is separated by a “slash” (120/240), an additional connection is possible since the mid-point becomes available for 240/120 3-wire operation." Resource pdf pg 4 Buy: Siemens industrial transformers Choose enclosure that is large enough Bud industries hinged box 6x8x4 Metal outdoor Enclosure/ with 1/2-3/4" knockouts Polycarbonate enclosures drill for knockouts Thomas and Betts 6x6x4 plastic with cover at Amazon Bud industries 11x7x5 box no knockouts Tapered drill bit 1/4"-1-3/8 holes Example Nema 3R indoor outdoor enclosures  |
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Encapsulated step down
Transformers Convert 240Volt to 120Volt without neutral wire from breaker box Buck-boost transformers buck voltage down, or boost voltage up. This transformer bucks down voltage. Convert 240Volt to 120Volt without neutral wire from breaker box. Convert 480Volt to 240Volt or 120Volt Type 3R outdoor enclosure Wiring: 480Volt input connects to H1 H4, and then H2 and H3 are connected together 240Volt input connects to H1 H4, and then H3 connects to H1, and H2 connects to H4 240Volt output connects to X1 X4, and then X2 and X3 are connected together 120Volt output connects to X1 X4, and then X3 connects to X1, and X2 connects to X4 Buy: Square D transformers Acme step down - 120/240 primary/ 120 240 secondary Resources: Acme (Hubble) T279740S specification sheet Match wire and breaker size How to wire a subpanel Read about household single-phase electricity Read about 3-phase How to wire 3-phase timers |
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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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Resource: Electricity: The grid is defined by three parts: transmission, distribution and end user. The following links show how it works Power plant to end user power pole Power pole to residential breaker box Power pole to commercial breaker box How to wire residential electric How to wire commercial 3-phase Why you need ground wire How to wire 3-phase timer 3-phase water heater |
 Contactors/ relays |
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