Wiring Difficulty

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Old 03-11-19, 03:22 PM
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Wiring Difficulty

I've run 2-2-2-4 direct bury aluminum wire 200 feet to a detached garage for a 240 V charging station. Problem is that the wire is so stiff, I can make the plug connection (not enough room to screw the plug to the weather proof box.) Can I splice (considering a Morris Inline Splicer) a more flexible wire to run to the box? Can I reduce the size of the wire at the splice?
 
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Old 03-11-19, 03:55 PM
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What size circuit is needed for the charger?
 
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Old 03-11-19, 03:59 PM
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You should get a bigger box. Note you are only allowed one feed to a detached structure so your cable should be going to a disconnect or panel first.
 
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Old 03-11-19, 04:36 PM
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You need to run the 2-2-2-4 to a subpanel that can handle that large wire and then go from the subpanel to the charging station using the wire size needed for the amp draw of the charging station. Is the 2-2-2-4 the only feeder supplying power to the garage?
 
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Old 03-11-19, 07:41 PM
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The 2-2-2-4 wires are dedicated to the charging station. There is other service to the garbage. I have a 60 A breaker in the main panel. The the charging station reduces that to the required 40A.
 
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Old 03-11-19, 07:53 PM
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You can have.only.one.source of power.to.the garage.
 
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Old 03-11-19, 08:39 PM
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You can have.only.one.source of power.to.the garage.
Only true if it is a detached garage. An attached garage can have many circuits to it.
 
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Old 03-11-19, 09:07 PM
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True, but O/P wrote:
I've run 2-2-2-4 direct bury aluminum wire 200 feet to a detached garage



Bottom line existing feed for lights and receptacles must be abandoned and a 100 amp main disconnect installed if one does not already exist.

Note #2 Al was never needed if 40 amps, only #6 AL on a 40 amp breaker and if the charger is 240v only only 2 conductors plus ground was needed. But that is moot since this is a detached garage and service may need to be increased. Of course if the loads in the garage are light the existing 60 amp feed might have been adequate for lights and receptacles if no other significant loads. O/P wrote:
There is other service to the garbage. I have a 60 A breaker in the main panel.
.
 

Last edited by ray2047; 03-11-19 at 09:55 PM.
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Old 03-12-19, 05:14 AM
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I would go with the subpanel route as this solves a number of problems in one step. You can terminate the large wire there, provide a disconnect for the building and provide a disconnect for the charger. This also allows you to meet the code requirement that any detached garage that has electricity must have at least one of each: general-purpose GFCI protected 120V receptacle, indoor switched light, exterior porch light at the human door.
 
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Old 03-12-19, 06:59 AM
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I'll assume the 2-2-2-4 is Mobile Home Feeder (MHF) so the protecting feeding breaker in the main panel is to be no larger than 90 amps. As said it will be best to have the MHF become the sole power feed to a subpanel in the detached garage. Now if the 2-2-2-4 is URD USE-2 only rated you have another problem because that type wire is not to enter a structure and must be terminated outside. Also either of these types of wire must be in conduit where above ground.
 
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Old 03-12-19, 10:26 AM
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Now if the 2-2-2-4 is URD USE-2 only rated you have another problem because that type wire is not to enter a structure and must be terminated outside.

I was wondering if anyone would mention that this might be URD and not MHF. If it is URD there is another problem in addition to not being able to be run inside a structure. 4-wire URD has 3 phase conductors and 1 neutral conductor, but has no grounding conductor. Typically 2-2-2-4 URD is a utility grade product used to feed a 3-phase 4-wire service/meter socket underground from the utility transformer.

The question to the OP is this, is this URD or MHF (Mobile Home Feeder)?
 
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Old 03-12-19, 11:08 AM
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URD can be used, the conductors used for the neutral and ground need to be remarked to the correct colors.
 
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