Aluminum Cable from meter to 100amp charger?

[F150LAQS]

My electrician's estimate includes aluminum over copper cable due to the cost. It looks like aluminum is durable/safe enough for 100amps, as long as you use the right size. Anyone else use aluminum for their charging setup? This is not a red flag, is it?

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[RickLightning]

If you're talking about the Ford Charge Station Pro, it specifically REQUIRES copper.

 

[Pioneer74]

You can run properly sized aluminum to a junction box close to the EVSE, but the terminals on the FCSP are rated for copper only.

 

[WhipSticks]

It would be considered standard practice to use Aluminum to a junction box near your charge station and only use copper for the last meter or two, as noted above. It is not a red flag if a box is included in the estimate.

 

[Maquis]

You need a disconnect near the EVSE anyway. Perfect place to transition from AL to CU.

 

[rraustad]

This is exactly why I like reading these posts. The disconnect, code compliant (line of sight) comment pulled it all together. Run whatever wire you want to the disconnect (assuming disconnect connectors allow that wire type) and then feed the FCSP what it requires. Gotta love these guys!

 

[Maquis]

This is exactly why I like reading these posts. The disconnect, code compliant (line of sight) comment pulled it all together. Run whatever wire you want to the disconnect (assuming disconnect connectors allow that wire type) and then feed the FCSP what it requires. Gotta love these guys!

A little more info.
The disconnect can be remote (not in sight) if it’s lockable and you post a sign at the EVSE noting the location of the disconnect. And it’s only required is your branch circuit is more than 60A.

 

[mme_and_lightning]

I used 100% copper to my subpanel and 100% copper to my FCSP.

I have no issues.

That's all I know. I do like that "I have no issues" and would do it again.

 

[WhipSticks]

A little more info.
The disconnect can be remote (not in sight) if it’s lockable and you post a sign at the EVSE noting the location of the disconnect. And it’s only required is your branch circuit is more than 60A.

Hmm... code says "lockable open". I interpret that to mean that it can't be locked shut (or otherwise made inaccessible.) Here is a scenario--and, I bet, a common one. Customer installs 80 amp EVSE in the garage, with a dedicated 100 amp line running from a basement mounted panel. The EVSE is hardwired directly from this line. You put up a plaque beside the EVSE that describes where the breaker is in the basement. Does this satisfy code? If "accessible" means that an owner or person otherwise responsible for the property can access the panel, then I think so. But if the term "accessible" is meant to cover use cases regarding emergencies related to charging (say a neighbor notes that your charge adaptor is smoking and you are out of the house, she tries to disconnect but can't access the basement because the doors are locked), then I would say this is problematic.

What do you think?

 

[Maquis]

Hmm... code says "lockable open". I interpret that to mean that it can't be locked shut (or otherwise made inaccessible.) Here is a scenario--and, I bet, a common one. Customer installs 80 amp EVSE in the garage, with a dedicated 100 amp line running from a basement mounted panel. The EVSE is hardwired directly from this line. You put up a plaque beside the EVSE that describes where the breaker is in the basement. Does this satisfy code? If "accessible" means that an owner or person otherwise responsible for the property can access the panel, then I think so. But if the term "accessible" is meant to cover use cases regarding emergencies related to charging (say a neighbor notes that your charge adaptor is smoking and you are out of the house, she tries to disconnect but can't access the basement because the doors are locked), then I would say this is problematic.

What do you think?

Lockable open does not mean that it cannot be locked closed. Generally, only disconnects for emergency equipment (fire pumps, for example) are locked closed.
Breaker locks are available for most modern panels, so that would comply.
”Accessible” just means you can get to it, nothing more. These terms are all defined in the NEC, chapter 100. Behind a locked door is still accessible. The term “Readily accessible” is also defined. Even then, requiring a key for access is acceptable under certain conditions.

 

[mme_and_lightning]

This is my experience. Not suggesting anything, just providing my experience.

Had the FCSP hard-wired directly from my main panel to the FCSP. Sunrun installed an open lock on the breaker. The breaker could not be turned off/on with the lock, the breaker was locked for power to the FCSP.

I had a wi-fi issue and Ford rep asked me to power cycle the FCSP. I had to remove the lock to power off/on.

The county inspector came to my home and I said I'm not sure how to replace the lock. The inspector said, "I see this all the time, but you don't need to lock the breaker open. You may need to cut power to the FCSP so I don't recommend putting it back. It is not a safety issue to not have a lock, but it could be safer to not have the lock so you can power down the FCSP."

I am confused to what is practical, safe, and necessary.

 

[Monkey]

You can run properly sized aluminum to a junction box close to the EVSE, but the terminals on the FCSP are rated for copper only.

Not just a junction box. Depends on local adoption of NEC and other factors, but the aluminum to copper transition usually requires a disconnect or sub-panel with separate breaker. But yes, aluminum from main panel to new sub-panel or disconnect and then copper the last few feet to the charger. This is definitely the way to do it if running any significant length.

I don't know of any EVSE on the market approved for connecting to aluminum wiring.

 

[Toby57]

Hmm... code says "lockable open". I interpret that to mean that it can't be locked shut (or otherwise made inaccessible.) Here is a scenario--and, I bet, a common one. Customer installs 80 amp EVSE in the garage, with a dedicated 100 amp line running from a basement mounted panel. The EVSE is hardwired directly from this line. You put up a plaque beside the EVSE that describes where the breaker is in the basement. Does this satisfy code? If "accessible" means that an owner or person otherwise responsible for the property can access the panel, then I think so. But if the term "accessible" is meant to cover use cases regarding emergencies related to charging (say a neighbor notes that your charge adaptor is smoking and you are out of the house, she tries to disconnect but can't access the basement because the doors are locked), then I would say this is problematic.

What do you think?

The last sentence (lockable open) refers to LOTO, not accessibility. NEC 110.25.
Basically means locked in open position, think blades not door, so that circuit cannot be energized beyond disconnect for safety of working on.
Edit to add, LOTO is short for lock out tag out.

 

[Monkey]

The county inspector came to my home and I said I'm not sure how to replace the lock. The inspector said, "I see this all the time, but you don't need to lock the breaker open. You may need to cut power to the FCSP so I don't recommend putting it back. It is not a safety issue to not have a lock, but it could be safer to not have the lock so you can power down the FCSP."

I am confused to what is practical, safe, and necessary.

Breaker locks are typically a commercial thing, I'm very surprised they did that on a residential install. They're placed there so someone has to call the right people to start meddling with specific breakers. Or to keep people from switching on a breaker that needs to be left off.

 

[Maquis]

Breaker locks are typically a commercial thing, I'm very surprised they did that on a residential install. They're placed there so someone has to call the right people to start meddling with specific breakers. Or to keep people from switching on a breaker that needs to be left off.

Yeah, I’d strongly suggest a local disconnect. If your FCSP loses connectivity or needs reset for any reason, it’s nice to be able to cycle power without heading to the basement (or wherever your panel is located).

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