Copper vs Aluminum wiring for Charge Station Pro

[tls]

Unlikely to find a large breaker rated other than 90C in a modern panel. And a 100A disconnect like the one you pictures is likely to cost about the same as a tiny residential outdoor panel, though with a 100A breaker too it may tip the scale. Either way will work.

The point Isn't to change the conductor size - it's to change the conductor material, if the charger itself is not rated for Al or the large Al conductors are hard to manipulate inside a tight charger enclosure. #3 copper will take 100A and is much more flexible and easier to work with than #2 Al wire - but it costs a lot!

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[Maquis]

Unlikely to find a large breaker rated other than 90C in a modern panel. And a 100A disconnect like the one you pictures is likely to cost about the same as a tiny residential outdoor panel, though with a 100A breaker too it may tip the scale. Either way will work.

The point Isn't to change the conductor size - it's to change the conductor material, if the charger itself is not rated for Al or the large Al conductors are hard to manipulate inside a tight charger enclosure. #3 copper will take 100A and is much more flexible and easier to work with than #2 Al wire - but it costs a lot!

#2 AL is only good for 90A at 70C. If you transfer to #3 CU at each end, you can use the 90C ampacity for the #2 AL which is then compliant. If you land the #2 on most any device terminal, it will be limited to the 70C ampacity, requiring #1 instead of #2.

 

[rdr854]

Residential HVAC disconnects are generally 50A or less. I’m not referring to those.
more like this:

Switching conductor sizes at the transition to take advantage of 90C ampacity is a worthwhile suggestion, but it requires careful attention to detail. The breaker at the supply end will be 70C rated, so it has to be done at both ends.

I have this disconnect in my garage for my charger that I will be getting. I believe my wiring is also copper for my 100 amp circuit.

 

[beatle]

Regarding prices, here's what I found on a few of the options regarding a disconnect vs. subpanel:

$43.56 panel:
https://www.homedepot.com/p/GE-Powe...-Lug-Circuit-Breaker-Panel-TL412R1P/100123400

$107.66 125a breaker:
https://www.homedepot.com/p/GE-Powe...-Lug-Circuit-Breaker-Panel-TL412R1P/100123400

($151.22 total)

OR

$155.83 100A non-fusible disconnect:
https://www.homedepot.com/p/GE-100-...r-General-Duty-Safety-Switch-TG3223/202978655

Pretty close in price. A panel seems like it gives you a bit more flexibility if you wanted to run two EVSEs at a slightly lower amperage down the road.

Does the disconnect have to be outside if the EVSE is outside? Does the panel?

 

[Maquis]

Regarding prices, here's what I found on a few of the options regarding a disconnect vs. subpanel:

$43.56 panel:
https://www.homedepot.com/p/GE-Powe...-Lug-Circuit-Breaker-Panel-TL412R1P/100123400

$107.66 125a breaker:
https://www.homedepot.com/p/GE-Powe...-Lug-Circuit-Breaker-Panel-TL412R1P/100123400

($151.22 total)

OR

$155.83 100A non-fusible disconnect:
https://www.homedepot.com/p/GE-100-...r-General-Duty-Safety-Switch-TG3223/202978655

Pretty close in price. A panel seems like it gives you a bit more flexibility if you wanted to run two EVSEs at a slightly lower amperage down the road.

Does the disconnect have to be outside if the EVSE is outside? Does the panel?

If the required disconnect (be it a standalone disconnect or a breaker in a panel) is not within sight of the EVSE, it must be capable of being locked in the ‘Off’ position.
The standalone disconnect has this feature inherently, you may need to purchase something additional for the breaker/panel.

 

[adoublee]

If the required disconnect (be it a standalone disconnect or a breaker in a panel) is not within sight of the EVSE, it must be capable of being locked in the ‘Off’ position.
The standalone disconnect has this feature inherently, you may need to purchase something additional for the breaker/panel.

For over 60A it has to be lockable in open position and readily accessible, no matter where it is placed. A simple locking HASP should be sufficient for breaker.

 

[tls]

Regarding prices, here's what I found on a few of the options regarding a disconnect vs. subpanel:

$43.56 panel:
https://www.homedepot.com/p/GE-Powe...-Lug-Circuit-Breaker-Panel-TL412R1P/100123400

$107.66 125a breaker:
https://www.homedepot.com/p/GE-Powe...-Lug-Circuit-Breaker-Panel-TL412R1P/100123400

($151.22 total)

OR

$155.83 100A non-fusible disconnect:
https://www.homedepot.com/p/GE-100-...r-General-Duty-Safety-Switch-TG3223/202978655

Pretty close in price.

You don't need a 125A breaker, you need a 100A breaker, for an 80A EVSE on 80A copper. 125A is the typical max load rating of the small 2-space panels.

These panels are sometimes bundled with 50A GFCI breakers and marketed as "spa disconnects" at very attractive prices.

125A branch circuit breakers are pretty uncommon; the 100A breaker should be a bit cheaper.

 

[Maquis]

For over 60A it has to be lockable in open position and readily accessible, no matter where it is placed. A simple locking HASP should be sufficient for breaker.

I think it only has to be “accessible”, not “readily accessible.” Unless there is something more strict about EVSEs.
I need to verify.

Edit - the disconnect does need to be readily accessible.

 

[rdr854]

Regarding prices, here's what I found on a few of the options regarding a disconnect vs. subpanel:

$43.56 panel:
https://www.homedepot.com/p/GE-Powe...-Lug-Circuit-Breaker-Panel-TL412R1P/100123400

$107.66 125a breaker:
https://www.homedepot.com/p/GE-Powe...-Lug-Circuit-Breaker-Panel-TL412R1P/100123400

($151.22 total)

OR

$155.83 100A non-fusible disconnect:
https://www.homedepot.com/p/GE-100-...r-General-Duty-Safety-Switch-TG3223/202978655

Pretty close in price. A panel seems like it gives you a bit more flexibility if you wanted to run two EVSEs at a slightly lower amperage down the road.

Does the disconnect have to be outside if the EVSE is outside? Does the panel?

My disconnect is inside the garage. The charger will be on an exterior wall. The disconnect was installed for my convenience and not required. It has also been permitted and inspected by my local building department.

 

[Maquis]

My disconnect is inside the garage. The charger will be on an exterior wall. The disconnect was installed for my convenience and not required. It has also been permitted and inspected by my local building department.

If the branch circuit is 60A (or greater), the disconnect is required.

 

[tls]

My disconnect is inside the garage. The charger will be on an exterior wall. The disconnect was installed for my convenience and not required. It has also been permitted and inspected by my local building department.

Code section 625.23 requires a separate, "readily accessible" disconnect for each charger rated at 60 amps or greater. Some local authorities take the stance that if a single charger is the only device on its breaker in the panel, this satisfies the requirement; others do not.

Generally if the disconnect is not line-of-sight to the device, inspectors will require a locking means for the disconnect - so if they allow you to treat a breaker in the main panel as the disconnect, they will want to see a breaker lock installed.

 

[rdr854]

Code section 625.23 requires a separate, "readily accessible" disconnect for each charger rated at 60 amps or greater. Some local authorities take the stance that if a single charger is the only device on its breaker in the panel, this satisfies the requirement; others do not.

Generally if the disconnect is not line-of-sight to the device, inspectors will require a locking means for the disconnect - so if they allow you to treat a breaker in the main panel as the disconnect, they will want to see a breaker lock installed.

I think my panel has a breaker lock on it as well. There is a silver thing with a hole in it that a lock tab can fit into.

 

[Tony Burgh]

If the branch circuit is 60A (or greater), the disconnect is required.

Is that an individual disconnect? Is proximity mentioned? Is a circuit breaker within 3 feet adequate?
I installed 4/2 wire from 60 amp circuit breaker to 60amp a/c pull disconnect. But I’m considering a 100 amp circuit w new wiring. I’d like to use the new 100 amp circuit breaker for my disconnect.

 

[Maquis]

Is that an individual disconnect? Is proximity mentioned? Is a circuit breaker within 3 feet adequate?
I installed 4/2 wire from 60 amp circuit breaker to 60amp a/c pull disconnect. But I’m considering a 100 amp circuit w new wiring. I’d like to use the new 100 amp circuit breaker for my disconnect.

The breaker can serve as the disconnect. It must be either in sight of the EVSE or lockable in the ‘Off’ position.

 

[Tony Burgh]

The breaker can serve as the disconnect. It must be either in sight of the EVSE or lockable in the ‘Off’ position.

Thanks

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