Generator install: connecting different gauge wire

[bones1]

Here is what I have to do
The 5449 generac panel was already installed and 2/2/2/4 ser was also already run from the panel( but not connected) over to the wall where it was all set to go to a large 20kw propane unit.I have a MEP003A instead so a pb-50 outside gen inlet will be installed instI ead.. Connecting to the 5449 is straight forward but connecting 2/2/2/4 to the PB-50 is where the issue is. I thought a small main lug panel, unbonded, mounted on the wall near the PB-50 could be use for connecting the #6 wire from the inlet to the 2/2/2/4 ser running over to the 5449 panel.
The 5449 will be run in manual only as I am not using a Generac generator. Although it can be made operate in auto with most any generator. I am using a MEP 003A generator on a trailer and would prefer to be home when it runs.

 

[DieselAddict]

That is more complicated than it needs to be. All you need to do is set a box and make the splice inside the box. For wire that size you can't use an outlet box. You'll need to use something like a 6x6 box. You are allowed to join 2 different sized wires as long as the branch circuit breaker is sized for the smaller wire.

If it were me I would set a box and spice it all together using split bolts. Cover each connection with a layer of self fusing tape (Scotch 23) then a couple layers of electrical tape (Scotch 33 or Scotch 88 ). Put the cover on and call it done!

 

[bones1]

Thanks for the help. I think I will do just that. The breaker on the panel where the #2 wire goes is 125 amp. I have to change that to 50 or 60 A correct?. Here is a very good picture of where it connects on the left side 125A. Will the new 60A breaker accept #2 wire size is my question?.

 

[DieselAddict]

That is correct. You will need to change the breaker to a 60a - assuming that you are using normal 6 gauge copper and not SOOW cord or other temperature limited (and lower current capable) cabling.

Nip off a bit of the 2 gauge wire and take it with you to shop for the breaker. You'll find that 60a breakers will work with 2ga. In general they size the terminals for a couple wire sizes larger than whats required for copper wire to accommodate someone using aluminum wire.

 

[bones1]

I will do that . Here is the picture I was talking about. The 6/4soow cable runs from the generator to the outside plug (pb-50) on the house.

http://www.homedepot.com/catalog/pdfImages/41/41ca3407-a9e3-4840-b765-d95efd7dd0dc.pdf


Thank You very much sir.

#6 solid wire from the back of the inlet to the combiner box.

 

[Isaac-1]

One thing to keep in mind is that you want to avoid vibration anywhere that you are using Aluminun wire.

 

[DieselAddict]

The 6/4soow cable runs from the generator to the outside plug (pb-50) on the house.

Since you are using a 50a plug and 6/4 SOOW cord you'll need to put in a 50a breaker instead of a 60a.

 

[bones1]

Is the pb-50 limiting me to 50A or the 6/4 soow that I haven't bought yet. Is there a better wire alternative for a cord from the generator to the house? It will need to be about 30 ft. When the MEP-003a really gets cranking (125% load that some folks say) what amperage is it putting out at that point?. I can use the PB-50 on my garage if there is a better option for the house. What do you guys use?. I will have to take back my 60A breaker I just bought. It's ok, I like going to lowes.

 

[DieselAddict]

Both are limiting you.

If you want to go with a 60a breaker you'll need to get 4/4 SOOW cord and a 60a inlet.

A MEP003 will do a little over 50a.

 

[jimbo913]

At 125% it is probably close to 52A. I run 4/4 wire, 60A plug and 60A breaker.

 

[bones1]

At 52 amps, I'll just take my 60 back and put in a 50A breaker.I bet 4/4 soow and A 60amp inlet is $$$$$$$$$. I looked for a 60 amp inlet for a long time to no avail.
Thanks for the help.

 

[DieselAddict]

I did a 50a setup for my mep003 and it was fine.

 

[bones1]

On the generator, did you mount a receptacle as well or just use the posts for connection?.

 

[DieselAddict]

I mounted a receptacle. It made things clean and tidy.

 

[bones1]

What type receptacle did you use on the generator? Any pics?.

 

[DieselAddict]

I used this:

Outlet - https://www.amazon.com/gp/product/B002MPQ4YC/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1

Box - http://www.homedepot.com/p/Red-Dot-...ox-Silver-with-4-3-4-in-Holes-S106E/100114047

Cover - http://www.homedepot.com/p/Bell-1-G...tra-Duty-While-in-Use-Cover-MM420CB/204208077

 

[bones1]

You have been very helpful and thank you.

 

[bones1]

Is there anything special needed to be done in regards to grounding at the generator, is the neutral bonded at the generator etc?.I don't think I need a ground rod when connected to the home with 4 wire but not sure on the generator end.

 

[DieselAddict]

When you are connected to your house with a 4 wire cable you want to remove the bonding strap that is along the bottom right side where the terminals are. A ground rod isn't required but won't hurt if you decide to drive one at the generator.

 

[bones1]

Thank You Sir. You know you can start billing me now for all the information.