Massive Wiring Upgrade: Tackling 4/0 Cables in a 125 Amp Box - Off-Grid Solar System
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- Опубліковано 29 лис 2023
- Join me in today's adventure where we tackle a significant wiring upgrade on the homestead. We're swapping out 6 gauge wires for massive 4/0 cables, navigating through the challenges of fitting these cables through existing conduits, and making creative adjustments along the way. This episode is packed with practical tips and a bit of improvisation as we work towards enhancing our power setup.
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Links to items used in this video:
🔗 Southwire Splicer | 6 STR - 4/0 STR
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🔗 Eaton 100 Amp Double-Pole Type-BR Circuit Breaker
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🔗 4/0 Easy-Splice in-Line Gel Splice Kit with Connector, 2-4/0 AWG Wire Range
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Metal clamps directly on 2/0 conductors. Three 4/0 splice blocks crammed into a 2" EMT conduit body when you could have used a weather proof electrical junction box with EMT hubs. Why run 4/0 to a panel only rated for and requiring 2/0? Never saw a residential or farm well pump rated over 20 amp but using an 8 gauge wire should be adequate for 800' of run. All of this over rating and undercutting the project is on another level. Hope you have good fire insurance. But the double hole saw was a good idea.
The metal clamps were probably a bad idea. I'll likely go back and change that. The well pump pulls up to 60 amps at startup and pulls a constant 25 amps while running. Sorry, you've not seen one. I'm glad you liked the hole saw trick. :)
I believe they sell larger lugs you can install on the load center. But the 2/0 probably made it easier to get them in there anyway.
I thought that was the case too but when I purchased the panel, from a nation wide electric supply store, they said they didn’t think this one could be changed. 🤷🏼 But you’re right. After working with the 4/0 on the other 3 panels I have, the 2/0 was a nice change.
2/0 is plenty enough wire to handle 18,000W for a least 250 feet. What is the reason you needed to put 4/0?
Our well is 800+ feet from there
What is the voltage and amperage of the load? Assuming a 120V load, 2/0 can handle 20 amps over 928 ft. 4/0 can handle 35 amps over 843 ft. If you are using 240V @ 20A, thats 4.8kW. Your well is pulling that much power? If my math is correct, a hydraulic pump that pulls 4.8kW should be able to pump more than 100 Gals/min at 100PSI. Thats a LOT of water at a really high pressure...
@@snwbrdn777 It's a 5 hp pump. it uses 25A at 240V. So yes, it pulls that much power. I don't think it pumps quite that fast but it's probably b/c it's 500 feet down and the head pressure is limiting its output.
As a man who has filled that penetrarion hole with foam, let me advise against it. I regretted this action within a few weeks of doing it as i could no longer use the penetration without a good amount of work. Come to find out, they make a putty specifically for filling the gaps of these wiring penetrations! Who'd have thought, right!? 😂
Who knew!?!? 🤣 thanks for talking me out of a bad idea. I’ll look into the putty. Thanks!
Maybe too late for you but for others. Instead of having 18" of voltage drop in the smaller cable you could have simply removed one strand of wire at a time until it fit into the lug. Then you would have less than 1/2" of smaller cable. Like you mentioned it may not be up to code like much of your system (not a dig), just the lesser of two evils. I have used those strain reliefs in a similar manner as you, but I add extra insulation. I would have extended the split loom through the strain reliefs. I am very interested in your inverters. I have three still in the box and hesitant to use them with all the roomers they are no longer being supported. I have been using the 6500's for over a year now and they have their issues (maybe resolved with firmware update). I started adding 6 more of their batteries yesterday to our existing 6. Thank you for sharing.
That's a fair point about pulling back strands until it fits. I thought about that but I would have had to remove almost half of them and that didn't feel right. As for the quality of the inverters, I'll get more videos out as soon as possible. I'm posting these about a month after they're shot just due to being too busy to get them out. So, i've been using the inverters 24/7 since the 2nd week of November. I've had some issues for sure. I'm working through some of them with SS Support. They work great until they fault and then I have to manually go in and reset them. It happens about every other day, which is a problem when I'm not home. I'll try to get the vids out soon.
This is a better option regardless of how it "feels". Like what another commenter said, I don't understand why you are using 4/0 in a panel that is obviously designed for 2/0.
@@snwbrdn777 It makes perfect sense to me. There are a couple reasons that come to mind. First the cost savings of using Aluminum vs Copper wire for a long run. Secondly for the same current carrying capacity Al need to be up sized as it doesn't conduct as well. There is negligible voltage loss in such a short down sizing of the cable. OP, hope you don't mind me responding.
@snwbrdn777 I don't need a panel designed for the 4/0 but I do need it to get 60 amps to the well pump ~1000 feed away. Thanks for the reply @McDIY
Why not just cut a few of the strands off until it fits? That would still be more efficient than a bit of 2/0.
In hindsight, that may have been a better idea, but I would have needed to remove over half of the strands to get it to fit, and I didn't think that was a good idea. I'm sure it would have been just fine and maybe even better.