electricalelectrical-panelsubpanelwiring
I've been reading posts but am still a little confused on this as each situation is slightly different and I am not familiar with the terminology.
Main breaker has two larger wires coming into it. The second one feeds a panel in the garage, which was an addition. Panel has 3 circuit breakers in it.
Here is picture. My home inspector mentioned it as a problem. Do I need to deal with this?
Leave just enough "extra" wire to route the wire along the edge of the board so it looks clean like the image below. Otherwise, do not bother leaving extra wire. You can splice more wire within the panel if you need to move things around later. Leaving a lot of additional coiled wire to try to account for the future could result in excess heat build-up and potentially an electrical fire. Note: Some excess wire is harmless, but if the panel begins to look like a mess of coiled wires, then you are likely creating the following situations the NEC tries to protect against in several areas of code (though not necessarily specific to the panels) to make sure the wire will not exceed the heat rating of its insulation at the expected current load:
Current running through a wire generates heat and relies on air to carry that heat away from the conductor. Therefore, the NEC protects against too many current-carrying conductors in close proximity for other areas of wiring:
310.15(B)(3)(a) More Than Three Current-Carrying Conductors in a Raceway or Cable. Where the number of current-carrying conductors in a raceway or cable exceeds three, or where single conductors or multiconductor cables are installed without maintaining spacing for a continuous length longer than 600 mm (24 in.) and are not installed in raceways, the allowable ampacity of each conductor shall be reduced as shown in Table 310.15(B)(3)(a). Each current-carrying conductor of a paralleled set of conductors shall be counted as a current-carrying conductor.
314.16 Number of Conductors in Outlet, Device, and Junction Boxes, and Conduit Bodies. Boxes and conduit bodies shall be of sufficient size to provide free space for all enclosed conductors. In no case shall the volume of the box, as calculated in 314.16(A), be less than the fill calculation as calculated in 314.16(B). The minimum volume for conduit bodies shall be as calculated in 314.16(C).
When wire is coiled or there are more than one conductor, there is potential to induce additional currents in the wires due to the additional electromagnetic fields not otherwise present with a single conductor. The NEC protects against this related to ferrous metal enclosures and raceways:
300.20(A) Conductors Grouped Together. Where conductors carrying alternating current are installed in ferrous metal enclosures or ferrous metal raceways, they shall be arranged so as to avoid heating the surrounding ferrous metal by induction. To accomplish this, all phase conductors and, where used, the grounded conductor and all equipment grounding conductors shall be grouped together.
Exception No. 1: Equipment grounding conductors for certain existing installations shall be permitted to be installed separate from their associated circuit conductors where run in accordance with the provisions of 250.130(C).
Exception No. 2: A single conductor shall be permitted to be installed in a ferromagnetic enclosure and used for skineffect heating in accordance with the provisions of 426.42 and 427.47.
Image obtained from https://en.wikipedia.org/wiki/File:EEUU%28GE%29BreakerpanelInnards.jpg
To answer your biggest question: I'm pretty sure it's not code-legal to tap into the feed from your meter panel with split-bolt connections. It's possible that your breaker panel has some lugs near the bottom of the load side bus bars to connect a feed to a subpanel, but most don't.
So a possible solution is what Doxy suggests: a new 100A panel that feeds your existing panel as a sub-panel. Before you consider that, I'd check to see if your panel type admits half-size tandem breakers. These are breakers that fit two half-size breakers into the space for one normal breaker, and this would free enough space for a 40A breaker to your EV charging circuit in the garage.
Another possible difficulty, though, is that your 100A service is awfully marginal for the addition for a 40A EV charging circuit. Although you didn't give all the relevant details, I assume your 1000 sq ft house (does this include the basement, if there is one?) has an electric dryer. In my jurisdiction, a load calculation shows you would require a 107A service. You may be able to get away with a 100A service, but it will depend on your inspector/permitting authority.
Best Answer
My bet is your panel is full and someone wanted to add the shed subpanel anyways so they simply fed it into the utility connection to the panel. There's several problems here
If your panel is full, you'll want a subpanel by the main panel to hook this to. That likely means you'll need an electrician. It's a mess, but I wouldn't leave this as-is.