A power distribution box would be nice for connecting different loads to a generator at an off-grid job or camp site. But commercial units are big, heavy, and expensive, and they offer some features I don't need, while lacking some of the connections I'd like.
Here's an example of a commercial product.
Could I build a safe, simpler, cheaper version of this myself?
My generator is rated for 40 A peak, 30 A continuous. Its 240 V output is on a NEMA 14-50 receptacle with a 40 A breaker. Like the commercial products, my box would have a suitable generator inlet, and I'd connect the generator to the box with an extension cord.
I'd like a distribution box with another 14-50, a duplex 5-20, a 6-50, and maybe a 6-20. I anticipate using the box with other equipment that needs to be sheltered from weather, so while a weatherproof enclosure might be nice to have, I don't require it.
What would make a suitable enclosure?
What should I use as connectors internally? I've seen terminal blocks but not with insulated jumpers rated for this current. I've also seen set-screw connectors with a cover that looks like a wire nut.
My understanding is that the generator breaker will protect my box from overcurrent, but should I use GFCI outlets for the 5-20s? Is there other protection I should incorporate? Any opinions about the usefulness of a power switch at the box?
Should the components be rated for 50 A like the generator outlet, even though it's on a 40 A breaker? Is there some standard derating applied here?
Best Answer
You absolutely need breakers for the 5-20 and 6-20 receptacles - can't connect those directly to a 40A breaker with any hint of safety. And all the outputs would benefit from GFCI protection, given that you plan outside use; clearly required on the 5-20s and highly advisable on the other outlets.
So, you need a subpanel, at least.
Given a 50A input connector, "your intended use with a 40A generator" is moot - someone could plug this thing into a 50A receptacle, so your provisioning, wire size and protection scheme needs to be based on that case. If (common, but can't be assumed, has to be checked) your 50A devices have connections rated for 75°C you can wire them with 8 Ga copper or 6Ga aluminum and suitable wirenuts or Polaris connectors, or split nuts insulated with tape if you want to go old-school (you probably don't.)
Your 20A stuff, on the far side of the 20A breakers feeding it, can be 12Ga copper.
Depending on your choice of subpanel, you might be able to simply attach a few 4x4 boxes to it to hold the inlet and receptacles. Otherwise you'll end up mounting them all (subpanel and boxes for receptacles/inlet) to a suitable substrate, such as a hunk of plywood, or a plywood box. Size the plywood box right and your inlet cord will fit into it.