Should the ground lug be bonded in the sub-panel

circuit breakersubpanelwire

I have 200 amp service at the house. I want to install a DP 60 amp breaker in that panel and run # 6 wire approximately 150 feet (10% added for swag) overhead to a dog rescue building. The building will have a window AC installed (7.8A@208V), plus a number of 20" box fans (0.8A each) , and LED lighting for a 480 square foot building. The AC unit is the only thing pulling a significant amount of power.

It is my understanding that the grounds and the neutrals need to be separated. Does that mean I should not install the bonding screw which I think is meant to tie the ground and the neutral together?

Next, can I run 6/3 without the additional ground as long as I sink 2 grounding rods at the sub-panel, at least 6 feet apart? This is not my house! The sub-panel (which had been fed by an extension cord) is either from HD or Lowe's (Homeline?). It has a factory installed 100 amp main breaker which does not appear to be replaceable.

Since the main panel has a DP 60 amp breaker this 100 amp breaker will basically be a switch to kill the sub-panel. If I use AL wire for the 150 ft should I drop the breaker in the main panel to a 50amp?

Best Answer

Neutral and ground being separated means you must remove the neutral-ground bonding device (commonly, a screw) from the neutral bar. You must also have a separate ground bar, which the cheapie big-box panels don't always come with.

You absolutely need both local grounding rods and a ground wire from the main panel. They do different jobs. Remember, electricity travels in loops and wants to return to source. The local grounding rod returns ESD and lightning, which is sourced from earth and should be returned right at the shed, not carried 150' on #6 wire to your house. Human electricity is sourced from the neutral bus on your transformer; the ground wire returns fault current to the neutral in your supply at the main panel. Dirt doesn't conduct well enough to do this job, all you will do is electrify all the grounds in your building.

Since you are doing a pole line, you really ought to use a "messenger wire" optimized for carrying the physical weight of the wire. This messenger can double as the ground wire, in fact you will want to earth it!

You are correct that a subpanel main breaker is simply a shutoff switch, which is mandatory in outbuildings. Its ampacity does not matter at all. Playing games with breaker sizes to try to get the nearer breaker to trip first, doesn't really work.

If you use aluminum wire use #4Al instead of #6Cu. They have the exact same current capacities and you will not need to change your calculations at all.

Also stop buying at big-box stores when you get as sophisticated as a pole line. Go to a real electrical supply, they have what you need in stock and they know what they're talking about.