How to enlarge lugs on a 60A 120/240 VAC single phase disconnect switch?

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I have a 60 A disconnect switch de-rated to 40 A. Its load lugs are .2294" Diameter
I need to feed 2 30A disconnect switches de-rated to 20A and connect a TVSS at the load terminals of the 60A disconnect switch.
The two 30 A switches have 12 AWG conductors, D= .08080"
The TVSS will either have a 6 AWG conductor (D=.1620") or 4 AWG conductor( D= .0808")

Is there a way I can land 2 12 AWG (.0808") conductors and 1 6 AWG conductor (.1620" )on the 60 A switch load lugs (.2294").

To the best of my knowledge they don't sell lug extenders for 60 A switches.

One way around this is to use a 100A switch and de rate it to 40A ?

Thank you in advance
 
See 312.8. Or if you are worried about meeting thise requirements then install a j-box adjacent to the switch.

I wouldn't have suggested something that violated the NEC.
 
Tap Rules
(the conductors are less than 7 feet long)
--The tap conductors do not extend beyond the switchboard,switchgear, panelboard, disconnecting means, or controldevices they supply.
-- Except at the point of connection to the feeder, the tapconductors are enclosed in a raceway, which extendsfrom the tap to the enclosure of an enclosed switchboard,switchgear, a panelboard, or control devices, or to the backof an open switchboard.
-- For field installations, if the tap conductors leave theenclosure or vault in which the tap is made, the ampacity ofthe tap conductors is not less than one-tenth of the rating ofthe overcurrent device protecting the feeder conductors

I think we are okay on the Tap Rules
My interpretation on all this ( which may be wrong) is, all the splices, or Polaris Blocks, must fit inside the housing of Disconnect Switch, which makes for a crowded install
 
Installer said:
...

I think we are okay on the Tap Rules
My interpretation on all this ( which may be wrong) is, all the splices, or Polaris Blocks, must fit inside the housing of Disconnect Switch, which makes for a crowded install
Click to expand...

No you could do the splices in an adjacent j-box like I said, if you're concerned about crowding.

The 'pigtail' i.e. the conductor between the switch and the splice, should be sized to not be a tap, which just means protected by that 40A fuse. It can be 8awg probably. Not sure why you have such a large conductor on the TVSS but I thought maybe voltage drop, saw no reason to question it. My point is that the pigtail doesn't need to equal the size of the other conductors combined.
 
jaggedben said:
No you could do the splices in an adjacent j-box like I said, if you're concerned about crowding.

The 'pigtail' i.e. the conductor between the switch and the splice, should be sized to not be a tap, which just means protected by that 40A fuse. It can be 8awg probably. Not sure why you have such a large conductor on the TVSS but I thought maybe voltage drop, saw no reason to question it. My point is that the pigtail doesn't need to equal the size of the other conductors combined.
Click to expand...

Thank you
I might have made a mistake and over sized the conductors from the TVSS but I wanted to err on oversize. My understanding is they have to be the same size as the Service Conductors.
 
One last question and sorry to bother you all. Unfortunately a lot of what we do lies in the details

Not all of our Electrical Inspectors are code proficient and they are going to jump on me when they see the splices in the J-Box.

They will say that I'm splitting Circuits in a J Box and interpret it as my trying to jury rig or even interpret it as a Makeshift Electrical panel.

Do you know what section of Code will defend me when I split the Output at the Main switch into two different circuits outside the Switch Housing in a separate J Box?
 
Installer said:
One last question and sorry to bother you all. Unfortunately a lot of what we do lies in the details

Not all of our Electrical Inspectors are code proficient and they are going to jump on me when they see the splices in the J-Box.

They will say that I'm splitting Circuits in a J Box and interpret it as my trying to jury rig or even interpret it as a Makeshift Electrical panel.

Do you know what section of Code will defend me when I split the Output at the Main switch into two different circuits outside the Switch Housing in a separate J Box?
Click to expand...

Sorry but if your inspectors can't grasp this simple installation then you're in trouble. I'm not sure I understand what the potential violation is. You have a junction box with splices in it.
 
Installer said:
One last question and sorry to bother you all. Unfortunately a lot of what we do lies in the details

Not all of our Electrical Inspectors are code proficient and they are going to jump on me when they see the splices in the J-Box.

They will say that I'm splitting Circuits in a J Box and interpret it as my trying to jury rig or even interpret it as a Makeshift Electrical panel.

Do you know what section of Code will defend me when I split the Output at the Main switch into two different circuits outside the Switch Housing in a separate J Box?
Click to expand...

Ask them to say what code section you are violating. Point to article 90 where it explains that you can do anything that isn't prohibited, as long as it doesn't fail to do what's required.

With that said...
If that's what you're facing, why not do this service with a panelboard, with a main breaker and three load breakers? It would surely be cheaper.
 
Installer said:
One last question and sorry to bother you all. Unfortunately a lot of what we do lies in the details

Not all of our Electrical Inspectors are code proficient and they are going to jump on me when they see the splices in the J-Box.

They will say that I'm splitting Circuits in a J Box and interpret it as my trying to jury rig or even interpret it as a Makeshift Electrical panel.

Do you know what section of Code will defend me when I split the Output at the Main switch into two different circuits outside the Switch Housing in a separate J Box?
Click to expand...

Ask us anything, that's the point of this place.:D

1. A junction box is a completely appropriate and code-compliant place for splices. In case the inspectors you're saddled with are the type who believe the wive's tale that you also can't put splices in a load center/panelboard, this too is fully compliant as long as the cabinet isn't loaded more than 40% at any cross-sectional area.

2. What do you mean by "Makeshift Electrical panel"? What is the concern here?

3. You don't need a code defense for splitting a conductor into two circuits. The inspectors need a code violation. If a method isn't prohibited, it is allowed, not the other way around. But stated plainly, multiple circuits are always created from one source....all the way back to the generating station. Creating two circuits from one in a junction box isn't the least bit unusual.

4. I agree with Ben that a small loadcenter might be an easier solution.
 
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