Upsizing existing outbuilding panel

[maverick302]

I have a barn with a 60a panel. The current run is straight about 100', 1" IMC. I have some equipment coming that calls for upsizing, ideally to 100a but could get by with 90. From my research it seems like 2awg THHN will be sufficient for 100a, but with a 4awg ground that puts me at 44% fill.

I'm not sure what viable options I have here - use the conduit as the ground? Use 3awg and stick with 90a? Or is upsizing the conduit just the best option?

 

[wyliesdiesels]

If you use #3 cu with #8 EGC you can do 100a...

 

[maverick302]

That would be 33%, which is waay better. Is voltage drop a concern at that distance? And should I still prepare for that being a PITA to pull?

 

[wyliesdiesels]

Naw 100’ will be fine for voltage drop.

Doubt you will even come close

 

[maverick302]

Thanks. Looks like that will be my best option then. Hopefully it pulls ok

 

[mike93lx]

Lots of lube, someone pushing and someone pulling. The straight shot will help. I'd get the old wire out and them send a new pull rope through with a plastic bag and a shop vac.

 

[maverick302]

Lots of lube, someone pushing and someone pulling. The straight shot will help. I'd get the old wire out and them send a new pull rope through with a plastic bag and a shop vac.

Wouldn't it be easier if I just pulled the pull rope through with the old wire?

 

[mike93lx]

Wouldn't it be easier if I just pulled the pull rope through with the old wire?

That should work, but Sucking a pull cord through with a shop vac is easy and fast, and will help clear out any water in the pipe too

Getting the old wire out may be harder than you expect, so not having anything else to get caught would be nice

 

[Jim greengo]

Wouldn't it be easier if I just pulled the pull rope through with the old wire?

Sometimes.

 

[Norcal]

That should work, but Sucking a pull cord through with a shop vac is easy and fast, and will help clear out any water in the pipe too

Getting the old wire out may be harder than you expect, so not having anything else to get caught would be nice

Water will return so what does it matter?

 

[mike93lx]

Water will return so what does it matter?

Just a matter of getting it clean for the pull.

You are the pro, not me. If you say it wont make any difference, I believe you. I'd just want to start with it clean. Minimize chances of issues