Home > EV > Why We Need Plug-Ins > 2009.05.17 Milbank Power Panel Installs
2009.05.17 Milbank Power Panel Installs

Disclaimer: Electricity can be dangerous and lethal if handled improperly. Do not attempt a similar power panel install without proper electrical training and knowledge. The below information is provided only for academic purposes. You assume all risk after reading beyond this line.

Milbank has been in business 80 years manufacturing electrical power distribution and metering panels. They are a "standard" when it comes to their UL approved power panels and pedestals for the RV industry. Two convenient power panels are their U5000-XL (unmetered) and U5100-XL (submetered) which I've honed in on as the best equipment for providing safe distribution of power via 240VAC 50Amp (NEMA14-50R) and 120VAC 20Amp (NEMA5-20R) outlets when paired with GFCI (Ground Fault Circuit Interrupter) breakers. The Milbank panels provide a sturdy metal chassis in which to mount both the power outlets and the GFCI breakers. The Milbank solution combines all the best aspects of safety, economical cost, and capability in a compact outdoor NEMA 3R rated enclosure. All components are readily available making installation, support, and any possible maintenance simple for any electrician. A safe connection to power can be made when following the proper connection procedure denoted on the panel's deadfront via the yellow warning sticker.

Turn disconnecting switch or circuit breaker off before inserting or removing plug.
Plug must be fully inserted or removed.


Milbank equipment can be purchased from the friendly staff at BB Electrical by calling Toll Free 1-888-391-3802.



2009.04.17 Milbank Power Panel Inventory & Staging

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One U5100-XL and three U5000-XL Milbank Power Panels. U5100-XL with meter. Paul's U5000-XL. Close up of breakers and outlets to be installed in Paul's Milbank.
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Howard and Linda's U5100-XL Milbank Power Panels. Cutler-Hammer GFCB250 50A GFCI dual pole breakers, Siemens 20A single pole GFCI breaker, NEMA14-50R outlets and coverplates, NEMA5-20R duplex outlet and coverplate, and 100A Murray feed breaker. Wiring the NEMA5-20R duplex outlet with 10AWG THWN-2. The NEMA14-50R outlets are wired with 6AWG THWN-2.


2009.05.14 Milbank Power Panel Install at Paul's

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Side of Paul's house mounting location. Zan and Paul. Pre-wired and stuffed Milbank U5000-XL. Milbank U5000-XL business internals. Fully populated in this configuration represents ~$350. The GFCI 50Amp breakers are the most costly item at ~$77 a piece. The panel itself is ~$70.
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Stefano removes the Milbank deadfront to facilitate panel mounting to wall. An assortment of tools. Milbank deadfront removed.
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The mounting location. Stefano grabs his amazing Zircon i700 digital stud finder. It actually located a stud through stucco the first time! Positioning the Milbank Power Panel prior to install.
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Drilling the mounting holes. Stefano levels the Milbank panel prior to marking the lower hole.
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Paul taking photos. Panel mounting upper hole and centerline. Drilling the lower hole.
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Sealing the lateral holes with some DAP Dynaflex 230 caulk. Final bolting the Milbank Power Panel to the wall. Paul taking a self pic.
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Paul inspecting his new Milbank Power Panel. All that remains is running the feed conduit to the main utility panel. Stefano is all smiles to finally see Paul has a StefSpec Milbank Power Panel installed. Paul and his Milbank Power Panel.
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The Milbank just behind the gate.


2009.05.17 Milbank Power Panel Install at Howard's

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Cutting all the 16inch 6AWG THWN-2 wire for the dual NEMA14-50R outlets. Temporary staging/assembly area. All four NEMA14-50R outlets wired (2 for Howard, 2 for Linda). Wiring and stuffing Howard's panel.
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Linda's panel is wired and stuffed.
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TESLAAH... Pre-wired 2AWG NM cable in Howard's garage. Deciding where exactly to mount the Milbank Power Panel.
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I forgot to bring my Roto-Zip so I used my drill to help cut open some raceway drywall. I found an old "Wake Up!!! Peak Oil" sign Linda had made years ago. Displaying the Peak Oil sign about where the Milbank Power Panel will be mounted. Making another hole in the raceway drywall to thread the NM cable through.
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All 4 mounting holes drilled. Linda monitors progress and helped define the height position of the Milbank Power Panel. The "work truck". This should have been a photo of a MINI E!!!
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Stefano happy the mounting effort is almost complete. Final bolting Howard's Milbank Power Panel to the left side garage wall. Pulling the NM 2AWG cable through the raceway and into the Milbank. Exterior main electrical utility panel.
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Milbank 100A feed breaker to be installed at the top.
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NM 2AWG cable final wired.
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Milbank deadfront installed. Some drywall work remains to form a protective raceway around the NM 2AWG cable and patch the 3 holes in the existing raceway.
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Dual NEMA14-50Rs and a NEMA5-20R duplex all GFCI breaker protected. Stefano is all smiles having completed another successful StefSpec Milbank install. Who wants to charge? Wiring up the 100A Milbank feed breaker at the 200A main electrical service panel.
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Brand new 200A Siemens main electrical service panel. Linda plugs in her Tesla MC120 while still awaiting delivery of her MC240.

Video: Plugging Into a Milbank U5000-XL Power Panel
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Parts list and info for building up a fully populated Milbank U5000-XL Power Panel with
GFCI breaker protected dual NEMA14-50Rs and a NEMA5-20R duplex outlets.

Milbank's site: http://www.milbankmfg.com/

Milbank's RV Power panel section: http://www.milbankmfg.com/Products/RvPedestals/index.asp

Milbank's RV Power Catalog in PDF: http://www.milbankmfg.com/Products/Catalogs/CatalogFiles/PDF/RV.pdf

A source for competitively priced drop shipped Milbank equipment is BB Electrical: http://www.bbelec.com/
Toll Free 1-888-391-3802 - Ask for Maggie.


The below are the parts for a fully populated MILBANK U5000-XL panel:

Qty 1 - U5000-XL RV unmetered blank panel - $69.37 each

Qty 1 - K5400-520GB - GFCI 20amp Circuit Breaker and NEMA5-20R Duplex kit - $57.25 each

Qty 2 - #708767-MO Milbank 50amp NEMA14-50R receptacle (Leviton brand) - $16.15 each

Qty 2 - #818056-SC Milbank 50amp receptacle Faceplate - $7.45 each


A source for the Cutler-Hammer GFCB250 GFCI 50Amp dual pole circuit breakers from Home Depot. You might have to special order them from their professional customer service desk for about $77 a piece. The larger formate Murray 50Amp GFCI dual pole breakers won't fit in the Milbank due to the bevel on the deadfront.

TinyURL-like redirect link to this "2009.05.17 Milbank Installs" page:
http://www.stefanoparis.com/redirect/MilbankInstalls.html


Related Links:


Available from Amazon.com and from JC Whitney.

  • Camco 55353 NEMA14-50R 50Amp Power Grip Replacement Receptacle with safety handle.


Available from Amazon.com.
(Note: Amazon has a typo for this part as a 55358 but it really is a 55353)

  • AVCON to NEMA14-50 adapter box from the EAA (scroll to bottom) allowing charging of modern EVs from existing AVCON EV charge stations. There are less than 100 of these adapter boxes left due to the female AVCON receptacle no longer being made and dwindling remaining inventory. Get yours while you still can. Prices have increased substantially due to limited availability of the female AVCON receptacle.

    An AVCON charge station (deployed in the mid 1990s) can provide ~32A at 240VAC or 208VAC depending on the charge station's feed circuit. For the forseeable next couple of years, AVCON charge stations will most likely remain in the public space until a J1772 level 2 32A charge station can replace them. As of May 2009 we continue to await a final vote on the SAE J1772 level 2 standard which would allow manufacturing of the connector to commence. Unfortunately, it appears manufacturers will initially only pursue the 12A J1772 level 2 connector this year (2009), and a 32A connector flavor next year (2010). I have not heard of anyone pursuing manufacture of a 70-80A J1772 level 2 connector which is sorely needed for all modern BEVs, especially the Tesla EVs. Until J1772 level 2 charge stations in at least 32A flavors are available, the AVCON adapter box is very relevant if you would like to charge a modern EV at any existing public EV charge location. AVCONs are not obsolete until J1772 level 2 32A or greater charge stations are manufactured and deployed.

Click Play to watch PLUG DOGS in action.

This text will be replaced
  • Coil n' Wrap's PLUG DOGS is an excellent accessory for NEMA14-50P plugs like the ones you'd find on a Tesla MC240 Mobile Connector or Martin Eberhard's Roadster Foundry Mobile Charging cable. PLUG DOGS often commonly referred to as Pull Dogs or Plug Pullers, fit the male and female ends of standard 30 & 50 amp plugs and cables. PLUG DOGS make unplugging and separating plugs much easier and safer by keeping your fingers away from the plug prongs. Of course you should always insure the outlet's breaker is off before plugging in or unplugging any higher amperage plug.

    Coil n' Wrap describes their PLUG DOGS: Grasp the strong, easy to grip handles and pull out or separate bulky, difficult to handle power plugs. They are safe to use, as PLUG DOGS pull the plugs out correctly, increasing the life of cables & receptacles. PLUG DOGS are made from heavy duty polypropylene nylon and are non-wicking, non-conductive and non-flammable. Ken Wilton, owner of Coil n' Wrap, has a write up on his PLUG DOGS product here.

    Click here to purchase your 50 Amp PLUG DOGS from Coil n' Wrap.

Tesla Roadster specific NEMA14-50 charging cordsets:

  • EV Components - Roadster Foundry Mobile Connector (RFMC)
    A 240VAC 40A cordset with adapters for charging the Tesla Roadster developed by Martin Eberhard. The primary/preferred adapter is the NEMA14-50 plug. The RFMC ships with NEMA14-50, NEMA10-30, and NEMA5-20 plug adapters. Others are available at additional cost. You'll notice this v2.0 RFMC now incorporates the safest and very excellent yellow Camco 55255 NEMA14-50P plug with handle.


  • Tesla Motors - Mobile Connector 240
    The original March 2009 release 240VAC 30A cordset for charging the Tesla Roadster from a NEMA14-50R receptacle. With the arrival of the new Tesla Motors Universal Mobile Connector with 40A capability and interchangable adapters, I predict the Tesla MC240 will disappear. The electronics box that is part of the MC240 cordset was rather large and unweidly for carrying around in the limited trunk space of the Roadster.



Find a Public EV Charging Station:


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Webpage created on: Sunday, May 17, 2009
Webpage last updated: Monday, September 7, 2009
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