Customer bought a Level 2 EV charger that can be set to 48 amps and wants it hardwired in the garage, 30 feet from the panel.

For a 48A EV charger hardwired 30 feet from the panel:

Breaker: 60A 2-pole (NEC 625.41 requires the branch circuit rating to match the charger's maximum current setting; 48A × 1.25 = 60A).

Wire: 6 AWG copper THWN-2 (minimum 60A ampacity per 310.16 at 75°C) or 4 AWG aluminum XHH-2. Use 10 AWG copper or 8 AWG aluminum for the equipment grounding conductor (250.122).

Cable assembly: 3 conductors + ground (2 hots, 1 neutral if the charger requires 120V control power—check specs; many 240V-only units don't need a neutral).

Installation notes:

• Use a dedicated circuit (625.41).
• Conduit or armored cable (e.g., ¾" EMT or 1" PVC) for physical protection.
• Hardwired connection per manufacturer's instructions; no receptacle allowed for hardwired units (406.88).
• GFCI protection may be required depending on local code amendments—check with AHJ.
• Torque connections per 110.14(D) using manufacturer's specifications.

Safety: This is electrical work requiring proper licensing in most jurisdictions. If you're not a licensed electrician, hire one—this involves high-amperage 240V circuits that can cause serious injury or fire if installed incorrectly.

Breaker: 60A 2-pole Wire: 6 AWG THHN/THWN-2 in conduit (or 6/3 NM-B if concealed and protected)

Code Basis (2023 NEC):

• 625.41(A): EVSE is a continuous load → breaker = 125% of nameplate. 48A × 1.25 = 60A.
• 625.42: Branch circuit ampacity ≥ nameplate (48A). 6 AWG copper = 55A (75°C column, Table 310.16) — but 625.41(A) requires 125% for OCPD, not conductor. Conductor must carry 48A continuous → 6 AWG (55A @ 75°C) is sufficient per 210.19(A)(1)(a) Exception.
• 310.14(C): 60A breaker protects 6 AWG (next standard size up per 240.4(B)).
• 300.22 / 334.15: NM-B allowed in garage walls/ceilings if protected from physical damage. Otherwise, EMT/PVC with THHN.
• 625.54: GFCI protection required (breaker or device). Most 48A units have built-in; verify. If not, use 60A 2-pole GFCI breaker.
• 625.43: Disconnect required within sight or lockable. Hardwired unit with lockable breaker satisfies.

Installation Notes:

• 30 ft run: voltage drop ~2.5% at 48A (6 AWG) — acceptable.
• Torque lugs to spec. Label circuit “EVSE – 48A Continuous.”
• Permit and inspection required.

If aluminum wire: Use 4 AWG Al (65A @ 75°C). Not recommended for short runs.

Bottom line: 60A breaker, 6 AWG Cu, GFCI-protected, permitted.