What to Expect During a Home Electrical Panel Upgrade
Your electrical panel is the heart of your home or business’s power system. It’s responsible for distributing electricity safely and efficiently throughout the property. But as appliances evolve and our electrical needs grow—with smart devices, electric vehicle chargers, home offices, and energy-hungry HVAC systems—many existing panels become outdated or undersized. That’s where an electrical panel upgrade comes into play.
Whether you’re planning a remodel, facing recurring electrical issues, or just want to future-proof your property, this guide will walk you through exactly what to expect from the electrical panel upgrade process—so you can plan confidently, avoid surprises, and ensure your electrical system is safe and reliable for years to come.
Why Upgrade Your Electrical Panel?
An outdated or overloaded panel isn’t just inconvenient—it’s a safety hazard. Here are some common reasons why homeowners and business owners choose to upgrade:
1. Insufficient Power Capacity
Older homes often have 60–100 amp panels, while modern homes and small businesses often require 200 amps or more to handle today’s electrical load.
2. Frequent Breaker Trips
If you’re constantly resetting breakers when running appliances or using multiple outlets, your panel may be at capacity.
3. Planning for Additions or Remodels
New appliances, a second HVAC unit, a hot tub, or even an electric vehicle charger may require more power than your current panel can provide.
4. Outdated Panels or Fuse Boxes
Many old panels—especially Zinsco, Federal Pacific, or fuse-based systems—are no longer up to code and are known fire hazards.
5. Code Compliance and Insurance
If you’re selling a property or applying for homeowner’s insurance, you may be required to bring your panel up to modern safety standards.
Signs You Need a Panel Upgrade
Not sure if it’s time to replace your electrical panel? Look for these signs:
- You still use a fuse box
- Breakers trip regularly
- Lights dim when appliances start
- You rely on power strips or extension cords for everyday use
- The panel smells like something is burning
- You’re adding large appliances or an EV charger
- Your current panel is warm to the touch or discolored
Types of Electrical Panels
Before upgrading, it helps to understand what kind of panel you’re working with:
| Panel Type | Description |
|---|---|
| Fuse Box | Outdated system using fuses that need replacing after trips |
| 100 Amp Panel | Common in older homes; often insufficient for modern loads |
| 150 Amp Panel | A mid-range upgrade suitable for some homes |
| 200 Amp Panel | Today’s standard for modern homes |
| Subpanel | Secondary panel that draws power from the main panel |
| Smart Panel | Advanced panels that support energy monitoring and automation |
What Happens During a Panel Upgrade?
1. Initial Assessment and Permit Application
A licensed electrician will:
- Inspect your existing electrical system
- Calculate your power usage and future needs
- Identify panel placement, meter location, and grounding requirements
- Pull permits and coordinate with your local city or county building department
If you’re working with professionals like EG Electrical Services, they’ll handle all the permitting and planning logistics for you.
2. Scheduling a Utility Disconnect
For safety, your utility company must temporarily disconnect power while the upgrade is being performed. This is typically scheduled a few days in advance and may require:
- Coordinating with PG&E or your local provider
- Informing tenants or business staff about temporary outages
- Power loss for 4–8 hours during the upgrade
3. Removing the Old Panel
On the day of the upgrade:
- The electrician disconnects all circuits and removes the old panel
- Old breakers and wiring are carefully labeled to ensure correct reconnection
- A new meter socket may also be installed, depending on local code
4. Installing the New Panel
The new panel is mounted, grounded, and connected. Tasks include:
- Replacing old breakers with new ones
- Upgrading main service wires
- Ensuring GFCI and AFCI compliance in appropriate locations
- Installing additional circuits if needed
This process must adhere to NEC (National Electrical Code) standards and any local regulations.
5. Inspection and Utility Reconnection
Once installation is complete:
- The project is inspected by your city’s building department
- If approved, the utility reconnects service
- The system is tested for safety and functionality
The total project often takes one full day, with prep and inspection potentially extending it over two to three days total.
How Much Does It Cost to Upgrade an Electrical Panel?
Prices vary based on service size, location, labor, and complexity. Here’s a general breakdown:
| Upgrade Type | Estimated Cost |
|---|---|
| Fuse Box to 100 Amp | $1,200 – $2,500 |
| 100 Amp to 200 Amp | $2,500 – $4,500 |
| 200 Amp to Smart Panel | $4,000 – $6,500+ |
| Subpanel Addition | $800 – $1,500 |
Other potential costs:
- Trenching or relocating the meter
- Rewiring or upgrading service mast
- Replacing main service wire from utility pole
How to Prepare for Your Panel Upgrade
- Clear Access: Make sure the area around the panel is free of obstructions.
- Plan for Outages: If working from home or running a business, arrange for a backup plan during the power shutoff.
- Protect Appliances: Unplug sensitive electronics before power is cut and restored.
- Schedule Around Weather: Outdoor meter or service upgrades may be weather-dependent.
Benefits of Upgrading Your Electrical Panel
✅ Improved Safety
Reduces fire risk, eliminates outdated equipment, and ensures grounding compliance.
✅ Increased Capacity
Handle modern appliances, home offices, EV chargers, and future growth with ease.
✅ Code Compliance
Meet local electrical codes and insurance requirements—especially important for property sales or renovations.
✅ Better Performance
Avoid flickering lights, surges, or interrupted service.
✅ Added Resale Value
Modern systems are a selling point for buyers who want a move-in-ready home or business location.
Common Questions About Panel Upgrades
Q: Will I need a whole-house rewiring, too?
A: Not necessarily. Many panel upgrades can be done without touching existing branch circuits, unless the wiring is outdated or damaged.
Q: Can I install a larger panel for future-proofing, even if I don’t need the capacity yet?
A: Yes—and it’s often encouraged. Installing a 200-amp panel now may prevent another upgrade in 5–10 years.
Q: Can I install a subpanel instead of upgrading the main panel?
A: Possibly. Subpanels are great for adding circuits in garages, additions, or workshops—but they still draw from the main panel, which may also need to be upgraded.
Why Hire a Licensed Electrician?
Panel upgrades are not a DIY project. Mistakes can be fatal or result in costly damage, fire, or failed inspections.
Professional electricians like those at EG Electrical Services offer:
- Permit and inspection handling
- Full system diagnostics
- Code-compliant installations
- Warranty-backed work
- Peace of mind
Conclusion: Upgrade for Safety, Efficiency, and Growth
An electrical panel upgrade isn’t just about fixing flickering lights—it’s about protecting your investment, enhancing safety, and preparing for the modern demands of today’s homes and businesses. Whether you’re planning an expansion or just want to stop resetting breakers every week, upgrading your panel is a smart long-term decision.
Make sure you work with a licensed, experienced electrical contractor who will not only install your new system correctly, but also explain your options, pull permits, and ensure everything is up to code.
When you're ready, EG Electrical Services can help guide you through every step of the panel upgrade process with professionalism, transparency, and care.
