Residential Service Panel Upgrade

Purpose

Define the residential service panel upgrade protocol - replacing an existing main panel with a larger or newer one (typically 100A → 200A upgrade, or any FPE Stab-Lok / Zinsco panel replacement). High-value job; the actual work day is long but planning + permitting determines whether the job lands right or becomes a stressful disaster.

Scope

Applies to:

• 100A → 200A service upgrades
• Like-for-like replacements of recalled panels (FPE Stab-Lok, Zinsco)
• Panel relocations within the same service

Excludes commercial three-phase upgrades + new service installations (separate scope + utility coordination).

Responsibilities

• Master electrician + journeyman team typical
• Permit coordinator files permit + schedules inspection
• Utility company coordinates the meter-drop / re-energize sequence
• Customer is given a clear timeline + power-out expectations

Procedure

Pre-job (1 - 2 weeks before installation):

1. Walk-through with customer. Identify panel location, plan for new panel placement (same location ideal; relocation adds complexity).
2. Load calculation per NEC 220. Document existing + planned future loads (EV charger, hot tub, addition).
3. File permit with the local AHJ. Most jurisdictions require an electrician's permit + a separate utility coordination.
4. Coordinate with utility company. They drop the meter for the work + re-energize. Lead time varies widely (a few days to 2+ weeks).
5. Customer briefing. "Power will be out approximately 6 - 8 hours on install day. Refrigerator + freezer should be eaten down OR plan for ice. Internet + alarms will be off."

Install day (6 - 10 hours typical):

1. Utility drops meter at scheduled time. Verify the meter base remains intact.
2. Document existing panel. Photograph every breaker label + every conductor termination before disconnecting.
3. Remove existing panel. Disconnect all branch circuits at the panel; cap conductors temporarily for safety.
4. Update service entrance if upgrading from 100A → 200A (typically requires larger service-entrance conductors + a new meter base).
5. Install new panel. Mount to wall studs; ensure clearance per NEC (30" wide × 36" deep + 6.5' headroom - all required for safe servicing).
6. Bond + ground the panel. Main bonding jumper per NEC 250; ground rod or Ufer ground per local code; bond water + gas piping per NEC 250.104.
7. Land main service-entrance conductors at the new main breaker. Torque to spec.
8. Re-land branch circuits at new breakers. Label each breaker correctly per panel directory (more legible + organized than the original).
9. Verify torque on every termination per the panel label spec.
10. Inspect everything BEFORE re-energizing. Hot conductors clear of debris, no exposed copper, ground bar complete, neutrals separated from grounds in sub-panels.
11. Utility re-energizes meter.
12. Energize main breaker + test each circuit individually. Note any issues immediately.
13. AFCI / GFCI test on every device installed (some upgrades add these on previously-unprotected circuits per current code).
14. Schedule inspection with AHJ for final sign-off.

Post-inspection:

1. Address any inspection items within their required timeframe.
2. Final customer walk-through showing the new panel + directory.
3. Document everything in customer file - panel photos, breaker directory, torque values, inspection sign-off.

Acceptance Criteria

• Permit issued + inspection passed
• Panel mounted per code with proper clearances
• All bonding + grounding complete + documented
• Branch circuits labeled + organized in directory
• All terminations torqued to spec
• Customer signs the field report with photos in file

References

• NEC Articles 230 (Services), 250 (Grounding), 408 (Switchboards + Panelboards)
• Local AHJ + utility company requirements
• Manufacturer install instructions
• Manuall internal: Annual Whole-Home Electrical Inspection, Whole-Home Surge Protector Installation