Electrical Panel Upgrades

Your electrical panel is the distribution center for your home's power. When it's undersized or outdated, it becomes a bottleneck - or worse, a safety hazard. We'll assess your current setup and recommend upgrades only when necessary.

Panels That Require Immediate Replacement

Federal Pacific Panels

Federal Pacific Electric (FPE) Stab-Lok panels have a documented 25-30% failure rate in testing. These panels may not trip when overloaded, creating significant fire risk. Many insurance companies now refuse coverage for homes with FPE panels. If you have one, replacement is strongly recommended.

Zinsco Panels

Zinsco (including Sylvania-Zinsco) panels have breakers that can melt to the bus bar, preventing them from tripping during overloads. This design flaw poses serious safety risks.

Increased Electrical Demands

Modern homes require more power than older electrical systems can safely provide. EV chargers need 40-60 amps, hot tubs require 50 amps. If your 100-amp panel is already near capacity, an upgrade to 200 amps may be necessary. We'll perform a load calculation to determine your actual needs.

Indicators Your Panel May Need Attention

  • Frequent breaker trips when using multiple appliances
  • Lights dimming when HVAC or large appliances start
  • Burning odor from the panel area - requires immediate attention
  • Panel warm to touch - indicates overloading or loose connections
  • Fuse-based system - typically 60-amp service, insufficient for modern needs
  • Home additions planned - increased square footage requires capacity review

Panel Upgrade Scope of Work

Modern code requirements have expanded what's involved in a panel upgrade. It's not just swapping boxes anymore:

  • New 200-amp panel with current code-compliant breakers
  • Updated grounding and bonding to 2023 NEC standards
  • Grouped service disconnects (new requirement)
  • Surge protection (now required in many jurisdictions)
  • Arc-fault breakers for required circuits
  • Proper torquing of all connections to spec
  • Complete load calculation documentation

What Affects Your Quote

Quotes depend on panel size, service entrance condition, grounding and bonding updates, and permitting/inspection requirements. We’ll perform a load calculation and provide a written estimate.

New Code Requirements (2023 NEC)

The latest electrical code brought significant changes:

  • Service disconnects: Must be grouped in one location
  • Surge protection: Required for all dwelling units
  • Grounding and bonding: Expanded requirements for safety
  • GFCI protection: Required for 250V receptacles (like dryer outlets)
  • Emergency disconnects: New labeling requirements

Why Proper Installation Matters

We see shortcuts that save installers time but compromise safety:

  • Improper grounding: Using water pipes instead of proper ground rods
  • Skipping bonding: Not bonding gas lines, water pipes, and other systems
  • Wrong torque specs: Over-tightening damages equipment, under-tightening causes fires
  • Missing surge protection: Required by code but often "forgotten"
  • Reusing old breakers: Breakers wear out and may not trip properly

Shortcuts can appear to save money upfront but create serious safety hazards. Electrical current needs a safe path to ground — shortcuts in grounding and bonding eliminate that safety route. Learn more about proper grounding and bonding →

⚠️ Important Safety Warning

Never pull your panel cover off. Even with the main breaker off, those fat wires at the top are still hot. 240 volts. It'll kill you before you hit the ground.

Professional Assessment Questions

When consulting with any electrician about panel upgrades, consider asking:

  • Can you perform a load calculation to verify upgrade necessity?
  • Are there alternatives to a complete panel replacement?
  • Will you coordinate with DTE Energy and handle permits?
  • What specific work is included in your quote?

Not Sure About Your Panel?

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