How to Replace an Old Circuit Breaker Panel

Replacing an old circuit breaker panel is an important electrical upgrade that improves safety and provides capacity for new appliances and devices. While it's best to hire a professional electrician, a homeowner can replace a panel with proper planning and care. Here's how to replace an old circuit breaker panel in your home.

Safety Precautions

Working with electrical wiring can be extremely dangerous if proper precautions aren't taken. Here are some key safety steps I take when replacing a circuit breaker panel:

• Turn off the main breaker - This disconnects power to the panel and prevents electrocution. I double check with a voltage tester.
• Use personal protective equipment (PPE) - This includes insulated gloves, eye protection, and flame resistant clothing. Safety comes first.
• Follow all electrical codes - panels must be installed to local and national electrical codes for safety. I research the requirements.
• Get permits - Permits are required in most areas and ensure code compliance. I check with the local building department.
• Hire an electrician if unsure - Panel work is complex. If I am not 100% confident, I hire a licensed electrician. Safety is priority number one.

Following safety procedures protects me and ensures the new panel is correctly installed.

Choosing a New Panel

Choosing the right replacement panel is key to a successful upgrade. Here are the factors I consider when selecting a new circuit breaker panel:

• Amperage rating - The new panel must meet or exceed the amperage of the existing panel. I check the amp rating on the old panel and get a replacement that matches or goes higher.

• Number of circuits - I count the number of circuits in the old panel and get a new one with equal or higher capacity. More spaces provide room to add circuits.

• Aluminum vs copper wiring - Panels must match the wiring type. I check if my home has copper or aluminum and get the correct panel.

• Brand - I stick with major brands like Square D, Eaton, Siemens, or GE. They make quality, reliable panels.

• Type - Main lug or main breaker panel? I replicate the existing type for easy replacement.

Carefully choosing the right panel prevents electrical issues down the road. I consult an electrician if needing guidance.

Turning Off the Power

Before going anywhere near the old circuit breaker panel, I take steps to disconnect the power:

• I locate the main breaker or pullout fuse that feeds power into the panel. This could be inside or outside the home.

• Using a non-contact voltage tester, I verify the main breaker cuts off power when flipped to the "off" position.

• I turn off the main, then use the voltage tester to double check nearby wires and terminals are dead. I test multiple spots for completeness.

• For good measure, I also switch off the individual breakers in the panel before working on it. Better safe than sorry!

• I put a piece of tape over the main breaker switch and post warning signs not to re-energize. Locking mechanisms can also prevent accidental activation.

Following proper lockout/tagout procedures is vital for preventing electrocution or shock. I always work on panels de-energized.

Removing the Old Panel

With power disconnected, I now focus on the panel removal:

• I remove the outer cover plate and take photos of the existing wiring connections. This is for reference later.

• One by one, I remove the individual wire connections and label them with tape. This keeps circuits organized.

• Once wires are detached, I unscrew the panel from the wall and detach it from the supply wires. I inspect these incoming wires.

• If the main service wires are undersized or damaged, I may choose to replace them while the power is off.

• I also close up any unused openings in the panel box using knockout seals. This prevents drafts or pests down the line.

Careful labeling maintains the existing circuit order in the new panel. I take notes or photos to keep wire connections straight.

Installing the New Panel

With the old panel removed, I now reverse the process to install the shiny new replacement:

• I mount the new panel securely in place. Most modern panels use a pre-drilled mounting hole pattern for easy placement.

• I connect the supply wires to the new panel, matching previous wire sizes and connections. Torque connections to spec.

• If I've upgraded the supply wires, I ensure proper breaker sizing for the new wire gauge. This prevents overheating.

• I insert individual circuit wires into the new panel based on my labels. I double check each connection.

• With all wires transferred, I securely screw closed the new panel cover. This protects internal connections.

• Lastly, I affix the included wiring diagram and updated labels for each circuit. This aids in future troubleshooting.

Carefully installing the new panel and connecting all wires properly ensures a smooth transition once power is restored.

Restoring the Power

The final step is safely restoring power to test my work:

• I verify all panel screws are tight, the cover is secure, and no bare wires are exposed.

• I remove any locking devices or warning signs from the main breaker.

• Standing to the side in case of flash, I switch the main breaker back on.

• Moving methodically around the home, I turn on each circuit to ensure proper function.

• I check for tripped breakers, lights not working, or appliance issues. These indicate a wiring mistake.

• If everything checks out, I button up the install by affixing the new panel access cover.

With power restored, I monitor the new panel for several days for any signs of problems. Carefully planning each step prevents electrical hazards and results in a successful panel replacement.