How to Replace a Circuit Breaker Panel

Replacing a circuit breaker panel is an important electrical project that requires proper planning and safety precautions. Here is a step-by-step guide on how to replace a circuit breaker panel correctly and safely.

Determine if You Need a New Panel

The first step is deciding if you really need a new circuit breaker panel. Here are some signs that indicate it's time to replace the panel:

Frequent tripping of breakers or fuses: If breakers trip repeatedly under normal loads, it likely means the panel is outdated and needs upgrading.
Not enough circuits or spaces: An outdated panel may not have enough circuits or open spaces for additional circuits to meet new needs.
Damage: Look for damage like corroded bus bars, cracked insulation, burned components, etc. Any visible damage means replacement is needed.
Older than 40 years: Panels older than 40 years have likely become unsafe due to wear. Replacement is recommended.
Aluminum wiring: Outdated aluminum wiring should be inspected; upgrading the panel provides an opportunity to rewire safely.

If you notice any of these signs, it's generally recommended to replace the circuit breaker panel.

Choose a New Panel

The next step is selecting a new circuit breaker panel.

Consider covering all your existing and future needs when choosing a panel. Opt for more spaces than you currently need.
Select a main breaker panel that allows you to shut off all power. Main breaker panels are now code requirement in most areas.
Choose a reputable brand like Square D, GE, or Eaton for safety. Stick with a major manufacturer.
Select the appropriate amperage - 100 amps for a small home, 200 amps for a large home.
Make sure the panel has enough spaces - a 16 space, 24 space, or 30 space panel.
Pick a suitable type - single phase or three phase - based on your electrical service.

Turn Off Power and Remove Old Panel

Once you have the new panel, it's time to replace the old one:

Turn off the main breaker and all individual breakers. Verify power is off with a voltage tester.
Remove the panel cover and take photos of existing wiring for reference.
Disconnect all wires from breakers and neutral bus bar. Label wires to identify circuits.
Remove the mounting screws or brackets and detach the panel from the wall.
Inspect the inside of the panel for any corrosion, damage or defects. Replace any questionable wiring.
Check the surrounding wall for scorch marks or holes that indicate unsafe conditions. Repair if needed.

Install New Panel and Make Connections

Now to install the new circuit breaker panel:

Position the new panel in place and reinstall any removed mounting screws to secure it.
Connect the neutral wires and grounding wires to the neutral bus bar using proper cable lugs or clamps.
Connect the hot wires to their corresponding new breakers, matching each labeled circuit.
Double check connections to verify wires are tight and in the proper breakers. Refer to photos.
Attach the new panel cover, insert labeled circuit index, and close up the panel.

Connect Grounding and Energize Panel

Final safety steps when replacing a breaker panel:

Ensure proper grounding by connecting a ground wire from the panel case to grounding rods or water pipes as per code.
Carefully energize the panel by turning on the main breaker first, followed by individual circuits.
Test outlets and devices on each circuit to ensure proper function.
Update labeling and documentation on the new electrical panel for your records.
Consider having an inspection done by the local building department to ensure compliance.

Replacing an outdated or defective breaker panel provides safety and opens options for new electrical circuits. Carefully following the right steps makes a panel replacement project manageable. If at any point the process seems unsafe or overly complex, call a licensed electrician to take over. Safety is paramount when undertaking major electrical work.