Replacing an outdated electrical panel in your home can seem like a daunting task, but with proper planning and safety precautions, it is possible for a motivated do-it-yourselfer to complete. As with any major electrical project, caution and attention to detail are paramount.
Reasons to Replace an Outdated Panel
There are several reasons you may want to replace an outdated electrical panel:
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Insufficient amperage - Older panels often top out at 60 or 100 amps, which may not provide enough power for modern homes with multiple appliances and electronics. Upgrading to a 200 amp panel ensures you have sufficient capacity.
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Safety hazards - Outdated panels can present fire and electrocution risks. Common hazards include:
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Faulty or outdated breakers - Breakers can weaken over time. Replacing an old panel ensures all new, properly rated breakers.
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Substandard wiring - Aluminum wiring in particular can present fire hazards if not properly maintained. Upgrading allows re-wiring with modern copper wiring.
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Lack of grounding - Ungrounded panels are extremely hazardous. A new panel must be properly grounded.
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Lack of capacity - If you find yourself constantly tripping breakers when multiple appliances are running, you may need a panel with more circuits to add capacity.
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Home resale value - Upgrading the panel can make a home more attractive to potential buyers.
Evaluating Your Existing Panel
Before deciding to DIY a panel replacement, take time to thoroughly evaluate your existing setup:
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Age of panel - If it is over 20 years old, replacement may be worthwhile. Very old fuse boxes should definitely be upgraded.
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Amperage rating - As mentioned above, 60-100 amp panels are undersized for most modern homes.
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Number of circuits - Count the number of breakers/fuses. If it is fewer than 16, an upgrade may provide needed capacity.
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Type of wiring - Aluminum wiring in particular should raise concern due to fire hazards if connections become loose over time.
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Grounding - Lack of grounding is very dangerous and must be addressed immediately, either by upgrading the panel or adding ground rods.
If your panel has any major deficiencies, it is wise to consider an upgrade. Consult with a licensed electrician if you have any concerns about the overall safety and fitness of your existing setup.
Selecting the New Panel
Once you decide to replace the panel, selecting the proper new unit is essential:
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Amperage - 200 amps is ideal for most homes. Larger homes may benefit from 400 amps. Match amperage to your home's needs.
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Number of circuits - Choose a panel with room to grow. 24 circuits is recommended for a typical home.
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Copper bus bars - Copper bus bars distribute power more efficiently than alternatives.
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Main breaker - This crucial safety feature shuts off all power. Choose a prominent main breaker.
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Surge protector - Highly recommended to protect electronics from spikes.
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Ground bus bar - Essential for proper grounding. Should be pre-installed.
Square D and Eaton are two reputable panel brands, available at home improvement stores for $250-500 depending on features. Select one designed for easy DIY installation.
Working Safely
Safety is paramount when working with electricity. Make sure to:
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Turn off the main breaker - This cuts power to the panel. Test with a non-contact voltage tester to be sure it is dead. Padlock the breaker box if needed.
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Wear protective gear - Eye protection, gloves, long sleeve shirt, etc. Protect yourself against shocks and arcs.
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Use insulated tools - Unsulated tools can cause accidental contact with live wires.
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Work with a partner - They can shut off the main breaker quickly in an emergency.
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Take precautions against shock - Use a mat on the ground and avoid wet conditions. Shocks can be fatal.
Follow all local permit and inspection requirements. Hire an electrician if you are ever uncertain about safely and properly completing the work.
Steps for Replacing the Panel
With proper planning and safety gear, you can methodically replace the outdated panel:
1. Turn Off Power and Remove Old Panel
Double check power is off at the main breaker before starting. Then remove the cover plate and unscrew the wire connections. Carefully detach the old panel but leave it hanging until the new one is wired to avoid unrestrained live wires.
2. Install New Panel
Mount the new panel as close to the old one as possible to avoid having to re-route wiring. Follow the manufacturer instructions. Make sure it is level and secure.
3. Connect Wires
Match the existing wire configurations. Securely connect the ground wires to the ground bus bar. Connect the neutral wires to the neutral bar. Attach the hot wires to their corresponding new breakers.
4. Connect Ground Rod
If the panel is ungrounded, connect a ground rod following local code requirements, typically driving an 8 foot copper rod into the earth near the main panel and securely wiring it to the ground bus.
5. Attach New Cover Plate
With all wiring complete, attach the new outer cover plate. Tighten the screws securely.
6. Power Up and Test
With connections double checked, turn the main breaker on and test operation of all circuits. Your new panel should be fully functional!
Replacing an electrical panel is a major project, but taking proper safety precautions and following good DIY practices can allow you to upgrade your outdated setup without hiring an electrician. Always get professional advice if unsure. But with adequate planning and preparation, a new modern panel can be within the abilities of many motivated do-it-yourselfers.