How to Safely Replace Your Own Electrical Panel

Introduction

Replacing an electrical panel can be a daunting task, but with proper planning and safety precautions, a homeowner can safely install a new panel. A new panel provides increased capacity, safety upgrades, and peace of mind knowing your home's electrical system is up-to-date. This guide will walk you through the key steps I took to replace my outdated fuse box with a new circuit breaker panel.

Reasons to Replace an Electrical Panel

There are several reasons you may need or want to replace your home's electrical panel:

• Insufficient capacity - If your home lacks enough circuits or amperage for today's power demands, upgrading the service capacity with a new panel is necessary. New larger appliances, added lighting circuits, or electric vehicle charging needs may require an upgraded panel.

• Safety upgrades - Older fuse boxes lack the safety of modern circuit breakers that can prevent fires. Upgrading provides vital protection.

• Age and condition - Old panels can become rusty or deteriorated over decades of use. Replacing an old panel eliminates the risk of malfunctions.

• Preparing for home additions - Any significant renovation like adding a pool, garage, or in-law suite will require upgraded electrical service. A new panel gives you capacity for additions.

• Increasing home value - Upgrading the electrical panel adds value and makes the home more attractive to potential buyers.

Key Steps to Safely Replace an Electrical Panel

Replacing the main electrical service panel is a job best left to licensed electricians, but homeowners can legally do it themselves through proper planning, permitting, and inspections. Here are the essential steps I followed to safely change my home's panel:

Research local permitting requirements

• Electrical work requires permits in most jurisdictions. Research what your local building department needs for a panel replacement permit. Requirements vary but may include submission of your planned work, one-line diagram of the new panel, and site plan.

Select the new panel

• Choose a main service panel rated for your home's electric needs with room for expansion. Using Square D or GE panels ensures safe, reliable equipment. Consult an electrician if unsure what amperage or spaces are needed.

Safely shut off power

• The power company must shut off service at the meter before starting work. This requires an advance service disconnect request. Never work on a panel with the power on!

Remove the old panel

• With power off, remove the old panel cover and disconnect all wires from breakers and neutrals from the bus bar. Remove the feeder wires and conduit or cable from the top. Unmount the panel box from the wall.

Install new panel mounting brackets

• Place the bottom of the new panel box where you want it, accounting for service conduit entry. Mark bracket locations, drill holes, and mount the supplied brackets at the proper height.

Mount the new panel

• Place the new panel on the mounted brackets and drill holes for the top mounting screws. Make sure the panel box is level and secure.

Connect the service feeder wires

• With all power still off, connect the service feeders to the main lugs or main breaker. Secure the cables or conduit. Ensure proper grounding connections.

Connect the branch circuits

• Referring to the panel labeling, connect the existing branch circuit wires to new breakers of the same amperage. Follow code for neutrals and grounds.

Inspect and energize the new panel

• Call for inspection before turning power on. Once approved, call the utility to reestablish service. Check voltages, grounding, and circuit functions. Install front cover.

Safety Tips for DIY Panel Replacements

Proper safety steps helped ensure my panel project went smoothly.

• Use appropriate PPE - Wear safety glasses and electrical gloves when handling wires.

• Label all wires - Correctly identifying existing circuit wires avoids mistakes.

• Double check connections - Improper wire installation can be deadly. Verify tight connections.

• Keep the area dry - Avoid damp areas and use tarps to keep work conditions dry.

• Follow torque specs - Use a torque screwdriver to achieve proper tightness on lug connections.

• Be prepared for surprises - Unknown issues like faulty wiring may appear once the old panel is uncovered.

Conclusion

While not an easy DIY, replacing my 1960s-era fuse box greatly improved my home. The sense of accomplishment coupled with modern safety and capacity was well worth the effort. Following proper planning and safety steps allowed me to do it safely myself, saving thousands over hiring an electrician. Your own capabilities and regulations should dictate whether you take on this project solo or leave it to the professionals.