How to Upgrade Your Business's Electrical Panel on a Budget

Upgrading your business's electrical panel can seem like a daunting and expensive task. However, with some planning and savvy shopping, you can upgrade your panel without breaking the bank. Here is a step-by-step guide on how to upgrade your business's electrical panel on a budget.

Assess Your Current Panel

The first step is to thoroughly assess your current electrical panel.

• What is the amperage rating and number of circuit breakers? This will determine if your current panel is sufficient for your business's needs.

• How old is the panel? Older panels may not be able to handle increased electrical loads. Anything over 20 years old should likely be replaced.

• Are there signs of corrosion, rust, or overheating? This can indicate faulty or failing components.

• Do you lack enough circuit breakers or available space for additional circuits? If you need more circuits added, an upgrade is necessary.

Take detailed notes and photos of your current panel. This information will come in handy when planning your upgrade.

Determine Your Electrical Needs

Once you've assessed your current panel, analyze your business's electrical needs:

• Make a list of all electrical devices and appliances used. Note the wattage, amperage draw, and voltage.

• Will you be adding any major electrical equipment or devices in the near future? Plan for projected needs.

• Do you experience frequent tripped breakers or power issues? This is a sign you need more capacity.

Crunching these numbers will tell you the ideal amperage rating and number of circuits your new panel should have. Add 25-30% more capacity than you need to allow for future growth.

Choose Your New Panel

With your requirements determined, start shopping for a new panel:

• Look for 100+ amp main breakers - This provides room to grow. 200 amps is ideal for many small businesses.

• Choose a recessed or surface mount panel - Recessed takes more work to install but looks more seamless. Surface mount is easier for DIY.

• Make sure the panel has enough circuit breaker spaces - Allow for some empty spaces for future expansion.

• Select bolt-on breakers - More reliable and easier to install than push-in.

• Buy from reputable brands - Square D, GE, and Eaton are quality affordable options.

• Get the right amperages for breakers - Most circuits require 15 or 20 amp breakers. Major appliances may need 30, 40, or 50 amp.

Safely Remove and Replace Your Panel

With your new panel purchased, it's time for installation. Safety should be your top priority:

• Turn off the main breaker and confirm power is off - Use a contactless voltage tester. Lock out the panel.

• Carefully remove the old panel - Document wiring locations for the new installation.

• Install mounting brackets and slide the new panel into place - Follow the manufacturer's instructions.

• Connect the feeder wires to the main breaker - Match colors (black, red, white, ground).

• Connect all the branch circuits to their corresponding breakers - Refer to your notes.

• Attach the ground wire and grounding bus bar

• Triple check connections are tight - Loose connections can cause arcing and fires.

• Energize the panel and test breakers - Turn main breaker on and flip each breaker on and off to test.

Make It Look Professional

If desired, you can take extra steps to improve the aesthetics of your new panel:

• Add a coat of clean white paint - This makes the panel blend in. Use an electrical-safe paint.

• Get a panel cover - Covers just the front and hides wires. Quick upgrade for under $10.

• Build an enclosure around the panel - Construct a secure box around the panel. Provides safety and visual appeal.

With proper planning and a methodical installation process, you can successfully upgrade your business's electrical service panel without overspending. Paying attention to details will ensure you complete a safe, long-lasting upgrade.