200A Panel Upgrade: How to Quote, What to Charge, and What to Watch For

A 200A panel upgrade is one of the highest-value jobs for a residential electrician. Here's how to do it right — and profitably.

When Does a Customer Need a 200A Upgrade?

Common triggers: - Adding an EV charger (50-60A dedicated circuit) - Kitchen remodel with new appliances - Home addition or ADU - Solar panel installation - Old 60A or 100A service that's overloaded - Federal Pacific or Zinsco panel replacement (safety hazard)

Typical Cost Breakdown

In most US markets, a 200A panel upgrade runs $2,000-$4,000. Here's a sample breakdown:

Step-by-Step Process

1. Pull the permit — most jurisdictions require a permit for service changes 2. Coordinate with the utility — they need to disconnect/reconnect at the weatherhead 3. Install new panel, meter socket, grounding — get everything ready BEFORE utility day 4. Schedule inspection — rough-in before utility reconnects 5. Transfer circuits — one at a time, label everything

The Grounding System

NEC 250 requires a grounding electrode system. For a 200A upgrade, you typically need: - Two 8-foot ground rods, spaced at least 6 feet apart - #4 bare copper GEC to the first rod - #6 bare copper bonding jumper between rods - Bond to the cold water pipe (within 5 feet of entry)

AFCI/GFCI Requirements

When you upgrade the panel, many jurisdictions require you to bring the circuits up to current code. That means adding AFCI breakers to bedroom and living area circuits, and GFCI breakers where required. Budget $40-60 per AFCI breaker.

Customer Communication Tips

• Explain WHY the upgrade is needed in plain English
• Show them the old panel vs new panel difference
• Give a firm quote, not an estimate
• Tell them power will be off for 4-8 hours
• Schedule on a weekday when the utility company is available