The meeting covered the full process, key code requirements, and best practices for upgrading an old 100 amp residential electrical service to 200 amps.
Detailed steps were given on equipment selection, panel installation, grounding, and bonding, with explanations of code compliance and safety considerations.
The discussion included lessons learned, tools used, and rationale for specific installation choices, such as the number of panel circuits and grounding methods.
Final installation, labeling, and preparation for inspection were completed, with plans for further minor electrical work and pending final electrical inspection.
Action Items
(Pending final inspection) – Contractor: Schedule and complete the final electrical inspection to close out the service upgrade.
(Today) – Contractor: Label each circuit breaker on the panel legend as required by code.
(Today) – Contractor: Install an exhaust fan in the bathroom.
(Today) – Contractor: Replace approximately 15 duplex receptacles.
(This week) – Contractor: Fill exterior conduit fitting with duct seal for weather protection.
Service Panel Review and Code Compliance
Identified multiple code violations with the previous panel (e.g., wrong breaker types installed, main breaker orientation).
Emphasized the importance of using only manufacturer-approved breakers for the panel to ensure safety and proper function.
Explained short circuit current ratings and required interrupting capacity for disconnects, especially relevant for inspectors.
Service and Meter Upgrade Process
Described installation of a new, larger 200 amp meter enclosure, ensuring it covers the old opening and is watertight.
Installation included use of appropriate hubs, irreversible screws, and correct mounting techniques.
Overhead service riser and weather head fitted above window per requirements, noting challenges with high riser placement.
Adjustments made for depth and height using 2x4s and plywood; tools and work techniques discussed.
Panel Installation and Wiring
Selected and installed a surface-mounted 200 amp Cutler Hammer BR panel with a 40 circuit (expandable to 80) capacity.
Routed conduit and cabling to maximize code compliance and ease of future expansion.
Stressed the importance of using a minimum 40-circuit panel for a 200 amp service for long-term value, especially with growing power demands (e.g., EV chargers, HVAC).
Grounding and Bonding
Grounding electrode conductor attached to copper water main within 5 feet of entry, using number two aluminum per code.
Two ground rods installed and interconnected using number six copper.
Detailed proper bonding techniques between neutral and ground at the main disconnect, avoiding parallel current paths by running four wires to the panel (two hots, neutral, ground).
Auxiliary bonding bridge set up for telecommunications or satellite grounding as needed.
Completed all exterior and interior grounding to meet inspection and safety standards.
Lessons, Tools, and Safety
Discussed tool choices and installation tips, including use of magnetic bits, circular saws, and appropriate extension ladders.
Noted lessons learned (e.g., avoid pre-gluing entire riser before measuring, ensure gloves for safety on conductive siding).
Praised the value of continuing education for licensed electricians, citing frequent code and practice updates.
Final Steps and Inspection Prep
Final checks included securing all connections, centering and fastening the panel, labeling circuits.
Necessary weatherproofing and labeling scheduled.
Awaiting final inspection to complete the upgrade.
Decisions
Chose a 40-circuit (expandable to 80) 200 amp panel for long-term capacity — Ensures future-proofing for increased electrical load, electric vehicles, and modern appliances, offering better value and code compliance than a 20-circuit panel.
Maintained original grounding method (jumper on water main) and left old clamps in place — Rationale: Minimize risk of leaks or interruptions to plumbing during upgrade.
Open Questions / Follow-Ups
Clarification pending from PSNG inspector regarding meter main acceptance for future projects.
Confirm if additional auxiliary grounding for telecom/satellite is required on this installation.
Ensure pending final electrical inspection is scheduled and passed.