When does a house need a panel upgrade?
When the panel is full, unsafe, or too small for what you're adding. A load calculation and inspection tell you which. Common reasons:
- No open spaces for a new breaker (PG&E lists space limits as a common reason to upgrade)
- Plans for an EV charger, heat pump, electric dryer, or induction range
- A fuse box, or a panel brand inspectors flag, such as FPE Stab-Lok, Zinsco, Pushmatic, or Challenger
- Breakers that run hot, show scorch marks, or won't stay on
- A split-bus panel with no single main breaker, which InterNACHI says was common from the 1950s to the mid-1980s
Why are homes going from 100 to 200 amps?
Going electric adds big loads. In PG&E's sample California home, switching to an induction stove, heat pump, heat pump water heater, electric dryer, and EV charger raised the estimated need from 43 amps to 122 amps, which is more than a 100-amp panel can handle.
PG&E says older homes can have panels from 60 to 150 amps. A 200-amp panel leaves room for a Level 2 EV charger, which SMUD says adds 25 or more miles of range per hour, plus electric heating, cooling, and cooking.
Bigger isn't always required. In the same example, a heat pump dryer, a 120-volt heat pump water heater, a lower-power EV charger, and circuit sharing cut the need to 89 amps, so the 100-amp panel worked. PG&E says avoiding an upgrade could save $2,000 to $6,000.
Can I avoid a panel upgrade?
Sometimes. If your panel is safe and in good shape, ask your electrician about these options first:
- Circuit-sharing devices: let an EV charger and a dryer take turns on one 240-volt circuit. SMUD offers up to $200 toward one.
- Energy management devices or smart panels: limit the total load so the main breaker isn't overloaded.
- Lower-wattage appliances: 120-volt heat pump water heaters and heat pump dryers draw less power.
- Adjustable EV chargers: can be set to a lower amperage to fit your panel.
- A subpanel: adds breaker space when the panel has load capacity but no open slots.
How does a panel upgrade work with SMUD, PG&E, or Roseville Electric?
The electrician does the work in your home, but the utility has to cut and restore power at the meter. The steps depend on your utility:
- SMUD: service changes start with SMUD's project application. SMUD won't connect service until the work passes inspection by the local building authority, and only SMUD crews make the final connection.
- PG&E (most Placer, El Dorado, and Yolo County cities): your electrician files in PG&E's Your Projects portal. PG&E checks whether nearby lines and transformers can handle the load (up to 30 days), may ask for a refundable advance of up to $5,000, and typically reconnects within a day after the inspector approves.
- Roseville Electric: submit its Electrical Panel Upgrade Application before you apply for the building permit. Roseville Electric says it responds within two business days.
- Permit: the contractor pulls it from your city or county building department, and a final inspection is required.
Which old panels should be replaced?
InterNACHI, the home inspectors' association, lists Federal Pacific Electric (FPE) Stab-Lok, Zinsco/GTE-Sylvania, Bulldog Pushmatic, and Challenger panels as the most commonly found problem panels and recommends replacing them. It says breakers in these panels fail to trip at rates far higher than industry standards.
Most were never recalled. The CPSC closed its FPE investigation in 1983 because the data didn't establish a serious risk, though its tests confirmed the breakers failed some UL calibration tests; it never declared them safe. Have an electrician evaluate yours.
Panel work is never a DIY job: EC&M notes the utility's incoming wires stay energized even with the main breaker off.
Are there panel upgrade rebates in 2026?
A few, and most come with conditions:
- SMUD Go Electric bonus: up to $2,000 (up to $500 per eligible circuit) when you replace a gas furnace or gas water heater with a qualifying heat pump and make the home all-electric ready. A SMUD Contractor Network contractor must submit it.
- PG&E Rebate Plus: income-qualified customers may get up to $5,000 for a panel upgrade plus an eligible EV charger. You must be pre-approved before a Trade Ally contractor buys the equipment.
- Federal tax credit: SMUD notes the panel upgrade credit covered only panels installed through December 31, 2025.
| Job | Range | Source and year |
|---|---|---|
| Upgrade to 200 amps | $1,800 to $4,500 | Fixr, 2025 |
| Upgrade an electrical panel | $1,300 to $3,000 | This Old House, 2026 |
| Replace a panel, same size | $1,000 to $3,500 | Fixr, 2025 |
| PG&E load assessment advance (refunded or credited) | Up to $5,000 | PG&E |
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Frequently asked questions
How long does a panel upgrade take?
Can I upgrade my own electrical panel?
What is a load calculation?
Sources
- Your home electrification project: How to switch to electric appliances without an electrical panel upgrade — PG&E
- A roadmap to your electrical panel upgrade — PG&E
- Inspecting the Main Electrical Panelboard — InterNACHI
- Residential electric vehicles — SMUD
- Electric Service Requirements: Residential Overhead — SMUD
- New & upgraded electric service (Electrical Panel Upgrade Application) — City of Roseville, Roseville Electric Utility
- Commission Closes Investigation of FPE Circuit Breakers and Provides Safety Information for Consumers (1983) — U.S. Consumer Product Safety Commission
- Panelboard Safety Matters — EC&M
- Go Electric bonus rebates — SMUD
- Residential Electric Vehicle (EV) Charging Rebate — PG&E
- Electrical Panel Upgrade Cost (updated January 31, 2025) — Fixr
- How Much Does an Electrician Cost? (updated June 5, 2026) — This Old House
- Handyperson Exemption to Increase to $1,000 in 2025 (CSLB #24-21, AB 2622) — Contractors State License Board (CSLB)
- Owner-Builder Responsibilities — Contractors State License Board (CSLB)
- City of Sacramento Guide to EVSE Permits for Residential Installations (revised 02-12-2026) — City of Sacramento Community Development Department