How Electricians Install Electrical Panels

Installing an electrical panel is one of the most important jobs an electrician can perform. It’s also one of the most misunderstood. While homeowners often focus on the visible parts of an electrical system, like outlets, switches, and light fixtures, the panel is the brain. It distributes power to the circuits that feed the entire house, and if it’s not installed correctly, nothing else will function as it should.

A lot of people hear the term electric panel upgrade when they’re adding new appliances or renovating their homes, but the actual work behind that phrase involves careful planning, code compliance, and a deep understanding of how electricity behaves.

Preparing for the Installation

Before a single tool comes out of the bag, electricians start with a plan. They’ll review the home’s existing electrical system, check the service entrance (where power comes in from the utility company), and determine whether the panel is being replaced or installed from scratch in new construction.

This is also when load calculations are done. Electricians assess how much power the home will need by looking at the square footage, HVAC systems, kitchen appliances, laundry, and potential future needs like EV chargers or home offices. It’s not guesswork. It’s a formula based on the National Electrical Code (NEC), and it ensures the new panel won’t be underpowered or overloaded.

Permits are usually required before installation begins, and a licensed electrician knows how to file these correctly. Skipping permits isn’t just risky, it’s illegal in most areas.

Shutting Off Power

On the day of the install, the first step is cutting the power. For panel replacements, this usually means coordinating with the utility company to temporarily disconnect service at the meter. For safety, nothing happens until the home is completely de-energized.

Electricians don’t take chances with live wires. Even after the main shutoff, they’ll test lines with a multimeter or voltage tester to confirm no voltage is present. Only then do they move forward.

Removing the Old Panel

If this is an upgrade or replacement, the old panel has to be carefully dismantled. Electricians remove the cover (known as a dead front) and label or photograph each existing breaker and wire. This helps them know where everything was and makes it easier to transfer circuits cleanly into the new panel.

They’ll then loosen the lugs (screw terminals) and pull out the individual wires, including hot wires, neutrals, and grounds. Everything is carefully organized to prevent confusion later on. Finally, the panel is unscrewed and removed from the wall.

Mounting the New Panel

The new panel isn’t just slapped onto the wall wherever it fits. It must be mounted at a specific height, anchored securely to studs or masonry, and positioned so that there’s enough working space around it, usually 30 inches wide and 36 inches deep.

Electricians knock out the correct holes on the panel’s back or top and run new conduit or cable into the box. Everything is supported properly with clamps or connectors, and any unused holes are sealed to keep pests and moisture out.

Making the Connections

This is where things get detailed. Electricians start with the grounding system, bonding the panel to the home’s ground rods, cold water pipes, or other approved grounding electrodes. The ground bar is where all bare copper or green-coated wires land.

Next, they connect the neutral wires to the neutral bar, being careful not to double-tap (putting more than one wire under a single screw, which is usually a code violation).

Then come the hot wires. Each circuit gets its own breaker, and electricians are careful to balance the load across both legs of the panel so that power draw is even. This helps avoid overheating and reduces the chance of nuisance tripping.

If it’s a main panel, it’ll also have a main breaker, typically rated for 100, 150, or 200 amps. This is the master shutoff for the whole house, and it’s connected directly to the incoming service wires from the utility company. Those lines are always treated with respect since they may still be live until reconnected by the utility.

Labeling and Testing

Once everything is connected and screwed down, electricians label each breaker with the circuit it controls, like kitchen outlets, living room lights, or the dryer. This isn’t just for convenience. It’s for safety. Future homeowners and other tradespeople need to know what’s what.

Then it’s time to test. Electricians will restore power at the meter, flip on the main breaker, and use voltage testers or clamp meters to check that each circuit is getting proper voltage. They’ll also inspect for heat buildup, loose connections, or any sign of arcing or grounding faults.

GFCI and AFCI breakers (used in kitchens, bathrooms, and bedrooms) are tested using their built-in test buttons and sometimes with dedicated testers to simulate a fault.

Code Compliance and Inspections

Even after everything appears to be working, the job’s not done. Most jurisdictions require an inspection by the local building department. The inspector will check things like:

- Proper grounding and bonding

- Breaker sizes vs. wire gauge

- Clear labeling

- Correct torque on lugs

- Overall neatness and compliance with the NEC

If the panel passes, the electrician will get a sign-off and close out the permit. If something doesn’t meet code, it must be fixed before the panel is considered legal.

Common Challenges Electricians Face

No two installs are exactly alike. In older homes, electricians often discover outdated wiring like knob-and-tube or aluminum branch circuits. These can’t always be safely reconnected to modern panels without additional upgrades.

Sometimes there’s not enough space in the existing location for a larger panel, or the wall may be concrete or brick, which makes mounting trickier. In those cases, electricians may install a subpanel elsewhere or run new conduit.

Weather can also be a factor. Outdoor panels must be rated for wet locations and sealed against the elements, and any penetrations into the home must be watertight to avoid future leaks.

Safety First

Throughout the whole process, electricians wear personal protective equipment, use insulated tools, and follow lockout tagout procedures to make sure no one accidentally re-energizes the system during work. Electrical panels can be deadly when handled improperly.

It’s not just about flipping breakers. Electricians must understand load balancing, fault current ratings, arc flash boundaries, and coordination with utility services. That’s why this is never a DIY job, even for the handy homeowner.

Final Thoughts

A properly installed electrical panel is silent and invisible most days, but it keeps everything in your home working the way it should. From your refrigerator to your Wi-Fi, your whole life depends on it.

That’s why electricians take such care with each step of the process. When done right, the panel will last for decades, power your future needs, and keep your family safe.

And that’s the kind of work that’s always worth doing right.