Electrical SOP Example

200A Electrical Service Panel Upgrade

Full service upgrade from 100A to 200A including new panel, meter base, ground rods, and load transfer.

1. Permit, utility coordination & pre-work planningPull electrical permit before beginning any work — panel upgrades require permit in all jurisdictions. Submit load calculation to the AHJ (Authority Having Jurisdiction) if required. Contact the utility company to schedule a meter pull — most utilities require 24–48 hour notice. Confirm meter pull date and time before scheduling the work day. Complete a load analysis of all existing circuits before the work day — list each circuit's breaker size, wire gauge, and connected load. Photograph the existing panel interior with all breakers labeled and each circuit's wire routing before any disconnection.
2. Service entrance & meter base installationWith meter confirmed pulled and utility conductors de-energized, remove the existing meter base. Install the new 200A rated meter base at the same location or per utility requirements — verify mounting height and clearances meet local utility specs. Route new 2/0 aluminum or 4/0 aluminum service entrance cable (SEC) from the new meter base to the new main breaker panel location — maintain proper drip loop at the meter to prevent water entry. Secure SEC at maximum 30" intervals. All penetrations into the structure must be sealed with appropriate weatherproof fittings.
3. New panel mounting & bondingMount the new 200A main breaker panel on the structure — use a solid mounting surface with lag screws into framing. Verify panel is level and plumb. Land the service entrance conductors: hot legs to the main breaker line side lugs (tighten to manufacturer torque spec), neutral to the neutral bus, ground to the ground bus. Verify the neutral-ground bond is in place at the main panel only — sub-panels must have separate neutral and ground buses with no bond. Install the main breaker and verify it operates smoothly.
4. Grounding electrode systemDrive two 8-foot copper-clad ground rods minimum 6 feet apart at the panel location. Connect 4 AWG bare copper wire from the first rod to the second rod, then to the panel ground bus — use irreversible compression or approved clamp connections at each rod. If the building has metal water pipe entering within the first 5 feet of the building, install a ground clamp on the metal pipe and run a bond conductor to the panel ground bus. All connections must be accessible for inspection — do not bury ground rod connections. Document rod locations.
5. Circuit transfer & AFCI/GFCI upgradeTransfer circuits from the old panel to the new panel one at a time — label each wire with the circuit description before disconnecting. Match wire gauge to breaker size: 14 AWG on 15A, 12 AWG on 20A — never increase breaker size on existing wire. Install AFCI breakers on all bedroom circuits and any circuits now required by the current NEC edition adopted in the jurisdiction. Install GFCI protection for all bathroom, kitchen, garage, exterior, unfinished basement, and crawlspace circuits as required. Verify all neutrals are landed on the neutral bus — not crossed with adjacent circuits.
6. Dead-front check & panel energizationBefore requesting meter reconnection, perform a complete dead-front inspection: verify all breakers are off, all conductors are properly terminated, no bare conductors are touching the enclosure, all knockouts are filled, and the neutral bus has no loose connections. Verify all ground connections are secure. Call for the meter to be reconnected — most utilities do not allow the homeowner or contractor to reconnect at the utility side. After the meter is set, turn on the main breaker and verify voltage on both legs (should be 120V leg-to-neutral, 240V leg-to-leg) before energizing branch circuits one at a time.
7. Labeling, inspection & documentationLabel every breaker in the panel directory with a clear, accurate description of the circuit it protects — room name and device type. Test every AFCI and GFCI device using the test button. Test every circuit for proper operation. Schedule the electrical inspection with the AHJ — have the permit and load calculation on site. After inspection approval, photograph the completed panel interior with all breakers labeled, the meter base, and both ground rods. Provide the homeowner with the passed inspection record, panel schedule, and any warranty documentation for the panel.