The answer is likely no, it's not generally possible to convert a Cutler Hammer CH main lug panel from the 80s-90s to a main breaker style. Here's why, and what your options likely are

Why it's unlikely:
Panel Design

Main lug panels and main breaker panels are fundamentally different in their design and bus structure. Main lug panels are designed to be fed directly by service entrance conductors, without a built-in overcurrent protection device (breaker). The main breaker is installed remotely (typically at the meter). A main breaker panel has specific points in the busbar where a large main breaker is designed to connect. CH panels were manufactured as one or the other, not convertible.

Busbar Configuration

The busbar configuration is different. A main lug panel doesn't have the necessary connection points or reinforcing for a large main breaker.

UL Listing and Safety

Converting a panel in this way would violate its UL listing and could create a dangerous situation. The panel wasn't designed or tested to function with a main breaker in that configuration.

What are your options?1. Replace the Panel

This is the most common and safest solution. Replace the existing main lug panel with a new 200A CH main breaker panel. This ensures that you have a panel designed and tested for your intended use.2.

Remote Main Breaker

If the panel is fed directly from the meter and the location is suitable, you can install a separate, enclosed 200A main breaker before the panel. This would provide the overcurrent protection you need. You need to check with your local electrical codes and the utility company if this is permissible. They may require specific enclosures and metering configurations.

Important Considerations



Local Electrical Codes

Any electrical work must comply with local electrical codes and be performed by a qualified electrician.

Permitting and Inspection

A permit and inspection are almost certainly required for this type of work.

Panel Space

Even if you could somehow physically fit a breaker into the panel, it would likely take up a significant amount of space that would be needed for branch circuits.

In conclusion, while it's technically possible that a very rare CH panel might have been designed with some ability to add a main breaker, it's highly unlikely, unsafe, and not something that would be done without violating the panel's UL listing. Replacing the panel is the best course of action. Flag for review