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Topic: Main Service Panel Upgrade

User: TRtoolman, Location: Southwest PA

Asked on: Friday, March 7, 2025 at 8:42 am EST
Answered on: Saturday, March 8, 2025 at 12:10 am EST

Question: I’m a retired electrician in western PA just south of Pittsburgh. It’s been about 12 years since I did any electrical work for anyone besides myself. I have a close friend that asked me to help him with a main panel upgrade. He has an old 100A main panel with Push-Matic breakers. We will be installing everything new from the weather head down to the panel, and upgrading the ground system with new ground rods, ground conductors and water meter bonding jumper.. I have done many services in the past and usually we only had to have the new service and grounding Inspected. I am wondering if any of that has changed with the new codes. Here in PA we are still using the 2017 NEC Code. The last code I did any work under was the 2008 NEC Code and the only Arc-Fault breakers requirement was in the bedrooms and that was only if those branch circuits were modified or newly installed. I see now that they are required in all living areas. Will I need to install Arc-Fault breakers in the new panel even though we are not doing any branch circuit modifications?Any info or advice would be greatly appreciated.

Okay, it's good you're brushing up on the code, especially since it's been a while. Here's a breakdown of what you need to know, keeping in mind you're under the 2017 NEC in Pennsylvania

Key Considerations for Your Service Upgrade Project:

1. Scope of Work Defines Requirements

The big question is: Is this considered a replacement or an upgrade of the service? Since you're replacing everything from the weatherhead to the panel and upgrading the grounding, it will likely be considered a complete service change or upgrade. This means new code requirements will apply.2.

Arc-Fault Circuit Interrupters (AFCIs) - VERY IMPORTANT



2017 NEC Requirement

Under the 2017 NEC, AFCI protection is required in many more locations than under the 2008 NEC. Specifically, 210.12(A) states that all 120-volt, single-phase, 15- and 20-ampere branch circuits supplying outlets or devices installed in dwelling units' kitchens, family rooms, dining rooms, living rooms, parlors, libraries, dens, bedrooms, sunrooms, recreation rooms, closets, hallways, laundry areas, or similar rooms or areas shall be protected by AFCI protection.

Even without branch circuit modifications

Because you are replacing the entire service, the AHJ (Authority Having Jurisdiction) will likely consider this a new installation that must meet current code requirements.

Therefore, YES, you will almost certainly need to install AFCI breakers for all circuits serving the areas listed above, even if you aren't touching the existing wiring in those rooms.
Exceptions are very limited

There are very few exceptions to this requirement. Don't count on an exception being applicable.3.

Ground-Fault Circuit Interrupters (GFCIs)

GFCI requirements have also expanded since 2008. Common GFCI protected areas include: Bathrooms Garages Outdoors Kitchen countertops Unfinished basements Crawl spaces Laundry areas Within 6 feet of sinks Dishwashers/Disposals4.

Grounding and Bonding



Updated Requirements

Grounding and bonding requirements have been refined and clarified significantly since 2008. Pay very close attention to:

Electrode System

You're on the right track with new ground rods, grounding electrode conductor, and water pipe bonding. Make sure the ground rods are properly spaced (at least 6 feet apart, ideally the length of one rod) and driven deep enough (check local requirements).


Sizing

Double-check the sizing of your grounding electrode conductor and bonding jumpers based on the size of the service conductors. Use Table 250.66.

Water Meter Jumper

This is crucial. You must bond around the water meter with a conductor sized per 250.66.


Metal Water Pipe

You must bond to the interior metal water piping system within 5 feet of where it enters the building.

Supplemental Electrode

If the water pipe is used as a grounding electrode, it MUST be supplemented by an additional electrode such as a ground rod or ground ring.


250.50 Grounding Electrode System.
All grounding electrodes must be bonded together to form the Grounding Electrode System. 250.104(A) Bonding of Piping Systems. Interior metal water piping and any other interior metal piping that may become energized shall be bonded to the service equipment enclosure, the grounded conductor at the service, the grounding electrode conductor where of sufficient size, or to the one or more grounding electrodes used. The bonding jumper(s) shall be sized in accordance with Table 250.102 using the largest ungrounded conductor(s) that supply the building or structure.
5. Service Entrance Cable (SEC)



Type SE Cable

Be sure to use the correct type of SE cable for your application (Type SE, Style U for above-ground, etc.).

Ampacity

The ampacity of the SEC must be sufficient for the calculated load of the dwelling (consider load calculations per Article 220).


Secure and Support

Properly secure and support the SEC according to code.6.

Panel Installation



Working Space

Ensure you have the required working space in front of the panel (36" deep, 30" wide, 6'6" high).


Clearances

Maintain proper clearances around the panel.

Labeling

Clearly label all circuits in the panel.


Torque

Torque all connections to the manufacturer's specifications. This is extremely important for safety and reliability.

Neutral/Ground Separation

Ensure proper separation of neutral and ground conductors in the panel.7.

Coordination with the Utility Company
Contact your local utility company to inform them of the service upgrade and coordinate the disconnection and reconnection of power. They may have specific requirements or inspections.8. Permits and Inspections



Required

Obtain the necessary permits from your local municipality before starting the work.

Inspections

Schedule inspections at the required stages (usually after the service is installed but before it's energized, and potentially another after the wiring is complete).

Recommendations and Advice



Contact the Local Inspector

This is the most important step. Call the electrical inspector in your friend's municipality before you start the project. Explain what you're planning and ask specifically about their interpretation of the AFCI requirements for a service upgrade like this. They have the final say. Get it in writing if possible.

2017 NEC Book

Get a copy of the 2017 NEC book. You can find these online or at electrical supply houses.


Load Calculation

Perform a proper load calculation for your friend's house to determine the appropriate size of the new service. Don't just assume 200A is sufficient.

Consider a Surge Protective Device (SPD)

Think about installing a surge protective device (SPD) at the service entrance. This can protect your friend's valuable electronics from power surges. It's a good selling point.


Document Everything

Keep detailed records of all materials used, measurements taken, and work performed. This will be helpful for the inspector and for future reference.

Safety First

Always prioritize safety. Disconnect power before working on any electrical equipment. Use appropriate personal protective equipment (PPE).

In summary:
AFCI protection is almost certainly required in this project, grounding and bonding requirements have evolved, and you need to communicate with the local inspector before you begin*. Doing your homework and planning carefully will ensure a safe and code-compliant service upgrade. Flag for review

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