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Topic: What breakers can I use?

User: Max Headroom, Location: Claremont CA 91711

Asked on: Tuesday, April 1, 2025 at 10:42 pm EDT
Answered on: Tuesday, April 1, 2025 at 10:42 pm EDT

Question: Hello, all I have so far is a few photos but I think this must be an old Challenger panel, I would like to add a 50 amp double pole or maybe even a 60 amp for a EVSE install. Does anybody know what modern breaker would work? Thank you

Okay, let's figure this out. Identifying the panel and finding compatible breakers can be tricky, especially with older panels. Without seeing the photos, I can give you some general guidance, but you'll definitely need to take photos of the panel for a definitive answer.

General Approach1. Panel Identification is Key

The brand and model of the panel are the most important factors. You need to find this information. It is almost always stamped on the inside of the panel door or the side of the enclosure itself.2.

Determine Compatibility

Once you have the brand and model, you can research which breakers are compatible. This can sometimes be found online (breaker cross-reference guides), by contacting a reputable electrical supply house, or contacting an electrician.3.

Safety First

Do not attempt to work on the panel live. De-energize the main breaker before inspecting or doing anything. If you are not comfortable working with electricity, hire a qualified electrician.

Information Needed
Photos



Overall Panel

A clear shot of the entire panel, both with the door closed and especially with the door open. Make sure the photo is in focus and well-lit.

Panel Label

A close-up, in-focus photo of the panel's label. This is
crucial. The label will contain the manufacturer, model number, voltage, amperage rating, and a list of approved breaker types.

Interior

A close up of the buss bar/interior rail where the breakers clip in.

Where to Look for Information on the Panel
Inside the Panel Door

The label is most often on the inside of the panel door.


On the Panel Enclosure

If not on the door, look for it on the sides, top, or bottom of the metal enclosure itself. Sometimes it's stamped into the metal or on a separate sticker.

Typical Challenger Panel Considerations (Keep in mind, this is general, and photo confirmation is needed)



Old Challenger panels are often compatible with Eaton CL series breakers.
This is a common substitute that is usually compatible. The CL series offers both 50 amp and 60 amp double pole breakers. Check for UL Listing

Any breaker you install
must be UL listed for use in that panel. Using an unapproved breaker is a safety hazard and a code violation.

Steps for Breaker Installation (Assuming You've Determined Compatibility and are Qualified)
1. Turn off the Main Breaker

Absolutely critical.2.

Verify No Voltage

Use a non-contact voltage tester to confirm that the panel is de-energized.3.

Remove the Panel Cover

Carefully remove the panel cover, being mindful of the live bus bars inside.4.

Prepare the Wires

Run the appropriate gauge wire (check the EVSE installation instructions and local codes for wire sizing) to the panel location. Strip the ends of the wires.5.

Install the Breaker

Snap the new breaker into the designated space on the bus bar. Make sure it is firmly seated.6.

Connect the Wires

Connect the wires to the breaker terminals and tighten the screws securely. Follow the manufacturer's torque specifications if available. Connect the ground wire to the ground bus bar in the panel.7.

Replace the Panel Cover

Carefully replace the panel cover, ensuring all wires are properly tucked away and not pinched.8.

Turn on the Main Breaker

Turn on the main breaker.9.

Test

Test the new circuit with a multimeter or by plugging in the EVSE (after it's properly installed).

Important Warnings
Aluminum Wiring

If the house has aluminum wiring (common in some older homes), you must use connectors and procedures specifically designed for aluminum-to-copper connections. Improper connections can cause fires.

Panel Overload

Make sure that adding a 50 or 60 amp circuit will not overload the panel's overall capacity. Consult an electrician to perform a load calculation if you are unsure.


Local Codes

Follow all local electrical codes. Permits may be required for this type of work.

In summary, please provide clear, in-focus photos of the panel, especially the label. Then I can give you more specific information.
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