How much does an electrical panel upgrade cost in Orange County?
Electrical panel upgrades in Orange County typically cost $1,800 to $7,000 in 2026 at Aerosphere Electric. A 100A to 200A upgrade runs $1,800-$3,500. A 200A new install runs $2,500-$4,500. A 200A upgrade with grounding and meter work runs $3,500-$5,500. A 320A or 400A service runs $4,500-$7,000. Free written estimates.
How long does a panel upgrade take?
A standard 200A panel upgrade takes Aerosphere Electric 1-2 days. Day 1: permit pulled, SCE disconnect coordinated, old panel removed, new panel installed, all circuits re-wired and tested. Day 2 (if needed): city inspection and SCE reconnect. Most homes are without power for 4-8 hours during the swap.
Do I need to upgrade my Federal Pacific panel?
Yes. Federal Pacific (FPE Stab-Lok) panels have well-documented failure modes where breakers fail to trip during a short circuit, creating fire risk. Most major insurance carriers will not insure homes with FPE panels. Aerosphere Electric strongly recommends immediate replacement. A 200A panel replacement runs $1,800-$4,500.
Do I need to upgrade my Zinsco panel?
Yes. Zinsco (also Sylvania-Zinsco and GTE-Sylvania) electrical panels have similar failure modes to Federal Pacific - breakers can melt to the bus bar and fail to trip during faults. Insurance companies typically require replacement. Aerosphere Electric recommends immediate replacement. A 200A panel swap runs $1,800-$4,500.
When do I need a panel upgrade?
You likely need a panel upgrade if: breakers trip frequently, lights dim when appliances start, you have scorched or melted outlets, your panel brand has been recalled (Federal Pacific, Zinsco, Challenger), you have only 100A service and a modern home, or you are planning to add an EV charger, hot tub, induction stove, or whole-home AC. Aerosphere provides free panel inspections.
Do I need a panel upgrade to install an EV charger?
Sometimes. If your existing panel has spare capacity (at least 40-50A free), you may not need an upgrade. If your panel is at or near capacity, an upgrade or sub-panel is needed before the charger can be installed safely. Aerosphere Electric evaluates your panel during a free EV charger site visit and quotes both options. Combined panel + EV charger projects typically run $3,000-$6,500.
Is a permit required for a panel upgrade?
Yes. Every Orange County city requires a permit for any electrical panel replacement or upgrade. Aerosphere Electric pulls the permit, schedules city inspection, and coordinates Southern California Edison (SCE) for disconnect and reconnect. Permit fees ($150-$400) are included in the quoted price.
Should I get 200A or 400A service?
200A is sufficient for most Orange County single-family homes, including those with central AC, gas water heater, and one EV charger. Upgrade to 320A or 400A if you have or plan: two EV chargers, all-electric home (induction stove + heat pump + electric water heater + EV), large pool/spa equipment, detached ADU with its own circuits, or a home over 4,000 sq ft. Aerosphere does a load calculation to recommend the right size.
Does Aerosphere Electric do sub-panel installation?
Yes. Aerosphere Electric installs sub-panels throughout Orange County. Sub-panels add capacity without replacing the main panel - useful for garages, ADUs, workshops, additions, and EV chargers when the main panel is full but recently upgraded. Sub-panel installs run $850-$2,200 depending on amperage and run distance.
What brand of panel does Aerosphere Electric install?
Aerosphere Electric installs all major panel brands including Square D QO and Homeline, Eaton BR and CH, Siemens Q and QP, and GE/ABB. Square D QO is the most common premium choice for Orange County homes. We match the panel brand to the breakers you already own when possible to save on breaker replacement costs.
Free Panel Inspection
Not sure if you need an upgrade? Aerosphere does free written panel inspections across Orange County.
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See full panel upgrade service page, EV charger FAQ, complete knowledge base, 10 signs you need a panel upgrade, or pricing guide.