When you actually need 200A
Not always. The free panel check from a network installer determines this with NEC 220 demand-load math, not assumption. Cases where a panel upgrade is genuinely necessary:
- You have an existing 100A panel and want a 48A Wall Connector (the math doesn't work)
- You're planning multiple electrification upgrades (heat pump, EV, induction range, electric water heater)
- Your panel is from before 1990 and is a known-defective brand (Federal Pacific, Zinsco)
- You're adding home solar with battery + EV — the energy management complexity calls for 200A
When you DON'T need 200A
Cases where the network recommends a cheaper path instead:
- 125A or 150A panel + 32A or 40A charger — usually fits with no upgrade
- 100A panel + load management system — adds $1,420, avoids the $4k+ panel upgrade
- 100A panel + 32A charger — sometimes the math fits without management
What's in a panel upgrade
- New service-entrance conductors from utility transformer or pole
- New meter socket (utility-compatible)
- New 200A main breaker panel with adequate breaker space (typically 40 spaces)
- Re-connect existing circuits with proper labeling
- Bonding + grounding to current code
- Utility coordination — typically 1-day power-off window
- City + utility inspection
Pricing in 2026
- 100A → 200A, simple overhead service — $3,800–$4,800
- 100A → 200A, underground service trenching needed — $5,400–$6,400
- Old defective panel (Federal Pacific, Zinsco) → 200A — $4,400–$5,200, factory-replacement scope
- + EV charger install on same day — package pricing typically $1,200–$1,800 less than separate scopes
The free panel check from a network installer is where this question gets answered. The installer reads the panel, runs NEC 220 demand-load math, considers any future electrification you're planning, and recommends the right path. No upsell pressure — the network's principle is "right-size the install."