The signs that a panel needs work: breakers that trip under normal use, flicker across the house, heat or a burning smell, aluminum branch wiring, a Federal Pacific or Zinsco panel, a 100-amp service you are about to add a big load to, rust, and loose or warm breakers. Some need a repair, some a replacement, and two need a call today.
This guide is part of our Electrical Panel Upgrades service in Dallas–Fort Worth.
These eight signs mean your panel needs attention: breakers that trip under normal use, flicker across the house, a burning smell, aluminum branch wiring, a Federal Pacific or Zinsco panel, a 100-amp service you are about to add a large load to, rust or moisture, and breakers that are loose or warm. A burning smell and a warm panel are same-day calls. The rest start with a diagnosis, and not every one ends in a new panel.
1. Breakers trip under normal use
A breaker trips to protect the wire. One that trips now and then when you run the microwave and the toaster together is doing its job. One that trips several times a week with ordinary use means the circuit is overloaded, a device or wire has a fault, or the breaker itself is worn. The fix may be a new circuit or a breaker rather than a panel; our breaker tripping guide walks through the causes.
2. Lights flicker across the house
One flickering light is usually the bulb, the dimmer or the socket. Flicker on several circuits points to something they share, such as the panel, the main breaker or the neutral. Lights that get brighter while others dim suggest a loose neutral and need a call the same day. See why lights flicker.
3. A burning smell at the panel
A burning or hot-plastic smell means something is overheating. Turn off the main breaker if you can reach it safely, keep away from the panel, and call 911 if you see smoke or flame. Then call us. Our burning smell guide covers what to do in order.
4. Aluminum branch wiring
This sign is about the 15- and 20-amp circuits feeding outlets and lights, not the large service cable entering the panel, which is commonly aluminum and is not a concern when installed correctly. Aluminum branch wiring was used in some homes in the 1960s and 1970s. A survey for the Consumer Product Safety Commission found homes built before 1972 with aluminum wiring were 55 times more likely to have an outlet connection reach "fire hazard conditions" than homes wired with copper (CPSC Publication 516). The CPSC's recommended repairs are rewiring with copper or connecting copper pigtails with COPALUM crimps or AlumiConn connectors. A new panel alone does not fix it. See aluminum wiring repair cost.
5. A Federal Pacific or Zinsco panel
The Consumer Product Safety Commission's testing confirmed that Federal Pacific Stab-Lok breakers "fail certain UL calibration test requirements," though it closed its investigation in 1983 without a recall (CPSC, 1983). We recommend planning a replacement, and treating it as urgent if there is heat, scorching or a loose breaker. Read whether every Federal Pacific panel needs replacing and what to know about Zinsco panels.
6. A 100-amp service and a big new load
An EV charger, a hot tub, a heat pump or a shop can add 30–60 amps of new load. Whether a 100-amp service can take it is answered by a load calculation under NEC Article 220, not a guess. Sometimes it can; sometimes the answer is a 200-amp upgrade or load management. Do the calculation before you buy the equipment. See EV charger installation cost and upgrading from 200 to 400 amps for larger homes.
7. Rust, corrosion or moisture
Rust on or inside a panel means water has been getting in, usually through the service mast, a conduit or a gap in an outdoor enclosure. Corrosion at breaker and bus connections creates resistance and heat. Find and stop the water first; then the panel can be assessed for repair or replacement.
8. Loose or warm breakers
A breaker that is warm to the touch, or one that looks loose in its slot, can mean a poor connection to the bus, which produces heat. Do not take the cover off to check. Call a licensed electrician the same day.
What a panel replacement costs
A typical 100-amp to 200-amp panel replacement runs $2,200–$4,800 all in, including the panel, breakers, permit, inspection and labor. That is an estimate, not your price. What moves it: the meter base, the service entrance, grounding and the panel's location. You get a written flat-rate quote after an on-site load calculation, or a detailed itemized one if you prefer. A 400-amp service, or an added panel feeding a separate building, is quoted after the load calculation. Replacing the service equipment also brings in the NEC's surge protector requirement; see whole-home surge protector cost.
If something is wrong now, troubleshooting starts at $240 and is credited toward the repair if you go ahead. Estimates for new work, such as a planned panel upgrade, are free. Financing is available through Synchrony Bank, subject to credit approval; Synchrony sets and discloses the terms. See financing.
What happens on install day
A straightforward panel replacement usually takes 4 to 8 hours. If the meter base, service cable or grounding also need work, plan on a full day or two. The power is off while the old panel comes out and the new one goes in, and we coordinate the disconnect and reconnect with the utility. We pull the permit and schedule the city inspection; the permit is included in the written quote. See Texas panel permit requirements.
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Frequently Asked Questions
Texas law exempts electrical work in a home you own and live in, unless the work is specifically regulated by a city ordinance (Texas Occupations Code §1305.003(a)(6)). Panel replacement usually needs a permit and a utility disconnect, so check with your city first. We strongly advise against it: the service conductors stay energized even with the main breaker off.
Yes, while the old panel is removed and the new one is connected. For a straightforward replacement the job takes 4 to 8 hours, and we coordinate the disconnect with the utility.
No. A worn breaker, a single overloaded circuit or a full panel can often be fixed with a new breaker, a new circuit or a subpanel. A Federal Pacific or Zinsco panel, a corroded panel or a service that is too small for the house is where we recommend replacement. See subpanels and breaker replacement.
For most single-family homes, yes. Large homes with several AC systems, an EV charger, a pool and electric cooking may need more; the load calculation decides. See 200 to 400 amp upgrades.
Home inspectors commonly note Federal Pacific and Zinsco panels and panels showing heat or corrosion, and buyers use inspection findings in negotiations. Replacing a problem panel before listing removes that item from the report. See our pre-purchase electrical inspection guide.
