MASSIVE 60-Circuit Electrical Panel | Westfield, NJ

In this video I replace an old Murray panel that was overloaded with too many circuits. It exceeded it’s rating and was not only a code violation but a fire hazard as well. All panels have a maximum amount of circuit breakers that can be installed according to the manufacturer. Violating these terms could be fatal. It was also not grounded properly! The new panel I put in is a 200 amp 60 FULL CIRCUIT/ 120 TWIN CIRCUIT main lug only panel made by Cutler-Hammer. It is the largest 200 amp panel that’s readily available and the largest panel I’ve ever installed!!
Classic Electric, LLC | Point Pleasant, New Jersey
License & Business # 16557
(732)-770-1437
Ron Pecina Jr. is a licensed electrician in the state of New Jersey. This allows him to apply for electrical permits, work with live conductors, remove meters, and disconnect service from the utility company. New Jersey observes the 2020 NEC and the Uniform Construction Code. The majority of the work seen here on this channel falls under the Rehabilitation Sub Code (Chapter 6 of the U.C.C.).
ALL New Jersey licensed electricians MUST complete 34-hours of continuing education units each tricentennial period. This includes a mandatory 10-hour code update course. Any work above 10-volts requires an electrical license in New Jersey.
Ron is an active member of the New Jersey Independent Electrical Contractors Association.
Become an NJ-IEC member here: www.nj-iec.org
IEC National: www.ieci.org
WANT TO SEE MORE? How to wire a Generac Standby Generator. WATCH HERE: • Generac Generator Inst...
Classic Electric, LLC is a Generac standby air-cooled generator installer. Generac Dealer # 1019500
Camera: Go Pro 9/ 10.
Editing software: Apple iMovie
Animation software: Apple Keynote
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Electrical Wiring is NOT a hobby. Call a licensed electrician.

[@jonbaxter5074]

Great work man, people just dont realize how much work goes into panel changes like this. Love your channel

[@electricalron]

Especially a panel this size with this many circuits!

[@mikemannarino5284]

Are you allowed to splice BX cable (1950s house) in a metal junction box with new NM Romex cable? Thanks !

[@linehandibew6205]

When I first started working for an electrician in 2001 my bosses were 65 years old. Old school guys. They wouldn’t let me use a bx skinner. They made me learn how to do it with a hacksaw. Old school bro. With I’m real bx with the steel jacket you’re not using dikes. Mc cable is aluminum so it’s much easier. Also a little thing I liked to when dress old wires in a new panel is I would use my screwdriver shaft to straighten the bends out of all the wires. Makes everything nice and neat

[@electricalron]

I've used sawzalls, hackzalls, and even a bandsaw to cut BX when I couldn't find the BX cutters.

[@linehandibew6205]

@@electricalron I remember the day they let me graduate to the bx cutter. Was a good day 🥹

[@randycarter2001]

I've watched several of these videos. I never see him using a torquing tool to set the screw torque. I think it's very important for the larger wires.

[@pedrodheming2044]

Thank you Ron for your videos great teaching

[@johnwalker890]

Good job Ron.

[@garycunningham8478]

Looks great.

[@bustersterling7667]

Another professional install.

[@Red1Wollip]

What a challenge they gave you!

[@michaelstaley9979]

Thank you for sharing Ron. I a like you I like to identify the whole entire conductor with tape, not just part of it. Nice clean install.

[@Nihilumbra]

Ну очень нравиться ваша работа 😉👍😎 смотрю и душа радуется 😀

[@wirewaykingelectric4978]

Fantastic work!

[@electricalron]

Thanks dude.

[@arnieselectric007]

Fantastic job Ron as always, I really like that you stress take your time and do it right first time...

[@electricalron]

Thanks Arnie!

[@rscelectrical7091]

Nice, methodical and neat 👍.

[@electricalron]

Thank you! Cheers!

[@jimanderson4495]

Another great job Ron. From rat’s nest to picture perfect. Thanks

[@electricalron]

It was a lot of work.

[@FrontRowOrBust]

Ron with the late night upload🎉

[@electricalron]

Yeah I was having some iMovie issues while I was editing this video but I got it straightened out.

[@thatguy4320]

Thank you so much for your videos, I find them very informative especially when you’re talking about code, panel change outs are some of my favorite jobs to do

[@electricalron]

Same here man. I could do a panel upgrade every day and it would make my business so much more easier to manage but people need other things fixed and Ring floodlights installed too.

[@thatguy4320]

Same I just installed like six of them plus a couple Ring doorbells as well

[@pawelelektryk2985]

nice job as always.That's a lot of armoured cable for a house!

[@spark83ify]

I just put this exact panel in a new house I wired back in November! I like the Eaton panels! Awesome video!!

[@electricalron]

Good choice!

[@hmrody]

Another home run of a video! Thank you, sir! Your videos are extremely informative, and I have learned so much from you! Very professional and craftsmanlike! I hope you are a mentor to others learning a trade.

[@electricalron]

Thank you for your sincere appreciation.

[@Christopher1964agm.comch-fb7nk]

Tuch not

[@Gruntled2001]

Great work, Ron!👍🏼💪🏼

[@electricalron]

Thanks! 👍

[@Nihilumbra]

Ага 😉

[@everythinghomerepair1747]

Nice job.

[@shan442us]

Hello I really appreciate your channel ( been watching for about 6 months and always give a thumbs up) and workmanship. Like you, I work alone and about the same age and cannot have enough Milwaukee tools. I hope you do not mind me passing along some procedures I do here in the Seattle Area which has paid huge dividends. On these long(standing in one place) jobs, I always bring a rubber mat to stand on, battery operated fan, a moving blanket to catch all those small Items which miss my 5 gallon trash bucket and a small shop vacuum to cleanup. When I bill the job, I provide no more than 4-6 before and after photos from the same angle and light. I also copy everyone,(owner, agent, brokers, etc.) so they can see the attention to the detail(s) of my work. I use those emails and photos for marketing myself when someone calls me or is referred to me for additional work. Many of these clients and influencers who provide me with endless referrals do not know the difference between a ground or a neutral, but they sure notice when I take 5 minutes to wipe up some dust with a damp cloth and leave zero debris behind. Keep up the great work and I look forward to future videos.

[@kennixox262]

Here in the west for some reason, many homes such as mine have 200 amp service but split between indoors and outside. The main circuit switch along with all the 220v breakers are on the outside panel and the 125v breakers are inside the garage. More interesting is that the main cable from the street comes in through the floor slab through the exterior walls and into the panel box(s).

[@chuckquinn8026]

That was absolutely insane for residential 😳😳😳😳. Gorgeous work as always. I’m loving my new Knipex wire strippers. Hope Mom is doing well 👍👍

[@electricalron]

Thanks Chuck.

[@mitchdenner9743]

Nice job, a man after my own taste, i too am a stickler for for wrapping the whole wire when coding. Interesting about the bx bronx thing, hmm,🤔 never knew that, pretty cool . First time watching, just subbed.

[@kmibuilding906]

Lots of work, hope you made it home in time for supper!

[@joemaldonado3]

juicy !!!

[@SORGIGERMANICO]

Had the same box in my old house and your right the main breaker was going bad in mine i had to play with it a few times to get it to restarted. It would trip when there was a load on the house here and there especially when the ac was going. I looked up to see how much a good used main was and they were nuts on price like 200 bucks i could have pretty much bought a whole new panel for that. I mean yeah i would have had more in a new panel after purchasing all the breakers needed and install put i have a few close family members that are master electricians so it wouldn't have been that bad. My cousin just did one of my moms rentals for about 700 bucks and that included the wire in the mast also

[@vince6829]

That’s a lot of conductors. It looked more like a commercial setting than a residential one. As always, you did a fantastic job. In addition to the “Romex” and “BX,” I thought I saw some flex (Greenfield) conduit in there, correct? Thanks for sharing. Much appreciated!!

[@Sparky-ww5re]

Good work. That's insane for a 200 amp panel, never knew 60 circuit panels existed, I'm assuming this was a special order item, because all the panels I've seen at home depot, Lowe's and similar big box stores max out at 40 spaces, with 20 - 30 typical for 100 and 150 amp panels which are seldom installed today except as a subpanel out in a detached garage for example. Always learning something new and seeing new things lol

[@electricalron]

This panel can do up to 120 circuits with twin breakers. The bus bar is rated for it. Can you imagine 120 circuits in this enclosure?

[@aaron74]

​@@electricalron Geezus, 120 circuits is nuts. Usually only the bottom half of a panel's backplane have the stabs that fit the tandem breakers

[@petercampbell4220]

Square d has 54? Space panels. The old nec maxed at 42, that went away. As long as the breakerbox is rated and listed by mfg.

[@Sparky-ww5re]

@@petercampbell4220 interesting. I wondered about the 40 circuit max rule in the NEC and when it went away, because if you go to your typical big box store like Lowe's or Home Depot all the 200 amp panels I've seen were 40 max. The new NEC rules still applies in a similar manner because equipment is to be installed in accordance with the manufacturers instructions, or the UL listing is void. On older panels you will sometimes run across tandem breakers modified to fit in panels not approved for that. Before 1981 when split bus panels were allowed, a maximum of 6 hand movements were allowed to disconnect all power to the house, but homeowners would often install single pole breakers in the upper main section during renovations to add more circuits in violation of the 6 throw rule not to mention most homes of that era were designed with 100 amp services which is marginal by today's standards.

[@aaron74]

@@petercampbell4220 That's weird the NEC would dictate a space maximum and not just leave that up to panel manufacturers and UL. Sounds like it was corrected so no big deal now.

[@joshman2338]

Now do they make panel (cabinets or tubs) with no KO's on sides at least. I feel like that would've been easier to trace out those EMT's and use a punch kit to get a nice clean hole. I cant imagine how you made holes with those knockouts in the way there is no way it was fun HAHA. I would love to know how you did it. As always Thanks RON for a professional video and all the tips and tricks I am always taking notes!!!

[@electricalron]

You can make a knockout wherever you'd like by using a step bit to make the hole for the arbor and knockout punch. That's what I did.

[@bobrub]

Hi Ron, Love your work and your channel, Regarding the BX cable you show here with no green ground wire, does the NEC talk about this "armor" portion as being an acceptable ground conductor and could you point me to that # in the NEC please? Does the thin aluminum wire play any part in the ground path or just to help hold in the red wire bushing? What are the dual bx cable connectors called you use here? So from that dual cable clamp-connector entering the box and tightened down properly, that is where the grounding is accomplished, is that correct? From there on, in the panel, it's just hots and neutrals to the breakers and nuetral bus bars, is that correct? Thanks much for your time here, Bob R.

[@davidhill3724]

you should do a before and after at the end its huge

[@atschirner]

Great video Ron, don't know how big this house is but i see the telephone key system to your right. Oh those '60s! One question I have about installing the two high amperage breakers on the same tabs, are you exceeding the CH per stab recommendation? Please keep your videos coming.

[@bestshot300]

EC here from so cal. I think there are couple products you will like to use that I also use from RACKATIERS. Since you do a of service changes. first one is the phasing marker to help instead using tape. and then NM cable connectors that work the same white arlingtons you use . (TT500 2-Way Loomex Connectors)

[@electricalron]

I'll have to check that out. Thank you.

[@nadien1958]

i helped install a 200 amp panel, didn't have 60 circuits in it since it went into a house --- an all electric house.

[@user-vq9cc8ze2j]

Ron, I also work by myself and know how time consuming and mentally tiring this can be. You really do a great job- Maybe I missed it, but I noticed that you seperated EGC's and neutrals at your new panel, but there is only 3 wire going back to your main disconnect. Without having your Main Bonding Jumper installed in the new panel- your "EGC's/grounds/cabinet" is left floating by being isolated from the Neutral. If there were a ground fault on one of those circuits or in that cabinet there would be no return path to the source- the neutral, thus no breaker would trip. I think the easiest way to solve this is to install the main bonding jumper in the panel. If i missed something please let me know. Im not a critic and it was just something that stuck out to me. Recently I was called to a mobile home where this exact situation had occurred. There was a dryer that had a ground fault(4wire cord)- it energized the main panels ground/cabinet where the neutrals and grounds had been separated. There was only 3 wire out to the meter , so the fault couldnt clear because all it was doing was energizing the "isoated" cabinet and ground rod. What it really needed was that 4th wire heading back to the meter main tying neutrals and equipment grounds together-i just installed a main bonding jumper at the panel Sorry if this is incredibly wordy, by no means am I trying to find fault.

[@braytonhackbarth]

He kept it separate because you only bond neutrals and and grounds at one point, usually at the first means of disconnect. If you bond at multiple points you can get objectionable current at equipment grounds. Not sure where the ground conductor entered the panel, it just wasn't at the bottom conduit.

[@kevinstrauss8020]

Nice neat job. However, 2/0 copper for a 200 amp load looks a little small. Second: Are you properly torquing the terminals as required? Third: CTs for a 200 amp meter? Unusual m

[@mcarroll598]

Those Greenlee armored cable cutters are the best IMO. They stopped making that style, the new style has a plastic handle it’s junk. The old style was made to last.

[@aaron74]

I have that Greenlee pair in the video, I remember buying it at Home Depot back in like 2005. It's a necessary tool even if you're going to do a little bit of work with MC or BX in my opinion, the time you save and avoiding risk nicking the conductors make it worth it. Buy, rent, or borrow one.

[@mcarroll598]

@@aaron74 yep those are really nice. I’ve been an electrician for 25 years., I have a few of them, I give the young guys a pair if they want them. Definitely need it when doing armored cable. Really clean cuts.

[@electricalron]

100% agree. Mine broke recently and I freaked out a bit. Bought another pair but they were plastic just like you said. I repaired the old ones and I'm crossing my fingers they don't break again.

[@aaron74]

@@electricalron That's a damn shame they're plastic. Ridiculous.

[@sharkey086]

We have a100a 80's Cuttler-Hammer (Eaton) CH panel I'd love to swap out! I noticed you didn't upgrade the main wires from the meter to the panel. Were they already rated for 200a service? Also I thought code now requires those insanely expensive AFCI breakers for common areas and bedrooms but didn't see them here. Or are the Eaton snap-on neutral ones different?

[@petercampbell4220]

I think the main protects the bus. Each circuit breaker has depending on design an inductor and or thermal overload. Each make heat. So the breaker count is part of design. Worst case too much heat for enclosure, breaker failure early tripping, hot terminations, arcing, brned bus on overheated breaker connections.

[@PaulDziomba]

Something you rarely get these days is someone taking their time and ensuring a nice job. Hope that home owner appreciates it! Just one question, how was the air conditioning running if the power was off?

[@electricalron]

It was "cool" from the night before. Also, this homeowner really didn't give a crap about the new panel because he was selling the house.

[@davidhill3724]

what a difference

[@aaron74]

Wow, I didn't know 200A panels could have 60 spaces. Did you use knockout compression dies to make the 1.25" and 2" KOs, or did you ream out the smaller factory KOs to enlarge them? I always wondered if it were possible or practical to make a die KO that could interfere with a factory KO. Might need a grounded bushing in such case. Nice work as always... was about to ask if that was a residence and it looks like you were at someone's McMansion.

[@electricalron]

For whatever reason I did not have the camera recording for the knockouts. I have the Greenlee carbide hole saw punch kit that makes holes through steel like a hot knife through butter.

[@abrelectric]

How do you handle your labeling on all the branch circuits? Do you use the same label maker or do it by hand?

[@electricalron]

Pretty sure I went back and did it while waiting for the inspector. Yes, used the Brother P Touch E550.

[@Truckguy1970]

Wow! 60 circuits in a single phase panel? I thought more than 30 or 40 was available in 3 phase panels only! I guess this is a mansion? I've rarely seen anything this big in a residential, this looks like something that would be seen in a commercial building. There"s more sub panels and older low voltage controllers and also old telephone equipment.

[@markmerrill5976]

I noticed when you verified that power was off to the panel you checked between the two hot legs. Maybe you checked each one to ground off video, but checking only that that there is no voltage between both legs can get you killed. If the main disconnect malfunctions and only opens one leg, checking leg to leg will show 0 volts, however one of the legs will still be hot relative to ground. I've seen this happen twice in my 40 years of electrical work.

[@electricalron]

I checked leg to leg and leg to ground. I’ve been doing this for awhile too. Thanks for looking out.

[@mrnetwurm]

Ron, in this case where do the grounds and neutrals come together? At the 200amp switch or outside ?

[@electricalron]

At the main disconnect

[@rickv5004]

Great channel and thanks for the explanation, i see you're a fellow trump support, salute!

[@extremeinvestor]

You have to use i-thimbles for more safety and efficient work

[@garbo8962]

Doubt if a buss bar can be overloaded ever when it has an approved main circuit breaker protecting it. What would you say in a large company that I worked in had two 3,000 amp buss ducts in a large room and each buss duct had over 8,000 amps of plug in buss ducts ? Nope neither one was overloaded ! Had a company come in and install & recorded each buds for a week. They were only drawing 2,300to 2,450 amps. was told at a IAEI class from a ta!ended guy working for UL that BX came from: B was the second type they designed & X was for experimental. Wish the NEC would ban the use of flimsy type AC ( YEA BX ) cable due to a flimsy aluminum ground wire in direct contact with a steel jacket. In my area in all commercial sites & offices you must use far superior type MC cable. Was in a 12 story medical building where they had at least eight 84 circuit panels on every floor ( 2 were emergency power )that had all the power leaving the top of panels thru 1" EMT with ten #10 gauge wires. Very hard to I stall over 170 #10 wires neatly no matter how many types rs before ret you use. Great job using the white taoe. Had way too many lazy cheap union electricians only installing one wrap of color tale on a wire longer then 4'.

[@russrockino-rr0864]

I remember when the code only allowed 42 poles in any panel. I believe it was 42. But that was 42 full size spaces only, no tandem breakers. I think the code has gotten rid of that 42 maximum, if I remember right. I have not done much residential in years. I installed alot of 40/40 resi panels early on in my career. A few custom homes I helped wire had 400 amp services with 2ea, 40/40 200 amp panels. Great video. Thanks, Russ 28 years in the Trade.

[@electricalron]

Great comment Russ! The listing of the panel probably allowed for only 42 circuits. The listing thing still exists per NEC 110.3(B).

[@mikedelaney1414]

Hey Ron, what percentage of your business is panel/service change outs? What do you do to advertise your business? I really appreciate your videos. I'm an electrical contractor in Colorado since 2003.

[@mikedelaney1414]

PS....the music when you're in the heat of battle is both funny, and cool! It's Electrician Ron to the rescue!!

[@electricalron]

Mike, this is it as far as advertising. These videos attract a lot of potential customers that turn into clients, who make referrals, and then ultimately customers for life.

[@Doug-gp2qw]

Why would they have a CT Cabinet for a 200 amp service? I'm guessing that CT cabinet feeds other panels, or at least did at one time. When I've seen it before there was no fused protection between the CT cabinet and the transformer. If you get a water leak or a short it will arc until the transformer fuse blows.

[@electricalron]

This was an underground service in a very nice part of the state. There was definitely "line side" equipment inside the home. The only MLO panel connected to the SEC's was the one I replaced and you see ion the video.

[@jeffmoss26]

I spy some old phone wiring too!

[@ericjorgensen4826]

Beautiful work. Curious what happened to all the circuits, since the old panel had 62 and the new 60/120 panel is no where near full? Were they from that vertically mounted gutter to the left of the panel and no longer needed or hooked up after you made the video?

[@electricalron]

It was a couple of years ago and I think that’s exactly what happened. The owner had me disconnect a few double pole heating circuits that were no longer being used.

[@mcarroll598]

Do you identify every circuit before you leave the job. That has to take a few hours just to do that.

[@aaron74]

Yeah, that's the boring work

[@electricalron]

You ain't kidding!

[@mcarroll598]

@@electricalron been there done that. It’s rough! Lol

[@MrAlejandro787]

Hi what brand is electric panel

[@electricalron]

This is a Cutler-Hammer 'CH' style (tan handle) MLO (main lug only). The is a "sub panel."

[@robertbarnes2419]

Dang the rats were busy up in there! Great job cleaning up that mess!

[@Pelo1969]

Great videos but I couldn't watch this one for more than 5 minutes because the camera was swinging all over the place

[@kevonslims7269]

I guess a ground wire is not need, the equipment is used as the ground?

[@electricalron]

Yes.

[@johnstancliff7328]

I just had to work on a older manufactured home that had been "Mickey-Moused" by some guy who clearly didn't know what he was doing. I had to go through the entire home and rewire and replace EVERY outlet and switch on the house. the original "electrician" daisey-chained" all the outlets and cut back the romex to 3" in every box! I had to pigtail every connection and and attempt to bring the system up to code... What a mess! it took me 2 days to correct mickey-mouses wiring and we still can't find the dead short on 1 circuit. we still have no power to the livingroom and the front bedroom. what a mess! have you ever run into a problem like this?

[@electricalron]

Definitely.

[@johnstancliff7328]

@@electricalron then I just got a call from the owner as to what I had left in the home, he had sold it for cash and the buyer was going to have their electrician take over.... had my partner gab my ladder I had there, and now the job is done....I hate mickey-mouse electricians!

[@Bob.W.]

Must be a large, real large, home.

[@electricalron]

It was! 6500 sq feet!

[@Kevin-wj4ed]

This in a house?

[@electricalron]

Yup, single family dwelling.

[@Kevin-wj4ed]

@@electricalron i wonder why they did it that way. Very different.

[@tellmesomething2go]

thanks. but we wanted to see the finished wiring, before you put the cover on.

[@electricalron]

Sorry about that

[@TheTubejunky]

I see the rats have been making the nests just as they did years ago!

[@Christopher1964agm.comch-fb7nk]

Thigh bite

[@gregrivera8520]

bro i see that you do good work. however, you seem to make excuses on how you forget to film this or that. get you act together bro, i want to see everything.

[@TCPLY]

I’m not an electrician, but that whole area you’re working in ( electrical) looks like 30 electricians kept adding and adding. Looks horrible to me, and unsafe to me. Like all previous workers were apprentices or owners doing their own work.

[@ausseamore8386]