GDV Utilities
Guide

Panel upgrades for
solar, EV & new loads

Adding solar, an EV charger or new electric appliances can push an existing panel past its limit. Here is how to tell if you need an upgrade and how the process works.

By Will Watson, VP of Power Line Construction · Updated October 2026

Signs you need a panel upgrade

  • You are adding rooftop solar or battery storage.
  • You are installing a Level 2 EV charger.
  • You are switching to a heat pump, electric water heater or induction range.
  • You are adding an ADU, addition or pool equipment.
  • Your panel is old, damaged or full, with no room for new breakers.

Common panel sizes

Residential and light commercial panels commonly come in 100A, 125A, 150A, 200A, 225A and 400A. Many older homes have 100A. Homes adding solar, EV charging and electric appliances often move to 200A, and larger homes or properties with several big loads may need more.

The right size comes from a load calculation of everything that will run on the panel, not a rule of thumb.

Solar note: The electrical code limits how much solar can backfeed into a panel based on its busbar and main breaker rating (often called the 120% rule). An upgrade can make room for the system size you want.

How the process works

  1. QuoteSend photos of your current panel, meter, any access issues and the utility pole feeding your property.
  2. Sizing and designWe review your existing and planned loads and recommend a panel size.
  3. PermitOnce the job is signed, we pull the electrical permit with your city or county. Permit fees are priced separately.
  4. Utility coordinationYour utility typically handles the service disconnect and reconnect. We coordinate with them and schedule our work around it.
  5. InstallationWe install the new panel. Power is off during part of the work, and we schedule it with you in advance.
  6. Inspection and reconnectThe building department inspects the work and the utility restores service.

When trenching is needed

If your property has an underground service, a larger panel may also need new underground conduit or conductors to the utility's service point. Our crews are qualified to handle the trenching, so you do not need a separate contractor. GDV Utilities is a one stop shop for all your electrical and engineering needs.

FAQ

Common questions

Do I need a panel upgrade for solar?

Not always. It depends on your panel rating and the size of the solar system. Send us photos of your panel and we will tell you.

Do I need a panel upgrade for an EV charger?

Often, if you have a 100A panel or one that is already heavily loaded. A load calculation tells us for sure.

Which panel sizes do you install?

100A, 125A, 150A, 200A, 225A and 400A.

Do you handle the permit and utility?

Yes. We pull the permit and coordinate with your utility, which typically handles the service disconnect and reconnect. Permit fees are not included in our quote; they are priced separately after the job is signed.

Contact

Planning an upgrade?

Send photos of your panel and meter and we will recommend the right size.