200 Amp Panel Upgrade Kit – Complete Materials Guide for Overhead & Underground Service

Upgrading to a 200 amp (or even 400 amp) panel is a critical step for increasing the electrical capacity of a home or commercial property. Whether you're powering high-demand appliances, electric vehicle chargers, or preparing for future solar or battery backups, a properly installed service upgrade ensures long-term safety, code compliance, and performance.

At Sonic Electric, we provide all the parts needed for both overhead and underground service upgrades — trusted by electricians across Southern California and beyond.

Overhead vs. Underground: What’s the Difference?

• Overhead Service: Utility lines are suspended from poles and drop down into a rigid conduit mast connected to the meter panel.

• Underground Service: Power is delivered via a buried conduit from a transformer or service pedestal directly into the meter panel from below.

Both installations require slightly different conduit and fittings but share most core components like the panel, breakers, and grounding system.

Full Materials Checklist for a 200A (or 400A) Panel Upgrade

1. Meter Panel Combo – 200A or 400A

Available in surface or flush mount. Choose ringless or ring-type based on your utility's specifications.

• 200A panels include a main breaker and 20–42 spaces for branch breakers.

• 400A configurations typically include dual 200A meter sockets with bypass options (check with utility).

• Brands available: Siemens, Milbank, Eaton – all UL listed and utility-approved.

2. Service Entrance Conductors

You’ll need:

• (2) hot conductors + (1) neutral + (1) ground

• Use 4/0 aluminum XHHW-2 or 2/0 copper XHHW-2

• Add #2 aluminum or #4 copper for ground

• Length: ~40 ft (verify based on run distance)

Contact Southern California Electric, our sister location for wire price. There phone number is (323) 939-9900. There address is 5512 W. Pico Blvd. Los Angeles, CA 90019.

3. Conduit, Fittings & Structural Support

A. Overhead Service Materials

• (1) 10' stick of 2" or 2-1/2" rigid metal conduit (mast)

• (1) Roof jack (2" or 2-1/2") for weatherproof roof penetration

• (1) Entrance cap (weatherhead or servicehead) (2" or 2-1/2") for overhead wire drop

• (1) Type B conduit hub (2") for weather-tight panel connection

• (1) LB conduit body for a smooth 90° wire entry into the panel

• Porcelain wire holder/insulator (if required by utility)

• Unistrut channel + Uni-Strut clamps for additional mast support at roof or wall

• (3–4) Rigid conduit straps (install every 3 ft per NEC)

⚠️ Use rigid metal — not EMT — for mast risers per utility code.

B. Underground Service Materials

• (2–3) 10' lengths of 2" or 2-1/2" Schedule 80 PVC conduit

• (1) PVC long-sweep 90° elbow for underground trench transitions

• (2) PVC male adapters for threaded connections into panel and utility box

• PVC conduit glue & primer – must be rated for electrical use

• Expansion couplings (if exposed to extreme heat/cold)

4. Grounding System (NEC Required)

Used in all upgrades to prevent shock hazards and ensure proper fault clearing.

• (2) 5/8" x 8' copper-bonded ground rods

• (2) Acorn-style ground rod clamps

• (1) #4 bare copper wire (approx. 25–30 ft)

• (1) Water pipe ground clamp (where required)

• Bonding bridge to bond ground to water or gas lines and other metallic systems

• Ground bar kit (if not included in panel)

• Split-bolt connectors or mechanical lugs for splicing grounds

NEC generally requires two ground rods spaced 6 ft apart, unless you can verify ground resistance is 25 ohms or less.

5. Circuit Protection & Panel Components

• Main breaker (pre-installed in panel)

• Branch circuit breakers (15A–60A depending on loads)

• AFCI / GFCI combo breakers (required for bedrooms, kitchens, laundry rooms, etc.)

• Surge protection device (SPD) – required in most jurisdictions for new services

• Breaker directory label kit

• Anti-oxidant compound (Noalox) – required for aluminum wire terminations

• Pulling lube + fish tape – for easier wire installation through conduit

• Temporary power tap – optional for jobsites needing temporary utility access

Optional Equipment for Larger Loads or Advanced Systems

• Dual Meter Panels (for 400A upgrades or multi-family units)

• Subpanels for detached garages or ADUs

• Load-shedding breakers (for generator or solar prep)

• Arc fault/surge protection combo units

• Smart panel upgrades (energy monitoring-ready)

Installation Support from Sonic Electric

Whether you're ordering one panel or outfitting an entire jobsite, Sonic Electric is here to help. We carry everything listed above — in stock, ready for pickup, or available for fast local delivery.

📞 Call (323) 934-3744
📧 Email hello@sonicelectric.com
🌐 Shop online: sonicelectric.com

Let us know your utility provider and job location, and our team will ensure you get the correct configuration.

Sonic Electric – Trusted by Pros. Delivered with Speed.

From Los Angeles to the Valley, Sonic Electric is the go-to source for fast-moving electrical and lighting materials, trusted by professionals for over 40 years.