Installing a 200 Amp Electrical Service: Full Breakdown
Upgrading an older home’s electrical system is an essential step toward improving both safety and functionality. In this walkthrough, we’ll show you how we upgraded a 60 amp service to a full 200 amp service, meeting code and delivering a neat, professional installation.
Service Height Requirements
Our minimum height for the point of attachment is 14 feet 6 inches to 15 feet, as required by code. To achieve this:
- We installed a 12-foot rigid steel mast on top of the meter base.
- This mast extends through the roof — a requirement set by code.
- The mast must project between 900 mm and 1.1 meters (approx. 3 to 4 feet) above the roofline. Any height above that would require a tie-back support to handle the tension from the incoming service wires.
In this case, our install height was within limits, so we didn’t need a tie-back.
Meter Base and Mast Setup
- The mast is 2.5 inches in diameter and secured with three mast straps.
- The base is a 200 amp overhead-position meter base.
- Coming out of the meter, we ran 2-inch PVC conduit with an offset and a 90-degree elbow, transitioning into an LB fitting that enters the house.
Inside the home, the service passes through a series of conduit fittings:
- From an LB to another LB
- Then over to an LL
- Finally into the main panel
Main Panel Installation
The panel is mounted at approximately five feet height. Behind the panel, we added new plywood backing for a clean, professional appearance.
Inside the panel:
- All branch circuits feed in cleanly.
- GFCI protection is provided for ungrounded circuits (common in older homes).
- We use faceless GFCIs rather than GFCI breakers due to cost-efficiency.
Wiring the Main Panel
- The conductors come in from the meter base and connect to the main bus bar.
- To save on cost, we used aluminum wire instead of copper.
- The current code requires 250 kcmil aluminum wire for 200 amp service (formerly 4/0).
Connections:
- Two hot conductors and one neutral enter from the meter.
- A #6 copper grounding conductor is routed to the grounding plate, which we buried 2 feet underground and photographed for inspection.
🔍 Important Note: The ground wire must enter through the main compartment of the electrical panel and connect directly to the neutral bar—not through the side or a separate opening.
There’s also a bonding strip inside the panel, connecting the neutral to the panel case. This is essential for the first point of connection in a service.
Branch Circuits and GFCIs
All branch circuit conductors enter from above, with the branch GFCIs located upstream. We’ll go over how to wire a double pole breaker in another post, but the key point here is that this service upgrade brings everything up to code.
Inside the Meter Base
The 200 amp meter base has:
- One hot conductor on each side
- Neutral conductor in the center
- Antioxidant compound (Antiox) applied to all aluminum conductors to prevent oxidation
From the bottom of the meter:
- The conductors enter the underground PVC conduit
- Run along the exterior wall
- Enter through an LB fitting into the panel
This is a single-phase 120/240V split-phase service.
Routing the Service Line
We route the service conduit along the outside of the house rather than cutting through walls. This is important because:
⚠️ Code only permits 10 feet of service conductor inside a building before it reaches the panel.
Otherwise, a main service disconnect must be installed at the point of entry.
By staying outside, we avoid the need for that additional disconnect.
Grounding Plate and Conduit Aesthetics
The grounding plate is buried right below the meter, with the grounding conductor running inside PVC conduit. While not required, the conduit keeps things neat and tidy.
Service Head Orientation and Drip Loop
At the top of the mast, the fitting head (or weatherhead) is pointed away from the rack. This orientation:
- Prevents damage to the fragile porcelain-like fitting
- Makes it easier to insert conductors
- Allows for proper drip loop clearance
A drip loop is essential to keep rainwater from entering the service mast and reaching the electrical system. It directs water to drip off safely before it gets inside the conduit.
Final Thoughts
This 200 amp service upgrade provides a safer, code-compliant electrical system for the home. From mast to meter to main panel, every component has been carefully installed to meet modern standards.
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