Panel Upgrades for EV Charging: When 200-Amp Service Isn’t Enough

Electrical panel requirements have gotten complicated with all the amp ratings, load calculations, and upgrade costs flying around. As someone who had to navigate this for my own installation, I learned everything there is to know about when upgrades are necessary. Today, I will share it all with you.

Understanding Your Panel

Probably should have led with this section, honestly—your panel’s capacity determines what’s possible:

• 100-amp panels: Common in older homes. Often too small for EV charging plus existing loads.
• 200-amp panels: Modern standard. Usually sufficient for one EV charger.
• 320+ amp panels: Rarely needed unless you have multiple EVs plus high-draw systems.

Do You Need an Upgrade?

That’s what makes load calculation endearing to us planners—you can estimate before calling an electrician:

• EV chargers typically need 40-50 amps
• Add your HVAC, water heater, range, dryer loads
• If total approaches or exceeds panel rating, upgrade likely needed

Upgrade Costs and Alternatives

Panel upgrade: $1,500-3,000 depending on complexity. Before committing:

• Lower-amperage chargers: 32-amp chargers are still plenty fast for overnight charging
• Load management systems: Some chargers adjust based on available capacity
• Scheduled charging: Charge when other loads are off

Have an electrician evaluate before assuming upgrade is needed. Sometimes workarounds exist.