200A panel upgrade in a Brooklyn brownstone

Problem

Homeowners planned kitchen upgrades and mini-split HVAC, but the existing 100A fuse panel overheated under current load and lacked space for new circuits.

Site conditions

• Occupied brownstone with limited shutdown windows
• Mixed legacy wiring with partial labeling
• Tight cellar access and shared gas/water lines nearby

Diagnosis

Load calculations showed the existing service was undersized. Multiple fused disconnects fed tandem circuits with unclear labeling, creating nuisance trips and heat at lugs.

Work performed

• Coordinated utility shutdown and installed new 200A meter pan and main breaker panel
• Separated kitchen, laundry, and HVAC onto dedicated breakers with updated labeling
• Re-terminated branch circuits with new torque specs and added AFCI/GFCI protection where required
• Planned spare capacity and conduit path for future EV charger circuit

Safety / code notes

• Verified bonding/grounding and replaced deteriorated grounding electrode conductor
• Applied torque verification on all terminations and documented panel labeling
• Maintained clearance and working space per NEC and local requirements

Outcome

New 200A service with cooler operation, clear labeling, and open spaces for future projects. Homeowners can add appliances and a charger without nuisance trips.