10 Common Mistakes DIYers Make In Circuit Breaker Boxes

When you color tape a white conductor to indicate a hot wire you absolutely must tape the other end where it terminates. A hot white wire in a box could be taken as a neutral and used opposite a hot from the opposite side of the panel resulting in a 240 volt feed applied to a 120 volt appliance.

It's worth mentioning that back in olden in the old days (say 25 years ago), All NM Romex style cable had the same white color sheathing, regardless of its gage. When checking for over fusing of circuits what appears to be an over fused 15 amp (14 gage) circuit may actually be correctly fused 20 amp circuit with white sheathed 12 gage wire.

Thank You sir ! As a retired Journeyman Electrician with more than 50 years of experience in the field I saw more than my share of the "rats nest" type of panels, gasoline stations that had been remodeled several times. I couldn't always make them look perfect, but I tried. Any of the new Installations that I worked on, looked like the 3 phase panel you showed. When I upgraded my own residence from 70 amp Zinsco to a 200 amp Homeline all my wires were formed and marked. When the city inspector came for final inspection he was taken aback and had to take a picture of the work. It is sad to say that too many tradesmen do not take pride in their work and only do the minimum.

Decades ago I took a studio engineering and sound reinforcement course at the local community college. The instructor did sound for hotels and arenas and other venues. He said that he always ran into tripping breakers because in most places like banquet halls and hotels, everybody uses the circuit breakers like a wall switch, and every time they manually trip the breaker to turn the power on and off it slightly reduces the friction or resistance necessary to trip it. So over years and years of being flipped open and closed, a 15 amp fuse might only be able to handle 12, or 13 amps. So he always carried a hand full of breakers in case he ran into one that would refuse to stay closed.

Dude waving his hands and fingers around near the main lugs was giving me cold sweats

Sir, you need to be super, super clear that the mains hardware in the breaker box will be hot even if your breakers are switched off. If newbies follow your example in the video, they would feel safe touching the mains connections and bus bars. You should make it crystal clear that those are no-touch areas unless you are absolutely sure the power is disconnected to those mains (often requiring the power company to remove the electric meter from your service entry).

The panel at 13:09 is beautiful. Personally, I always leave extra length on the hot wires, because you never know when in the distant future things may have to be rearranged, or a panel upgraded. I usually run the wire down to near the bottom of the enclosure and back up to the breaker. I still make it nice and pretty, but that extra length can be a life saver in the future. I've personally thanked quite a few electricians who came before me for doing this, as I'm sure some electricians in the future will thank me long after I'm dead.

It is worth mentioning load balancing - installing circuits such that current is taken from each side of the 120 volt split evenly.

A few points: If you home is pre-2001, you won't see a yellow jacket on 12ga wire. That started becoming available in 2001, and older wire jacketing will be white, or possibly gray. Most new panels come with covers for the primary lugs. If your panel has a master breaker and it's turned off and the covers are in place, it becomes VERY difficult to accidentally ground those out. They're also available as an option for some older panels. It's within NEC code to have two ground wires under a single screw, but NOT for a neutral. The reason you see that in the example panel is because some bus bars don't come with all the screws populated. Of course, you should always check with the jurisdiction having authority. NEC is a top-level thing. A state, county, or city can have more stringent requirements than the NEC. Lastly, it's always wise to remove jewelry when working in a hot panel. If your ring or watch manages to bridge a hot and neutral or ground, it'll turn to molten metal pretty quick.

one point: it is currently acceptable to code to land two SAME SIZE AND STRANDING ground wires in one terminal. in some brands of boxes, it is also necessary to do that, or to add additional grounding bars.

5:51 if you are going to use a wire nut to combine grounds, consider using a green "grounding wire nut" that has a hole on the end allowing one of the wires to continue at full lenght to land on the grounding bar. This way you don't have an unnecessary extra wire in a "pig tail" to make the final connection to the grounding bar.

I would add one more important one: turning off the main breaker with all the branch circuits left in the on position. The branch circuits should be turned off first and turned on last when shutting off and turning back on the main breaker to avoid damage to the breaker due to arcing.

I love turning chaos panels into art! I done a panel during COVID shutdown when I was on layoff from my 9-5 and let me tell you it was the worst I'd seen, made the rats nest panel showed in this video look like a work of art. Well 2 days later a fully upgraded panel that looked beautiful, a fully rewired basement, and several changes in the main part of the house were complete and I was totally satisfied with my work. More so impressed was my buddy who hired me to do the work, he knew I had an electrical background but didn't realize I was that good. I just wish I could share the pictures here so you too could see what I walked into and how great it looked when I left. Oh and I didn't mention this place had more junction boxes than any 25 houses I've seen. I done away with as many as I could but to save money most of the old wiring stayed but I got it up to par as best I could with the budget he gave me to work with. Sparky for life.

Although wiring a residential main panel to look like a machine tool panel with tight bends and labeling each conductor looks sharp I have always thought of the person that might have to work in the panel down the road. For this reason I forgo the form for function and provide a service loop when landing the hot/feed conductors! When done correctly it will look nice and allow for moving a circuit’s location without having to break out the cumbersome wire stretcher tool 😋

Excellent run down on how to properly wire a panel. I'm about to rewire my shop panel, so this will be a big help in doing it right.

You’re doing a very nice job explaining all the code that’s involved with electrical panels I’ve been doing it for 50 years and I’ve seen a lot of changes

The guy that wired my house used the wrong screw on my neutral wire to my sub panel, I came home one day and walked by my panel and thought it was awful warm as I walked by, I removed the cover and sparks was flying out and the plastic clip that was holding the neutral bar was melting as well. The house was 7 years old at the time. It took that long for it to happen. The sad part was the correct screw was lying in the bottom of the box. I had to relocate the wire and up higher due to the damage threads and 10 years on still working great.

As a DIYer, I use a P-Touch labeler to stick labels onto the breakers (makes it easy to see what’s what even with the cover off) and onto each cable coming out of the panel. Saves so much headache down the line and 3rd party p-touch tape is available in a wide variety of colors and sizes (6mm tape is the perfect size for labeling romex)

I recently had a panel added that had a few more spaces than the old panel. Since the house is older, several circuits had outlets & switches from different rooms on one circuit. What I did was typed up a sheet laying out each breaker as shown in the panel and listed each outlet, switch, etc, placed it in a sheet protector and taped it to the outside of the panel.

Thanks very much for your carefully descriptive video. As a DIY I have done sporadic amounts of outlet and circuit breaker box wiring in the home and shop but need reminders about how things should be done.