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Challenger Panel Replacement and 200A Service Upgrade in Charlotte, NC
Our Charlotte team from the Matthews branch completed a code-compliant replacement of a recalled Challenger panel for homeowner Steve Janson. On October 29, 2025, technician Mark Viktorovich upgraded the home to a 200-amp indoor main panel, improved grounding and bonding, installed new breakers, and added whole-home surge protection. The project included permitting and inspection to ensure everything met current electrical standards.
Why this upgrade was needed
Challenger panels are a known recall concern. To support other work planned at the home and to improve safety and reliability, we removed the recalled equipment and installed a modern 200A panel that meets current NEC and local code requirements for Charlotte, NC.
What we upgraded
- 200A indoor main panel (aluminum bus): Brought the service up to current code, replaced the main lug, labeled circuits, reconnected the service entrance conductors, and reconnected existing branch circuits.
- Grounding and bonding: Upgraded the grounding system, including a new ground rod and a continuous grounding electrode conductor run to the main service panel.
- Surge protection: Installed whole-home surge protection to help safeguard appliances and sensitive electronics.
- Permitting and inspection: Filed the electrical permit and coordinated final inspection with the authority having jurisdiction.
- Power outage coordination: Power was temporarily disconnected for the switchover. A generator was made available for limited power usage during the outage.
Note: This project’s main panel scope did not include a service disconnect, feeder, or meter upgrade, which can be added when required by existing site conditions.
New breakers installed
As part of the panel swap and to align with present-day safety standards, we supplied and installed new breakers for the home’s critical loads and general circuits:
- 12 × 15A standard breakers for lighting and general-purpose circuits
- 8 × 20A standard breakers for kitchen and small appliance circuits
- 4 × 30A standard double-pole breakers for larger 240V equipment
- 1 × 40A standard breaker
- 1 × 60A standard breaker
The new panel is backed by a transferable 20-year warranty from the manufacturer specified for this installation.
Code updates and AFCI considerations
With NEC 2020 adoption expanding in our area, inspectors may require certain circuits to be protected by AFCI (Arc-Fault Circuit Interrupter) breakers. In some homes, preexisting wiring conditions—such as shared neutrals—can cause immediate nuisance tripping when AFCI protection is added. If that occurs, additional diagnostic work may be needed to isolate and correct the issue to keep the circuits compliant and operating properly.
Reviewed by the customer
Steve Janson praised our team’s work after the upgrade. Read and share his feedback on Google: View the Google review.
Serving Charlotte from our Matthews branch
Touchstone Electric provides professional panel replacements and service upgrades throughout Charlotte, NC and surrounding areas. Whether you’re addressing a recalled panel, planning future renovations, or simply improving safety and reliability, our Panels & Service Upgrades team is ready to help with permitting, inspections, and a clean, code-compliant installation.
If you need an electrical panel upgrade in Charlotte, contact our local team to schedule an assessment and get your home’s electrical system up to today’s standards.