How to Convert Fuses to Breaker Boxes

Upgrading a fuse box to a breaker panel can increase the safety and usability of the electrical system of a house. Some cities have requirements that fuse boxes be upgraded before the resale of a house, and many insurance companies see breaker panels as safer. Changing the fuse box to a breaker box requires some confidence in your electrical wiring ability and isn't something that everyone will be comfortable doing.

Things You'll Need

• Work lighting
• Pen
• Masking tape
• Screwdriver
• Hammer
• Breaker panel
• Drill

Instructions

1. Count the number and sizes of breakers that will be needed in the new breaker box. Counting the wires that are fed into the fuse box is a good place to start. Only one wire should be connected to each fuse. If two wires are connected to a fuse, it is a breach of electrical code and each wire should be provided its own breaker in the new system.

2. Set up work lighting that is battery operated around the work site. The power will need to be turned off completely, so it is necessary to bring in extra lighting.

3. Turn off the power to the house by turning the main power disconnects to the "OFF" position. Remove the cover of the main power disconnect box, then unscrew and remove the fuses from the box. This will protect the person completing the work from being accidentally shocked if the handle is turned back to the "ON" position.

4. Remove the cover of the fuse box. Use a pen and masking tape to label each of the wires. Disconnect each of them from the fuse terminals and pull them through the box connectors.

5. Remove the hex nut from the inside of the fuse box that secures the pipe between the fuse box and the main disconnect.

6. Use a drill to remove the screws that are securing the fuse box to the wall and remove it.

7. Determine which knockout on the side of the new breaker panel will line up with the pipe coming from the disconnect panel. Use a hammer and a flat-head screwdriver to break out the knockout.

8. Insert the wires through the knockout of the breaker panel and insert the end of the pipe into the knockout hole. Thread the wires through the hex nut and secure the pipe in place. Secure the breaker panel to the wall with a drill and the screws provided.

9. Connect the heaviest gauge wires first. The heaviest gauge wires will be the ones that are routed from the main disconnect box. Connect the double-pole breakers in the upper breaker slots and any 15-amp wires in the lower breaker slots. Allow only one circuit per breaker slot. Each breaker needs to be connected in the following sequence: hot wire on breaker, neutral wire on the neutral bus barn and the ground wire to the grounding screws. Check the connections by gently tugging on the wires. The wires should be snug and not allow movement or pull from the terminal.

10. Mount the cover plate on the breaker panel according to the instructions of the manufacturer. Install the fuses into the main disconnect and turn the power back on.

References

• Renovation Headquarters: Changing a Fuse Panel to a Circuit Breaker Panel