Signs You Need a New Electric Control Panel

January 15, 2026

“Out of sight; out of mind” certainly can be used to describe your electric control panel.  Hidden in your basement or furnace room, it is the nerve center of your home, controlling everything from your heating and AC units to your appliances to your lighting and electronics.  It’s all good, until it isn’t. A control panel that malfunctions in any way presents numerous risks, including:

The easy way to avoid those risks is to be mindful of the following signs that you may need a new electric control panel.

Signs the Panel May Just Be Too Old or Can’t Keep Up

  1. Age. If your panel is 25 years or older, it very likely will have problems meeting your demand for power as you add energy-sapping appliances and electronics.  You may want to invest in a new panel before you encounter problems.  In fact, the following panels have been recalled or are considered out of date:
    1. Pushmatic panels
    2. Federal Pacific Electric (PBE) Stab-Lok panels
    3. Zinsco panels (aka GTE Sylvania-Zinsco panels)
    4. Challenger panels made by Challenger Electrical Equipment Corp. or Eaton/Cutler Hammer
  2. Fuses.  Control panels that still use fuses (especially likely in homes built before 1980) are more likely to cause problems and present a greater risk for fire.
  3. No space for new breakers. As your power needs soar you may need to add new breakers to meet the demand.  If you cannot add new breakers to your panel, that may be a sign you need a new one.
  4. Reliance on extension cords and power strips. If you cannot add additional breakers, you might be tempted to just use power strips and/or extension cords.  That still means you don’t have enough outlets, and the panel cannot provide the required power.
  5. Your panel is undersized. Do you have a 200-amp panel?  Most new homes do, but if your panel is not 200 amps it is undersized, as your demand for electricity will only continue to rise.
  6. Think ahead.  Even if your panel is working OK now, consider a new one if you are contemplating any of the following:
    1. Buying an electric car and thus needing an EV charging station
    2. Adding a second refrigerator and/or freezer
    3. Replacing your central air conditioner
    4. Renovating, remodeling or adding on to your home

You’re Experiencing Any of These Problems

  1. Dimming lights. If your lights dim or flicker, that is a sign your panel is overloaded. This is most likely to happen when large appliances or your air conditioner are being used.
  2. Tripping circuits. Another sign is if your circuit breakers frequently trip, (or if you still have fuses. those keep blowing).
  3. Power surges. Another indicator of an overused electrical system. Power surges can damage electronics and appliances, so if they happen frequently, it should not be ignored.
  4. Strange noises. Your control panel should not buzz, hum or pop, or make any other unusual noises.
  5. Burning or melting breakers and wires. These are signs your panel is overheating and, worst case, can be a fire hazard.
  6. Burning smell.  Even if you do not see burning or melting breakers or wires, if you detect a burning smell, that too is a problem and potential fire hazard.
  7. Hot to the touch. If the panel feels hot or warm, that is another sign of overheating.
  8. Physical damage. There should be no corrosion, burn marks or rust on the panel or the breakers.  If you see any of these, that is another sign your panel needs replacement.
  9. Increasing electric bills. Problems associated with your control panel such as degraded components, inefficient power supply and loose connections can make your system inefficient and drive up electric bills.

Contact Ravinia Plumbing, Sewer, Heating & Electric to See if You Need a New Electric Control Panel

The licensed and insured electricians at Ravinia Plumbing can help you determine whether you need a new electric control panel and then help you select and install the one that is right for you. Our customers have relied on us since 1928 (that’s 97 years!) for quality products, knowledgeable technicians, and superior service, including 24/7/365 emergency service. That is why we’ve made a name for ourselves as the most trusted plumbing, sewer, heating and air conditioning, and electrical company in Chicago’s North Shore and Northwest suburbs. Contact Ravinia Plumbing today to schedule an appointment.