We have a 2003 build in Vaughan with the original 100-amp panel. When we bought a Tesla Model Y last year and wanted a Level 2 charger, our electrician told us the panel could not support it alongside our existing loads. We decided to do the full panel upgrade at the same time.
The load calculation: Our electrician did a proper load calculation. Existing loads: electric range (8.8kW), electric dryer (6kW), two air conditioners (3.2kW total), hot water heater (4.5kW, electric). Without any of these running simultaneously, just the baseline — we were at 68% of 100 amp capacity. Adding a 50-amp EV circuit made the calculation untenable.
The utility coordination: We are on PowerStream (now Alectra). Our electrician submitted the upgrade application on our behalf. Alectra came out to assess the service drop — ours was 100A rated aluminum wire that needed to be replaced to 200A copper. Alectra’s work: 6 weeks after application. Their cost: $0 (absorbed by the utility). Our electrician had to coordinate with them to disconnect and reconnect.
The work:
- New 200A Square D panel (40-circuit), all breakers reconnected: $1,980 labour
- Service entrance cable replacement: $420
- New 50A circuit to garage for EV charger: $380
- Hardwired 50A Flo charger unit: $1,100 (supply) + $280 install
- ESA permit and two inspections: $340
- Total: $4,500
Notes on the ESA inspection: Inspector came for rough-in and final. He checked the service entrance cable work, the panel labelling, and the AFCI/GFCI circuit compliance (Ontario now requires AFCI on bedroom circuits in new work — two of our bedroom circuits that were touched needed AFCI breakers, $280 extra).
EV charger is excellent. Full charge from 20% overnight on a 16-hour park. No regrets.