Replace main panel to reuse in garage?

[Artes]

While I'm still messing around with a lighting and outlet plan for my attached garage, I want to proceed with the sub panel installation. I'm not an electrician or have stayed at a Holiday Inn recently. I'll be hiring a pro for most or all of the work and would like a better understanding for our discussion.

My current demands for the garage are small and include several circuits for lighting, several 120v outlets, a couple of 240v outlets for a compressor, and garage door opener. I may add a welder in the future to one 240 outlet.

The main panel is a 150A Challenger panel. The panel is running out of space and I'm unsure if it can or should accommodate a 60A breaker for the sub panel.

If we plan to stay in the house, is it recommended to replace the main panel with a 200A Square D AO and use the 150A Challenger panel in the garage feeding it for 60A or 80A? Alternatively, don't use the Challenger and go with a Square D both main and sub panel?

The run from panel to sub panel would be 40' across the basement ceiling with three 90 degree turns. Part of the run would be along the wall and through a dropped part of the ceiling to run along an open area by the furnace. Is 2-2-2-4 AL SER optimal for the run and can it be installed within PVC or EMT conduit for protection?

Thanks for taking the time to read and respond! Below is a picture of the main and manufacturer's label.

 

[jhelrey]

Change that one into the subpanel and put the main in the garage...

Let me clarify... Put a new one in the garage. This one would have the meter, etc. connected to it. Then run wires from it to the panel pictured making this the subpanel.

 

[pattenp]

I'd dump the Challenger panel. The 2-2-2-4 aluminum SER is good to 90A. The SER doesn't need to be in conduit but if there are places where it may be subject to damage then it needs to be in conduit. If you are doing the whole run in conduit don't use SER, use individual wires.

 

[Norcal]

That main is a Zinsco design, but Challenger is a successor to Zinsco/Sylvania gear, one of the 2 most reviled names in the electrical industry, FPE, Federal Pacific Electric is the other, I am of the belief that Zinsco & it's successors gear needs to go to scrap.

Other companies that use/used Zinsco style mains are Westinghouse*, (defunct), Unicorn, & Milbank.

*Westinghouse owned Challenger.

Did I forget to say I HATE Zinsco.

 

[wyliesdiesels]

That main is a Zinsco design, but Challenger is a successor to Zinsco/Sylvania gear, one of the 2 most reviled names in the electrical industry, FPE, Federal Pacific Electric is the other, I am of the belief that Zinsco & it's successors gear needs to go to scrap.

Other companies that use/used Zinsco style mains are Westinghouse*, (defunct), Unicorn, & Milbank.

*Westinghouse owned Challenger.

Did I forget to say I HATE Zinsco.

I hate zinsco too! Rented a house about 7 years ago that caught fire because the damn Zinsco breakers didnt trip when they should have.

All of those brands ****! Especially FPE with their fradulent/deceptive U/L stickers! Ive read about many house fires that were caused by faulty FPE panels.

 

[aandpdan]

Don't reuse the old panel. You can get a new one cheap enough and won't have to deal with filling in the knockouts or the open breaker locations.

One nice thing about having all panels the same is that if you keep spare breakers on hand, you only have one brand to deal with.

 

[Highbeam]

New panels are very very cheap and they are sparkly new with all the latest refinements.

 

[Full Size 66]

I tend to agree with those who say to replace with new. While your at the point of disassembly you might as well do both panels. They would be new, up to code and the best quality if you go with a good name. I just put in a new 200 amp panel for the garage, along with the proper service modifications, and it did hurt a good deal financially. The peace of mind knowing it is up to the task of supplying power for my garage is worth more than what I paid! In the area of wiring I would encourage you to go up to code and better. Make double sure your safe.