Your breakers keep tripping, lights dim when the air conditioner kicks on, and that new appliance seems to knock out half the room every time it starts. Maybe a contractor has already told you that you “probably need more power,” but nobody has explained what that really means. Living with an electrical system that feels fragile is frustrating, and it is hard to know if you are just annoyed or actually unsafe.
In Dallas, we see these kinds of issues all the time in homes and small commercial buildings that have gone through one or more remodels. A kitchen upgrade here, a garage conversion there, a new backyard workshop, and suddenly the electrical system feels like it is held together with luck. Often, the real problem is not one bad breaker or one overloaded outlet. It is a subpanel that was never sized correctly for what you are asking it to do.
At ElectricMan, our licensed and insured electricians have been working on Dallas electrical systems since 2004. We are a family-owned company, and we have opened thousands of panels across the area. Again and again, we find the same pattern. An undersized or poorly planned subpanel quietly strains the whole system. In this article, we will break down how subpanel sizing really works, how it goes wrong, and how a proper evaluation can stabilize your property before small annoyances turn into expensive damage.
How Subpanel Sizing Actually Affects Your Dallas Electrical System
Every property has a main service panel. This is where power from the utility enters your building and gets distributed to the rest of your circuits. A subpanel is a secondary panel fed from the main one. It exists to make distribution more flexible and to serve specific areas like an addition, a garage, or part of a commercial space. The key detail is that the subpanel depends completely on the size of its feeder and its amp rating. It does not create extra power, it only re-routes what your service can supply.
Many people assume that if there are open breaker spaces in a subpanel, they still have plenty of capacity. In reality, capacity is determined by the panel’s amp rating and the size of the feeder conductors that supply it. A 60 amp subpanel with several empty spaces is still only designed to safely carry 60 amps in total. The number of slots is about physical organization, not how much power the panel can safely deliver. Treating empty spaces as “extra capacity” is one of the most common mistakes we see.
The feeder between the main panel and the subpanel is just as important. It must be sized to handle the maximum current the subpanel is expected to carry. If the subpanel is rated for 100 amps but it is fed with conductors suited for only 60 amps, the weakest link controls the system. The main panel breaker feeding that subpanel has to be sized to protect the smaller wire, and the subpanel will never be able to safely use its full nameplate capacity. This mismatch is exactly how a system looks fine on the surface yet keeps misbehaving under load.
Because our electricians at ElectricMan perform panel and subpanel load evaluations across Dallas on a regular basis, we see how these details play out in real homes and businesses. When we open a panel, we are looking not just at how many breakers are installed, but at the amp rating stamped on the panel, the wire sizes feeding it, and what those circuits are actually serving. That real-world view is what lets us connect your symptoms to a sizing issue instead of guessing.
The Dallas Additions & Remodels That Overload Subpanels
Very few Dallas properties are still in the exact configuration they were built in. Kitchens get remodeled with more lighting and bigger appliances. Garages turn into bedrooms or offices. Backyard shops and outdoor kitchens are added. Each project puts new demands on the electrical system, and at some point someone decides to “just add a subpanel” to get more spaces for breakers. This is often where subpanel sizing problems begin.
We often see small 60 amp or 70 amp subpanels added during a kitchen remodel or garage conversion. The goal at the time was usually to make room for a few new circuits without upgrading the main service. In many of these jobs, there was no full load calculation performed. An electrician or contractor looked at the existing panel, found a breaker they thought they could spare, and used it to feed a small subpanel. That approach might work briefly, but it leaves almost no room for real-world usage or future expansion.
Over time, more and more gets tied to that same subpanel. A homeowner adds a window unit in a back room, a freezer in the garage, or tools in a new workshop. In commercial settings, additional office equipment, small HVAC units, or breakroom appliances get added. Each new load seems minor in isolation. Collectively, they push the subpanel and its feeder beyond what they were ever intended to handle. At that point, the system becomes fragile.
In older Dallas neighborhoods, this pattern is especially common. Original services were smaller, and each wave of remodeling tried to stretch them a bit further. Without a proper load calculation, the subpanel sizing decision during each project is based more on cost and convenience than on physics. As a family-owned company with more than 20 years working on these homes, we recognize the signs quickly, because we have seen the same shortcut repeated all over the city.
What Happens Electrically When a Subpanel Is Undersized
When a subpanel is undersized, the problem is not just on paper. Electrically, the system behaves differently under stress. The most obvious symptom is frequent tripping of breakers in the subpanel or the breaker in the main panel that feeds it. Those breakers are doing their job. They sense too much current flowing through the circuit or feeder and open to prevent overheating. Resetting them without reducing the load simply restarts the stress cycle.
As current flows through undersized conductors, those wires heat up more than they should under heavy load. Electrical resistance turns extra current into heat, and that heat pushes breakers closer to their trip point. In some cases, you do not see constant trips. Instead, you see subtle clues such as a warm panel cover, labels that feel hot to the touch near certain breakers, or a faint smell of warm insulation after heavy use. These are signs that the conductors and breakers are carrying more than they should for long periods.
Voltage drop is another direct effect of an overloaded or undersized subpanel feed. If the feeder to a detached garage or backyard workshop is too small or too long for the load it now supplies, voltage at the far end can sag when big tools or equipment start. In a home, this shows up as lights dimming right when the air conditioner, pool pump, or compressor starts. In a shop, motors may sound strained when starting and may run hotter than they should. All of these are electrical consequences of a feeder that is asked to do more than it is sized for.
The main panel also feels the stress. The breaker feeding the subpanel may run hot and occasionally trip when multiple large loads run at the same time. Over years, repeated heating and cooling cycles at lugs and breakers can loosen connections. Loose connections create arcing and more heat. At that point, you no longer have just a sizing problem. You have a wear and safety problem that can affect the entire service. These are the patterns our licensed electricians watch for when we investigate subpanel issues across Dallas.
Why Breaker Trips Are a Warning, Not Just an Annoyance
When a breaker trips in the middle of dinner or during a busy workday, it feels like a nuisance. The natural reaction is to flip it back on and hope it was a one-time event. However, breakers are safety devices. They are designed to sense overcurrent and open the circuit before the wires or equipment get dangerously hot. Treating trips as purely annoying misses the message your electrical system is trying to send.
In a properly sized system, occasional trips happen, but they are rare. When we hear about the same subpanel circuits tripping repeatedly, particularly when certain combinations of appliances are used, it is a strong indicator of overload. Many people assume the breaker itself is “weak” or defective. While breakers can fail, in our field work we find that repeated trips usually point to a circuit or subpanel that is carrying more load than it should, especially after years of additions.
There is also a long-term cost to ignoring trips. Every time a breaker operates under heavy load, there is heat at terminations, bus bars, and inside the device itself. Over time, this can degrade insulation, loosen screws, and increase contact resistance. Higher resistance means more heat for the same current. It is a feedback loop that quietly increases the risk of equipment failure or, in the worst case, arcing and fire. Frequent trips are one of the earliest and most visible warnings that something in the sizing or load distribution is not right.
Our electricians at ElectricMan often get called after months or even years of this flip-and-forget routine. By then, the underlying issue has usually grown, and the panel may already show signs of aging faster than expected. When we evaluate the system, our goal is not just to replace a breaker. We look for the reason it is being asked to work so hard and correct that root cause so you are not stuck in the same cycle.
How Proper Subpanel Sizing & Load Calculations Are Done
Subpanel sizing is not guesswork, and it is not as simple as asking, “How many breakers do we need?” A proper load calculation starts with a detailed inventory of what is actually connected and what is planned in the future. This includes large appliances such as HVAC units, ovens, dryers, and water heaters, as well as general-purpose circuits serving lighting and receptacles in the area fed by the subpanel. The calculation considers not just how many loads exist, but how they are likely to be used together.
Electricians use standard methods, based on the National Electrical Code, to total expected demand. Different types of loads receive different treatment. Continuous loads, which run for three hours or more at a time, are typically sized at 125 percent of their rated current. General lighting and receptacles are calculated using demand factors, which recognize that not every light and outlet is at full use at the same moment. This mix of diversity and continuous load planning is what helps ensure the panel and feeders can handle real-world usage, not just a list of devices.
Once the calculated load is known, we select a subpanel with an amp rating that meets or exceeds that demand with a margin for future growth. The feeder conductors and the breaker feeding the subpanel are then chosen to match that amp rating. For example, a 100 amp subpanel serving a detached workshop with significant equipment needs requires a feeder and breaker sized for 100 amps, not just whatever spare breaker happened to be free in the main panel. Anything less builds in a bottleneck from day one.
There are also safety details that must be handled correctly, such as keeping neutrals and grounds separated in subpanels and ensuring that breakers and wires are properly matched. These may seem like technical fine points, but together they define whether your system is safely protected or quietly vulnerable. Our certified, licensed, and insured electricians at ElectricMan perform this kind of load calculation and sizing work daily for Dallas homes and businesses. We rely on a clear, standards-based process because it gives you a system that behaves predictably under load instead of one that only works until the next upgrade.
Signs Your Dallas Property Needs a Subpanel Evaluation
Not every property with a subpanel problem looks like a disaster. Often, the signs are subtle, and they show up only when the system is under stress. One common red flag is frequent tripping of the same breakers, especially when multiple appliances run together. For example, if running the microwave and toaster in the remodeled kitchen reliably trips a breaker, or if starting a compressor in the garage knocks out part of the house, that pattern suggests an overloaded circuit or subpanel.
Another sign is dimming or flickering lights when large loads turn on. If overhead lights dip every time the air conditioner starts, a well pump kicks in, or power tools spin up in a detached building, it may point to voltage drop on a heavily loaded or undersized feeder. Warm panel covers, discoloration near breakers, or a buzzing or humming sound from a panel are also reasons to call for an evaluation. These indicate that components are working harder than they should.
History matters as well. If your Dallas property has had several remodels, additions, or converted spaces over the years, and especially if those projects were done by different contractors at different times, your load distribution is likely to be uneven. A small subpanel that was adequate for a single kitchen remodel years ago may now be feeding a kitchen, a converted garage office, and a backyard patio space. Even if nothing is tripping yet, that growth can leave you with no safe capacity left for future plans.
When we respond to these situations, our goal is to give you clear answers, not just more questions. Our well-stocked service vans usually allow us to correct obvious hazards or temporary issues on the spot, such as loose terminations or mislabeled circuits. From there, we can discuss whether the system as a whole needs resizing, load redistribution, or a more substantial upgrade to stay safe and reliable as your property continues to evolve.
What Our Electricians Look For During a Subpanel Inspection
When you schedule a subpanel evaluation with ElectricMan, we start with a thorough visual and mechanical inspection. Our electricians look at the panel’s labeling and rating, the feeder breaker in the main panel, and the size and condition of the conductors feeding the subpanel. We check for signs of overheating, such as discoloration, melted insulation, or a panel that feels unusually warm under normal load. We also look for concerning details like double-lugged breakers, where two conductors are improperly landed on a single terminal.
Next, we examine how circuits are laid out and what they serve. In many Dallas homes, we open a subpanel and find tandem breakers squeezed into slots, circuits that are mislabeled or not labeled at all, and multiple heavy loads clumped onto one panel that was never sized for them. We compare what we see on paper and in the panel to real-world use in the home or business. Large loads such as HVAC equipment, electric water heaters, ovens, dryers, and shop tools get particular attention, because they drive much of the demand on the system.
We also verify that the subpanel is wired correctly from a safety standpoint. That includes confirming that neutrals and grounds are properly separated, that there is no bonding screw installed where it should not be, and that breakers and conductors are matched in size and type. These checks may seem detailed, but they are a big part of preventing hidden faults that only show up under stress. An undersized feeder combined with incorrect bonding, for example, can create both performance issues and shock hazards.
After the inspection, we walk you through what we found in plain language. We outline whether the panel and feeders appear adequate for your current load, how much room you have for future expansion, and where we see vulnerabilities. Because we have been a family-owned Dallas company since 2004, we understand that you need more than jargon. We back our recommendations with our satisfaction guarantee, so you can be confident that the work we suggest is aimed at long-term stability and safety, not just a quick repair.
Stabilizing Your System: Repair, Resize, or Upgrade
Once we understand how your subpanel and main panel are handling the load, the next step is to choose the right path forward. In some cases, a relatively simple fix is enough. That might mean redistributing a few circuits between panels to balance load, correcting wiring issues inside the subpanel, or replacing a clearly defective breaker. These adjustments can make a noticeable difference when the underlying sizing is close but not drastically off.
In many Dallas properties with older or heavily remodeled systems, the better answer is to resize the subpanel, replace it with a larger one, or add a new subpanel with properly sized feeders. For example, a 60 amp subpanel that now feeds a workshop full of tools and some household loads may need to be replaced with a 100 amp unit and new conductors that can safely carry that demand. In some situations, especially when the main service is small and fully loaded, we discuss upgrading the main panel and service as well so the entire system has enough capacity.
These projects vary in cost and complexity. Adding a new, correctly sized subpanel in the same area with adequate feeders is less disruptive than a full service upgrade, but it still requires careful planning and professional installation. The key is to avoid repeating the same shortcut that created the problem in the first place. Cutting corners on panel size, conductor sizing, or load calculation will only bring you back to the same set of issues a few years down the road.
We know that electrical upgrades are often unplanned expenses. That is why ElectricMan offers affordable pricing and financing options. Our goal is to make it practical for you to choose the complete, safe solution instead of another short-term patch. Stabilizing your system through proper subpanel sizing and, when needed, main service upgrades helps protect your property, your equipment, and your peace of mind for years to come.
Get Your Subpanel Sizing Checked Before Small Issues Become Big Problems
If your Dallas home or commercial space feels like it is always one appliance away from darkness, there is usually a clear reason. Undersized or poorly planned subpanels and feeders quietly strain breakers, dim lights, and heat up equipment long before anything fails completely. A focused evaluation of your subpanel and main panel can reveal where the bottlenecks are, how much real capacity you have left, and what it will take to bring your system back into a safe, stable operating range.
You do not have to live with constant nuisance trips or guess whether your wiring can handle the next upgrade. The licensed electricians at ElectricMan have spent decades working on Dallas properties, and we use proven load calculations and inspection methods to find and fix the real problem. Schedule a subpanel and main panel evaluation so we can show you exactly what is happening behind your breakers and give you clear options for moving forward.
Call (972) 362-1804 today to schedule your electrical evaluation.