A commercial panel upgrade San Jose project is rarely just the panel. It's the switchgear, the PG&E pad-mount, the transformer pairing, the conduit run, and a four-to-twelve-week lead time on the gear itself. Here's the checklist we run on every commercial three-phase upgrade from 400A through 1,600A.

When the service needs upsizing

Three triggers drive most commercial three phase commercial panel upgrades. None of them are surprises by the time they show up:

  • Tenant fit-out blocked. A new tenant brings equipment that pushes the existing service past capacity. Most common on machine-shop and restaurant builds.
  • Aging gear. Switchgear over 30 years old often fails arc-flash analysis or has parts no longer manufactured.
  • Building expansion. Added floor, added wing, added rooftop HVAC. The load calc tips past the existing service capacity.

Sizing the service

Commercial three-phase services come in standard sizes. The math runs against NEC 220 commercial load calculation rules with demand factors specific to the building type:

  1. 400A three-phase. Multi-tenant retail, small office, restaurant build. 208V wye is the standard.
  2. 600A and 800A. Mid-size office, larger retail, mid-tier manufacturing. 208V or 480V depending on equipment.
  3. 1,200A. Manufacturing fit-outs, machine shops, larger TI, multi-floor commercial. 1200 amp panel typically runs 480V with step-down transformer downstream.
  4. 1,600A and above. Heavy manufacturing, biotech, larger multi-tenant commercial. 1600 amp service is 480V three-phase with switchgear and metering. Lead time is the constraint.

The voltage decision drives every conductor and every step-down for the next ten years. Get it right at design.

PG&E coordination

Customer-side work is one half of the project. The PG&E side is the other:

  • Planning application. New service entrances and major upsizes require a PG&E planning application before any gear is ordered. Lead time on the planning approval alone runs four to eight weeks.
  • Pad-mount transformer. Most 1,200A and 1,600A services need a new PG&E-owned pad-mount. PG&E sets the pad spec; the customer (with our help) pours the pad and runs the primary conduit.
  • Primary work. PG&E runs the primary conductor to the pad. Their schedule, their crew.
  • Meter set and energization. Final step. We coordinate the date so the customer-side work is ready and the meter set is the only outstanding item.

Switchgear lead time

The single biggest scheduling risk on a commercial electrical service upgrade is switchgear lead time. Standard configurations on Square D, Eaton, or ABB run six to ten weeks. Anything custom (specific breaker layouts, integrated metering, special trim) runs twelve weeks or longer.

Two practical implications:

  • Order early. Get the gear on order as soon as the design is approved. Permits and PG&E planning run in parallel.
  • Avoid custom unless required. Standard configurations ship faster and have replacement parts available. Custom is only worth it when the application requires it.

Install day, end to end

Most commercial three-phase installs run two to five days on the customer side once gear is on site. The sequence:

  1. Switchgear set in position, anchored, leveled.
  2. Primary and secondary conductors pulled. Meter base, CT cabinet, and main breaker installed.
  3. Distribution panels and transformer (if applicable) set and wired.
  4. Customer-side load circuits transferred from old service to new. Done in stages where the building is occupied.
  5. PG&E coordination for meter set and energization. Final inspection scheduled by us.

The full scope sits on the three-phase commercial panels page.

Closeout and as-built

Commercial closeout is more substantial than residential. Documentation delivered:

  • Permit closeout signed by the AHJ.
  • As-built one-line diagram showing the new gear, ratings, and downstream feeders.
  • Insulation resistance test results.
  • Arc-flash labels installed on the gear.
  • PG&E PTO documentation if applicable.
  • Manufacturer warranties on file.

Frequently asked questions

  • What sizes of three-phase commercial panel do you install?
    400A, 600A, 800A, 1,200A, and 1,600A three phase commercial panel sizes are standard. Smaller commercial sites use 200A or 400A three-phase. Larger fit-outs occasionally need 2,000A or higher.
  • How long does a commercial panel upgrade take in San Jose?
    Two to five days on the customer side once gear is on site. Total commercial panel upgrade San Jose project lead time runs four to twelve weeks driven by switchgear manufacture and PG&E utility-side scheduling.
  • Do you handle PG&E pad-mount transformer coordination?
    Yes. New 1200 amp panel and 1600 amp service installs typically require a PG&E-owned pad-mount transformer. We handle the customer-side gear, the pad and primary conduit, and the secondary connection.
  • What's the difference between 208V and 480V three-phase commercial?
    208V wye serves most office, retail, restaurant, and light commercial. 480V wye is the standard for manufacturing, larger HVAC, and process equipment.
  • Can you bundle the panel upgrade with the tenant build-out?
    Yes. Most commercial electrical service upgrade projects pair with downstream distribution, transformer scope, and tenant fit-out. Same crew, same quote, same closeout package.

What to do next

If a tenant fit-out is in design or aging switchgear is on the property's capital list, the right time to start is now. PG&E planning runs in parallel with switchgear ordering, and both run in parallel with permit pull.

Send the equipment list and the floor plan and get an estimate.