Thanks for the replies and confirmation.
1) Yes, if relocating the panel approximately 60 feet away, the National Electrical Code as well as your local electrical inspector will require a separate disconnect as close as possible to the service point of entry. An external built-in 200 amp main breaker located in the meter base is code compliant. I also recommend that the main panel be a 200 amp main breaker type and not a main lug type.
2) If relocating the main panel 60 feet away, a new 200 amp panel would be configured as a sub-panel. NEC recommends that the voltage drop be 3% or less. From the meter base extending out to the 200 amp rated sub-panel will need to be a 4 wire feeder circuit comprised of 2 hots, 1 neutral and 1 equipment ground.
In calculating the voltage drop using a 240 volt circuit @ 200 amps and 60 feet results in using 2/0 Copper for the 2 hots and 1 neutral and a 6 AWG Copper for the equipment grounding conductor. This results in a voltage drop of 1% or a loss of 2.3 volts. Therefore, code compliant.
3) Since upgrading to a 200 amp service you will also need to replace the existing ground rod and/or cold metal pipe water main ground connection using 4 AWG Copper.
4) Conduit size would be 1 1/2" diameter for EMT or 1 1/2" diameter Sch. 40 PVC gray electrical conduit on the interior of the home and 2" diameter Sch. 80 gray electrical PVC on the exterior (from the meter base to the inside penetration of the home). Sch. 40 PVC is not allowed on the exterior since it may be subject to damage near the meter base. EMT conduit
will provide the best overall protection on the inside of the home for the Service Entrance conductors. Other forms of cable (SER) or flexible conduit (Greenfield) are another option, but I always recommend EMT conduit as the best choice.
5) If upgrading to a 200 amp service, you will also require a new weatherhead and riser mast. You will need to check with your local electrical inspector on the riser mast to confirm the size they require. Most inspectors will want a 2" or 2 1/2" diameter Rigid Metal Conduit as the riser mast for rigidity purposes.
Hope this helps………If you have any additional questions, let me know and I’ll be glad to answer them for you.
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The next time you have an electrical question, you can also request for me at: http://www.justanswer.com/home-improvement/expert-your-electrician ……….Thanks…………..Kevin!