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The equation for amperage is I = W/E, Amps = Watts/Volts. The amperage for the furnace would be, Amps = 15000/240 = 62.5 amps. So to answer the question, yes a 100 amp breaker with a #4 copper conductor will be sufficient to operate a 15 kW furnace. A 70 amp breaker will work but it is cutting the edge a bit too fine as you don't need the furnace to trip off during the winter months (northern hemisphere) if you are away from your home for an extended period of time.

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Its not recommended because your new main breaker will allow up to 100 amps and your old wire can only safely handle 60amps. If you put a 60amp main breaker in the new box, that would be acceptable. No, it is perfectly safe. Because the box is overrated, there is no problem. If the box is the main panel, and not a subpanel, install a 60A main breaker so you cannot overload your service. If it is a subpanel this 60A breaker should be in the main panel.


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