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Electrical Circuit Breaker Failure, Photos of Burned Circuit Breaker Which Failed to Turn Off
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Electrical Circuit Breaker Burns, Fails to Trip, Continues to Conduct Power: this document demonstrates detection and fire risks of a bad electrical circuit breaker which burned, failed to trip, and remained live in the electric panel. The example is used to inform electrical inspectors, home inspectors, electricians who inspect building electrical panels for defects. Photographs and comments describe a modern residential electrical service panel with aluminum bus parts which corroded, overheated, and in which a circuit breaker which had burned but was continuing to power the circuit!

You don't need a VOM or digital volt meter to see bad burn ups like this but this failure is a strong recommendation for use of digital multimeters or simple neon testers to confirm that circuit breakers really do turn off the power.

Other critical electrical system failures are explained and photo-documented at Federal Pacific Electric Stab-Lok and Zinsco Electrical Circuit Breaker Failures and Aluminum Wiring Information Website © Copyright 2008 Daniel Friedman, All Rights Reserved. Information Accuracy & Bias Pledge is at below-left. Use the links at page left to navigate this document or to go to Other Website Topics. Green links at left show where you are in our document & website.

Full View of Electrical Panel with a Burned Circuit Breaker

On opening the panel, arcing and burn marks were obvious. Note the black stains along the left side of the right-hand bus bar above the highest breaker in the panel. Note also the corrosion present at the neutral bus and bus bar connector at the panel bottom right corner. This panel was in a wet utility basement of an old house in New York state. However it did not appear that moisture in the panel from basement conditions was the root cause of overheating and damage. There was not general corrosion throughout the panel. The panel itself was relatively new, less than ten years old.

A Look at the Electrical Panel Center

A look at the center of the panel shows pieces of circuit breaker plastic and other debris that was obviously a product of arcing and burning at one of the circuit breakers.

Close up View of the Electrical Panel Center

A closer look at the same area shows a piece of one of the right-hand breakers sitting atop the lower breaker on the left. Notice the red and white corroded material at the lower right corner of the top breaker. J. Aronstein suggests that overheating in the breaker burned off zinc or other anti-corrosive plating leading to bleed-out of rust particles. Other breakers in the panel, presumably of the same age, did not show these visual indications of damage.

Burned, arced breaker still in place, still "live"

Finally, shifting the angle and getting some better light on the subject one could see that the lower of the uppermost two breakers in the panel right side had burned badly where it was connected to the aluminum bus of the panel.

It was remarkable that despite severe damage to the breaker and panel bus, the breaker was still conducting current to the circuit connected to it.

During a home inspection inspectors should not touch equipment like this. Using a TIF Instruments Tic Tracer it was possible to confirm live electrical power at various points. Of course, what's called-for is an immediate repair which most likely requires replacement of the bus assembly and breakers if not the whole panel.

Home inspectors are not forensic engineers, but it appears obvious to anyone looking at this equipment in-situ that overheating at the connection of the breaker to the panel bus must have led to arcing, breaker damage, and thus creation of an unsafe condition in which there is very likely no overcurrent protection being provided by this equipment. You don't need a VOM or digital volt meter to see bad burn ups like this but this failure is a strong recommendation for use of digital multimeters or simple neon testers to confirm that circuit breakers really do turn off the power.

More expert information on this topic

More Information on Electrical Inspection, Electric Wiring Hazards, and Building Failure Forensic Investigation

• * Safety Hazards and Safe Inspection Procedures for Electrical and Home Inspectors at Residential Electric Panels
• Aluminum Wiring Information Website Aluminum Electrical Wiring Hazards and Repairs: in-depth authoritative info, photos, documents including selection of proper vs. ineffective repair methods. E.g.: Ideal 65 "Twister" purple connector fails in field and lab testing with aluminum wire.
• Ampacity of an Electrical Service: How to determine the electrical service size or ampacity entering a building
• Circuit Breaker, a bad one fails to trip failure at aluminum bus-to-circuit breaker connection - field report and photographs
• Electrical Panels, How to Inspect in Buildings, safety for electrical inspectors, electrical panel, fusing, wiring defects, defective products. Inspection Class Presentation
• Federal Pacific Electric (FPE) Stab-Lok Circuit Breaker Panel Hazards Website - Latent fire hazards, in-depth authoritative research, documents, advice on Stab-Lok electric panel and circuit breaker failures and what to do when this equipment is found in buildings.
• Zinsco Electrical Circuit Breaker Failures: overheating, failure to trip, burn-ups involving Zinsco and certain Sylvania electrical panel components - page under development March 2006.
• Lightning Strike Risk Assessment, Protection Systems & Services
• Multi-wire branch circuit inspection and defects
• "Electrical System Inspection Basics," Richard C. Wolcott, ASHI 8th Annual Education Conference, Boston 1985.
• "Simplified Electrical Wiring," Sears, Roebuck and Co., 15705 (F5428) Rev. 4-77 1977 [Lots of sketches of older-type service panels.]
• "How to plan and install electric wiring for homes, farms, garages, shops," Montgomery Ward Co., 83-850.
• Rust and Corrosion in Electrical Panels, A Study and Report on Frequency and Cause for Electrical and Home Inspectors at Residential Electric Panels


• Directory of Home Inspectors accessible via internet
• Electrical System & Wiring Hazard Inspection, Detection, Cause, Remedy, Prevention - Main Electrical Page

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