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"Federal Pacific" Breaker box

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"Federal Pacific" Breaker box kellyj00@gmail.com 11-07-2006
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Posted by Bud-- on November 8, 2006, 12:36 pm


dpb wrote:
> kellyj00@gmail.com wrote:
>
>>I have a 200-amp capable "Federal pacific" breaker box in my 44 year
>>old home. I've been told by a home inspector that the box is
>>unreliable and the breakers "can occasionally no-trip and could
>>potentially cause a fire" This, obviously, scares me.
>
> ...
>
>
>>Should I consider replacing the service panel and breakers to a current
>>model like a Square D as part of this remodel? After all, it doesn't
>>make much sense remodel a house that's going to just burn to the ground
>>anyway.
>
>
> You pretty much answered your own question, didn't you?
>
> http://www.inspect-ny.com/fpe/fpepanel.htm
>
> This guy is promoting himself, of course, as well, but it appears the
> data referenced are real and FPE did go under after a set of legal
> challenges and lawsuits. The CPSC began and closed an inconclusinve
> investigation way back in '83 or so and while I've not found it
> directly(but haven't looked extensively, either) there's at least an
> implication that FPE may have actually falsified some data supplied
> from tests supplied for UL testing and that UL "de-listed" the original
> FPE breakers. The replacements from Federal Pioneer in Canada have, to
> the best of my knowledge, a UL or equivalent rating, whether that is
> somehow based on previous qualification or were/are newly qualified
> I've also not been able to resolve unambiguously. (But, again, I've
> not done extensive "research", only poked around at what I could find
> on occasion as there are several FPE panels here in the house, barn,
> other outbuildings dating to roughly same time frame.)
>
> http://www.schneider-electric.ca/www/en/products/stab-lok/html/cb.htm
>
> Overall, it does appear is that there is at least a risk of a trip
> failure from a mechanical "jam" of the handle preventing opening w/ the
> older FPE breakers. Without substantiating data, there's no real way
> to judge the frequency of this as compared to other breakers, which
> I've not seen at any point.
>


Reliance Electric bought FPE and discovered that FPE fraudulently
supplied test information to UL. UL then delisted most of the FPE line.
Reliance Electric sued the seller of FPE and setteled for about 43
million dollars to cover future liability. I believe there is currently
a class action law suit in New Jersey. The problem probably covers the
1965-1980 time period although the current Canadian manufacturer won't
say what changes have been made to the line.

The link from dpb at
http://www.inspect-ny.com/fpe/fpepanel.htm
has a lot of information of FPE, much of it derived from the
investigation by the Consumer Product Safety Commission. It includes
information on the limited testing done for the CPSC. Two pole breakers
may not trip (can jam and never trip) if the current on both poles is
not the same (like ground fault). (Service disconnect size breakers were
not tested.) Another problem - single pole breakers may never trip at
135% of rating. Also bus failures which cannot be seen as they are
developing without panel disassembly.

One reason the CPSC investigation was dropped was the high cost of
testing required to allow regulatory action vs. the size of the CPSC
funding. This was probably also the start of the Reagan years which were
not favorable to regulation. And perhaps most important, the CPSC had
tried to regulate aluminum wire and in the predictable industry lawsuit
the court ruled aluminum wire was not a consumer item and thus could not
be regulated by the CPSC. Circuit breakers would probably have also not
been under the CPSC.

Another source:
http://www.codecheck.com/pdf/electrical/240overcurrent/FPE%20Article%20from%20DH%20-%20Nov2003.pdf
includes additional problems with FPE panels, including the bus problems
referred to by Pete C.

--
bud--

Posted by Chris Lewis on November 9, 2006, 12:45 pm



> FPE breakers. The replacements from Federal Pioneer in Canada have, to
> the best of my knowledge, a UL or equivalent rating, whether that is
> somehow based on previous qualification or were/are newly qualified
> I've also not been able to resolve unambiguously.

I believe this is a fair summary of the issue:

The problem with Federal Pacific in the US is that of dual
20A breakers getting into a fail-to-trip mode and caused
major fires.

The lawsuits essentially bankrupted them. The remnants of the
company were bought out by Schneider Electric in Canada and sell
under the name Federal Pioneer. Schneider is a pretty well
respected company, and does a lot more than Federal Pioneer.

These breakers had to be certified by CSA (on the whole slightly
more stringent than UL) before sold in Canada - CSA or explicitly
named equivalent approval is a legal requirement here.

They're also certified by ULC (UL Canada), which is more or less
exactly equivalent to UL.

Approximately two years worth of Schneider-made Federal Pioneer
_single_ 15A breakers were recalled several years back.
[I _think_ this was Schneider-initiated.]

Manufacturing dates around 1998 if I recall correctly. The
inspect-ny (and Schneider's) web site has a copy of the recall notice.

As I understand, no fires/injuries have resulted from the defective
15A breakers, and there's no indication that Federal Pioneer
breakers/panels are a problem otherwise.

My experience (several full panels worth) has been that Federal
Pioneer breakers are just fine. That can't be said of
Square D Homeline (over the past 10 years, 3 of 4 Homeline
breakers in the pony panel under my cooktop have fried. We
hates them, we really do.).

If your Federal Pacific (US) _panel_ is in good shape, rather than
replacing it, I'd consider net/mail-ordering some replacement dual
20As from a Schneider distributor or retailer, and not worrying
about it anymore. Current Schneider production in 15A singles
is fine, and you can still get free replacements for the recalled
15A single breaker (tho, they're unlikely to be found in US
FP panels).

There are areas here where the electricians will use _only_
Federal Pioneer, and will even refuse to replace an existing
Federal Pioneer panel with something else, despite the money
they'd make.

[My SIL had an opportunity to swap out a panel essentially
free to her to use something else, but the electrician, a
good one, said "what the hell for? Nobody around here
uses anything else, and we never have any problems with
them.". Talked himself out of about $1200 ;-)]
--
Chris Lewis,

Age and Treachery will Triumph over Youth and Skill
It's not just anyone who gets a Starship Cruiser class named after them.

Posted by Pete C. on November 7, 2006, 9:48 am


"kellyj00@gmail.com" wrote:
>
> I have a 200-amp capable "Federal pacific" breaker box in my 44 year
> old home. I've been told by a home inspector that the box is
> unreliable and the breakers "can occasionally no-trip and could
> potentially cause a fire" This, obviously, scares me.
>
> The breakers aren't the cheapest or super-easy to find, but I haven't
> had to replace any in the year or so I've lived in this house, the unit
> seems reliable. Also, the breakers have tripped a few times as the
> circuits have around 8-10 receptacles on a few runs in some cases.
>
> I'm considering doing some remodeling, including the addition of can
> lights (about 20 of them) and a few receptacles...all on new runs as
> the breaker box isn't much more than half full.
>
> Should I consider replacing the service panel and breakers to a current
> model like a Square D as part of this remodel? After all, it doesn't
> make much sense remodel a house that's going to just burn to the ground
> anyway.

I'd strongly recommend replacing the FPE incendiary device. I replaced
the one in my house with a good Square D QO series 40 space panel and
sleep much better at night. I had heard all the bad things about FPE
before and had replacement high on my to do list anyway, but it wasn't
until I started tearing the old POS apart that I realized what a POS it
really was. As an additional note, since the FPE panels are pretty old,
replacing them may get you an insurance discount if your insurance
company charges more for 30+yr old electrical.

Pete C.

Posted by on November 7, 2006, 10:18 am


Any electrical panel with breakers that old should be considered
suspect, irregardless of brand. If you could just replace the breakers
with new ones, you would be perfectly fine. However, that's not
economically viable in your case, so replacement is probably a good
idea.

Having said all of that, I have one fo these panels, and I have
replaced many of my 1962 breakers with newer ones made in the 80's and
I am perfectly fine with the panel. I have also tested all of my
breakers and they all work fine. The single pole breakers are as good
as any others their age. The two pole FPE breakers are the ones that
are notoriously bad. And unlike almost all the other FPE bashers, I
actually have an electrical Engineering degree and actually know what
I'm talking about.


Posted by kellyj00@gmail.com on November 7, 2006, 10:29 am


I'm glad I asked. You guys are amazing!

How much should I expect to pay to replace just the service panel and
all the breakers? (I don't do stuff that can kill me alone) Also,
what brand and size should I replace it with? It's a 200 amp now,
should I spring for a 200 this time around?

Thanks again gents!


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