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FIRES WAITING TO HAPPEN - Federal Pacific Electric Panels: Fires Waiting to Happen, Debate Waiting to Be Ended       FPE Stab-Lok® : FIRES WAITING TO HAPPEN - Latent Fire, Shock Hazards of FPE Stab-Lok® Equipment How Many Stab-Loks Stab-Lok® Failure Rate Proper Repair - separte article Proving the Hazard - separte article Multiwire Circuits - separte article Single Pole Breakers Latent Safety Hazard Failure Reports - separte article Technical Reports - separte article Questions & Answers about the latent nature of fire and shock hazards associated with Federal Pacific Electric FPE StabLok panels and breakers References

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This document explains the latent electric shock and fire hazards associated with Federal Pacific Electric Stab-Lok® electric panels and circuit breakers. Federal Pacific Electric "Stab-Lok® " service panels and breakers are dangerous and can fail, leading to electrical fires. The problem is that some 240-Volt FPE circuit breakers and possibly also some 120-Volt units simply may not work.

Replacement FPE Stab-Lok® circuit breakers are unlikely to reduce the failure risk of this equipment. We recommend that residential FPE Stab-Lok® electrical panels be replaced entirely or the entire panel bus assembly be replaced, regardless of FPE model number or FPE year of manufacture. We do not sell circuit breakers nor any other products.

Green links show where you are. © Copyright 2013 InspectAPedia.com, All Rights Reserved. Author Daniel Friedman.

How Many FPE Stab-Loks Are There? Why Are They Still In Place?

Readers of this document should also see FPE FIRES: Failure Reports and The Federal Pacific Stab-Lok® Electric Panel Hazard Website.

It has been suggested that there are as many as 28 million of these FPE Stab-Lok® breakers in use in the U.S. which means that in some conditions as many as one million of them may fail to provide proper fire protection. This includes "new old stock" and appears to include "substitute" FPE Stab-Lok® circuit breakers, none of which have shown an improvement in reliability in independent testing. So the right "repair" is to replace the FPE Stab-Lok® electric panel.

But where are they? Most homeowners whose houses are served by these panels are unaware of the hazards. So too are some inspectors and contractors. Because most homeowners do not order periodic electrical safety inspections, the presence of these panels is often undiscovered until an inspection made in the course of renovating or selling a property. Our field experience indicates that even when problems occur with this equipment, often it is simply removed or replaced with little publicity. Neither manufacturers nor some electricians are inclined to frighten consumers.

See How to Identify FPE Federal Pacific Stab-Lok® Electric Panels - is yours one of these? ALSO: A History of the FPE Stab-Lok® Issue. But come back and finish this article too!

What is the FPE Stab-Lok® Failure Rate and How Much Worse Is It Than Other Equipment?

FPE Stab-Lok® or Federal Pacific Electric Stab-Lok® circuit breakers can fail to trip at an alarming rate. In the original testing, at a modest overload (135% of rating) switches that had never been touched (never mechanically switched) were energized on both poles. These failed 25% of the time, followed by a lockup that meant the switch would never trip in the future at any overload. Once these switches had been flipped on and off (mechanically energized), failures increased to 36%!

Worse, when individual poles on these switches were energized under the same conditions, 51% of the "virgin" switches failed, and for switches that had been mechanically energized, a whopping 65% of them failed!1

In the most recent independent tests of FPE Stab-Lok® equipment, using a larger pool of FPE Stab-Lok® circuit breakers than the older CPSC and Wright Malta tests found significantly higher failure rates of FPE Stab-Lok® circuit breakers, including a look at critical safety failures (breaker failed to trip at 200% of rated current or jammed) which found up to 80% failure rate for FPE Stab-Lok® GFCI circuit breakers (n=4), 12% failure rate for double pole FPE Stab-Lok® circuit breakers (n=120), and a 1% failure rate for FPE Stab-Lok® single pole circuit breakers (n=345). (To download this article see "Technical Reports" below.)

When a circuit breaker will not trip in response to an overload there is a serious risk of fire.

What is the Proper Repair for FPE Stab-Lok® Panels and Circuit Breakers?

Homeowners and renovators who encounter these panels should replace the entire panel and circuit breaker set with new equipment. Panel replacement, can involve significant expense, typically $800 to $1200 depending on service size and other factors.

Do not simply replace individual FPE Stab-Lok® circuit breakers: first of all, there is no data suggesting that new stock, replacement FPE breakers, or "new old stock" FPE breakers found in storage somewhere perform any better than the ones already in the FPE Stab-Lok® panel. Second, there are other functional and safety concerns in the panel besides the breakers themselves. We've seen panel bus damage, panel bus meltdowns, and failure of breakers to remain secured in or onto the connecting bus itself.

Replacement Federal Pacific Electric FPE Stab-Lok® Circuit Breakers

For several reasons I do not recommend attempting to "repair" an individual failed Stab-Lok® breaker by buying a replacement either from used stock, new stock, or "compatible" stock:

• The replacement equipment and parts for FPE Stab-Lok® panels has not been independently tested and demonstrated to perform any better than the original materials
• Engineers involved in FPE Stab lok research have explained that a good part of the source of product failure for FPE Stab-Loks was in the original design and its specifications. It appears that while there were some "on the fly" (and unapproved) changes from time to time on the manufacturing line for this product, there was never a redesign suitable to attempt to "design out" the product failure. One expert opined to me privately that he believed that the original product's price point in the electrical equipment market was at the low end, and that had Federal Pacific attempted a redesign they'd not have had a product they could sell at their price point.
• There are other hazards in FPE electrical panels besides the breakers, including bus and bus insulation meltdowns and shorts.

A few other warnings:

• "Exercising" the FPE stablok circuit breakers by turning them on and off has not been shown to "un-stick" or in any other manner improve the probability of working properly, and conversely, such activity may in fact increase the chances of a future failure
• "Testing" FPE circuit breakers by applying a load may give an instantaneous picture of the performance of individual breakers but it does not predict their performance when a real safety problem occurs (overcurrent) later. More important, except if performed by a very expert person, in-place testing is very dangerous, risking fires in the building being tested.

In sum, if you could replace all the FPE Stab-Lok® equipment with (somehow magically obtained) all "new" FPE Stab-Lok® equipment (found in a used-or new-old-stock warehouse for example) the risk level for the building would not be sufficiently different from before the replacement and would remain high: there remains a latent risk of fire from failure of these breakers to trip in response to overcurrent.

Replacement Federal Pacific Electric FPE Stab-Lok® Panels is Recommended

For some cost and method alternatives when replacing an Federal Pacific Electric Stab-Lok® Panel or "load center" see REPLACEMENT PANELS which describes conventional Option#1 - "remove and replace" the electrical panel and Option#2 - FPE Load Center Replacement using Cutler Hammer (CH) Adjustable Retrofit Kit

See FPE REPLACEMENT BREAKERS for details about and advice against replacement circuit breakers sold for retrofit or installation into Federal Pacific Electric Stab-Lok® electrical panels.

Frequently Asked Questions (FAQs)

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Questions & answers or comments about the latent nature of fire and shock hazards associated with Federal Pacific Electric FPE StabLok panels and breakers.

Technical Reviewers & References

Related Topics, found near the top of this page suggest articles closely related to this one.

• Dan Friedman is a building consultant in Poughkeepsie, NY. He served as chairman of both the Education Committee and the national Technical Committee of the American Society of Home Inspectors. For Content Suggestions, Contact information is at his website. Because of website traffic volume, if you are seeking contact to ask a technical question, please handle it by email, not telephone.
• Rex Cauldwell: "Safe Wiring Practice," Rex Cauldwell, Journal of Light Construction, letter March 1995, p.6.
• Note: as we didn't add this reviewers list until 2007, this list of technical reviewers is incomplete; we have received comments and suggestions regarding this topic, edits and remarks included, from engineers and management from the US CPSC, electricians (many listed at our page on field reports of FPE failures), home inspectors, licensed electricians, and electrical engineers, and even a few attorneys and real estate agents, since 1986. Technical review, critique, content suggestions, questions, or clarifications are invited and where a contributor wishes, credit and links will be provided to that source. Contact us to provide feedback.
• Dr. Jess Aronstein, electrical engineer, Poughkeepsie, NY, forensic engineering services, independent laboratory testing for various agencies protune@aol.com (independent electrical panel testing, including FPE Stab-Lok® panels, to April 2010)
• David Carrier, electrical engineer, 53 Henmond Blvd., Poughkeepsie, NY 12603 845-430-7527 davidwcarrier@earthlink.net (independent electrical panel testing, including FPE Stab-Lok® panels, beginning 2010)
• Alan Carson, Carson Dunlop Associates, Toronto, Ontario. Mr. Carson is a home inspection professional, educator, researcher, writer, and a principal of Carson Dunlop Associates, a Toronto home inspection and education firm. Mr. Carson is a past president of ASHI, the American Society of Home Inspectors
• Mark Cramer Inspection Services Mark Cramer, Tampa Florida, Mr. Cramer is a past president of ASHI, the American Society of Home Inspectors and is a Florida home inspector and home inspection educator.
• Carl Grasso, Esq., Herzfeld & Rubin, New York, NY. Mr. Grasso is an attorney who managed a plaintiff's class action litigation against Federal Pacific Electric in New Jersey.
• William King, US CPSC Director of Electrical Engineering (Ret).
• Licensed Electricians: FPE Fire and Failure Reports includes electricians who have provided cases and photographs of field failures of FPE equipment at this website.
• Homeowners, Home Inspectors, Electricians: Federal Pacific Electric (FPE) Panel Fires and other Failures includes anecdotal field reports provided by a range of contributors including electricians (and some home owners or home inspectors) who have provided cases and photographs of field failures of FPE equipment at this website.

Books & Articles on Building & Environmental Inspection, Testing, Diagnosis, & Repair

• Our recommended books about building & mechanical systems design, inspection, problem diagnosis, and repair, and about indoor environment and IAQ testing, diagnosis, and cleanup are at the InspectAPedia Bookstore. Also see our Book Reviews - InspectAPedia.

The Home Reference Book - the Encyclopedia of Homes, Carson Dunlop & Associates, Toronto, Ontario, 25th Ed., 2012, is a bound volume of more than 450 illustrated pages that assist home inspectors and home owners in the inspection and detection of problems on buildings. The text is intended as a reference guide to help building owners operate and maintain their home effectively. Field inspection worksheets are included at the back of the volume. Special Offer: For a 10% discount on any number of copies of the Home Reference Book purchased as a single order. Enter INSPECTAHRB in the order payment page "Promo/Redemption" space. InspectAPedia.com editor Daniel Friedman is a contributing author. Or choose the The Home Reference eBook for PCs, Macs, Kindle, iPad, iPhone, or Android Smart Phones. Special Offer: For a 5% discount on any number of copies of the Home Reference eBook purchased as a single order. Enter INSPECTAEHRB in the order payment page "Promo/Redemption" space.

Building inspection education & report writing systems from Carson, Dunlop & Associates Ltd

• 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 System & Wiring Hazard Inspection, Detection, Cause, Remedy, Prevention - Main Electrical Page
• Electrical Panels, How to Inspect in buildings, safety for electrical inspectors, electrical panel, fusing, wiring defects, defective products. Inspection Class Presentation

• The Federal Pacific Stab-Lok® Electric Panel Hazard Website Safety Information for Consumers.
• 2007 FPE Stab-Lok® TECHNICAL REPORT - an updated test report of independent testing (a large 1.2MB PDF file) using a larger pool of FPE Stab-Lok® circuit breakers than the older CPSC and Wright Malta tests found significantly higher failure rates of FPE Stab-Lok® circuit breakers, including a look at critical safety failures (breaker failed to trip at 200% of rated current or jammed) which found up to 80% failure rate for FPE Stab-Lok® GFCI circuit breakers (n=4), 12% failure rate for double pole FPE Stab-Lok® circuit breakers (n=120), and a 1% failure rate for FPE Stab-Lok® single pole circuit breakers (n=345).
• FPE FIRES: Failures continue: FPE breaker fails, results in fires: field reports
• Federal Pacific Electric Fires Waiting to Happen, Debate Waiting to Be Ended, detailed article
• Home Inspection Reporting Language and discussion for FPE panels
• Home Inspection Reporting Language and discussion for FPE panels
• How to Identify FPE Federal Pacific Stab-Lok® Electric Panels - is yours one of these? ALSO: A History of the FPE Stab-Lok® Issue.
• Federal Pacific Electric Panels: Fires Waiting to Happen, Debate Waiting to Be Ended
• How to Identify Federal Pacific Electric Panels Stab Lok Breakers & History of the Federal Pacific Electric Stab Lok Hazard
• Replacement Circuit Breakers for FPE Stab-Lok® Electric Panels? are not recommended
• Replacement Panels for FPE Stab-Lok® load centers - options include conventional complete panel replacement and a less costly replacement of the panel interior load center/bus assembly
• Schneider Canada Federal Pioneer circuit breaker recall
• 1983 CPSC Investigation of FPE Circuit Breakers Safety Information for Consumers
• 1982 Reliance Electric Co. SEC Quarterly Report: Note C. reports litigation between Reliance and UV Liquidating Trust and contends that "... improper and deceptive practices were employed for many years to secure UL listings for Federal Pacific's circuit protective products..."
• 1980 Reliance Electric Co. Press Release: improper practices used to obtain UL Listing for most of FPE's circuit breakers and notes testing which indicates "possible defects." 1980, Reliance Electric Co.
• 1980 FPE - Exxon Buys A Scandal Along With A Company improper practices used to obtain UL Listing for most of FPE's circuit breakers and notes testing which indicates "possible defects." 1980, Reliance Electric Co.
  
  
• Safety Hazards and Safe Inspection Procedures for Electrical and Home Inspectors at Residential Electric Panels
• ...