Federal Pacific Electric Panel Tests Indicate Failures

Results of independent testing on an FPE Stab-Lok® panel obtained from a homeowner
- Subset of the entire UL 489 Standard, is intended to determine proper electrical circuit breaker function in response to overcurrent.
- FPE PANEL Test Performed - 4 breakers (green tabs in various photos) performed properly
- FPE PANEL Test Results - 13 breakers (yellow tabs in various photos) did not work properly,
- Photos of FPE Stab-Lok® Panel - 2 breakers "tripped" but failed to open at least one pole
- In the electrical industry, the failure rate for non-trip breakers is virtually zero.
FPE Stab-Lok® TECHNICAL REPORT - separate article
FPE Stab-Lok® TECHNICAL REPORT-2004 - separate article
Questions & Answers about tests on FPE Panels and Breakers
References

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Independent tests of FPE Equipment: October 15, 2000, Poughkeepsie, NY. Tests by an independent forensic engineer confirmed failures of circuit breakers in a Federal Pacific Stab-Lok® residential electric panel that was contributed by a homeowner.

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.

Federal Pacific Electric Test Performed on Homeowner's FPE Breaker Panel

The breakers in this Federal Pacific Stab-Lok® panel were tested according to the Underwriters Laboratories UL Standard UL 489 calibration test.

This test, a subset of the entire UL 489 Standard, is intended to determine proper electrical circuit breaker function in response to overcurrent.

40-Amp breakers were tested at 135% of rated load and should trip within an hour. 20-Amp and 15-Amp breakers were tested at 200% of rated load and should trip within 2 minutes.

Federal Pacific Electric (FPE Panel) Test Results

The FPE panel tested contained 19 circuit breakers.

4 breakers (green tabs in various photos) performed properly: the breaker opened the circuit within the prescribed time and the toggle switch moved to the "tripped" position.
13 breakers (yellow tabs in various photos) did not work properly, demonstrating mechanical irregularities within the product: while all "opened" the circuit, some moved to the full-off position and others stayed in the full-on position.
2 breakers (red tabs in various photos), nominally "tripped" in that there was partial or full toggle movement. However, they failed to open the circuit on at least one pole.

10% (2 out of 19) of the Federal Pacific Electric Stab-Lok® breakers in the panel tested failed to perform properly. In the electrical industry, the failure rate for non-trip breakers is virtually zero.

Photographs of Federal Pacific Electric Panel Tested

FPE PANEL after testing - oblique view - note variations in toggles after every breaker was subjected to overcurrent
FPE breaker failure - did not open the circuit in response to overcurrent
FPE breaker mechanical variations - this breaker moved to full "off" position after tripping - mechanically inconsistent with breakers which usually move to a "tripped" position
FPE breaker - proper function - tripped properly after testing as described above
FPE PANEL after testing - front view
FPE PANEL identification label - from panel tested

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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.
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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
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