Can Home Electrical Breakers go Bad?

Electrical breakers are essential components of your home’s electrical system, acting as safety devices that help prevent electrical overloads and potential fires. But can home electrical breakers go bad? In short, the answer is yes. But before diving into the reasons breakers can fail, it’s crucial to understand their basic operation and the types commonly found in residential settings 

How Electrical Breakers Function

Electrical breakers are designed to automatically cut off electrical power when they detect a fault condition such as an overload, short circuit, or ground fault. This interruption helps prevent wires from overheating, which can lead to electrical fires. The breaker detects excess current and mechanically trips to break the circuit, halting the flow of electricity. 

To grasp the inner workings of electrical breakers, it’s essential to break down the components which make them up and the purpose behind them. Here’s a deeper look into the technical aspects of how breakers function: 

Basic Types & Operation

Thermal-Magnetic Breaker: A thermal-magnetic breaker is the most commonly found type you will see inside your home electrical panel. Inside a breaker, there is a small electromagnet whose magnetic field strength increases with the current flow. Under normal conditions, the magnetic force is not strong enough to trigger a trip. However, in an overload situation where the current exceeds safe levels, the increased magnetic force pulls a lever or similar mechanism that triggers the breaker to trip, immediately cutting off the power. 

Alongside the magnetic element, these breakers also feature a bimetallic strip that responds to the heat generated by electrical current. This strip is made from two metals with different rates of thermal expansion welded together. As the current increases, heat causes the metals to expand at different rates, bending the strip. If the current is too high for too long, this bending moves mechanical linkages inside the breaker to trip it, cutting off the circuit. 

The dual mechanism of magnetic and thermal tripping allows breakers to respond to both immediate, high-current conditions (like short circuits) and slower, moderately over-limit conditions (typical overloads). They offer a reliable way of improving electrical safety but like any other device, can certainly “go bad”, wear out or suffer from faulty design. 

Specialized Breakers 

Ground Fault Circuit Interrupters (GFCI): GFCIs are designed to protect against electric shock by detecting ground faults. They monitor the balance between the “hot” (incoming current) and “neutral” (returning current) in a circuit. Under normal conditions, these currents are equal. If there is an imbalance, as would occur if electricity is leaking to the ground (possibly through a person), the GFCI trips the circuit within milliseconds, preventing serious injury or death. 

Arc Fault Circuit Interrupters (AFCI): AFCIs are designed to prevent electrical fires caused by accidental discharges of electricity (arcs) which can occur in damaged or deteriorated wires and cords. AFCIs detect the unique electrical signatures of these arcs and will trip the circuit to prevent the arc from igniting flammable materials. 

Can Electrical Breakers Go Bad? Common Causes of Breaker Failure

The answer is yes, electrical breakers can certainly “go bad” or fail to function properly for a number of different reasons. Like any electro-mechanical device, breakers can deteriorate and fail over time. Understanding the common causes of breaker failure can help in diagnosing issues and preventing potential safety hazards. Here’s a deeper look at why breakers can go bad: 

Mechanical Wear and Tear 

• Tripping Mechanism Deterioration: Each time a breaker trips, it subjects its mechanical components to stress. Over time, the components that engage the tripping mechanism can wear out or weaken, reducing the breaker’s ability to trip in response to a fault. This wear can lead to failure in effectively breaking the circuit during critical times.

• Contact Fatigue: The contacts within the breaker that open and close to interrupt or allow the flow of current can become pitted, corroded, or otherwise damaged through regular use. Damaged contacts may fail to make a complete circuit when closed, leading to poor conductivity and potential overheating.

Electrical Surges 

• High Voltages: Surges—sudden spikes in voltage that can be caused by lightning strikes, power outages, or malfunctions in the utility grid—are particularly damaging to electrical breakers. High voltage can overwhelm the electrical insulation within the breaker, leading to internal short circuits or arcing that permanently damages the breaker’s functionality.

• Repeated Exposure: Frequent exposure to surges can accelerate the deterioration of both mechanical and electrical components of a breaker, shortening its effective lifespan and increasing the likelihood of failure.

Corrosion and Environmental Factors 

• Moisture: Breakers located in environments with high humidity or exposure to water are susceptible to corrosion, which can impair their mechanical and electrical functions. Corrosion can degrade metal components, leading to failures in the mechanical linkage or contacts.

• Chemical Exposure: In industrial environments or areas where chemical vapors are present, breakers can be exposed to corrosive gases that accelerate the wear on electrical contacts and other metal parts.

Overloading and Improper Use 

• Chronic Overloading: Consistently drawing more current through a breaker than it is rated to handle can cause the breaker to heat up and wear out more quickly. This excessive current can eventually lead to insulation breakdown or mechanical fatigue.

• Mismatched Breaker and Circuit Load: Using a breaker that is not properly matched to the electrical load of a circuit can lead to frequent tripping, which strains the breaker and can lead to premature failure.

Manufacturing Defects 

• Quality Control Issues: In some cases, breakers may go bad due to flaws introduced during the manufacturing process. These defects might include inadequate material quality, improper assembly, or flaws in the design of the breaker itself, which can manifest as failures under normal operating conditions. This was a problem best illustrated by “Stab-Lok”, a brand of breaker commonly used in past decades which suffered from faulty design, causing many of these breakers to trip at excessively high currents, or sometimes fail to trip at all. More information on the hazards of Stab-Lok breakers can be found here.

Understanding these causes of breaker failure is essential for maintaining the electrical safety and reliability of a home. Regular inspections, proper installation practices, and immediate attention to any signs of breaker malfunction are critical steps in ensuring that your electrical system remains safe and functional. 

When to Replace Electrical Breakers

Electrical breakers are crucial for ensuring the safety of your home’s electrical system, but they do not last forever. Knowing when to replace a breaker can help prevent electrical hazards such as fires, shocks, and appliance damage. Here’s a detailed guide on identifying the right time to replace your electrical breakers, incorporating both technical considerations and safety guidelines. 

Age of the Breaker 

• Lifespan Expectancy: The general lifespan of a circuit breaker is typically between 25 to 40 years, depending on the brand, quality, and usage conditions. However, it’s advisable to evaluate their performance as they approach the 20-year mark, as the components may begin to degrade even if visible signs are not yet apparent.

• Degradation Over Time: Components within the breaker, such as the mechanical linkages, springs, and contacts, deteriorate with age and usage. Aging breakers are more prone to failure, which could compromise your home’s electrical safety.

Performance Issues 

• Frequent Tripping: If a breaker trips regularly, it may be a sign that it is unable to handle the circuit’s current demands, either due to physical wear or an actual increase in load. Regular tripping can also weaken the breaker’s internal mechanism over time, necessitating its replacement.

• Failure to Trip: A breaker that fails to trip when a circuit is overloaded or short-circuited is a major safety hazard. This indicates a potential mechanical failure or a problem with the breaker’s sensing ability, which can lead to severe consequences such as electrical fires.

Physical Signs of Damage 

• Visible Damage: Signs like scorch marks, burning smells, or melted components on or around the breaker indicate serious problems. Such physical damage is irreversible and requires immediate replacement of the breaker.

• Corrosion: For breakers in environments with high moisture or chemical exposure, signs of corrosion can impair electrical contacts and mechanisms. Corroded breakers are less reliable and should be replaced to maintain safety.

Testing and Inspection Results 

• Professional Evaluation: Regular inspections by qualified electricians can uncover issues that are not obvious to homeowners. Electricians can perform tests to assess the breaker’s condition and functionality, providing an expert opinion on whether replacement is necessary.

• Testing Failures: During routine checks, if a breaker does not perform as expected under test conditions (such as failing to trip at its rated current), it should be replaced. Specialized equipment is used by professionals to simulate faults and test breaker response.

Upgrades and Code Compliance 

• System Upgrades: Upgrading your home’s electrical system or significant renovations might require breaker replacements to handle new electrical loads or to comply with updated safety standards.

• Code Compliance: Electrical codes evolve, and newer standards might require types of breakers that provide better protection, such as AFCIs in bedrooms or GFCIs in bathrooms and kitchens. Compliance with the latest codes not only ensures safety but also enhances the value and insurability of your home.

Regular monitoring and timely replacement of electrical breakers are key to maintaining an effective and safe electrical system. Being proactive about replacing outdated, damaged, or malfunctioning breakers can help prevent electrical accidents and ensure that your system meets current electrical safety standards. 

Do you have concerns about breaker failures or electrical safety? Celtex Electric & Automation are your local Calgary specialists in all things electric. Call the Celtex team for emergency service or a free no obligation quote today.