How To Replace Zinsco Circuit Breakers

Zinsco Replacement Circuit Breakers & Electrical PANELS

• POST a QUESTION or COMMENT about finding replacements for Zinsco & Zinsco-Sylvania electric panels & excursion breakers

InspectAPedia tolerates no conflicts of interest. We take no relationship with advertisers, products, or services discussed at this website.

Zinsco Replacement Panels & Excursion Breakers:

This document describes how to supercede Zinsco Circuit Breakers, Zinsco Electric Panels, or Zinsco-blazon Sylvania Electric breakers and electrical panels in buildings. We depict ii methods for correcting this rubber hazard in buildings.

Choice i - replacement of the panel jitney assembly or "load center" while leaving the original electric console enclosure or "box" and its attached wires intact, by using the Eaton Corp., Cutler Hammer Products "Adjustable Retrofit Kit" and

Pick 2 - conventional removal and replacement of the entire electric panel.

We also provide an Article INDEX for this topic, or you lot can endeavour the folio top or bottom SEARCH BOX as a quick way to find information you need.

Replacement Electrical Panels: for Replacement of Zinsco or Zinsco-blazon Sylvania Electric Panels

How should Zinsco electric panels be repaired: Options for Replacing Zinsco Electric Panels & Zinsco-Sylvania Electrical Panels. Zinsco electric panel replacement alternatives. Field reports on operation of CE or other Zinsco replacement circuit breakers.

Article Contents

• ZINSCO REPLACEMENT PANELS - CONTENTS: How should Zinsco electrical panels exist repaired: Zinsco electrical panel replacement alternatives
  • OPTION #one RETROFIT KIT Selection of using a retrofit electric console replacement kit tin can save a big part of repair toll
  • WHY IT WORKS
  • RETROFIT COST What are the typical costs to replace a Zinsco or Zinsco-Sylvania Electrical Panel?
  • RETROFIT INSTALLATION process
  • COMPONENT SELECTION for replacing Zinsco panel motorbus assemblies, breakers
  • PRODUCT SOURCES for replacement Zinsco panel motorbus assemblies, breakers
  • Code COMPLIANCE for replacement Zinsco console charabanc assemblies, breakers
  • Groundwork & reasons for using replacement Zinsco panel bus assemblies, breakers
  • Pick #2 REPLACEMENT of the entire panel instead of the bus associates
  • OPTION #i vs OPTION #ii comparing costs & benefits

Watch Out: working with electrical equipment can involve fire, and fatal shock hazards. Electrical repairs must be performed past a qualified, licensed professional electrician. Good workmanship, post-obit manufacturer's instructions, and local and other appropriate code compliance are likewise essential for a rubber and successful issue.

[Click to enlarge whatever image]

This is information for building inspectors, dwelling house buyers, home owners, and electricians regarding steps to reduce the hazards associated with Zinsco and Zinsco-type GTE Sylvania Zinsco circuit breakers and electric panels.

Watch Out: equally with any electric installation or repair, these steps must exist performed by a licensed and qualified electrician and must comply with appropriate building codes and regulations.

Adept workmanship and an accurate assessment of the status of the electric panel enclosure which is to be re-used are important for Zinsco Electric Panel.

Watch Out: We practice not recommend mere replacement of Zinsco circuit breakers themselves.

Option1 - replace the Zinsco Sylvania panel interior bus assembly using a retrofit kit:  The first section of this certificate Selection #1 RETROFIT KIT describes how to replace Zinsco or Zinsco-blazon Sylvania Electrical Panels in buildings using a retrofit kit provided past Eaton Corp., Cutler Hammer Products (E-CH):

Option 1 - replacement of the panel motorcoach assembly or "load heart" while leaving the original electrical panel enclosure or "box" and its attached wires intact, by using the Eaton Corp., Cutler Hammer Products (E-CH) "Adjustable Retrofit Kit".

Choice two - replace the unabridged Zinsco Sylvania electrical panel: In a second document department Pick #2 REPLACEMENT we discuss Selection 2 - conventional complete removal and replacement of the entire electrical panel.

Comparison of Options 1 & 2 for Zinsco electrical panel repair or replacement: In a third document section OPTION #ane vs Selection #2 nosotros express an opinion which compares these two methods.

Where the original console enclosure is in skilful condition, Option one should toll less and be a faster chore than Option ii considering less labor and less disruption is involved.

We practice not recommend mere replacement of Zinsco excursion breakers themselves, as discussed at ZINSCO REPLACEMENT CIRCUIT BREAKERS. As well see FPE REPLACEMENT BREAKERS.

This is information for building inspectors, home buyers, home owners, and electricians regarding steps to reduce the hazards associated with Zinsco Electrical circuit breakers and service panels.

Safety warning: as with any electrical installation or repair, these steps must be performed by a licensed and qualified electrician and must comply with appropriate building codes and regulations. Good workmanship and an accurate assessment of the condition of the electrical panel enclosure which is to exist re-used are of import for Zinsco Electrical Panel

Pick #1 RETROFIT KIT - Zinsco/Sylvania Panel Replacement - Option #1 Using the Eaton Corp., Cutler Hammer (Due east-CH) Products Adjustable Retrofit Kit

Adjustable Zinsco Sylvania Electric Panel Retrofit Kits produced by Eaton Corp., Cutler Hammer Products are a patented blueprint new electrical panel interior designed to replace crumbling electric panels in residential and low-cal commercial applications.

The unique features are that the existing box and wiring can exist re-used for convenience, if still in good working status. Also, a custom trim to fit the existing box is bachelor.

Using the retrofit kit involves disconnecting the electrical circuits from the existing load eye "passenger vehicle assembly" excursion breakers. The old bus assembly and other internal parts (neutral bus, ground bus, etc) in the existing panel are removed. The panel box or "enclosure" itself is left in place, and the electric circuit wires which entered that box are left undisturbed.

Later inspection past the installer to ostend the soundness of the panel box, any openings in the box body are closed, a new load center (panel bus and circuit breaker set, ground and neutral bus bars) is mounted in the existing electric panel box, and the existing circuits are continued to the new circuit breakers.

The "field adaptable electric console interior associates" consists of an adjustable riser, the required interior bus assembly, and the appropriate neutral assembly and basis bar assembly. Additional kit components permit a new panel face to correctly fit the new bus assembly which has now been mounted in the quondam console box.

On completion, all of the electrical parts inside the original electrical panel accept been replaced. Only the steel panel enclosure or "box" has been retained.

The new parts and installation are made using UR and UL canonical components. Wiring to comply with the electric code, workmanship, and terminal lawmaking blessing are the responsibility of the installing electrician, assured by an inspection by the local electrical inspector.

Not all Electrical Panels tin can be Upgraded using the Retrofit Kit - Size Matters

Field reports and comments from the manufacturer have pointed out that not every electrical panel is a candidate for upgrading using the retrofit kit discussed here. If the original electrical panel enclosure is itself as well pocket-sized to see the size and infinite requirements of current electric codes the entire panel will need to be replaced.

The following text provides an case of a case where, unfortunately, the one-time electrical panel was but too small to upgrade:

From email between a reader and the product manufacturer
While researching the service panel in a abode I purchased this summer, I came across your retrofit kit for FPE service panels at https://InspectAPedia.com/fpe/fpereplace.htm I have a Stab-Lock C1410-14-125NI panel, 125amp, 120/240, 1 phase 3 wire. Information technology currently has one 30a (dryer), ane 40a (range) and one 50a (all other circuits) decision-making 6 15a and four 20a.

I would like to upgrade to 150amp with a few more than breaker spaces, if possible. The box measures 4 inches deep, 10 inches wide, 22-3/4 inches high inside measurements. The load centre westward/breakers is approximately six-1/2inches wide by 15 inches loftier.

The range wire is aluminum. I'm not sure if the incoming service wires are aluminum besides. The domicile was congenital in 1960. The existing panel is in first-class status, no rust, all holes intact or in use. The existing wiring is in splendid shape. One local electrician told me that your product violates code.

Here is a clear and curtailed reply from the manufacturer:

Our retrofit kits are designed to be installed into enclosures where there is sufficient space to wire according to the National Electric Code. As the local electrician pointed out, the enclosure that you have is not large enough to allow for our kits to piece of work.

Being from 1960, the existing electric panel was constructed prior to two NEC revisions that expanded the necessary wire bending space requirements. In addition, to increase the ampacity of the panel would require slightly more infinite. Unfortunately, for the awarding described, a new service will demand to exist installed.

WHY Information technology WORKS - Key Features of the Eaton Corp., Cutler Hammer Products (E-CH) Adjustable Retrofit Kit

Primal in making this retrofit arroyo possible in the replacement of Zinsco or other problematic electrical panels is E-CH's development of:

• Load Centers: a series of replacement load centers of varying capacity in amperage and number of excursion breakers, and varying also in overall dimensions
• The Adjustable Retrofit Kit: which offers a set of parts which permit the new load center, mounted in the old electrical panel enclosure, to be framed-in or enclosed properly regardless of the dimensions of the enclosure itself.

  The electrician only measures the existing enclosure and orders the advisable load center and adapter kit parts. The Adjustable Retrofit Kit parts may include:

  • A "movie frame" which adapts the existing enclosure to allow a new "trim/cover" assembly to be mounted as seen in the figure on folio 2 of the E-CH product PDF file available hither (450KB to download).

    The "picture frame" is .073 powder coat painted galvanized steel which not but adapts the trim to the existing enclosure, information technology extends past the enclosure edge several inches to provide a professional looking end when the old plaster or drywall is damaged.

  • An adjustable "riser" combined with the adjustment feature in the dead front end solves the depth bug and helps greatly when the former enclosure was not installed plumb/square.
  • The "trim/encompass associates" is the standard replacement loadcenter/panelboard trims that offered past CH equally replacement items and as such carry the standard UL cabinet front label.

One of the biggest hurdles the manufacturer faced was the panel enclosure depth issue. To solve this, CH offers the adjustable depth feature. This allows the "riser" to be adjusted to accommodate enclosures from 4" to half-dozen" in depth. When this is combined with the "pic frame" and "trim" the final product is a very safe, solid, and professional looking final assembly.

To date (June 2014) CH engineers accept not had any reports of any make or model specific enclosure that these have not worked in. Due to the adaptability of the CH kit, it is unlikely there would exist an electric panel model that these kits wouldn't fit.

Very shallow panel enclosures:

Eaton Corp., Cutler Hammer Products accept just finished the design & patent piece of work on phase 2 of this plan. This will consist of an adaptable "extension collar" which will attach to the enclosure and extend it out from the wall for those installations that are very shallow. This will extend them out then the standard "Retrofit Kit" tin be used. This will accommodate enclosures clear down to 3" or less in depth.

More Reading:
Eaton Corp., Cutler Hammer Products Adaptable Retrofit Kit Ordering Instructions PDF file 450KB to download.

RETROFIT COST - Cost of Replacing an Zinsco Console with the Eaton Corp., Cutler Hammer Products Adaptable Retrofit Kit

CH was unable to inform me of "typical" costs are hard to cite as there really isn't a typical application for this production - it is used in a wider variety of circumstances than just replacement of Zinsco electric panels or Zinsco-blazon Sylvania electrical panels. These vary from the smallest single phase, chief lug, 125amp units to the largest 3 phase, main breaker, 42-circuit. 225-AMP kits.

In addition, custom size adapter collars can add to the costs equally well. Materials costs typically run from $225 to $500 per kit plus installation cost. From the feedback CH has received from the field, when y'all figure in labor, the installed kit is less than half the price of Option #2 - complete removal and replacement of the electrical panel.

That is exactly in line with my own (DJF's) guess based on the labor and edifice disruption savings. If in that location is much cosmetic piece of work with the Remove-and-Supplant process, the savings are even greater.

Quotes from electrical contractors on Zinsco electrical panel replacement using the retrofit kit or using a consummate new replacement electric console tin be expected to vary by area of the country, hardware needed, replacement panel size in ampacity and number of circuits, accessibility to perform the work, and other factors that affect labor or materials.

That said, we've heard Zinsco Sylvania electrical console replacement costs using the Cutler Hammer retrofit console ranging from about $900. all the way up to $4000. If you are surprised by the quotation you receive from your electrician, ask for a bid from a competitor and compare labor, materials, and other costs.

Run across
REPLACEMENT PANEL COSTS for the latest data we have on typical electrical console replacement costs.

RETROFIT INSTALLATION - Eaton Corp., Cutler Hammer Products Hammer Adjustable Retrofit Kit Installation Tips

Run across the E-CH PDF file (450KB) which explains how this replacement program works. Obtain and follow the installation instructions that come with the equipment. Hither are some boosted comments:

Distinctive about this approach is that it is not necessary to cut the existing building wall for wire admission, and not necessary to disconnect the existing circuits from the original metallic panel enclosure "box". Avoiding these steps significantly reduces the labor and installation time.

The Adaptable Retrofit Kit installation process is roughly this:

• Cull electric load heart size: select the proper sized load-centre that will fit in the existing panel enclosure - measure the existing panel interior dimensions, including depth carefully.
• Buy other electric panel parts needed: if necessary, buy additional panel enclosure parts such as a frame extension (if the panel Enclosure is too shallow) and a new panel cover forepart and door may be needed.
• Disconnect the old electric panel "bus associates": remove the existing load center (ability has been cutting off of course). If I were doing it I'd Unscrew each circuit then as to have plenty of length to work with, merely virtually will probably just Cut private circuit wires shut to the quondam breaker.
• Remove the quondam Zinsco-Sylvania bus assembly: remove the sometime load center from the electric panel
• Cover the remaining electrical panel enclosure openings: cover with metal whatsoever improper openings such as knockouts (to clinch that the existing enclosure is properly burn down resistant
• Install the new electrical console coach assembly in the onetime panel enclosure: mount the new load center
• Connect existing circuits to new load heart: connect the existing circuits to breakers in the new load middle
• Install whatever "fit" parts needed: mount any panel enclosure box extensions (the "pic frame") and electric console cover
• Clinch the Existing Panel Enclosure is Audio: before ordering the CH Replacement Load Center and Electrical Console Enclosure Adapter parts, the electric contractor should take a careful, honest, look at the existing enclosure. If it is non structurally sound don't use the retrofit kit. Some of those older enclosures are l+ years old, rusted, aptitude upwards etc. In that case pull it out and commencement over. These kits are designed and intended to be used in practiced, safety, sound enclosures. [Run into More Reading below.'

• Cover Openings in the existing panel enclosure (which is to be re-used). Any existing unused holes should be covered. On the smaller holes, this can unremarkably be accomplished by inserting a pan caput sail metallic screw of appropriate size to embrace the hole. Any unused open knockouts in an enclosure should always be accordingly plugged whether it'due south a retrofit, repair, new installation etc.
• Mensurate carefully: earlier ordering the particular retrofit enclosure parts, including the depth of the existing panel enclosure, so that the correct retrofit can be supplied.
• Existing studs or other protrusions: if in the (to be re-used) panel enclosure there are existing studs in the old enclosure that are in the way these will have to be cutting off and removed.
• Flush Mountain vs. Surface Mount: These are intended equally a "affluent mount" application. While they could exist used as a "surface mount" the "picture show frame" which acts as the adapter collar will extend by the edges of the existing enclosure and may non requite a "finished" advent. This may or may not be of consequence to the owner.

COMPONENT SELECTION - Selecting the Proper Retrofit Kit Components

Past following the Zinsco Sylvania electric panel "Retro Size Grid" on page 5 of the PDF file (450KB), in combination with the pick charts on the following pages, information technology can exist determined merely what exactly tin be installed in which size enclosure and come across NEC requirements, wire bend etc.

The Zinsco panel retrofit kit sizing charts in the PDF (450KB) detail the most common devices asked for and explicate the coach amperage rating, number of circuits, and wire size restrictions for minimum enclosure sizes. Nonetheless since we tin can not possibly foresee all of the combinations, we accept included our 800# to assistance explain or offer guidance when needed for those who are not sure or have questions or concerns.

The one thing stress by CH is that these are guidelines to run into the minimum requirements per National Electrical Code. Cutler Hammer cannot presume responsibility for these units when they are not sized or installed correctly.

All last decisions are the responsibility of the AHJ. To date, with 2 years feel, nosotros take had no issues with any AHJ when these are properly installed.

More Reading:
Rust and Corrosion in Electrical Panels, A Written report and Written report on Frequency and Cause for Electrical and Home Inspectors at Residential Electrical Panels

PRODUCT SOURCES - Sources for Adjustable Retrofit Kit for Zinsco/Sylvania Panels

Eaton Corp., Cutler Hammer Products Adjustable Retrofit Kits, E-CH Load Centers and load middle parts can be purchased through any Eaton Corp., Cutler Hammer Products benefactor.

If your electrician reports that local electrical suppliers are having difficulty finding or specifying kits any of the CH sales forcefulness can help. If that effort is not satisfactory contact CH directly at 800-330-6479 or by Email to FlexCenterLincoln@eaton.com.

Other electrical panel brands for replacing Zinsco Sylvania products: if you are not taking the retrofit kit route (run into Selection #1 vs OPTION #2) then a wide range of electrical panels are available from electric suppliers and edifice supply sources.

Lawmaking COMPLIANCE - Lawmaking and Legal Acceptance of the Replacement Load Center and CH Adaptable Retrofit Kit

I have corresponded with the lead design engineer for Eaton Corp., Cutler Hammer Products, the company that produces these Replacement load centers. He said that all interiors, neutrals & grounds are their standard UR listed OEM interior components and bear a UR label.

• UL-Listed The products are all UL Listed. The individual internal components are UR listed and the trim/cover is UL listed as a cabinet front end.
• Code authority accepted: CH have had no code say-so refusals
• Field installations: CH has sold these products in large numbers, sometimes in the thousands to public housing government.

Local lawmaking approval: Readers should review the CH production specifications and listing information with their electrician and with local lawmaking enforcement officials. Equally with whatever electrical piece of work, contained inspection and approving of the work is recommended and is required in many jurisdictions.

As CH informed me: As nosotros have no control over how /where these are installed, nosotros don't have a "file" we tin list these nether. Individual OEMs that use many of these on a repeat basis really go a UL list on their own device.

This is where CH relies on the local inspectors or AHJ to brand sure that electricians are installing these products in a safe, and professional manner.

Groundwork - Eaton Corp., Cutler Hammer Products Adjustable Electric Panel Retrofit Kit Development Background

The E-CH electrical panel adjustable retrofit programme was begun in response to an overwhelming number of contractors who were buying consummate load centers (metal enclosure, bus assembly, breakers, neutral and ground bars, etc), removing the interior components, neutrals etc and trying to "cobble" something together with "whatever" cover/trim in order to retrofit a new bus assembly into an existing, already mounted electric panel.

The manufacturer reports that often they saw electric panel interiors shimmed with an unbelievable assortment of items, covers that were questionably attached and in general a "less than professional" final job. Early it was discovered that in that location is a tremendous assortment of quondam electrical enclosures in the field.

These former enclosures vary greatly in size (width, length & depth) and in how they were originally installed.

In response to those bug E-CH patented the "Adaptable Retrofit Kit".

OPTION #ii REPLACEMENT - Zinsco/Sylvania Complete Panel Replacement - Option #2 Conventional R & R Method

Traditional Electric Console Replacement by Consummate Removal of Onetime Equipment

The traditional and conventional method of replacement of an obsolete (or in this case unsafe) electrical panel has been to completely remove the complete original electric panel by disconnecting all wires from their individual circuit breakers, disconnect every strain relief, pull the wires out of the panel enclosure, and and so to remove the entire electrical console, enclosure and all.

The new electric panel is then mounted in place and all of the existing wires are routed back into the new console, strain reliefs secured, and wires routed to breakers in the new panel. (See "Short wire trouble" below).

If the console beingness replaced has been mounted on a finished wall (such every bit backside drywall or paneling) boosted labor and disruption are necessary to provide access for wiring and panel mounting.

Electric Panel REPLACEMENT COST Typical cost of the traditional Zinsco or Zinsco Sylvania Electrical Panel Replacement

A number of factors affect the actual cost of replacing an electrical console, including base labor cost variations in different geographic areas, costs of electrical permits, and the specifics of a particular installation: working space, wire lengths, condition of old wiring, and other factors.

In order to more easily add electrical cost updates in i identify, our section on typical costs to replace an electrical panel take been moved to a separate web page. Please encounter
REPLACEMENT PANEL COSTS

Choice #i vs Selection #ii - Comparison Use of the CH Adjustable Retrofit Kit vs. Complete Replacement of Zinsco Electric Panels

WHEN TO Use OPTION#2 - When replacing an Zinsco Electric Panel When Should the Unabridged Panel and Enclosure be Replaced?

Using the Retrofit Kit is not appropriate, and complete electrical panel removal and replacement, including the console enclosure or "box" is going to be necessary when:

• The existing panel enclosure is not structurally audio, such as if it has get badly rusted.
• The building needs a larger ampacity service, say moving from 100A to 200A at a edifice, and the building needs more electrical distribution circuits than what are shortly installed.

  In this example it is likely that even if a new double-decker associates that could handle the higher ampacity of a new service it volition not handle the needed number of circuit breakers. The installer may consider a retrofit anyhow, using a circuit in the retrofit console to feed a new subpanel which is located elsewhere in the building and which provides additional circuits.

  That approach may suit where the added circuits and ampacity are in support of a building addition such every bit a new fly or level.

• The area where the panel is located is being gutted and re-modeled in concert with installing a new larger panel, service, ampacity, and number of circuits.
• The electric panel is not built into a finished wall (for example exposed in a basement or garage), and then that all of the console's exterior is readily accessible, and the console chapters is non being upgraded. In this case I'd practice a cost comparison of all of the retrofit equipment needed vs. the whole new box approach. CH believes that even in this example the retrofit approach might be less costly.
• The electrical panel needs to be relocated for other reasons.

More Reading:
Rust and Corrosion in Electrical Panels, A Study and Report on Frequency and Cause for Electric and Home Inspectors at Residential Electric Panels

Comparing the 2 Electric Panel Options: #one-Adjustable Retrofit Kit or #two-Complete R&R Replacement of Everything

[Stance offered by the web author]

• Cost: Option #2, Zinsco/Sylvania Panel removal and replacement with a new Brand-x electrical panel is likely to cost twice as much as Choice #1 with the CH Replacement Load Center and Electric Panel Enclosure Adapter.
• Time: Option #2 tin be expected to crave at least twice the labor of Option #1.
• Disruption: When the original Zinsco Electric Panel (or Sylvania) is installed in a finished wall, Option #two requires fractional demolition for working infinite that should not be necessary for Option #1
• Availability: Option #2 permits choice of any manufacturer's electrical equipment; Option #1 is available only from Eaton Corp., Cutler Hammer Products. This is a widely distributed brand but may not be stocked at the aforementioned levels as products by other manufacturers. Boosted delay may exist encountered if your electrician's electrical supply firm has to order the CH Console Enclosure Adapter parts. I will report here what readers meet - feedback is invited.
• Suitability: Option #2 is required when the original console enclosure is damaged or for other reasons I listed earlier. Option #one is non suitable in those cases.

Where Option #1 is suitable it strikes me as appealing for reasons of price and trouble.

When performing a conventional electrical panel replacement, in order to accept acceptable wire length to connect things in the new electrical console the electrician would have to not but disconnect or clip wires at each breaker, s/he would as well have to unscrew every strain relief and pull each individual wire out of the existing console enclosure - a crowded and tedious performance that has to exist washed with great care and so as not to damage the insulating jacket on the existing wires.

This has to have considerably more time than just replacing the load eye in the existing console enclosure where all of the wires inbound the original box tin be left in place.

There is no cosmetic damage to the wall where the existing console is mounted when using Option #1. By comparison, with an conventional electrical panel replacement if the panel is in a finished area, the electrician has to cutting away the finished wall surface to have access to the individual wire strain reliefs entering the panel box in club to disconnect them, and also in order to have working room to get the new wires into the new electrical panel enclosure.

Further, information technology is unlikely that a new panel enclosure will have the same dimensions or "footprint" equally the sometime, maybe meaning additional adjustments at the cease wall.

Many people take contacted me to ask communication about Zinsco electric panel replacement options. More than I am able to answer by telephone or even email. Both for private dwelling house owners and especially for larger buildings or building complexes where at that place are many, sometimes hundreds of Zinsco electric panels installed, the cost of a complete gut-out replacement of the panel is a significant burden.

If this sounds as if I'm writing a commercial, that's not my intention, and I accept no connection with the manufacturer of this product nor any financial involvement in it nor in any other products discussed at this website.

I am afraid that the cost of complete electrical console replacement has been a gene in moving some owners to try to just "replace the Zinsco circuit breakers themselves" with the mistaken notion that somehow this reduces their risk of a burn down or other failure. Unfortunately it does not appear to practise so.

I have found no data suggesting that replacement Zinsco breakers, if they tin can fifty-fifty exist located, perform whatever better than their predecessors, non to mention the price gouging that goes on when buying obsolete electric equipment.

Fifty-fifty if a new perfectly reliable circuit breaker were congenital to fit these panels, I doubtable that there are underlying bug with the Zinsco double-decker pattern, bus materials, breaker to bus connections, and bus overheating and failures would remain. This is why I continue to recommend a complete panel replacement for these problem brands.

Information Source Citations & Feedback Request on Zinsco Electrical Panels

Data Source Notice: portions of the text of this document are from email exchanged between the web writer and the Eaton Corp., Cutler Hammer Products Lead Design Engineer and Eaton Product Managing director involved with the products discussed in this document. The illustration at page meridian is from the Eaton Electrical PDF which describes their production line. The author has no financial nor any other connection with Eaton Corp., Cutler Hammer Products, nor any other visitor whose products are discussed at this website. Corrections of errors or omissions, product user feedback, or other critique are invited. Our editorial policies are at Accuracy & Bias Pledge

I'd welcome some photos and description of field experience from installing electricians and from consumers. Contact United states to report field feel with this equipment.

Question: 2 Zinsco breaker failures, pitted burned busbars, where to put new breakers?

Sir,
I have read your listings and they are informative.  I have a Zinsco 100 A external panel on my firm.  A stove switch failed then did the 40 A Zinsco breaker.  I pulled out the double breaker and purchased another.

However as I inspected the panel I found that in the position of the failed billow the bus bar is pitted.  I would like to replace the double-decker bar or fifty-fifty easier just purchase a Zinsco breaker that has the autobus bar clips on the opposite side of the breaker and so the the new breaker contact clips would contact that part of the bus bar that is not used.  Is that possible?

If so who makes information technology or were tin can I obtain such a breaker? - Thank You - your insight has been invaluable - M. & L., Gilroy CA

Reply:

I don't know of offside zinsco breakers, but as we elaborate beneath, another alternative is to u.s. a previously unoccupied spot in the panel and a new breaker.

As doubtless you read at ZINSCO SYLVANIA ELECTRICAL PANELS, my opinion is you should supervene upon the Zinsco electrical console entirely.

Scout out: don't presume the known-bad breaker connection is the only ane in the panel. Because corrosion, arcing burns, pitting, and other circuit billow and connection problems tin can be hidden from straight view (unless the panel is disassembled) there may be other problems developing in the same electrical panel where you have already had ii failures.

Indeed nosotros do not recommend connecting circuit breakers to a burned pitted bus bar in whatsoever electric console. Options include complete electrical panel replacement, replacement of just the bus confined themselves, and in some cases, a temporary repair might be made by installing the new circuit breaker at a location in the panel such that it will connect to a clean, un-damaged double-decker bar spot.

Question: failure report involving a Zinsco Circuit Breaker - can I use a CE Replacement for Zinsco Excursion Breakers

When my wife and I retired we acquired a minor house in Ponte Vedra FL. In adding a light in the laundry room I accidentally cut into a live wire. Half melted my wire cutters, but did not trip the breaker. The electrical shop had a new CE breaker which he said was a "safe" replacement for the zinsco. He told me plenty that I checked out this result on line and found your site. Since ripping out and replacing the erstwhile console is way over our expense budget, my intended fix was to replace the Zinsco breakers with new CE breakers and perhaps "clean" the principal bus, leaving only the " Chief " switch. Does this sound like a reasonable fix? Thanks, J.D., Ponte Vedra FL 11/5/2012

Answer:

Deplorable, I don't know - we have no information on the field operation of CE breakers used as replacements for original Zinsco circuit breakers.

Watch out: in any example, even if the CE breakers have an improved design or arcing and corrosion resistant components (Zinsco breakers frequently corrode and arc and burn down at their motorbus connection, leading to catastrophic failures) here may remain an important take a chance as the Zinsco problem also burns the bus to which breakers attach.

Thus when you lot practice not replace the entire original Zinsco bus associates, failure risks remain including:

• Connecting a new or replacement excursion breaker, CE or other make, to a burned or damaged jitney position in an electric panel is unreliable and unsafe
• Removing and replacing a circuit breaker from a Zinsco electrical panel tin score or cut plating on the existing bus, possibly a factor in time to come corrosion and failure
• The performance of the replacement breakers when inserted into a known problematic designed electrical panel bus associates has not been adequately tested - y'all should consider that its performance at a level of reliability comparable with "non-problematic" products (where such failures are by and large rare) cannot exist assured.

  Look into a whole electrical bus associates replacement instead, run across Eaton Cutler Hammer Zinsco replacement options discussed in the article above.

Question: why not merely apply antioxidant paste on Zinsco Bus Bars to avoid trouble?

I see expensive suggestions for the issue with the bus bars and clips simply I haven't seen any mention about using NOAlux at the contact points. While it might not solve the occasional problem with a breaker not tripping, it certainly should prevent or reduce impairment to the motorcoach bar and possibly the breaker. I have seen the burned damage to Zinsco (and other) breakers but never have heard of a fire starting.

Nearly all of the damaged breakers I accept seen were on 220 circuits where someone had failed to use NoAlux with aluminum wiring which tells me the wiring is more of a culprit than the breakers. Have you seen or heard of an actual fire occurring that damaged something other than inside a panel? - A.R. Sacramento CA

Reply:

Thanks, Andy

You've asked an interesting question, and I agree in principle that if there are more than than one sound and safety approaches to solving a problem, peculiarly where costs vary widely, it makes sense to report them. A competent onsite inspection by an adept ordinarily finds additional clues that assist accurately diagnose a problem or explain a failure, including in a Zinsco panel; most failures are not examined past experts.

That said, here are some things to consider:

You lot haven't seen an InspectApedia recommendation for using anti-corrosive or antioxidant paste at the breaker-motorbus connexion in a Zinsco console considering the bus bars are oftentimes severely burned, breakers are ofttimes internally damaged, even burned or diddled-out; no i wants to bet their house and kids' education on promising the safety of a blanket as a retrofit. In sum, where in that location is already damage, the antioxidant is nearly certainly an unsafe repair - worse if owners recollect that the organisation is now safe and and then might ignore future warning signs.

Your comment nearly aluminum wiring of course adds fuel to the fire of overheating and failing electrical console parts. It's well established that antioxidant is non a recommended "repair" for nor will information technology alone foreclose overheating and failures of aluminum electrical wire.

Simply where you lot are seeing failures in aluminum-wired Zinsco electric panels, the hazards are multiplied. And antioxidant would exist past no means an acceptable mode to repair the wiring. See ALUMINUM WIRING HAZARDS & REPAIRS for details.

Near electrical console burnups and accident-outs,  of grade we've heard of, and have published many such reports, though fewer specifically for Zinsco than FPE - a different product with different concerns.

For examples of field reports of Zinsco failures take a look at these 4 manufactures:

• ZINSCO FAILURE REPORTS
• ZINSCO OVERHEAT IR PHOTOS
• GTE-SYLVANIA-ZINSCO FAILURE MECHANISM & PHOTOS
• ZINSCO OVERHEAT IR PHOTOS

But even if someone you ask has not personally "heard of" something, relying on such a answer as authoritative would be nonsense. It makes more and safer sense to look for more than authoritative sources - which nosotros do. Interesting also, CPSC and other experts gauge that only a very small per centum of electric panel fires or failures ever get reported (for many reasons); and when there is a edifice fire, much of the causal evidence is burned to a well-baked, making authentic identification of the original cause difficult for those who are non real forensic experts; That ways that even a few reports are almost certainly representative of a much larger trouble occurrence rate.

On the other manus, Andy, it MIGHT be a safety improvement to use antioxidant on the electrical connections you lot describe if showtime they are inspected and confirmed to be undamaged; but fifty-fifty that makes me very nervous.

The arcing, overheating, and burnups appear to occur in Zinsco panels precisely at the point of origin of the scratch that was made on the bus bar when the billow was first installed there; The scratch may be cutting through a plating; At least in some products we've learned that repeated removal and installation of parts, where scratching is a relevant factor, can actually increment the subsequently hazard. Only if the manufacturer recommends using a coating or antioxidant would it sound safe to me.

Reader Comments & Q&A

Thanks Glenn

I'll see what I can detect - indeed I haven't checked on availability for some time.

In my OPINION it'south non a cracking option anyway, as by today's standards these older panel boxes are likely to be likewise pocket-size for the number of circuits a modernistic home wants to use.

Eaton said:

If your electrician reports that local electrical suppliers are having difficulty finding or specifying kits any of the CH sales force can assist. If that effort is not satisfactory contact CH directly at 800-330-6479 or by EMAIL to FlexCenterLincoln@eaton.com.

I am in Sacramento CA. Neither the local Cutler Hammer distributor nor our electrical supply specializing in breakers and distribution pnels of all types accept heard of this retrofit for Zinsco boxes. Is this however available?

Joanne,

The folio height EXPERTS DIRECTORY is one way to notice some electricians who are familiar with the Zinsco console, though any licensed electrician ought to be able to supervene upon whatever console.

The retrofit, while it'due south viable, may non make sense depending on the house age and number of circuits.

We are in San Mateo, California and demand to retro-fit or replace Zinsco panel for an flat edifice. Is there anyway to locate an electrician who has retro-fit in my area.

I'm looking for a zinsco panel box that measures 12 inches wide 29 inches alpine where tin can I find one located in Georgia

I have a GTE/Sylvania 390-205-09 electrical breaker box that I only want to replace the surface cover and door. Any suggestions where I can find the proper size?

Robert, you could practise that provided the old box is only working every bit a junction box, that is all of its breakers are removed. Information technology's a fleck messy and I'thousand non sure all of that splicing and wiring is easier than removing and replacing the one-time panel.

Even so I have washed exactly equally you depict when we needed to relocate an electrical panel that was in an incorrect location or where it lacked adequate working infinite.

In those cases the old panel became a large junction box and all of the circuits were extended over to the new, properly-located electrical panel. It saved a lot of re-wiring ripout work.

Why go to the problem of tearing out the onetime console? Instead why not install a new console side by side to it and apply the old one as a large junction box to tie into the existing co-operative circuits?

...

Continue reading at ZINSCO REPLACEMENT Console COSTS or select a topic from the closely-related manufactures beneath, or come across the consummate Commodity Alphabetize.

Or see ZINSCO REPLACEMENT CIRCUIT BREAKERS

Or see this

Recommended Articles

• ZINSCO SYLVANIA ELECTRICAL PANELS - habitation
  • GTE-SYLVANIA-ZINSCO FAILURE MECHANISM
  • GTE-SYLVANIA-ZINSCO FAILURE REPORTS
  • HISTORY of ZINSCO Electrical PANELS
  • IDENITFY FRANK ADAM Electric PANELS
  • IDENTIFY GTE SYLVANIA-ZINSCO PANELS
  • IDENTIFY KEARNEY PANELS
  • Place SYLVANIA ELECTRICAL PANELS
  • Place WALKER ELECTRICAL PANELS
  • IDENTIFY ZINSCO Electric PANELS
  • IDENTIFY ZINSCO SYLVANIA METER BASE
  • OK to Employ ZINSCOS?
  • UBI FPE CIRCUIT Billow Examination RESULTS
  • ZINSCO CIRCUIT BREAKER Contained TESTS
  • ZINSCO CIRCUIT Breaker Exam Report
  • ZINSCO Electrical PANEL AGE
  • ZINSCO FAILURE PHOTOGRAPHS
  • ZINSCO FAILURE REPORTS
  • ZINSCO OVERHEAT IR PHOTOS
  • ZINSCO FAILURE REPORT Procedure
  • ZINSCO REPLACEMENT Circuit BREAKERS
  • ZINSCO REPLACEMENT PANELS
  • ZINSCO REPLACEMENT PANEL COSTS
  • ZINSCO Rubber PRECAUTIONS
  • ZINSCO SUMMARY PAGE for Reproduction
  • ZINSCO WARRANTY & CONTACT INFO

Suggested citation for this web page

ZINSCO REPLACEMENT PANELS at AuditApedia.com - online encyclopedia of building & ecology inspection, testing, diagnosis, repair, & problem prevention advice.

Or encounter this

Index to RELATED ARTICLES: ARTICLE Index to Electric INSPECTION & TESTING

Or use the SEARCH BOX institute below to Enquire a Question or Search InspectApedia

...

Ask a Question or Search InspectApedia

Try the search box only beneath, or if yous adopt, postal service a question or comment in the Comments box beneath and we will respond promptly.

Search the InspectApedia website

Note: appearance of your Comment below may be delayed: if your comment contains an prototype, web link, or text that looks to the software as if it might be a web link, your posting will appear after it has been canonical past a moderator. Apologies for the filibuster.
You will not receive a notification when a response to your question has been posted.
Please bookmark this page to brand information technology piece of cake for you to cheque back for our response.
Our Comment Box is provided past Countable Web Productions countable.ca

Technical Reviewers & References

Click to Testify or Hibernate Citations & References

Source: https://inspectapedia.com/electric/Zinsco_Panel_Replacement.php

Share this post