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Why Causes of Burnt or Melted Neutral Wires in Sub Panels

In the world of electrical systems, safety and functionality are paramount. The neutral wire plays a critical role in balancing electrical loads, ensuring safety, and preventing electrical fires. However, there are instances when neutral wires in a sub-panel become burnt or melted, raising concerns among homeowners and electricians alike. In this article, we will delve into the reasons behind this perplexing issue and explore solutions to prevent it.

NEC 110.14(D) was not adhered to in this case, as a torque wrench was not utilized to properly set the screw torques. This specific requirement was introduced into the NEC in 2014 as a safety measure.

If the electrical work in question was conducted before the 2014 NEC update, it would have been considered legally compliant and should not have encountered any issues. However, it’s important to note that electrical faults do not discriminate based on the year of installation.

The circuit you discovered to be loose may have been in that state prior to your inspection, potentially contributing to the problems at hand. Arcing is a highly concerning issue within electrical systems.

In the context of series arcing, it can involve a significant amount of power, comparable to what the load is designed to draw. For resistive loads, the current may decrease as some of it is consumed by the arcing, but motor loads could draw even more current, and constant-power switching power supplies are prone to drawing increased current as arcing worsens, leading to a potential race condition. This is a common concern in scenarios like EV charging, where constant current is expected despite the presence of arcing.

burnt or melted neutral wires

Understanding Neutral Wires


Before we dive into the burning and melting of neutral wires, it’s essential to grasp their fundamental function. The neutral wire in an electrical circuit serves as a return path for electric current. It completes the circuit by carrying electricity back to the source, balancing the electrical load. This balance is crucial to prevent voltage fluctuations, which can damage appliances and pose safety risks.

burnt or melted neutral wires

Factors Leading to Burnt or Melted Neutral Wires

1. Overloading

1.1 Heavy Electrical Loads
One common reason for burnt or melted neutral wires is overloading. When a sub-panel is subjected to heavy electrical loads consistently, the neutral wire can overheat, leading to melting or burning.

1.2. Unbalanced Loads

Uneven distribution of electrical loads across the phases can also strain the neutral wire. If one phase carries significantly more load than others, the neutral wire can become overwhelmed and damaged.

2. Poor Connections

2.1. Loose Terminals
Loose connections or terminals within the sub-panel can result in resistance and heat buildup. Over time, this can lead to the degradation of the neutral wire.

2.2. Corrosion
Corrosion on the connections can increase electrical resistance, causing the neutral wire to heat up and potentially melt or burn.

3. Faulty Wiring

3.1. Substandard Wiring
Inadequate or substandard wiring materials may not be able to handle the electrical load, causing excessive heat generation in the neutral wire.

3.2. Aging Wiring
As wiring ages, it can become brittle and less capable of handling current loads. This can contribute to the degradation of the neutral wire.

burnt or melted neutral wires

4. Overcurrent Situations

In cases where there is a sudden surge in electrical current, such as a short circuit or a lightning strike, the neutral wire can experience an overload, leading to damage.

Preventive Measures

To avoid the issue of burnt or melted neutral wires in a sub-panel, homeowners and electricians can take several preventive measures:

Regular Inspections: Conduct routine inspections of your electrical panel to check for loose connections, corrosion, or signs of overheating.

Balanced Loads: Ensure that electrical loads are evenly distributed among the phases to prevent overloading of the neutral wire.

Proper Wiring: Use high-quality wiring materials and ensure that your sub-panel’s wiring is up to code.

Surge Protection: Install surge protectors to safeguard your electrical system from sudden voltage spikes.

Professional Maintenance: Seek the expertise of a qualified electrician for periodic maintenance and safety checks.

Read also: Learn How To Repair Swollen Laminate Flooring Without Replacing

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