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Yikes! Sub Panel Melt

6.1K views 20 replies 8 participants last post by  frenchelectrican  
#1 ·
Greetings,

Several months ago I installed a sub panel in my shed/shop. It's a 120/240v service and with some basic wiring experience, I carefully went forward guided by a home depot wiring book. However, upon recent inspection I found significant heat damage to the panel interior (see attached photo).

Can anyone advise me as to what has caused this problem? I suspect it has something to do with a grounding issue, however I don't know for sure. I'd greatly appreciate any advice. Needless to say my shop is shut down at the moment until this is repaired.

thanks in advance,
JDK
 

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Discussion starter · #4 ·
Thank you both, Frenchie and A7E, for your response. I'll do my best here to fill in the details.

Frenchie, when you ask for size of the conductor, what are you referring to? Is it the gauge of the wire, or the size of the load? The wire is 8 gauge I believe, and the panel lugs are aluminum.

The grounding bus bar is a 50 ft run from the sub panel. It's on a main panel installed by a licensed electrician.

Below is a photo of the whole panel as requested.

A7E, are your questions answered by this new photo?

thanks again,
JDK
 

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Discussion starter · #9 ·
Yes it does appear that I've made a mess of things. Apologies to those who shutter at the sight. It has made me plenty uneasy as well. All the more reason to sort it out.

Mark, the wire is 8 guage and made of copper.

I'm going to replace the panel and lose the 240v service. I didn't end up using it anyway and it makes things more complicated.
Apart from as Frenchie said, improper tourqe on the lug nut, does anybody else have suggestions to help the next install go smooth?


Thanks in advance
Jdk
 
Discussion starter · #11 ·
A7e. Thanks for getting back to me.

The 60 amp was going to be used for a welder that never arrived. The heaviest load that went through the panel was a 1800w baseboard heater last winter and an airconditioner in the summer. That combined with lights, powertools tools and a refrigerator.
 
Discussion starter · #14 ·
Hey Grrgzoll, the grounds are connected to the grounding bar, seen behind the scorched wiring. Is this not the correct place? It is according to the book called the ultimate guide to wireing.

I've been reading that it necessary to isolate the neutral bar in a subpanel. Apparently this needs to be manually done with some panels, however with this panel (siemens 100a) I've not seen any connection beteen the neutral and the ground. Am I possibly missing something here? Any ideas?
 
Discussion starter · #18 ·
A7e the wire that feeds this panel was originally used to power a mill mixer from that same 100a breaker. It's a cable made of 6 smaller wires and reads - type twh 75 C - 600 v. From the main panel there are 4 wires, 2 black, white neutral and a ground. The 2 hot wires run from the 100A breaker on the main panel, the neutral from the bar on the main panel and the ground from the grounding bar linked to a cable that runs to a grounding spike.

Thanks again for your help with this.