How to Repair Obsolete Pushmatic Circuit Breakers

Pushmatic circuit breakers were very popular in the 1950s through the 1970s for their ease of installation compared to fuse boxes. However, they have largely fallen out of favor due to problems with reliability, availability of parts, and safety issues. This article provides a step-by-step guide on how to repair and maintain these obsolete circuit breakers.

What are Pushmatic Circuit Breakers?

Pushmatic circuit breakers (circuit breakers) were developed in the 1950s by the Federal Pacific Electric Company as an alternative to traditional screw-in fuse boxes. They got their name from their "push-to-reset" design - instead of flipping a switch, you would push a button to reset a tripped breaker.

Some key features of Pushmatic circuit breakers:

• Plug-in design - They plug into a bus bar in a breaker box and can be easily removed and replaced. This made DIY electrical work simpler.

• Push-to-reset button - A distinctive large button is used to reset tripped circuit breakers instead of a switch.

• Non-interchangeable - Each breaker fits a specific slot in the breaker box. Different amperages and poles are not interchangeable.

• Lack of magnetic trip - Pushmatics rely on a thermal-mechanical trip rather than a magnetic trip, raising questions about their ability to quickly trip on sudden overloads.

Dangers and Downsides of Pushmatic Breakers

While Pushmatic breakers were very popular initially, they were plagued by several problems that led to their decline:

• Reliability issues - The breakers had a tendency to fail over time, often not tripping when they should. This created fire hazards.

• Difficult to find replacement parts - As they became obsolete, replacement breakers and parts for Pushmatic panels became hard to find.

• Safety hazards - Lack of a magnetic trip meant they reacted slower to sudden overloads. Also, deteriorating breaker contacts could overheat and be a fire risk.

• Limited amperage options - Most Pushmatic breaker panels max out at 60-100 amps, which is insufficient for modern homes with updated wiring and appliances.

For these reasons, Pushmatic panels are no longer NEC code compliant and should be replaced rather than repaired if possible. But cost may make repair the only viable option.

Steps to Repair Pushmatic Breakers

If you need to repair obsolete Pushmatic circuit breakers, here are the general steps to follow:

1. Turn Off Power

The first step is to turn off power to the breaker box by flipping the main breaker switch. Verify power is off by testing with a multimeter or voltage tester. Remember to never work on a hot panel to avoid being electrocuted.

2. Remove the Faulty Breaker

Locate the faulty Pushmatic breaker and remove it by pulling it straight out. You may need to use a bit of force to unclip it from the bus bar. Check for corrosion on the breaker contacts and bus bar. Clean any corrosion with sandpaper or a wire brush.

3. Disassemble the Breaker

Disassemble the faulty breaker using a screwdriver. This allows access to the internal contacts, mechanisms and parts. Inspect the parts for any signs of damage or wear. Look for:

• Burned, pitted or corroded contacts - May need cleaning or replacement
• Broken or binding mechanisms - May need replacement parts
• Melted or damaged wiring - Requires new wiring and likely full breaker replacement

4. Attempt Repairs

For minor problems, you may be able to revive the breaker:

• Clean contacts with sandpaper
• Lubricate mechanisms with electric motor oil
• Adjust tension on thermal strip if loose
• Replace damaged wiring

However, any significant damage likely warrants total replacement.

5. Test Repaired Breaker

With power still off, install the repaired or replaced breaker in the panel and switch power back on. Test the breaker by pressing the Push-to-Test button, which should click and trip the breaker. Flip it back on to reset it. Confirm it is providing power to the circuit before returning the panel to normal operation.

6. Upgrade if Needed

If the Pushmatic panel is faulty or parts are too hard to find, consider upgrading the main panel to a modern breaker panel. Though more costly, this improves safety and allows adding more circuits.

When to Call an Electrician

Repairing circuit breakers carries electrical risks. Consult a licensed electrician if:

• You lack experience working with breaker panels
• There are signs of melted wires or heat damage
• The main panel may need replacement
• Upgrading the electrical service is required

They can properly evaluate if repair is safe, or if replacement is needed. Home electrical work should only be done by qualified DIYers comfortable working with live electrical systems.

Conclusion

• Pushmatic circuit breakers are now considered obsolete and replacements hard to source
• Repair is an option but upgrades may be needed for safety
• Use caution when doing any DIY electrical repairs and consult a professional if needed
• Replacement of Pushmatic panels provides modern safety features and capacity

Repairing Pushmatic breakers can restore power, but comes with risks. For problematic obsolete panels, replacement is the best long-term solution.