Illustrated Catastrophe2 631b484b5b177

Illustrated Catastrophes: Overpacked Panelboard

Sept. 8, 2022
See the latest code violations from NEC Consultant Russ LeBlanc.

All references are based on the 2020 edition of the NEC. 

Lousy Light Fixture Wiring

Henry Caratura was kind enough to share this photo with us. He found this on a rehab job where he rewired the whole house. “When the plug is plugged in, the outside light comes on,” says Caratura. While this may be a quick and easy way to provide power to the outside light, it certainly does not mean this installation is Code-compliant or safe. While Sec. 400.10(A)(2) does permit flexible cords and flexible cables for wiring of luminaires, Sec. 400.12(1)-(7) imposes many restrictions on the use of flexible cords, flexible cables, cord sets, and power supply cords, including: (1) As a substitute for fixed wiring; (2) Where run through holes in walls, ceilings, or floors; and (5) Where concealed by walls, floors, or ceilings. It seems like all those restrictions were ignored here. Another concern I have is the lack of connection to an equipment grounding conductor (EGC) for the outside luminaire. If the luminaire is metal, Sec. 410.42 requires either a connection to an EGC or a listed system of double insulation. After seeing this photo, I have a feeling neither of those options was implemented here.

Overpacked Panelboard

Thomas Carlins, P.E., LC for Carlins Consulting LLC of Pittsburgh, shared this photo with us. “The panel looks innocent from the front (except for the tandem circuit breakers),” says Carlins. “When I took the cover off, I discovered a 2-pole circuit breaker in the bottom gutter of the panel. It was hot and in use. We are now including the replacement of the panelboard in the construction documents.” Thomas, I think replacing this panelboard is a great idea. Panelboards must not have more overcurrent devices than the amount for which the panelboard is designed, rated, and listed. Installing too many overcurrent devices is a violation of Sec. 110.3(B). Section 408.54 requires a panelboard to be provided with means to prevent the installation of too many overcurrent devices. The free-floating breaker in the bottom of the enclosure is very dangerous, since this type of device is designed to be plugged onto the busbars of the panelboard. This type of installation is a recipe for poor connections and an elevated risk of fire and shock. Misusing this breaker in this manner is also another violation of Sec. 110.3(B).

About the Author

Russ LeBlanc | Owner

Russ started in the electrical trade as an apprentice in 1985. He worked his way up to become a Journeyman Electrician and then eventually became a Master Electrician and Licensed Construction Supervisor. In 1999 Russ become an Electrical Instructor for The Peterson School of Engineering in Massachusetts where he developed his passion for teaching, and quickly became Department Head of Electrical Instruction. Russ has taught thousands of apprentices, electricians, engineers, inspectors, and other electrical professionals during his career as an instructor. He continues to provide electrical professionals with Electrical Code seminars, Arc-Flash Awareness training seminars and educational material through his LeBlanc Consulting Services in North Reading, MA whose specialty is educating electricians. He has been an active member of the NFPA Electrical Section and has authored hundreds of National Electrical Code proposals and comments which have become Code rules to improve the safety for the electrical industry. Russ is also an IAEI certified Electrical Inspector.

Please visit www.russleblanc.net for more information.

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