How to cool the circuit breaker?

If your breaker is overheating, there are a few things you can do to cool it down.

However, overheating of the circuit breaker indicates a problem that needs to be addressed. If you ignore this problem and only try to cool the breaker temporarily, you could allow a dangerous situation to develop. Breaker cooling is not the only solution.

If the temperature of the switch or panel is significantly higher than room temperature, this indicates a serious problem, so turn off the entire power supply immediately. Then conduct an investigation to identify and urgently eliminate the real cause. Even if the overheating is minor or related to the location or condition of the panel, you should not just try to cool it down, but eliminate the cause. This may require replacing the breaker.

When should the switch be cooled down?

All circuit breakers are rated for the maximum current level.

For safety reasons, the operating current of the load must not exceed 80% of this rated value. If this is exceeded, the resistance increases, the switch heats up and eventually trips. If the current is constantly high, the switch may fire.

As far as temperature is concerned, the switch will typically withstand temperatures up to 140°F (60°C). If you cannot keep your finger on it for a long time when touching it, it is too hot. Even temperatures around 120°F (~49°C) will make it abnormally warm.

Cooling an abnormally warm circuit breaker

If the overheating is abnormally high (but not significant), you should still take action to investigate and consider ways to cool the panel for safety reasons. Two possible causes of overheating are the location and condition of the panel.

Switch panel location and condition

Is the switch panel exposed to direct sunlight, or is there glass or other reflective surface reflecting the sun's rays onto the switch panel?

If so, then the problem lies in the location of the switch panel. In this case, you will have to provide shade to keep you cool. Another thing you can do in combination is paint the panel white or silver. If either of these is not possible, you may need to move the panel to a cooler location.

Another reason for high temperatures is usually dust buildup or the wrong coloration of the panel in a dark color. Therefore, only cleaning or repainting may be required instead.

If the location or condition of the switch panel is not an issue, there are other things you should check to resolve the overheating issue.

Cooling significantly hot breaker

If the overheating is significantly high, this indicates a serious problem requiring immediate action.

First, you must turn off the circuit breaker if you can, or immediately turn off the power to the breaker panel completely. If you notice smoke or sparks in any part of the panel, consider it an emergency.

After turning off the switch or panel, try to cool it down as much as possible, for example with a fan. Otherwise, you can let it cool down by giving it time before unplugging or removing the problem switch from the panel.

You can also use an infrared scanner or camera to identify a switch or other component that is generating excess heat if you are not sure which switch is responsible.

What's next?

Cooling down the circuit breaker or cooling it down does not by itself solve the problem.

Further investigation is needed to eliminate the cause of overheating. Do not turn on the circuit breaker or main switch in the panel until you have done so, especially if the overheating is significant. You may need to replace the breaker.

Also check the following and correct the problem accordingly:

• Are there signs of discoloration?
• Are there any signs of melting?
• Is the breaker installed securely?
• Are the screws and rods tight?
• Is the baffle the right size?
• Does the breaker control an overloaded circuit?
• Does the appliance using this switch need a separate dedicated circuit?

Summing up

A very hot breaker (~140°F) indicates a serious problem. Turn off the power immediately and investigate to eliminate the cause. Even when it's too hot (~120°F), you need to not just try to cool it down, but fix the cause. You may need to replace the switch, clean the panel, shade it, or reposition it. We have also mentioned other things to look out for and if any of them are the cause, you should act accordingly.