Hazardous Zinsco Main Electrical Panels: What’s the Story?
- Amy Atchley
- Apr 17
- 3 min read
At Amy’s Roofing & Solar, we’re big believers in making homes safer, smarter, and more energy efficient. Often, that means helping homeowners upgrade their main electrical panel — either to support a new solar system, or to make the switch to electric appliances like heat pumps and heat pump water heaters. It’s a crucial step in modernizing homes for the future and achieving California and Sonoma County’s stated goals for a sustainable future. But here’s where things get tricky.
As a company specializing in solar installation in Petaluma, we receive dozens of requests each year to replace aging Zinsco brand electrical panels, especially those located within three feet of a gas meter. These panels — along with brands like Federal Pacific and Challenger — are widely known in the industry to be fire hazards. In fact, at the national electrical contracting company where my husband Brian worked before we started our own company, they had a strict policy: no work was to be done inside these panels, period. The liability risk was just too high.
Policy vs. Safety: A Dangerous Catch-22
Now here’s the problem: Our local Utility company typically won’t approve a “like-for-like” panel replacement if the panel is located within 36 inches of a gas meter — unless the city issues a letter stating that the replacement is required.
Unfortunately, some building departments are hesitant to provide such letters because of the utility’s policies. And so we’re stuck.
Essentially it’s a catch 22 based on the following logic: It’s unsafe to install a new, code-compliant electrical panel within 36 inches of a gas meter — but perfectly fine to leave in place a 40-year-old, obsolete panel that’s known to cause fires.
And what’s the alternative? In many cases, the only other option is to move the entire meter and main panel to a new location — a job that can run anywhere from $10,000 to $30,000. For most homeowners, that’s simply out of reach.
A Safe and Compliant Solution
A like-for-like panel replacement in the existing location offers a sensible, safe, and cost-effective solution. It allows us to remove a dangerous panel and replace it with a modern, code-compliant one, without forcing families to take on massive additional costs or live with a known fire hazard.
Some cities, like Rohnert Park, and just recently Petaluma, already have the right idea. They’ve implemented policies that allow like-for like swaps with Zinsco panels. It’s a smart move that prioritizes safety and liability protection for both residents and municipalities.
How Can You Tell if You Have a Zinsco/Hazardous Panel?
Typically there is a sticker or a placard on the panel that will tell you the make and model. They often have colorful breakers. Here are some examples:
Zinsco Panel Examples
Non-Zinsco Examples
Other Hazardous Brand Names to Look Out For
Sylvania
Challenger (pictured above)
Federal Pacific
What is The Reason For These Failures?
Zinsco panels have a few failure modes. Below are a few potential causes of failure.
The use of dissimilar metals which corrode
The breakers can become affixed to the busbars through corrosion, arcing, high current and/or heat
Sometimes they don’t trip so the wires can catch on fire
7 Questions to Determine If Your Panel Already Has Damage?
Do your breakers trip frequently?
Have you ever noticed a burning smell near your main panel?
Do you have flickering lights?
Are there any buzzing sounds coming from your panel?
Do you see any charred, melted or burnt components in your main panel?
Are some breakers noticeably warm to the touch?
What To Do If You Suspect Your Panel is Damaged?
If any of the above issues apply to you, please call a licensed electrician to do a more thorough inspection.
After they take off the front cover known as the “Dead Front” they can inspect for:
Signs of corrosion - pitting, white crust
Signs of melting - wavy shiny plastic
Signs of arcing - pitted or discolored bussing, burnt plastic
Removal force required to remove and replace a breaker
Broken plastic - cracks
Breakers that are stuck on
Loose connections
Proper grounding
Design flaws (lack of busbar overcurrent protection)
Take Action on Hazardous Electrical Panels!
Aging and faulty electrical panels pose a significant safety risk and the potential for fire and electrical hazards shouldn’t be ignored. As a trusted Petaluma solar company, we’re deeply invested in the safety and well-being of our neighbors. We urge you to take proactive steps!
If you’re considering making this important safety decision and need a trusted professional on your side, contact us today or give us a call at (707) 981-9801. Let’s work together to ensure our homes are not only energy-efficient but safe, for ourselves, our families, and our community.
