Why Is My Electrical Panel Overheating?

Electrical panel overheating is more than a minor issue—it’s a common safety concern in Prescott homes and businesses. If your panel is running hot, smells like burnt plastic, or your breakers are acting up, it’s time to pay attention.

At Assurance Electrical Services, we work with homeowners and property managers in Northern Arizona who ask us questions like, “What causes electrical panels to overheat?” or “How do I know if my panel is overloaded?” In this article, we’ll cover the answers and give clear advice to help you stay safe.

Your electrical panel, also called a breaker box or service panel, distributes power throughout your home. When heat builds up inside, it’s usually caused by electrical resistance—either from too much current, a bad breaker, or faulty wiring.

If the heat isn’t addressed, you could end up with melted insulation, damaged wiring, or even an electrical fire hazard.

Here’s what often leads to electrical panel overheating:

• Overloaded or undersized circuits
• Loose or corroded wires
• Faulty or aging circuit breakers
• Poor installation or outdated panel models

Even if your panel looks fine on the outside, things inside could be heating up. Don’t wait for a burning smell or blackened wires to take action.

It’s not always obvious at first, but there are signs that your panel might be in trouble. Catching them early can help you avoid serious electrical issues.

Here’s what to look for:

• Burning plastic or smoky odor near the panel
• Breakers or panel doors feel warm or hot to the touch
• Lights flicker or dim when appliances run
• Breakers trip often
• A buzzing or humming sound coming from the panel
• Discoloration or scorch marks around breakers

These are all signs of an overloaded electrical panel or a deeper issue. A panel that runs hot could mean damaged wiring or a home’s electrical demand that is too high for your current setup.

There are a few main causes behind overheating. As licensed electricians in Prescott and surrounding areas, we see these often:

1. Overloaded Circuits

If you’re asking, “How do I know if my electrical panel is overloaded?”—start with your breakers. If they’re tripping often or you’ve added several new appliances recently, it could be a sign that your panel can’t handle your power usage.

Older homes with 100-amp service weren’t built for today’s demand. Microwaves, air conditioners, EV chargers, and home offices all pull significant power. Too much on one circuit = overheating.

2. Loose or Corroded Connections

Wires that aren’t tightly secured or have oxidized over time will generate resistance. Resistance produces heat. And inside a confined metal box, that heat has nowhere to go. It can cause breakers to get hot and eventually melt wiring insulation.

3. Faulty or Aging Breakers

A breaker that doesn’t trip when overloaded becomes dangerous. Instead of shutting off power, it stays on and lets the current flow—adding stress to the circuit and increasing the chances of panel overheating.

4. Outdated Panels or Poor Installation

Some panels, like those made by Zinsco or Federal Pacific, have known safety issues and are no longer considered compliant. We also see DIY jobs or outdated configurations where breakers aren’t rated for the panel, causing hot spots and unsafe connections.

5. Environmental Factors in Arizona Homes

Many panels in Northern Arizona are installed in garages, closets, or exterior utility boxes. Hot weather, restricted airflow, and dust buildup can all worsen internal temperatures—especially in the summer months.

We often get this question from customers who are concerned about their home’s safety. An overloaded panel is usually easy to spot—you’ll notice signs like:

• Breakers tripping regularly
• Flickering or dimming lights
• Warm or hot breakers
• A buzzing or humming noise
• Appliances turning off unexpectedly

Your panel may not keep up if you’ve recently added new electronics or appliances (like a hot tub, home office, or workshop equipment).

We use infrared thermography to inspect panels during service visits. It helps us detect heat levels and locate trouble spots without opening the panel while it’s live.

Electrical panel overheating is a common cause of house fires. The NFPA reports that home electrical problems cause nearly 47,000 fires annually—many tied to old or overloaded panels.

Risks of an overheating panel include:

• Fire hazards due to damaged insulation or arcs
• Appliance damage from surges or inconsistent power
• Code violations that could affect resale or insurance
• Electric shock risk for anyone near the panel

If the panel isn’t catching the overload, it’s failing its job. The longer you leave it, the more dangerous the situation becomes.

You don’t have to wait until something goes wrong to fix your electrical system. Here’s what we recommend to keep things running safely:

Schedule Regular Panel Inspections

Have your electrical panel checked every 1–2 years—especially if your home is 25+ years old. We’ll check for loose connections, breaker wear, and signs of overheating.

Upgrade to a 200-Amp Service Panel

If you still use a 100-amp panel, it may be time to upgrade. A modern panel provides more power, improves safety, and is compatible with today’s energy use.

Install a Whole-House Surge Protector

Arizona homes are prone to voltage surges from lightning or grid issues. A surge protector protects your panel and electronics and helps reduce strain on your breakers.

Work with Licensed Electricians

We’ve seen unsafe DIY jobs create more problems than they solve. Always hire a certified electrician who knows Arizona code and wiring systems.

If you’re noticing heat, burning smells, or tripping breakers, don’t wait. These are signs of a potentially overloaded or failing electrical panel.

Contact us if you see:

1. Breakers getting hot or won’t reset
2. Buzzing or humming near the panel
3. Breakers that trip constantly
4. A burning plastic smell
5. Soot or discoloration around breakers

We’ll run a full inspection and give you honest answers—no pressure or sales tactics.

We’re a local team of licensed electricians who care about quality, safety, and doing the job right. We’ve worked on homes and businesses across Prescott, Prescott Valley, Chino Valley, and Dewey-Humboldt for years.

Our customers choose us because:

1. We’re fully licensed, bonded, and insured
2. We explain things clearly
3. We show up when we say we will
4. We follow code and prioritize safety

Whether you need a panel repair, an inspection, or a full upgrade, you’ll always know what to expect—and we’ll always treat your home with respect.

If you’re worried about overheating electrical panel, don’t wait for it to worsen. We offer thorough inspections, quick diagnostics, and expert repairs.

Call us at (928) 713-2177 Or request a service appointment online.

We’ll check your panel, give you honest answers, and help you stay safe.