My first issue was with the water heater. It is solar with an electric assist. When the water heater started leaking I noticed that the wiring was fried - no breaker ever tripped. I was running completely solar for an unknown amount of time. I installed the new water heater and fixed the wiring. The next issue I have noticed many times that my A/C compressor has been locked up and just humming away doing nothing. Usually it was caused by a short power flicker. Again a breaker did not trip. The other day, my air conditioner would not start - no compressor or condensor fan.
I happen to have one of those FPL energy cutoff boxes and it was showing a green light - meaning it has power. I opened up the A/C and checked for power at the compressor relay - no power at all there. I opened up the disconnect box and pulled out the insert. Half of the insert stayed in the box. Here is what it looked like - this picture is after I already replaced the disconnect.
I went to Home Depot to get a new disconnect and decided I should change the 30 amp breaker to something lower since it never trips. Most of the breakers where $8.00 to $15.00 for a dual pole 25 amp breaker. I had to ask a rep to find a breaker for a Federal Pacific one. These breakers were locked up in a special case and the price was $45.00. Luckily they were out of stock because I ended up looking around on the internet only to discover the Federal Pacific breakers are mostly defective and don't trip. Since I needed my A/C working, I went back to Home Depot and bought an outdoor breaker panel and got a Square D 25 amp Dual pole breaker for it. Maybe one of the breakers will trip now when there is a problem instead of melting wires.
If you think you might have one of these panels, here is what the offending Federal Pacific Panel looks like.
I have yet to get an estimate on the cost to replace the entire panel but I think it's necessary.