I just installed a new hot tub running off a 50A GFCI sub panel to a 60A circuit breaker in the main panel. After about ten minutes of running both pumps on the hot tub, the main 100A breaker trips and it is warm with an odour coming from the main breaker. I have checked all the breakers in the panel for loose wires or obvious problems but nothing definitive was found. It has only been the main breaker that has tripped so I am assuming that is the source. Is there anything else I should check before calling an electrician to look at the main breaker?

I bet:
A) You are close to maxing out that 100A service.
And
B) The main breaker contacts are burned at the buss causing the heat, small and premature tripping.

I would almost guarantee you need a new panel, and at the same time an upgrade to 200A will most certainly be necessary.


CALL AN ELECTRICIAN RIGHT AWAY!