Switch – Melted switch replacement

switch

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Was taking a shower and smelled some melting plastic. Turns out that the switch to the heat function of my bathroom fan was the cause of the melting smell. That one switch is part of a box that has 3 other switches and that particular switch has it's own circuit due to the heater. The other 3 switches are all grounded together using one copper wire connected to each switch but the melted switch was not grounded.

Is this what caused the switch to melt?

Will a 20A switch suffice or do I need one rated higher?

Best Answer

The switch is a goner, so you'll have to replace it

What happened here was the initial connection at that screw terminal was made improperly (mistorqued), which caused it to overheat and progressively fail further until it started smelling...melty. The good news is that you caught it soon enough that it didn't start anything serious (like a fire!). The bad news is that the switch is toast and needs to be replaced with a new decorator-style double switch, preferably one rated for 20A.

When you replace it, you'll want to use a torque screwdriver that reads in inch-pounds to tighten the screws on the new switch to the specified torque (12-14 in-lbs, as per this Leviton specification, if your switch didn't come a number). You'll also need to fit a grounding pigtail to the new switch, connecting it to the existing ground wire bundle in the box.