Lots of wires may or may not be a National Electrical Code (NEC) violation, and the NEC may not be the most applicable code (could be IEC, NEMA, IEEE, UL, etc.). Circuit breaker distribution panels get very busy inside when all the breaker slots are filled. Usually, you hope that the manufacturer designed it for the worst case (e.g. 100% utilitization). But, codes change over time, and what was okay 10 years ago often isn't okay today. Any modifications will need to be brought up to the current code(s).
Are the insulation chips from sloppy workmanship (stripping), or are they insulation that has fallen off the conductors? Uninsulated hot or neutral conductors is going to be a code violation.
> incoming power cables have some sort of junction in them that's the size of a 1-liter bottle (on each wire) and is covered in layers of electrical tape...
In-line devices and/or splices may or may not be a code violation, depending upon the wires and what's under that tape.
It sounds like this panel has been modified over the years, possibly without engineering supervision, building permits, qualified personnel, and/or inspections. Unfortunately, such is all too common. It may or may not be legal, depending upon jurisdiction.
"Neat and workmanlike installation" is usually in the construction specifications, and subject to interpretation/negotiation by the owner, engineer, contractor, and inspector.
> putting the panel back on... nasty cracking noise and half the breakers blew (all breakers in one of the 2 columns)...
Curious (and scary) failure mode.
Are the breakers ground-fault interrupter (GFI)?
Did everything go dark when the breakers tripped? E.g. both the loads on the tripped breakers and the loads on the untripped breakers?
Did you reset the tripped breakers? If so, what happened?
Were any of the loads (equipment, lights, etc.) damaged by the event?
> How do you industrious Slashdot readers go about fixing a mess like this (on a tight budget, no less) without getting a mains- induced glimpse at the great beyond?"
1. Don't touch.
2. Warn others not to touch.
3. Tell your boss. The rest depends upon he/she and/or your company. If he/she/it is ethical and has a spine, he/she/it will immediately have a licensed professional inspect the entire electrical system and take appropriate steps to shut it down and/or fix it. If not, you have a test ahead of you.
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> 220 outlet... rats nest...
... nasty cracking noise and half the breakers blew (all breakers in one of the 2 columns)...
I will assume a U.S.A. installation.
Lots of wires may or may not be a National Electrical Code (NEC) violation, and the NEC may not be the most applicable code (could be IEC, NEMA, IEEE, UL, etc.). Circuit breaker distribution panels get very busy inside when all the breaker slots are filled. Usually, you hope that the manufacturer designed it for the worst case (e.g. 100% utilitization). But, codes change over time, and what was okay 10 years ago often isn't okay today. Any modifications will need to be brought up to the current code(s).
> broken-down cloth/plastic insulation strewn everywhere...
Are the insulation chips from sloppy workmanship (stripping), or are they insulation that has fallen off the conductors? Uninsulated hot or neutral conductors is going to be a code violation.
> incoming power cables have some sort of junction in them that's the size of a 1-liter bottle (on each wire) and is covered in layers of electrical tape...
In-line devices and/or splices may or may not be a code violation, depending upon the wires and what's under that tape.
It sounds like this panel has been modified over the years, possibly without engineering supervision, building permits, qualified personnel, and/or inspections. Unfortunately, such is all too common. It may or may not be legal, depending upon jurisdiction.
"Neat and workmanlike installation" is usually in the construction specifications, and subject to interpretation/negotiation by the owner, engineer, contractor, and inspector.
> putting the panel back on
Curious (and scary) failure mode.
Are the breakers ground-fault interrupter (GFI)?
Did everything go dark when the breakers tripped? E.g. both the loads on the tripped breakers and the loads on the untripped breakers?
Did you reset the tripped breakers? If so, what happened?
Were any of the loads (equipment, lights, etc.) damaged by the event?
> How do you industrious Slashdot readers go about fixing a mess like this (on a tight budget, no less) without getting a mains- induced glimpse at the great beyond?"
1. Don't touch.
2. Warn others not to touch.
3. Tell your boss. The rest depends upon he/she and/or your company. If he/she/it is ethical and has a spine, he/she/it will immediately have a licensed professional inspect the entire electrical system and take appropriate steps to shut it down and/or fix it. If not, you have a test ahead of you.