Lets see if I can cover all these....... thanks for all the suggestions.
It is a home quality switch, bought in Home Depot, have used many of these over the years, with no problems.. Given I've used so many on this circuit, given I tried different models they sell....all with the same results.... I think it is not the switch.
I agree, very little load on this circuit. Less than 5amps. There is no other load.
The fixtures have 2 screws on each pole. I used them to tie my circuit together.... example, ran wire to the first light, connected it with proper polarity, then again with proper polarity conected the wire going to the next fixture to the second set of screws. Someone mentioned christmas tree lights, the circuit passes thru the fixture to the next fixture, not thru the bulb to the next bulb. Standard practice in all our homes, to save wire and expense.
There is no arching heard, took the circuit apart 3 times, no burns, nothing hot or warm not a clue toward the problem.
Yes, the switch is connected as shown in the diagram. Of course replacing it numerous times has made me very familiar with it.
In total, the lights have been on for many hours... 50 or more. Switch, breaker nothing shows signs of failure or problem, until you cycle the switch on average 3 to 10 times.
I've tried a multi-meter, don't see a spike, I think at this point I'm going to buy another roll of wire and start over. Using the breaker as a switch is a pain as it is not nearby the door. It has been like this for awhile, thought maybe eventualy it would get bad enough and show signs of failure in the circuit somewhere. Of course never left it on when I'm not there in case it set the place on fire. :-)
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