I'd like to give some attention to the breaker with no wire.
If you set up a test in a lab and wanted to make a breaker go from on to OFF with no wire connected, how would you go about it? Or could you go about it?
If you set up a test in a lab and wanted to make a breaker go from on to TRIP with no wire connected, how would you go about it? Or could you go about it?
I agree.
When that is figured out I would like to know the answer. I suspect a batch of bad breakers. I doubt anything environmental would be the cause.
Not related, but an indication of how strange an electrical device can be and drive a troubleshooter crazy, I have a snap switch that turns on fine, but when it's turned off, the switch stays closed for about 15 seconds then opens. Even with no load, it would do it on my desk and verified with an ohm meter.
The easiest way to verify would be to do a complete breaker swap with a unit that is having no issues. A swap to new could still have the same problem. If the problem follows the breakers, there is your answer. If not, that is one thing you can rule out.