The only thing I can think of that would cause the starting electrode to fail immediately would be a ballast failure. As for your circuit breaker popping that could be from the ballast drawling more current after being turned on. I have run my 1000W ballast on the same circuit as my computer, which is plugged into an uninterruptible power supply (UPS). Immediately after plugging in the ballast the UPS beeps as if the power had been cut or there was a brown out. If the circuit you run your ballast on is on a 10A breaker it is possible that the higher current drawl right after starting could be to blame for your breaker popping. A 1000W ballast drawls ~8.333A during normal operation. I'm not sure what the current drawl is during startup, but I believe it would be higher than 8.333A.
I guess you could also just have a bad lamp. Did you say the starting electrode was completely melted, or just slightly? As far as I know Osram Sylvania mercury lamps are not particularly know for their quality...