Circuit Breaker Tripping Troubleshooting GuideUpdated 5 days ago

Understanding Why Circuit Breakers Trip
Circuit breakers are critical safety devices that protect your home's electrical system. When they trip, they're doing their job - preventing potential fire hazards and electrical damage.

How Breakers Work
Thermal Protection: Breakers contain a thin metal alloy strip that heats up as current flows through it
Temperature Threshold: When the metal reaches a certain temperature, it bends and breaks the circuit
Time Factor: Breakers don't trip based on instantaneous current readings - they trip from sustained heat buildup
Gradual Degradation: Consistent overcurrent situations cause the breaker to degrade over time, leading to more frequent trips

The 80% Rule (NEC Code Requirement)
The National Electrical Code (NEC) mandates that continuous loads should not exceed 80% of the circuit breaker rating. This is why:

Maximum Safe Charging Rates:
   - 20A Breaker: Maximum 16A continuous charging
   - 30A Breaker: Maximum 24A continuous charging
   - 40A Breaker: Maximum 32A continuous charging
   - 50A Breaker: Maximum 40A continuous charging

Important: The Smart Splitter has an internal software breaker designed to protect your system by shutting off the Secondary outlet during extended overcurrent situations.

Critical First Step: Verify Smart Splitter Settings
Your Smart Splitter MUST be configured to match your circuit breaker. The Smart Splitter's switching limit determines when it cuts off the Secondary outlet. If this is set incorrectly, your breaker may trip even when you're within safe limits.

How to Check and Adjust Your Smart Splitter Settings:
1. Open the NeoCharge app
2. Select your Smart Splitter
3. Go to Settings → Circuit Configuration
4. Verify the switching limit matches your breaker:

*Switching limit is when Secondary outlet shuts off
**30A and 20A circuits cannot support simultaneous charging

Common Misconfiguration Issue:
Problem: Your 50A circuit has the Smart Splitter set to 40A switching limit (thinking this is "safer")
Result: Secondary shuts off unnecessarily at 40A combined load
Solution: Set switching limit to 44A for 50A circuits

Problem: Your 40A circuit has the Smart Splitter set to 44A (50A setting)
Result: Breaker trips because Smart Splitter allows too much current
Solution: Set switching limit to 34A for 40A circuits

Why Your Breaker is Tripping
Scenario 1: Incorrect Smart Splitter Configuration
If your Smart Splitter switching limit is too high for your breaker:
   - The Smart Splitter allows more current than your breaker can handle
   - Your breaker trips to protect the circuit
   - Fix: Adjust Smart Splitter settings to match your breaker (see table        above)

Scenario 2: Charging Above Safe Limits
If you're charging above the 80% rule limits:
32A charging on a 30A breaker: This exceeds the 24A safe limit by 33%
   - Initial tolerance: The breaker may not trip immediately due to thermal mass
   - Progressive degradation: Over weeks or months, the breaker's metal alloy weakens from repeated overheating
   - Eventual failure: The breaker begins tripping more frequently as it degrades

Real-World Example: 
A 32A charger on a 30A circuit might work fine for months. However, the consistent 8A overcurrent gradually damages the breaker's thermal element, eventually causing frequent trips. This is the breaker protecting your home from potential fire hazards.

Solutions (In Order of Recommendation)
Solution 1: Verify and Adjust Smart Splitter Settings (Immediate)
1. Check your circuit breaker amperage at the electrical panel
2. Open NeoCharge app → Settings → Circuit Configuration
3. Set the correct switching limit based on the table above
4. Save settings and test charging

Solution 2: Reduce Charging Amperage (Immediate Fix)
For 20A Circuits:
   - Set charging to 16A or les
For 30A Circuits:
   - Set charging to 24A or less
   - Check your vehicle's app or dashboard settings
   - Some vehicles allow in-car amperage adjustment (Tesla, BMW, etc.
For 40A Circuits:
   - Set charging to 32A or less
For 50A Circuits:
   - Set charging to 40A or less

Solution 3: Purchase an Adjustable EV Charger
If your current charger is locked at 32A (common with Ford, VW, and some other manufacturer-provided chargers):

Recommended Options:
   - LENZ Level 2 Charger: Manual amperage adjustment via dip switches
      - Wallbox Pulsar Plus: Smart charger with app-based amperage control
   - You'll need a NEMA adapter (~$35) to match your outlet configuration
   - These remain compatible with your Smart Splitter

Solution 4: Electrical Panel Upgrade (Long-term Solution)
If you have available panel capacity:
   - Install a 50A dedicated circuit
   - Allows full 32A+ charging without issues
   - Future-proof for dual EV charging with Smart Splitter
   - More expensive due to installation costs
   - Requires licensed electrician

Troubleshooting Steps
Step 1. Verify Smart Splitter Configuration
   - Most important first step
   - Confirm switching limit matches breaker rating
   - Adjust if needed via NeoCharge app

Step 2. Verify Current Charging Rate
   - Check your EV's app or dashboard
   - Contact your EV manufacturer if unsure
   - Some chargers display current draw on the unit itself

Step 3. Adjust If Possible
   - Try setting to 20A initially (safe for all circuits)
   - Gradually increase if needed, staying within limits

Step 4. Monitor Performance
   - If breaker continues tripping at safe amperage levels with correct Smart Splitter settings, the breaker may be damaged
   - Consider having an electrician inspect/replace the breaker

Quick Diagnostic
1. Breaker trips frequently? 
    Check Smart Splitter switching limit first
2. Settings correct but still tripping? 
    Reduce charging amperage
3. Already at safe amperage? 
    Breaker may be damaged, consult electrician
4. Can't reduce amperage on charger? 
    Consider adjustable charger or circuit upgrade

When to Take Action
Immediate Action Required If:
    - Breaker trips frequently (daily/weekly)
    - Smart Splitter settings don't match breaker rating
    - You smell burning or see discoloration at the outlet
    - The breaker feels hot to touch
    - You cannot reduce charging amperage

Contact Support If:
   - You need help configuring Smart Splitter settings
   - You're unsure of your circuit breaker rating
   - You want specific charger recommendations
   - The issue persists after adjusting settings and reducing amperage

Safety Reminder
The Smart Splitter's internal protection and your home's circuit breaker are working together to keep you safe. When they trip or shut off, they're preventing potentially dangerous situations. Never attempt to bypass or modify these safety features.

Always consult a licensed electrician for:
   - Breaker replacements
   - Circuit upgrades
   - Any electrical work beyond adjusting charging settings
   - Verifying your actual circuit capacity if unsure

Note: It's better to charge slower and safely than to risk electrical fires or damage to your home's wiring. The Smart Splitter's switching limits are designed to work within safe parameters - ensure they're set correctly for your specific circuit breaker.