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Circuit Breaker Tripping Troubleshooting GuideUpdated 3 months 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:

  • 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.

Why Your Breaker is Tripping

If you're charging above the safe 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: Reduce Charging Amperage (Immediate Fix)

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 2: 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 3: 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

  1. 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
  2. Adjust If Possible
    • Try setting to 20A initially (safe for all circuits)
    • Gradually increase if needed, staying within limits
  3. Monitor Performance
    • If breaker continues tripping at safe amperage levels, the breaker may be damaged
    • Consider having an electrician inspect/replace the breaker

When to Take Action

Immediate Action Required If:

  • Breaker trips frequently (daily/weekly)
  • 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 identifying your charging rate
  • You want specific charger recommendations
  • The issue persists after 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

Remember: It's better to charge slower and safely than to risk electrical fires or damage to your home's wiring.


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