For those working in a busy West Coast commercial or industrial building, a tripped breaker can mean more than just a simple power loss. It often points to a larger issue, which can lead to significant downtime that costs you - and the business - money.

There are many reasons that your building’s breaker can keep tripping, and an electrical engineer can help you diagnose the root cause of the issue and identify a solution that will help get you up and running in no time.

Below, we’ll cover common reasons your building’s breaker is tripping, what these repeated trips can mean, and when you should call in a professional to stop it from happening in the future. 

Common Reasons Commercial and Industrial Building Circuits Trip

An electrical circuit is an important component of any building, especially commercial or industrial ones in the Southern California area. It’s what safely controls the flow of power in your facility. If there is something wrong, the circuit will trip - cutting off the flow of power before something worse happens.  

While a circuit can trip for any number of reasons, the top five reasons are discussed in detail below. 

1. Overloaded Circuits

Overloaded circuits are the most common cause of a tripped electrical breaker in industrial and commercial buildings. Too many things - machines, devices, appliances, etc. - are pulling power from the same line, causing it to exceed its capacity. Once it does, the circuit will shut off, cutting off all power to that area. 

You’ve likely experienced this when you plug in one too many things. The second you turn it on, the whole circuit will trip. You can try to flip it back, but often, until you remove some of the power sources, it will continue to turn off. 

You may be able to identify a potentially overloaded circuit before it flips.

• Flickering lights, especially when you turn something new on or plug something new in
• Warm to the touch outlets
• Discolored outlet covers
• Burning smell or sparks when you plug something in

Pay attention if the breakers are tripping during peak times. You may be overloading the circuits during business hours. Even if they are equipped to handle the power flow at certain times of the day, overloaded circuits can still be a problem. 

2. Short Circuits

Short circuits can happen when hot wires come into contact with one another. Instead of traveling the intended path (ie, through encased wires), the energy current can bypass it, causing a sudden burst of electricity. This can damage or break machinery or even lead to electrical fires. 

Short circuits can occur due to: 

• Bad wiring, including old, frayed wires and bad insulation 
• Overloaded circuits can cause insulation to melt over time
• Loose connections can allow wires to wiggle free and touch other wires 
• Broken appliances or plugs can cause short circuits, damaging themselves and the electrical connection

Additionally, wires may accidentally be severed during construction, causing the circuit to short. Keep an eye out if you experience:

• Unexplained burning and/or metallic smells
• Sparks around outlets and power sources
• Discoloration around power sources 

If the breaker keeps tripping and you aren’t using additional power, it may also indicate that you have a short circuit. 

3. Ground Faults

Where some short circuits are caused by wires touching, ground faults happen when a hot wire touches a grounded surface, like the actual ground, metal, or other conduits. It is a type of short circuit that can lead to electric shocks when touched. 

While ground faults can occur anywhere, they can often be found in areas adjacent to water - restrooms, kitchens, basements, utility rooms, and even outdoors. Moisture can cause condensation or corrosion in wiring that can lead to ground faults.

Signs of a ground fault include:

• Shocking sensations, especially when touching metal
• Burning smell
• Rusted panels or electrical outlets 
• Ground Fault Circuit Interrupter (GFCI) trips

Ground faults can cause serious harm, so it’s critical to call an electrical engineer if you believe that you may be experiencing one. 

4. Aging Equipment

Older equipment may draw more power than its energy-efficient counterparts. That can overload circuits, but that’s not the only reason aging equipment can trip your building’s breaker.

• Outdated wiring and setup may not be compatible with modern electrical interfaces.
• Wear and tear can cause wires to get loose, insulation to fray, or wiring to corrode over time.
• Expend too much heat, causing melted components.

While many people think that if it’s not broken, don’t fix it, that may not be the path of least resistance. Aging equipment can cause more damage in the long run to your electrical components if you’re not careful. 

5. Issues with Connected Machinery and Electrical Panels 

Connected machinery in San Diego commercial and industrial facilities can make work a lot easier. However, they can also add new electrical challenges that can impact your electrical panels if you aren’t careful. 

They can add an additional drain on your power due to the sensors, network connectivity, and software requirements. They can often trip your building’s breaker, especially if you have an older electrical panel that may not be able to handle as much power. It may be time to upgrade your building’s electrical panel to keep up with it. 

What Repeated Breaker Tripping Means

Tripped breakers may be common, but that doesn’t mean that they should be ignored. It can point to significant risks and safety hazards, including electrical fires, shocks, and burns. 

Building staff should document potential warning signs, but if they experience any of the following, it may be time to call in a licensed electrical engineer. 

• Constant tripped breakers, especially right after they have been reset 
• Burning smells
• Outlets radiating heat 
• Visible signs of fire or heat damage, including outlets, plugs, and switches

You can avoid more costly fixes by engaging with an electrical engineer as soon as you suspect there may be an issue with your electrical panel. 

Benefits of an Electrical Engineer Evaluation

While it can feel like an investment, there are many benefits of engaging with an electrical engineer before there’s a significant issue in your commercial or industrial facility.

• Prevent downtime: You can catch the issue before it causes you to shut down operations for a significant time. Any unplanned outage will have a financial impact on your business. 
• Avoid equipment damage: Tripped breakers and faults can damage equipment. Not only will you need to address the electrical issue, but you will also need to repair your equipment, which can be expensive. 
• Reduce safety hazards: Electrical issues can lead to significant safety hazards, including OSHA recordable injuries. 

Ultimately, an electrical engineer's evaluation helps promote a safe and secure workplace, ensuring you are in compliance with all regulations. 

Call In the Professionals Today

Mark Thomas & Associates Electrical Engineers (MTA) provides comprehensive, high-quality electrical service for all your commercial and industrial building needs in the San Jose and Southern California area.

Whether you’re looking for electrical testing or other engineering services, our team of experienced professionals has you covered, and we offer 24/7 emergency response services because an electrical emergency doesn’t always happen during regular business hours.

Contact us today for a free quote!

Frequently Asked Questions

What are the most common causes of tripped breakers?

Overloaded circuits, short circuits, ground faults, aging equipment, and connected machinery can all cause tripped breakers in industrial facilities. 

Are tripped breakers dangerous?

Repeated tripped breakers can be dangerous as they can indicate a deeper electrical issue.

What can happen from tripped breakers?

Issues with commercial and industrial facilities' breakers can cause electrical fires, burns, and shock, depending on the underlying issue.