An RCCB (Residual Current Circuit Breaker) is one of the most essential safety devices in any electrical installation. It protects people from electric shock and prevents electrical fires by detecting earth leakage currents and disconnecting the circuit instantly.
However, even the best electrical systems can face issues over time, and RCCBs may trip frequently, malfunction, or show inconsistent behaviour. Understanding the root cause of RCCB problems is the first step toward ensuring a safe and reliable electrical environment.
In this detailed guide, we cover:
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The most common RCCB issues
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Why these problems occur
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Step-by-step solutions
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Why choosing a trusted brand like BCH Electric can prevent most RCCB-related issues
✅ What Is an RCCB and Why It’s Important
An RCCB continuously monitors the current flowing through the live and neutral wires.
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Under healthy conditions: Current in Live = Current in Neutral
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During leakage: Live ≠ Neutral
The imbalance indicates a possible shock hazard or insulation failure, prompting the RCCB to trip.
So, if your RCCB is misbehaving or tripping repeatedly, it is acting as a safety alarm.
🔧 Most Common RCCB Problems and Their Solutions
Below are the issues homeowners, electricians, and facility managers face most frequently.
1. RCCB Tripping Frequently
✔ Why It Happens
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Faulty appliances
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Moisture in wiring
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Neutral–earth leakage
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Damaged insulation
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Shared neutral connections
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Cumulative leakages from multiple devices
✔ How to Fix
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Turn OFF all MCBs under the RCCB.
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Switch ON the RCCB alone.
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Turn ON each MCB one by one to isolate the problem circuit.
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Inspect wiring, appliances, and sockets of the faulty circuit.
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Repair or replace the defective appliance or damaged wiring.
2. RCCB Doesn’t Trip When the Test Button Is Pressed
✔ Why It Happens
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Internal mechanism failure
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Dust, ageing, or corrosion
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Poor-quality RCCB
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Incorrect installation
✔ How to Fix
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Replace the RCCB immediately.
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Never continue using an RCCB that fails the test procedure.
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Choose RCCBs from trusted manufacturers like BCH Electric to ensure long-term reliability.
3. RCCB Gets Warm or Emits a Burning Smell
✔ Why It Happens
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Loose terminals
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Overloading
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Undersized RCCB rating
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Poor electrical contacts or internal faults
✔ How to Fix
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Tighten all terminals to the recommended torque.
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Avoid overloading circuits.
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Upgrade to a suitable RCCB rating as per load calculations.
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Replace any RCCB showing signs of burning or heat damage.
4. RCCB Trips Only During Rainy Season or High Humidity
✔ Why It Happens
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Moisture entering outdoor sockets
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Water in junction boxes
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Damp wall wiring
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Corroded terminals in washrooms and balconies
✔ How to Fix
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Replace damaged or corroded sockets and switches.
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Seal outdoor electrical boxes properly.
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Check for wall dampness and rectify leakage.
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Improve earthing to ensure stable RCCB performance.
5. RCCB Trips Only When Certain Appliances Are Used
✔ Why It Happens
Specific appliances like:
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Geysers
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Washing machines
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Refrigerators
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Water pumps
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Air conditioners
may have internal leakage currents, faulty heating elements, or worn-out insulation.
✔ How to Fix
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Test the appliance on a different circuit.
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Check the wiring for loose neutral or earth contacts.
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Repair or replace the appliance if leakage persists.
6. RCCB Trips When Inverter or Generator Switches Over
✔ Why It Happens
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Improper changeover wiring
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Shared neutral between grid and backup supply
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Sudden surge during switching
✔ How to Fix
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Ensure separate neutral for DG/Inverter circuits.
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Use proper changeover devices.
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Install Surge Protection Devices (SPDs) to reduce transient imbalance.
7. RCCB Trips Randomly Even with No Load
✔ Why It Happens
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Neutral touching earth somewhere in the circuit
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Incorrect DB wiring
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Hidden wiring faults
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Poor-quality RCCB
✔ How to Fix
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Inspect neutral bars thoroughly.
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Ensure neutrals from different RCCBs are not mixed.
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Use insulation resistance testing to locate hidden leaks.
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Replace unreliable or worn-out RCCBs with BCH Electric RCCBs for stable performance.
8. RCCB Trips When Multiple Devices Run Together (Cumulative Leakage)
✔ Why It Happens
Each electronic device has minor leakage. When many devices operate simultaneously, total leakage may exceed RCCB sensitivity (e.g., 30 mA).
✔ How to Fix
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Split loads across multiple RCCBs.
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Use 30 mA RCCB for human protection and 100–300 mA for heavy circuits.
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Prevent overloading on a single circuit.
9. Wrong RCCB Type Installed
✔ Why It Happens
If modern electronics (LED drivers, inverters, EV chargers, VFDs) are connected to a Type AC RCCB, frequent tripping is common.
✔ How to Fix
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Use Type A RCCB for electronic devices.
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Use Type F/B RCCB for advanced installations (drives, solar, EV charging).
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Consult manufacturer selection guides for correct type.
10. Poor-Quality or Counterfeit RCCBs
✔ Why It Happens
Cheap or unbranded RCCBs often:
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Trip unnecessarily
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Fail to trip during real faults
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Have unreliable internal components
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Lack proper testing and certification
✔ How to Fix
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Replace immediately with a certified, branded product.
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Choose RCCBs from BCH Electric, known for safety, reliability, and durability.
⭐ Why BCH Electric Is the Best RCCB Manufacturer in India
Choosing the right RCCB brand is the most important step to avoid nuisance tripping and unreliable protection.
BCH Electric stands out because:
🔹 Trusted Indian Brand Since 1946
A long-standing leader in electrical safety solutions.
🔹 High-Quality Manufacturing Standards
Designed to meet IS/IEC standards, ensuring maximum protection and durability.
🔹 Advanced RCCB Technology
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2 Pole & 4 Pole options
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Multiple sensitivities (30 mA, 100 mA, 300 mA)
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Suitable for homes, offices, industries, and commercial installations
🔹 Built for Indian Conditions
RCCBs engineered to handle:
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Voltage fluctuations
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High loads
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Dusty and humid environments
🔹 Reliable Performance With Minimal Nuisance Tripping
Reduces false tripping while ensuring accurate detection of leakage currents.
🔹 Strong After-Sales Support & Nationwide Network
Ensures installation and maintenance convenience across India.
By choosing BCH Electric RCCBs, homeowners and industries alike get safe, stable, and long-lasting protection.
🛠 Final Thoughts
Most RCCB problems arise from:
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Wiring issues
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Faulty appliances
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Moisture
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Incorrect selection
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Poor-quality devices
A well-installed and correctly selected RCCB hardly ever causes issues.
🔒 To ensure maximum safety:
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Use high-quality RCCBs from BCH Electric
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Test your RCCB monthly
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Fix wiring faults immediately
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Split circuits logically
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Avoid cheap substitutes
A reliable RCCB is not just an electrical component — it’s an investment in your safety.
