A reliable electrical system is an important part of keeping a business operating. Electrical problems can cause unexpected downtime, damaged equipment, safety concerns, and costly emergency repairs.

Our Commercial Electrical Learning Center is designed to answer common questions business owners, facility managers, and maintenance personnel have about their electrical systems. The goal is to help identify developing problems early, better plan maintenance and upgrades, and keep electrical equipment operating safely and reliably.

Preventive Electrical Maintenance

Why Is Preventive Electrical Maintenance Important?

Many electrical problems do not begin as sudden failures. Connections can loosen, components can deteriorate, dirt buildup equipment, and electrical loads can change over time.

A preventive electrical maintenance program provides an opportunity to identify these conditions before they lead to an unplanned failure.

Depending on the facility and equipment, maintenance may include:

• Visual inspection of electrical equipment

• Checking for signs of overheating or deterioration

• Cleaning electrical equipment where appropriate

• Testing protective devices

• Thermal imaging inspections

• Testing / Reviewing electrical loads

• Identifying equipment that may be approaching the end of its useful service life

• Installing and reviewing power logging equipment

• Documenting findings and recommended repairs

The right maintenance program depends on the type of facility, operating environment, importance of the equipment, and how heavily the electrical system is used.

How Often Should Electrical Equipment Be Inspectioned?

There is not one survey / inspection interval that applies to every piece of electrical equipment.

The environment, equipment condition, manufacturer recommendations, operating load, and importance of the equipment all affect how frequently it should be inspected or maintained.

For many facilities, an annual electrical inspection or thermal imaging survey can be a useful starting point. Equipment in harsh environments, heavily loaded equipment, or equipment that is critical to production may need more frequent attention.

The goal is to build a maintenance schedule around the equipment and the consequences of that equipment failing rather than waiting for a problem to occur.

Signs Electrical Equipment May Have a Problem

Some electrical problems are obvious, while others develop without noticeable symptoms.

Possible signs of electrical equipment problems can include:

• Discoloration or evidence of overheating

• Burning odors 

• Unusual sounds

• Repeatedly tripping breakers

• Loose or damaged equipment

• Corrosion or contamination

• Thermal imaging reports showing abnormal heating

• Changes in equipment performance

• Insufficient electrical capacity as additional loads are added

Electrical equipment should not have to reach the point of visible failure before its condition is evaluated.

Thermal imaging is one tool that can help identify abnormal heating before damage becomes visible.

Visit our Thermal Imaging Resource Center to learn more about using infrared inspections as part of an electrical maintenance program.

When Should a Panelboard or Electrical Equipment Be Replaced?

Age alone does not necessarily determine when electrical equipment should be replaced.

When evaluating existing equipment, some of the things we consider include:

• Overall physical condition

• Evidence of overheating or deterioration

• Corrosion or environmental damage

• Available replacement parts

• Electrical capacity

• Changes in the electrical load

• Reliability of the equipment

• Accessibility for maintenance

• Plans for future expansion

Older equipment may continue operating reliably when properly maintained, while equipment in a harsh environment may deteriorate much faster.

In some cases, replacement is less about the equipment having already failed and more about planning ahead before an important piece of electrical distribution equipment becomes difficult or costly to repair.

Arc-Flash Awareness for Business Owners

An arc flash is a serious electrical hazard that can occur when electrical energy travels through the air between conductors or from a conductor to ground.

The amount of energy involved can be significant and can create extreme heat, pressure, and other hazards to anyone working near the equipment.

Businesses with employees who work on or around energized electrical equipment should understand the hazards involved and have appropriate safety procedures in place to help reduce the risk of injury.

Arc-flash risk assessments, safe work practices, equipment labeling, personal protective equipment, and employee training may all be part of an electrical safety program depending on the facility and work being performed.

NFPA 70E is commonly used as a framework for electrical safe work practices and arc-flash risk assessment.

An arc-flash study and a thermal imaging inspection serve different purposes. An arc-flash study evaluates the potential hazard associated with electrical equipment, while thermal imaging helps evaluate the operating condition of equipment by looking for abnormal heat.

Both can be valuable parts of a broader electrical safety and maintenance program.

Thermal Imaging & Electrical Maintenance

Thermal imaging allows electrical equipment to be inspected while it is operating under normal load.

An infrared camera measures radiant heat that components naturally emit and can help identify electrical components operating at abnormal temperatures.

Thermal imaging may help identify conditions such as:

• Loose or deteriorating electrical connections

• Overloaded circuits or equipment

• Unbalanced electrical loads

• Deteriorating breakers, switches, and disconnects

• Problems with motors, bearings, or cooling systems

Thermal imaging is especially valuable when results are documented and compared over time. Performed on a regular basis, it allows the viewer to have the ability to compare potential problems to previous surveys. A developing problem may be discovered and repaired during scheduled maintenance rather than after equipment fails unexpectedly. 

Visit our Thermal Imaging Resource Center for more information about the inspection process, reporting, and how a thermal survey can be incorporated into a preventive maintenance program.

Backup Power Planning

For some businesses, a power outage is simply an inconvenience. For others, even a short outage can stop production, interrupt communications, damage products, or create safety concerns.

Backup power should be planned around the equipment that actually needs to continue operating.

Depending on the facility, important loads may include:

• Refrigeration or freezers

• Production equipment

• Pumps

• Heating equipment

• Computers and network equipment

• Security and access-control systems

• Emergency or essential lighting

• Communication equipment

• Other process-critical equipment

Some businesses may only need selected critical loads supplied by a generator, while others may want a much larger portion of the facility backed up.

Commercial generators are available in a variety of sizes and may operate on natural gas, propane, or diesel fuel depending on the application.

The electrical load, required run time, available fuel, starting requirements of equipment, and importance of the loads should all be considered when planning a backup power system.

Visit our Generator Resource Center to learn more about generator sizing, fuel options, transfer equipment, and planning for commercial backup power.

Energy Efficiency & Electrical Controls

Energy efficiency is about more than replacing older lighting with LEDs.

In many commercial buildings, energy use can also be reduced by controlling when equipment operates and identifying equipment that is running unnecessarily.

Depending on the facility, improvements may include:

• LED lighting upgrades

• Occupancy or motion controls

• Lighting timers and scheduling

• Photocell controls

• Building automation

• Equipment scheduling

• Motor controls

• Variable frequency drives

• Monitoring electrical usage

A simple improvement may be preventing lighting from operating when an area is unoccupied. A more advanced system may automatically control lighting or equipment based on schedules, occupancy, or operating conditions.

Power monitoring equipment can also be used to better understand how and when electricity is being consumed. That information can help identify where energy is being used and whether changes may be worthwhile.

Emergency & Exterior Lighting

Emergency Lighting

Emergency lighting is easy to overlook because it normally operates only when something goes wrong.

Emergency and exit lighting should be included in a facility's regular inspection and maintenance program so that the equipment is ready when it is needed.

Basic checks can include confirming that fixtures operate properly, batteries function as intended, and equipment has not been damaged or obstructed.

Facility personnel may be able to perform some routine checks, while other testing and repairs may require qualified service personnel.

A documented inspection checklist can help ensure these systems are not forgotten.

Parking Lot & Exterior Lighting

Exterior lighting affects more than the appearance of a property.

Properly operating parking lot and building lighting can improve visibility, security, and safety for employees and customers.

Exterior lighting should be periodically inspected for:

• Failed fixtures or lamps

• Damaged wiring or equipment

• Photocell or timer problems

• Water intrusion

• Corrosion

• Physical damage

• Poor lighting coverage

LED upgrades and lighting controls may also provide an opportunity to reduce maintenance and energy use.

GFCI Protection in Commercial Facilities

GFCI protection helps protect people from electrical shock and should be included in a facility's inspection and maintenance program where applicable.

GFCI devices can be tested to make sure the protective function operates properly. Depending on the facility and equipment, these checks may be performed by facility personnel using an established procedure or incorporated into a broader electrical maintenance program.

Repeatedly tripping GFCI protection should not simply be ignored, continuously reset or bypassed. It may indicate a problem with equipment, wiring, or the protective device itself.

Power Quality & Sensitive Electronics

Modern businesses rely on increasingly sensitive electronic equipment.

Computers, network equipment, electronic controls, variable frequency drives, automation systems, and other electronics can sometimes be affected by electrical disturbances that may not noticeably affect traditional electrical loads.

If a facility experiences unexplained equipment resets, communication issues, premature equipment failures, or other recurring electrical problems, additional testing may be useful.

Power-monitoring equipment can record electrical conditions over time and help identify when problems occur.

Depending on the situation, testing may help evaluate:

• Voltage conditions

• Electrical loading

• Equipment starting events

• Power interruptions

• Other electrical disturbances

The goal is to gather enough information to understand whether the electrical system may be contributing to the problem rather than simply replacing equipment and hoping the issue goes away.

Planning for Future Electrical Needs

Commercial electrical systems often change as businesses grow.

New equipment, additional production, building additions, automation, EV charging, communications equipment, or changes in how a facility operates can place additional demands on an electrical system.

When completing an electrical project, it is worth considering what the facility may need in the future.

Planning ahead may include:

• Installing electrical distribution equipment with room for expansion

• Leaving space for additional circuits

• Installing spare conduit

• Planning for additional machinery

• Providing pathways for communications or network wiring

• Planning for future generator connections

• Considering future automation or controls

It is not always necessary to install future equipment immediately. Sometimes simply leaving the capacity or pathway for it can make the eventual project significantly easier.

Have a Commercial Electrical Question?

Not every electrical problem has an obvious answer.

If you are experiencing recurring electrical problems, planning an expansion, considering preventive maintenance, or trying to improve the reliability of your facility, we can help evaluate the electrical system and discuss your options.

As we receive more questions from business owners and facility managers, we will continue adding them to this Learning Center to make it a useful resource for commercial electrical maintenance, planning, and upgrades.