Finding the Right LV Power Breaker Solution Can Be Easy if the Right Questions are Asked.
Eaton provides the widest range of solutions for Low Voltage Circuit Breaker problems of any LV Circuit Breaker manufacturer in the world. These solutions range from being a supplier of new factory parts and accessories for breaker maintenance all the way to being a supplier of LV replacement switchgear, and all points in between. There are so many solutions, and some that seem to compete with each other, that choosing the right solution for LV Power Breaker problems is sometimes a problem in itself. Finding the right solution is easy provided the right questions are asked.
All of the LV solutions can be placed in two broad categories – maintenance solutions (maintenance of older, pre-existing technologies) vs. upgrade solutions (upgrades to the latest technologies).
Maintenance solutions include renewal parts and accessories for normal maintenance, Class 1 reconditioning, and loaner breakers. These solutions are aimed at keeping the older technology breakers in good working order over an extended period of time. And as the description implies, the breakers will be maintained, but they will never exceed the original specifications.
Upgrade solutions include Air Replacement Breakers (AR Series), Vacuum Starter Replacements (VSR Series), Breaker Cell Retrofills (CR Series), and Trip Unit Retrofits. These solutions share the common thread of replacing the older technology elements with the latest in technology offerings. The latest technology permits significant improvements to be realized in longer service intervals, reductions in maintenance labor and even increases in interruption capability.
Is the old technology breaker still good enough?
That depends on the answers to the following questions.
- Are replacement parts available for the breaker from the original manufacturer?
The issue here is the suitability of the replacement part to do its job. If the part came from a used equipment dealer, you don’t know much about the part – it may be worn, it may be reverse engineered with questionable tolerances, it may be no better than the part it is replacing. If the part came from the original breaker manufacturer, you can be confident that the part is properly made and right for your breaker.
- Is the breaker experiencing excessive operations?
The classic case of a breaker experiencing excessive operations is where the breaker is used as a motor starter. Breakers can experience hundreds or even thousands of operations per year, simply wearing them out at an accelerated pace. Breakers were designed to be circuit protectors, not load switchers.
- Does the breaker reliably perform as expected?
Some circuit breakers have a history of troublesome operation. If the breaker is not a reliable performer even when properly maintained, it should be considered for replacement.
- Does the breaker trip system perform reliably?
Older technology breakers used electromechanical trip systems, which are no longer being supported by the original OEM. Even some early vintage electronic trip systems are experiencing unreliable or inaccurate trip behavior. If this is the case, the trip system should be replaced.
- Is There a Need for Energy Management?
Breakers with older technology trip systems could not support the demands of Energy Management. Modern trip systems provide not only protection, but energy monitoring, power quality measurement and communications. If any of these are desired, the trip system should be replaced.
- Are the recommended maintenance intervals being followed?
There is a tendency to stretch the maintenance interval well beyond the manufacturer’s recommendations. This is dangerous. Some studies have shown that if a circuit breaker is left closed for a period of five to seven years, it may not open if called to do so.
If the answers to the above all indicate that the existing trip system or circuit breaker does not need to be replaced, then the old technology breaker is still good enough, and Maintenance Solutions are recommended:
- Maintain the breaker at 1 to 2-year intervals using original OEM parts.
- Perform Class 1 reconditioning every 5 to 8 years.
Eaton can provide loaner breakers to maintain system up time while the maintenance or reconditioning is being performed.
If any answer to the above questions indicate that the trip system or the circuit breaker should be replaced, then the old technology breaker is no longer good enough, and Upgrade Solutions are recommended.
- Trip System Retrofit
- Air Replacement Breaker
- Cell Retrofill (Old Tech Breaker to Modern Breaker)
- Vacuum Starter Replacement
How do we choose the right upgrade solution?
- Does the breaker experience excessive operations? If “Yes”, then the Vacuum Starter Replacement is the preferred solution.
- Does the breaker perform reliably except for the trip system? If “Yes”, then a Trip System Retrofit is the preferred solution.
- Does the breaker perform reliably but Energy Management is desired? If “Yes”, then a Trip System Retrofit is the still the preferred solution.
- Is breaker reliability and / or renewal parts availability a problem? If “Yes”, then either a Replacement Breaker or a Cell Retrofill is the appropriate solution.
The Cell Retrofill will require an outage, but it will result in interchangeability with modern DSII or DS Magnum circuit breakers.
The Replacement Breaker, if available, will not require an outage and will result in the advantages of the modern DSII or DS Magnum circuit breakers with limited interchangeability with the old technology breaker.
