Circuit Breaker Replacement Guide
When your circuit breaker needs replacement, understanding your options is critical. This guide covers replacement strategies from direct drop-in replacements to complete retrofits, helping you make informed decisions for your electrical infrastructure.
Understanding Your Replacement Options
When a circuit breaker fails or reaches end-of-life, replacement isn't always straightforward. The original manufacturer may no longer exist, the model may be discontinued, or modern standards may require upgraded protection. Group CBS helps you navigate these challenges with engineering expertise and access to new, surplus, refurbished, and retrofit solutions.
Our Approach
We evaluate every replacement request individually, considering cost, timeline, reliability, and long-term supportability. Our goal is to recommend the most appropriate solution for your specific situation, not simply the most expensive option.
Replacement Strategies
Direct Replacement
Direct Replacement
Same manufacturer, same model number. The breaker drops directly into the existing cubicle with no modifications.
When the exact model is available from surplus or refurbished inventory
3-10 business days
$
Equivalent Replacement
Equivalent Replacement
Same manufacturer, different series with equivalent ratings and dimensions. May require minor modifications.
When the original model is unavailable but the manufacturer has a compatible current product
1-3 weeks
$$
Cross-Manufacturer Replacement
Cross-Manufacturer Replacement
Different manufacturer breaker with equivalent specifications. Requires adaptation or retrofit kit.
When the original manufacturer no longer exists or has no compatible product
2-4 weeks
$$-$$$
Retrofit / Retrofill
Retrofit / Retrofill
Modern breaker installed with a retrofit kit designed for the existing switchgear. Provides latest technology in legacy equipment.
Long-term solution providing modern protection with improved reliability and features
4-8 weeks
$$$
Switchgear Replacement
Switchgear Replacement
Complete replacement of the switchgear lineup. Required when the existing equipment is beyond economical repair or upgrade.
End-of-life equipment where retrofit is not cost-effective
12-24 weeks
$$$$
Common Replacement Cross-References
These are examples of typical replacement scenarios. Actual compatibility depends on specific ratings, dimensions, and application requirements. Contact our engineering team for detailed recommendations.
Westinghouse DB-50
Westinghouse
Westinghouse DB-50 (Refurbished)
Eaton Magnum DS
Eaton Magnum SB Retrofit Kit
GE AK-25
General Electric
GE AK-25 (Refurbished)
GE AKR Series
GE EntelliGuard Retrofit
ITE K-1600
ITE
ITE K-1600 (Refurbished)
Siemens WL (via acquisition)
Siemens 3WL Retrofit Kit
Square D DS-206
Square D
Square D DS-206 (Refurbished)
Square D Masterpact NW
Masterpact NW Retrofit
Factors to Consider When Selecting Replacements
Electrical Ratings
- Continuous current rating
- Voltage rating
- Interrupting rating (kAIC)
- Short-time withstand
Physical Dimensions
- Cubicle dimensions
- Mounting pattern
- Draw-out mechanism
- Bus stab configuration
Protection Functions
- Trip unit type
- Protection curves
- Ground fault protection
- Communication requirements
Application Requirements
- Arc flash reduction
- Zone selective interlocking
- Coordination requirements
- Code compliance
Our Replacement Engineering Process
Information Gathering
We collect details about your existing equipment: nameplate data, cubicle dimensions, application requirements, and any constraints (budget, timeline, outage windows).
Options Analysis
Our engineers evaluate available replacement options, considering direct replacements, equivalent models, and retrofit solutions. We verify electrical and physical compatibility.
Recommendation
We provide a detailed recommendation with pricing, lead times, and installation considerations. For complex retrofits, we include scope of work and coordination requirements.
Execution
Once approved, we source, test, and deliver the replacement equipment. For field retrofits, our service teams handle installation, commissioning, and testing.
Related Resources
Need Replacement Help?
Submit your existing breaker details and requirements. Our engineering team will analyze your situation and provide replacement options with pricing and lead times.