Industrial Circuit Breaker Repair Services

industrial circuit breaker repair services
Circuit Breaker Rebuilding, Retrofits, and Certified Reconditioning

At Quad Plus, we understand that your power distribution and switchgear equipment is critical to the operation of your business. It is also a significant financial investment that must be maintained properly to ensure a long and productive life.

At the heart of every power distribution system are the circuit breakers that control the flow of power to protect your crew and your equipment from injury and damage. Our process for servicing circuit breakers set the industry standard and includes preventive maintenance, inspection, evaluation, repair, reconditioning, and retrofitting. Our team has been trusted with some of the most critical applications, including steel and manufacturing processes in every industry, from industrial and commercial to government and utilities. Quad Plus is the only PEARL certified shop in the Chicagoland area, meaning we adhere to strict inspection, testing, and reconditioning standards.

industrial circuit breaker repair services

Circuit Breaker Services

experienced circuit breaker repair technician

Circuit Breaker Repairs

Our team of repair experts visually inspects each circuit breaker for worn or missing mechanisms. They perform electrical testing and analysis to determine any issues with the circuit breaker. Upon approval for repair, defective circuit breaker parts are removed and replaced with new parts. A final test and inspection are performed before the circuit breaker is returned.

cleaned industrial circuit breaker after refurbishment

Circuit Breaker Refurbishment

During the refurbishment process, our expert technicians completely disassemble, inspect, clean, plate, and paint if required. We then reassemble the circuit breaker with replacement parts before a final test and inspection are performed before the circuit breaker is returned.

retrofit large industrial circuit breakers

Improve Production

Correcting problems and product defects before they occur means your line runs for longer and produces more. Fewer serious interruptions and less downtime mean better efficiency and happier customers.

repairing circuit breakers

How to Repair Circuit Breakers

For industrial circuit breakers that have failed to operate correctly or meet the manufacturer’s performance specifications during periodic routine testing, speak to our Quad Plus experts for fast circuit breaker repair. In most cases, we can complete repairs within 2 to 3 days, depending on your needs and the availability of parts. Emergency turnaround service is available. If you’re unsure whether your circuit breaker is in need of repair, take a look at our guide and understand what to look out for.

We know that your power distribution and switchgear equipment is critical to your safety and ability to operate effectively. Whether you need emergency service for a critical breaker, retrofitting to improve the safety and reliability of your existing system, or need help establishing an effective preventive maintenance schedule, we can help. Our process for servicing and repairing circuit breakers will protect your crew and ensure a long life for critical equipment.

Every repair begins with a visual inspection of each circuit breaker for worn or missing components. Electrical testing and analysis are then performed to determine if there are any issues with the circuit breaker. Upon approval for repair, defective parts are removed and replaced with new parts. A final test and inspection is performed to ensure proper operation before the circuit breaker is returned.

Circuit Breaker Repair Process

testing industrial circuit breakers


Visual and qualitative inspection to look for soundness, signs of overheating or excessive arcing, alignment, pressure, wear, corrosion, and indicator operation. Includes (when present) power control fingers, main contacts, arc chutes and contacts, close, trip, and cell interlock mechanisms, auto trip indicator, and breaker frame. Additional tests include insulation resistance tests of power conductors, DC contact resistance measurements, high-potential tests, and operation of the breaker in the test position.

industrial circuit breaker evaluation


A test sheet will be supplied, showing results and observations along with recommended remedial actions. Each item is assigned with a grade of A, B, C , or E to indicate the breaker’s condition, wear, use, and operation. Breakers given an “A” are in good condition with slight wear and used under light conditions. A “B” grade is satisfactory condition with normal wear under heavy conditions. A “C” indicated immediate action required for proper operation. An “E indicated unacceptable condition and the breaker should not be used.

industrial circuit breaker reconditioning and repair

Repair and Clean Up

Once the breaker has been repaired, it will be cleaned and prepared to be put back into operation. Dust and light residue will be removed as well as any mechanisms that need lubrication will be attended to. If the breaker shows any abnormal corrosion or is otherwise in an abnormal condition or state, this will be reported to the customer.

refurbishing and reconditioning circuit breakers

Circuit Breaker Refurbishment and Reconditioning

Quad Plus is PEARL certified and follows strict reconditioning and refurbishment processes as defined by ANSI/IEEE C37.59. We use only OEM or manufacturer-recommended parts without altering the breaker’s original design. We offer partial reconditioning that focuses solely on problem areas or a complete teardown and rebuild of the breaker to return mature breakers into a “like new” condition. Every new OEM part replaced comes with a one-year warranty so you can be confident of your repaired parts.

The process begins with disassembly, inspection, cleaning, and repainting (or zinc-dichromate plating) if required. The circuit breaker is then reassembled with replacement parts and lubricated as needed. The final step is mechanical operation and electrical testing to verify the proper functioning of the breaker before returning it to the customer.

pearl certification for circuit breaker reconditioning
industrial circuit breaker pearl certification

Industrial Circuit Breaker Retrofitting

Do you have breakers that are decades old and want the advanced protection features available on modern breakers, but without the expense of a new system? Quad Plus will retrofit circuit breakers to provide a robust and reliable system that reduces losses resulting from downtime and upgrades. Retrofit components can be installed using existing facilities and require no additional space, saving up to four times the area of replacing existing equipment with new systems.

Quad Plus experts will retrofit with solid-state upgrades, state-of-the-art trip units, and arc flash compliant devices. Gain additional safety and security without the hassle and expense of a complete system upgrade.

retrofit industrial circuit breaker
prevenative measures for circuit breakers

Why is Preventative Maintenance Important?

Proper maintenance will ensure the ongoing operation of your equipment and the safety of your crew while eliminating problems before they develop into serious repairs and costly downtime. Quad Plus experts develop breaker preventive maintenance procedures that are specific to your operations. By doing this, you can be confident that your systems are cared for properly while also improving the safety and reliability of your electrical system.

Supported Devices and Circuit Breaker Parts Availability

With more than 30 years in the industry, we have relationships with manufacturers and a unique sourcing process that allows us to supply parts for a variety of circuit breakers and switchgear–even obsolete parts. If the circuit breaker part you need is not available, we have remanufacturing sources to get most obsolete parts made.

We support low voltage breakers and switches, including open type, insulated case (hybrid), and molded case breakers. For medium-voltage breakers, we support up to 38KV, including air break, vacuum, and oil-filled, SF6 breakers, 2.4 & 5KV medium voltage starters, disconnect devices, and insulated case breakers. Some of the manufacturers we support include (but are not limited to!) Westinghouse, General Electric, ABB, Allis-Chalmers, Roller Smith, ITE, Square-D, Nelson, Mears, McGraw Edison, Cutler-Hammer, Eaton, Federal Pacific, and Siemens.

supported devices and available parts

Why Choose Quad Plus for Circuit Breaker Repairs?

The Quad Plus process for circuit breaker repair has set the standard for the industry. When you need the best of the best for industrial circuit breaker repair and to retrofit circuit breakers, we are the right choice. Our customers enjoy pickup and delivery service from trained and certified breaker technicians to ensure the safe transport of your equipment.

We provide 24/7 emergency services along with rental circuit breakers to maintain the integrity of your operation–even when critical breakers need immediate attention. Our professional-quality control team tracks and documents each breaker from arrival to return, and we offer a one-year warranty on all serviced breakers.

We provide maintenance on equipment from most manufacturers, including:

siemens system integration partners
abb system integration partners
eaton system integration partners cutler hammer
square d system integration partners
westinghouse system integration partners
allis-chalmers system integration partners
general electric system integration partners

Learn More About Circuit Breakers With Our Guides and Case Studies

Industrial Circuit Breaker Repair Experts

From frequent tripping to visible damage, when you see these signs, it’s time to call an industrial circuit breaker repair expert right away! industrial circuit breaker circle arrow button blue

Getting the Most from Your Industrial Circuit Breakers

Broken or damaged industrial circuit breakers don’t have to be trash. Get more from yours with expert reconditioning, refurbishment, and retrofitting services. industrial circuit breaker circle arrow button blue

Preventive Maintenance Guidance for Industrial Circuit Breakers

Proper testing and maintenance schedules will help you prevent industrial circuit breaker repair and costly downtime. industrial circuit breaker circle arrow button blue