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    How To Replace An Eaton Circuit Breaker

    Circuit breakers play a critical role in your electrical system. Circuit breakers are designed to disrupt the flow of current in the event of a short circuit or overload. This allows them to prevent damage to your electrical circuit, appliances, electronics, and your home or building, by shutting down certain circuits as needed. That’s why it’s imperative to have properly functioning circuit breakers.

    For a guide on how to replace an Eaton circuit breaker, continue reading. This article will delve into Eaton circuit breakers, their unique components, and when and how to replace them.

     

    Five Components of Eaton Circuit Breakers

    Virtually every circuit breaker has universal components, and Eaton circuit breakers are no different. However, there can be some variation between low and medium voltage breakers, as they have distinct designs specific to voltage, amperage, and application. 

    Generally speaking, there are five universal circuit breaker components, including:

    1. Frame: The frame protects the internal circuit breaker components from outside materials.
    2. Operating mechanism: This provides a way to open and close the circuit breaker, turning the power on and off. 
    3. Contacts: The contacts allow the current to move through the circuit breaker when it is closed (on).
    4. Arc extinguisher: This extinguishes an arc when the circuit breaker interrupts a fault.
    5. Trip unit: The trip unit opens the operating mechanism if there is a prolonged overload or short circuit, shutting off power to that circuit. 

    Are Eaton Circuit Breakers Reliable?

    Eaton circuit breakers have reliability data available that was calculated based on page 83 from the Institute of Electrical and Electronics Engineers (IEEE) standards book. The IEEE is “a professional association for electronic engineering and electrical engineering.”

    The data shows a very low failure rate of 0.0036%, or in simpler terms, 3.6 failures per year on a base of 1,000 installed breakers. 

    These reliability rates are excellent, making Eaton circuit breakers a very reliable and reputable component in your electrical system.

     

    When Should You Replace Eaton Circuit Breakers?

    Generally, circuit breakers don’t need to be replaced unless they are broken, worn out, or aren’t functioning as they should. One key sign that your circuit breaker needs a replacement or repair is when the breaker is hot to the touch. 

    In addition, if there’s a burning smell or evident visual damage, such as burned or blackened material or frayed wiring, it’s time for a replacement. 

    That said, circuit breakers typically last a very long time—typically between 30 to 40 years. As a result, circuit breaker devices aren’t always to blame for electrical issues you may have in your home. In many cases, the problem stems from elsewhere, meaning you should first eliminate all other options before replacing the circuit breaker.

    If the circuit breaker trips frequently and you are unsure of what may be causing it or cannot pinpoint the issue itself, it’s best to call in a professional. Malfunctioning electrical systems in your home or building are a hazard you should address immediately. 

     

    Requirements to Replace An Eaton Circuit Breaker

    Removing and replacing a circuit breaker is not incredibly complex, but it likely isn’t an appropriate task for most people. Homeowners that are unfamiliar with electrical systems shouldn’t attempt to replace a circuit breaker. That’s because the replacement process requires removing the panel cover, which exposes live elements that may carry lethal levels of electricity. 

    That said, if you’re familiar with electrical panels and are prepared to complete the replacement process, you’ll need a few materials, including:

    • Cordless drill or screwdriver
    • Non-contact voltage tester
    • Paper towels or rags - to dry the area, if necessary

     

    How To Replace An Eaton Circuit Breaker—Step by Step

    Once you have gathered the materials needed, follow these steps to replace the circuit breaker. 

    1. Turn off the main breaker.

    Start by verifying that the ground and electrical service panel are completely dry. If not, use paper towels or dry rags to soak up any residual moisture as necessary. Once everything in the area is dry, open the door to the panel while standing away to the side. 

    Reach into the panel and switch the main breaker into the OFF position. Standing to the side will protect you in the unlikely but hazardous event of an arc flash while shutting off the breaker. After the main breaker is off, you have shut off power to every circuit in your house. 

    2. Unscrew the panel cover.

    Remove the panel’s outer cover screws using the cordless drill or screwdriver. Support the cover with your free hand as you remove the last few screws. Note that the panel is heavy, so be prepared to bear its weight once you remove all the screws. 

    3. Remove the panel cover.

    After unscrewing the cover, tilt it away from the panel, supporting it with both hands. Set it aside. Be cautious and avoid touching anything inside the panel. Although you shut off the main breaker and the individual branch circuit breakers don’t have power, the power company cables are still live. Refrain from touching them.

    4. Test again to ensure power is off.

    Before starting, test for power, using the non-contact voltage tester to confirm the power is off. Locate the breaker you are removing, then touch the tester probe to the wire connected to the breaker. The tester shouldn’t detect any voltage. 

    Note: If the tester detects voltage, and you are positive you turned off the main breaker, do not proceed with the replacement process. Instead, replace the panel cover very carefully, then call an electrician. The panel or wiring may have issues that will require a professional.

    5. Turn off the breaker you will be replacing.

    Next, switch the specific breaker you will remove to the OFF position. Although this step is redundant since it isn’t receiving power from the panel, it’s a good idea to follow through with it anyways.

    6. Remove the breaker back.

    Begin to remove the circuit breaker by unsnapping it from the bus bar. Do so by gently rocking it away from the middle of the panel. Don’t use tools to remove the breaker, as it should come out with ease using only your hands. 

    7. Pull the breaker out.

    To release the breaker from the bus bar, pull it directly straight out. On the breaker body, there is a tab on the outside corner. It fits into a slot located on the bus bar. Freeing the tab may require gently wiggling the breaker. 

    8. Unscrew the breaker wire.

    Unscrew the breaker wire by loosening the terminal screw on the backside of the circuit breaker. Next, pull the wire, which is the hot wire from the circuit cable, from the breaker. A neutral wire will also be connected to the neutral bus bar, and a ground wire connected to the ground bar. There is no need to disconnect those wires unless you need to remove the cable from the box entirely. 

    9. Install the new breaker.

    Since you are replacing the breaker, install the new breaker at this time, reconnecting the hot wire to your new breaker. If you weren’t installing a new breaker, you would need to cap and secure the hot wire within the panel so it couldn’t possibly touch any other terminals or breaker wires. 

    Install the new breaker, reinstall the panel cover, and turn the main breaker back on. Don’t leave the panel open and uncovered if you aren’t actively working on it.

    10. Power on your new breaker.

    Now is the time to test your work. First, turn the new breaker on, then check to ensure there’s power at your electrical devices on that circuit. 

     

    Conclusion

    Replacing an Eaton circuit breaker should only take a few minutes of your time, as it is a straightforward process. However, if you are unfamiliar with electrical systems or run into any issues along the way (such as voltage detection when the breaker is off), leave the breaker replacement process in the capable hands of a professional.