Warning signs
- Hot spots found by infrared scans, discoloration or a burning smell
- Frequent nuisance tripping or breakers that won't reset
- No spare spaces, or capacity exhausted by new loads
- Obsolete breakers or brands with known reliability concerns
- Interrupting (AIC) rating below the available fault current after utility or transformer changes
- Corrosion, water ingress or physical damage
Upgrade options
| Option | When it fits |
|---|---|
| Full replacement | Equipment at end of life or under-rated |
| Retrofill / retrofit breakers | Structure and bus sound; breakers obsolete |
| Add a section or sub-panel | Capacity needed but existing gear is healthy |
| MCC bucket upgrades | Adding VFDs or smart motor protection |
Planning the project
- Survey and document the existing gear, loads and fault current.
- Update or create the single-line diagram, plus short-circuit, coordination and arc flash studies.
- Specify new equipment, considering lead times, which can be long for switchgear.
- Plan the outage: temporary power, generator, phased cut-over and weekend work.
- Install, test and commission. Update labels and documentation.
Benefits
Modern gear can bring higher interrupting ratings, arc-energy reduction features (required for breakers 1,200 A and above under NEC 240.87), metering and remote monitoring, and space for growth. Talk to us through Services or contact us directly.