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Introduction to Standard Number 1200, Revision 5
Inspection, Reconditioning and Testing of
Low Voltage Circuit Breakers

I. Introduction
Low voltage circuit breakers covered in PEARL Section 1200 Standards include molded case, insulated case and power breakers. Whether using thermal magnetic current sensing and tripping or solid state, they are removed from service and at some point reapplied more than nearly any other type of electrical hardware. The greatest volume of these re-applications is completed with no shop or field testing performed. The need for re-qualification to the extent possible is extreme. While manufacturer product is typically very robust and suitable for reuse under the proper circumstances, performance verification is critical prior to re-installation.

Individual standards covered in this introduction are:

  • 1211 Low Voltage Molded Case Circuit Breaker with Thermal Magnetic Trip Unit
  • 1212 Low Voltage Molded Case Circuit Breaker with Solid State Trip Unit
  • 1214 Low Voltage Molded Case Switch (Non-Automatic Circuit Interrupter
  • 1215 Low Voltage Molded Case Motor Circuit Protector
  • 1221 Low Voltage Insulated Case Circuit Breaker with Solid State Trip Unit
  • 1231 Low Voltage Power Circuit Breaker with Series Trip Units
  • 1236 Low Voltage Power Circuit Breaker with Solid State Trip Unit

    II. Components
    Parts and assemblies to be reconditioned under Section 1200 Low Voltage Circuit Breakers include but are not limited to:

  • Case
  • Terminals, Lugs
  • Arc Chutes
  • Mechanism
  • Arcing Contacts
  • Main Contacts
  • Interlocks
  • Interphase Separators
  • Thermal Magnetic or Magnetic Only Trip Unit
  • Programmer or Electronic Trip Unit
  • Current Sensors
  • Flux Shifter
  • Wiring harness
  • Brackets
  • Programmer Window
  • Shunt Trip
  • Under Voltage Release
  • Auxiliary Contacts
  • Fuses
  • Motor Operator

    III Testing and Inspection
    The PEARL Section 1200 Low Voltage Circuit Breaker Standard begins with the definition of the term “Reconditioning” as “the process of returning electrical equipment to safe and reliable operating condition based upon the design of the original manufacturer at the time of manufacturing.” This is followed by reference tables used to calculate test results and tolerances and the necessary test equipment required by the PEARL Section 1200 Low Voltage Circuit Breaker Standard. The Low Voltage Circuit Breaker Standard continues with a “Recondition Evaluation,” which is a detailed inspection of all parts of the low voltage circuit breaker, including but not limited to the components listed above.

    Section I for PEARL Section 1200 Low Voltage Circuit Breakers begins with reference table identification and identification of the test equipment necessary to complete the standards. The following test equipment is required to perform the testing requirements of this reconditioning standard:

    1. Insulation Resistance Test Set (Megohmeter) 1000 Vdc minimum

    2. High Current Test Set

    One of the following pieces of test equipment is required to perform the contact resistance testing requirements of this reconditioning standard:

    1. Digital Low Resistance Ohmmeter (DLRO - 10 amp unit is sufficient.)

    2. DC Current Source and a Millivoltmeter

    One of the following pieces of test equipment may be required to perform the testing requirements of this reconditioning standard, depending on the accessories:

    1. AC Voltage Supply

    2. DC Voltage Supply

    Section II Recondition Evaluation-Inspection and Testing identifies each component and assembly part that must be inspected to determine the components viability and scope of reconditioning required to bring the component back to original operating condition. Results and notes from the pre-reconditioning inspection and test are recorded in the PEARL Reconditioning Evaluation and Test forms that accompany each respective standard.

    IV Reconditioning
    Section III Reconditioning Procedures describes how to recondition each component and assembly, beginning with the disassembly of the low voltage circuit breakers down to the major subassemblies. Reconditioning for low voltage circuit breakers includes:

  • Disassembly
  • Cleaning
  • Drying
  • Deoxidizing
  • Removal of corrosion
  • Degreasing
  • Plating
  • Painting
  • Lubricating
  • Adjusting

    Assembly of the reconditioned components and subassemblies is followed by final inspection and testing. As with all testing, inspection, and reconditioning operations, final inspection and test results are recorded onto the Evaluation and Test forms included with the standard. If a PEARL certified technician follows the reconditioning standard, the low voltage circuit breakers assembly is eligible for a Blue PEARL Reconditioned Quality Seal.

    Links to the full reconditioning standards for low voltage circuit breakers:

    Link to the full Standard Number 1211
        Low Voltage Molded Case Circuit Breaker with Thermal Magnetic Trip Unit
    Link to the full Standard Number 1212
        Low Voltage Molded Case Circuit Breaker with Solid State Trip Unit
    Link to the full Standard Number 1214
        Low Voltage Molded Case Switches (Non-Automatic Circuit Interrupters)
    Link to the full Standard Number 1215
        Low Voltage Molded Case Motor Circuit Protectors
    Link to the full Standard Number 1221
        Low Voltage Insulated Case Circuit Breakers with Solid State Trip Unit
    Link to the full Standard Number 1231
        Low Voltage Power Circuit Breakers with Series Trip Unit
    Link to the full Standard Number 1236
        Low Voltage Power Circuit Breakers with Solid State Trip Unit

    Link to view and/or download PEARL's 137 reconditioning standards for electrical equipment.


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