When managing older industrial electrical systems, finding replacement molded case circuit breakers (MCCBs) is crucial. As key components in power distribution, MCCBs protect systems from overloads and short circuits. However, sourcing compatible replacements can be difficult when dealing with discontinued or legacy models. Here’s a comprehensive guide to locating high-quality MCCBs, ensuring your systems remain operational, safe, and compliant.

Begin with Accurate Specifications

The first step in finding a compatible replacement is documenting the breaker’s detailed specifications. Molded case circuit breakers come in a range of configurations, so you’ll want to record the following:

• Model Number and Brand: These indicate the exact type and often help suppliers match specifications.
• Voltage and Amp Rating: Ensure compatibility with the system’s power requirements.
• Trip Characteristics: Different MCCBs have specific trip functions that need to align with the system.
• Physical Dimensions: Size compatibility is essential to fit the breaker’s enclosure and maintain system integrity.

These details are critical in minimizing downtime, as accurate documentation allows for quick identification and sourcing of the correct replacement breaker and helps our sales staff ensure we get the exact breaker you need.

* Note the example below with the red arrow the amperage, voltage and model number for that specific Square D breaker.
If you're unsure about the specific breaker model, just send us a photo, and we'll assist you in identifying it.

Explore Refurbished, Tested Options from a Trusted Supplier

While new MCCBs are ideal, they can be expensive, especially if the model is obsolete or specific to legacy systems. Used and tested MCCBs are an excellent alternative, often available at a fraction of the cost of new models while offering similar performance. Quality used units undergo a rigorous testing process to ensure they meet or exceed industry standards and may come with documented test results.

Why Choose Used and Tested MCCBs?

Refurbished MCCBs provide:

• Cost Savings: Ideal for budget-conscious operations without sacrificing quality.
• Extended Component Life: Refurbishment processes allow older equipment to perform reliably.
• Reliability and Warranty: Reputable suppliers back their refurbished MCCBs with warranties and stringent testing procedures, offering peace of mind.

EMSCO specializes in providing high-quality refurbished MCCBs that meet these criteria. Our molded and insulated case breakers are thoroughly tested, restored, and come with warranties to ensure dependable performance.

Work with a Supplier Experienced in Hard-to-Find Parts

For those managing legacy systems, finding specific MCCBs that may be discontinued or obsolete can be difficult. Working with a supplier specializing in vintage and hard-to-find components simplifies this process. EMSCO’s extensive inventory includes many obsolete breakers, allowing us to meet the needs of facilities requiring unique or discontinued models.

An experienced supplier can provide:

• Personalized Sourcing: Identifying compatible replacements when exact models aren’t available.
• Technical Expertise: Offering guidance on selecting equivalent options or advising on alternatives.

At EMSCO, our team brings decades of industry experience to each customer interaction, ensuring that you get reliable support to make informed decisions.

Ensure Availability and Prioritize Quick Lead Times

Minimizing downtime is a top priority for contractors, facilities managers, and engineers alike. Quick access to replacement MCCBs is essential to avoid costly delays. Partnering with a supplier that maintains a large, well-organized inventory of MCCBs can reduce lead times significantly.

Why EMSCO’s Inventory Matters
EMSCO’s 250,000-square-foot Minneapolis warehouse houses one of the largest selections of MCCBs, with thousands of models tested in-stock and ready to ship. Our centralized location allows for efficient shipping across North America, ensuring fast access to essential parts. With EMSCO’s extensive stock, you’re better positioned to receive the breaker you need without prolonged wait times, keeping your projects on track and facilities operational.

Verify Quality and Warranties on Refurbished Parts

When it comes to MCCBs, quality is paramount. Replacement components must not only fit correctly but also meet safety standards to perform effectively. Partnering with suppliers who follow strict refurbishing and quality control processes is key to ensuring that each breaker functions as intended.

Quality Standards to Look For Suppliers who adhere to recognized standards like PEARL (Professional Electrical Apparatus Reconditioning League) demonstrate a commitment to quality. PEARL standards ensure that refurbished components have undergone comprehensive inspection and testing to meet specific industry requirements. Additionally, a warranty provides extra assurance, underscoring the supplier’s confidence in their refurbished products.

EMSCO’s quality assurance process is rigorous. Each breaker is tested for safety and durability, meeting or exceeding industry standards, and comes with a warranty to protect your investment. Our commitment to quality ensures that the equipment we provide is ready to perform reliably in critical settings.

Plan for the Long Term with Dependable Replacements

By selecting high-quality refurbished MCCBs, you can extend the life of your existing system without investing in a full upgrade. Reliable replacements are essential for managing equipment costs and maintaining operational efficiency. With the right MCCBs, you can keep your legacy systems functioning as intended, meeting safety standards and avoiding the high costs associated with complete system replacements.

Why EMSCO?

Sourcing replacement MCCBs doesn’t have to be complicated. EMSCO’s vast inventory, fast lead times, and experienced team provide a streamlined solution to meet your needs. Whether you’re a contractor needing quick parts for a project, a facilities manager seeking to minimize downtime, or an engineer looking for performance-tested breakers, EMSCO is ready to assist.

Explore our molded and insulated case breakers or contact us today to see how EMSCO can support your replacement circuit breaker requirements with quality, efficiency, and expertise.

Introduction

In today’s industrial environments, efficient and flexible power distribution is key. Bus plugs are crucial components in ensuring reliable power delivery through busway systems. Whether you're expanding your facility or maintaining an older system, choosing the right bus plugs can greatly impact your operation's safety and performance. At EMSCO, we specialize in providing used and reconditioned bus plugs, offering solutions from trusted brands like GE, Square D, and Cutler-Hammer, ensuring cost-effective and reliable options for all industrial power needs.

What Are Bus Plugs and Why Are They Important?

Bus plugs connect electrical equipment to busway systems, distributing power efficiently across facilities. Bus plugs offer flexibility in power distribution, allowing for easy reconfiguration as industrial layouts change. In addition to their adaptability, they provide essential circuit protection, ensuring equipment is safeguarded against overcurrent and electrical faults.

EMSCO is proud to offer reconditioned bus plugs that meet or exceed industry standards, giving you access to reliable equipment from trusted manufacturers at a fraction of the cost of new components.

Benefits of Choosing Used and Reconditioned Bus Plugs

Opting for used or refurbished bus plugs offers numerous benefits, especially for businesses looking to optimize costs without sacrificing quality:

1. Cost Savings: Purchasing used bus plugs can save up to 50% compared to new products. With reconditioned options from brands like Square D and Siemens, you get the same quality at a reduced price.
2. Access to Obsolete Parts: If you're working with an older busway system, finding parts that are no longer manufactured can be a challenge. We offer a wide selection of obsolete bus plugs, including those from legacy brands like Westinghouse and ITE.
3. Faster Lead Times: At EMSCO, we maintain a large inventory of reconditioned bus plugs, which allows us to deliver products faster than competitors who rely on factory orders for new parts.
4. Environmental Sustainability: Reusing and refurbishing electrical equipment reduces waste, supporting your company’s sustainability goals while keeping your operations running smoothly.

Types of Bus Plugs Available

At EMSCO, we stock a wide range of bus plugs to meet various industrial needs, including:

• Fusible Bus Plugs: These provide built-in circuit protection using fuses that disconnect the power in the event of an overcurrent, helping prevent equipment damage.
• Non-Fusible Bus Plugs: These use circuit breakers instead of fuses, allowing for quick resetting in case of a fault, reducing downtime for your operations.

We offer configurations for both high- and low-voltage systems, including 3-phase bus plugs, 10-amp bus plugs to 1600-amp bus plugs in three and four wire configurations.

Why Choose EMSCO for Your Reconditioned Bus Plugs?

With over 70 years of experience in the electrical distribution industry, EMSCO is a trusted provider of used and reconditioned electrical equipment. We offer:

• The largest inventory of used bus plugs in the country, ensuring that you get the equipment you need quickly.
• Expertise in refurbishing electrical components to meet PEARL standards, ensuring the reliability and safety of all our products.
• A one-year warranty on all reconditioned bus plugs.
• Competitive pricing on reconditioned equipment from top brands, such as GE, Square D, and Eaton, helping you reduce costs without compromising on quality.
• Dedicated customer support to assist in selecting the right bus plug for your specific needs.

Key Considerations for Selecting Bus Plugs

When choosing the appropriate used bus plug for your system, there are several important factors to keep in mind:

• Current and Voltage Ratings: Ensure that the bus plug you choose is compatible with your busway system and the equipment it powers. Our team at EMSCO can help guide you through this process.
• Installation Requirements: Depending on your facility's layout, you may need horizontal or vertical configurations. We offer both, along with expert advice to ensure a smooth installation.
• Compatibility with Legacy Systems: If your facility uses an older busway system, finding obsolete bus plugs can be difficult. We carry a wide range of hard-to-find parts from manufacturers like Cutler-Hammer / Westinghouse to keep your system running smoothly.

Conclusion

Bus plugs are integral to maintaining efficient, reliable, and safe power distribution in industrial settings. Whether you're looking to expand your existing system, replace outdated equipment, or find cost-effective solutions, EMSCO is here to help. With our vast inventory of refurbished bus plugs from trusted brands like GE and Square D, we ensure your facility operates at peak performance without breaking the bank.

For more information or to explore our selection of reconditioned bus plugs, visit our Bus Plugs Category Page today. Let us help you find the right solution to keep your power distribution system running smoothly and efficiently.

Upgrading or replacing your existing busway and bus plugs with Bulldog Busway and Bus Plugs—whether new, reconditioned, or used — brings benefits to your facility.

Reconditioned used or inspected and safety-tested Bulldog bus plugs can significantly lower your investment compared to purchasing new ones. These options provide the reliability and efficiency of new equipment at a fraction of the cost, allowing you to allocate budget to other critical areas of your operations.

Bus Plug Testing and Quality Assurance:

EMSCO Reconditioned used and inspected, safety-tested bus plugs undergo testing processes to meet industry standards and your specific operational requirements. This means you can trust that these components will perform reliably, maintaining the safety and integrity of your electrical system.

Bulldog Bus Plugs In Stock for Reduced Lead Times:

Used and reconditioned Bulldog Busway and Bus Plugs are often more readily available than new ones, which can have long lead times due to manufacturing processes and supply chain delays. This means you can upgrade your busway system faster, minimizing disruptions and keep your business moving.

Buyers Checklist Questions for ITE/Siemens Bulldog Bus Plugs

☑️ Amperage

Knowing the available amperage for bus plug options ensures you choose a bus plug that can handle your specific electrical load, preventing overloading and ensuring efficient operation. Selecting the correct amperage rating matching the bus plug's capacity to your system's leads to safety and optimal performance.

☑️ Ground

Review the grounding options provided by ITE Bulldog Bus Plugs. Proper grounding options are essential for electrical safety and system stability, preventing potential hazards and ensuring compliance with safety standards.

☑️ Fusible or Breaker Style Bus Plugs

Choose between fusible and breaker style: Fusible Bus Plugs are ideal for applications where cost is a primary concern, and where high fault current handling capability is needed. Breaker Style Bus Plugs are better suited for applications where minimizing downtime is critical, and where power options are important.

☑️ Voltage

Correct voltage ratings to ensure that the bus plug can handle the electrical potential of your system, preventing mismatches that could lead to equipment failure or safety issues.

☑️ Bus Plug Wiring

Wire compatibility ensures that the bus plug can be securely and effectively connected to your existing wiring, which is critical for maintaining system integrity and performance. This also reduces the risk of faults and improves overall system performance.

ITE/SIEMENS Bulldog Series Busway Voltage and Amperage

5 Questions to Ask When Choosing Bus Plug Replacements

1. What factors should I consider when selecting the amperage rating for my bus plugs?

Answer:

When deciding on an amperage rating for your bus plugs, keep in mind your system's electrical load requirements, the maximum current the bus plug can carry, and the possibility of future extension. Using the proper amperage rating reduces overloading, improves safety, and extends the life of your electrical components.

2. Should I choose fusible or breaker style bus plugs for my system?

Answer:

Your special needs will determine whether you use fusible or breaker style bus plugs. Fusible bus plugs are inexpensive and can take greater fault currents, but they require fuse replacement after usage. Breaker style bus plugs are resettable and have customizable trip settings, which reduces downtime and increases operating flexibility; still, they are often more expensive upfront.

3. How important is proper grounding for bus plugs, and what options are available?

Answer:

Correct grounding is necessary for electrical safety and system performance. It protects against electrical faults and surges, lowering the risk of equipment damage and providing compliance to safety regulations. To maintain a safe and stable electrical environment, be sure that the bus plugs you purchase have sufficient grounding options that meet the requirements of your system.

4. What voltage ratings should I consider when selecting bus plugs for my electrical system?

Answer:

Check your electrical system's voltage needs for safe compatibility with bus plugs. To guarantee safe and efficient operation, the bus plug's voltage rating must be equal to or greater than the system operating voltage. Common voltage ratings include 120V, 208V, 240V, 480V, and 600V. To avoid malfunctions or safety issues, check whether the bus plugs you choose are capable of handling the voltage in your system.

5. Are there benefits to using reconditioned or inspected and safety-tested bus plugs compared to new ones?

Answer:

These options can provide significant cost savings while still offering reliability and performance equivalent to new components. Reconditioned bus plugs undergo thorough testing to make certain they meet industry standards, making them a practical and economical choice for maintaining and upgrading your electrical system.

Request help online or call a product specialist at 800-328-1842.

Reconditioned, used busway and bus plugs that are inspected and safety tested offer a viable option for your electrical needs. These products go through our evaluation and testing processes to certify they meet safety standards for safety and performance.

In any industrial or commercial setting, ensuring the safety of personnel and equipment is paramount. One critical aspect of electrical safety is the proper implementation of safety switches and disconnects. These devices play a crucial role in protecting against electrical hazards, preventing accidents, and facilitating maintenance work on electrical systems and machinery. In this blog post, we'll delve into the basics of safety switches and disconnects, exploring their functions, types, and importance in maintaining a safe working environment.

Understanding Safety Switches and Disconnects

Safety switches, also known as disconnect switches or isolators, are devices designed to quickly and safely disconnect electrical power to a circuit or piece of equipment. They serve as a means of isolating electrical circuits, machinery, or appliances to prevent electric shock, fire, or damage to equipment during maintenance, repair, or emergency situations.

Functions of Safety Switches and Disconnects

Isolation: Safety switches provide a physical break in the electrical circuit, ensuring that no power is supplied to the connected equipment or circuit when in the off position. This isolation is essential for preventing accidental contact with live electrical components.

Emergency Shutdown: In case of electrical faults or emergencies, safety switches offer a quick and reliable means of shutting off power to affected circuits or equipment, minimizing the risk of further damage or injury.

Lockout/Tagout (LOTO): Safety switches are often used in conjunction with lockout/tagout procedures to ensure that equipment remains de-energized during maintenance or servicing, preventing unauthorized activation and safeguarding personnel working on the equipment.

Types of Safety Switches and Disconnects

Fused Disconnect Switches: These devices incorporate fuses into the disconnect switch mechanism, providing overcurrent protection when excessive current flows along with the ability to disconnect power, preventing damage to equipment and minimizing safety risks.

Non-Fused Disconnect Switches: Non-fused disconnect switches offer a means of isolating power without the inclusion of fuses. They are commonly used in applications where overcurrent protection is provided elsewhere in the circuit.

Circuit Breaker Disconnects: Circuit breaker disconnects combine the functions of a disconnect switch and a circuit breaker, allowing for both disconnection and overcurrent protection.

Importance of Safety Switches and Disconnects

Electrical Safety: By providing a means of isolating power, safety switches and disconnects help prevent electric shock and electrocution hazards, safeguarding personnel working on electrical systems.

Equipment Protection: Disconnecting power during maintenance or repair activities helps prevent damage to equipment and extends its operational lifespan.

Fire Prevention: Properly functioning safety switches can mitigate the risk of electrical fires by quickly disconnecting power in the event of a fault or overload.

Compliance with Regulations: Many regulatory standards and codes mandate the use of safety switches and disconnects in industrial and commercial settings to ensure compliance with safety requirements and prevent accidents

Key Considerations When Choosing Safety Switches

Voltage and Amperage Rating: Select safety switches that match the voltage and amperage requirements of the electrical system they will be protecting.

Enclosure Type: Consider the environmental conditions (e.g., indoor, outdoor, hazardous locations) when choosing the appropriate enclosure type for the safety switch and select the appropriate NEMA rating for the disconnect switch.

Fused or Non-Fused: Ensure that you select the correct type for the applications of your electrical system.

Conclusion

Safety switches and disconnects are indispensable components in electrical systems, serving to protect both personnel and equipment from electrical hazards. Understanding their purpose, types, and key considerations is essential for ensuring a safe and compliant electrical environment. By prioritizing safety and selecting the right safety switches for your application, you can mitigate risks and create a secure work environment. Remember, when it comes to electrical safety, there's no room for compromise.

Shop the largest selection of used and reconditioned safety switches

One of the most common challenges in our industry is accurately distinguishing between the different series of vintage Westinghouse/Cutler-Hammer busway systems. Despite their nearly identical appearances, the TAP, ITAP, and ZTAP series are entirely distinct and cannot be interchanged.

Fortunately, there are quick and straightforward methods for correctly identifying the specific vintage series you require. In the following discussion, we will explore these differences, highlighting easy-to-spot clues on the plugs to help you correctly identify the type you need.

 
Identifying the types:

TAP

In any industrial power distribution system, safety and reliability are of paramount importance. To protect electrical circuits and equipment from potential hazards such as overcurrents and short circuits, engineers and electricians often employ protective devices like fuses and circuit breakers. These devices play a crucial role in safeguarding the entire system, but they differ in design, operation, and response to electrical faults. In this blog post, we will explore the key differences between fuses and circuit breakers in industrial power distribution.

1. Function and Operation:

   • Fuses: A fuse is a one-time, non-resettable protective device that contains a metal strip or wire designed to melt when exposed to excessive current flow. When the current exceeds the fuse's rated value, the metal inside the fuse will melt, opening the circuit and stopping the current flow. Fuses are inexpensive and simple in design, making them suitable for basic protection.
   • Circuit Breakers: Circuit breakers, on the other hand, are resettable protective devices designed to interrupt the current flow upon detecting an overcurrent or short circuit. They consist of an electromechanical switch that opens the circuit when an abnormal condition occurs. After tripping, circuit breakers can be manually or automatically reset, restoring power to the circuit once the fault is resolved.

2. Response Time:

   • Fuses: Fuses generally have a faster response time compared to circuit breakers. When subjected to overcurrent conditions, fuses blow quickly, thereby interrupting the current flow almost instantaneously. This swift response is essential in protecting sensitive equipment from damage due to high currents.
   • Circuit Breakers: Circuit breakers may have a slightly slower response time compared to fuses. The tripping mechanism needs a brief moment to detect the fault and open the circuit. While the delay is minimal, it can be a critical factor when dealing with highly sensitive electronic devices.

3. Protection Accuracy:

   • Fuses: Fuses provide good protection against overcurrent conditions, but their accuracy depends on the type and rating of the fuse. They might not always respond precisely to minor overloads or fluctuating currents, which can lead to undesired nuisance trips or insufficient protection in some cases.
   • Circuit Breakers: Circuit breakers offer more precise protection since they can be equipped with various types of trip units that allow customization of the tripping characteristics. This adaptability ensures that circuit breakers respond accurately to specific overcurrent levels, providing better protection for critical equipment.

4. Maintenance and Resetting:

   • Fuses: Once a fuse blows due to a fault, it must be replaced manually. This process can be time-consuming, especially in large industrial setups with numerous fuses. Additionally, identifying the faulty fuse might require careful inspection, further adding to the downtime.
   • Circuit Breakers: Circuit breakers have the advantage of being resettable, which significantly reduces downtime in the event of a fault. After isolating the faulty circuit, the breaker can be reset with a simple switch, restoring power to the system almost immediately.

5. Cost and Longevity:

   • Fuses: Fuses are generally more cost-effective than circuit breakers, making them a popular choice for lower current applications. However, their one-time use means they must be replaced after each fault, resulting in higher long-term maintenance costs.
   • Circuit Breakers: While circuit breakers may have a higher initial cost, their reusability and longer lifespan offset this drawback. They are an economically viable option for higher current applications and provide better value in the long run.

In conclusion, both fuses and circuit breakers play critical roles in safeguarding industrial power distribution systems. Fuses offer fast response times and cost-effectiveness, while circuit breakers provide more precise protection and are easier to maintain. The choice between these protective devices ultimately depends on the specific requirements of the industrial application and the level of protection needed for the equipment and personnel involved.

It's been a while since we discussed one of our main product categories in an overview post. In the past, we've covered topics like bus plugs to provide general information about the products EMSCO offers. In this post, we'll delve into the basics of Motor Control Centers (MCC).

Shop MCC Buckets and Structure

Bus plugs are a critical component of industrial power distribution systems. This blog post explores what bus plugs are, how they function, and the advantages they offer over traditional wiring methods. Learn how bus plugs can enhance flexibility, safety, and efficiency in your facility's power distribution.

WIRING BASICS

In most residential and commercial settings, power is distributed through hardwiring in the walls. In industrial settings, however, the large open floor plans make it difficult to distribute power in this way. That's where bus duct and bus plugs come in.

In industrial settings, bus duct is often used to distribute power to various areas of a facility. Bus duct [also known as busway] is essentially metal enclosures that contain conductors for distributing electricity and generally come in 10-foot sections that connect to one another to create the exact length necessary for a run. They can be installed overhead or under the floor, and they're designed to be flexible, so they can be easily repositioned or rearranged as needed.

However, just having bus duct isn't enough to distribute power to all the equipment in a facility. That's where bus plugs come in.

INTRODUCING THE BUS PLUG

Bus plugs are essentially large industrial electrical plugs that connect to a section of bus duct overhead and then feed electricity down to the equipment below.

Bus plugs typically come in a variety of sizes and styles to fit different types of bus duct and equipment. They're designed to be easy to install and remove, so they can be quickly repositioned or replaced if needed.

WHY BUS PLUGS?

One of the benefits of using bus plugs is that they allow for greater flexibility in terms of the layout of a facility. Because the bus duct and bus plugs can be easily repositioned, it's possible to change the layout of a facility without having to rewire the entire electrical system. This can save a lot of time and money in the long run.

Another benefit of using bus plugs is that they provide a higher level of safety compared to traditional hardwiring. With hardwiring, it's possible for a fault to occur in the wiring, which can lead to electrical fires or other hazards. With bus duct and bus plugs, the conductors are contained within metal enclosures and the bus plugs are equipped with either fuses or circuit breakers, which provide an extra layer of protection against faults and other issues.

Overall, bus plugs are an important component of industrial power distribution systems, allowing for greater flexibility and safety compared to traditional hardwiring.

We hope this has served to give a basic understanding of what exactly a bus plus is, how it works, and why it is used. If you’re looking for replacement bus plugs for your system, look no further! EMSCO stocks the largest selection of used and reconditioned bus plugs from all the major manufacturers (GE, Square D, and more) and from all vintages, from obsolete to modern systems. Simply browse our store or give us a call to find the model you need.

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Updated March 2024