If a Hybird breaker has been identified as faulty (through troubleshooting or RMA assessment), follow this procedure to safely replace it.
Before you begin
Confirm you have the replacement breaker of the correct type and rating (same model, same current rating, same curve type).
Note the faulty breaker's Modbus ID and name in Hybird OS.
Ensure you have appropriate PPE and tools for working in a live panel, or isolate the panel entirely.
Step 1: Isolate the circuit
Switch the faulty breaker to OFF. If possible, also isolate the upstream supply to the circuit for additional safety.
Step 2: Disconnect the RS485 wiring
Disconnect the RS485 wire from both terminals of the faulty breaker. Note which wire goes to the upstream (controller-side) breaker and which goes to the downstream breaker. If this is the last breaker in the chain, there will be only one RS485 connection (from the upstream side).
Step 3: Disconnect the power wiring
Disconnect the line, neutral, and earth conductors from the faulty breaker.
Step 4: Remove the breaker
Release the breaker from the DIN rail using the release lever or clip.
Step 5: Install the replacement
Clip the new breaker onto the DIN rail in the same position.
Reconnect the line, neutral, and earth conductors.
Reconnect the RS485 wiring - upstream wire to the same terminal position, downstream wire to the other. Maintain the same polarity (A to A, B to B).
Use the pre-cut RS485 wire included with the replacement breaker if the existing wire is damaged.
Step 6: Configure in Hybird OS
The replacement breaker should be assigned the same Modbus ID as the faulty unit. If the ID needs to be set, follow the Modbus ID assignment procedure in Hybird OS.
Run a breaker scan from the controller page in Hybird OS.
Verify the new breaker appears with the correct Modbus ID.
Rename the breaker if needed to match the circuit label.
Step 7: Verify
Switch the breaker ON.
Check that the breaker reports measurements in Hybird OS: voltage, current, power, leakage, and temperature.
Verify the load on the circuit is operating normally.
Check that all downstream breakers on the RS485 chain are still communicating.
Step 8: Return the faulty unit
If the replacement was provided under RMA, return the faulty breaker to Hybird within 14 days at the address specified in your RMA confirmation. See the RMA Process article for return instructions.
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