How fast can one truck be replaced?

With the Drop-in Cart — from a few hours up to 1–2 shifts; with Base-Adapt the timing depends on modifications required.

Do we need to replace the entire switchgear to get a modern breaker?

No. The cubicle, busbars, and cables remain; only the switching unit and associated mechanisms are upgraded.

Which breakers are supported?

Vacuum circuit breakers 6–10 kV, 630–1600 A, 20–31.5 kA, per short-circuit studies and geometry.

Is door-closed operation possible?

Depends on the cubicle design and delivery option; implemented subject to agreement.

What does post-installation testing include?

Geometry, interlocks, electrical tests, breaker runs; FAT/SAT and routine test protocols.

What initial data do you need?

Single-line, short-circuit data, feeder list, photos/measurements, secondary connector details, IP/climate/altitude.

How does the retrofit affect selectivity and settings?

Settings are re-verified and coordinated with AR/ATS and adjacent feeders considering VCB dynamics.

Service and spares after implementation?

We supply spares list, maintenance schedule, lubricant recommendations, and training materials.

KVE-10/13 Switchgear - Withdrawable Element Replacement (Retrofit)

The KVE-10/13 retrofit is not a “box-for-box” swap. It is an engineered re-configuration of the medium-voltage switching unit that preserves the existing cubicle and terminations. We design and supply a withdrawable truck that mirrors the KVE-10/13 mating geometry, integrates a modern vacuum circuit breaker (VCB), and extends functionality without full switchgear replacement. The goal is long-term reliability, reduced operational risk, and readiness for digital operation scenarios.

What the KVE-10/13 retrofit solves

Service life & predictability: a vacuum interrupter delivers stable switching performance and long mechanical endurance.
Robust interlocking: prevention of human error, position/status control of all critical mechanisms.
Ready for P&C/SCADA: unified secondary interfaces, remote monitoring, operation logging.
Minimal civil works: the cubicle, busbar systems, cable terminations, and foundation remain in place.
No oil handling: eliminates dielectric oil operations, leaks, and related downtime.

Project scope options

We tailor the delivery to your operating scenario and outage windows:

Base-Adapt — install a VCB on the existing truck using adapter frames, tune the shutter assembly, and unify the secondary plug-in cassette.
Drop-in Cart — a new withdrawable truck “to KVE-10/13 form-fit” with mirrored connection dimensions, stops, and interlock logic.
Factory Block — a factory-built module with implemented mechanical/electrical interlocks and shutters, extended FAT program, and door-closed operation capability (per design).

Implementation stages

Engineering survey: field measurements, photo record, review of the single-line and short-circuit data, verification of the secondary scheme.
Design: 3D model of the truck, racking kinematics, force calculation for primary contact engagement, interlock matrix.
Manufacture: frame and adapters, subassembly build, secondary harness marking, mechanism setting.
FAT (factory test bay): verification of “service/test/disconnected” positions, breaker functional operations, secondary continuity checks, test reports.
Delivery & site supervision: on-site geometric verification, SAT, operators’ training.
Energization: final checks, handover of O&M documentation, commissioning to service.

Technical data (typical ranges for KVE-10/13)

Parameter	Value / range	Notes
Rated voltage class, kV	10 (6 on request)	Insulation coordination and clearances
Frequency, Hz	50/60	Compatible with modern protection relays
Breaker rated current, A	630–1250 (option 1600)	Thermal and dynamic verification
Rated short-circuit breaking capacity, kA	20–31.5	Selection per short-circuit calculations
Mechanical endurance	≥ 10 000 operations	Depending on VCB series
Truck positions	Service / Test / Disconnected	Position latches and indication
Breaker operating mechanism	Spring-charged / electro-magnetic	Per switching duty profile
Front degree of protection	IP per project (typ. IP20…IP54)	Improved with covers and gaskets (IEC 60529)
Secondary circuits	Removable cassette/connector	Unified marking and pinout
Form-fit to KVE-10/13 envelope	Yes, “drop-in”	Adapter frames and guides included
Testing	FAT/SAT + routine tests	Reports and checklists

Interfaces and mating tolerances

Interface	Scope	Project control
Primary contacts	Plug-and-socket concentricity, closing forces, pole centerline height	Templates, gauges, geometry record
Shutter mechanism	Auto-closing of apertures when leaving service position	Functional runs and position checks
Interlocks	Mechanical/electrical; blocking of hazardous actions	Interlock matrix and bench scenarios
Secondary connector	Keyed cassette, unified X1/X2 pinout	Continuity test, labeling, wiring diagrams
Earthing switch	Independent drive, indication and interlocking	“On/Off” functions and interlocks
Door & IP	Front with viewing window, higher IP, anti-condensation measures	Seal and ventilation inspection

Options and extensions

Door-closed racking — subject to cubicle design.
Motorized racking and remote truck position monitoring.
Status sensors (O-C counter, coil currents, travel time, drive diagnostics).
Compatibility with existing CTs/VTs; VPIS (voltage presence indicating system) installation per IEC 61243-5.
Integration with Protection & Control and SCADA/DCS: signal lists, event records, and disturbance archives.

Implementation scenarios — comparison

Criterion	Base-Adapt	Drop-in Cart	Factory Block
Project duration	Moderate	Short	Minimal
Factory completeness	Partial	High	Maximum
On-site works	Elevated	Low	Minimal
Sensitivity to geometry	High	Medium	Low/medium
Budget level	Low	Medium	High
Ability to keep old truck as spare	Limited	Yes	Yes

Quality control and tests

Geometry and coupling force checks; primary contact alignment control.
Interlock and shutter functional scenarios; blocking of unsafe operations.
Insulation tests and primary contact resistance measurements.
Breaker no-load operation runs, drive and auxiliary circuit checks.
Documentation: routine tests per IEC 62271, FAT/SAT reports, inspection sheets, non-conformity and corrective action logs.

Documentation & manufacturing package

Questionnaires, preliminary docs for tenders, complete fabrication drawings (DWG/DXF), 3D models (STEP/Parasolid), BOMs and QA plans, schematic and wiring diagrams, routings, assembly/adjustment guides, routine test procedures, typical retrofit design sets, O&M manuals. Documentation is adapted to your standards and processes.

Service conditions

Indoor MV switchgear rooms with climatic category per project; temperature and humidity per substation conditions; installation altitude up to 1000 m (higher on request with insulation re-assessment); enclosure degree of protection — per specification. On request: anti-condensation measures, reinforced fixings, seismic assessment, and higher IP.

FAQ — KVE-10/13 retrofit

How fast can one truck be replaced?

With the Drop-in Cart — from a few hours up to 1–2 shifts (including routine checks). For Base-Adapt the timing depends on the scope of modifications to the existing truck.
Do we need to replace the entire switchgear to get a modern breaker?

No. The truck retrofit keeps the cubicle, busbars, and cable terminations, upgrading only the switching unit and associated mechanisms.
Which breakers are supported?

Vacuum circuit breakers 6–10 kV rated 630–1600 A with 20–31.5 kA breaking capacity. Final selection is based on short-circuit studies, KVE geometry, and required mechanism type.
Is door-closed operation possible?

Subject to cubicle design and the selected delivery option. We will implement mechanisms and interlocks if permitted by the enclosure.
What does post-installation testing include?

Geometry verification, interlock scenarios, electrical tests, breaker operation runs, FAT/SAT and routine test protocols per the agreed program.
What initial data do you need from us?

Single-line diagram, short-circuit parameters, list of feeders, photos and measurements of contact window/rails, secondary connector data, IP/climate/altitude requirements.
How does the retrofit affect selectivity and settings?

We will review protection settings and time-current curves considering VCB dynamics, and coordinate with AR/ATS schemes and adjacent feeders.
Service and spares after implementation?

We provide a recommended spares list, maintenance schedule, lubricant/gauge guidance, and training materials for O&M staff.

Standards & compliance

The project is executed in line with current medium-voltage equipment and enclosure standards, interlocking requirements, IP ratings, and test programs. On request we configure to modern reliability classes and internal arc classification — evidence by component manufacturers’ documentation and test results (e.g., IEC 62271-200 IAC, IEC 62271-100, IEC 62271-102, IEC 60529).