Manufactured Flex RangeRetro-Flex Range
A quick, safe and cost-effective medium-voltage retrofit that renews ageing switchgear without replacing the whole switchboard.
Retro-Flex replaces the worn breaker components in Siemens 3AF breakers (as used in 8BD1 switchboards) with a new Tavrida vacuum circuit breaker block and electronic control module — reusing the original truck, busbar fingers and racking so the main busbar and control wiring stay untouched. Engineered by PPE Technologies.
Built around your installed switchgearRenew the breaker, keep the switchboard
Retro-Flex gives ageing switchgear a practical path forward by modernising critical breaker functionality while preserving the installed system around it. The approach extends the usable life of existing infrastructure and creates a more dependable platform for ongoing operation without the disruption of a complete replacement.
Renew, don't replace
Retrofit only the worn, at-risk breaker components — no changes to the fixed switchgear, main busbar or existing relay and control wiring — cutting cost and downtime versus a full switchboard replacement.
Brand-new switchgear reliability
A new Tavrida SF6-free vacuum circuit breaker with 30-year maintenance-free life and continuous self-supervision, retaining the original 3AF look, feel and racking mechanism.
Safer operations
Modern vacuum switching mitigates arc-flash risk and unplanned outages, with the breaker tested by KEMA to IEC 62271-100.
Typical project environmentsWhere Retro-Flex can be positioned
Retro-Flex is intended for installations where existing medium-voltage infrastructure still has value, but key switching equipment has reached the point where modernisation makes sense. Its retrofit approach allows ageing assets to be upgraded within a wide range of operating environments while keeping the broader system in service.
Ageing MV switchboards
Modernise Siemens 3AF breakers in 8BD1 switchboards without replacing the panels.
Mining & heavy industry
Restore reliability on critical MV switchgear where a full replacement means costly downtime.
Power generation & utilities
Extend the life of installed switchgear investment with modern vacuum breaker technology.
Continuous-process plants
Phased breaker refurbishment across a switchboard with minimal disruption.
Technical overviewModernisation without starting over
Retro-Flex provides a focused upgrade path for ageing medium-voltage switchgear by renewing the breaker technology while preserving the wider installed system. The technical overview alongside shows how this retrofit approach is structured and where it fits within an existing electrical installation.
Product category
Medium-voltage vacuum circuit breaker retrofit for Siemens 3AF breakers (8BD1 switchboards)
Configuration
New Tavrida ISM15_Shell_2 vacuum breaker block on the refurbished original 3AF truck; 17.5 kV, 1250 / 2000 A, 50/60 Hz; short-circuit breaking and short-time 31.5 kA (4 s), 82 kA peak, 95 kV BIL; existing busbar, racking and control wiring retained
Protection & control
CM_16 microprocessor control module (ISM operation, protection and data logging), one per breaker; 6 NO + 6 NC auxiliary contacts and visual position indicator; monostable magnetic actuator
Interfaces
Retains the original relay and breaker control wiring and connecting plug; ABB AC500 automation and PLC/SCADA integration
Manufacturing
Engineered and assembled by PPE Technologies; Tavrida SF6-free vacuum breaker tested by KEMA to IEC 62271-100
Project support
Site assessment, phased breaker refurbishment, installation and commissioning; 5-year VCB warranty, 30-year maintenance-free life, 30,000 CO-cycles
Documentation
Project drawings, test records, operating information and supporting product documents
Product resourcesExplore the Retro-Flex resources
The supporting material provides added context around the retrofit approach, helping explain how Retro-Flex fits into an existing switchgear environment. The resources below offer a deeper view of the solution, its engineering philosophy and the practical considerations behind modernising ageing equipment.
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Breaker Retrofit Terminology
A breaker is the switching apparatus that opens or closes an electrical circuit. In this terminology, a vacuum circuit breaker block is the switching assembly, while an original truck is the withdrawable carrier associated with a switchboard arrangement. A racking mechanism moves the truck between defined positions. Busbar fingers provide a removable connection between truck-mounted apparatus and a main busbar, while control wiring carries operating and indication circuits between the apparatus and surrounding control equipment.
Electrical Status and Actuation Terms
In electrical-control terminology, protection refers to functions that detect defined abnormal conditions and initiate an appropriate switching response. Data logging records selected operating or event information for later review. Auxiliary contacts are electrically separate contacts used to provide status or interlock signals. A visual position indicator gives a local indication of apparatus position. A monostable magnetic actuator has one stable resting state and changes state when energised, subject to the arrangement in which it is used.
Industrial Monitoring Terms
A connecting plug is a detachable electrical connection between mating parts of an assembly. A Programmable Logic Controller (PLC) is a control apparatus that executes programmed logic using inputs and outputs. Supervisory Control and Data Acquisition (SCADA) refers to supervisory monitoring, control, and data-acquisition functions across an electrical or industrial system. In general usage, these terms describe electrical connections and supervisory functions within an industrial control architecture.
Retro-Flex Flyer
A concise introduction to Retro-Flex, outlining the retrofit concept and the value of modernising existing switchgear.
Retro-Flex Brochure
A more detailed look at Retro-Flex, with added context around the upgrade approach, system fit and lifecycle benefits.
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Discuss your switchgear retrofit
Speak to the PPE Technologies team about your existing switchgear and explore a Retro-Flex upgrade tailored to your installation and operational requirements.