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O & M Manual - Russelectric

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1. This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A D AN G ER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation which if not avoided can result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided can result in minor or moderate injury H a CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided can result in property damage Please Note Electrical equipment should be installed operated serviced and maintained only by qualified personnel No responsibility is assumed by Russelectric Inc for any consequences arising out of the use of this material Section Hazard Categories and Special Symbols Page 6 of 52 Pusselectric O amp M Manual 90E1720004 Section 2 Introduction This manual contains instructions for the proper installation operation and maintenance of Russelectric bypass isolation transfer switches The purchaser s engineering installation and operating staff supervisors should familiarize themselves with this manual and become acquainted with the appearance and characteristics of each piece of equipment mounted or contained in the transfer switch These instru
2. be isolated while still in the enclosure but keep the switch rolling out of the enclosure The roll out stop is removable allowing the switch to be installed or removed from the enclosure WARNING The 1000 4000A transfer switch rollout weighs between 1500 and 5 000 pounds If the bypass isolation switch mounting surface floor is not level the transfer could roll out into the aisle Rollout stops are provided with these units for shipping and operational purposes Do not defeat the purpose of the stop unless precautions have been taken Failure to follow this instruction can result in personal injury equipment damage and or property damage Figure 21 Rollout Stop for 1000 4000A Bypass Isolation Switches To remove the transfer switch completely from the enclosure 1 Remove the cradle carriage stop from the guide track for the 1000 4000A unit 2 Replace the stop on the guide track when re installing the switch sms Figure 22 Withdrawing the Transfer Switch 1000 4000A Returning the Transfer Switch to Service To reconnect the transfer switch after isolating follow these instructions 1 Push the transfer switch back in the enclosure until it hits the stops Section 8 Operation Page 33 of 52 Pusselectric O amp M Manual 90E1720004 2 Grasp the isolating handle and push up until the switch is fully engaged Note Depending on the position of the transfer switch and the RPTCS controller st
3. l o Lo pb o Source 2 Ij H M a Figure 15 Transfer Switch Cradle Bypass Mode RTSO3 ABL Load Break Operation Load break bypass isolation switches allow the transfer switch to be bypassed and isolated for repair or inspection regardless of the position and condition of the transfer switch Itis designed to break power to the load while being bypassed After the switch has been bypassed it can then be isolated and racked out of the enclosure RTSO03 ABO Overlapping Operation Overlapping bypass isolation switches allow the transfer switch to be bypassed and isolated for repair or inspection without interrupting power to the load It is designed to bypass to the same source that the transfer switch is connected This is accomplished by overlapping the load and source bypass contacts briefly during bypass operation There are internal interlocks that prevent bypassing to the source that the switch is not connected After the switch has been bypassed it can then be isolated and racked out of the enclosure Load Test and No Load Test Load tests and no load test can be performed without affecting the load when the transfer switch is bypassed and racked in not isolated Section 8 Operation Page 29 of 52 RPusselectric O amp M Manual 90E1720004 To Bypass the Transfer Switch Paie HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH When
4. 90E1720004 ECURE SWITCHBOARD TO FORKLIFT WITH SAFETY STRAP HERE FORKS berks R ENTIRI D gt CHEOA RD AAS ooo TOP HEAVY LOAD MAY TIP RESULTING IN DEATH BODILY INJURY OR DAMAGE TO EQUIPMENT SECURE TO FORKLIFT WITH SAFETY STRAP Figure 4 Forklift Safety Strap Cradle Rollout Cradles and rollouts from 100A to 2500A are shipped in their enclosure They should be removed and or withdrawn and inspected before energizing See Section 8 for removing or withdrawing the cradle or rollout Storage If the Russelectric bypass isolation transfer switch is to be stored before being placed into service perform the steps listed below 1 Unpack the equipment to check for completeness and condition 2 Reseal the equipment in its packing for protection until installation When storing the equipment 1 Keep the equipment in a clean dry place that is free from corrosive elements and mechanical abuse NOTE Indoor equipment should be stored in an atmospherically controlled building until installation Keep the equipment clean and dry with a humidity less than 80 and temperature between 32 F 0 C and 104 F 40 C Avoid moisture changes in temperature cement dust and corrosive atmospheres 2 Covering the equipment with a tarpaulin may be necessary to protect it from contaminants or moisture 3 Do not store indoor units outdoors 4 If itis necessary to store the equipment outdoors make special arrangements
5. Gen Start and Xfer or Gen Start Only by scrolling down to CDT Event Load using lt up and down arrow function hard keys gt Press lt enter gt and highlight what type of exerciser you want Press lt enter gt again to set this exerciser mode EXERCISER TYPES Yearly There can be up to 24 programmable events with 365 days Set the date and start time duration of the test and type of test Monthly There can be up to 7 programmable events with 28 days Set the date and start time duration of the test and type of test Set exercise duration by scrolling down to CDT Event 1 Duration using the lt up and down arrow function hard keys gt Press lt enter gt to open up CDT Event 1 Duration window and set duration time using the lt up and down arrow function hard keys gt and the lt left and right arrow soft keys gt similarly to start time setting above Then press lt enter gt again Biweekly There can be up to 7 programmable events with 14 days Set the date and start time duration of the test and type of test Weekly There can be up to 7 programmable events with 7 days Set the date and start time duration of the test and type of test There can be up to 7 programmable events Set the start time duration of the test and type of test The exerciser is disabled Section 8 Operation Page 43 of 52 Puaselectric O amp M Manual 90E1720004 Performing a Load Test or a No Load Test 1 Press the
6. Usa Ra aa ow Nia dua bs Late UR a Nolan ae Nile yaek dhe 28 LTONSTCF Sw CREC AEA ROU OUN AEE sian de tases ETENA A KR ea peu ese ow NOTE AAE ECE E Gis Sdn DUPRE hee 28 AUS I LU ces ae area re i ts ats tes nape see nt esate Ce eae scale seals ce aco Ute uian an iaudon neni esean enema denies 28 By ASS MO assist scree eta nncte essa ers ahss est asa a a Mingnutsesanenal aseuist tuna tusouisestances wee 29 A O 13 aS the PAIS ER 5 WAL CIN 5550595 cesses a a oa not oul Dusowouidy nui a dunenclilidanuistenacet aa 30 Folan TE Tran CE SW UCM eTa E NEET ENE NONE EI EE LGR WEN OSES Hi etn NEE 3 Withdrawimes the Transfer Switch LO0 S00A corset ie eii EE EE O AE RA 32 Withdrawing the Transfer Switch LOOO 40OOOA cccccccccccccsseesseccccccnaaesssececceeeaaaaasseeceeeeaaaassseceeessaaaaasceessaaaanssees 32 RetUmnine Ne Tranfer SWEN SETCE a EE EE A E ET EN 33 TCHHGL Monna OD CTA ON ir Raa EE eden E NENE 34 EXernGL Mannal OPEra tOM E MIO si nE wee aaa adele austin oe eMail tea h Ae a Mews E EENE 36 TOP TGS COMO LS S SO i tine EE aac See chee Sasa ea ee EA E A 37 OVE N erain a a E E E a E A 37 Graphical Control Pane TOVEIVICW rarae nain a E a T R T a A 37 Summary OL FUNCUOM KEV Opera ONS oenl a a a a a AN 38 Suna yO LED Tnd CAtOrs ein a a aa a aa a a e AN 39 Summary of Control Pushbuttons eeeeesesssessssseeeeeeeesssssssssssssseterereessssssssssssscrreereesssssssssssseeerressssssssseeeeeeeeeo 39 Summary of the Graphical Display 000sesoo
7. and slide it either right or left then pull down on the handle to bypass the switch to either the S1 or S2 source Figure 16 Bypass Operation Section 8 Operation Page 30 of 52 RPusselectric O amp M Manual 90E1720004 Bypass to S1 Position Bypass to S2 Position Figure 17 Bypass Position Isolating the Transfer Switch The bypass switch must be in the bypassed position to either S1 or S2 1 Grasp the isolating handle then pull down all the way the transfer switch will now be disconnected Transfer Switch Isolated Position Figure 18 Isolating the Transfer Switch Section 8 Operation Page 31 of 52 RPusselectric O amp M Manual 90E1720004 Withdrawing the Transfer Switch 100 800A Once the transfer switch is isolated it can then be withdrawn from the enclosure 1 Grasp the rails on either side of the cradle near the bottom and slide them out see figure 19 Slide rails are located on the lower left and right of the cradle Figure 19 Sliding out the cradle rails 2 Pull the transfer switch out onto the rails see figure 20 Figure 20 Withdrawing the Transfer Switch 100 SO0A Withdrawing the Transfer Switch 1000 4000A The transfer switch cradle carriage roll out stops are supplied in front of the guide track at the bottom of the enclosure The rollout stop allows the transfer switch to move forward enough to Section 8 Operation Page 32 of 52 RPusselectric O amp M Manual 90E1720004
8. for testing relays instruments meters circuit breakers and other electronic devices that are included in the assembly are given in the instruction bulletin for each individual device Settings for protective devices are determined from a coordination study performed by the purchaser consultant or provided by Russelectric Factory settings are used for production testing and may not reflect specific site requirements Selection of test equipment depends on the rating and type of installation A multi meter is necessary to check the continuity of control circuits A megohm meter is also needed for testing Check the Power Circuit Connections Perform the following steps to check power circuits 1 Check wire connections and bolted bus connections to confirm that no loosening or damage occurred during shipment or installation Immediately replace any covers or barriers that were removed to check connections Note Correct torque values are listed on labels located in the transfer switch enclosure and in table 1 of this manual Check the External Equipment Perform continuity checks for the connections to external equipment such as remote controls interlock circuits and auxiliary switches Refer to the appropriate procedures in the instruction bulletin for each individual device being tested Check the Auxiliary Equipment Relays included on or in the instrument panels are set for manufacturing testing levels when shipped 1 Determine
9. green test button on the face of the controller this will bring up the exerciser test screen 2 Press the grayed out disabled inactive lt Xfer Load soft key gt and a passcode dialog box pops up 3 Enter the level 1 passcode and press lt enter gt The transfer switch times out and then transfers to Source 2 To end the load test press the lt end soft key gt and the transfer switch times out and retransfers to Source 1 NOTE A NO Load test is performed in a similar manner by pressing the lt noXfer soft key gt on the 4 The lt Xfer Load soft key gt is now enabled and has turned orange Press the orange lt Xfer Load soft key gt to initiate load test exerciser test screen Section 8 Operation Page 44 of 52 Russelectric O amp M Manual 90E1720004 Section 9 Maintaining the Bypass Isolation Transfer Switch A DAN G ER HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH e Inspect and perform preventative maintenance only on switches and equipment to which power has been turned to the OFF position disconnected and electrically isolated unless otherwise specified so that no accidental contact can be made with energized parts e Follow safety related work practices as described in NFPA 70 Standard for Electrical Safety Requirements for Employee Workplaces and ASHA Standards 29 CFR Part 1910 Subpart S Electrical Failure to follow these instructions will result in death or serious injury Periodic maint
10. in death or serious injury AWARNING Warning Lethal voltages exist inside the bypass switch enclosure Only Trained Personnel should perform this procedure Follow all NFPA 70E safety procedures and wear proper PPE Follow these instructions to manually operate the transfer switch 1 Open the lower door 2 Verify the current position of the transfer switch by observing the position indicator labels on the S1 and S2 cross arms see figure 23 There is a mechanical interlock on the transfer switch that prevents the switch from being connected to both sources at the same time On dual operator switches the closed source must be opened first and then the open source can be closed Section 8 Operation Page 34 of 52 Puaselectric O amp M Manual 90E1720004 5 w Sic MODEL RISUL ABLAIOMANFTAFTEST oaae fe VOLTAGE lara OP 7 Position Jf Indicator es gt i L PHASE 3 wne s lne ao j B i j t A A l Di 100 800A Transfer Switches 1000 3000A Transfer Switches Figure 23 Transfer Switch Position Indicators 3 Locate the manual operators on the end of the electrical operators 100 800A Transfer Switches 1000 3000A Transfer Switches Figure 24 Internal Manual Operators 4 Crank the handle per the instructions on the label Section 8 Operation Page 35 of 52 RPusselectric O amp M Manual 90E1720004 External Manual Operation EMO Open transition tra
11. rated cables or chains with safety hooks or shackles Do not pass cables or chains through holes in lifting straps 2 Use a load rated spreader beam to prevent structure damage Rig so that the minimum angle between the lifting cables or chains and equipment top is 45 degrees Handling with Sling Rigging When elevating a switch an overhead crane equipped with either of the following may be used 1 A chain coupled to a sling rigging 2 A wire cable with safety hooks and shackles 3 Wrap the sling completely around the switch and shipping stringers DUN T PASS RUPES UR CABLES THROUGH LIFT HOLES USE SLINGS S S SAFETY HOOK R SHACKLE SPANNER BAR J CHANNEL a BYPASS ISULATION SWITCH a Z al Pia a eee BLOCKS 2 z A o AES ASI SER Figure 3 Lifting with Sling Rigging Handling with a Forklift A forklift is an alternative method of handling the switch NOTE Always check the fork lengths to ensure that the forks extend under the entire transfer switch Carefully balance the load and always use a safety strap when handling or moving the transfer switch with a forklift Section 4 Receiving Handling and Storage Page 11 of 52 O amp M Manual
12. the final relay settings from a coordination study performed by the purchaser consultant or provided by Russelectric 2 Make necessary modifications to the relay settings according to the instruction bulletin for that particular relay 3 Circuit monitors and power meters included on the front of the equipment may or may not be properly configured The final configuration of these devices must be set by the purchaser or consultant Refer to the circuit monitor and power meter instruction bulletins when setting these devices Section 5 Installation Page 22 of 52 Puaselectric O amp M Manual 90E1720004 Check the Equipment Ground Fault Systems Paragraph 230 95 c of the National Electrical Code requires that all equipment ground fault protection systems be tested when first installed Record results on the ground fault system test log Note If a complete check of the ground fault system is necessary use primary injection testing If the system is multiple source and or requires field connections at the job site use primary injection testing Note Some ground fault systems require field connections at the job site Consult the switchgear interconnection wiring drawing for details Conduct the Electrical Insulation Resistance Test Russelectric bypass isolation transfer switches are factory tested for dielectric insulation strength Conduct dielectric testing once the switch is installed This testing will help identify shor
13. 020 Failure to follow this instruction can result in equipment damage 1 Bus bar joints are maintenance free Do not retighten them after the pre energizing checkout procedure is complete 2 Check all bus bar joints and terminal lugs for any pitting corrosion or discoloration resulting from high temperatures or subjection to high fault conditions If any damage has occurred replace the bus bars or lugs If cleaning is required use Lectra Clean made by CRC 3 Inspect all insulating materials Before re energizing the switch replace insulators having any visible damage such as cracks Section 9 Maintaining the Bypass Isolation Transfer Switch Page 48 of 52 Russelectric O amp M Manual 90E1720004 Section 10 Adverse Circumstances This section includes but is not limited to all electrical components of the switch PNTA HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH e Turn off all power supplying the switch before cleaning e Always use a properly rated voltage sensing device to confirm power is off Failure to follow these instructions will result in death or serious injury Note Before attempting to re energize the switch following adverse circumstances contact Russelectric Services at 1 800 654 3020 for special instructions Inspection Following a Short Circuit If a short circuit occurs make a thorough inspection of the entire system and verify that no damage to conductors or insulation has occurred High mech
14. O amp M Manual Type RTS03 Bypass lsolation Transfer Switches Tialda Power Control Systems Russelectric Inc South Shore Park Hingham Massachusetts 02043 Service 800 654 3020 www russelectric com 90E1720004 rev D Puaselectric O amp M Manual 90E1720004 Table of Contents EAS EOS Sa eae A ao estate N A E E E E E E E I E AA EE E S E 5 Section Hazard Cate cores and Special Symbols csere a a a a a 6 SECON Modeno a a a a r a a a 7 Gener dt ES APUORI E E 7 L O n A AT A A N AA E E RT SOS AMOGELINUIMDETI NE S VSIT berisi ren rr oT ETE E E OE ETE EAE EEE 8 SECHOM SACLE Te CAUIONS lt lt c1ics jovscassuapsonaccsesanemens EE EAN 9 Sechon Receiving Pande and S Orde iin cinssosscaseroidoodcspenmmeosisocaacenss sandtusnadueanerinacodsowaseipenenscutucahestnagerionausabes 10 RECI Onen EEE E E EEN EEE EO E E E EEA 10 VEL A LAERET E E Te Cee E O E EA EE AA N TEE N AA EAE 10 Hajdine vit EyeDO lS so EE a A 10 Hadin wim ENE ANS ES pE E 10 Handie wih SNE RIOM esias E EENE 1 Hajdine witha PORK eng na halen ducaiaasontenae on mesene inate eedeadaksenen meet cae ug tanessedmeaseensteneee 1 CHAGIETIROWMOUL fap 2 asec E E E E A E O T E T E O Mott camwasn E OE yeast 12 EOI A ARNAN TE E NE AE SETE TA PE E AONA E E E ETAO E P RA A PEA E 12 Secon S stallinn sxe r a ee cteeesie e oie ad AEN E 14 Installing the Bypass Isolation Transfer Switch cccccccccccccccccccsssssseccceccaassseeececcasaessseeeeeesaaaasseeeeeesaaauaaseeseeesaaaaaa
15. Sc Sak a a N 35 Pioure 25 External Manual Operator EMO Handle ii ccccsecsieccaciccsceavecsGiciewececenveatesorn eecea vouenieieoreneatentnrcsbatementeatees 36 Figure 26 External Manual Operator EMO Operation cccccccccceeeeceeeeeaeeeeesessssesseeececeeeeeeeeeaaaaaasaesenseeeeeeeees 36 Fig re 27 Graphical Control Pate OV ery 16 W peracta E AN E ens A aes ase ees eee ese 37 Figure 28 Summary of Punction Key Operations issccvscasiesevicaeeces ad brceeacesdes GMa escent ao ee eee ees 38 Figure 29 Summary of LED Tn GiCatons ssasirsssacvea excised ai E EA dose ates danse escea ea T OE a 39 Figure 30 Summary of Control Pushbutton a ncdecnidscesteveieeces ai Oar icecdes oun ee ee eee ee 39 Picure o k Suminaty Or the Grapmical iS pla Va awai sires ian hele ee aan 40 Table of Contents Page 5 of 52 Russelectric O amp M Manual 90E1720004 Section Hazard Categories and Special Symbols Read these instructions carefully and look at the equipment to become familiar with the equipment before trying to install operate service or maintain it The following special messages may appear throughout this bulletin or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure _ e The addition of either symbol to a Danger or Warning safety label A indicates that an electrical hazard exists which will result in personal injury if the instructions are not followed
16. abel Volts 120 BTR Disabled ESC J will show the active page Job ATS Load Shed Disabled T ee Mod ATS Exerciser None ENTER mie oe S 51 Utility Commit Disabled unctions ALARM G Test Mode Status red label used as an Generator z de Not Active HELP RESET indicator on some functions Selects the Soft Key Label directly above The button is inactive if the Soft Key Label is grayed out Figure 31 Summary of the Graphical Display Performing Common Setup and Control Tasks This section is a guide to performing common setup and control tasks on the RPTCS controller For further information about the RPTCS controller and please refer to the RPTCS control users manual If external accessories have been provided please refer to the specification sheet provided in the shop drawing package for proper operation of these accessories Setting Security Access There are three levels of access in the RPTCS The default setting for level 1 is 11111 and level 2 is 22222 these passcodes can be reset The level 3 passcode is a Russelectric factory passcode that you cannot reset Go to setpoints security Highlight access switch level and press lt enter gt A passcode dialog box appears depending upon which passcode you want to change Scroll down to the passcode level to be changed and press lt enter gt When the passcode dialog box pops up set your new passcode using the lt up and down arrow
17. and or humid climate e The equipment is exposed to damaging fumes vapors steam salt air and or oil vapors e The equipment is exposed to seismic shock or abnormal vibrations or tilting Circuit Loading e The transfer switch operates frequently due to overloading or fault e Transfer switching exceeds 208 times annually e Welding loads or jogging loads represent greater than 15 of a circuit s load Equipment Installation e Torque all bus bar joints lugs and bolts to their appropriate tightness at installation e Securely tighten all control and communications wiring at installation e Follow pre energizing checkout rigorously General Inspection and Cleaning CAUTION HAZARD OF EQUIPMENT DAMAGE e Do not use an air hose to blow out the switch The dust may settle inside relays and over current devices causing overheating and improper operation e Do not allow paint chemicals or petroleum based solvents to contact plastics or insulating materials Failure to follow this instruction can result in equipment damage 1 Vacuum the switch interior to remove any dirt or dust deposits Wipe all bus bars insulators cables and so forth with a clean dry lint free cloth 2 Check the switch interior carefully for moisture condensation build up or signs of any previous wetness Moisture can cause insulation breakdown and rapid oxidation of current carrying parts Inspect all conduit entrances and cracks between the enclosure p
18. anels for dripping leaks Condensation in conduits may be a source of moisture and must not be allowed to drip onto live parts or insulating material Take the necessary steps to eliminate the moisture and seal off all leaks 3 Inspect the switch for any signs of overheating Discoloration and flaking of insulation or metal parts are indications of overheating Note If overheating occurs be sure that all conditions that caused the overheating have been corrected Loose or contaminated connections can cause overheating 4 Check for signs of rodent nesting in the enclosure If required use a good exterminating technique in the general area of the equipment Note Do not place or use exterminating substances and chemicals inside the switch Some of these products attract rodents 5 Carefully inspect all devices for any visibly worn out cracked or missing parts 6 Open and close contacts several times to verify they are working properly 7 Verify that all key interlocks and door interlocking provisions are working properly Section 9 Maintaining the Bypass Isolation Transfer Switch Page 47 of 52 Pusselectric O amp M Manual 90E1720004 Bus Bar Joints Lug Terminations and Insulating Materials CAUTION HAZARD OF EQUIPMENT DAMAGE e Do not stand or remove plating on any bus splice plate or terminal lug e Damage to plating can result in overheating Replace damaged part Contact Russelectric Inc Field Services at 1 800 654 3
19. anical and thermal stresses developed by short circuit currents may damage conductors and insulation Check the overcurrent protection device that interrupted the short circuit current for possible arcing damage Do not open sealed devices such as molded case circuit breakers These devices should be replaced if damaged before re energizing the switch Clean up Following a Short Circuit The insulating properties of some organic insulating materials may deteriorate during an electrical arc If so 1 Remove any soot or debris 2 Replace carbon tracked insulation Water Soaked Switches Do not clean or repair a transfer switch that has been exposed to large volumes of water or submerged at any time Current carrying parts insulation systems and electrical components may be damaged beyond repair Do not energize the equipment Contact Russelectric Field Services at 1 800 654 3020 Section 10 Adverse Circumstances Page 49 of 52 Russelectric O amp M Manual 90E1720004 Section 11 Insulation Resistance Chart Always use a 500 or 1000 VDC megohm meter when testing insulation resistance Note The Neutral Ground column is provided to record the results of the pre energizing checkout procedure only A DAN G ER HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH e Turn off all power supplying the switch before testing e Always use a properly rated voltage sensing device to confirm power is off Failure to follow these instructions w
20. atus the transfer switch may automatically transfer as soon as it is connected RTSO3 ABL Load Break 3 Grasp the bypass handle and then push up on the handle until the bypass switch is in the un bypassed position RTS03 ABO Overlapping 4 Verify that the transfer switch position is the same source that the bypass switch is bypassed by checking the switch position lights on the RPTCS controller or the optional status indicator lights on the accessory panel Note You can only bypass an overlapping bypass switch to the source that the transfer switch is connected Do not force the handle There are solenoid interlocks that prevent bypass to the source that the transfer switch is not connected 5 Push the solenoid interlock pushbutton while keeping the pushbutton depressed grasp the bypass handle and then push up on the handle until the bypass switch is in the un bypassed position Internal Manual Operation Open transition transfer switches can be manually operated by operating a crank handle on the end of the operator s A D AN G FR HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH 2 e Only properly trained personnel should perform this procedure AN e Itis preferable to perform this procedure when the switch is de energized and locked and tagged out e If this procedure is to be performed on a live switch follow all NFPA 70E safety procedures and wear proper PPE Failure to follow these instructions will result
21. ctions and procedures apply to Russelectric bypass isolation transfer switch installations When special features or non standard components are incorporated in the bypass isolation transfer switch detailed instructions for these components are included in the equipment drawings specific to the project General Description Russelectric bypass isolation transfer switches are manufactured from formed channel framework and code gauge sheet steel All steel parts are prepared for painting by a five step cleaning phosphatizing and sealing process The parts are then painted utilizing a polyester powder coating applied by the electrostatic method and cured in a baking oven and is designed to stand up to normal industrial environments Russelectric Transfer Switches are listed to UL1008 Underwriters Laboratories UL Russelectric bypass isolation transfer switches provide automatic or manual transfers between the utility and an alternate source The operating temperature of this equipment is 10 40 C Each bypass isolation transfer switch is custom designed to specifications Structures and bus configurations are arranged according to customer specifications Complete customer drawings are furnished for each transfer switch assembly and should be reviewed before installing the equipment The drawings include elevation one line diagrams control schematics and wiring diagrams Extra features and special control options are often incorporated when
22. e equipment is operating under the normal operating conditions outlined below it should be inspected and maintained every 1 3 years or more frequently based on the user s experience Environmental e Ambient room temperature is between 22 F 30 C and 104 F 40 C e Altitude is less than 6600 ft 2012 m e The effect of solar radiation is not significant Note Refer to the principles outlined in IEEE Standard C37 24 1986 for additional information Circuit Loading e Transfer switching is no more than 104 cycles annually e Welding or jogging loads represents less than 15 of a circuit and or equipment loading Equipment Installation e Torque all bus bar joints lugs and bolts to their appropriate tightness at installation e Securely tighten all control and communications wiring at installation e Follow pre energizing checkout rigorously Harsh Operating Conditions When the equipment is operating under the harsh operating conditions outlined below it should be inspected and maintained every 6 months or more frequently based on the user s experience Environmental e Ambient room temperature is less than 22 F 30 C or greater than 104 F 40 C e Altitude exceeds 6600 ft 2012 m Section 9 Maintaining the Bypass Isolation Transfer Switch Page 46 of 52 Puaselectric O amp M Manual 90E1720004 e The effect of solar radiation is significant e The equipment is exposed to hot
23. e the lt up and down arrow function hard keys gt to incrementally increase or decrease the timer and press lt enter gt when the desired time is set 3 Use the lt up and down arrow function hard keys gt to scroll to the Post load Control Timer press lt enter gt Set the Post Load Control Timer in the same manner as the Pre Load Timer noted in 4 above Setting up the Exerciser Function 5 Use the lt up and down arrow function hard keys gt to choose the desired exerciser type also called CDT Events press lt enter gt There are six options in this menu Yearly Monthly Biweekly Weekly Daily and Off as detailed below Use the lt up and down arrow function hard keys gt to scroll down to CDT Event 1 start time press lt enter gt 7 Set start time in 24 hr format separately for second minute and hour starting time values When the screen first comes up it defaults to seconds Use the lt up and down arrow function hard keys gt to increment or decrement the starting seconds value use the lt left arrow soft key gt to move from setting seconds to setting minutes value As with the seconds use the Use the lt up and down arrow function hard keys gt to set the minutes for Starting time Repeat the above to set the hour value for starting time Press lt enter gt to save time setting to set duration time Set mode of exerciser
24. efore the switch is energized to ensure that all components function and operate properly Complete every step of the checkout procedure listed before energizing the transfer switch L P ge ee 9 Check all field installed bus bar connections Check all accessible connections for tightness Check all factory and field installed lug terminations for tightness Check the rigidity of all bus bar supports Verify the phase rotation of both the S1 and S2 sources are the same Check the enclosure for dents or other damage that reduces electrical clearances inside the enclosure On closed transition switches Verify that at least one of the source breakers 1s equipped with a shunt trip and is wired to either the source 1 or source 2 circuit breaker trip connections on the customer connection terminal strip Insure the transfer switch is in the utility source position S1 On closed transition switches insure that the switch contacts are not closed on both sources by observing the position indicator on the contact shafts Sa Sa Sew Iw a a cre S PSS WW a N Va 4 FN A f a S eee k PAR lt Remove all foam blocks or other temporary cushioning or retaining material from the electrical devices 10 If provided open and close all circuit breakers and other operating mechanisms checking for correct alignment and free operation 11 Check all relays
25. enance on the transfer switch includes cleaning lubrication and exercising component parts The interval between maintenance checks can vary depending upon the amount of usage and environmental conditions of each installation The maximum recommended inspection interval is one year This definition for periodic maintenance applies throughout this manual unless otherwise noted Always inspect the switch after a fault Transfer Switch Inspection Guidelines In general the following guidelines may be followed However as conditions vary the maintenance program must also be adapted to provide a long life for the equipment and the electrical system Periodic inspection of the equipment will be necessary to establish the conditions to which the transfer switch is subjected see Ideal Operating Conditions below and Normal Operating Conditions and Harsh Operating Conditions Perform inspections and maintenance according to these conditions Inspect the equipment immediately after abnormal or stressful operating conditions occur or after the equipment experiences a fault current These inspection and maintenance guidelines cover only Russelectric bypass isolation transfer switches If conditions cannot be established and documented then the harsh operating condition must be assumed These inspection and maintenance guidelines do not warrant any field connections field modifications or supersede any maintenance procedures or sc
26. es 14 PEC Pal OSE SILC attest aiccrataa a ta ade tet shes et oite eater r S atte E Me eteonec 14 Pre pari he Founda U OM sete teeccentco cup a tal carte nelnatias ats Se adele h loi deict seit eenee ed 14 ATCHOMS INES Witch NOM SCISIN naaa a a a a aN 14 PATICHOTI E SV CRESES E oaa a a a a a a das NN N 15 Connect the Power Cables Controls GUO WNE aeina E A A E A A 15 Connectthe POwer CaBles maiii a a a a a a a teats 15 Forgue Values tor Mec hari al OS menroroina a a a a a aN 16 Conductor Restraint forShort Circuit Current Rano aca a a O N 18 Connec tine C onrolsand W Ini erone a E a EEE 18 Transfer Switch Inspection and Testing Before Operation cccccccccccscseccccccccccecnnssssecceeeeeaeneseeeeeeeeaaaeeeeseeseeuaaaanseeees 22 Cheek the Power C ircut Connec ions ma aa a a a r O 22 Check thevEx ternal EgUpmEen eana E N E EE E E a E E T 22 Check the Aux Wary Egu pmen eon a E a a E O eet 22 Check the Equipment Ground Pault Sy Stems srira a A E E T 23 Conduct the El ctrical Insulation Resistance Test inisinia a E 23 Secon G Pre Enersizing Checkout Procedure screens i stele aurea lan aan aeons 24 Section 7 Energizing the Bypass Isolation Transfer Switch cc ccc cssssssssseeeeeccceeeeceeeeaasseseseseeeeeceeeeeeeeeeeeeeeaaaagees 26 PECL OVE ME SWUM orita T AE E aed Wawa os cms TRU wk ae Sa SA vba E N ASTR 26 ECHO e OPERA OM sap ces len rae creas vets E ake omen echen lop decane seen ae neecda lee 28 BIDASSOA dove tide AA yh ode pC Naa Maa OEE
27. h LIFT POINT MAX THE HEIGHT OF THE LIFT POINT ABOVE THE SPREADER SHOULD BE AT LEAST 172 OF A CTHE DISTANCE BETWEEN EYEBULTS THIS ASSURES A MAXIMUM ANGLE OF 45 AS SHOWN ER BYPASS ISOLATION SWITCH Figure l Lifting with an Overhead Crane and Eyebolts Handling with Lifting Angles Russelectric provides optional lifting angles for heavy switches Use rigid spreaders or a spanner bar to provide vertical lift on the lifting angles This will help to avoid damaging the frame or finish Section 4 Receiving Handling and Storage Page 10 of 52 O amp M Manual 90E1720004 T PASS ROPES OR ES THROUGH LIFT HOLES USE SLINGS AFETY HOOKS THE HEIGHT OF THE LIFT POINT FSS es ABOVE THE LIFT ANGLE SHOULD BE AT LEAST 1 2 OF A THE DISTANCE BETWEEN LIFT HOLES THIS ASSURES A MAXIMUM ANGLE F 45 AS SHOWN LIFT HOLE BYPASS ISOLATION SWITCH a LIFT ANGLE Figure 2 Lifting with an Overhead Crane Integral Lifting Angles and Cables or Chains Follow these instructions to handle the switch 1 Use load
28. hedules recommended by component manufacturers For more information regarding the warranty of this product refer to Russelectric Conditions of Sale Ideal Operating Conditions When the equipment is operating under the ideal operating conditions outlined below it should be able to operate without maintenance for a period of five years Environmental e Ambient room temperature range is 50 F 10 C to 104 F 40 C e Altitude is less than 6600 ft 2012 m e Equipment is located indoors in a climate controlled room heat AC Section 9 Maintaining the Bypass Isolation Transfer Switch Page 45 of 52 Pueselectric O amp M Manual 90E1720004 e Absence of dust or debris either airborne or settled e Relative humidity averaging less than 70 e Absence of vibrations or seismic activity Circuit Loading e Continuous loading with 100 rated devices is between 20 80 of the equipment ratings Average loading not exceeding 70 of the equipment rating Only resistive or continuous motor loads no welding or jogging loads Transfer switching less than 52 cycles annually Maximum of two circuit breaker trips due to overload or fault annually Equipment Installation e Torque all bus bar joints lugs and bolts to their appropriate tightness at installation e Securely tighten all control and communications wiring at installation e Follow pre energizing checkout rigorously Normal Operating Conditions When th
29. ill result in death or serious injury aB BC CA A Ground B Ground C Ground NeutralGround cf CCC CSS a CO SC OO S a Section 11 Insulation Resistance Chart Page 50 of 52 Russelectric O amp M Manual 90E1720004 Section 12 Maintenance Log Section 12 Maintenance Log Page 51 of 52 PROUDLY MADE IN THE Ze RUSSELECTRIC russelectric com O amp M Manual 90E1720004
30. in bypass mode and with the transfer switch racked in not H AN isolated the S1 and S2 sources are still connected to the transfer switch Depending upon the status of the sources the transfer switch may still be electrically live The transfer switch is not electrically dead until it is isolated RTS03 ABL Load Break 1 Verify that the source that you are bypassing to is available by checking the source available LED on the RPTCS controller or the optional status indicator light on the accessory panel 2 Grasp the bypass handle and slide it either right or left then pull down on the handle to bypass the switch to either the S1 or S2 source RTSO3 ABO Overlapping 1 Verify that the source that you are bypassing to is available by checking the source available lights light on the RPTCS controller or the optional status indicator lights on the accessory panel 2 Verify that the source that the transfer switch is connected by checking the source and 2 position LEDs on the RPTCS controller or the optional status indicator lights on the accessory panel Note You can only bypass an overlapping bypass switch to the source that the transfer switch is connected Do not force the handle There are solenoid interlocks that prevent bypass to the source that the transfer switch is not connected 3 Push the solenoid interlock pushbutton while keeping the pushbutton depressed grasp the bypass handle
31. is equipment before working on or inside equipment e Always use a properly rated voltage sensing device to confirm power is off e Before performing visual inspections tests or maintenance on this equipment disconnect all sources of electric power Assume all circuits are live until they are completely de energized tested and tagged Pay particular attention to the design of the power system Consider all sources of power including the possibility of backfeeding e Always practice lock out tag out procedures according to OSHA and NFPA7OE requirements e Conduct electrical testing to confirm no short circuits were created during installation maintenance or inspection e Be aware of potential hazards wear personal protective equipment and take adequate safety precautions e Carefully inspect your work area and remove any tools and objects left inside the equipment e Replace all devices doors and covers before turning on power to this equipment e All instructions in this manual are written with the assumption that the customer has taken these measures before performing maintenance or testing Failure to follow these instructions will result in death or serious injury Section 3 Safety Precautions Page 9 of 52 Russelectric O amp M Manual 90E1720004 Section 4 Receiving Handling and Storage Russelectric bypass isolation Transfer Switches are shipped assembled in one or several shipping sections depending on the si
32. keys gt and the up and down arrow soft keys gt to select the military Entering the Switch Designation Go to setpoints config ATS should be highlighted Press lt enter gt and a passcode dialog box will pop up on the screen Enter this level 2 passcode and press lt enter gt again An ATS name dialog box pops up on the screen lt left and right arrow soft keys gt lt up and down arrow soft keys gt and a lt shift soft key gt appear on the screen The lt shift soft key gt allows toggling between upper and lower case letters The screen will display a blinking first character Press the lt up and down arrow soft keys gt to select the appropriate character that pertains to the name of the switch Press the lt right arrow soft key gt to move the curser to the next field Use the lt left arrow soft key gt as needed to move back to the previous field Repeat steps 4 and 5 to enter the complete name of the transfer switch Press lt enter gt to save transfer switch name NOTE There is a five minute time limit for programming this data Section 8 Operation Page 41 of 52 Pueselectric O amp M Manual 90E1720004 Setting Timers Note All timers are set at the factory either as default factory settings or as a specified setting Please refer to the specification sheet provided with the switch for these settings Go to Setpoints operation timers Delay for generator start is automatically highlighted A pa
33. ld be followed in determining the minimum bending radii of the cables This will vary with the type and size of cable involved Refer to the NEC requirements for more information regarding minimum bending radii of cables 3 Securely lace and support the line and load cables as directed in Conductor Restraint for Short Circuit Current Rating on page 17 Note This helps avoid strain or load on the terminals Torque Values for Mechanical Lugs Socket Size Torque Value Across Flats 1 4 in 200 in lbs 5 16 in 275 in lbs 3 8 in 375 in lbs 1 2 in 500 in Ibs Table 1 Torque Values for Mechanical Lugs Load Power Connections 250 OVER BOLT HEADS HANDLA Source 1 Power EXTENTION LOCATION OF CABLE CONNECTORS FOR LOAD CIRCUIT g a Connections LOCATION OF CABLH CONNECTORS FOR NORMAL FEEDER LOCATION OF CABLE CONNECTORS FOR EMERGENCY FRRDER Source 2 Power Connections SOLID NEUTRAL BAR MOUNTED ON LEFT SIDE IF REQUIRED ATS CHASSIS SHOWN IN CONNEICTED POSITION Section 5 Installation Page 16 of 52 Pusselectric O amp M Manual 90E1720004 Figure 6 Bypass Isolation Power Connections 400A 4P shown Section 5 Installation Page 17 of 52 Pusselectric O amp M Manual 90E1720004 Conductor Restraint for Short Circuit Current Rating CAUTION HAZARD OF CONDUCTOR MOVEMENT UNDER SHORT CIRCUIT CONDITIONS e Restrain conductors in the bypass isolation transfer switch based on Table 2 Failure to foll
34. le 4 4 Pole A 277 480V B 480V C 120 208V D 208V E 120 240V F 240V G 347 600V H 265 460V 460V K 120V M Mechanical Lug O Other C Compression Lug F Freestanding OV Open Style 1 Type 1 2 Type 2 3 Type 3 3R Type 3R 4 Type 4 4X Type 4X 12 Type 12 1G Type 1 Gasketed Section 2 Introduction a We eb ab Q OQ gt 4 SIF iS D D L pes pas b oO 5 5 79 wn O c oO 2 O O Cc Cc Cc O LL LL O M F 1 RPTCSO1 RPTCS01 Level 1 Controller RPTCS02 Level 2 Controller RPTCS03 Level 3 Controller RPTCS04 Level 4 Controller RPTCS05 Level 5 Controller Page 8 of 52 Russelectric O amp M Manual 90E1720004 Section 3 Safety Precautions This section contains important safety precautions that must be followed before attempting to lift move install use or maintain Russelectric bypass isolation transfer switches and associated components HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH e Follow NFPA 70E safety procedures and safe work practices and wear appropriate personal protective equipment PPE gh e This equipment must be installed and serviced only by qualified FAILURE TO COMPLY CAN RESULT IN DEATH OR DOURY electrical personnel REFER TO NFPA TE e Perform such work only after reading and understanding all of the instructions contained in this manual e Turn off all power supplying th
35. meters and instrumentation to verify that all field installed wiring connections are made properly and that the devices function properly Section 6 Pre Energizing Checkout Procedure Page 24 of 52 Pusselectric O amp M Manual 90E1720004 12 On switches containing an electronic trip circuit breaker set the tripping characteristic curve of the adjustable electronic trip unit per the job requirements or as outlined in the respective instruction manual 13 Verify that all grounding connections are correctly made If the transfer switch is used as a service entrance double check to see that the main bonding jumper is connected 14 Check all field installed wiring Make certain it is clear of all live parts and when instructed secured to withstand fault currents 15 Vacuum to remove any dust scrap wire or other debris 16 Replace all covers check for any pinched wires and close doors Make certain all enclosure parts are properly aligned and fastened securely Section 6 Pre Energizing Checkout Procedure Page 25 of 52 Russelectric O amp M Manual 90E1720004 Section 7 Energizing the Bypass Isolation Transfer Switch A DAN G ER HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH ur a e Correct short circuit conditions detected during the checkout A procedures described in Section 6 Pre Energizing Checkout Procedure e Qualified electrical personnel must be present when energizing this equipment for the first
36. nsfer switches can be supplied with an optional external manual operator J HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH 4 e e Only properly trained personnel should perform this procedure Failure to follow these instructions will result in death or serious injury Warning Follow all NFPA 70E safety procedures and wear proper PPE Follow these instructions to external manually operate the transfer switch 1 Verify the current position of the transfer switch by observing the position LEDs on the on the RPTCS controller or the optional status indicator lights on the accessory panel There is a mechanical interlock on the transfer switch that prevents the switch from being connected to both sources at the same time On dual operator switches the closed source must be opened first and then the open source can be closed 2 Locate the external manual operator handle EMO that was supplied with the switch A separate mounting kit was also supplied with the switch to mount the handle either on the enclosure or another location Figure 25 External Manual Operator EMO Handle 3 Open the EMO covers located on the lower door 4 Insert the EMO handle into the socket on the end of the operator and follow the instructions on the door Figure 26 External Manual Operator EMO Operation Section 8 Operation Page 36 of 52 Puaselectric O amp M Manual 90E1720004 RPTCS Control System Note The f
37. nt without distortion or sagging NOTE Refer to the shipping documents for actual weights of the equipment 3 Confirm that the concrete is level left to right and front to rear to within 1 8 inch per square yard 4 Install equipment on a smooth level base to keep tolerances and adjustments to a minimum Anchoring the Switch Non Seismic 1 Four 5 8 inch diameter holes are supplied to anchor the free standing enclosure Use all four mounts to anchor the switch to the foundation properly Section 5 Installation Page 14 of 52 Pusselectric O amp M Manual 90E1720004 2 Anchor the switch to the floor Figure 5 with four 1 2 inch Grade 2 minimum bolts flat washers and anchors not furnished and torque to 60 ft lbs AVAILABLE CONDUIT ENTRANCE SPACE AT TOP Figure 5 Anchoring the Switch Anchoring the Switch Seismic During an earthquake the switch can move in any direction Any incoming cables must accommodate this motion The switch enclosure should not be used to mount exterior equipment Any mounted equipment will negate seismic certification When anchoring for a seismic location 3 When anchoring for a seismic location consideration must be given to the design of the pad or foundation Minimum concrete thickness and psi minimum anchor edge distance centerline spacing and effective embedment are all factors that will influence the anchoring 4 Refer to a seismic study done by a certified engineer for pro
38. nter security Job ATS Load Shed Disabled passcode Mod ATS Exerciser None S1 Utility Commit Disabled Generator TestMode Not Active Displays context sensitive help and Modbus address of a Ae x selected function if applicable RPTCS Figure 28 Summary of Function Key Operations Single press seca pop up TA editing T field moves to previous page sustained press logs out cancels security passcode entry Single press freezes scrolling and selects field edits selected field saves edited value double press sets the selected field page as default sustained press logs in enter security passcode HELP Displays context sensitive help and Modbus address Section 8 Operation Page 38 of 52 Pusselectric O amp M Manual 90E1720004 Summary of LED Indicators Summary of the 7 LED Indicators TOACTIVE Jame ATS ans Type Deloued Type Std Open Trans Mode Auto nps 1004 BupRufriImr Disabled i 120 Y BTF Disabled lob ATS Load Shed Disabled fod ATS Exercise None Utility ommit Disabled Generator Not Active x z x a m i owas RPTCS Figure 29 Summary of LED Indicators Summary of Control Pushbuttons Summary of the Control Pushbuttons 3 26 4 36 A m ALARM Load Connected t T osl fr moen Type onfiguratior lame ATS Trans Type pemer je Std Open Trans Mode Auto 100 BupRufrimr Disabled its 120 BTI Disabled ob ATS Load Shed Disabled Mod ATS Exercise None Utility Commi
39. nueud sala eeeuimtte acral 45 Normat Operati ondion S aoeeoe EE E ETA E A E 46 Farsi GQ peratimie Condon Soei TN EE NE E E R 46 General Inspeccion and CLC QIAO save sx casei nT EE AETA a a 47 Bus Bar Joints Lug Terminations and Insulating Material ccccccccccccccccce ss eeeesececeeeeeeaeeeseecceeeeaaaeeseeesseeaaaaasees 48 SECON AO Adverse Creuna Sse a A a anos eed cman AE loves iauatueteialannsdecssnots toned 49 Mispeci on T ollow a SNOME CE U Aa a EEE TA TE E E E O ee 49 Clean up F OMOW ING ASNO CECU aE EEEE E E ENE E ET 49 Water Soaked SWUCIIOS ss EE E E T A E E a E E 49 Secon 1 Insulation Resistance Chart 2ic6 cds tedsscces nnne n e E E T E EE 50 Section 12 Maintenance LOS seroso er a E E oie E E 51 Table of Contents Page 4 of 52 O amp M Manual 90E1720004 List of Figures Figure 1 Lifting with an Overhead Crane and Eyebolts 2 0 0 0 cceccccceeeessesseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 10 Figure 2 Lifting with an Overhead Crane Integral Lifting Angles and Cables or Chains ccccccseseeeeeseeeeeeeees 1 Pisur 32 ittine with Se Rio C1 asnan AEN A 11 Piero 42 POrkiiit Saty SEIP arra A AE AE 12 Fiure DCMU MeS wE iea A E E E anes 15 Figure 6 Bypass Isolation Power Connections 400A 4P shoWn ssssssssessssssssessssssssssssssessssssssssesseeeseeseeeeereeeeeeee 17 Prue Wrap Pie het AD ICS 6 aoan ei tet sles ets secant EEA HENE E besa ot aes E E E E a iaa 18 Figure W rapping the s
40. oO o 0 ot pe A211 oO 16 JO O O e SPI A2 12 Oo 17 Jo o o st spe A1 6 Figure 13 Locate the TB5 Terminal Block 2 Refer to the wiring diagrams supplied with the switch for proper field connections to the TB5 terminal block Note The TB5 terminal block has been tagged at the factory and is shown on the connection diagrams for each installation 3 Check control wiring with the connection diagram to confirm all connections have been made properly and loose connections tightened properly Note Jf the control power source is other than an internal control power transformer the wires from the source to the switch must be of adequate size to avoid excessive voltage drop during operation Section 5 Installation Page 21 of 52 Russelectric O amp M Manual 90E1720004 Transfer Switch Inspection and Testing Before Operation After the Russelectric bypass isolation transfer switch and components have been installed and all control and primary connections made perform a final inspection and test before placing the Switch into service When installed correctly the bypass isolation transfer switch conforms to the following requirements 1 Front panels and doors form a straight true line and when transformers and or other gear are included the front panels line up or form parallel lines 2 The switch is fastened securely to the floor channels or base pad 3 Bus and control wiring connections are connected properly Directions
41. oeeeeeessssssssssssssseteerrrerresssssssssssssectreeeresssssssssssseeereressessssssssseeeeeeeeo 40 Performing Common Setup and Control Tasks o00000nnnnneennnoooennnnsssseeennnssssseeronssssseerenssssseereossssseeeresssssseereesssss 40 SCN E S COY ACCO SS A eee tat Seeds cnt ahtNas ae ee 40 SAADE r aE T AE EEEE AEEA ETIE MEEA AE EEE EETA 41 Table of Contents Page 3 of 52 Puaselectric O amp M Manual 90E1720004 SENEE C IO Cia asc ecceiesten Baton ese e ee a See ctiewrta headin Setroatiew cegueane cto aeateas 41 SELIM TAVIS SAVIN OS oot aoe cat cadena ecctnetducsulub a Nes auee abaciaea EE 41 Entenas The Switch DesiOnaiO niin tessec wiesadd ssdtatconereneds E eonintcantnlantacaidads 41 SAn I E E tins cimdancandcemmestattnniiudad A 42 Setting Voltage and Frequency Setpoints for S1 VFS1 and S2 VFS2 eessssssssssssssssssserrersssssssssssssseeerrereeeee 42 sctting Transition ModeonaClosed Transition Swithin a a 42 Sene Pre and Post Tor Elevator CONMCIS versiri R a 43 SENS Ue XCrciSer ECON e E teberteniiudad sued yet asbuedaamiareataalacs 43 Performing GLoad Test OF GINO Load TOSI wiicesusstes cous lndseebedikiessaavesieeianesuassiveteopedstesavesienlaheciat E e eE 44 Section9 Maintaining the Bypass Isolation Transfer Switch cccccccccccceeccccceeeceeeeaaaeeeessseeeeeceeeeeeeeeeeaaaaasaeeees 45 Transfer SWUCh ANSP CCHON GUIG CLINGS sissien en Ee sean T E SA E O a a aea a 45 Pde al CO per atic Condit IONS disie a E E wonsie
42. ollowing is a brief overview of the basic setup and control tasks of the RPTCS controller There are many other control features internal and external accessories that may be included Please refer to Instruction Manual 90E1730001 and the specific project documents for more information on these features Overview The RPTCS is a modular control and monitoring system designed specifically for low and medium voltage transfer switch applications The RPTCS provides the following key benefits 1 Modular design reduces the number of spare components for maintenance and testing 2 Multiple communication protocols allow simple integration into monitoring and control systems 3 Graphical control panel Interface provides local control and access to system information Integrated pushbuttons and LED Indicators reduce external components and wiring Automation FlexLogic with interlocking and programmable logic control oe Graphical Control Panel Overview Graphical Control Panel overview The Graphical Display is a 320 by 240 Red amp Green LED Indicators pixel 3 5 inch backlit color LCD Function Keys to provide screen that provides the operator with to perform the Alarm Indication rapid access to relevant information on labeled Time delay Indication the ATS status controls and settings functionality eTransfer Inhibit Indication using intuitive sequences Source Available Indication Source Connected Indication Front Panel Con
43. ow this instruction can result in equipment damage Refer to Table 2 to determine if cable restraints are required If restraints are required perform the steps following the table Supply Cables Up to 2000A 3200A 4000A 5000A Load Cables 100 ka 200 ka Up to 800A Yes 1600A Yes 2000A Yes 3200A Yes 4000A Yes 5000A Yes Table 2 Conductor Restrain Requirements Note Wrap conductors using I 2 inch 13 mm diameter sisal rope or equivalent Lugs 1 Begin wrapping the conductors Figure 7 6 inches from the end of the lugs Conductors N a Wrap the conductors four 4 times as shown leaving 3 ft 1 m of excess rope at the first end A b Pull the rope B taut Wrap 1 2 i Figure 7 Wrapping the Cables 3mm al rope or equivalent 2 Wrap the rope several times Figure 8 until the space between the conductors are completely filled a Weave the final rope loop underneath the p aides loop Starting from b Bring the rope through the right hand space inside wrap c Pull the rope taut eae a Figure 8 Wrapping the Space between Cables Section 5 Installation Page 18 of 52 SPusselectric O amp M Manual 90E1720004 3 Wrap the rope several times until the spaces between the conductors Figure 9 are completely filled a Weave the final rope loop underneath the previous rope loop b Pull the rope taut Bring the cables together and wrap the cables 6 inches from the first wrap Contin
44. pace Di ween ADICS 45 25 04 sceshesresten te saateseetyilarea segue uated decline aes 18 Figure 9 Finch Wrappine the space between Cables ities a a wn ees 19 Ficar JOC ontinue Wrappine thie Ca Ole Ss aranea a sve lage csaul ya Sateisnoiael N elegance eaceaiels 19 Fiewer Secunns C ables 10 Sup pors Optional etre tatereaisncts teehee tas ceauut a Setassonsaa N A aaceaeeds 19 Picure 1221 vine the Rope Eads TOsether neria r saintoeet a tessesee etl aarti itets ae ete eee 20 Figure 32 Locate ihe TBS Penninal BOCK 2 33 3 tsissseeeei ulate aioe aaa N 21 Picure 14 By pass witch and Accessory Pane lenei ne aa a E E 28 ep Pea b hea to Trans rer SWE EEr a E E r E O E aN Sheer ter E 29 Ficare tO Bypass Opera Oena ae a E O A O E T daeeaiacesnaeisidaniaigueeeas 30 Fieorc 17 Bypass PO ON a T E A O O idawiaigueeea 31 Picure 18 gt Tsolatiie the Erans or Sw Ne Moserin aA r A E 31 Fieu t9 Shidine Our the Cradle Tilni eE E EN 32 Figure 20 Withdrawing the Transfer Switch 100 8004 cee eeeccccceeeeeceeeeeeeeeeeeesseeseeseeeeeeseeeeeeeeeseeeeeeeeeeeeeeeeeeees 32 Figure 21 Rollout Stop for 1000 4000A Bypass Isolation Switches ccececccccececeeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 33 Figure 22 Withdrawing the Transfer Switch 1000 4000A 0 cece cece cceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 33 Piewre2 35 Transier Switeh Position INGiCalOEs viavs esate tes a aa aes ENN 35 Beas ire 24nn Mana CP Sr UO
45. per anchor detail information 5 Use an anchor that meets or exceeds the strength of a 1 2 inch Grade 5 bolt with Yy USS large flat washer Connect the Power Cables Controls and Wiring Connect the Power Cables CAUTION LOSS OF EQUIPMENT GROUND FAULT PROTECTION e Do not connect grounding conductors to any load neutral terminal s Failure to follow this instruction can result in equipment damage NOTE When connecting power cables use 90 C insulated conductors based on the ampacity of 75 C conductors unless otherwise indicated by supplemental instructions Russelectric bypass isolation transfer switches are provided with compression or mechanical type lugs for terminating the main power cables 1 Determine the Source or Load and phase of each cable before making the connection See Figure 6 Note Viewing the switch from the front the pole sequence is phased N A B C left to right Non standard arrangements may be necessary to meet specific requirements If so the bus is marked A B C and N in the order specified by the customer If an optional solid neutral is provided all the connections for the neutral are labeled Section 5 Installation Page 15 of 52 RPusselectric O amp M Manual 90E1720004 2 Avoid sharp turns corners and edges when forming cables for termination within the switch This reduces the risk of damage to equipment or weakening of the cable insulation The cable manufacturer s instructions shou
46. rations Press the S1 or the S2 soft key Scroll down to parameter you want to set using the lt up and down arrow function hard keys gt and press lt enter gt i A passcode entry dialog box appears enter level 1 passcode and press lt enter gt Highlight parameter you want to set and press lt enter gt Use the lt up and down arrow function hard keys gt to set the desired parameter and press lt enter gt NOTE All Voltage parameters are set by percentage values Setting Transition Mode on a Closed Transition Switch Go to setpoints control general Scroll down to transition mode select and press lt enter gt A passcode dialog box appears enter level 2 passcode Press lt enter gt again and a transition mode select dialog box appears 5 Use the lt up and down arrow function hard keys gt to scroll to the desired transition mode press lt enter gt Press the lt HOME gt function key and confirm on the operator panel that the desired transition mode was selected Section 8 Operation Page 42 of 52 Pusselectric O amp M Manual 90E1720004 Setting Pre and Post for Elevator Contacts Go to setpoints operations timer Use the lt down arrow function hard key gt scroll down to Pre load Control Timer and press lt enter gt A passcode dialog box appears enter level 1 passcode Press lt enter gt again and a dialog box appears which allows you to set the timer Us
47. soft keys gt and the lt left and right arrow soft keys gt Press lt enter gt to set passcode NOTE Passcode reset to level 0 after five minutes of passcode activation Press sustained lt escape gt key to reset passcode to zero Press sustained lt enter gt key and the passcode dialog box appears Contact customer with encrypted code if you lose your passcode You can find this code on the passcode dialog box Section 8 Operation Page 40 of 52 Pusselectric O amp M Manual 90E1720004 Setting the Date Go to setpoints config system Scroll to set date and press lt enter gt A passcode dialog box appears enter level 1 passcode Press lt enter gt again and a set date dialog box appears Use the lt right and left arrow soft keys gt and the lt up and down arrow soft keys gt to select the date al Press lt enter gt to save the date settings Setting the Clock 5 Use the lt right and left arrow soft keys gt and the lt up and down arrow soft keys gt to select the military 24 hour time 6 Press lt enter gt to save time settings Setting Daylight Savings 1 Go to setpoints config system 2 Scroll to daylight savings and press lt enter gt 3 A passcode dialog box appears enter level 1 passcode Press lt enter gt again and a set daylight savings dialog box appears 24 hour time Press lt enter gt to save daylight savings settings Use the lt right and left arrow soft
48. sory panel See Section 8 Operation Bypass to the energized source Close the S2 circuit breaker mo h Perform a no load test per Section 8 Operation of this manual pum o Verify the generator started by checking the S2 available LED 1s lit Cancel the no load test After the engine cooldown timer TDEC times out the engine will shut down Qi o k Perform a load test Section 7 Energizing the Bypass Isolation Transfer Switch Page 26 of 52 Puaselectric O amp M Manual 90E1720004 l Verify that the transfer switch transfers to the S2 source by check the status on the RPTCS OIP m Cancel the load test and verify that the engine shuts down n Take the bypass switch out of bypass to the non bypass position o Close all downstream load circuit breakers p Perform a load test q Verify that the transfer switch transfers to the S2 source by checking the status on the RPTCS OIP r Cancel the load test and verify that the engine shuts down Section 7 Energizing the Bypass Isolation Transfer Switch Page 27 of 52 RPusselectric O amp M Manual 90E1720004 Section 8 Operation This section describes the proper operation of the bypass isolation transfer switch Bypass Switch The bypass isolation switch provides three sets of fully rated contacts for bypassing the transfer switch to either source A manual operator is used to operate the contacts There are also auxiliary contacts for the control system and c
49. specified by the purchaser s order The special features are shown on the drawings and diagrams for the specific transfer switch assembly Instructions for the control panel can be found in the user s manual Section 2 Introduction Page 7 of 52 Identification O amp M Manual 90E1720004 Each Russelectric bypass isolation transfer switch is identified by a unique combination of model and serial numbers These numbers along with the electrical rating data are provided on a nameplate affixed to the bypass isolation transfer switch and control system Write the necessary information in the spaces provided on the sample nameplate to keep a permanent and readily available record This data is required to specifically identify your unit when contacting Russelectric personnel lt Pusselectric Power Control Systems South Shore Park 781 749 6000 Hingham MA 02043 Russelectric com MODEL SERIAL VOLTAGE PHASE RTS03 Model Numbering System Q D gt Il g SF 5 S 5 ssal 8 igis SASS 2 eis RTS 03 A BL A 100 3 A A Automatic M Manual BL Load Break BO Overlapping A Single Operator B Dual Operator C Closed Transition 100 100A 150 150A 225 225A 260 260A 400 400A 600 600A 800 800A 1000 1000A 1200 1200A 1600 1600A 2000 2000A 2500 2500A 3000 3000A 4000 4000A 2 2 Pole 3 3 Po
50. sscode dialog box appears enter level 1 passcode and press lt enter gt Scroll down to the timer to be set and Press lt enter gt Use the lt up and down arrow function hard keys gt to increase or decrease the timer setpoint by its incremental value noted in the Setpoints section or Using the dialog box for setting the timers press the lt left and right arrow soft keys gt and the lt up and down arrow soft keys gt to navigate the numeric keypad on the screen and then the lt select soft key gt to enter each digit of the timer setting directly within the maximum minimum and incremental limits for that timer as noted in the Setpoints section i Press lt enter gt to save the timer settings NOTE Timer designation cross reference Delay for generator start is the same as TDES Delay xfer to nonpreferred source is the same as TDNPS Delay xfer to preferred source is the same as TDPS Delay cntr off position to nonpreferred source is the same as TDNNP Delay cntr off position to preferred source is the same as TDNP Delay for engine cool down is the same as TDEC Setting Voltage and Frequency Setpoints for S1 VFS1 and S2 VFS2 Note All setpoints for are set at the factory either as default factory settings or as a specified setting Please refer to the specification sheet provided with the switch for these settings S Go to setpoints ope
51. t circuits and undesirable grounds in the switch and help identify any potential damage to the insulation during transport and installation 1 Refer to ANSI IEEE C37 20 1 for information regarding field dielectric testing 2 Disconnect the RPTCS controller plugs If supplied open all control power and metering disconnects or remove the fuses from the control circuits 3 If supplied Isolate all supply voltage to solid state controls on closed transition switches 4 Isolate any and all control power equipment for metering or annunciation accessories Consult factory concerning how to handle other special wiring conditions 6 With the neutral isolated from the ground and the power switches and circuit breakers open conduct electrical insulation tests from phase to phase phase to ground phase to neutral and neutral to ground Note Jf the resistance reads less than one megohm while testing with the branch circuit devices in the Open position the system may be unsafe and should be investigated Consult Russelectric Services at 1 800 654 3020 to help you correct any problems 7 After completing the electrical insulation test replace all control power fuses that may have been removed and close power disconnects that have been opened Energize supplies as desired Section 5 Installation Page 23 of 52 Pusselectric O amp M Manual 90E1720004 Section 6 Pre Energizing Checkout Procedure Conduct a complete inspection b
52. t Disabled Generator Not Active a a st sa it a yer fered RPTCS Figure 30 Summary of Control Pushbuttons Section 8 Operation Page 39 of 52 Pusselectric O amp M Manual 90E1720004 Summary of the Graphical Display Summary of the Graphical Display SELECTED PAGE PATH INDICATION ACCESS LEVEL To improve readability some Pages are organized in a hierarchical Indicates the present passcode level When pages are labeled with or tree based menu structure performing operations that require a higher level rectangular outlines or colored Pressing the ESC key will bring of security a passcode entry dialog box opens back grounds Some pages the page up one level Pressing the There are various operations cannot be performed contain too many fields to display Home key will navigate straight to in lower access levels A sustained press on the at once These pages display the home page as shown here ESC key clears the security passcode arrow bars at the right edge to indicate that the page continues above or below the screen TIME amp DATE t 28 Jan 09 14 36 Load Connected toS1 m ALARM TOACTIVE XFER INHIBIT T SOFT KEY LABELS ie Navigation blue or gray Type Configuration label Used to traverse across Names Trans Type Delayed 4 J T and down the hierarchy of jpe Std Open Trans Mode Auto 1 2 pages and the numeric setpoint amps 1004 BupRsfrtmr Disabled popup screens A blue l
53. time e Follow the instructions in this section to properly energize this transfer switch Failure to follow these instructions will result in death or serious injury A WARNING Warning Only Trained Personnel should perform this procedure Follow all NFPA 70E safety procedures and wear proper PPE Note It is standard practice when energizing a transfer switch for the first time to close one of the source feeder breakers and leave the other source breaker locked out and tagged out until all settings and timers are verified correct Note This procedure does not replace startup by a qualified Russelectric field service technician such service should be scheduled by calling Russelectric services at 1 800 654 3020 Energize the Switch 1 No load should be on the bypass isolation transfer switch when it is energized Turn off all downstream loads The transfer switch should be racked in and in the SI position The bypass switch handle should be in the up or non bypass position 2 Energize the switch in the following sequence Close any open doors and or covers a b Close the preferred source S1 circuit breaker o Verify the RPTCS controller and OIP power up fa Verify all settings and timers per the specification sheets provided with the switch e Verify the transfer switch is connected to or transferred to the energized S1 source by checking the indicators on the OIP or the optional LED indicators on the acces
54. to keep the equipment clean dry and within the temperature and humidity limits stated above e It may be necessary to cover the equipment and install temporary heating units Section 4 Receiving Handling and Storage Page 12 of 52 Pusselectric O amp M Manual 90E1720004 e Place the equipment on level surfaces for storage to maintain structural integrity 5 In areas of high humidity such as installations near oceans or rivers monitor the transfer switch closely e If necessary use additional heat to keep the equipment dry e Contact Russelectric Services at 1 800 654 3020 if the internal heaters are not adequate for your location 6 If optional internal heaters are supplied with the bypass isolation transfer switch connect them to an external power source Energize the heaters inside the transfer switch or add heat from a separate source such as a light bulb or blower Use a minimum of 250 watts of heat per switch to keep the equipment dry during storage Section 4 Receiving Handling and Storage Page 13 of 52 Pusselectric O amp M Manual 90E1720004 Section 5 Installation Before installing Russelectric bypass isolation transfer switches read and understand 1 All precautions in this manual 2 All manuals for associated components 3 All drawings and diagrams included with the equipment Installing the Bypass lsolation Transfer Switch When correctly installed the 1 Enclosure is straight level and perpendic
55. trol E 28Jan09 14 36 A aa Pushbuttons u ay a Various System Tests Control Mode Screens eInformation Screens Type Configuratior Name ATS Trans Type Delayed Type Std Open Trans Mode Auto Amps 1004 ByupRefrimr Disabled Volts 120 BTR Disabled Job ATS Load Shed Disabled Mod ATS Exerciser None 1 Utility Commit Disabled 52 Generator TestMode Not Active Front Port USB 2 0 Type Mini B for serial communication with Laptop to download Ne e e n control functions TC RPTCS Figure 27 Graphical Control Panel Overview Section 8 Operation Page 37 of 52 Pusselectric O amp M Manual 90E1720004 Summary of Function Key Operations Summary of Function Key Operations DOWN key UP key HOME key ESCAPE key Scroll down Scroll up Single press Single press closes pop up page select page select recalls the home cancels editing deselects field field tab to field tab to page double moves to previous page previous field next field press recalls the sustained press logs out cancels decrement increment default page security passcode entry value value t a A 4 pp ENTER key ns Single press freezes TOACTIVE Load Connected to 1 SOE sae i field edits selected field Type Configuration saves edited value Name ATS Trans Type Delayed double press sets the Type Std Open Trans Mode Auto selected field page as Amps 1004 BypRufrtmr Disabled default sustained press Volts 120 BTR Disabled logs in e
56. ue wrapping the cables every 11 inches until the cables exit the switch Figure 10 Loop end A under cables If cable supports are provided optional wrap cable supports Figure 11 Tie the rope ends together Figure12 until they are taut Cut off excess rope and tape ends to prevent fraying Figure 9 Finish Wrapping the Space between Cables Recheck torques of wire binding screws after securing the conductors 3 m Support channel shown Figure 11 Securing Cables to Supports optional Section 5 Installation Page 19 of 52 Section 5 Installation O amp M Manual 90E1720004 Figure 12 Tying the Rope Ends Together Page 20 of 52 RPusselectric O amp M Manual 90E1720004 Connect the Controls and Wiring 1 Locate the customer control terminal block TB5 Figure 13 located behind the upper door Caen Ea AEREE BRIE TBS Terminal Block Fits CH H Pepa i MH om a END STOF f o 1 Jo o o e Est RPTCS sF solz Ho olaet ese Rees SRT to ol 3 E Jo o o ot Esc RPTes opriona Fe Ol 4 F_3 0 O 0 ef DOP PSNC SIGNAL O o 5 J0 0 amp DCN PSWC ACC XC1 T eoj 6 f oo epf i S 0 7 p J0 0 0 ef LR LR ACC CS1P ro O 8a B30 0 0 Al A1 7 0 9 p J0 0 0 OA A1 8 ACC CS2P oO 10 30 o o e4 A1 9 O 11 J0 O O OAs A110 ACC CSIP 4 re O12 Pb 30 o 0 01 A1 11 e ojis jo o o G 02 A1 12 ACC CS2P 0 14 J0 o D3 A2 10 ojis
57. ular to the mounting surface 2 The switch is fastened securely to the floor or wall 3 The shipping sections are bolted together securely if applicable 4 Cable and control wiring connections are connected properly Preparing the Site Before positioning the equipment check these items to ensure that the site is ready for final installation 1 Compare the site plans and specifications with the equipment drawings to be sure no discrepancies exist 2 Check the site to confirm switch will fit properly 3 Provide area ventilation at all times to maintain the ambient temperature around the equipment between 50 F 10 C and 104 F 40 C 4 Provide adequate permanent lighting and convenience outlets near the equipment Route sewer water and steam lines away from the equipment Provide floor drains near the equipment 7 When installing the equipment consider the aisle space required at the front and rear of the equipment as well as either side a NOTE Required minimum clearances around the transfer switch are given in Article 110 26 of the National Electrical Code NEC These clearances are only a minimum Additional space may be required for maintenance or removal of components Preparing the Foundation 1 Special consideration must be taken when preparing the foundation Follow all applicable local and international building codes 2 Confirm that the floor or foundation is strong enough to support the equipme
58. ustomer use The bypass section of the switch includes a bypass handle isolating handle and an accessory panel that includes the RPTCS interface panel bypass status lights and optional accessories Isolating Handle RPTCS Interface Panel Bypass Handle Bypass to S2 Position Bypass to S1 Bypass Switch Position Status Indicators Optional Transfer Switch Status Indicators ATS Isolated Poemon Solenoid Optional Accessories Interlock Pushbutton Accessory Panel Figure 14 Bypass Switch and Accessory Panel Transfer Switch Cradle Rollout Cradle Rollout The transfer switch is either cradle mounted 100 800A or rollout 1000 3000A and provides two sets of fully rated contacts for transferring the load between source 1 and source 2 One or two unidirectional motors or solenoids are used to operate the contacts There are also auxiliary contacts for the control system and customer use Fully rated finger clusters are provided to disconnect the switch from the power circuit Section 8 Operation Page 28 of 52 Puaselectric O amp M Manual 90E1720004 O o Source 1 5 Peka Motor Ob 4 Finger oo fo Clusters Ol 6 f a O Oo Load ral ip k is oO pD sy
59. ze of the lineup and the handling facilities at the installation site Bypass isolation transfer switches are mounted on wooden skids and enclosed in a covering to protect them from atmospheric conditions Receiving Upon receipt check the packing list against the equipment received to ensure the order and shipment are complete Also upon receipt immediately inspect the bypass isolation transfer switch for any damage that may have occurred in transit If damage is found or suspected file a claim with the carrier immediately and notify Russelectric Field Services at 1 800 654 3020 Handling Ensure that proper equipment such as an overhead crane is available at the installation site to handle the switch This equipment will help avoid injury to personnel and damage to the switch For ease of handling by a crane all free standing switches are equipped with eye bolts or lifting angles at the top of each switch The lifting angle if provided has multiple 2 inch diameter holes for acceptance of crane hooks as shown in Figure 2 on page 10 Use a suitable spreader beam to maintain the integrity of the lifting straps Variations in the center of gravity may cause the equipment to tilt to one side or the other Handling with Eyebolts Russelectric provides eyebolts as standard equipment for freestanding enclosures Use rigid spreaders or a spanner bar to provide vertical lift on the eyebolts This will help to avoid damaging the frame or finis

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