Remote Power Racking System (RPR-2)

Instruction Book IB182071EN Supercedes IB02707071E Effective Remote Power Racking System RPR-2 Low Profile Shown

Instruction Book IB182071EN Remote Power Racking System DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY The information, recommendations, descriptions and safety notations in this document are based on Eaton s experience and judgment and may not cover all contingencies. If further information is required, an Eaton sales office should be consulted. Sale of the product shown in this literature is subject to the terms and conditions outlined in appropriate Eaton selling policies or other contractual agreement between Eaton and the purchaser. THERE ARE NO UNDERSTANDINGS, AGREEMENTS, WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES. In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or other-wise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information, recommendations and descriptions contained herein. The information contained in this manual is subject to change without notice. IMPROPERLY INSTALLING OR MAINTAINING THESE PRODUCTS CAN RESULT IN DEATH, SERIOUS PERSONAL INJURY OR PROPERTY DAMAGE. READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE ATTEMPTING ANY UNPACKING, ASSEMBLY, OPERATION OR MAINTENANCE OF THE CIRCUIT BREAKERS. This product was manufactured by Eaton at the Power Breaker Center (PBC): 310 Maxwell Avenue, Greenwood, SC 29646. All possible contingencies which may arise during installation, operation or maintenance, and all details and variations of this equipment do not purport to be covered by these instructions. If further information is desired by purchaser regarding his particular installation, operation or maintenance of particular equipment, contact a Eaton representative. INSTALLATION OR MAINTENANCE SHOULD BE ATTEMPTED ONLY BY QUALIFIED PERSONNEL. THIS INSTRUCTION BOOK SHOULD NOT BE CONSIDERED ALL INCLUSIVE REGARDING INSTALLATION OR MAINTENANCE PROCEDURES. IF FURTHER INFORMATION IS REQUIRED, YOU SHOULD CONSULT EATON S ELECTRICAL SERVICES & SYSTEMS. THE CIRCUIT BREAKERS DESCRIBED IN THIS BOOK ARE DESIGNED AND TESTED TO OPERATE WITHIN THEIR NAMEPLATE RATINGS. OPERATION OUTSIDE OF THESE RATINGS MAY CAUSE THE EQUIPMENT TO FAIL, RESULTING IN DEATH, BODILY INJURY AND PROPERTY DAMAGE. ALL SAFETY CODES, SAFETY STANDARDS AND/OR REGULATIONS AS THEY MAY BE APPLIED TO THIS TYPE OF EQUIPMENT MUST BE STRICTLY ADHERED TO. THESE VACUUM REPLACEMENT CIRCUIT BREAKERS ARE DESIGNED TO BE INSTALLED PURSUANT TO THE AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI). SERIOUS INJURY, INCLUDING DEATH, CAN RESULT FROM FAILURE TO FOLLOW THE PROCEDURES OUTLINED IN THIS MANUAL. ii

Remote Power Racking System Instruction Book IB182071EN Table of Contents SECTION 1: INTRODUCTION 4 1.1 VISUAL PRESENTATION 4 1.2 QUICK RESPONSE CODE 4 SECTION 2: SAFE PRACTICES 6 SECTION 3: RECEIVING, HANDLING, AND STORAGE 7 3.1 RECEIVING 7 3.2 HANDLING 7 3.3 STORAGE 7 3.4 RPR-2 APPROXIMATE WEIGHTS 7 SECTION 4: RACKING PROCEDURES 10 4.1 INSERTING POWER CIRCUIT BREAKERS 10 4.2 REMOVING POWER CIRCUIT BREAKERS 12 APPENDIX A: ITE-HK AIR CIRCUIT BREAKER 17 A.1 INSERTION PROCEDURE USING THE RPR-2 17 A.2 REMOVAL PROCEDURE USING THE RPR-2 18 APPENDIX B: GE AM-5 CIRCUIT BREAKER 19 B.1 INSERTION PROCEDURE USING THE RPR-2 19 B.2 REMOVAL PROCEDURE USING THE RPR-2 20 APPENDIX C: GE MAGNEBLAST VERTICAL LIFT 21 C.1 INSERTION PROCEDURE USING THE RPR-2 21 C.2 REMOVAL PROCEDURE USING THE RPR-2 23 APPENDIX D: WESTINGHOUSE DH AIR CIRCUIT BREAKERS 24 D.1 INSERTION PROCEDURE USING THE RPR-2 24 D.2 REMOVAL PROCEDURE USING THE RPR-2 25 SECTION 5: WARRANTY 13 5.1 GENERAL 13 5.2 PROCEDURE FOR POWER MODULE REMOVAL 13 5.3 REMOVING UPS MODULE FROM RPR-2 DEVICE 14 5.4 REPLACEMENT OF THE UPS MODULE BATTERIES 15 SECTION 6: REPLACEMENT PARTS 16 6.1 GENERAL 16 6.2 ORDERING INSTRUCTIONS 16 iii

Instruction Book IB182071EN SECTION 1: INTRODUCTION Eaton s RPR-2 provides a means of remotely racking most Power Circuit Breakers that utilize the rotation of a shaft for insertion and removal. The person can be 25 feet or more away from the switchgear door during the racking process. This need for distance away from the switchgear is due to safety precautions from potential Arc Flash occurrences. Electric arcs result from thermal ionization that occurs when current flow is interrupted by the separation of conductors. Thermal ionization can generate temperatures as high as 35,000 o F. Conductor materials melt into metal vapor and the surrounding air is ionized. If the arc is outside the interrupting chamber of a power circuit breaker, then a violent explosion occurs resulting in an inferno of ionized gases, molten debris, metal shrapnel, and a flash of light (Arc Flash). When Arc Flash initiates in a switchgear cabinet, the rapidly escalating pressure will dislodge compartment doors and side sheets of the switchgear and turn hardware into high-speed projectiles. Arc Flash levels are a function of circuit voltage, maximum available short circuit current at the point of flashover, conditions of confinement, and the distance between the point of flashover and the point of measurement. Many Arc Flash incidences with Low Voltage and Medium Voltage switchgear occur during the process of inserting and removing (racking) Power Circuit Breakers in switchgear cubicles. Personnel are typically within two feet of the front of the power circuit breaker during the racking process and this close proximity to an Arc Flash can cause serious injury. Published records indicate over 2000 people are treated annually in burn centers from exposure to Arc Flash and some result in death. A company s financial exposure is rarely less than $100,000 for medical care and insurance claims per incident. NFPA 70E provides guidance for the requirements of personal protective equipment (PPE) to protect personnel from arc flash exposure. PPE for high levels of Arc Flash can be bulky, hot, and uncomfortable. This may dissuade personnel from wearing proper protection. The best way to limit exposure to Arc Flash during the process of racking power circuit breakers is to put more distance between the person and the possible point of exposure. Eaton s RPR-2 can allow personnel to wear a lower level of PPE, increasing worker comfort and mobility, while operating the RPR-2 from an increased distance from the power circuit breaker. Since personnel can be outside the Arc Flash protection boundary while operating the RPR-2, the power circuit breaker door does not have to be closed during the racking process. Closed door racking is possible with many designs, however structure modifications may be necessary. Customer surveys have shown that any remote racking device must: Be easily and quickly set up Does not require programming Be portable and easy to maneuver Be capable of racking numerous manufacturers models of power circuit breakers The RPR-2 system is the solution that provides the value and features customers request. The RPR-2 unit comes pre-programmed for up to eight different power circuit breakers. The programs are pre-selected by the customer to meet their requirements, and the unit is programmed per these requirements at the Power Breaker Center. No additional programming is necessary; simply select the applicable program for the power circuit breaker. 1.1 VISUAL PRESENTATION Remote Power Racking System Eaton provides additional documentation designed to enhance the technical information provided in this instruction booklet for the RPR-2. The digital supplemental booklet features informative videos intended to assist with the RPR-2. The document is available for immediate access at /RPR-2. 1.2 QUICK RESPONSE CODE There is a quick response code (QR Code) on the escutcheon of the head unit and UPS sleeve of the RPR-2. This QR Code is a matrix barcode that provides direct access to download RPR-2 specific documentation, such as product instruction booklets and a visual presentation documentation. See Figure 1.1 for the featured RPR-2 QR Code. A smart phone with an adequate QR Code Scanner application must be used. Downloading content may incur data charges from the mobile service provider. Figure 1.1. Quick Response Code RPR-2 QR Code 4

Remote Power Racking System Instruction Book IB182071EN A B G C E D F Table 1. RPR-2 and RPR-2 Plus Dimensions Profile Type Overall Height Stanchion Height Max. Racking Height Min. Racking Height Width Depth A B C D E F G RPR-2 Universal Profile 100 98 81 4.875 28 29 36 RPR-2 Medium Profile 88 86 68 4.875 28 29 36 RPR-2 Low Profile 68 66 48 4.875 28 29 36 360 o Rotational Clearance 5

Instruction Book IB182071EN Remote Power Racking System SECTION 2: SAFE PRACTICES Eaton s RPR-2 assists in the insertion and removal of power circuit breakers. Although proper use of the RPR-2 reduces the probability of injury by increasing the distance of the qualified operating personnel from the arc flash boundary, must follow local safe practices and the requirements of personal protective equipment (PPE) to protect personnel from arc flash exposure as determined by NFPA 70E. TO PROTECT THE PERSONNEL ASSOCIATED WITH INSTALLATION, OPERATION, AND MAINTENANCE OF POWER CIRCUIT BREAKERS, THE FOLLOWING PRACTICES MUST BE FOLLOWED: Only qualified persons, as defined in the National Electrical Safety Code, who are familiar with the installation and maintenance of power circuit breakers and equipment, should be permitted to insert or remove power circuit breakers. Read these instructions carefully before attempting any installation, operation or maintenance of power circuit breakers. Refer to the OEM power circuit breaker instruction manual for proper installation and operation procedures of each power circuit breaker the RPR-2 is intended to rack. Power circuit breakers are equipped with safety interlocks. Do not defeat them. This may result in death, bodily injury or equipment damage. Do not leave the breaker in an intermediate position in the cell. Always have the breaker either in the Test or Connected position. Failure to do so could result in a flash over and possible death, personnel injury or property damage. Always remove the RPR-2 device from the breaker before attempting to charge, close or operate the breaker. 6

Remote Power Racking System Instruction Book IB182071EN SECTION 3: RECEIVING, HANDLING, AND STORAGE Remote Power Racking units are subjected to complete factory production tests and inspection before being packed. They are shipped in containers designed to provide maximum protection to the equipment during shipment and storage and at the same time to provide convenient handling. 3.1 RECEIVING Until the RPR-2 unit is ready to be delivered to the switchgear site for usage, DO NOT remove it from the shipping container. If the RPR-2 unit is to be placed in storage, maximum protection can be obtained by keeping it in its container. A 120V power supply will be needed for the UPS at this time. shelter from sun, rain, snow, corrosive fumes, dust, dirt falling objects, excessive moisture, etc. must be provided. If the building is not heated, containers should be arranged to permit free circulation of air on all sides and temporary heaters should be used to minimize condensation. Moisture can cause rusting of metal parts. A heat level of approximately 400 watts for each 100 cubic feet of volume is recommended with the heaters distributed uniformly throughout the structure near the floor. Figure 3.2. RPR-2 Transport Latch Upon receipt of the equipment, inspect the containers for any signs of damage or rough handling. Open the containers carefully to avoid any damage to the contents. Use a nail puller rather than a crow bar when required. When opening the containers, be careful that any loose items or hardware are not discarded with the packing material. Check the contents of each package against the packing list. Examine the RPR-2 unit for any signs of shipping damage such as broken, missing or loose hardware, damaged or deformed components. File claims immediately with the carrier if damage or loss is detected and notify the nearest Eaton s Electrical Service and Systems Office. After examining the unit place the RPR-2 in a location which has a 120V power supply for the UPS. Figure 3.3. RPR-2 Storage Cover Figure 3.1. Typical Tools and Accessories 3.2 HANDLING The RPR-2 unit shipping containers are designed to be handled by a fork lift truck. If containers must be skidded for any distance, it is preferable to use roller conveyors or individual pipe rollers. When the RPR-2 unit is ready for use, it can be rolled upright with the casters or tilted back and rolled on the larger wheels. 3.3 STORAGE If the RPR-2 unit is to be placed in storage, maximum protection can be obtained by keeping it shielded with the provided cover (Figure 3.3). Before placing it in storage, checks should be made to make sure that the RPR-2 unit is free from shipping damage and is in satisfactory operating condition. The RPR-2 unit is shipped with the Transport Latch engaged (Figure 3.2). The RPR-2 unit requires a 120V power supply for the UPS during storage and must remain plugged in during this time. Outdoor storage is NOT recommended. Indoor storage should be in a building with sufficient heat and circulation to prevent condensation. The building must be well drained and a temporary 3.4 RPR-2 APPROXIMATE WEIGHTS Refer to Table 2. Table 2. RPR-2 Weight by Type Type LBs RPR-2 Universal Profile 315 RPR-2 Medium Profile 310 RPR-2 Low Profile 300 7

Instruction Book IB182071EN Remote Power Racking System Figure 3.5. Profile External View of RPR-2 1 9 2 3 5 6 10 4 7 8 Profile External View of RPR-2 (Univeral Profile Shown) 1 Stanchion 5 UPS Power Cable 9 Counterweight Cable 2 Status Light Tower 6 Jog Button 10 Power Module Cable 3 Control Pendant 7 Mechanical Over-Torque Protector 4 Storage Compartment 8 Insertion Shaft 8

Remote Power Racking System Instruction Book IB182071EN Figure 3.6. Detail View of RPR-2 Head Unit 1 5 2 6 3 7 8 4 Front External View 1 Transport Latch 4 Insertion Shaft Lock 7 Nameplate 2 Computer Access Port 5 Power Switch 8 Foot Brake 3 Power Cable 6 Pendant Connection Port 5 1 6 2 3 4 Rear External View 1 Control Pendant Cable Standoff 3 Insertion Shaft 5 UPS Display 2 Jog Button 4 Mechanical Over-Torque Protector 6 UPS Power Button (ON/OFF) 9

Instruction Book IB182071EN SECTION 4: RACKING PROCEDURES REFER TO THE APPENDIX FOR ADDITIONAL BREAKER SPECIFIC RACKING PROCEDURES. 4.1 INSERTING POWER CIRCUIT BREAKERS 1) Follow all procedures defined by company s Personal Protective Equipment and Safety policy. Follow all precautions and requirements listed in the circuit breaker IB for racking the breaker. 2) Move the RPR-2 unit in front of the switchgear cell. Open the cell door to allow for access to the rotary type racking mechanism of the breaker. If the cell has closed door racking capability, insert the racking adaptor through the provided opening with the cell door closed. 3) Verify that the power circuit breaker is open and ready to be racked in from the correct position. The position depends on what type of power circuit breaker is being inserted. This position is determined by the ability to rack in the given power circuit breaker from the position that it can be racked completely into the Connected position without needing any adjustments (foot pedal pressed etc.). In most cases this is the Test position in the cell. This can be confirmed by referring to the breaker s Instruction Book. Figure 4.1. RPR-2 Control Panel Fusion Controller Breaker Select Button Insert / Remove Switch Figure 4.3. RPR-2 Control Pendant Status Indicator Light Remote Power Racking System 6) Turn on the power to the Power Module with the Power Switch. (Figure 3.6) 7) The choice of the perf-a-torque will be dependent on the breaker that is being racked. The PT-50 will be used on all medium voltage circuit breakers and the PT-30 will be used on all the low voltage circuit breakers. For changing the perf-a-torque: A 1/8 allen wrench is required to loosen the setscrew. Once the attached perf-a-torque has been removed, replace with the desired perf-a-torque model as indicated above. Using the 1/8 allen wrench, secure the perf-a-torque to the racking shaft. Setscrew Tightness: Insert Button Remove Button After the RPR-2 has been used to rack several breakers, check that the perf-a-torque is tight on the racking shaft. Tighten as needed. Figure 4.4. Perf-A-Torque Models Figure 4.2. Height Adjustment of Power Module 4) If engaged, release the Transport Latch to allow for vertical movement of the Power Module. (Figure 3.3) 5) Turn on the Powerware UPS for the RPR-2 by pressing the On button for approximately five seconds and allow for the unit to initialize. (Figure 4.5) For all other menu settings and features, please refer to the UPS instruction CD. 8) Select the correct breaker program on the Power Module by pressing and releasing the Breaker Select Button until the desired program is displayed on the Fusion Controller. (Figure 4.1) 9) Select the INSERT direction with the Insert/Remove switch. (Figure 4.1) 10

Remote Power Racking System Instruction Book IB182071EN Figure 4.5. UPS Power Button Figure 4.6. Foot Brake Set 9) Select the correct racking adaptor for the breaker being inserted. (Figure 3.1) If applicable, place the racking adaptor on the breaker s racking mechanism shaft. Position the RPR-2 shaft with the racking adaptor. Turn the Insertion Shaft Lock to Unlatched position to allow for connection the RPR-2 into the racking adaptor on the power circuit breaker. (Figure 3.6) If necessary, the Jog button (Figure 3.6) can be pressed to rotate the shaft for correct alignment (amber pendant and tower light will illuminate). Horizontal alignment can be achieved with the casters and vertical alignment by raising or lowering the Power Module. (Figure 4.2) 10) Once the RPR-2 is connected, properly adjust the unit toward the cell to insure the proper amount of travel is available for the power circuit breaker insertion process. When an adequate amount of travel distance is achieved, the green tower light will illuminate. 11) Engage the foot brake on the RPR-2 truck by stepping down on the lever. (Figure 4.6) Verify that the correct power circuit breaker program and the Insert direction are selected by viewing the LCD screen on the Fusion Controller (Figure 4.1). SELECTION OF THE INCORRECT POWER CIRCUIT BREAKER PROGRAM MAY RESULT IN THE RPR-2 UNIT SIGNALING COMPLETION OF THE INSERTION CYCLE WITH THE POWER CIRCUIT BREAKER ONLY PARTIALLY INSERTED. 12) Take the Pendant and move a safe distance away from front of the power circuit breaker. (The distance should be predetermined through Arc Flash calculations.) 13) When area is clear, depress and hold the Insert button (white with black arrow) on the pendant. (Figure 4.3) This will initiate the insertion process on the RPR-2 unit. The amber light on the pendant and on the tower light will illuminate while the power circuit breaker is in the insertion process. If at any time during the insertion process the Insert button is released, the tower lights and pendant light will not be illuminated. 14) When the power circuit breaker is in the Connected position, the red tower light will illuminate and the amber light on the pendant will turn off. This indicates that it is now safe to approach the power circuit breaker. Figure 4.7. Racking Adapter Connected To Breaker IF AT ANY TIME DURING THE INSERTION PROCESS AN OVER-TORQUE OCCURS THE AMBER LIGHT ON THE PENDANT AND TOWER WILL FLASH. (THE AUTO REVERSE SELECTION IS NOTED ON THE NAMEPLATE OF THE RPR-2 UNIT.) IF THE AUTO-REVERSE FUNCTION IS SELECTED IN THIS SITUATION THE RPR-2 WILL THEN INITIALIZE THE REMOVAL PROCESS. ONCE THIS PROCESS IS COMPLETED THE GREEN AND AMBER LIGHTS ON THE LIGHT TOWER WILL FLASH AND THE AMBER LIGHT ON THE PENDANT WILL TURN OFF INDICATING IT IS SAFE TO APPROACH THE POWER CIRCUIT BREAKER. IF THE AUTO-REVERSE FUNCTION IS NOT SELECTED, PRESS AND HOLD THE REMOVE BUTTON (BLACK WITH WHITE ARROW) ON THE PENDANT. WHEN THE POWER CIRCUIT BREAKER IS COMPLETELY REMOVED, THE AMBER LIGHT ON THE PENDANT WILL TURN OFF AND THE GREEN AND AMBER TOWER LIGHTS WILL FLASH INDICATING IT IS SAFE TO APPROACH THE POWER CIRCUIT BREAKER. 15) To disconnect the RPR-2 unit, push the unit toward the switchgear cell to disengage the brakes. Lift the brake lever up to engage the holding magnet. 11

Instruction Book IB182071EN 16) Turn the Insertion Shaft Lock to the Latched position. Push the unit forward until the insertion shaft latches. 17) Pull the unit away from the switchgear, while disconnecting the insertion shaft from the racking adaptor. 18) Remove the racking adaptor from the breaker and place it back into the storage box on the RPR-2 unit. 19) Turn Off the Power Module with the Power Switch. To turn off the UPS, press and hold the Off button for approximately five seconds. 20) Lower the Power module to the lowest position and engage the Transport Latch. (Figure 3.3) The pendant can be stored by wrapping the cord around the post at the base of the RPR-2 unit. (Figure 3.5) Place the RPR-2 unit cover over the base while in storage. (Figure 3.4) 21) The UPS should be connected to a wall receptacle when not in use to maintain a charge on the batteries. 4.2 REMOVING POWER CIRCUIT BREAKERS 1) Follow all procedures defined by company s Personal Protective Equipment and Safety policy and the precautions and racking instructions in the breaker IB. 2) Move the RPR-2 unit in front of the switchgear cell. Open the cell door to allow for access to the rotary type racking mechanism of the breaker. If the cell has closed door racking capability, insert the racking adaptor through the provided opening with the cell door closed. 3) Verify that the power circuit breaker is open and ready to be racked out from the Connected position. 4) If engaged, release Transport Latch to allow for vertical movement of the Power Module. (Figure 3.6) 5) Turn on the Powerware UPS for the RPR-2 by pressing the On button for approximately five seconds and allow for the unit to initialize. (Figure 4.5) For all other menu settings and features, please refer to the UPS instruction CD. 6) Turn on the power to the Power Module with the Power Switch. (Figure 3.6) 7) Select the correct breaker program on the Power Module by pressing and releasing the Breaker Select Button until the desired program is displayed on the Fusion Controller. (Figure 4.1) Before attempting to rack the circuit breaker, ensure the nameplate matches the predetermined circuit breaker program on the Eaton display of the Fusion Controller. 8) Select the REMOVE direction on the Insert/Remove switch. (Figure 4.1) 9) Select the correct racking adaptor for the breaker being inserted. (Figure 3.1) If applicable, place the racking adaptor on the breaker s racking mechanism shaft. Position the RPR-2 shaft with the racking adaptor. Turn the Insertion Shaft Lock to Unlatched position to allow for connection the RPR-2 into the racking adaptor on the power circuit breaker. (Figure 3.6) If necessary, the Jog button (Figure 3.6) can be pressed to rotate the shaft for correct alignment (amber pendant and tower light will illuminate). Horizontal alignment can be achieved with the casters and vertical alignment by raising or lowering the Power Module. (Figure 4.2) 10) Once the RPR-2 is connected, properly adjust the unit away from the cell to insure the proper amount of travel is available for the power circuit breaker insertion process. When an adequate amount of travel distance is achieved, the red tower light will illuminate. 11) Engage the foot brake on the RPR-2 truck. Verify that the correct power circuit breaker program and the Remove direction are selected by viewing the LCD screen on the Fusion Controller (Figure 4.1). Remote Power Racking System SELECTION OF THE INCORRECT POWER CIRCUIT BREAKER PROGRAM MAY RESULT IN THE RPR-2 UNIT SIGNALING COMPLETION OF THE REMOVAL CYCLE WITH THE POWER CIRCUIT BREAKER ONLY PARTIALLY REMOVED. 12) Take the Pendant and move a safe distance away from front of the power circuit breaker. (The distance should be predetermined through Arc Flash calculations.) IF AT ANY TIME DURING THE REMOVAL PROCESS AN OVER-TORQUE OCCURS THE AMBER LIGHT ON THE PENDANT AND TOWER WILL FLASH. THE UNIT WILL NOT REMOVE THE BREAKER FURTHER UNTIL THE PROBLEM IS RESOLVED. FOLLOW THE COMPANY S SAFETY PROCEDURES WHEN APPROACHING THE SWITCHGEAR CELL. 13) When area is clear, depress and hold the Remove button (black with white arrow) on the pendant. (Figure 4.3) This will initiate the removal process on the RPR-2 unit. The amber light on the pendant and on the tower light will illuminate while the power circuit breaker is in the removal process. If at any time during the removal process the Remove button is released, the tower lights and pendant light will not be illuminated. 14) When the power circuit breaker is in the Disconnected position, the green tower light will illuminate and the amber light on the pendant will turn off. This indicates that it is now safe to approach the power circuit breaker. 15) To disconnect the RPR-2 unit, push the unit toward the switchgear cell to disengage the brakes. Lift the brake lever up to engage the holding magnet. 16) Turn the Insertion Shaft Lock to the Latched position. Push the unit towards the breaker until the insertion shaft latches. 17) Pull the unit away from the switchgear, while disconnecting the insertion shaft from the racking adaptor. 18) Remove the racking adaptor from the breaker and place it back into the storage box on the RPR-2 unit. 19) Turn Off the Power Module with the Power Switch. To turn off the UPS, press and hold the Off button for approximately five seconds. 20) Lower the Power module to the lowest position and engage the Transport Latch. (Figure 3.3) The pendant can be stored by wrapping the cord around the post at the base of the RPR-2 unit. (Figure 3.5) Place the RPR-2 unit cover over the base while in storage. (Figure 3.4) 21) The UPS should be connected to a wall receptacle when not in use to maintain a charge on the batteries. 12

Remote Power Racking System Instruction Book IB182071EN SECTION 5: WARRANTY 5.1 GENERAL All Standard Remote Power Racking Systems are furnished with a Powerware UPS system and are covered by the warranty stated in Eaton s Electrical Services and Systems Selling Policy 25-000, except the warranty is extended for a total of three (3) years from the date of shipment. The Warranty expiration date is printed on the nameplate mounted on the Power Module (Figure 3.6). If the unit does not function as described in this instruction book, do not attempt any repair. Attempts to repair the unit will void the warranty. DO NOT ATTEMPT TO INSERT OR REMOVE ANY POWER CIRCUIT BREAKER WITH A REMOTE POWER RACKING SYSTEM THAT IS NOT FUNCTIONING PROPERLY. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN DEATH, SERIOUS PERSONAL INJURY OR PROPERTY DAMAGE. 6) With one person holding each side of the Power Module, slide it off the end of the stanchion. Figure 5.1. RPR-2 In Power Module Removal Position (Unit Supported By Standard Post For Demonstration Purposes) Figure 5.2. Removing Cable Retaining Hex Socket Button Head From Power Module PLUGGING THE POWER SUPPLY CABLE OF THE POWER MODULE DIRECTLY INTO A WALL OUTLET VOIDS THE WARRANTY. THE POWER MODULE MUST BE PLUGGED INTO THE UPS SYSTEM ONLY. THE COUNTERWEIGHT CABLE IS MANUFACTURED WITH AN INFUSED LUBRICANT THAT MAY MIGRATE OUT AND DRIP DOWN ON THE BASE. THIS SHOULD SIMPLY BE WIPED UP. Contact the Power Breaker Center (PBC) immediately by calling toll free (877) 276-9379. Normal business hours are 7:30 AM until 4:30 PM, Monday through Friday, except for holidays. If the call is placed after or before normal business hours, you may leave a voice message. A Power Breaker Center representative will return your call within 24 hours (48 hours on holidays and weekends), determine the cause of the problem, and advise if any replacement components or modules are required to restore the Remote Power Racking System to normal operation. If it is necessary to replace the Power Module, UPS system, or other components, the representative will initiate an express air shipment that typically arrives within 48 hours after the PBC representative contacts the customer. The representative will also convey any special instructions, if required, for return of the defective unit. The UPS unit must remain plugged in when not in use. Upon receipt of the replacement equipment, inspect the container for any signs of damage or rough handling. Open the container and save all hardware and packing material. These materials as well as the shipping container will be used to repack and return the defective equipment to the PBC. A set of shipping instructions and a shipping label will be in the container. Be careful not to discard these items. There is no charge for the return shipment if packed in the original shipping container. Figure 5.3. Bottom View of Power Module 5.2 PROCEDURE FOR POWER MODULE REMOVAL This procedure requires assistance. 1) Lay the RPR-2 over on a brace approximately half way up the stanchion. Make sure the Power Module is located closest to the top end of the stanchion for removal. 2) Move the Power Module up the stanchion until the counterweight hits the bottom allowing for some slack in the connection cable. 3) Using a 7/32 Allen wrench, remove the cable retaining hex socket button head from the bottom of the Power Module, retain lock washer. 4) With some slack on the cable, slide the end of the connecting cable out of the slot in the bottom of the Power Module. 5) Tape the cable end to the stanchion to keep the cable in line with the openings. 13

Instruction Book IB182071EN Remote Power Racking System 5.3 REMOVING UPS MODULE FROM RPR-2 DEVICE In certain cases where the UPS needs to be replaced due to a warranty repair, the UPS will need to be removed. 1. Locate the UPS module on the lower base of the RPR-2. 2. Remove the UPS retaining bracket hardware (x4), and store the UPS retaining bracket for reassembly. (Figure 5.4) 3. Disconnect the 120V power supply from the UPS Module (Figure 5.5) and carefully slide the UPS module forward to remove it from the UPS sleeve. (Figure 5.6) Figure 5.4. Removing UPS Retaining Bracket (x4) 5.4 REPLACEMENT OF THE UPS MODULE BATTERIES Once the UPS module has been removed from the RPR-2 device, the UPS module batteries can be replaced. All three batteries should be replaced at the same time. 1. Remove the front cover of the UPS module by pulling the left two corners away from the unit. (Figure 5.7) 2. Disconnect the battery by pulling apart the battery terminals. (Figure 5.8) Figure 5.7. Removing UPS Module Front Cover Figure 5.5. Disconnecting 120V Power Supply From UPS Module Figure 5.8. Unpluging UPS Module Figure 5.6. Removing UPS Module From RPR-2 Device Figure 5.9. Removing UPS Battery Cover Plate Hardware (x1) 14

Remote Power Racking System Instruction Book IB182071EN 3. With the battery disconnected, the internal battery cover plate may be removed. Remove the battery cover plate retaining hardware (x1) (Figure 5.9) and slide the battery cover plate in an upward and outward direction. (Figure 5.10) 4. Remove the UPS module battery pack from the UPS module. (Figure 5.11) 5. To ensure replacement is correct, replace each battery one at a time. The wiring connections will remain the same. Each wire connection is marked for clarity. (Figure 5.12) Figure 5.10. Removing UPS Battery Cover 6. Once the batteries have been replaced, the battery pack plastic tray should be re-taped to secure a tight fit when returning it to the UPS module. 7. Slide the battery pack back into the UPS module and replace the internal battery cover plate using the existing cover plate hardware. 8. Reconnect the main battery terminals and replace the UPS module front cover. 9. Reconnect thew 120V power supply to the UPS module. 10. The RPR-2 head unit can now be reconnected. 11. Contact your local recycling or hazardous waste center for the information on proper disposal of the used batteries. DO NOT DISPOSE OF BATTERY OR BATTERIES IN A FIRE. EXPLOSION MAY OCCUR. PROPER DISPOSAL OF BATTERIES IS REQUIRED. REFER TO YOUR LOCAL CODES FOR DISPOSAL REQUIREMENTS. DO NOT ATTEMPT TO OPEN OR DESTROY THE BATTERY. TOXIC AND HARMFUL MATERIAL CAN DAMAGE THE SKIN AND EYES. Figure 5.11. Removing UPS Battery Pack DO NOT DISCARD THE UPS OR THE UPS BATTERIES IN THE STANDARD TRASH. THIS PRODUCT CONTAINS SEALED, LEAD-ACID BATTERIES AND MUST BE DISPOSED OF PROPERLY. FOR ANY QUESTIONS PLEASE CONTACT YOUR LOCAL RECYCLING OR HAZARDOUS WASTE CENTER. 5.5 REMOVING/REPLACING THE UPS MODULE SLEEVE In certain cases the UPS module sleeve may need to be replaced due to damage and/or upgrading from previous RPR-2 UPS revision. Follow the steps listed in section 5.3 to remove the UPS module from the sleeve. 1. Remove the ¼-20 nuts (x4) that hold the sleeve to the RPR-2 base (Figure 5.13) When upgrading from the previous RPR-2 UPS revision, discard the entire UPS assembly and replace it with the new UPS sleeve and module. 2. To replace/install the UPS sleeve, align the ¼-20 bolts (x4) to the existing holes on the RPR-2 base. 3. Securely fasten the sleeve to the base using ¼-20 nuts (x4) and install the UPS module using the method from section 5.3 in reverse order. Figure 5.12. Disconnecting UPS Battery Lead Figure 5.13. Removing the UPS Sleeve 15

Instruction Book IB182071EN Remote Power Racking System SECTION 6: REPLACEMENT PARTS 6.1 GENERAL In order to minimize production downtime, it is recommended that an adequate quantity of spare parts be carried in stock. The quantity will vary from customer to customer, depending upon the service severity and continuity requirements. Each customer should develop his own level based on operating experience. 6.2 ORDERING INSTRUCTIONS a. Always specify all information printed on the nameplate. b. Describe the item, give the style number, and specify the quantity required. c. Specify the method of shipping desired. d. Send all orders or correspondence to the nearest Eaton s Electrical Services & Systems sales office or contact the PBC at (877) 276-9379 for assistance. 16

Remote Power Racking System APPENDIX A: ITE-HK AIR CIRCUIT BREAKER A.1 INSERTION PROCEDURE USING THE RPR-2 1) Follow all procedures defined by company s Personal Protective Equipment and Safety policy. Follow all precautions and requirements listed in the circuit breaker IB for racking the breaker. 2) Move the RPR-2 unit in front of the switchgear cell. Open the cell door to allow for access to the rotary type racking mechanism of the breaker. If the cell has closed door racking capability, insert the racking adaptor through the provided opening with the cell door closed. 3) Verify that the power circuit breaker is open and ready to be racked in from the correct position. The position depends on what type of power circuit breaker is being inserted. This position is determined by the ability to rack in the given power circuit breaker from the position that it can be racked completely into the Connected position without needing any adjustments (foot pedal pressed etc.). This is the Test position for HK breakers. 4) If engaged, release the Transport Latch to allow for vertical movement of the Power Module. (Figure 3.3) 5) Turn on the Powerware UPS for the RPR-2 by pressing the On button for approximately five seconds and allow for the unit to initialize. (Figure 4.5) For all other menu settings and features, please refer to the UPS instruction CD. 6) Turn on the power to the Power Module with the Power Switch. (Figure 3.6) 7) Select the correct breaker program on the Power Module by pressing and releasing the Breaker Select Button until the desired program is displayed on the Fusion Controller. (Figure 4.1) 8) Select the INSERT direction with the Insert/Remove switch. (Figure 4.1) 9) Select the correct racking adaptor for the breaker being inserted. (Figure 3.1) Place the racking adaptor on the breaker s racking mechanism shaft. Position the RPR-2 shaft with the racking adaptor. Turn the Insertion Shaft Lock to Unlatched position to allow for connection the RPR-2 into the racking adaptor on the power circuit breaker. (Figure 3.6) An extension can be used if a longer length is needed. If necessary, the Jog button (Figure 3.6) can be pressed to rotate the shaft for correct alignment (amber pendant and tower light will illuminate). Horizontal alignment can be achieved with the casters and vertical alignment by raising or lowering the Power Module. (Figure 4.2) 10) Once the RPR-2 is connected, properly adjust the unit toward the cell to insure the proper amount of travel is available for the power circuit breaker insertion process. When an adequate amount of travel distance is achieved, the green tower light will illuminate. 11) Engage the foot brake on the RPR-2 truck by stepping down on the lever. (Figure 4.6) Verify that the correct power circuit breaker program and the Insert direction are selected by viewing the LCD screen on the Fusion Controller (Figure 4.1). SELECTION OF THE INCORRECT POWER CIRCUIT BREAKER PROGRAM MAY RESULT IN THE RPR-2 UNIT SIGNALING COMPLETION OF THE INSERTION CYCLE WITH THE POWER CIRCUIT BREAKER ONLY PARTIALLY INSERTED. Instruction Book IB182071EN Figure A.1. Interlock Paddle Held Aside and Jog Button Pressed To Start ITE-HK Racking Process 12) In order to start racking the HK air breaker, the racking shaft interlock must be held aside. Do this by holding the interlock paddle aside while pressing and holding the RPR-2 Jog button for the duration of one cycle. (Figure A.1) this will turn the breakers racking shaft far enough to hold the interlock paddle aside. 13) Take the Pendant and move a safe distance away from front of the power circuit breaker. (The distance should be predetermined through Arc Flash calculations.) 14) When area is clear, depress and hold the Insert button (white with black arrow) on the pendant. (Figure 4.3) This will initiate the insertion process on the RPR-2 unit. The amber light on the pendant and on the tower light will illuminate while the power circuit breaker is in the insertion process. If at any time during the insertion process the Insert button is released, the tower lights and pendant light will not be illuminated. 15) When the power circuit breaker is in the Connected position, the red tower light will illuminate and the amber light on the pendant will turn off. This indicates that it is now safe to approach the power circuit breaker. IF AT ANY TIME DURING THE INSERTION PROCESS AN OVER-TORQUE OCCURS THE AMBER LIGHT ON THE PENDANT AND TOWER WILL FLASH. (THE AUTO REVERSE SELECTION IS NOTED ON THE NAMEPLATE OF THE RPR-2 UNIT.) IF THE AUTO-REVERSE FUNCTION IS SELECTED IN THIS SITUATION THE RPR-2 WILL THEN INITIALIZE THE REMOVAL PROCESS. ONCE THIS PROCESS IS COMPLETED THE GREEN AND AMBER LIGHTS ON THE LIGHT TOWER WILL FLASH AND THE AMBER LIGHT ON THE PENDANT WILL TURN OFF INDICATING IT IS SAFE TO APPROACH THE POWER CIRCUIT BREAKER. 17

Instruction Book IB182071EN Remote Power Racking System IF THE AUTO-REVERSE FUNCTION IS NOT SELECTED, PRESS AND HOLD THE REMOVE BUTTON (BLACK WITH WHITE ARROW) ON THE PENDANT. WHEN THE POWER CIRCUIT BREAKER IS COMPLETELY REMOVED, THE AMBER LIGHT ON THE PENDANT WILL TURN OFF AND THE GREEN AND AMBER TOWER LIGHTS WILL FLASH INDICATING IT IS SAFE TO APPROACH THE POWER CIRCUIT BREAKER. 16) To disconnect the RPR-2 unit, push the unit toward the switchgear cell to disengage the brakes. Lift the brake lever up to engage the holding magnet. 17) Turn the Insertion Shaft Lock to the Latched position. Push the unit forward until the insertion shaft latches. 18) Pull the unit away from the switchgear, while disconnecting the insertion shaft from the racking adaptor. 19) Remove the racking adaptor from the breaker and place it back into the storage box on the RPR-2 unit. 20) Turn Off the Power Module with the Power Switch. To turn off the UPS, press and hold the Off button for approximately five seconds. 21) Lower the Power module to the lowest position and engage the Transport Latch. (Figure 3.3) The pendant can be stored by wrapping the cord around the post at the base of the RPR-2 unit. (Figure 3.5) Place the RPR-2 unit cover over the base while in storage. (Figure 3.4) 22) The UPS should be connected to a wall receptacle when not in use to maintain a charge on the batteries. A.2 REMOVAL PROCEDURE USING THE RPR-2 1) Follow all procedures defined by company s Personal Protective Equipment and Safety policy and the precautions and racking instructions in the breaker IB. 2) Move the RPR-2 unit in front of the switchgear cell. Open the cell door to allow for access to the rotary type racking mechanism of the breaker. If the cell has closed door racking capability, insert the racking adaptor through the provided opening with the cell door closed. 3) Verify that the power circuit breaker is open and ready to be racked out from the Connected position. 4) If engaged, release Transport Latch to allow for vertical movement of the Power Module. (Figure 3.6) 5) Turn on the Powerware UPS for the RPR-2 by pressing the On button for approximately five seconds and allow for the unit to initialize. (Figure 4.5) For all other menu settings and features, please refer to the UPS instruction CD. 6) Turn on the power to the Power Module with the Power Switch. (Figure 3.6) 7) Select the correct breaker program on the Power Module by pressing and releasing the Breaker Select Button until the desired program is displayed on the Fusion Controller. (Figure 4.1) 8) Select the REMOVE direction on the Insert/Remove switch. (Figure 4.1) 9) Select the correct racking adaptor for the breaker being inserted. (Figure 3.1) Place the racking adaptor on the breaker s racking mechanism shaft. Position the RPR-2 shaft with the racking adaptor. Turn the Insertion Shaft Lock to Unlatched position to allow for connection the RPR-2 into the racking adaptor on the power circuit breaker. (Figure 3.6) An extension can be used if a longer length is needed. If necessary, the Jog button (Figure 3.6) can be pressed to rotate the shaft for correct alignment (amber pendant and tower light will illuminate). Horizontal alignment can be achieved with the casters and vertical alignment by raising or lowering the Power Module. (Figure 4.2) 10) Once the RPR-2 is connected, properly adjust the unit away from the cell to insure the proper amount of travel is available for the power circuit breaker insertion process. When an adequate amount of travel distance is achieved, the red tower light will illuminate. 11) Engage the foot brake on the RPR-2 truck. Verify that the correct power circuit breaker program and the Remove direction are selected by viewing the LCD screen on the Fusion Controller (Figure 4.1). 12) While holding the interlock paddle aside, press and hold the RPR-2 Jog button for the duration of one cycle. (Figure A.1) This will turn the breakers racking shaft far enough to hold the interlock paddle aside. SELECTION OF THE INCORRECT POWER CIRCUIT BREAKER PROGRAM MAY RESULT IN THE RPR-2 UNIT SIGNALING COMPLETION OF THE REMOVAL CYCLE WITH THE POWER CIRCUIT BREAKER ONLY PARTIALLY REMOVED. 13) Take the Pendant and move a safe distance away from front of the power circuit breaker. (The distance should be predetermined through Arc Flash calculations.) IF AT ANY TIME DURING THE REMOVAL PROCESS AN OVER-TORQUE OCCURS THE AMBER LIGHT ON THE PENDANT AND TOWER WILL FLASH. THE UNIT WILL NOT REMOVE THE BREAKER FURTHER UNTIL THE PROBLEM IS RESOLVED. FOLLOW THE COMPANY S SAFETY PROCEDURES WHEN APPROACHING THE SWITCHGEAR CELL. 14) When area is clear, depress and hold the Remove button (black with white arrow) on the pendant. (Figure 4.3) This will initiate the removal process on the RPR-2 unit. The amber light on the pendant and on the tower light will illuminate while the power circuit breaker is in the removal process. If at any time during the removal process the Remove button is released, the tower lights and pendant light will not be illuminated. 15) When the power circuit breaker is in the Disconnected position, the green tower light will illuminate and the amber light on the pendant will turn off. This indicates that it is now safe to approach the power circuit breaker. 16) To disconnect the RPR-2 unit, push the unit toward the switchgear cell to disengage the brakes. Lift the brake lever up to engage the holding magnet. 17) Turn the Insertion Shaft Lock to the Latched position. Push the unit towards the breaker until the insertion shaft latches. 18) Pull the unit away from the switchgear, while disconnecting the insertion shaft from the racking adaptor. 19) Remove the racking adaptor from the breaker and place it back into the storage box on the RPR-2 unit. 20) Turn Off the Power Module with the Power Switch. To turn off the UPS, press and hold the Off button for approximately five seconds. 21) Lower the Power module to the lowest position and engage the Transport Latch. (Figure 3.3) The pendant can be stored by wrapping the cord around the post at the base of the RPR-2 unit. (Figure 3.5) Place the RPR-2 unit cover over the base while in storage. (Figure 3.4) 22) The UPS should be connected to a wall receptacle when not in use to maintain a charge on the batteries. 18

Remote Power Racking System APPENDIX B: GE AM-5 CIRCUIT BREAKER B.1 INSERTION PROCEDURE USING THE RPR-2 Instruction Book IB182071EN Figure B.1. Only Use The RAISE Lifting Mechanism ONLY USE THE RAISE LIFTING MECHANISM INTERFACE (INDICATED BY THE ARROW IN FIGURE B.1) DURING RACKING OPERATIONS WITH RPR-2 UNIT. 1) Follow all procedures defined by company s Personal Protective Equipment and Safety policy. Follow all precautions and requirements listed in the circuit breaker IB for racking the breaker. 2) Move the RPR-2 unit in front of the switchgear cell. Open the cell door to allow for access to the rotary type racking mechanism of the breaker. If the cell has closed door racking capability, insert the racking adaptor through the provided opening with the cell door closed. 3) Verify that the power circuit breaker is open and ready to be racked in from the correct position. The position depends on what type of power circuit breaker is being inserted. This position is determined by the ability to rack in the given power circuit breaker from the position that it can be racked completely into the Connected position without needing any adjustments (foot pedal pressed etc.). This is the Test position for HK breakers. 4) If engaged, release the Transport Latch to allow for vertical movement of the Power Module. (Figure 3.3) 5) Turn on the Powerware UPS for the RPR-2 by pressing the On button for approximately five seconds and allow for the unit to initialize. (Figure 4.5) For all other menu settings and features, please refer to the UPS instruction CD. 6) Turn on the power to the Power Module with the Power Switch. (Figure 3.6) 7) Select the correct breaker program on the Power Module by pressing and releasing the Breaker Select Button until the desired program is displayed on the Fusion Controller. (Figure 4.1) 8) Select the INSERT direction with the Insert/Remove switch. (Figure 4.1) 9) Select the correct racking adaptor for the breaker being inserted. (Figure 3.1) Place the racking adaptor on the breaker s racking mechanism shaft. Position the RPR-2 shaft with the racking adaptor. Turn the Insertion Shaft Lock to Unlatched position to allow for connection the RPR-2 into the racking adaptor on the power circuit breaker. (Figure 3.6) An extension can be used if a longer length is needed. If necessary, the Jog button (Figure 3.6) can be pressed to rotate the shaft for correct alignment (amber pendant and tower light will illuminate). Horizontal alignment can be achieved with the casters and vertical alignment by raising or lowering the Power Module. (Figure 4.2) 10) Once the RPR-2 is connected, properly adjust the unit toward the cell to insure the proper amount of travel is available for the power circuit breaker insertion process. When an adequate amount of travel distance is achieved, the green tower light will illuminate. 11) Engage the foot brake on the RPR-2 truck by stepping down on the lever. (Figure 4.6) Verify that the correct power circuit breaker program and the Insert direction are selected by viewing the LCD screen on the Fusion Controller (Figure 4.1). SELECTION OF THE INCORRECT POWER CIRCUIT BREAKER PROGRAM MAY RESULT IN THE RPR-2 UNIT SIGNALING COMPLETION OF THE INSERTION CYCLE WITH THE POWER CIRCUIT BREAKER ONLY PARTIALLY INSERTED. 12) Take the Pendant and move a safe distance away from front of the power circuit breaker. (The distance should be predetermined through Arc Flash calculations.) 13) When area is clear, depress and hold the Insert button (white with black arrow) on the pendant. (Figure 4.3) This will initiate the insertion process on the RPR-2 unit. The amber light on the pendant and on the tower light will illuminate while the power circuit breaker is in the insertion process. If at any time during the insertion process the Insert button is released, the tower lights and pendant light will not be illuminated. 14) When the power circuit breaker is in the Connected position, the red tower light will illuminate and the amber light on the pendant will turn off. This indicates that it is now safe to approach the power circuit breaker. NOTICE IF AT ANY TIME DURING THE INSERTION PROCESS AN OVER-TORQUE OCCURS THE AMBER LIGHT ON THE PENDANT AND TOWER WILL FLASH. (THE AUTO REVERSE SELECTION IS NOTED ON THE NAMEPLATE OF THE RPR-2 UNIT.) IF THE AUTO-REVERSE FUNCTION IS SELECTED IN THIS SITUATION THE RPR-2 WILL THEN INITIALIZE THE REMOVAL PROCESS. ONCE THIS PROCESS IS COMPLETED THE GREEN AND AMBER LIGHTS ON THE LIGHT TOWER WILL FLASH AND THE AMBER LIGHT ON THE PENDANT WILL TURN OFF INDICATING IT IS SAFE TO APPROACH THE POWER CIRCUIT BREAKER. 19

Instruction Book IB182071EN Remote Power Racking System IF THE AUTO-REVERSE FUNCTION IS NOT SELECTED, PRESS AND HOLD THE REMOVE BUTTON (BLACK WITH WHITE ARROW) ON THE PENDANT. WHEN THE POWER CIRCUIT BREAKER IS COMPLETELY REMOVED, THE AMBER LIGHT ON THE PENDANT WILL TURN OFF AND THE GREEN AND AMBER TOWER LIGHTS WILL FLASH INDICATING IT IS SAFE TO APPROACH THE POWER CIRCUIT BREAKER. 15) To disconnect the RPR-2 unit, push the unit toward the switchgear cell to disengage the brakes. Lift the brake lever up to engage the holding magnet. 16) Turn the Insertion Shaft Lock to the Latched position. Push the unit forward until the insertion shaft latches. 17) Pull the unit away from the switchgear, while disconnecting the insertion shaft from the racking adaptor. 18) Remove the racking adaptor from the breaker and place it back into the storage box on the RPR-2 unit. 19) Turn Off the Power Module with the Power Switch. To turn off the UPS, press and hold the Off button for approximately five seconds. 20) Lower the Power module to the lowest position and engage the Transport Latch. (Figure 3.3) The pendant can be stored by wrapping the cord around the post at the base of the RPR-2 unit. (Figure 3.5) Place the RPR-2 unit cover over the base while in storage. (Figure 3.4) 21) The UPS should be connected to a wall receptacle when not in use to maintain a charge on the batteries. B.2 REMOVAL PROCEDURE USING THE RPR-2 ONLY USE THE RAISE LIFTING MECHANISM INTERFACE (INDICATED BY THE ARROW IN FIGURE B.1) DURING RACKING OPERATIONS WITH RPR-2 UNIT. 1) Follow all procedures defined by company s Personal Protective Equipment and Safety policy and the precautions and racking instructions in the breaker IB. 2) Move the RPR-2 unit in front of the switchgear cell. Open the cell door to allow for access to the rotary type racking mechanism of the breaker. If the cell has closed door racking capability, insert the racking adaptor through the provided opening with the cell door closed. 3) Verify that the power circuit breaker is open and ready to be racked out from the Connected position. 4) If engaged, release Transport Latch to allow for vertical movement of the Power Module. (Figure 3.3) 5) Turn on the Powerware UPS for the RPR-2 by pressing the On button for approximately five seconds and allow for the unit to initialize. (Figure 4.5) For all other menu settings and features, please refer to the UPS instruction CD. 6) Turn on the power to the Power Module with the Power Switch. (Figure 3.6) 7) Select the correct breaker program on the Power Module by pressing and releasing the Breaker Select Button until the desired program is displayed on the Fusion Controller. (Figure 4.1) 8) Select the REMOVE direction on the Insert/Remove switch. (Figure 4.1) 9) Select the correct racking adaptor for the breaker being inserted. (Figure 3.1) Place the racking adaptor on the breaker s racking mechanism shaft. Position the RPR-2 shaft with the racking adaptor. Turn the Insertion Shaft Lock to Unlatched position to allow for connection the RPR-2 into the racking adaptor on the power circuit breaker. (Figure 3.6) An extension can be used if a longer length is needed. If necessary, the Jog button (Figure 3.6) can be pressed to rotate the shaft for correct alignment (amber pendant and tower light will illuminate). Horizontal alignment can be achieved with the casters and vertical alignment by raising or lowering the Power Module. (Figure 4.2) 10) Once the RPR-2 is connected, properly adjust the unit away from the cell to insure the proper amount of travel is available for the power circuit breaker insertion process. When an adequate amount of travel distance is achieved, the red tower light will illuminate. 11) Engage the foot brake on the RPR-2 truck. Verify that the correct power circuit breaker program and the Remove direction are selected by viewing the LCD screen on the Fusion Controller (Figure 4.1). SELECTION OF THE INCORRECT POWER CIRCUIT BREAKER PROGRAM MAY RESULT IN THE RPR-2 UNIT SIGNALING COMPLETION OF THE REMOVAL CYCLE WITH THE POWER CIRCUIT BREAKER ONLY PARTIALLY REMOVED. 12) Take the Pendant and move a safe distance away from front of the power circuit breaker. (The distance should be predetermined through Arc Flash calculations.) NOTICE IF AT ANY TIME DURING THE REMOVAL PROCESS AN OVER-TORQUE OCCURS THE AMBER LIGHT ON THE PENDANT AND TOWER WILL FLASH. THE UNIT WILL NOT REMOVE THE BREAKER FURTHER UNTIL THE PROBLEM IS RESOLVED. FOLLOW THE COMPANY S SAFETY PROCEDURES WHEN APPROACHING THE SWITCHGEAR CELL. 13) When area is clear, depress and hold the Remove button (black with white arrow) on the pendant. (Figure 4.3) This will initiate the removal process on the RPR-2 unit. The amber light on the pendant and on the tower light will illuminate while the power circuit breaker is in the removal process. If at any time during the removal process the Remove button is released, the tower lights and pendant light will not be illuminated. 14) When the power circuit breaker is in the Disconnected position, the green tower light will illuminate and the amber light on the pendant will turn off. This indicates that it is now safe to approach the power circuit breaker. 15) To disconnect the RPR-2 unit, push the unit toward the switchgear cell to disengage the brakes. Lift the brake lever up to engage the holding magnet. 16) Turn the Insertion Shaft Lock to the Latched position. Push the unit towards the breaker until the insertion shaft latches. 17) Pull the unit away from the switchgear, while disconnecting the insertion shaft from the racking adaptor. 18) Remove the racking adaptor from the breaker and place it back into the storage box on the RPR-2 unit. 19) Turn Off the Power Module with the Power Switch. To turn off the UPS, press and hold the Off button for approximately five seconds. 20) Lower the Power module to the lowest position and engage the Transport Latch. (Figure 3.3) The pendant can be stored by wrapping the cord around the post at the base of the RPR-2 unit. (Figure 3.5) Place the RPR-2 unit cover over the base while in storage. (Figure 3.4) 21) The UPS should be connected to a wall receptacle when not in use to maintain a charge on the batteries. 20

Remote Power Racking System Instruction Book IB182071EN APPENDIX C: GE MAGNEBLAST VERTICAL LIFT C.1 INSERTION PROCEDURE USING THE RPR-2 1) Follow all procedures defined by company s Personal Protective Equipment and safety policy. Follow all precautions and requirements listed in the circuit breaker IB for racking the breaker. 2) The switchgear must be in good condition and setup per the original switchgear IB. 3) Move the RPR-2 unit in front of the switchgear cell. 4) If engaged, release the Transport Latch to allow for vertical movement of the Power Module. (Figure 3.3) 5) Turn on the Powerware UPS for the RPR-2 by pressing the On button for approximately five seconds and allow for the unit to initialize. (Figure 4.5) For all other menu settings and features, please refer to the UPS instruction CD. 6) Turn on the power to the Power Module with the Power Switch. (Figure 3.6) 7) Select the correct breaker program on the Power Module by pressing and releasing the Breaker Select Button until the desired program is displayed on the Fusion Controller. (Figure 4.1) 8) Select the INSERT direction with the Insert/Remove switch (Figure 4.1) Figure C.2. Inserting Axial Compliant Racking Adapter Figure C.3. Attaching Mechanical Torque Limiter Figure C.1. Removing Access Cover Figure C.4. Removing Lifting Motor 9) Remove the access cover from the Special Applications Racking Shaft. (Figure C.1) 10) Insert the Axial Compliant racking adapter into the Special Application Racking Shaft on the RPR-2. (Figure C.2) 11) Remove the mechanical torque limiter (Perfa-torq) from the normal insertion shaft. 12) Install the mechanical torque limiter onto the Axial Compliant racking adapter. (Figure C.3) 13) Open the switchgear door and verify that the power circuit breaker is open and is ready to be racked. 14) Remove the original lifting motor, if it is present. (Figure C.4) 15) Install the racking adapter housing in the location where the original lifting motor was mounted. (Figure C.5) 21

Instruction Book IB182071EN Remote Power Racking System 16) Insert the pull back handle into the racking adapter housing. The hook on the handle will need to be positioned behind the clutch handle. (Figure C.6) 17) Insert the retaining clip between the hook and the clutch handle. (Figure C.7) 18) Attach the vertical control box to a convenient location in the switchgear. The control box has magnets to allow easy attachment to the switchgear. (Figure C.8) 19) Connect the motor plug from the vertical control box into the switchgear female motor connection plug. (Figure C.9) Figure C.5. Installing Racking Adapter Housing Figure C.8. Installing Racking Adapter Housing Figure C.6. Attaching Pull Back Housing Figure C.9. Connecting Vertical Control Box Motor Plug Figure C.7. Attaching Retaining Clip 22

Remote Power Racking System Instruction Book IB182071EN 20) Position the RPR-2 in front of the cell, near the racking adapter housing. 21) Align the RPR-2 and the Axial Compliant racking adapter with the shaft on the racking adapter housing in the cell and connect the two together. (Figure C.10) 22) Connect the amphenol connector from the vertical control box into the Vertical Control Box Connector located on the RPR-2. Figure C.12. Engaging The Clutch with the Racking Handle Figure C.10. Alignment of RPR-2 with Racking Adapter Figure C.11. Attach Amphenol Connector (Figure C.11) 23) Pull back the racking handle in the racking adapter housing and latch it to the housing. If needed adjust the handle to ensure proper engagement of the clutch handle. (Figure C.12) 24) Once the clutch handle is pulled back and latched, the green tower light will illuminate. If the breaker was inserted, the green light will be off and no insertion racking will be allowed. 25) Engage the foot brake on the RPR-2 truck by stepping down on the lever. (Figure 4.6) Verify that the correct power circuit breaker program and the insert direction are selected by viewing the LCD screen on the Fusion Controller. (Figure 4.1) 26) Take the Pendant and move a safe distance away from front of the power circuit breaker. (The distance should be predetermined through Arc-Flash calculations.) 27) When the area is clear, depress and hold the insert button (white with black arrow) on the pendant. (Figure 4.3) This will initiate the insertion process on the RPR-2 unit. The amber light on the pendant and on the tower light will illuminate while the power circuit breaker is in the insertion process. If at any time during the insertion process the insert button is released, the tower lights and pendant light will not be illuminated. 28) When the power circuit breaker is in the Connect position, the red tower light will illuminate and the amber light on the pendant will turn off. This indicates that it is now safe to approach the power circuit breaker. C.2 REMOVAL PROCEDURE USING THE RPR-2 1) Follow the same setup procedures as indicated in Steps 1 through 26 of Appendix C.1 for the insertion of the GE Magneblast. 2) When the area is clear, depress and hold the remove button (black with white arrow) on the pendant. (Figure 4.3) This will initiate the removal process on the RPR-2 unit. The amber light on the pendant and on the tower light will illuminate while the power circuit breaker is in the removal process. If at any time during the removal process the remove button is released, the tower lights and pendant light will not be illuminated. 3) When the power circuit breaker is in the Remove position, the green tower light will illuminate and the amber light on the pendant will turn off. This indicates that it is now safe to approach the power circuit breaker. 23

Instruction Book IB182071EN APPENDIX D: WESTINGHOUSE DH AIR CIRCUIT BREAKERS D.1 INSERTION PROCEDURE USING THE RPR-2 Refer to the installation manual provided with each DH air breaker racking adapter kit. 1) Follow all procedures defined by company s Personal Protective Equipment and Safety policy. Follow all precautions and requirements listed in the circuit breaker IB for racking the breaker. 2) Move the RPR-2 unit in front of the switchgear cell. Open the cell door to allow for access to the rotary type racking mechanism of the breaker. 3) Verify that the power circuit breaker is open and ready to be racked in from the correct position. The position depends on what type of power circuit breaker is being inserted. 4) If engaged, release the Transport Latch to allow for vertical movement of the Power Module. (Figure 3.3) 5) Turn on the Powerware UPS for the RPR-2 by pressing the On button for approximately five seconds and allow for the unit to initialize. (Figure 4.5) For all other menu settings and features, please refer to the UPS instruction CD. 6) Turn on the power to the Power Module with the Power Switch. (Figure 3.6) 7) Select the correct breaker program on the Power Module by pressing and releasing the Breaker Select Button until the desired program is displayed on the Fusion Controller. (Figure 4.1) 8) Select the INSERT direction with the Insert/Remove switch. (Figure 4.1) 9) Select the correct racking adaptor for the breaker being inserted. (Figure 3.1) Place the racking adaptor on the breaker s racking mechanism shaft. Position the RPR-2 shaft with the racking adaptor. Turn the Insertion Shaft Lock to Unlatched position to allow for connection the RPR-2 into the racking adaptor on the power circuit breaker. (Figure 3.6) An extension can be used if a longer length is needed. If necessary, the Jog button (Figure 3.6) can be pressed to rotate the shaft for correct alignment (amber pendant and tower light will illuminate). Horizontal alignment can be achieved with the casters and vertical alignment by raising or lowering the Power Module. (Figure 4.2) 10) Once the RPR-2 is connected, properly adjust the unit toward the cell to insure the proper amount of travel is available for the power circuit breaker insertion process. When an adequate amount of travel distance is achieved, the green tower light will illuminate. 11) Engage the foot brake on the RPR-2 truck by stepping down on the lever. (Figure 4.6) Verify that the correct power circuit breaker program and the Insert direction are selected by viewing the LCD screen on the Fusion Controller (Figure 4.1). SELECTION OF THE INCORRECT POWER CIRCUIT BREAKER PROGRAM MAY RESULT IN THE RPR-2 UNIT SIGNALING COMPLETION OF THE INSERTION CYCLE WITH THE POWER CIRCUIT BREAKER ONLY PARTIALLY INSERTED. 12) In order to start the racking process for the Westinghouse DH Air breaker the installed Push Handle will need to be pushed in to rack the breaker. The Push Handle will be in this position for the entire racking process. (Figure D.1) 13) Take the Pendant and move a safe distance away from front of the power circuit breaker. (The distance should be Remote Power Racking System Figure D.1. Westinghouse DH Adapter Kit Installed predetermined through Arc Flash calculations.) 14) When area is clear, depress and hold the Insert button (white with black arrow) on the pendant. (Figure 4.3) This will initiate the insertion process on the RPR-2 unit. The amber light on the pendant and on the tower light will illuminate while the power circuit breaker is in the insertion process. If at any time during the insertion process the Insert button is released, the tower lights and pendant light will not be illuminated. 15) When the power circuit breaker is in the Connected position, the red tower light will illuminate and the amber light on the pendant will turn off. This indicates that it is now safe to approach the power circuit breaker. IF AT ANY TIME DURING THE INSERTION PROCESS AN OVER-TORQUE OCCURS THE AMBER LIGHT ON THE PENDANT AND TOWER WILL FLASH. (THE AUTO REVERSE SELECTION IS NOTED ON THE NAMEPLATE OF THE RPR-2 UNIT.) IF THE AUTO-REVERSE FUNCTION IS SELECTED IN THIS SITUATION THE RPR-2 WILL THEN INITIALIZE THE REMOVAL PROCESS. ONCE THIS PROCESS IS COMPLETED THE GREEN AND AMBER LIGHTS ON THE LIGHT TOWER WILL FLASH AND THE AMBER LIGHT ON THE PENDANT WILL TURN OFF INDICATING IT IS SAFE TO APPROACH THE POWER CIRCUIT BREAKER. IF THE AUTO-REVERSE FUNCTION IS NOT SELECTED, PRESS AND HOLD THE REMOVE BUTTON (BLACK WITH WHITE ARROW) ON THE PENDANT. WHEN THE POWER CIRCUIT BREAKER IS COMPLETELY REMOVED, THE AMBER LIGHT ON THE PENDANT WILL TURN OFF AND THE GREEN AND AMBER TOWER LIGHTS WILL FLASH INDICATING IT IS SAFE TO APPROACH THE POWER CIRCUIT BREAKER. 16) When the Red indicator light is illuminated the Push Handle will need to be released to operate the breaker. By lifting up the Operator Lock the Push Handle can be disengaged and released 17) To disconnect the RPR-2 unit, push the unit toward the switchgear cell to disengage the brakes. Lift the brake lever up to engage the holding magnet. 18) Turn the Insertion Shaft Lock to the Latched position. Push the unit forward until the insertion shaft latches. 24