Russelectric RTS03 Series User manual

O & M Manual
Type RTS03 Bypass-Isolation Transfer Switches
Russelectric Inc.
South Shore Park, Hingham, Massachusetts 02043
Service 800 654-3020
www.russelectric.com 90E1720004 rev. B

O&M Manual –90E1720004
Table of Contents Page 3 of 52
Table of Contents
List of Figures .............................................................................................................................................................5
Section 1 Hazard Categories and Special Symbols .................................................................................................6
Section 2 Introduction .............................................................................................................................................7
General Description...............................................................................................................................................7
Identification........................................................................................................................................................... 8
RTS03 Model Numbering System ...........................................................................................................................8
Section 3 Safety Precautions ...................................................................................................................................9
Section 4 Receiving, Handling and Storage .......................................................................................................... 10
Receiving ..............................................................................................................................................................10
Handling...............................................................................................................................................................10
Handling with Eyebolts.................................................................................................................................... 10
Handling with Lifting Angles.......................................................................................................................... 10
Handling with Sling Rigging ........................................................................................................................... 11
Handling with a Forklift...................................................................................................................................11
Cradle/Rollout......................................................................................................................................................12
Storage.................................................................................................................................................................. 12
Section 5 Installation............................................................................................................................................. 14
Installing the Bypass-Isolation Transfer Switch...................................................................................................14
Preparing the Site.............................................................................................................................................14
Preparing the Foundation.................................................................................................................................14
Anchoring the Switch –Non Seismic...............................................................................................................14
Anchoring the Switch -Seismic........................................................................................................................ 15
Connect the Power Cables, Controls, and Wiring................................................................................................15
Connect the Power Cables ...............................................................................................................................15
Torque Values for Mechanical Lugs................................................................................................................ 16
Conductor Restraint for Short Circuit Current Rating .....................................................................................17
Connect the Controls and Wiring..................................................................................................................... 20
Transfer Switch Inspection and Testing Before Operation................................................................................... 21
Check the Power Circuit Connections .............................................................................................................21
Check the External Equipment ........................................................................................................................21
Check the Auxiliary Equipment.......................................................................................................................21
Check the Equipment Ground-Fault Systems.................................................................................................. 22
Conduct the Electrical Insulation Resistance Test...........................................................................................22
Section 6 Pre-Energizing Checkout Procedure...................................................................................................... 23
Section 7 Energizing the Bypass-Isolation Transfer Switch.................................................................................. 25
Energize the Switch ..............................................................................................................................................25
Section 8 Operation............................................................................................................................................... 27
Bypass Switch.......................................................................................................................................................27
Transfer Switch –Cradle/Rollout.......................................................................................................................... 27
Cradle/Rollout.................................................................................................................................................. 27
Bypass Mode....................................................................................................................................................28
To Bypass the Transfer Switch........................................................................................................................29
Isolating the Transfer Switch................................................................................................................................30
Withdrawing the Transfer Switch 100-800A.........................................................................................................31
Withdrawing the Transfer Switch 1000-4000A..................................................................................................... 31
Returning the Transfer Switch to Service .............................................................................................................32
Internal Manual Operation................................................................................................................................... 33
External Manual Operation (EMO) ..................................................................................................................... 35
RPTCS Control System......................................................................................................................................... 36
Overview.......................................................................................................................................................... 36
Graphical Control Panel Overview.................................................................................................................. 36
Summary of Function Key Operations ............................................................................................................37
Summary of LED Indicators............................................................................................................................ 38
Summary of Control Pushbuttons.................................................................................................................... 38
Summary of the Graphical Display..................................................................................................................39
Performing Common Setup and Control Tasks.................................................................................................... 39
Setting Security Access....................................................................................................................................39
Setting the Date................................................................................................................................................40

O&M Manual –90E1720004
Table of Contents Page 4 of 52
Setting the Clock..............................................................................................................................................40
Setting Daylight Savings.................................................................................................................................. 40
Entering the Switch Designation...................................................................................................................... 40
Setting Timers..................................................................................................................................................41
Setting Voltage and Frequency Setpoints for S1 (VFS1) and S2 (VFS2)........................................................41
Setting Transition Mode on a Closed Transition Switch .................................................................................41
Setting Pre and Post for Elevator Contacts ......................................................................................................42
Setting up the Exerciser Function....................................................................................................................42
Performing a Load Test or a No Load Test.......................................................................................................... 43
Section 9 Maintaining the Bypass-Isolation Transfer Switch................................................................................44
Transfer Switch Inspection Guidelines.................................................................................................................44
Ideal Operating Conditions.............................................................................................................................. 44
Normal Operating Conditions.......................................................................................................................... 45
Harsh Operating Conditions.............................................................................................................................45
General Inspection and Cleaning......................................................................................................................... 46
Bus Bar Joints, Lug Terminations, and Insulating Materials...............................................................................47
Section 10 Adverse Circumstances..........................................................................................................................48
Inspection Following a Short Circuit ................................................................................................................... 48
Clean-up Following a Short Circuit.....................................................................................................................48
Water-Soaked Switches......................................................................................................................................... 48
Section 11 Insulation Resistance Chart ................................................................................................................... 49
Section 12 Maintenance Log...................................................................................................................................50

O&M Manual –90E1720004
Table of Contents Page 5 of 52
List of Figures
Figure 1: Lifting with an Overhead Crane and Eyebolts...........................................................................................10
Figure 2: Lifting with an Overhead Crane, Integral Lifting Angles and Cables or Chains.......................................11
Figure 3: Lifting with Sling Rigging.........................................................................................................................11
Figure 4: Forklift Safety Strap................................................................................................................................... 12
Figure 5: Anchoring the Switch. ...............................................................................................................................15
Figure 6: Bypass-Isolation Power Connections (400A 4P shown)............................................................................ 16
Figure 7: Wrapping the Cables..................................................................................................................................17
Figure 8: Wrapping the Space between Cables.........................................................................................................18
Figure 9: Finish Wrapping the Space between Cables..............................................................................................18
Figure 10: Continue Wrapping the Cables ................................................................................................................ 18
Figure 11: Securing Cables to Supports (optional).................................................................................................... 19
Figure 12: Tying the Rope Ends Together ................................................................................................................19
Figure 13: Locate the TB5 Terminal Block............................................................................................................... 20
Figure 14: Bypass Switch and Accessory Panel........................................................................................................27
Figure 15: Transfer Switch Cradle ............................................................................................................................ 28
Figure 16: Sliding out the cradle rails. .....................................................................................................................31
Figure 17: Withdrawing the Transfer Switch Cradle 100-800A ..............................................................................31
Figure 18: Rollout Stop for 1000-4000A Bypass-Isolation Switches ....................................................................... 32
Figure 19: Withdrawing the Transfer Switch Rollout 1000-4000A.........................................................................32
Figure 20: Transfer Switch Position Indicators........................................................................................................ 34
Figure 21: Internal Manual Operators...................................................................................................................... 34
Figure 22: External Manual Operator (EMO) Handle...............................................................................................35
Figure 23: External Manual Operator (EMO) Operation ..........................................................................................35
Figure 24: Graphical Control Panel Overview..........................................................................................................36
Figure 25: Summary of Function Key Operations ....................................................................................................37
Figure 26: Summary of LED Indicators....................................................................................................................38
Figure 27: Summary of Control Pushbuttons............................................................................................................ 38
Figure 28: Summary of the Graphical Display..........................................................................................................39

O&M Manual –90E1720004
Section 1 Hazard Categories and Special Symbols Page 6 of 52
Section 1 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.
The addition of either symbol to a “Danger” or “Warning” safety label
indicates that an electrical hazard exists which will result in personal
injury if the instructions are not followed.
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.
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.
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.

O&M Manual –90E1720004
Section 2 Introduction Page 7 of 52
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 instructions 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 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.

O&M Manual –90E1720004
Section 2 Introduction Page 8 of 52
Identification
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.
RTS03 Model Numbering System
RTS 03-
Operation Type
A
Switch Type
BL
Operator
A
Ampere Rating
100
Poles
3
Terminal Type
M
Voltage
A
Enclosure Type
F
Enclosure Rating
1
Controller Type
RPTCS01
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 Pole
4 = 4 Pole
A = 277/480V
B = 480V
C = 120/208V
D = 208V
E = 120/240V
F = 240V
G = 347/600V
H = 265/460V
I = 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
RPTCS01 = Level 1 Controller
RPTCS02 = Level 2 Controller
RPTCS03 = Level 3 Controller
RPTCS04 = Level 4 Controller
RPTCS05 = Level 5 Controller

O&M Manual –90E1720004
Section 3 Safety Precautions Page 9 of 52
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
Follow NFPA 70E safety procedures and safe work practices and
wear appropriate personal protective equipment (PPE).
This equipment must be installed and serviced only by qualified
electrical personnel.
Perform such work only after reading and understanding all of the
instructions contained in this manual.
Turn off all power supplying this equipment before working on or
inside equipment.
Always use a properly rated, voltage sensing, device to confirm
power is off.
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.
Always practice lock-out/tag-out procedures according to OSHA
and NFPA70E requirements.
Conduct electrical testing to confirm no short-circuits were
created during installation, maintenance, or inspection.
Be aware of potential hazards; wear personal protective
equipment, and take adequate safety precautions.
Carefully inspect your work area, and remove any tools and
objects left inside the equipment.
Replace all devices, doors, and covers before turning on power to
this equipment.
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.

O&M Manual –90E1720004
Section 4 Receiving, Handling and Storage Page 10 of 52
Section 4 Receiving, Handling and Storage
Russelectric bypass-isolation Transfer Switches are shipped assembled in one or several
shipping sections, depending on the size 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 finish.
Figure 1: 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.