RX-RC Rev 7 PDF

Installation, Operation & Maintenance Manual
For Rapier RX-RC Air Break Switch
D600087 REV 7

RX-RC
Servo Controlled Rocking Isolator
Installation, Operation & Maintenance Schedule
Introduction
The Rapier RX-RC is a servo controlled operating mechanism designed to operate switch disconnectors
at voltages up to 36kV and current carrying capability of up to 630A.
The integral Gemini-RTU and actuator allows the disconnector to be either locally or remotely controlled.
The Gemini RTU consists of control electronics and battery charger allowing the switchgear to be
monitored and controlled for up to 24 hours under power failure conditions. The control electronics
includes DNP3 and IEC 60870-5-101 communication protocols as standard (others on request) and can
communicate via a range of media including low Power Radio, Paknet, GSM, Optical fibre, PSTN, RS
232 and RS485
This manual sets out the requirements for the installation of the equipment to a suitable structure, setting
of the switch mechanism for correct operation. The operation of the equipment once installed and set
and the recommended maintenance for the equipment.
The manual should be used in conjunction with the contract drawings supplied by Power Isolators Ltd. for
the equipment.
Contents:
Page No.
1.0 Mounting Steel Work To Pole...............................................................2
1.1
Mounting Crossarms..............................................................2
2.0
Mounting 12-24kV Phase Assemblies.................................................3

2.1 Fitting Load Break Heads........................................................ 3
2.2 Mounting 36kV Phase............................................................. 4
2.3 Fitting Phase Coupling............................................................ 4
3.0
Drive Lever Position............................................................................6
4.0 Mounting Spring Mechanism............................................................... 6

5.0
Fitting Top Drive Rod & Setting Double Acting Spring Mechanism..... 7
5.1 Fitting Middle & Bottom Drive Rod........................................... 8
6.0
Mounting & Operating Gemini RTU..................................................... 9

6.1 Alternative Mounting............................................................... 9
7.0
Connecting Drive Rod To Gemini RTU.................................................10

7.1 Cutting Middle Drive Rod To Length.........................................10
8.0
Lock Off Brackets................................................................................10
9.0
Typical Arrangement Drawing............................................................. 12
10.0 Options Fault Passage Indicator........................................................ 13

10.1 Animal Guard........................................................................14
10.2 Surge Arrestor...................................................................... 15
11.0
Maintenance......................................................................................16
12.0 Product Data Health and Safety Requirements................................... 17

13.0 Contact Details................................................................................... 20
Page 01

1.0 Mounting steelwork to pole.
Fit to pole as shown on contract drawing
Fig. 1
Drill 2off
22mm
Holes
M20 Bolts
(See Contract Drg.)
1.1 Mounting crossarms

Note - For correct operation of the switch it is important that the crossarms are horizontal and
parallel. This will provide a flat platform for the switch disconnector and once this is achieved
tighten all bolts.
Fig. 2
Crossarms
M16X45mm
Bolts
Page 02

2.0 Mounting 12-24kv Single Phase Assemblies
Place the single phase units on the support steelwork at the phase centres specified on the contract
drawing. (Fit phase unit fixing bolts, only finger tight at this stage). Refer to item 2.1 for fitting 36kV
Load Break Heads.
Fig. 3
Single Phase
Assembly
Folded
Channel
Base
Bearing
Clamping
U Bolt
Slide Base Fixing

Bolts down
Channel Base
Crossarms
(M12X30mm Bolts)
Base Fixing
Support Steelwork
2.1 Fitting Load Break Heads (if required).

!
!
Note- If load break heads are not required go to 2.2.

Fit the load break heads to the single phase units before fitting the phase units to the support
steelwork as shown in (Fig.4).
Fit the load break heads into the appropriate sleeves, rotate the LBH until it is aligned with the lugs
on the striker plate, then lightly tighten the clamping bolt.
Check the alignment by operating each single phase manually, ensure the LBH is operated
during Opening and reset during closing. When alignment is correct fully tighten the clamp bolt
Fig.4
Load Break
Head
Striker
Plate
Clamping
Bolt
Page 03

2.2 Mounting 36kV Single Phase Assemblies
!
Place the single phase units on the support steelwork at the phase centres specified on the contract
drawing.(See Fig. 5)
Fit phase unit fixing bolts, only finger tight at this stage.
Fig.5
Load Break
Head
Single Phase
Assembly
Bearing
Clamping
U Bolt (M10)
Crossarms
(M20X110mm Bolts)
Base Fixing
Support Steelwork
2.3 Phase Coupling Tube

!
Place the square coupling tube through all three phase units, thus aligning the three main bearings.
Fully tighten the M10 nuts on the bearing clamp U bolts on each phase to a minimum of 19Nm
Torque (Fig.6).
Manually push the switch to the Closed position to line up the phase units.
Fully tighten the phase unit fixing bolts to a minimum of 32Nm(M12) / 160Nm(M20) Torque.
At this stage, close the switch by hand until fully home, i.e. On to factory set stops. In this position
the male contacts should protrude through the female contacts by a minimum of the chamfer length
on the male contact and the flicker blades should be latched in, if fitted (Fig.7 & 8).
If any of the phases are significantly lagging, undo the phase unit fixing bolt and shim the phase unit
until the phase is no longer lagging.
Fig.6
Phase
Coupling
Bearing
Clamping
U Bolt
Page 04

Drawing of RX Contact
Shown Fully Home
Flicker Blade Shown

Latched in Position
Fig. 7
Arc-Chute
Fig. 8
Female Contact
Latch
Chamfer
Male Contact
Flicker Blade
View A
Ensure Flicker is Aligned

Centrally With Arc-Chute
View A
Arc-Chute
Flicker Blade
Page 05

3.0 Drive Lever Position

!
The universal drive lever has been designed so that it can be used with the majority of mounting
arrangements. The switch position is shown as Closed.
See the contract drawing for the specific mounting arrangement. The drive lever is then fixed to the
phase coupling with the U bolts.
The drive rods are not added at this time.
Fig.9
Fig.10
Holes
Not Used
4.0 Mounting Spring Mechanism.

Fig.11
On Rear Of DASM Remove M10

Nut, Washer & Spring Washer
From Mounting Bolts.
Double Acting
Spring Mechanism
Mounting
Plate
Double Acting
Spring Mechanism
Page 06
Align Studs On DASM

With Holes On Mounting
Plate & Refit M10 Nut,
Washer & Spring Washer.

5.0)Fitting Top Drive Rod & Setting DASM (Drive Lever to Double Acting Spring Mech)
Fig.12
This End To
Eye-Bolt on
Drive Lever
Mech / Switch
Drive Rod
Rotate Clockwise
To Shorten, AntiClockwise to
Lengthen
Eye-Bolt
& Lock
Nut
DASM
Ensure that when the switch is closed the profiled latch on the D.A.S.M is fully latched in.
This is achieved by fully closing the switch i.e. on to factory set stops, and rotating the top drive rod to
lengthen it. When the latch drops in, the rod should be rotated a further 1/2 turn and then locked off.
Fig.13
Page 07

5.1 Fitting Middle & Bottom Drive Rod.(Double Acting Spring Mech To Rapier RTU)
The middle drive rod & insulating insert, (as specified on the contract drawing) is connected to the Double
Acting Spring Mech.
Note: The middle drive rod requires cutting to the correct length, this must not be done until the RTU has
been fitted to the pole see stage 7.0.
Fig.14
Fig.15
Top Drive
Rod
Mech / Switch
Drive Rod
Insulating
Insert
Switch Shown in
ON Position
Insulating
Insert
Middle Drive
Rod
Top
Drive Rod
Middle
Drive Rod
Coupling
Bottom
Drive Rod
Bottom Drive
Rod
Page 08

6.0 M o u n t i n g
Of
Gemini
RTU
Refer to Gemini RTU manual (Section 4) &

Contract Drawing for exact mounting details.
Lock Off
Bracket
Fig.16
Lifting
Eyes
Drill 2off
22mm
Holes
Locking Pin
& Chain
Mounting
Pole
Mounting
Bracket
M20 Bolts
(See Contract Drg.)
6.1 Optional Mounting Of Gemini RTU

(For use with round steel poles and where
drilling of mounting holes is not possible)
Attach the mounting brackets onto the M10 studs
on the rear of the RTU. Refer to Gemini RTU
manual (Section 4) & Contract Drawing for exact
mounting details.
Clamps
Fig.17
Mounting
Pole
Actuator
Mounting
Brackets
Page 09

7.0 Connecting Drive Rod RTU
7.1 Cutting Middle Drive Rod To

Length
Connect Bottom Drive Rod To RTU As

Shown In Fig. 18 (Note: RTU Should Be In
The On Position)
Note: The Switch & RTU Must Be In The

Closed Position i.e ON.
Fig.18
Fig.19
Fit Coupling
To RTU
Cut Line, Central

With Coupling
Middle
Drive
Rod
Fit
Locking
Pin
Top
Drive
Rod
Coupling
Fit
Pad-Lock
Bottom
Drive
Rod
Cut Off Hatched Area,

Insert Rod Into Coupling
& Tighten Grub Screw.
(Note: Fine Adjustment
Of The Length Of The
Drive Rod Is Done By
Turning The Drive Rod,
The Limits On The RTU
Must Not Be Adjusted
For This Purpose)
8.0 Locking Off Instructions.

The Locking Off Procedure Is Identical For Locking The Switch In The ON Or
OFF Position, Instructions Show Locking Off The Switch In The
OFF Position.
View Of RTU
Coupling.
(Switch In Off
Position)
Unlock Padlock
And Remove.
Lock Off
Position OFF
Lock Off
Position ON
Page 10

Remove
Locking
Pin From
Drive Rod.
Disconnect
Drive Rod.
Move Drive
Rod To Other
Side Of Bracket
And Fit Locking
Pin.
Fit Pin Through

Bracket.
Fit Padlock
Through
Locking Pin.
View With Switch

Locked In The
ON Position.
Note:- Unlocking is a reversal of the above procedure.

Note:- When replacing locking pin into drive rod ensure chain is free from
snagging.
Page 11

9.0 Typical Arrangement Drawing
ra w
ing
Fig. 20
Remote controlled RX-RC

switch at normally
open point
ng
em
Double acting
spring mechanism
en
tD
VT option for
voltage sensing
and power supply.
(Not included in
standard offer)
Insulating
Insert
lA
rr a
Antenna
Hook stick
manual overide
Note: Actuator
drive to be
disconnected
& locked off
before use.
Communication via
Low power radio, GSM etc
Ty
pic
a
Protocol - DNP V3.0
Primary substation
SCADA
Control system
Locking points
for use when
manual override
is required
Servo controller
Secondary Automation scheme for

control of Automated air break
switches
Page 12

10.0Options Fault Passage Indicator (FPI)
!
!
A fault passage indicator is available for use with the RX-RC. This is a retrofitable unit which will
detect fault currents and has adjustable threshold sensitivity. It consists of a sensor unit and
umbilical cable which is connected to the Gemini RTU mains terminal block. The general
arrangement is a shown below.
For detailed installation and performance details refer to the FPI installation and user guide.
Fig.21
FPI Sensor Unit
Umbilical
Cable
Gemini
RTU
GROUND LEVEL
Page 13

10.1RX-RC Options- Animal Guard
An optional animal guard is available to protect the exposed cables e.g. power or aerial leads, if
live stock is likely to be in the vicinity of the control cabinet.
Fig.22
Run The Cable Inside

The RTU Mounting
Bracket
Remove Two Screws

From Gland Plate &
Fit Animal-Guard, Refit
The Two Screws
Animal Guard
Using Suitable Coach
Screw (Not Supplied)
Fasten Guard To Pole
Page 14

10.2RX-RC Options- Surge Arrestor
Surge arrestor mounting plates are available to allow the fitting of Surge Arrestors to Rapier RX
switches.
Fig.23
Bolt Surge Arrestor

Mounting Bracket
Using Supplied
M12 Bolts
Fit Surge Arrestor

To Mounting Bracket
Single Connector
Mounting Hole
Surge
Arrestor
Page 15

11.0 Maintenance
Note: all maintenance should be carried out by suitably qualified personnel.
Preventative Maintenance
Biannual Check
We recommend a visual inspection of the equipment biannually (every 2 years) including the workings
of the mechanisms.
As a general requirement, all fixings should be secure and free from any corrosion that may weaken
them, and all moving parts should be clean and free to move without excessive friction or obstruction.
Worn parts should be noted and Power Isolators Ltd contacted for further advice on whether
replacement is necessary.
A close inspection of the Insulators is advisable in areas of vandalism, to check for cracks or chips from
impact. Insulators may be cleaned and wiped down using a non-abrasive detergent to remove heavy
build-up of deposits on the sheds. Necessity and frequency of cleaning will depend upon climatic and
environmental conditions.
Where possible all parts (both the disconnector and the earth switch, interlocks etc) should be operated
to confirm they are working correctly
Ten Year Check
Power Isolators equipment has a design life of 25 years. However, on a ten year periodic basis the
following additional checks should be made, particularly in cases of high pollution or salt spray
environment, or high current loading and frequent operational conditions.
Contacts
A visual inspection should be made to look for signs of electrical erosion and physical wear.
Mechanism
Any auxiliary wiring should be checked for signs of deterioration of insulation, loose contacts etc. Wiring
integrity can ne checked using a multi-meter connected each end.
Page 16

12.0 Product Data Health and Safety Requirements

High Voltage Isolators and Disconnectors
1. RANGE OF MANUFACTURE
Power Isolators Ltd manufacture a wide range of high voltage Isolating Switches and
Disconnectors using various metals and porcelain insulators.
2. TESTING OF PRODUCTS
All products are type tested in accordance with relevant British or International Standards and
are routine tested during, or on completion of manufacture. The tests are made in accordance
with the purchaser's standard or the relevant British or International Standard.
3. RATING OF PRODUCTS
All products are assigned a rating - which forms the basis of testing.
4. SPECIFIED REQUIREMENTS
The customer is always made aware of the assigned rating and usually specifies requirements in
relation to the eventual duty. All isolating switches and disconnectors are fitted with a Rating
Label.
5. UTILISATION OF ISOLATING SWITCHES & DISCONNECTORS
The customer or ultimate user is fully responsible for the utilisation of isolating switches and
disconnectors taking into account the assigned rating, the service conditions and the required
factor of safety; the manufacturers responsibility is to provide isolating switches and
disconnectors which when tested in accordance with the relevant specification achieves the
specified rating.
During the construction of overhead lines or substations incorporating isolating switches or
disconnectors, care must be taken to avoid excessive force on the equipment especially on the
porcelain insulators. In particular reliance should not be placed on the insulators as a means of
support for personnel or erection equipment during erection or construction operation.
6. HEALTH HAZARDS
There are no significant health or fire hazards associated with isolating switches or
disconnectors as supplied by the manufacturer.
7. MATERIALS
7.1 The metal components, iron, steel, aluminium, copper and copper alloy, present no
significant health or fire hazards.
7.2 The porcelain insulators incorporated into the product are made from materials listed in the
European Care Inventory 06-402-64-4. All the constituent materials are banded into a simple
vitreous mass.
7.3 Some Metal Components are electro plated or galvanised. Insulators are cleaned in a
manner which may leave a fine film of Refined Mineral Oil on the surface. The manufacturer's
Health & Safety data on this substance is available on application to Power Isolators Limited.
Page 17

12.0 Product Data Health and Safety Requirements Continued.

7.3 Continued: These do not constitute a significant health hazard. However, personal hygiene could
be important and it is recommended that hands are washed after handling isolating switches or
disconnectors. Prolonged skin contact should be avoided.
8. PACKAGING
Isolating Switches & Disconnectors are normally packed in wooden cases, with internal
separation being achieved by interlays of wood. Hence there is a fire hazard.
All packing cases must be stored away from sources of heat or other means of ignition.
9. FIRE
9.1 In the event of fire occurring there are no health hazards arising from metal or porcelain
components (other than from zinc coating). The fumes from burning packaging and from the
small amount of grease require the use of H.S.E. normal approved protective equipment in such
circumstances to avoid health hazard. If high temperatures are reached there may also be
fumes from the zinc protective coating applied to ferrous components and H.S.E. approved
respiratory protection should be worn when involved in fires of this nature.
9.2 After a fire porcelain insulators incorporated into isolating switches and disconnectors will
probably be broken and will require the exercise of the same precautions as covered in Section
12 below.
10 . WEIGHT
The weight of individual isolating switches varies from 20Kg to over 2000Kg. Isolating switches
and disconnectors are delivered in packages ranging from 30Kg to in excess of 2000Kg in
weight. The weights of isolating switches and corresponding packages may be obtained from
despatch/shipping documentation, or by case markings, or by application to the Commercial
Department, Power Isolators Limited.
11. HANDLING OF ISOLATING SWITCHES & DISCONNECTORS
In lifting and moving of isolating switches and disconnectors, whether in transportation storage or
for erection at the ultimate site due regard must be given to several relevant factors i.e.
11.1 Mechanical aids e.g. fork lift trucks or cranage must always be used to lift/move isolating
switches, phase units or packages in excess of the weight assessed as safe for manual
handling. When lifting individual heavy phase units, isolating switches or disconnectors special
attention must be given to the method of attachment of lifting gear or slings in order that correct
distribution of load is obtained. Lifting methods which create excessive bending loads, in relation
to the loads applied during normal duty, should be avoided.
11.2 The porcelain of the insulators is a brittle material, despite the possession of inherent
strength in all normal loading conditions. Impact damage or dropping will usually cause fracture
of the porcelain into numerous pieces of various sizes. These have extremely sharp edges,
capable of causing dangerous incised wounds.
Page 18

12.0 Product Data Health and Safety Requirements Continued.

12. DISPOSAL OF BROKEN INSULATORS
12.1 Loading of broken insulators into skips, etc., by whatever means requires use of the
heaviest protective gloves and footwear and possibly gaiters to protect the operator from the risk
of injury. Face protection should also be worn since badly handled pieces may shatter further
with a risk of flying shards. It is recommended that visors are of the extra length variety with
brow guards.
12.2 Ultimate disposal of damaged metalwork and broken insulators may only be made in
authorised landfill sites. There is now environmental hazard associated with such disposal.
13. PROVISION OF INSTRUCTION
The contents of this document should be brought to the attention of all personnel concerned with
the handling, storage and use of isolating switches and disconnectors.
14. INFORMATION
The information on this Product Data Sheet is in accordance with the latest knowledge. The use
of this information by the customer or ultimate user and the use to which the isolating switches
and disconnectors are put are beyond the control of Power Isolators Limited. This information is
provided without any representation or warranty expressed or implied.
Page 19

13.0 CONTACT DETAILS

Power Isolators Ltd.
Unit 14, Thorpe Lane, Thorpe Way
Industrial Estate, Banbury,
Oxon OX16 4UT
Tel: +44(0)1295 270448
Fax: +44(0)1295 270446
Email: sales@powerisolators.co.uk
Power Isolators Ltd is a wholly owned subsidiary of the Lucy Group of companies.
Page 20

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Installation, Operation & Maintenance Manual

For Rapier RX-RC Air Break Switch

Installation, Operation & Maintenance Manual

Mounting 12-24kV Phase Assemblies.................................................3

Drive Lever Position............................................................................6

4.0 Mounting Spring Mechanism............................................................... 6

Mounting & Operating Gemini RTU..................................................... 9

Connecting Drive Rod To Gemini RTU.................................................10

Lock Off Brackets................................................................................10

Typical Arrangement Drawing............................................................. 12

10.0 Options Fault Passage Indicator........................................................ 13

12.0 Product Data Health and Safety Requirements................................... 17

Installation, Operation & Maintenance Manual

1.1 Mounting crossarms

Installation, Operation & Maintenance Manual

Slide Base Fixing

2.1 Fitting Load Break Heads (if required).

Note- If load break heads are not required go to 2.2.

Installation, Operation & Maintenance Manual

2.3 Phase Coupling Tube

Installation, Operation & Maintenance Manual

Flicker Blade Shown

Ensure Flicker is Aligned

Installation, Operation & Maintenance Manual

3.0 Drive Lever Position

The drive rods are not added at this time.

4.0 Mounting Spring Mechanism.

On Rear Of DASM Remove M10

Align Studs On DASM

Installation, Operation & Maintenance Manual

Installation, Operation & Maintenance Manual

Installation, Operation & Maintenance Manual

Refer to Gemini RTU manual (Section 4) &

6.1 Optional Mounting Of Gemini RTU

Installation, Operation & Maintenance Manual

7.1 Cutting Middle Drive Rod To

Connect Bottom Drive Rod To RTU As

Note: The Switch & RTU Must Be In The

Cut Line, Central

Cut Off Hatched Area,

8.0 Locking Off Instructions.

Installation, Operation & Maintenance Manual

Fit Pin Through

View With Switch

Note:- Unlocking is a reversal of the above procedure.

Installation, Operation & Maintenance Manual

Remote controlled RX-RC

Protocol - DNP V3.0

Secondary Automation scheme for

Installation, Operation & Maintenance Manual

FPI Sensor Unit

Installation, Operation & Maintenance Manual

Run The Cable Inside

Remove Two Screws

Installation, Operation & Maintenance Manual

Bolt Surge Arrestor

Fit Surge Arrestor

Installation, Operation & Maintenance Manual

Installation, Operation & Maintenance Manual

12.0 Product Data Health and Safety Requirements

Installation, Operation & Maintenance Manual

12.0 Product Data Health and Safety Requirements Continued.