EATON - Remote Power Racking 2

Supercedes October 2013
Instruction Book IB182071EN Effective July 2018
Remote Power Racking System

(RPR-2)
RPR-2 Low Profile Shown

Instruction Book IB182071EN Remote Power Racking System
July 2018 (RPR-2)
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.
This product was manufactured by Eaton at the Power Breaker

m WARNING Center (PBC): 310 Maxwell Avenue, Greenwood, SC 29646.
IMPROPERLY INSTALLING OR MAINTAINING THESE PRODUCTS CAN All possible contingencies which may arise during installation,
RESULT IN DEATH, SERIOUS PERSONAL INJURY OR PROPERTY DAMAGE. operation or maintenance, and all details and variations of this
equipment do not purport to be covered by these instructions. If
READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE ATTEMPTING further information is desired by purchaser regarding his particular
ANY UNPACKING, ASSEMBLY, OPERATION OR MAINTENANCE OF THE installation, operation or maintenance of particular equipment,
CIRCUIT BREAKERS. 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.
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Remote Power Racking System Instruction Book IB182071EN
(RPR-2) July 2018
Table of Contents
SECTION 1: INTRODUCTION 4 APPENDIX A: ITE-HK AIR CIRCUIT BREAKER 17

1.1 VISUAL PRESENTATION 4 A.1 INSERTION PROCEDURE USING THE RPR-2 17
1.2 QUICK RESPONSE CODE 4 A.2 REMOVAL PROCEDURE USING THE RPR-2 18
SECTION 2: SAFE PRACTICES 6 APPENDIX B: GE AM-5 CIRCUIT BREAKER 19
SECTION 3: RECEIVING, HANDLING, AND STORAGE 7 B.1 INSERTION PROCEDURE USING THE RPR-2 19
3.1 RECEIVING 7 B.2 REMOVAL PROCEDURE USING THE RPR-2 20
3.2 HANDLING 7 APPENDIX C: GE MAGNEBLAST VERTICAL LIFT 21
3.3 STORAGE 7 C.1 INSERTION PROCEDURE USING THE RPR-2 21
3.4 RPR-2 APPROXIMATE WEIGHTS 7 C.2 REMOVAL PROCEDURE USING THE RPR-2 23
SECTION 4: RACKING PROCEDURES 10 APPENDIX D: WESTINGHOUSE DH AIR CIRCUIT BREAKERS 24
4.1 INSERTING POWER CIRCUIT BREAKERS 10 D.1 INSERTION PROCEDURE USING THE RPR-2 24
4.2 REMOVING POWER CIRCUIT BREAKERS 12 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
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July 2018 (RPR-2)
SECTION 1: INTRODUCTION 1.1 VISUAL PRESENTATION

Eaton’s RPR-2 provides a means of remotely racking most Power Eaton provides additional documentation designed to enhance the
Circuit Breakers that utilize the rotation of a shaft for insertion technical information provided in this instruction booklet for the
and removal. The person can be 25 feet or more away from the RPR-2. The digital supplemental booklet features informative videos
switchgear door during the racking process. This need for distance intended to assist with the RPR-2. The document is available for
away from the switchgear is due to safety precautions from potential immediate access at www.eaton.com/RPR-2.
Arc Flash occurrences.
1.2 QUICK RESPONSE CODE
Electric arcs result from thermal ionization that occurs when
current flow is interrupted by the separation of conductors. Thermal There is a quick response code (QR Code) on the escutcheon of the
ionization can generate temperatures as high as 35,000oF. Conductor head unit and UPS sleeve of the RPR-2. This QR Code is a matrix
materials melt into metal vapor and the surrounding air is ionized. barcode that provides direct access to download RPR-2 specific
If the arc is outside the interrupting chamber of a power circuit documentation, such as product instruction booklets and a visual
breaker, then a violent explosion occurs resulting in an inferno of presentation documentation. See Figure 1.1 for the featured RPR-2
ionized gases, molten debris, metal shrapnel, and a flash of light QR Code.
(Arc Flash). When Arc Flash initiates in a switchgear cabinet, the
NNote: A smart phone with an adequate QR Code Scanner application
rapidly escalating pressure will dislodge compartment doors and must be used. Downloading content may incur data charges from the
side sheets of the switchgear and turn hardware into high-speed mobile service provider.
projectiles.
Arc Flash levels are a function of circuit voltage, maximum Figure 1.1. Quick Response Code
available short circuit current at the point of flashover, conditions
of confinement, and the distance between the point of flashover RPR-2 QR Code
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.
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(RPR-2) July 2018
B G
C
E
F
D
Table 1. RPR-2 and RPR-2 Plus Dimensions

Overall Stanchion Max. Racking Min. Racking 360o Rotational
Height Height Height Height Width Depth Clearance
Profile Type 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”
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July 2018 (RPR-2)
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.
m WARNING
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.
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(RPR-2) July 2018
SECTION 3: RECEIVING, HANDLING, AND shelter from sun, rain, snow, corrosive fumes, dust, dirt falling
objects, excessive moisture, etc. must be provided. If the building is
STORAGE not heated, containers should be arranged to permit free circulation
Remote Power Racking units are subjected to complete factory of air on all sides and temporary heaters should be used to minimize
production tests and inspection before being packed. They are condensation. Moisture can cause rusting of metal parts. A heat
shipped in containers designed to provide maximum protection to level of approximately 400 watts for each 100 cubic feet of volume is
the equipment during shipment and storage and at the same time to recommended with the heaters distributed uniformly throughout the
provide convenient handling. structure near the floor.
3.1 RECEIVING
Until the RPR-2 unit is ready to be delivered to the switchgear site Figure 3.2. RPR-2 Transport Latch
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.
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.
Figure 3.3. RPR-2 Storage Cover
After examining the unit place the RPR-2 in a location which has a
120V power supply for the UPS.
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
3.4 RPR-2 APPROXIMATE WEIGHTS
If the RPR-2 unit is to be placed in storage, maximum protection
can be obtained by keeping it shielded with the provided cover Refer to Table 2.
(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 Table 2. RPR-2 Weight by Type
the Transport Latch engaged (Figure 3.2). The RPR-2 unit requires Type LBs
a 120V power supply for the UPS during storage and must remain
plugged in during this time. RPR-2 Universal Profile 315
Outdoor storage is NOT recommended. Indoor storage should RPR-2 Medium Profile 310
be in a building with sufficient heat and circulation to prevent RPR-2 Low Profile 300
condensation. The building must be well drained and a temporary
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July 2018 (RPR-2)
Figure 3.5. Profile External View of RPR-2
1 9
10
3
6
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
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(RPR-2) July 2018
Figure 3.6. Detail View of RPR-2 Head Unit
2 6
3
7
8
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
1 6
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)
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July 2018 (RPR-2)
SECTION 4: RACKING PROCEDURES Figure 4.3. RPR-2 Control Pendant

NNote: 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 Insert Button
completely into the Connected position without needing any
adjustments (foot pedal pressed etc.). In most cases this is the Status Indicator Light
Test position in the cell. This can be confirmed by referring to Remove Button
the breaker’s Instruction Book.
6) Turn on the power to the Power Module with the Power
Switch. (Figure 3.6)
Figure 4.1. RPR-2 Control Panel 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:
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.
Fusion Controller
Breaker Select Button Figure 4.4. Perf-A-Torque Models
Insert / Remove Switch
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)
8) Select the correct breaker program on the Power Module by
5) Turn on the Powerware UPS for the RPR-2 by pressing the pressing and releasing the Breaker Select Button until the desired
On button for approximately five seconds and allow for the program is displayed on the Fusion Controller. (Figure 4.1)
unit to initialize. (Figure 4.5) For all other menu settings and
features, please refer to the UPS instruction CD. 9) Select the INSERT direction with the Insert/Remove switch.
(Figure 4.1)
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(RPR-2) July 2018
Figure 4.5. UPS Power Button Figure 4.6. Foot Brake Set
Figure 4.7. Racking Adapter Connected To Breaker

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).
m WARNING
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. m WARNING
IF AT ANY TIME DURING THE INSERTION PROCESS AN OVER-TORQUE
12) Take the Pendant and move a safe distance away from OCCURS THE AMBER LIGHT ON THE PENDANT AND TOWER WILL FLASH.
front of the power circuit breaker. (The distance should be (THE AUTO REVERSE SELECTION IS NOTED ON THE NAMEPLATE OF THE
predetermined through Arc Flash calculations.) RPR-2 UNIT.)
13) When area is clear, depress and hold the Insert button (white
• IF THE AUTO-REVERSE FUNCTION IS SELECTED IN THIS SITUATION
with black arrow) on the pendant. (Figure 4.3) This will initiate
THE RPR-2 WILL THEN INITIALIZE THE REMOVAL PROCESS. ONCE THIS
the insertion process on the RPR-2 unit. The amber light on the
PROCESS IS COMPLETED THE GREEN AND AMBER LIGHTS ON THE
pendant and on the tower light will illuminate while the power
LIGHT TOWER WILL FLASH AND THE AMBER LIGHT ON THE PENDANT
circuit breaker is in the insertion process.
WILL TURN OFF INDICATING IT IS SAFE TO APPROACH THE POWER
NNote: If at any time during the insertion process the Insert button is released, CIRCUIT BREAKER.
the tower lights and pendant light will not be illuminated.
14) When the power circuit breaker is in the Connected position, • IF THE AUTO-REVERSE FUNCTION IS NOT SELECTED, PRESS AND HOLD
the red tower light will illuminate and the amber light on the THE REMOVE BUTTON (BLACK WITH WHITE ARROW) ON THE PENDANT.
pendant will turn off. This indicates that it is now safe to WHEN THE POWER CIRCUIT BREAKER IS COMPLETELY REMOVED, THE
approach the power circuit breaker. 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.
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July 2018 (RPR-2)
16) Turn the Insertion Shaft Lock to the Latched position. Push the
unit forward until the insertion shaft latches. m WARNING
17) Pull the unit away from the switchgear, while disconnecting SELECTION OF THE INCORRECT POWER CIRCUIT BREAKER PROGRAM MAY
the insertion shaft from the racking adaptor. RESULT IN THE RPR-2 UNIT SIGNALING COMPLETION OF THE REMOVAL
CYCLE WITH THE POWER CIRCUIT BREAKER ONLY PARTIALLY REMOVED.
18) Remove the racking adaptor from the breaker and place it back
into the storage box on the RPR-2 unit.
12) Take the Pendant and move a safe distance away from front
19) Turn Off the Power Module with the Power Switch. To turn of the power circuit breaker. (The distance should be predetermined
off the UPS, press and hold the Off button for approximately through Arc Flash calculations.)
five seconds.
20) Lower the Power module to the lowest position and engage m WARNING
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 IF AT ANY TIME DURING THE REMOVAL PROCESS AN OVER-TORQUE
unit. (Figure 3.5) Place the RPR-2 unit cover over the base OCCURS THE AMBER LIGHT ON THE PENDANT AND TOWER WILL
while in storage. (Figure 3.4) FLASH. THE UNIT WILL NOT REMOVE THE BREAKER FURTHER UNTIL THE
PROBLEM IS RESOLVED. FOLLOW THE COMPANY’S SAFETY PROCEDURES
21) The UPS should be connected to a wall receptacle when not in WHEN APPROACHING THE SWITCHGEAR CELL.
use to maintain a charge on the batteries.
4.2 REMOVING POWER CIRCUIT BREAKERS 13) When area is clear, depress and hold the Remove button
(black with white arrow) on the pendant. (Figure 4.3) This will
1) Follow all procedures defined by company’s Personal Protective initiate the removal process on the RPR-2 unit. The amber light
Equipment and Safety policy and the precautions and racking on the pendant and on the tower light will illuminate while the
instructions in the breaker IB. power circuit breaker is in the removal process.
2) Move the RPR-2 unit in front of the switchgear cell. Open NNote: If at any time during the removal process the Remove button is
the cell door to allow for access to the rotary type racking released, the tower lights and pendant light will not be illuminated.
mechanism of the breaker. If the cell has closed door racking 14) When the power circuit breaker is in the Disconnected
capability, insert the racking adaptor through the provided position, the green tower light will illuminate and the amber
opening with the cell door closed. light on the pendant will turn off. This indicates that it is now
3) Verify that the power circuit breaker is open and ready to be safe to approach the power circuit breaker.
racked out from the Connected position. 15) To disconnect the RPR-2 unit, push the unit toward the
4) If engaged, release Transport Latch to allow for vertical switchgear cell to disengage the brakes. Lift the brake lever up
movement of the Power Module. (Figure 3.6) to engage the holding magnet.
5) Turn on the Powerware UPS for the RPR-2 by pressing the 16) Turn the Insertion Shaft Lock to the Latched position. Push the
On button for approximately five seconds and allow for the unit towards the breaker until the insertion shaft latches.
unit to initialize. (Figure 4.5) For all other menu settings and 17) Pull the unit away from the switchgear, while disconnecting
features, please refer to the UPS instruction CD. the insertion shaft from the racking adaptor.
6) Turn on the power to the Power Module with the Power 18) Remove the racking adaptor from the breaker and place it back
Switch. (Figure 3.6) into the storage box on the RPR-2 unit.
7) Select the correct breaker program on the Power Module by 19) Turn Off the Power Module with the Power Switch. To turn
pressing and releasing the Breaker Select Button until the off the UPS, press and hold the Off button for approximately
desired program is displayed on the Fusion Controller. (Figure five seconds.
4.1) Before attempting to rack the circuit breaker, ensure the
nameplate matches the predetermined circuit breaker program 20) Lower the Power module to the lowest position and engage
on the Eaton display of the Fusion Controller. 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
8) Select the REMOVE direction on the Insert/Remove switch. unit. (Figure 3.5) Place the RPR-2 unit cover over the base
(Figure 4.1) while in storage. (Figure 3.4)
9) Select the correct racking adaptor for the breaker being 21) The UPS should be connected to a wall receptacle when not in
inserted. (Figure 3.1) If applicable, place the racking adaptor use to maintain a charge on the batteries.
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).
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(RPR-2) July 2018
SECTION 5: WARRANTY 6) With one person holding each side of the Power Module, slide it
off the end of the stanchion.
5.1 GENERAL
All Standard Remote Power Racking Systems (RPR-2) are furnished
with a Powerware UPS system and are covered by the warranty Figure 5.1. RPR-2 In Power Module Removal Position (Unit
stated in Eaton’s Electrical Services and Systems Selling Policy Supported By Standard Post For Demonstration Purposes)
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.
NNote: Attempts to repair the unit will void the warranty.
m WARNING
DO NOT ATTEMPT TO INSERT OR REMOVE ANY POWER CIRCUIT BREAKER
WITH A REMOTE POWER RACKING SYSTEM (RPR-2) THAT IS NOT
FUNCTIONING PROPERLY. FAILURE TO FOLLOW THIS WARNING COULD Figure 5.2. Removing Cable Retaining Hex Socket Button Head
RESULT IN DEATH, SERIOUS PERSONAL INJURY OR PROPERTY DAMAGE. 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.
Figure 5.3. Bottom View of Power Module
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.
5.2 PROCEDURE FOR POWER MODULE REMOVAL

NNote: 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.
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July 2018 (RPR-2)
5.3 REMOVING UPS MODULE FROM RPR-2 DEVICE 5.4 REPLACEMENT OF THE UPS MODULE BATTERIES
In certain cases where the UPS needs to be replaced due to a Once the UPS module has been removed from the RPR-2 device,
warranty repair, the UPS will need to be removed. the UPS module batteries can be replaced.
1. Locate the UPS module on the lower base of the RPR-2. NNote: All three batteries should be replaced at the same time.
2. Remove the UPS retaining bracket hardware (x4), and store the 1. Remove the front cover of the UPS module by pulling the left
UPS retaining bracket for reassembly. (Figure 5.4) two corners away from the unit. (Figure 5.7)
3. Disconnect the 120V power supply from the UPS Module 2. Disconnect the battery by pulling apart the battery terminals.
(Figure 5.5) and carefully slide the UPS module forward to (Figure 5.8)
remove it from the UPS sleeve. (Figure 5.6)
Figure 5.4. Removing UPS Retaining Bracket (x4) 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 www.eaton.com
(RPR-2) July 2018
3. With the battery disconnected, the internal battery cover plate 6. Once the batteries have been replaced, the battery pack plastic
may be removed. Remove the battery cover plate retaining tray should be re-taped to secure a tight fit when returning it to
hardware (x1) (Figure 5.9) and slide the battery cover plate in an the UPS module.
upward and outward direction. (Figure 5.10) 7. Slide the battery pack back into the UPS module and replace
4. Remove the UPS module battery pack from the UPS module. the internal battery cover plate using the existing cover plate
(Figure 5.11) hardware.
5. To ensure replacement is correct, replace each battery one at a 8. Reconnect the main battery terminals and replace the UPS
time. The wiring connections will remain the same. Each wire module front cover.
connection is marked for clarity. (Figure 5.12) 9. Reconnect thew 120V power supply to the UPS module.
10. The RPR-2 head unit can now be reconnected.
Figure 5.10. Removing UPS Battery Cover 11. Contact your local recycling or hazardous waste center for the
information on proper disposal of the used batteries.
m WARNING
• 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.
• 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.
Figure 5.11. Removing UPS Battery Pack
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)
NNote: 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
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July 2018 (RPR-2)
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 www.eaton.com
(RPR-2) July 2018
APPENDIX A: Figure A.1. Interlock Paddle Held Aside and Jog Button Pressed
To Start ITE-HK Racking Process
ITE-HK AIR CIRCUIT BREAKER
A.1 INSERTION PROCEDURE USING THE RPR-2
breaker.
power circuit breaker from the position that it can be racked
adjustments (foot pedal pressed etc.). This is the Test position
for HK breakers.
5) Turn on the Powerware UPS for the RPR-2 by pressing the
On button for approximately five seconds and allow for the
features, please refer to the UPS instruction CD.
pressing and releasing the Breaker Select Button until the
desired program is displayed on the Fusion Controller. (Figure
4.1) 12) In order to start racking the HK air breaker, the racking shaft
8) Select the INSERT direction with the Insert/Remove switch. interlock must be held aside. Do this by holding the interlock
(Figure 4.1) paddle aside while pressing and holding the RPR-2 Jog button
for the duration of one cycle. (Figure A.1) this will turn the
9) Select the correct racking adaptor for the breaker being breakers racking shaft far enough to hold the interlock paddle
inserted. (Figure 3.1) Place the racking adaptor on the breaker’s aside.
racking mechanism shaft. Position the RPR-2 shaft with the
racking adaptor. Turn the Insertion Shaft Lock to Unlatched 13) Take the Pendant and move a safe distance away from
position to allow for connection the RPR-2 into the racking front of the power circuit breaker. (The distance should be
adaptor on the power circuit breaker. (Figure 3.6) An extension predetermined through Arc Flash calculations.)
can be used if a longer length is needed. If necessary, the Jog 14) When area is clear, depress and hold the Insert button (white
button (Figure 3.6) can be pressed to rotate the shaft for correct with black arrow) on the pendant. (Figure 4.3) This will initiate
alignment (amber pendant and tower light will illuminate). the insertion process on the RPR-2 unit. The amber light on the
Horizontal alignment can be achieved with the casters and pendant and on the tower light will illuminate while the power
vertical alignment by raising or lowering the Power Module. circuit breaker is in the insertion process.
(Figure 4.2)
NNote: If at any time during the insertion process the Insert button is
10) Once the RPR-2 is connected, properly adjust the unit toward released, the tower lights and pendant light will not be illuminated.
the cell to insure the proper amount of travel is available for 15) When the power circuit breaker is in the Connected position,
the power circuit breaker insertion process. When an adequate the red tower light will illuminate and the amber light on the
amount of travel distance is achieved, the green tower light will pendant will turn off. This indicates that it is now safe to
illuminate. approach the power circuit breaker.
on the lever. (Figure 4.6) Verify that the correct power circuit
breaker program and the Insert direction are selected by m WARNING
viewing the LCD screen on the Fusion Controller (Figure 4.1). 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
m WARNING RPR-2 UNIT.)
RESULT IN THE RPR-2 UNIT SIGNALING COMPLETION OF THE INSERTION • IF THE AUTO-REVERSE FUNCTION IS SELECTED IN THIS SITUATION
CYCLE WITH THE POWER CIRCUIT BREAKER ONLY PARTIALLY INSERTED. 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.
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July 2018 (RPR-2)
• IF THE AUTO-REVERSE FUNCTION IS NOT SELECTED, PRESS AND HOLD 10) Once the RPR-2 is connected, properly adjust the unit away
THE REMOVE BUTTON (BLACK WITH WHITE ARROW) ON THE PENDANT. from the cell to insure the proper amount of travel is available
WHEN THE POWER CIRCUIT BREAKER IS COMPLETELY REMOVED, THE for the power circuit breaker insertion process. When an
AMBER LIGHT ON THE PENDANT WILL TURN OFF AND THE GREEN adequate amount of travel distance is achieved, the red tower
AND AMBER TOWER LIGHTS WILL FLASH INDICATING IT IS SAFE TO light will illuminate.
APPROACH THE POWER CIRCUIT BREAKER. 11) Engage the foot brake on the RPR-2 truck. Verify that the
16) To disconnect the RPR-2 unit, push the unit toward the direction are selected by viewing the LCD screen on the Fusion
switchgear cell to disengage the brakes. Lift the brake lever up Controller (Figure 4.1).
12) While holding the interlock paddle aside, press and hold the
17) Turn the Insertion Shaft Lock to the Latched position. Push the RPR-2 Jog button for the duration of one cycle. (Figure A.1)
unit forward until the insertion shaft latches. This will turn the breakers racking shaft far enough to hold the
18) Pull the unit away from the switchgear, while disconnecting interlock paddle aside.
the insertion shaft from the racking adaptor.
19) Remove the racking adaptor from the breaker and place it back m WARNING
into the storage box on the RPR-2 unit. SELECTION OF THE INCORRECT POWER CIRCUIT BREAKER PROGRAM MAY
20) Turn Off the Power Module with the Power Switch. To turn RESULT IN THE RPR-2 UNIT SIGNALING COMPLETION OF THE REMOVAL
off the UPS, press and hold the Off button for approximately CYCLE WITH THE POWER CIRCUIT BREAKER ONLY PARTIALLY REMOVED.
five seconds.
21) Lower the Power module to the lowest position and engage 13) Take the Pendant and move a safe distance away from
the Transport Latch. (Figure 3.3) The pendant can be stored front of the power circuit breaker. (The distance should be
by wrapping the cord around the post at the base of the RPR-2 predetermined through Arc Flash calculations.)
unit. (Figure 3.5) Place the RPR-2 unit cover over the base
while in storage. (Figure 3.4) m WARNING
22) The UPS should be connected to a wall receptacle when not in IF AT ANY TIME DURING THE REMOVAL PROCESS AN OVER-TORQUE
use to maintain a charge on the batteries. OCCURS THE AMBER LIGHT ON THE PENDANT AND TOWER WILL
FLASH. THE UNIT WILL NOT REMOVE THE BREAKER FURTHER UNTIL THE
A.2 REMOVAL PROCEDURE USING THE RPR-2 PROBLEM IS RESOLVED. FOLLOW THE COMPANY’S SAFETY PROCEDURES
1) Follow all procedures defined by company’s Personal Protective WHEN APPROACHING THE SWITCHGEAR CELL.
Equipment and Safety policy and the precautions and racking
instructions in the breaker IB. 14) When area is clear, depress and hold the Remove button
2) Move the RPR-2 unit in front of the switchgear cell. Open (black with white arrow) on the pendant. (Figure 4.3) This will
the cell door to allow for access to the rotary type racking initiate the removal process on the RPR-2 unit. The amber light
mechanism of the breaker. If the cell has closed door racking on the pendant and on the tower light will illuminate while the
capability, insert the racking adaptor through the provided power circuit breaker is in the removal process.
opening with the cell door closed. NNote: If at any time during the removal process the Remove button is
released, the tower lights and pendant light will not be illuminated.
racked out from the Connected position. 15) When the power circuit breaker is in the Disconnected
position, the green tower light will illuminate and the amber
4) If engaged, release Transport Latch to allow for vertical
light on the pendant will turn off. This indicates that it is now
safe to approach the power circuit breaker.
unit towards the breaker until the insertion shaft latches.
18) Pull the unit away from the switchgear, while disconnecting
desired program is displayed on the Fusion Controller. (Figure 19) Remove the racking adaptor from the breaker and place it back
4.1) into the storage box on the RPR-2 unit.
8) Select the REMOVE direction on the Insert/Remove switch. 20) Turn Off the Power Module with the Power Switch. To turn
(Figure 4.1) off the UPS, press and hold the Off button for approximately
five seconds.
inserted. (Figure 3.1) Place the racking adaptor on the breaker’s 21) Lower the Power module to the lowest position and engage
racking mechanism shaft. Position the RPR-2 shaft with the the Transport Latch. (Figure 3.3) The pendant can be stored
racking adaptor. Turn the Insertion Shaft Lock to Unlatched by wrapping the cord around the post at the base of the RPR-2
position to allow for connection the RPR-2 into the racking unit. (Figure 3.5) Place the RPR-2 unit cover over the base
adaptor on the power circuit breaker. (Figure 3.6) An extension while in storage. (Figure 3.4)
can be used if a longer length is needed. If necessary, the Jog 22) The UPS should be connected to a wall receptacle when not in
button (Figure 3.6) can be pressed to rotate the shaft for correct use to maintain a charge on the batteries.
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)
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(RPR-2) July 2018
APPENDIX B: Figure B.1. Only Use The “RAISE” Lifting Mechanism

GE AM-5 CIRCUIT BREAKER
B.1 INSERTION PROCEDURE USING THE RPR-2
m WARNING
ONLY USE THE “RAISE” LIFTING MECHANISM INTERFACE (INDICATED BY
THE ARROW IN FIGURE B.1) DURING RACKING OPERATIONS WITH
RPR-2 UNIT.

breaker.
power circuit breaker from the position that it can be racked
adjustments (foot pedal pressed etc.). This is the Test position
for HK breakers.
On button for approximately five seconds and allow for the m WARNING
6) Turn on the power to the Power Module with the Power CYCLE WITH THE POWER CIRCUIT BREAKER ONLY PARTIALLY INSERTED.
7) Select the correct breaker program on the Power Module by 12) Take the Pendant and move a safe distance away from
pressing and releasing the Breaker Select Button until the front of the power circuit breaker. (The distance should be
desired program is displayed on the Fusion Controller. (Figure predetermined through Arc Flash calculations.)
4.1) 13) When area is clear, depress and hold the Insert button (white
8) Select the INSERT direction with the Insert/Remove switch. with black arrow) on the pendant. (Figure 4.3) This will initiate
(Figure 4.1) 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.
inserted. (Figure 3.1) Place the racking adaptor on the breaker’s
racking mechanism shaft. Position the RPR-2 shaft with the NNote: If at any time during the insertion process the Insert button is
racking adaptor. Turn the Insertion Shaft Lock to Unlatched released, the tower lights and pendant light will not be illuminated.
position to allow for connection the RPR-2 into the racking 14) When the power circuit breaker is in the Connected position,
adaptor on the power circuit breaker. (Figure 3.6) An extension the red tower light will illuminate and the amber light on the
can be used if a longer length is needed. If necessary, the Jog pendant will turn off. This indicates that it is now safe to
button (Figure 3.6) can be pressed to rotate the shaft for correct approach the power circuit breaker.
Horizontal alignment can be achieved with the casters and
vertical alignment by raising or lowering the Power Module. m NOTICE
(Figure 4.2) IF AT ANY TIME DURING THE INSERTION PROCESS AN OVER-TORQUE
10) Once the RPR-2 is connected, properly adjust the unit toward OCCURS THE AMBER LIGHT ON THE PENDANT AND TOWER WILL FLASH.
the cell to insure the proper amount of travel is available for (THE AUTO REVERSE SELECTION IS NOTED ON THE NAMEPLATE OF THE
the power circuit breaker insertion process. When an adequate RPR-2 UNIT.)
amount of travel distance is achieved, the green tower light will
illuminate. • IF THE AUTO-REVERSE FUNCTION IS SELECTED IN THIS SITUATION
11) Engage the foot brake on the RPR-2 truck by stepping down THE RPR-2 WILL THEN INITIALIZE THE REMOVAL PROCESS. ONCE THIS
on the lever. (Figure 4.6) Verify that the correct power circuit PROCESS IS COMPLETED THE GREEN AND AMBER LIGHTS ON THE
breaker program and the Insert direction are selected by LIGHT TOWER WILL FLASH AND THE AMBER LIGHT ON THE PENDANT
viewing the LCD screen on the Fusion Controller (Figure 4.1). WILL TURN OFF INDICATING IT IS SAFE TO APPROACH THE POWER
CIRCUIT BREAKER.
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July 2018 (RPR-2)
• IF THE AUTO-REVERSE FUNCTION IS NOT SELECTED, PRESS AND HOLD can be used if a longer length is needed. If necessary, the Jog
THE REMOVE BUTTON (BLACK WITH WHITE ARROW) ON THE PENDANT. button (Figure 3.6) can be pressed to rotate the shaft for correct
WHEN THE POWER CIRCUIT BREAKER IS COMPLETELY REMOVED, THE alignment (amber pendant and tower light will illuminate).
AMBER LIGHT ON THE PENDANT WILL TURN OFF AND THE GREEN Horizontal alignment can be achieved with the casters and
AND AMBER TOWER LIGHTS WILL FLASH INDICATING IT IS SAFE TO vertical alignment by raising or lowering the Power Module.
APPROACH THE POWER CIRCUIT BREAKER. (Figure 4.2)
15) To disconnect the RPR-2 unit, push the unit toward the from the cell to insure the proper amount of travel is available
switchgear cell to disengage the brakes. Lift the brake lever up for the power circuit breaker insertion process. When an
to engage the holding magnet. adequate amount of travel distance is achieved, the red tower
16) Turn the Insertion Shaft Lock to the Latched position. Push the light will illuminate.
unit forward until the insertion shaft latches. 11) Engage the foot brake on the RPR-2 truck. Verify that the
17) Pull the unit away from the switchgear, while disconnecting correct power circuit breaker program and the Remove
the insertion shaft from the racking adaptor. direction are selected by viewing the LCD screen on the Fusion
19) Turn Off the Power Module with the Power Switch. To turn m WARNING
off the UPS, press and hold the Off button for approximately SELECTION OF THE INCORRECT POWER CIRCUIT BREAKER PROGRAM MAY
five seconds. RESULT IN THE RPR-2 UNIT SIGNALING COMPLETION OF THE REMOVAL
CYCLE WITH THE POWER CIRCUIT BREAKER ONLY PARTIALLY REMOVED.
20) Lower the Power module to the lowest position and engage
by wrapping the cord around the post at the base of the RPR-2 12) Take the Pendant and move a safe distance away from
unit. (Figure 3.5) Place the RPR-2 unit cover over the base front of the power circuit breaker. (The distance should be
while in storage. (Figure 3.4) predetermined through Arc Flash calculations.)
21) The UPS should be connected to a wall receptacle when not in
use to maintain a charge on the batteries. m NOTICE
IF AT ANY TIME DURING THE REMOVAL PROCESS AN OVER-TORQUE
B.2 REMOVAL PROCEDURE USING THE RPR-2 OCCURS THE AMBER LIGHT ON THE PENDANT AND TOWER WILL
FLASH. THE UNIT WILL NOT REMOVE THE BREAKER FURTHER UNTIL THE
m WARNING PROBLEM IS RESOLVED. FOLLOW THE COMPANY’S SAFETY PROCEDURES
WHEN APPROACHING THE SWITCHGEAR CELL.
ONLY USE THE “RAISE” LIFTING MECHANISM INTERFACE (INDICATED BY
THE ARROW IN FIGURE B.1) DURING RACKING OPERATIONS WITH
RPR-2 UNIT. 13) When area is clear, depress and hold the Remove button
initiate the removal process on the RPR-2 unit. The amber light
1) Follow all procedures defined by company’s Personal Protective on the pendant and on the tower light will illuminate while the
Equipment and Safety policy and the precautions and racking power circuit breaker is in the removal process.
instructions in the breaker IB.
NNote: If at any time during the removal process the Remove button is
2) Move the RPR-2 unit in front of the switchgear cell. Open 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
racked out from the Connected position.
4) If engaged, release Transport Latch to allow for vertical to engage the holding magnet.
5) Turn on the Powerware UPS for the RPR-2 by pressing the unit towards the breaker until the insertion shaft latches.
17) Pull the unit away from the switchgear, while disconnecting
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.
4.1) 20) Lower the Power module to the lowest position and engage
8) Select the REMOVE direction on the Insert/Remove switch.
by wrapping the cord around the post at the base of the RPR-2
(Figure 4.1)
9) Select the correct racking adaptor for the breaker being while in storage. (Figure 3.4)
inserted. (Figure 3.1) Place the racking adaptor on the breaker’s
21) The UPS should be connected to a wall receptacle when not in
racking mechanism shaft. Position the RPR-2 shaft with the
use to maintain a charge on the batteries.
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
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(RPR-2) July 2018
APPENDIX C: Figure C.2. Inserting Axial Compliant Racking Adapter

GE MAGNEBLAST VERTICAL LIFT
C.1 INSERTION PROCEDURE USING THE RPR-2
Equipment and safety policy. Follow all precautions and
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.
6) Turn on the power to the Power Module with the Power Switch.
(Figure 3.6)
4.1) Figure C.3. Attaching Mechanical Torque Limiter
8) Select the INSERT direction with the Insert/Remove switch
(Figure 4.1)
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)
16) Insert the “pull back handle” into the racking adapter housing.
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July 2018 (RPR-2)
The “hook” on the handle will need to be positioned behind the the switchgear. The control box has magnets to allow easy
clutch handle. (Figure C.6) attachment to the switchgear. (Figure C.8)
17) Insert the retaining clip between the “hook” and the clutch 19) Connect the motor plug from the vertical control box into the
handle. (Figure C.7) switchgear female motor connection plug. (Figure C.9)
18) Attach the vertical control box to a convenient location in 20) Position the RPR-2 in front of the cell, near the racking adapter
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
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(RPR-2) July 2018
housing. Figure C.12. Engaging The Clutch with the Racking Handle
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.11)
Figure C.10. Alignment of RPR-2 with Racking Adapter
C.2 REMOVAL PROCEDURE USING THE RPR-2

1) Follow the same setup procedures as indicated in Steps
Figure C.11. Attach Amphenol Connector
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
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.
NNote: If at any time during the removal process the remove button is
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) 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.
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.
NNote: If at any time during the insertion process the insert button is
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.
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July 2018 (RPR-2)
APPENDIX D: Figure D.1. Westinghouse DH Adapter Kit Installed

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.

breaker.
mechanism of the breaker.
racked in from the correct position. The position depends on
what type of power circuit breaker is being inserted.
6) Turn on the power to the Power Module with the Power predetermined through Arc Flash calculations.)
Switch. (Figure 3.6) 14) When area is clear, depress and hold the Insert button (white
7) Select the correct breaker program on the Power Module by with black arrow) on the pendant. (Figure 4.3) This will initiate
pressing and releasing the Breaker Select Button until the the insertion process on the RPR-2 unit. The amber light on the
desired program is displayed on the Fusion Controller. (Figure pendant and on the tower light will illuminate while the power
4.1) circuit breaker is in the insertion process.
8) Select the INSERT direction with the Insert/Remove switch. NNote: If at any time during the insertion process the Insert button is
(Figure 4.1)
9) Select the correct racking adaptor for the breaker being 15) When the power circuit breaker is in the Connected position,
inserted. (Figure 3.1) Place the racking adaptor on the breaker’s the red tower light will illuminate and the amber light on the
racking mechanism shaft. Position the RPR-2 shaft with the pendant will turn off. This indicates that it is now safe to
racking adaptor. Turn the Insertion Shaft Lock to Unlatched approach the power circuit breaker.
position to allow for connection the RPR-2 into the racking
adaptor on the power circuit breaker. (Figure 3.6) An extension m WARNING
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 IF AT ANY TIME DURING THE INSERTION PROCESS AN OVER-TORQUE
alignment (amber pendant and tower light will illuminate). OCCURS THE AMBER LIGHT ON THE PENDANT AND TOWER WILL FLASH.
Horizontal alignment can be achieved with the casters and (THE AUTO REVERSE SELECTION IS NOTED ON THE NAMEPLATE OF THE
vertical alignment by raising or lowering the Power Module. RPR-2 UNIT.)
(Figure 4.2)
• IF THE AUTO-REVERSE FUNCTION IS SELECTED IN THIS SITUATION
10) Once the RPR-2 is connected, properly adjust the unit toward THE RPR-2 WILL THEN INITIALIZE THE REMOVAL PROCESS. ONCE THIS
the cell to insure the proper amount of travel is available for PROCESS IS COMPLETED THE GREEN AND AMBER LIGHTS ON THE
the power circuit breaker insertion process. When an adequate LIGHT TOWER WILL FLASH AND THE AMBER LIGHT ON THE PENDANT
amount of travel distance is achieved, the green tower light will WILL TURN OFF INDICATING IT IS SAFE TO APPROACH THE POWER
illuminate. CIRCUIT BREAKER.
on the lever. (Figure 4.6) Verify that the correct power circuit • IF THE AUTO-REVERSE FUNCTION IS NOT SELECTED, PRESS AND HOLD
breaker program and the Insert direction are selected by THE REMOVE BUTTON (BLACK WITH WHITE ARROW) ON THE PENDANT.
viewing the LCD screen on the Fusion Controller (Figure 4.1). WHEN THE POWER CIRCUIT BREAKER IS COMPLETELY REMOVED, THE
AMBER LIGHT ON THE PENDANT WILL TURN OFF AND THE GREEN
m WARNING 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
CYCLE WITH THE POWER CIRCUIT BREAKER ONLY PARTIALLY INSERTED.
will need to be released to operate the breaker. By lifting up
the Operator Lock the Push Handle can be disengaged and
12) In order to start the racking process for the Westinghouse DH released
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 17) To disconnect the RPR-2 unit, push the unit toward the
the entire racking process. (Figure D.1) switchgear cell to disengage the brakes. Lift the brake lever up
13) Take the Pendant and move a safe distance away from
front of the power circuit breaker. (The distance should be 18) Turn the Insertion Shaft Lock to the Latched position. Push the
unit forward until the insertion shaft latches.
24 www.eaton.com
(RPR-2) July 2018
19) Pull the unit away from the switchgear, while disconnecting m WARNING
20) Remove the racking adaptor from the breaker and place it back RESULT IN THE RPR-2 UNIT SIGNALING COMPLETION OF THE REMOVAL
into the storage box on the RPR-2 unit. CYCLE WITH THE POWER CIRCUIT BREAKER ONLY PARTIALLY REMOVED.
21) Turn Off the Power Module with the Power Switch. To turn
off the UPS, press and hold the Off button for approximately 13) Take the Pendant and move a safe distance away from
five seconds. front of the power circuit breaker. (The distance should be
22) Lower the Power module to the lowest position and engage predetermined through Arc Flash calculations.)
by wrapping the cord around the post at the base of the RPR-2 m WARNING
while in storage. (Figure 3.4) IF AT ANY TIME DURING THE REMOVAL PROCESS AN OVER-TORQUE
OCCURS THE AMBER LIGHT ON THE PENDANT AND TOWER WILL
23) The UPS should be connected to a wall receptacle when not in FLASH. THE UNIT WILL NOT REMOVE THE BREAKER FURTHER UNTIL THE
use to maintain a charge on the batteries. PROBLEM IS RESOLVED. FOLLOW THE COMPANY’S SAFETY PROCEDURES
WHEN APPROACHING THE SWITCHGEAR CELL.
D.2 REMOVAL PROCEDURE USING THE RPR-2
1) Follow all procedures defined by company’s Personal Protective 14) When area is clear, depress and hold the Remove button
Equipment and Safety policy and the precautions and racking (black with white arrow) on the pendant. (Figure 4.3) This will
instructions in the breaker IB. initiate the removal process on the RPR-2 unit. The amber light
2) Move the RPR-2 unit in front of the switchgear cell. Open on the pendant and on the tower light will illuminate while the
the cell door to allow for access to the rotary type racking power circuit breaker is in the removal process.
mechanism of the breaker. If the cell has closed door racking NNote: If at any time during the removal process the Remove button is
capability, insert the racking adaptor through the provided released, the tower lights and pendant light will not be illuminated.
opening with the cell door closed. 15) When the power circuit breaker is in the Disconnected
3) Verify that the power circuit breaker is open and ready to be position, the green tower light will illuminate and the amber
racked out from the Connected position. light on the pendant will turn off. This indicates that it is now
4) If engaged, release Transport Latch to allow for vertical
movement of the Power Module. (Figure 3.6) 16) When the Green indicator light is illuminated the Push
Handle will need to be released on the breaker. By lifting up
5) Turn on the Powerware UPS for the RPR-2 by pressing the the Operator Lock the Push Handle can be disengaged and
On button for approximately five seconds and allow for the released.
features, please refer to the UPS instruction CD. 17) To disconnect the RPR-2 unit, push the unit toward the
6) Turn on the power to the Power Module with the Power to engage the holding magnet.
7) Select the correct breaker program on the Power Module by unit towards the breaker until the insertion shaft latches.
desired program is displayed on the Fusion Controller. (Figure 19) Pull the unit away from the switchgear, while disconnecting
4.1) the insertion shaft from the racking adaptor.
8) Select the REMOVE direction on the Insert/Remove switch. 20) Remove the racking adaptor from the breaker and place it back
(Figure 4.1) into the storage box on the RPR-2 unit.
9) Select the correct racking adaptor for the breaker being 21) Turn Off the Power Module with the Power Switch. To turn
inserted. (Figure 3.1) Place the racking adaptor on the breaker’s off the UPS, press and hold the Off button for approximately
racking mechanism shaft. Position the RPR-2 shaft with the five seconds.
racking adaptor. Turn the Insertion Shaft Lock to Unlatched 22) Lower the Power module to the lowest position and engage
position to allow for connection the RPR-2 into the racking the Transport Latch. (Figure 3.3) The pendant can be stored
adaptor on the power circuit breaker. (Figure 3.6) An extension by wrapping the cord around the post at the base of the RPR-2
can be used if a longer length is needed. If necessary, the Jog unit. (Figure 3.5) Place the RPR-2 unit cover over the base
button (Figure 3.6) can be pressed to rotate the shaft for correct while in storage. (Figure 3.4)
Horizontal alignment can be achieved with the casters and 23) The UPS should be connected to a wall receptacle when not in
vertical alignment by raising or lowering the Power Module. use to maintain a charge on the batteries.
(Figure 4.2)
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
direction are selected by viewing the LCD screen on the Fusion
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)
www.eaton.com 25
Eaton
1000 Eaton Boulevard
Cleveland, OH 44122
United States
Eaton.com
© 2018 Eaton
All Rights Reserved Eaton is a registered trademark.
Printed in USA
Publication No. IB182071EN All trademarks are property
July 2018 of their respective owners.

EATON - Remote Power Racking 2

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EATON - Remote Power Racking 2

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Supercedes October 2013

Instruction Book IB182071EN Effective July 2018

Remote Power Racking System

RPR-2 Low Profile Shown

DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY

This product was manufactured by Eaton at the Power Breaker

INSTALLATION OR MAINTENANCE SHOULD BE ATTEMPTED ONLY

THE CIRCUIT BREAKERS DESCRIBED IN THIS BOOK ARE DESIGNED AND

ALL SAFETY CODES, SAFETY STANDARDS AND/OR REGULATIONS AS

THESE VACUUM REPLACEMENT CIRCUIT BREAKERS ARE DESIGNED TO

SECTION 1: INTRODUCTION 4 APPENDIX A: ITE-HK AIR CIRCUIT BREAKER 17

SECTION 1: INTRODUCTION 1.1 VISUAL PRESENTATION

Table 1. RPR-2 and RPR-2 Plus Dimensions

SECTION 2: SAFE PRACTICES

• Only qualified persons, as defined in the National Electrical

When opening the containers, be careful that any loose items or

Figure 3.1. Typical Tools and Accessories

Figure 3.5. Profile External View of RPR-2

Profile External View of RPR-2 (Univeral Profile Shown)

Figure 3.6. Detail View of RPR-2 Head Unit

Front External View

Rear External View

SECTION 4: RACKING PROCEDURES Figure 4.3. RPR-2 Control Pendant

Figure 4.2. Height Adjustment of Power Module

4) If engaged, release the Transport Latch to allow for vertical

Figure 4.7. Racking Adapter Connected To Breaker

PLUGGING THE POWER SUPPLY CABLE OF THE POWER MODULE DIRECTLY

THE COUNTERWEIGHT CABLE IS MANUFACTURED WITH AN INFUSED

Contact the Power Breaker Center (PBC) immediately by calling

5.2 PROCEDURE FOR POWER MODULE REMOVAL

• PROPER DISPOSAL OF BATTERIES IS REQUIRED. REFER TO YOUR

• DO NOT ATTEMPT TO OPEN OR DESTROY THE BATTERY. TOXIC AND

• DO NOT DISCARD THE UPS OR THE UPS BATTERIES IN THE

SECTION 6: REPLACEMENT PARTS

6.2 ORDERING INSTRUCTIONS

APPENDIX B: Figure B.1. Only Use The “RAISE” Lifting Mechanism

1) Follow all procedures defined by company’s Personal Protective

APPENDIX C: Figure C.2. Inserting Axial Compliant Racking Adapter

Figure C.1. Removing Access Cover

Figure C.4. Removing Lifting Motor

9) Remove the access cover from the Special Applications Racking

Figure C.6. Attaching Pull Back Housing

Figure C.9. Connecting Vertical Control Box Motor Plug

Figure C.7. Attaching Retaining Clip

Figure C.10. Alignment of RPR-2 with Racking Adapter

C.2 REMOVAL PROCEDURE USING THE RPR-2

APPENDIX D: Figure D.1. Westinghouse DH Adapter Kit Installed

1) Follow all procedures defined by company’s Personal Protective

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