Instruction Leaflet
30-471 (E)
Westinghouse Canada
Electronics, Control and Distribution Products Division
Page 1
September, 1984
New Information
Robonic II Automatic
Transfer Switches
Operation and
Maintenance Manual
Index
Warranty .........................................2
Westinghouse Offices.....................3
General Description ........................4
Component Identification ................7
LRO Description .............................5
RO Description ...............................6
PRO Description.............................6
Application Information ...................7
Logic Control ..................................7
Replacing Parts ............................ 13
Trouble Shooting Guide ................ 14
Recommended Maintenance ........14
AUTOMATIC TRANSFER SWITCH
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Instruction Leaflet
30-471 (E)
Page 3
Westinghouse industrial products, and a complete line of electrical construction products, are
distributed across Canada by WESCO (Westinghouse Sales & Distribution Company). For product
application, delivery or pricing information, call the WESCO office nearest you.
For Supply
WESCO Sales Office
St. John’s
Halifax
Moncton
Chicoutimi
Montreal
Quebec
Rimouski
Sept-Iles
Hamilton
Kitchener
London
726-9073 95 O’Leary Ave,
454-5851 3377 Kempt Rd.
854-8600 400 Edinburgh Dr.
549-0368 1533, boul. Talbot
631-9471 2125, 23 ave.
656-1025 2385, rue Watt
724-9224 170 rue industrielle
962-6552 253, avenue Joliette
528-8811 1910 Barton St. E.
893-6630 10 Goodrich Drive
1-800-265-8241
Regina
Saskatoon
Calgary
525-5841 1625-8th Avenue
242-1296 509-44th St E.
253-7561 810-59th AveSE
Calgary
253-756
11316-11th Ave SW
Edmonton
Edmonton
Red Deer
Abbotsford
Kamloops
Kelowna
Nanaimo
452-7920 14760-116th Ave NW
437-3660 4484-97 St NW
343-2113 1-7743 - 50th Avenue
859-3111 34446 S. Fraser Way
374-2112 961A Laval Cresent
860-3918 1936 Kent Road
758-1777 1809 Freemont Road
Ottawa
Sarnia
733-2500 1800 Bank St.
336-0722 1127 N. McGregor St.
673-8413 48 Pacific Ave.
622-0638 700 Norah Crescent
445-0550 840 York Mills Rd.
966-2300 59 Eugenie St. E.
772-9401 1460 Ellice Avenue
Prince George 562-3306 2223 Nicholson St N.
Surrey
588-6501 13811-103rd Avenue
368-6474 1050 Eldorado St.
688-0277 1000 Beach Avenue
382-7265 481 Cecelia Road
299-5566 6000 Lougheed Hwy.
Sudbury
Thunder Bay
Toronto
Windsor
Winnipeg
Trail
Vancouver
Victoria
Burnaby
Westinghouse products for electrical utilities are available through the listed Utility Sales offices.
Call the office nearest you.
Utility Sales Offices
Fredericton
Halifax
Montreal
Toronto
454-6952 460-440King St.
Winnipeg
Calgary
Edmonton
Burnaby
772-9906 1460 Ellice Acve.
422-4441 720 Barrington St Tower
842-2566 2723-1, Complexe Desjardins
595-9551 1012-790 Bay St.
265-1204 707-324 8th Ave SW
428-7540 516-10303 Jasper Ave
299-5566 6000 Lougheed Hwy.
Westinghouse Service Centres provide after-sales service, installation and start-up supervision,
also testing and inspection, system verification, field repairs, alignment and balancing, rewind of
all types of motors and generators, modification and rebuilding for all makes of electrical and
mechanical equipment. Call the centre nearest you for service at all hrs.
For Service
Service Centres
St. John’s
Dartmouth
Sydney
Moncton
Campbellton
Saint John
Montreal
Quebec
Sept-Iles
Chicoutimi
Hamilton
Kingston
Kitchener
London
722-7282 89 O’Leary Ave,
469-8400 71 Wright Avenue
562-2242 RR2 Marion Bridge
382-4457 80 Enterprise St.
753-3590 144 Water Street
542-7708 71 Crown Street
748-8811 180, rue Authier
656-1026 2385, rue Watt
962-9803 180, rue Maltais
549-6968 1533 Boul. Talbot
545-1151 717 Woodward Ave.
389-8565 637 Justus Drive
744-1161 20 Alpine Court
453-0470 45 Pacific Court
Sudbury
Swastika
Thunder Bay
Toronto
Windsor
Winnipeg
Regina
Saskatoon
Calgary
Edmonton
674-3356 48 Pacific Avenue
642-3252 Westinghouse Ave.
577-4267 635 Mountdale Avenue
255-8551 55 Goldthorne Ave.
944-0121 4080 E.C. Row Ave. E.
775-8643 1460 Elice Avenue
352-5606 545 Dewdney Ave. E.
934-5251 800-47th Street E.
273-0991 1856 Centre Ave. S.E.
465-7541 8011 Davies Rd., NW
Ft. McMurray 743-8123 8204 Fraser Avenue
Nanaimo 758-9171 2311 McCullough Road
Prince George 562-5571 2235 Nicholson St N.
Vancouver 278-9841 13300 Vulcan Way
St. Catharines 277-1020 475 Glendale Avenue
Sarnia 337-3285 348 Queen Street S.
You can be sure...if it’s Westinghouse
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Instruction Leaflet
30-471 (E)
Page 4
General Description
Mechanical Component Identification
CSA Standard C22.2 No. 178-1978 defines an automatic transfer
switch as, “self acting equipment for transferring one or more load
conductor connections from one power source to another.” The same
Standard also gives definitions for type A and type B automatic transfer
switches. “Transfer” switch type A means an automatic transfer switch
that does not employ integral overcurrent devices.” “Transfer switch,
type B means an automatic transfer switch that (does) employ integral
overcurrent protection”. Westinghouse Robonics in type A are
equipped with special instantaneous magnetic only interrupter. The trip
settings of these special interrupter are set (and fixed) at higher than
standard values. They are intended to trip only if the upstream
protective device fails to clear a fault. Incorporating these special
magnetic only interrupter, a type A Robonic operates in exactly the
same way as a transfer switch not having this feature. In the event that
both devices trip, the Robonics control circuitry will automatically
initiate transfer to the alternate source. The transfer operation will reset
the “tripped” magnetic only interrupter. Information on instantaneous
trip value, interrupting, closing and withstand ratings, and recommen-
dations for maximum upstream protective devices for type A Robonics,
are given in tables 1, 2, 3 on page 7. The information given in these
tables is necessary for proper application. Type B “Robonics” are
equipped with standard thermal-magnetic breakers which will provide
the required overload and short circuit protection. Type B Robonics can
also be built using Seltronic or SCB breakers which could include
ground fault tripping as well as overload and short circuit protection.
For application information or assistance with type B Robonics, refer to
Westinghouse.
The Robonic II provides automatic transfer of an electrical load to a
stand-by power supply in the event of drop or loss of voltage of any or
all phases of the normal power supply. Upon the restoration of the
normal supply, the electrical load is automatically re-transferred to the
normal power supply.
Type RO
The transfer motor utilizes the power from the source to which the
electrical load is being transferred. The mechanism is also designed to
leave both breakers trip free in the closed position, permitting incorpo-
ration of the thermal and short-circuit protection in either or both
breakers. In the higher ampacity models, type RO and PRO, an alarm
switch contact is supplied. This contact is connected in the transfer
motor circuit to lock the motor circuit out of operation when the
breaker(s) trip on an overload or short-circuit condition. Then the
breaker has to be manually reset. Instructions for the reset procedure
are located on the front of the operating mechanism.
All of the control modules are plug-in units which are easily replaced.
Type LRO
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Instruction Leaflet
30-471 (E)
Page 5
Solid State Logic Control Panel
Type LRO Robonic II Automatic Transfer Switch
Rated 30 amperes through 100 amperes at 600 volts Ac maximum 50
or 60 Hertz.
Emergency
Normal
The mechanism is a lever operated device controlled by a 120 volt
unidirectional motor.
The transfer motor drives a nylon cam which in turn operates a steel
lever by sliding a pin along a slot in the back of the lever. The lever, in
turn, operates the two breaker handles. The distance travelled is
determined by two projections on the cam. These projections operate
two micro switches (NLS, ELS) which in turn disconnect the power to
the transfer motor causing a brake to operate.
Projection To
Operate Limit Switch
Pivot Post
Operating Arm
The type LRO has three operating positions. They are the normal
breaker closed and the emergency breaker open, the emergency
breaker closed and the normal breaker open or both the normal and
emergency breakers open but never both normal and emergency
breakers closed.
Cam
The type LRO can also be easily manually operated. Open the lever
cover, remove the slide pin and place it in the hole supplied in the lever
cover and close the cover. Then the lever can be manually operated for
what ever position desired without interference by the automatic
control. For automatic control again, simply align the lever slot with the
hole in the operating cam and replace the slide pin.
The various automatic control components are described under the
section titled “Logic Control”.
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Instruction Leaflet
30-471 (E)
Page 6
Type “RO” Robonic II Automatic Transfer Switch
Type “PRO” Robonic II Automatic Transfer Switch
A complete line rated from 150 amperes through 1000 amperes at 600
volts Ac or at 250 volts Dc.
Rated 1200 amperes through 3000 amperes at 600 volts Ac or 250
volts Dc.
The transfer mechanism consists of the transfer motor, a gear train and
two breaker operating cams.
The transfer mechanism consists of a transfer motor, a gear train and
two breaker operating cams.
Scribe Line
Scribe Line
Scribe Line
Scribe Line
Spur Gear Meshing Relationship
Spur Gear Meshing Relationship
(bottom view of top cover)
(bottom view of top cover)
The transfer motor drives the centre gear which in turn operates the
two secondary gears. There is a projection in the secondary gears
which slides in a groove in the operating cams moving the cams from
side to side. The breaker handles are set inside two outer guides of the
cam and are also moved from side to side. There are two micro
switches (NLS, ELS) inside the breakers which are operated by the
breaker’s main contacts to disconnect the transfer motor power supply
and allow the brake to operate.
The transfer motor drives a centre gear which in turn drives two inner
secondary gears. These two inner gears then drive larger, outer
secondary gears. There are projections from these outer secondary
gears which slide in a groove at the back of each operating cams
moving the cam up and down. The breaker handles are set inside two
outer guides on the cams, moving up and down with the cams. There
are two micro switches (NLS, ELS) inside the breakers which are
operated by the breaker’s main contacts to disconnect the transfer
motor power supply and allow the brake to operate.
The type “RO” transfer switch has three operating positions, the normal
breaker closed and the emergency breaker open, the emergency
breaker closed and the normal breaker open or both the normal and
the emergency breakers open but never both the normal and emer-
gency breakers closed at the same time.
The type “PRO” transfer switch has three operating positions, the normal
breaker closed and the emergency breaker open, the emergency
breaker closed and the normal breaker open or both the normal and
emergency breakers closed at the same time.
The type “RO” Robonic II Transfer Switch is also easy to operate
manually. Simply remove the transfer motor fuse and turn the black
handle on the front of the transfer mechanism in a counter clockwise
direction until you hear the breakers operated and the indicator is in the
desired position. There will be no interference from the solid state
control. For automatic control again, replace the transfer motor fuse
and the Robonic II transfer switch will seek the power available.
The type “PRO” Robonic II Automatic Transfer Switch is also easy to
operate manually. Simply remove the transfer motor fuse and turn the
black handle on the front of the transfer mechanism in a counter-clockwise
direction until you hear the breakers operated and the colour indicator
shows the desired position. For automatic control again, replace the
transfer motor fuse and the Robonic II Transfer switch will seek the
power available.
The various control components are described under the section titled
Logic Control.
The various control components are described under the section titled
Logic Control
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Instruction Leaflet
30-471 (E)
Page 7
Table 1 — Interrupting, Closing and Withstand Rating —
Robonic Type A
Table 3 — Maximum Upstream Circuit Protective Devices for
Type A Robonics, 90% or Larger Motor Load
Robonic
Continuous
Rating
rms symmetrical amperes
Robonic
Maximum Upstream
Maximum Upstream
Fuse-Rating¬
Type
600 Vac
480 Vac
120,208,240 Vac
Type Continuous Breaker Frame Size
Class
J or L
Class
K5 or R
30 to 100 amps
LRO
RO
RO
14,000
22,000
22,000
65,000
14,000
22,000
30,000
65,000
18,000
25,000
42,000
125,000
Rating
(amps)
150 to 225 amps
300 to 1000 amps
1200 to 3000 amps
PRO
LRO 30, 70, 100
EB, EHB, FB, HFB, FB-P
LA-P c/w 400LAP10
300
400
100
225
RO 150,200,225 CA,CAH,JA,KA,HKA,LA,HLL,LB,
HLB, MA, NB, HLC, MC, HMC, NC,
Since type A Robonics employ magnetic only breakers, their interrupt-
ing, closing and withstand ratings are the same value. Under fault
HNC, LA-P, NB-P c/w 500 NAB12
conditions, with it’s “normal” breaker closed, a Robonic is required to
withstand the energy let through of the normal service protective
device while the fault is being cleared. At the same time, should the
normal voltage fall below the voltage sensing relay’s selected value, -
and if the alternate source were available, the Robonic could transfer
before the normal service protective device cleared the fault.
RO 400
LB, HLB, LC, HLC, LA, HLA, LA-P
MA,HMA,MC, HMC, NB, HNP, NC,
MNC, NB-P
600
400
600
RO 600, 800
MA, HMA, MC, HMC, NB, MNB, NC, 1200
MNC, NB-P
RO 1000
NB, HNB, NC, HNC, PB-P
NB,HNB,NC,HNC,PB-P
PB, PC, PB-P
1200
1200
2000
...
...
...
This would require that the Robonic be capable of interrupting the
protective device’s let through current. In addition, the Robonic could
be required to close in on a fault. Thus can be seen the need for
Robonics to have, interrupting, closing and withstand ratings.
PRO 1200
PRO 1400, 2000
¬
Fuse ratings given are as allowed by C.E.C. If other ratings are desired, refer to C.E.C.
The interrupting, closing and withstand ratings shown in Table 1 are
those for standard type A Robonics. For higher values, consideration
can be given to use of Robonics built with Mark 75, Tri-Pac or SCB
breakers.
Logic Control
Voltage Sensing Modules
1Ø Undervoltage
3Ø Undervoltage
S# 1266C79G04
S# 1266C79G03
Option#5C, 26B
Option#5C, 26A
Table 2 — Maximum Upstream Circuit Protective Devices for
Type A Robonics, All Classes of Loads
These cards are normally set at 70% dropout and 90% pickup.
1Ø Overvoltage
3Ø Overvoltage
S# 1266C79G02
S#12266C79G01
Option#5B, 26C
Option#5B, 26C
Robonic
Maximum Upstream
Maximum Upstream
Fuse-Rating¬
These cards are normally set at 105% pickup and 115% dropout. All
styles are applicable to both emergency and normal source monitoring.
Type Continuous Breaker Frame Size
Class
J or L
Class
K5 or R
Rating
(amps)
LRO 30
LRO 70
LRO 100
EB, EHB, FB, HFB, FB-P
EB, EHB, FB, HFB, FB-P
FB, HFB
100
100
100
100
100
100
RO 150
RO 200
RO 225
CA,CAH,JA,KA,HKA,LC,HLC,LA-P 225
225
225
225
DA, LBB, LB, HLB, LC, HLC, LA-P
DA, LBB, LB, HLB, LC, HLC, LA-P
225
225
RO 300
RO 400
RO 600
RO 800
RO 1000
DA, LBB, LB, HLB, LC, HLC, LA-P
LA, HLA, LC, HLC, NB-P
MA, HMA, MC, HMC, NB-P
NB, HNB, NC, HMC, PB, PC, PB-P
PB, PC, PB-P
400
400
600
800
1200
400
400
600
...
Frequency Sensing Modules
1Ø Underfrequency
1Ø Overfrequency
S#1275C74G04
S#1275C74G06
Option#5D, 26D
Option#5E, 26E
...
PRO 1200
PRO 1400
PRO 2000
PB, PC, PB-P
PB, PC
PB, PC
1200
2000
2000
...
...
...
¬
Fuse ratings given are as allowed by C.E.C. If other ratings are desired, refer to C.E.C.
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Instruction Leaflet
30-471 (E)
Page 8
Both under and overfrequency cards are factory calibrated at 60 Hz.
The actual values of pickup and dropout are as follows:
Relay Driver
S#1266C77G02
Option#1A, 1B, 1C, 3A, 3B, 3C, 4A, 4B, 4C, 4D
Type
Dial Setting
Hz
Pickup
Hz
Dropout
Hz
This card is used in place of any of the timing modules when
instantaneous operation is required.
Underfrequency
Underfrequency
Overfrequency
Overfrequency
60
50
60
50
57
47
63
53
55
45
65
55
Undervoltage / Underfrequency Module
S#1288C58G01 Option# 5A, 26F
Monitors one phase of power source.
Blank
S#1266C77G01
Used to cover any unused card slots.
Time Delay Modules
1-60 sec. timer
S#1275C74G01
Option#1A, 3A, 4A
0.1-10 min. timer S#1275C74G02
0.2-30 min. timer S#1275C74G03
Option#1B, 3B, 4B
Option#1C, 3C, 4C
Option#4D
5 min fixed
S#1275C74G08
All can be used to accomplish TDEC, and TDNE functions.
All Cards Mechanically Interlocked
All cards are interlocked mechanically to prevent insertion into the
wrong function slot. All cards have a repeat accuracy over a 20 to
+60°C temperature change of (+ or -) 3%. Dial settings are (+ or -) 10%
of indication.
After making adjustments, tighten locking screw to secure setting.
Tighten mounting screws (screws are not captive).
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Instruction Leaflet
30-471 (E)
Page 9
Adjustments
The relay is incorporated in the control scheme to stop the transfer
switch with both breakers open. This is to allow residual load voltage
to decay prior to closing on another supply which could be out of
phase. When the timing cycle is complete, the relay re-initiates transfer
to the available source.
Timer and frequency modules can be adjusted as per module front
plate. Voltage sensing modules can be adjusted as follows:
Undervoltage Module
Time Delay Engine Starting Relay
Solid State Type Option #2A
Set
Description
1
2
3
Set Dropout knob maximum Counter-clockwise
Set pick-up knob maximum Counter-clockwise
Increase line volts to desired Dropout value
(normally 70%) LED should be “ON”
Rotate Dropout Clockwise until LED goes “OFF”
Rotate Pick-up to maximum Clockwise LED is “OFF”
Increase line volts to desired Pick-up value
(normally 90%) LED is “OFF”
Ratings - 1.2 Watts Power Consumption
Input coil voltage - 120 volts at 50/60 Hertz.
Contact Rating - 10 amperes resistive at 120 volts
Time Range - 2 to 3 seconds - nonadjustable.
Operating Temperature Range - -10oC to +55oC.
4
5
6
7
8
Rotate Pick-up knob Counter-clockwise until LED comes
“ON”
Re-check Pick-up and Drop-out by running voltage up and
down check by LED indication.
Overvoltage Module
Step Description
1
2
3
Set Dropout to maximum Counterclockwise
Set Pick-up to maximum Counterclockwise
Set line voltage to pull in value desired (normally
105%) LED is “OFF”
4
5
6
Rotate Pick-up Clockwise until LED comes “ON”
Rotate Dropout maximum Clockwise
Set line voltage to Dropout value desired
(normally 15%)
Pneumatic Type Option #2B
7
8
9
Rotate Dropout Counterclockwise until LED is
“OFF”
Drop line voltage to pull-in desired value. LED
should come “ON”
Increase line voltage to desired Dropout value.
LED should go “OFF”
Rating - 8 Watts Power Consumption
Input Coil Voltage - 120 volts 50/60 Hertz.
Contact Rating - 10 amperes resistive at 120 volts Ac.
Time Ranges - Various available.
Operating Temperature Range - -30oC to +75oC.
DT and DTM Time Delay Relays Option #32A, 32B
Ratings - 6 Watts Power Consumption
Input coil Voltage - 120 volts
Contact Rating - 3 amperes at 220 volts Ac 50/60 Hertz
Operating Temperature Rating - -10oC to +50oC
Time Ratings - Various available
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Instruction Leaflet
30-471 (E)
Page 10
This time delay relay is an octual plug-in, sychronous motor type. It is
complete with clutch and mechanical load switch giving one instantane-
ously operated normally open contact and a timed single pole double
throw contact in a dust-tight grey capsule. The mechanism is con-
structed to operate for the time set on the indicating dial and then
disconnect itself when the timing cycle is complete. A red pilot light on
the face plate indicates that the relay is timing to operate its contacts.
When de-energized, the relay requires a reset time of at least 0.5
seconds. Time delay begins immediately upon energizing the coil.
Plant Exerciser Option# 23A, 23B, 23C
Ratings - Input voltage 120 volts
Contact rating 20 Amps at 120 volts resistive S.P.D.T.
Description
Dial A is divided into a 24 hour day and night scale, and has tabs
around the periphery which may be adjusted to operate the micro
switch within intervals each 24 hours. Each tab represents a 15 minute
interval. Dial B has 7 spokes and advances one position for each
revolution of Dial A. Each spoke has provision to add a pin to operate
the micro switch. These pins represent days of the week and their
function is to prevent operation of the micro switches on selected days.
When the timing cycle is complete, a mechanical latch holds the
contacts in position and the coil is de-energized.
Transformer Modules
Application
The plant Exerciser is a Program Time Switch which functions to start
and stop the engine-generator set and transfer switch automatically at
pre-selected intervals or times. It consists of a synchronous electric
motor and a gear assembly to rotate a dial 360°C each day for a week
(168 hours). On the periphery of the dial there are levers or tabs which
can be set to operate a mechanical load switch as dial rotates. These
levers can be selected to operate the switch at specific times of the
day daily or specific days of the week. The cycle repeats weekly. The
Plant Exerciser may be used in two different ways as an accessory for
transfer switches.
1. It may to simulate an interruption in the normal source of supply at
selected intervals, at least once per week, causing the transfer
switch components to function, including start-up of the engine-
generator set and transfer of load to the generator supply. At the
end of the interval it will initiate the transfer back to normal supply
and shut down the engine-generator.
Modules include all necessary control, voltage sensing and logic
transformers.
Two versions are available. The standard module has three phase
monitoring of the normal source and one phase monitoring of the
emergency source. The optimal module has three phase monitoring on
both the normal and emergency sources.
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Instruction Leaflet
30-471 (E)
Page 11
or
2. It may be used to start an engine-generator set at selected
intervals, at least once per week, but without causing the transfer
switch to operate and transfer the load to the generator supply.
At the end of the interval it will cause the engine-generator to
shutdown.
INSTRUCTIONS — TO OPERATE THE ENGINE FOR AN INTERVAL
ONCE EACH WEEK, WITH OR WITHOUT OPERATION OF THE
TRANSFER SWITCH.
1. Extend the tabs of Dial A outwards, except those representing the
time of day for the running of the engine or operation of the
transfer switch.
2. Determine the day of the week for this testing. Install the six brass
pins (called skip pins) in the spokes of Dial B representing the
other six days of the week.
Portable Test Kit #50
3. Turn Dial A counterclockwise until the special tab at 12:00 midnight
advances Dial B. Turn Dial B until present day of the week is
opposite the copper arrow. Turn Dial A counterclockwise until the
correct time of day (or night) is opposite the arrow on the nameplate.
An inexpensive, portable test kit, #1278C67G01, is available for
convenient field testing and calibration of all plug-in cards and output
relays. The only power source required is a 120V convenience outlet.
A selector switch allows the operator to test individual cards or to
simulate ATS operation by having the source monitoring cards drive
the time delay cards which in turn drive the output relays, exactly as in
actual use. Calibration checks or changes can thus be accomplished
without necessity of energizing the alternate power source.
4. If the interval of running the engine is desired more than one day
per week but at the same time of day, remove the skip pin from
the appropriate spoke of Dial B.
Caution
DO NOT insert skip pins in any spoke when that spoke is pointing
towards the copper arrow
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Instruction Leaflet
30-471 (E)
Page 12
Schematic of Robonic II Transfer Switch
Consider the Robonic II in the normal operating position, with normal
power available and the normal interrupter closed. The following are
energized: U.V. (undervoltage module), TDES (time delay engine
start), and NR (normal relay).
First, the normal interrupter is opened, and then the emergency
interrupter is closed. At this point, the ELS (emergency limit switch)
contacts change state, and the BS (motor brake) closes, preventing
TM over travel. The NLS (normal limit switch) contacts change state in
preparation for re-transfer to the normal power source.
The U.V. monitoring all 3 phases of the normal power, senses a dip or
loss of voltage which instantly causes NR to deenergize. Contacts NR2
and NR4 open, and contacts NR1 and NR3 close. TDES times out,
closing it’s contacts and initiating the emergency system start up. When
the emergency system reaches correct levels of voltage and frequency,
ER is energized and contact ER2 closes. This completes the emergency
control circuit, and TM (transfer motor) begins to operate.
Upon return of stabilized normal power, NR is re-energized disabling
the emergency control circuit, and enabling normal control circuit. The
TM operates, opening the emergency interrupter and closing the
normal interrupter. When the re-transfer is completed, the NLS contacts
change state isolating TM, and BS closes. TDES becomes energized
opening it’s contacts. TDEC times out to allow the emergency generator
to run unloaded and cool off before shutting down. The Robonic II is
now ready to react to another normal power failure.
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Instruction Leaflet
30-471 (E)
Page 13
Replacing Parts
Parts List
The Robonic Automatic Transfer Switch has been designed to have all
components accessible and readily removable from the front of the
panels. The Robonic Transfer Switch is divided into two basic sections.
The upper section consists of the main contacts and transfer mechanism,
the lower section consisting of all the automatic control devices.
Part Name
Style No.
Parts Common to Robonic II
Plug-in Modules
Timer,1-60 sec. adjustable, for TDEN,TDEC,TDNE
1275C74G01
Timer,0.1-10 min. adjustable, for TDEN,TDEC,TDNE 1275C74G01
Timer,0.2-30 min. adjustable, for TDEN,TDEC,TDNE 1275C74G03
Caution
Timer, 5 min. adjustable, for TDEN,TDEC,TDNE
Relay driver — used in place of timers, for
instantaneous operation
1275C74G08
When replacing any parts of the mechanism, control transformers or
breakers, isolate the Robonic Transfer Switch from any possible source
of power.
1266C77G02
Instantaneous relay, used for NR,ER and EC 1Ø
under frequency module, for “normal” or “emergency 1275C74G04
1Ø over frequency module, for “normal” or “ermergency” 1275C74G06
3Ø over voltage module, for “normal” or “emergency” 1266C79G01
1Ø over voltage module, for “normal” or “emergency” 1266C79G02
3Ø under voltage module, for “normal” or “emergency” 1266C79G03
1Ø under voltage module, for “normal” or “emergency” 1266C79G04
To remove the transfer mechanism of the LRO transfer switch, first
open the cover and remove the slide pin from the operating cam, then
remove the centre bolt, the mechanism will lift straight off. The breakers
and transfer motor bracket are held by four screws for ease of removal
and replacement. When replacing the mechanism, first set it on the
Robonic with the breaker handles in the holes provided and then fasten
the centre bolt reasonably tight with the mechanism fully movable with
an equivalent swing distance up and down.
Blank cover, for unused module space
Time delay relay for engine starting, 2.5s fixed
1266C77G01
3152A51H01
Time delay relay for engine starting, adjustable 1-300s 688A886H11
Options
Plant Exerciser
Battery Charger 12V
Battery Charger 24V
4 Position s/s fixed
4 Position s/s keyed
To remove the transfer mechanism of the RO transfer switch, remove
the four bolts holding it, taking note of which holes the bolts were in,
then lift the mechanism straight off. The breakers are held by two bolts
at one end and the bus connectors on the other end. The transfer motor
is mounted to the transfer mechanism cover and centre drive gear.
When replacing any part of the transfer mechanism, be sure that the
scribe lines of the gears are in a straight row (example shown on page 6).
688A888G01
1259C26G01
1259C26G03
7070A56H01
7070A56H02
Transformer Modules
600V, for LRO, RO
480V, for LRO, RO
416V, for LRO, RO
240V, for LRO, RO
208V, for LRO, RO
600V, for PRO
480V, for PRO
416V, for PRO
240V, for PRO
208V, for PRO
Standard
Optional
160D997G05
160D997G04
160D997G03
160D997G02
160D997G01
160D997G10
160D997G09
160D997G08
160D997G07
160D997G06
160D997G15
160D997G14
160D997G13
160D997G12
160D997G11
160D997G20
160D997G19
160D997G18
160D997G17
160D997G16
To prevent operation of the transfer switch while replacing mechanism
or components, disconnect all sources of power.
When replacing the mechanism move it about until the breaker toggles
fit between the mechanism fingers and then fasten the bolts tightly. To
test for proper operation first operate manually and then connect 120
volt, 60 Hertz supply to motor leads and observe operation for free
movement and proper breaker operation.
The PRO transfer switch mechanism is similar to the RO with the
exception that the PRO mechanism has five gears and is mounted
horizontally. The breakers are fastened to the panel by six bolts.
For Type LRO Robonic II
Mechanism
Motor Assembly
Motor
Operating Cam
Slide Pin
833C222G02
All Robonic transfer switch breakers and mechanisms have allowed
some adjustments for mounting to assure proper operation without
slipping or binding. Be sure all hardware is tightened sufficiently before
re-energizing any transfer switch.
833C223G01
688A732H02
688A458G01
688A731H01
688A747H01
Limit Switch
To replace any of the octal plug-ins relays, pull old units straight out
and insert the replacement unit. Due to the tight fit of the receptacle
and pins, you may have to move the relay about a little to pull it out.
DO NOT INTERCHANGE ANY RELAY WITH ANY OTHERS.
For Type RO Robonic II
Mechanism 150 to 400A
Mechanism 600 to 1000A
Motor
Solenoid
Brake Shoe Assembly
Operating Cam
833C226G01
833C226G01
688A749H01
688A740H01
688A738G01
572B774H01
688A747H01
To replace any solid state logic modules, pull straight out and insert the
replacement unit.
Auxiliary & Limit Switch
For Type PRO Robonic II
Mechanism
Motor
Solenoid
688A109G01
688A749H02
688A740H01
688A747H01
Auxiliary & Limit Switch
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Instruction Leaflet
30-471 (E)
Page 14
Trouble Shooting Guide
Symptoms
Recommended Maintenance
Possible Causes
1. DO NOT perform dielectric tests on the equipment with the control
components in the circuit.
• refusal to re-transfer to normal
source upon restoration
• a voltage sensing relay did not
energize
2. DO NOT use loctite.
• emergency to normal time delay
relay has failed
3. Check lubricant in high speed bearings of the motor and the low
speed bearings of the gear box. For lubrication use Dow Corning
Silicon DC44 or equivalent on the high speed bearings and Aero
Shell No. 6 grease or equivalent in gear box after 5000 operations.
• a loose control connection
• will not transfer to emergency
source upon failure of normal
source
• engine-generator did not start
4. Check if control components are tight in sockets.
• generator not producing enough
voltage at a high enough
frequency
5. Periodically inspect all terminals (load, line and control) for tightness.
Retighten all bolts, nuts and accessible hardware. Clean or replace
any contact surfaces which are dirty, corroded or pitted.
• a loose control connection
6. Robonics should be in clean, dry and moderately warm locations. If
signs of moisture are present, dry and clean transfer switch. If there
is corrosion try to clean off, if cleaning is unsuitable replace the
corroded parts. Should dust and/or debris gather on the transfer
switch, brush, vacuum or wipe clean. DO NOT blow dirt into breaker
or terminals.
• normal to emergency time
delay, if supplied, has failed
• if voltage sensing modules
supplied in emergency, there
may be a failure of one
7. Test the transfer switch operation. While the Robonic is exercising,
check for freedom of movement, hidden dirt or corrosion and any
excessive wear on the mechanical operating parts. Clean, lubricate
or replace parts where necessary.
• transfer without a power failure
in the normal source
• a voltage sensing module has
failed
• emergency to normal time delay
has failed
8. Check all adjustable control components (time delay and voltage
sensing relays) for correct settings.
• no time delay when there
should be
• that particular time delay has
failed
9. If the type “RO” mechanism is removed be sure that the scribe lines
on the gears are in line. When reassembling the drive mechanisms
be sure that they are fastened to the correct holes in the frame and
that the breaker handles are between the cam fingers (one breaker
has to be on and the other off).
• engine-generator starts when
the normal source has not
failed
• the engine start time delay has
failed
• a plant exerciser has been built
into the system
Note: When servicing logic control, or transformer module, disable the
motor circuit
• a voltage sensing module has
failed
Type LRO Robonics
CAUTION
• normal source has failed and
the transfer switch cycles
without stopping in emergency
• the operating cam in the
mechanism has either broken
or come out of the breaker
handle
DO NOT overtighten the pivot screw inside the operating arm. This
screw was correctly adjusted at the factory to provide low friction
movement of the operating arm without excessive play.
• ELS has failed to operate
DO NOT overtighten the set screw holding the operating cam on the
motor shaft.
• if the power is not available on
the load terminals with either
the normal or emergency
sources available and the
transfer switch will not operate
• the breakers may be complete
with trip units and if there has
been a fault on the system, the
motor circuit has been opened
by either EAS and NAS.
Correct and manually reset the
breakers in the transfer switch
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