Form 6 Microprocessor-Based Service Information Pole · PDF fileDescription The Kyle® Form 6 pole mount microprocessor-based recloser control includes extensive system protection

1

Form 6 Microprocessor-BasedPole Mount Recloser ControlInstallation and Operation Instructions

ReclosersService Information

Safety Information ..................................................... 2

Product Information .................................................. 3

Introduction ............................................................ 3

ANSI Standards ..................................................... 3

Quality Standards ................................................... 3

Acceptance and Initial Inspection .......................... 3

Handling and Storage ............................................ 3

Control Power ........................................................ 3

Battery Replacement and Disposal ........................ 3

Operation Upon Loss of AC Power ........................ 4

Form 6 Recloser Control Description ..................... 5

Description ............................................................. 5

Theory of Operation ............................................... 5

Control Front Panel ................................................ 6

Control Features ....................................................11

Communications ....................................................14

Control Information .................................................14

Control Back Panel ................................................14

Installation Procedure ..............................................15

Initial Programming Prior to Installation .................15

Control / Recloser Compatibility .............................15

Duty Cycle Monitor .................................................16

Control Cable .........................................................16

Mounting the Control ..............................................17

Grounding the Control ............................................18

Customer Connections for AC Power ....................21

Before Placing Control and Recloser into Service ...30

Using Removable Inserts .......................................31

Accessories ...............................................................32

Low Voltage Closing ..............................................32

Incoming Power Receptacles ................................32

BCT Terminal Blocks ..............................................34

Auxiliary Terminal Block .........................................34

Front Panel with Expanded LEDs ..........................35

Discrete Interface Board Accessory .......................35

Cable Locking Sleeves ..........................................35

120 Vac GFI Duplex Outlet ....................................35

RS-232 Cable .........................................................35

Stainless Steel Cabinet ..........................................35

Fiber Optic Interface Accessory .............................36

Radio Mounting Accessory ....................................36

Testing ........................................................................37

Testing an Installed Control ....................................37

Remove the Control from Service ..........................38

Testing with Type MET Tester ................................38

Closing the Recloser During Testing ......................39

Battery Test and Charging Procedures ..................42

Return the Control to Service ................................43

Additional Information ..............................................44

Replacement Kits ...................................................44

Factory-Authorized Service Centers ......................44

Factory Maintenance Classes ................................44

Contents

S280-70-3

Printed in USA1January 2004 • Supersedes 10/03

Figure 1.Kyle® Form 6 Microprocessor-Based Pole Mount Recloser Control.

030001KM

For Type F6-PA Control,Serial Numbers 464 through 9999;and Type F6-PB Control,Serial Numbers 1015 through 9999.

• F6-PA applies to Form 6 controlfor use with W, VS, and auxiliary-powered NOVA reclosers.

• F6-PB applies to Control-PoweredNOVA Form 6 control for use withcontrol-powered reclosers.

Form 6 Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

2

The instructions in this manual are not intended as a sub-stitute for proper training or adequate experience in thesafe operation of the equipment described. Only compe-tent technicians who are familiar with this equipmentshould install, operate, and service it.

A competent technician has these qualifications:

• Is thoroughly familiar with these instructions.

• Is trained in industry-accepted high- and low-voltagesafe operating practices and procedures.

• Is trained and authorized to energize, de-energize,clear, and ground power distribution equipment.

• Is trained in the care and use of protective equipmentsuch as flash clothing, safety glasses, face shield,hard hat, rubber gloves, hotstick, etc.

Following is important safety information. For safe instal-lation and operation of this equipment, be sure to readand understand all cautions and warnings.

Safety InstructionsFollowing are general caution and warning statementsthat apply to this equipment. Additional statements, relat-ed to specific tasks and procedures, are located through-out the manual.

SAFETY INFORMATION

SAFETY FOR LIFECooper Power Systems products meet or exceed all applicable industry standards relating to product safety. We activelypromote safe practices in the use and maintenance of our products through our service literature, instructional trainingprograms, and the continuous efforts of all Cooper Power Systems employees involved in product design, manufacture,marketing, and service.

We strongly urge that you always follow all locally approved safety procedures and safety instructions when workingaround high voltage lines and equipment and support our “Safety For Life” mission.

!SAFETYFOR LIFE

!SAFETYFOR LIFE

WARNING: This equipment is not intended toprotect human life. Follow all locally approved

procedures and safety practices when installing oroperating this equipment. Failure to comply canresult in death, severe personal injury, and equip-ment damage. G102.1

!

DANGER: Hazardous voltage. Contact withhazardous voltage will cause death or severe

personal injury. Follow all locally approved safety pro-cedures when working around high and low voltagelines and equipment. G103.3

!

WARNING: Before installing, operating, main-taining, or testing this equipment, carefully read

and understand the contents of this manual. Improperoperation, handling or maintenance can result indeath, severe personal injury, and equipment damage.

G101.0

!

WARNING: Power distribution equipment mustbe properly selected for the intended application.

It must be installed and serviced by competent person-nel who have been trained and understand proper safe-ty procedures. These instructions are written for suchpersonnel and are not a substitute for adequate trainingand experience in safety procedures. Failure to proper-ly select, install, or maintain power distribution equip-ment can result in death, severe personal injury, andequipment damage. G122.2

!

This manual may contain four types of hazardstatements:

DANGER: Indicates an imminently haz-ardous situation which, if not avoided, will

result in death or serious injury.

WARNING: Indicates a potentially hazardoussituation which, if not avoided, could result in

death or serious injury.

CAUTION: Indicates a potentially hazardoussituation which, if not avoided, may result in

minor or moderate injury.

CAUTION: Indicates a potentially hazardous situ-ation which, if not avoided, may result in equip-ment damage only.

!

!

Hazard Statement Definitions

!

IntroductionService Information S280-70-3 provides installation andoperation instructions for the Kyle® Form 6 microproces-sor-based pole mount electronic recloser control belowserial number 10,000.

Refer to Service Information S280-70-4 Kyle Form 6Microprocessor-Based Recloser Control ProgrammingGuide for additional information.

Read This Manual FirstRead and understand the contents of this manual and fol-low all locally approved procedures and safety practicesbefore installing or operating this equipment.

Additional InformationThese instructions cannot cover all details or variations inthe equipment, procedures, or process described, norprovide directions for meeting every possible contingencyduring installation, operation, or maintenance. When addi-tional information is desired to satisfy a problem not cov-ered sufficiently for the user's purpose, please contactyour Cooper Power Systems sales representative.

ANSI StandardsKyle® reclosers are designed and tested in accordancewith the following ANSI standards: C37.60 and C37.85and ANSI Guide C37.61.

Quality StandardsThe Quality System at the Cooper Power Systems KyleDistribution Switchgear plant is certified to the ISO 9001standard.

Acceptance andInitial InspectionEach Form 6 Recloser Control is completely assembled,tested, and inspected at the factory. It is carefully cali-brated, adjusted and in good condition when accepted bythe carrier for shipment.

Upon receipt, inspect the carton for signs of damage.Unpack the control and inspect it thoroughly for damageincurred during shipment. If damage is discovered, file aclaim with the carrier immediately.

Handling and StorageBe careful during handling and storage of the control to min-imize the possibility of damage. If the control is to be storedfor any length of time prior to installation, provide a clean,dry storage area. If storage is in a humid atmosphere, makeprovisions to keep the control circuitry energized.

Note: To energize the control, apply ac power to the ac sup-ply input terminal block located in the lower right handcorner of the back panel of the control. Refer to theCustomer Connections for AC Power section in thismanual.

Control Battery Storage and ChargingThe 24 Vdc control battery in the Form 6 recloser controlis fully charged prior to shipment and is ready for use.

Temperature has an effect on battery life. Sealed leadacid batteries should be stored, fully charged, at roomtemperature. Never store lead acid batteries at tempera-tures exceeding 47°C (117°F), as damage can result inapproximately one month.

To keep the battery charged, energize the control’s built-in charger with ac power applied to the user ac supplyinput connector block TB1. See Customer Connectionsfor AC Power. In addition, if power to the control is notpossible a separate portable charger accessory is avail-able. Catalog Number KA43ME7001 provides a 120 Voltbattery charger to power individual batteries.

Note: When shipped from the factory, the battery source isdisconnected and its output plugs are taped to the cab-inet. Connect the battery plugs into the mating connec-tors to complete the battery circuit.

Control PowerThe control is powered from 120 or 240 Vac. The selec-tor switch on the power supply board allows the user toselect between 120 Vac or 240 Vac.

Note: The selector switch is factory-set for each controlbased upon the customer order requirement.

Battery Replacement andDisposalThe 24 Vdc control battery has a life expectancy of fourto six years. It is recommended that the battery bereplaced after four years.

Dispose expired batteries in an environmentally respon-sible manner. Consult local regulations for proper batterydisposal.

S280-70-3

3

!SAFETYFOR LIFE

PRODUCT INFORMATION

IMPORTANT: To maintain sufficient charge to oper-ate the control and prevent battery cell damage, thesealed lead-acid batteries should be charged after nomore than three months of storage.

IMPORTANT: Connect the control battery when acpower is connected to the control’s ac supply InputTerminal Block. The battery must be disconnectedprior to shipping or storing the control.

Operation Upon Loss of ACPowerThe control is equipped with either an 8 Amp-Hour or 13Amp-Hour 24 Vdc lead acid battery for operation uponloss of ac power. The control maintains full operationfrom the battery for a period of time dependent upon thebattery size:

• 8 Amp-Hour — 15 hour maximum (20°C)

• 13 Amp-Hour — 25 hour maximum (20°C)

In the event that the ac power has not returned within thetimes listed above, the control will disconnect the batteryfrom the circuit.

Note: The control continuously monitors the battery voltage.To prevent battery damage, the control shuts downautomatically upon detection of low battery voltage(below 22 Vdc) for 60 seconds.

Control programming settings and parameters—includ-ing event recorder—are stored in non-volatile memoryand retained upon loss of control power. The time/dateclock will continue to operate for approximately 30 daysafter loss of control power.

Phase B (Ø) is the factory default phase. Unless changedby the user, the B PHASE VOLTAGE red LED illuminatesindicating ac is the operating power. If BØ (or the user-indicated phase) loses ac power, the ALARM red indica-tor LED will illuminate. The ALARM log on the LCDDisplay will indicate NO AC PRESENT and the CON-TROL OK LED will not be illuminated.

The control clock may require resetting if the operatingpower has been disconnected for more than thirty days.Refer to Service Information S280-70-4 Kyle Form 6Microprocessor-Based Recloser Control ProgrammingGuide for information on setting the control clock.

Note: When ac power is present, the control will operateregardless of back-up battery presence.


4

Figure 2.Form 6 pole mount recloser control is accessiblefrom both the front and back of the cabinet.

030034KM

IMPORTANT: If the the control shuts down due tolow battery voltage before ac power is restored, andthe connected energized recloser is CLOSED; it willonly TRIP and LOCKOUT via front panel pushbuttoncommand.

A control that has shut down due to low battery volt-age before ac power is restored will have a blank LCDdisplay (no text message shown).

DescriptionThe Kyle® Form 6 pole mount microprocessor-basedrecloser control includes extensive system protectionfunctionality, including phase, ground, and negativesequence overcurrent protection, over/underfrequency,and voltage protection, directionality, sensitive groundfault, and sync check.

Analysis tools include fault locating, event recording,TCC EditorTM II, Idea WorkbenchTM, and oscillographyfunctions, including oscillography replay.

Metering functions include demand and instantaneouscurrent on a per-phase basis, instantaneous voltage andpower factor on a per-phase basis, and power (real, reac-tive, apparent) on a per phase or total basis. Symmetricalcomponents for both voltage and current are displayedalong with kilowatt-hours for energy metering. Harmonicsfrom the 2nd to the 15th harmonic are also included.

The front panel LCD display is used to configure theoperating settings for the control. It is also used to displaymetering, counter information, control parameters, resetalarms, and provide diagnostic information.

Control parameters can also be programmed via a per-sonal computer connected to the control through the frontpanel RS-232 port. Control programming, interrogation,and operations are performed with Form 6 ProViewTM

interface software on a personal computer.

ProViewTM interface program software includes additionalfunctions used to create and graphically display TimeCurrent Curves and provides the Idea WorkbenchTM forconfiguring user-selected inputs and outputs, config-urable event and alarm data, and selectable communica-tion points for serial communication.

The control operates on 50 and 60 Hz systems.

The control can be configured, by the factory or by theuser, for a wide variety of applications. If user require-ments change, the control functions can be modified tomeet the new requirements.

The control is accessible from both the front and back ofthe cabinet (Figure 2).

Theory of OperationA functional block diagram of the Form 6 recloser controlis shown in Figure 3. Current sensing is provided by threecurrent transformers located in the recloser and inter-faced to the Form 6 recloser control via the control cable.This cable also supplies Trip, Close, and Recloser status,and connects to the Recloser Interface (RIF) module toprovide isolation for reliable operation. Voltages formetering are connected to the analog input modulethrough terminal block TB8.

Line current flowing through the recloser is converted bythe CPU module to a digital signal suitable for meteringand fault current calculations. Data sampling occurs at arate of 64 times per cycle. The CPU contains a dataacquisition section that uses the acquired samples tocompute the fundamental currents and voltage for use inovercurrent, under/overvoltage, and under/overfrequen-cy protection, as well as currents and voltages for meter-ing functions. The current for overcurrent protection iscalculated on a sub-cycle basis; it includes only the fun-damental and DC component.

When the phase or ground current exceeds its pro-grammed minimum-trip value and associated time-cur-rent-curve (TCC) timing, the control initiates the pro-grammed sequence of recloser tripping and reclosingoperations via the CPU and RIF modules. If the fault is

S280-70-3

5

!SAFETYFOR LIFE

FORM 6 RECLOSER CONTROL DESCRIPTION

TRIP SOLENOID

CLOSE SOLENOID

A Ø CT

B Ø CT

C Ø CT

OPEN / CLOSESWITCHES

CT COMMON

RECLOSER

FILLERBOARD POWER BATTERY

INTERCON-NECTIONBOARD

CPU

I/O

FRONTPANEL

RS-232(PROVIEW

PROTOCOLONLY)

RS-232

RS-485

FIBEROPTIC

CONVERTERACCESSORY

TB7TERMINAL

BLOCK

120/VACOUTLETDUPLEX

ACCESSORY

TB8TERMINAL

BLOCKSENSINGVOLTAGEINPUTS

3 inputsUSER

CONNECTIONS5 outputs

8 inputsUSER

CONNECTIONS8 outputs

POWERCONNECTIONS

120/240

MATCHINGTRANSFORMERS

AND SIGNALCONDITIONING

ANALOG INPUT

RIF

OPTICALISOLATION

OPTICALISOLATIONOPTICAL

ISOLATION

OPTICALISOLATION

Figure 3.Form 6 recloser control operational flow diagram.

temporary, the control ceases to command recloser oper-ations after a successful reclose, and the control resetsto the start of its operating sequence after a preset timedelay. If the fault is permanent, the control performs itscomplete programmed sequence of reclose commandsand locks out with the recloser open. Once locked out,the control must be closed via the operator panel orSCADA communications. This resets the control to thestart of the operating sequence.

The following chain of events occurs for an operatingsequence of two trips to lockout (one trip on TCC1, onetrip on TCC2):

1. The overcurrent signal is integrated with time on theselected curve for the first trip operation (TCC1) toproduce the signal which energizes the trip circuit.

2. Energizing the trip circuit connects the supply to thetrip solenoid to open the recloser.

3. Upon opening, the control starts timing on the firstreclosing interval-delay time.

4. Upon expiration of this reclosing interval-delay, aclosing signal is issued from the control, closing therecloser, and selecting the time-current characteris-tics for the second trip operation (TCC2).

5. If current remains above the minimum-trip level, therecloser will trip on TCC2 and lockout the recloser.

Control Front PanelThe front panel is separated into two clearly identified,color-coded sections (Figure 4). The top portion of thefront panel is used for programming the control and pro-viding LED status indication. The lower portion of thefront operating panel is used for operating the control andrecloser.

Note: The control includes a Power Save feature that will turnoff the backlit LCD display and all LEDs if no front panelkeypad is pressed within five minutes. Pressing anykey will reactivate the display and LEDs.


6

CONTROL POWERCONTROL OK

CONTROL LOCKOUTRECLOSER OPEN

RECLOSER CLOSED

A PHASE FAULT

B PHASE FAULTC PHASE FAULTGROUND FAULT

SENSITIVE GND

ALARM

ABOVE MIN TRIPINDICATOR 1INDICATOR 2

INDICATOR 3

A PHASE VOLTAGE

B PHASE VOLTAGEC PHASE VOLTAGEFREQUENCY TRIP

VOLTAGE TRIP

METERING

RESETTARGETS

EVENTS

LAMP TEST

MENU

ENTER

+—

SETTINGS

OPERCOUNTER

ALARMS

CHANGE

F1 F2 F3 F4

TRIP CLOSE

HOT LINE TAG

ON

CLOSECIRCUITDISABLE

GRD TRIPBLOCKED

NONRECLOSING

SUPERVISORYOFF

ALTERNATEPROFILE #1

ALTERNATEPROFILE #2

ALTERNATEPROFILE #3

KYLE FORM 6 RECLOSER CONTROL

RS232 DATA PORT

OPTION #1 OPTION #2 OPTION #3

(LOCKOUT)

LCD Display

LCD DisplayDedicated

Function Keys

One-TouchAnalysis Keys

Hot Line Tag Toggle Switch and Three-Segment LED Indication

RS-232ConfigurationData Port

CLOSE PushbuttonTRIP (LOCKOUT)Pushbutton(Hardwire Connected)

LED Indicators

LCD DisplayDedicatedFunction Keys

One-TouchFunction Keys

Close CircuitDisable Fuseand Fuseholder

Cursor Movement Arrows

LCD Menu Function Keys

One-TouchAnalysis Keys

>Mod Group Overcurrent Setting Oper Sequence Reclose Intervals

Norm

Figure 4.Form 6 recloser control front panel.

Programming PanelThe Programming panel has the following sections:

One-Touch Analysis Keys

There are eight analysis keys (Figure 5) that allow one-button access to a variety of control and monitoring func-tions that appear in the LCD display. Pressing these but-tons causes the following information to display or func-tion to occur:

METERING: Displays the systems instantaneous meter-ing values for current and voltage on the LCD display.

RESET TARGETS: Resets the fault target indicators onthe operator panel.

EVENTS: Displays fault location information, includingdistance in miles, fault current, duration, and fault type.

LAMP TEST: All operator panel LEDs are illuminated forverification of proper connection and operating status ofall indicator lights. All status indicators will then return totheir previous state. While in the LAMP TEST mode, thecontrol response to operator panel keys is disabled,except for the TRIP (LOCKOUT), CLOSE, and HOTLINE TAG switches.

SETTINGS: Displays recloser settings on the LCD display.

OPER COUNTER: Displays the total number of trip oper-ations and target counters for each A, B, and C Phase;Ground, and Sensitive Ground on the LCD display.

ALARMS: Provides status information on the LCD dis-play for all recloser alarms. Alarms are issued if user-specified settings are exceeded.

CHANGE: Allows the user to change the state of the con-trol functions on the operator panel function keys.

Note: The CHANGE mode is a ten second period in which onefunction setting can be changed. If no change is madein that time, the control returns to the current setting.

LCD Display

The LCD Display is a backlit 4-line, 20-character displaythat provides extensive distribution system, recloser, andcontrol status information using a minimum of eight nav-igation keypads (Figure 5).

Note: The LCD display panel contrast is field-adjustable to allowfor various mounting heights and applications. Press theMENU key and then press the (+) or (–) key to increaseor decrease the contrast.

The four LCD navigation buttons are as follows:

MENU: Identifies the LCD Display menu options.

ENTER: Selects a menu option.

+: Scrolls up menu or increases value selection.

–: Scrolls down menu or decreases value selection.

The four LCD menu function keys activate specific menucommands. When a command appears in the LCD dis-play directly above one of the four LCD menu functionkeys, the user can press the key to accept/select thecommand.

The four LCD menu function keys are as follows:

F1 F2 F3 F4

The four cursor movement arrows allow movement in thefollowing directions:

Moves the cursor left.

Moves the cursor right.

Moves the cursor up one line.

Moves the cursor down one line.

S280-70-3

7

!SAFETYFOR LIFE

METERING

RESETTARGETS

EVENTS

LAMP TEST

MENU

ENTER

+—

SETTINGS

OPERCOUNTER

ALARMS

CHANGE

F1 F2 F3 F4

Figure 5.Form 6 recloser control shortcut keys, LCD display, LCD menu function keys, and cursor movement arrows.

Status Indicator LEDs

The status indicator LEDs (Figure 6) in the Programmingsection of the Operator Panel give instant information onthe control and recloser status:

CONTROL OK: The green LED indicates the control isoperating normally and not in an alarm state. The CON-TROL OK LED will not be illuminated during thesealarms (indicated by the red ALARM LED and displayedin the alarm status log):

• Battery Alarm: This alarm indicates battery voltage islow or the battery failed an operator-initiated manualtest.

• Memory Test: This alarm indicates a failed ROM orRAM memory test.

• No AC Power: This alarm indicates AC power wasunavailable for 10 continuous seconds. This alarmresets when AC power is restored.

• Internal Power Failure: This alarm indicates internalcontrol operation power was outside of its operatingtolerance for more than 20 seconds. This alarmresets when the internal control operation powerreturns to operation within its normal tolerances.

CONTROL POWER: The green LED indicates there isadequate charge (voltage) on the trip circuit capacitor totrip or close the recloser. This LED does not indicate thepresence of AC or battery power.

CONTROL LOCKOUT: The green LED indicates therecloser is open and a reclosing sequence is not inprogress. Manual tripping of the recloser is an example ofcontrol lockout.

RECLOSER OPEN: The green LED indicates the reclos-er is in the open position.

RECLOSER CLOSED: The red LED indicates the reclos-er is in the closed position.

A PHASE FAULT, B PHASE FAULT, C PHASE FAULT,GROUND FAULT, SENSITIVE GROUND FAULT: The redLEDs indicate the control issued an overcurrent trip sig-nal while A, B, or C phase or ground current exceededthe minimum pickup value. The red LEDs will also indi-cate if A, B, or C phase or ground current was within 80%of minimum pickup when another phase exceeded mini-mum trip value.

ALARM: The red LED indicates an alarm has beenissued. Review the alarm status and log on the LCD dis-play for the specific alarm.

ABOVE MINIMUM TRIP: The red LED indicates the cur-rent exceeds the level set for minimum trip.

INDICATOR 1, INDICATOR 2, INDICATOR 3:Customizable LEDs that are used with functions pro-grammed through the Idea WorkbenchTM. The LED indi-cators do not have active default values. The LEDs areilluminated when the status configured via the IdeaWorkbenchTM is present. These status indicators alsoinclude a user-customizable removable label insert.Refer to Using Removable Inserts for information onchanging the labels in the removable insert.

A PHASE VOLTAGE, B PHASE VOLTAGE, C PHASEVOLTAGE: The red LED indicates a presence of voltageon the respective phases. The undervoltage phase pick-up setting controls the voltage indication for the frontpanel LEDs as defined in the Low Voltage Setting dialogbox for the active setting profile. Refer to Settings -Voltage in the Schemes section of S280-70-4 Form 6Control Programming Guide.

FREQUENCY TRIP: The red LED indicates the reclosercontrol has issued a trip signal based upon frequencysettings.

VOLTAGE TRIP: The red indicator LED indicates the volt-age exceeds or fails to achieve a certain threshold.

Operating PanelThe Operating section includes the following sections:

RS-232 Configuration Data Port

The RS-232 Connector (Figure 7) on the front operatingpanel allows direct connection to a personal computerwithout any special cables or connectors. This port isused only for configuring the control with an internalCooper Power Systems protocol. All settings, metering,events, and oscillography data are available from thisport. The port is Data Communication Equipment (DCE)wired for direct connection to a personal computer.


8

CONTROL POWER

CONTROL OK


RECLOSER CLOSED

A PHASE FAULT


SENSITIVE GND

ALARM


INDICATOR 3

A PHASE VOLTAGE


VOLTAGE TRIP

Figure 6.Status indicator LEDs.

RS232 DATA PORTFigure 7.RS-232 Configuration Data Port.

HOT LINE TAG ON/OFF Toggle Switch and LEDIndicator

Hot Line Tag is provided for live-line work applications. Allclosing operations are disabled when the Hot Line Tagfeature is activated. While active, the control utilizes anindependent, user-selectable time-current curve for tripoperations.

Hot Line Tag prevents all closing attempts and shifts pro-tection to one trip-to-lockout on the composite curve of theHot Line Tag definite time and the TCC1 curve (whichev-er is faster). Hot Line Tag takes precedence over ColdLoad Pickup, Non-Reclosing, and Fast Trips Disabled.

Hot Line Tag is activated from either the operator panel tog-gle switch, serial communications, or a discrete SCADAfunction. All sources must be off to de-activate Hot Line Tag.

To activate the function from the operator panel, flip tog-gle switch up to the ON position. See Figure 8. The LEDindicator illuminates when the function is active.

The Hot Line Tag function may only be reset by the sourcewhich initiates it. For example, if Hot Line Tag is activatedat the operator panel, the reset function is only possible atthe operator panel, and not via SCADA command.

CLOSE CIRCUIT DISABLE

Close Circuit Disable (Figure 8) is a removable fuse that,when removed from the front operating panel, disablesthe close circuit from the control to the recloser.Removing the cartridge from the control disables all elec-trical closing of the recloser and provides a physical dis-connect to the recloser closing circuit. As a result, thecontrol cannot perform a close operation. This disconnectoverrides all close functions and makes a remote or man-ual close operation impossible.

Note: When the Close Circuit Disable fuse is removed, thetrip circuit remains active and will trip per the pro-grammed time current curve for a faulted condition.

TRIP (Lockout) Pushbutton

The TRIP pushbutton (Figure 8) provides front-panelaccess to trip (lockout) the recloser. When pressed, theTRIP pushbutton opens the recloser and locks out thecontrol. The TRIP pushbutton operates independent ofthe microprocessor and is directly connected to the tripcoil in the recloser.

Note: In the event of microprocessor failure, the trip circuitcan operate independent of the main microprocessor.

CLOSE Pushbutton

When pressed, the CLOSE pushbutton (Figure 8) returnsthe control to the initial or home sequence position, clos-ing the recloser. The control is ready for the start of a newtrip/close sequence.

Note: Pressing the CLOSE pushbutton from the Lockout posi-tion initiates Cold Load Pickup (CLPU) protection, if thefeature is enabled.

The user does have the ability to block COLD LOADPICKUP through one of the user-configurable Optionkeys on the Operator Panel Function keypad (Figure8). If the COLD LOAD PICKUP BLOCKED option but-ton has been pushed, pressing the CLOSE pushbuttonfrom the Lockout position will not initiate Cold LoadPickup Protection, even if the feature has been enabledfrom the interface software Protection Profile screen.

If the recloser is closed, pushing and holding theCLOSE pushbutton does not activate the Cold LoadPickup feature. See Cold Load Pickup in the ControlFeatures section of this manual.

One-Touch Function Keys

Quick access to frequently operated Form 6 features isprovided with nine function key pushbuttons on the con-trol operator panel (Figure 9). These nine features can beactivated locally from the membrane-type pushbuttons,or remotely via the interface software or SCADA.

Red LEDs located on each function key indicate the sta-tus of the function, regardless of local or remote activa-tion. For example, if Ground Trip Blocked is activatedfrom a SCADA signal, the red indicator will illuminateeven though it is not activated from the operator panel.

S280-70-3

9

!SAFETYFOR LIFE

TRIP CLOSE

HOT LINE TAG

ON

CLOSECIRCUITDISABLE


(LOCKOUT)

Figure 8.TRIP (Lockout) pushbutton; CLOSE pushbutton;Close Circuit Disable removable fuse; and Hot LineTag switch and Hot Line Tag red indicator LED.

WARNING: Hazardous voltage. Do not use HotLine Tag as a substitute for a visible disconnect.

Always establish a visible disconnect prior to perform-ing any work requiring a de-energized line. Failure tocomply may cause death, severe personal injury, orequipment damage. T276.0

!

IMPORTANT: Hot Line Tag is intended solely for live-line work applications, such as maintenance, repairs orimprovements to the distribution system, that occurwhile the line remains energized.

IMPORTANT: Hot Line Tag activation does not causethe recloser to trip open. It only prevents the recloserfrom closing.

IMPORTANT: If the CLOSE button is pressed afterthe Close Circuit Disable fuse is removed, do not rein-stall the fuse until after the ALARM LED illuminates(within approximately five seconds) to indicate CLOSEMALFUNCTION. Re-installing the Close Circuit Disablefuse prior to the CLOSE MALFUNCTION ALARM indi-cation will cause the control to close the recloser.

Operator panel function key activation or de-activationrequires the operator to first press the CHANGE key toenter the CHANGE mode. A function must then be select-ed or de-selected within ten seconds to activate or de-acti-vate the function. Once selected, the control returns to nor-mal operation until prompted for another change request.This prevents accidental changing of settings.

GRD TRIP BLOCKED

The Ground Trip Blocked function blocks all ground sens-ing in the control for the active profile. This red indicatoris illuminated when Ground Trip Block is activated fromthe serial port, I/O, the interface software, or locally (viathe front panel) causing the control to block all groundsensing.

NON RECLOSING

The control is operating in a non-reclosing mode whenthe NON RECLOSING red indicator is illuminated. Non-reclosing mode disables any automatic reclosing opera-tions. Non-reclosing does not alter the active TCC.Activation is possible from the serial port, I/O, the inter-face software, or locally (via the front panel).

SUPERVISORY OFF

When the SUPERVISORY OFF red indicator is illuminat-ed, supervisory commands are blocked. Supervisoryfunctions through the back panel serial communicationports and the discrete I/O are blocked. Serial communi-cations through the front panel RS-232 port remain activeindependent of the status of the SUPERVISORY OFFswitch. Activation of this function key is restricted to theoperator panel and is accomplished by pressing theCHANGE key and then pressing the SUPERVISORYOFF key. Operational data and metering information areavailable while the control is in the SUPERVISORY OFFposition. The TRIP and CLOSE pushbuttons and HotLine Tag are active independent of the SUPERVISORYOFF function.

ALTERNATE PROFILE #1, #2, and #3

The Form 6 has four separate protection profiles; aNormal profile, and Alternate Profiles 1, 2, and 3. Eachprofile changes all protection parameters for the control.Except for the normal profile, each has an indication andselection key. When the operator panel display lights areactive and none of the three indicators are on, the normalprofile is active. Only one profile can be active.

To select an alternate profile, press the CHANGE keyand then press the desired alternate profile.

To return to the normal profile, press the CHANGE keyand then press the active alternate profile to deselect it.These functions can also be completed remotely viacommunications interfaces.

OPTION #1, OPTION #2, AND OPTION #3

There are nine additional functions available to programas Option #1, Option #2, or Option #3 function keys. Anythree of these nine functions can become an option onthe operator panel function key pad. The available func-tions are as follows:

• Sensitive Earth Fault Enable: Allows activation ofSensitive Earth Fault protection with a minimum sen-sitivity of 0.5 Amps selectable in 0.1 Amp increments.

• Cold Load Pickup Blocked: For applications where noloss of diversity occurs.

• Sequence Coordination Disable: Disables sequenceCoordination for testing purposes.

• Fast Trip Blocked: Disables tripping on TCC1; trips onTCC2 time setting for total operating sequence.

• Underfrequency Trips Enable: Activates underfre-quency protection pickup and time-delay settings.

• Overfrequency Trips Enable: Activates the overfre-quency pickup and time-delay settings.

• Single-Phase Undervoltage Trips Enable: Activatesthe single-phase only undervoltage pickup and timedelay settings.

• Three-Phase Undervoltage Trips Enable: Activatesthe three-phase only undervoltage pickup and timedelay settings.

• Overvoltage Trips Enable: Activates both single-and three-phase overvoltage pickup and time-delaysettings.

The OPTION #1, OPTION #2, and OPTION #3 functionkeys must be programmed via the Idea WorkbenchTM.The options do not have active default values. The optionLEDs are illuminated when the options configured via theIdea WorkbenchTM are selected. These function keys alsoinclude a user-customizable removable label insert.Refer to Using Removable Inserts for information onchanging the labels in the removable insert.

Note: The OPTION #1, OPTION #2, and OPTION #3 functionkeys are intentionally not defaulted to any function. Thefunctions are assigned to each OPTION key via theIdea WorkbenchTM application.


10

GRD TRIPBLOCKED

NONRECLOSING

SUPERVISORYOFF

ALTERNATEPROFILE #1

ALTERNATEPROFILE #2

ALTERNATEPROFILE #3

OPTION #1 OPTION #2 OPTION #3

Figure 9.Operator panel function keys.

IMPORTANT: Unused alternate profiles should beprogrammed with the same settings as one of theapplicable profiles. Default settings on unused alter-nate profiles can cause unnecessary outages if theyare below normal system requirements.

IMPORTANT: Check minimum trip values prior tochanging an alternate profile to avoid misoperation ofthe control under load conditions.

Control FeaturesThe Form 6 recloser control offers numerous standardfeatures and accessories that allow the user the utmostflexibility applying the recloser control.

Control SecurityThe Form 6 recloser control has multiple customer-pro-grammable security codes to limit control programmingand viewing function access to authorized personnel.The front panel Human-Machine Interface (HMI) includesa user-selected security code to access the settings.Plus, the ProViewTM interface software has it’s own secu-rity levels for multiple-user access.

Refer to Service Information S280-70-4 Kyle Form 6Microprocessor-Based Recloser Control ProgrammingGuide for additional information.

Protection ProfilesFour protection profiles capable of fully specifying controloperation are standard in the control. Each protectionprofile includes the following as a minimum:

• Overcurrent Protection

• Over/Undervoltage Protection

• Over/Underfrequency Protection

• Directional Protection

• Hot Line Tag Functionality

• Sync Check

• Sensitive Earth Fault Protection

• Sequence Coordination

• Operation Settings

Time Current CurvesTime-current curves are available for numerous functions,including fast and delayed operations for phase, ground,and negative sequence protection. Each time-current isselected from a defined fifty curves which can be furthercustomized by the user. The time-current curves are alsoselected from a graphical TCC EditorTM II to visualize anymodifications prior to configuring the control.

The time-current curves include the following modificationsfor phase, ground, and negative sequence protection:

• Time Multiplier with a range of 0.1 to 25 in .1 increments.

• Time Adder with a range of 0 to 30 seconds in .01second increments.

• Minimum Response Time with a range of 0.1 to 1 sec-onds in .001 second increments.

• High Current Trip multiplier with a range of 1 to 32multipliers in increments of 0.1.

• High Current Trip Time Delay with a range of .016 to.150 second in .001 second increments.

• Time Dial Reset co-efficient with a range of .1 to 30seconds in 1 second increments.

Sequence CoordinationSequence Coordination eliminates nuisance trippingthrough trip coordination. It allows the control to stepthrough selected operations in the operating sequencewithout tripping. The number of Sequence Coordinationadvances is programmable from one to three operationsto provide trip coordination with a downline recloser. Thisfeature is independently selectable for each protectionprofile.

Cold Load PickupThe control includes a Cold Load Pickup feature to pre-vent the control from tripping while energizing non-faultsystem loads. This feature has independently program-mable minimum trip value time-current curve, recloseinterval, and number of independent operations to lock-out for each protection profile. Cold Load Pickup alsoincludes TCC Multipliers, TCC Adders, MinimumResponse Time, Time Dial Reset, and High CurrentLockout. Also, direct values, not multiples of minimumtrip, are provided for high current lockout.

Fast Trips DisabledThe control includes a Fast Trips Disabled feature tomodify protection, so that all trip operations use the pro-grammed TCC2. This feature is independently selectablefor each protection profile. All trip operations will time onTCC2. Typically, TCC1 is fast and TCC2 is delayed. So,as an example, the control will change it’s sequence from2 fast and 2 delayed operations to 2 operations on TCC2when Fast Trips Disabled is active.

High Current LockoutThe High Current Lockout feature will automatically lock-out the control on the selected operation when currentexceeds a programmable level. The active trip numbersfor the lockout is selectable for phase, ground, and neg-ative sequence. This feature is independently selectablefor each protection profile.

Sensitive Ground/Earth FaultOperationThe control has a Sensitive Ground/Earth Fault Trip fea-ture that provides tripping of the recloser after a pro-grammable, definite time for ground currents below nor-mal ground minimum trip levels. The feature has pro-grammable operations to lockout and reclose intervalsindependent of the ground settings. This feature is inde-pendently selectable for each protection profile.

Thermostatically Controlled HeaterThe control has a standard 15 Watt thermostatically con-trolled heater (ON 70°F, OFF 85°F) for humidity controland voltage input independent. The heater is poweredfrom the power supply board.

S280-70-3

11

!SAFETYFOR LIFE

MeteringThe control provides instantaneous and/or demandmetering with programmable integration intervals for thefollowing functions:

• Real and reactive power for each phase and total,including directional, on an individual phase basis.

• Demand currents on a per phase basis.

• Instantaneous currents, including ground current.

• Instantaneous voltage on a per phase basis.

• Instantaneous frequency.

• Positive, negative, and zero sequence voltages.

• Instantaneous power factor on a per phase basis.

• Metering settings to include demand interval, andalarm thresholds for current, single-phase kW, three-phase kW, single-phase kVAr, and three-phase kVAr.

Event RecorderThe Form 6 contains capabilities to perform Sequence ofEvents time-stamping for up to 33 event types. Sixteen ofthese inputs are user-defined through the IdeaWorkbenchTM.

Factory-defined event types include:

• Overcurrent Protection Trip

• External Trip

• Non-Reclose Trip

• External Close

• Lockout

• Reset

The Event Recorder maintains a minimum of 90 eventrecords. The last 25 events are viewable on the frontpanel LCD display. Refer to S280-70-4 Form 6 ControlProgramming Guide for additional information.

Recloser Duty MonitorThe Form 6 recloser control software is equipped with aRecloser Interrupting Duty Monitor. The Duty Monitoraccumulates the summation of I1.5 for all interrupted cur-rents on each interrupter. This feature permits program-mable entries to preset the duty of an existing recloser.The recloser duty monitor displays interrupting duty inpercent of duty used. If the duty cycle monitor exceeds100%, the recloser should be examined for maintenance.

Discrete SCADA CommunicationsThe control provides five configurable output status con-tacts and three configurable input control contacts asstandard. Each status contact is configurable usinggraphical interface software to combine status functional-ity along with Boolean algebra. Default output status con-tacts are: Lockout, Recloser Open, Recloser Closed,Ground Trip Block, and Hot Line Tag. One output statuscontact is a solid state output (SS1) with a pickup time nolonger than two milliseconds.

The control also provides a minimum of three config-urable input control contacts. Each control contact is con-figurable using a graphical interface software. Contactsaccept a whetting voltage range of 12–48 Vdc or 48–125Vdc, 120 Vac based upon the option selected at the timeof the order. Each digital input is configured for either amomentary, maintained, or maintained with precedencecontact. Default input control contacts are: SupervisoryTrip and Lockout, Supervisory Close, and Remote Tripand Lockout.

A Discrete Interface Board is also available as an acces-sory to provide an additional eight output status contactsand eight input control contacts. The expansion I/O boardis completely user-configurable.

TCC EditorTM IICoordination and actual time current modifications areavailable with a graphic interactive TCC EditorTM or simi-lar graphical software.

The TCC EditorTM II includes a complete database ofstandard recloser industry time current curves (TCC),both ANSI and IEC types, along with the ability to cus-tomize the TCCs with multipliers, constant time adders,or minimum response time adders. Also, the user is ableto derive their own specific TCC through data point entry.Each modified time current curve can be identified with auser-customized name and is selectable for configuringthe control. The grid and format for presenting the TCCshas a user-adjustable scale, including the option of pre-senting multiple TCCs in various user-configured colors.

OscillographyOscillography is provided to present current and voltagewaveforms, along with protection element and recloserresponse status changes. Filtered and unfiltered data areprovided for viewing.

The recorded values are super-imposed on the protec-tion scheme, and the state or value at any point in thescheme is displayed. The user has the capability to movethrough the event and watch the response of every func-tion. All analog signals, digital inputs, and contact outputsare monitored. Analog oscillography is displayed at 16samples per cycle.

Oscillographic data is recorded to analyze multipleevents during a permanent fault or other event type. Theoscillographic data shows two cycles before the triggerpoint and eight cycles after the trigger point (default).

Note: The configuration settings are programmable.

Oscillography automatically initiates trigger points for thefollowing functions:

• Above Minimum Trip for Phase, Ground, andSensitive Ground Fault

• Single- and Three-Phase Overvoltage• Single- and Three-Phase Undervoltage• Over- and Underfrequency• Trip Signal Issued• Close Signal Issued


12

Removable InsertsRemovable inserts are included with the control designfor customization of specific protection requirements.Inserts are available for LED Indicators 1, 2, and 3, andfor keypad Options 1, 2, and 3. The removable insertsare designed for use without adhesives, labelmakers, ortemporary labels. Refer to Using Removable Inserts formore information.

An electronic label template is included on the ProViewTM

application software CD and can be accessed throughthe following default address:

C: / Program Files / Cooper / Proview40 / Form6 / Form6 Inserts.doc

Idea WorkbenchTM

The Idea WorkbenchTM provides access to various inputs,intermediate variables, and internal Form 6 alarms, sta-tus, and targets to allow user-customization of the Form6 recloser control to meet specific and unique applica-tions. Idea WorkbenchTM also gives the user the ability toperform logical functions with these variables by using asimple graphical user interface. Use of Idea WorkbenchTM

is not a requirement for operation.

To access the menu function in the user-defined schemein the Idea WorkbenchTM drag the desired menu items tocreate the desired logical functions.

Refer to Service Information S280-70-4 Kyle Form 6Microprocessor-Based Recloser Control ProgrammingGuide for additional Idea WorkbenchTM information.

Over/Underfrequency ProtectionThe control includes two-stage operation for both under-frequency and overfrequency protection. A fixed timedelay ranging from 0 to 100 seconds in .001 second incre-ments is available for both over and underfrequency. Afrequency restoration function, enabled or disabled by theuser, is provided to allow the recloser to automaticallyclose should frequency return to within configured set-tings for a user-settable time. Over and UnderfrequencyProtection is included as part of each protection profile.

Over/Undervoltage ProtectionThe control includes single-phase and three-phaseundervoltage tripping. The control also includes three-phase overvoltage tripping. Both over and undervoltagefunctions include a single-phase and three-phase pick-upsetting; a single-phase and three-phase time delay set-ting ranging from 0 to 100 seconds.

DirectionalDirectional functionality is included to maintain systemcoordination from multiple sources, as well as circuitreconfiguration for each profile. Directional applies tophase, ground, and negative sequence protection,selected independently. A maximum torque angle has arange of 0–90 degrees.

Note: Three potential transformers are required for direction-al protection on the Form 6 control because it uses zerosequence voltage as a reference.

Fault LocationThe control includes an impedance-based fault locatorbased upon the Takagi algorithm. Load-compensatedimpedance calculation is used for calculating the distance.Positive and zero sequence is configured in ohms, and thefault locator line length is configured in kilometers/miles.

Sync CheckSync Check is a permissive system used to qualify anyclose signal to the mechanism when enabled via the synccheck settings. Sync check allows for closing for anycombination of dead/live bus/line, and to perform antici-patory closing for a live bus/live line condition by calcu-lating slip and anticipating the mechanism closing delay.In addition to the anticipatory close calculation, the synccheck system performs verification of line and bus volt-age magnitudes and frequencies to determine that theyare within pre-determined ranges, and that the angulardifference between the two systems is also within thepre-determined range. For a live/live close, where thereis no slip between the systems, the sync check systemallows permissive closing after the two systems are with-in frequency and voltage limits, and the angular differ-ence between the systems has been within the allowablelimits for a pre-determined time.

Sync Check functionality includes the following applica-tions: Hot Line/Hot Bus Closing; Dead Line/Hot BusClosing; Hot Line/Dead Bus Closing; and DeadLine/Dead Bus Closing.

Sync Check Parameters include the following config-urable settings: Voltage Angle; Mechanism OperatingDelay; Static Angle Delay; Dead Threshold; LiveThreshold; Positive Sequence Dead Threshold; UpperVoltage Limit; Lower Voltage Limit; Lower FrequencyLimit; Upper Frequency Limit; and Fail to Close Timer.

Data ProfilerA fully-configurable data profiler is available which allowsthe user to collect information by sampling data at selec-table intervals. These time-stamped values can then beviewed to determine weekly load profiles, daily harmonicdisturbances or hourly voltage fluctuations. The numberof days of information the data profiler can providedepends upon configuration parameters.

Refer to Service Information S280-70-4 Form 6Microprocessor-Based Recloser Control ProgrammingGuide for additional information.

Manual Close DelayManual Close Delay provides a delay from the time thatthe manual CLOSE button is pushed to the time the man-ual close operation is performed. The delay is program-mable from 0 to 60 seconds in 1 second increments. Aprogrammed delay value can be overridden for immedi-ate closing by pressing the CLOSE button a second time.An active Manual Close Delay can be canceled by press-ing the TRIP/LOCKOUT button. The default setting hasthe feature disabled (0 seconds). A countdown on thefront panel LCD screen indicates Manual Close Delay isactive.

S280-70-3

13

!SAFETYFOR LIFE

CommunicationsCommunication PortsThe Form 6 recloser control has two user-accessiblecommunication ports, plus a front panel configurationdata port. The front panel configuration data port isdescribed in the Operating Panel section of this manual.

There is one standard 9-pin RS-232 and one RS-485communication port on the back operator panel, as wellas a standard IRIG-B port for user time-syncing. SeeFigure 10.

Communication ProtocolsThree communication protocols are available for theForm 6 recloser control:

• Modbus

• DNP3

• 2179

One communication protocol can be selected for eitherthe back panel RS-232 or RS-485 port.

All three protocols are selected and configured by theuser with the ProViewTM Communications WorkbenchTM

application software.

When Modbus, DNP3, or 2179 communication protocol isselected for the RS-485 serial port, the RS-232 serial portis defaulted to ProViewTM interface software protocol.

When Modbus, DNP3, or 2179 communication protocolis selected for the RS-232 serial port, the RS-485 serialport is not active. The RS-485 serial port does not sup-port ProViewTM interface software protocol. DNP3 is fac-tory-defaulted to the RS-232 port.

The user can simultaneously communicate to the Form 6pole mount control using both the front panel data portand the appropriate back panel serial communicationport (provided the back panel RS-232 port is not config-ured to be ProView protocol).

Control InformationControl information includes firmware identification bycatalog number and name, date code, and ProViewrelease number. Control information is available throughthe Settings menu on the front panel (Figure 4).

Control Back PanelThe control back panel is easily accessible through theback door of the control cabinet (Figure 11) with readilyidentifiable serial ports and connections (Figure 10).


14

TB11

2

3 5 7 9 11 13 15 17 19

4 6 8 10 12 14 16 18

CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4

CI4


TB31 3 5 7 9 11 13 15 17 19 21

CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6

TB4

2 4 6 8 10 12 14 16 18 20CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6

1 3 5 7 9 11 13CO7 CO8 CO9 CO10 CO11 CO12

2 4 6 8 10 12CO7 CO8 CO9 CO10 CO11CO12

J1 RS232 J2 IRIG-B

TTL IRIG-B

J3 RS485

2-Wire RS485

RECLOSER INTERFACE CONNECTIONSA1

D3

F5 7

2B

4C

6E

TB6

RS232 DTE

TB2 •1 2

•3 4

•5 6

•7 8

•9 10

•11 12

•13 14

•15 16

•17 18

•19 20

I(1-2) I(3-4) I(5-6) V(1-2) V(3-4) V(5-6) V1I(SEF)

Discrete InterfaceBoard (Accessory)

AC Power Fuse

RS-232 Serial Communication Port

IRIG-B Connection

Power Supply Board

AC Customer ConnectionTerminal Block TB7

Grounding Terminal, OneExternal & One Internal

(#14 to #4 Stranded)

1 65432

TB5

6 5 4 3 2 178910

Power Supply LEDPower Connections

1 432 7 12111098Voltage Sensing

Customer ConnectionTerminal Block TB8

120/240 VacSelector Switch

Battery Connector (2-position)

RS-485 Serial Communication Port

Figure 11.Form 6 pole mount recloser control cabinet.

030034KM

Figure 10.Form 6 recloser control back panel terminal block and communication port identification.

Initial ProgrammingPrior to Installation

The control must be programmed with all necessaryoperating settings, all alternate profiles, and parametersprior to operation with an energized recloser.

Note: Initial programming of the control is the responsibility ofa qualified technician or engineer familiar with controlfunctions and programming parameters required for thespecific recloser installation.

The control must be programmed with the Form 6 inter-face software. Refer to Service Information S280-70-4Kyle Form 6 Microprocessor-Based Recloser ControlProgramming Guide for additional information.

Note: The Pole Mounted Control checkbox in the ProViewSystem Configuration screen must be selected for allForm 6 pole mount controls. This includes both poleand substation applications.

Control / Recloser CompatibilityThe Form 6 pole mount recloser control is adaptable tothe following Kyle reclosers:

WE*, WVE27, WVE38X, VWE, VWVE27, VWVE38X,VSA12, VSA16, VSA20, VSA12B, VSA20A, VS012,VS016, NOVA15, and NOVA27.

* This control is not compatible with Form 1 Type WE reclosersbelow s/n 300 and RE reclosers below s/n 400.

Reclosers manufactured prior to June 1989 are equippedwith Type A bushing current transformers. Thesereclosers were designed for use with Form 2, Form 3,and Form 3A controls. Because the Form 6 recloser con-trol is designed for use with reclosers equipped with TypeB current-sensing Transformers, reclosers retrofitted withForm 6 recloser controls should be retrofitted with Type Bcurrent transformers. All reclosers manufactured since1989 are equipped with Type B (1000:1, 1000/500:1, or2000:1) sensing CTs.

Reclosers equipped with Type B sensing CTs are com-patible with all Kyle recloser controls (Form 2, Form 3,Form 3A, Form 4A, Form 4C, FXA, FXB Form 5, Form 5LS/UDP, and Form 6 recloser controls), and are identi-fied with the following label prominently displayed on therecloser sleet hood or the front of the operator cabinet:

The Form 6 recloser control can be used with the old-style Type A CTs; however, the event recorder and dutycycle monitor will have limited accuracy for currentsabove 5000 Amps.

Retrofit kits with the new Type B sensing CTs areavailable to upgrade existing families of reclosers foroperation with Form 6 recloser controls. For additionalinformation, contact your Cooper Power Systems rep-resentative.

For identification, Table 1 lists the serial number breaksbetween old-style Type A and the new-style Type B sens-ing CTs. Below this serial number, the recloser isequipped with the Type A CTs.

Note: For reclosers shipped prior to June 1989 and not listedbelow, please contact your Cooper Power Systems rep-resentative with the recloser type and serial number forverification of type A or B bushing current transformers.

S280-70-3

15

!SAFETYFOR LIFE

INSTALLATION PROCEDURE

CAUTION: Equipment misoperation. Do notconnect this control to an energized recloser until

all control settings have been properly programmedand verified. Refer to the programming information forthis control. Failure to comply can result in control andrecloser misoperation, equipment damage, and per-sonal injury. G110.3

!

NOTICERECLOSER IS EQUIPPED WITHTYPE B SENSING CTs.RECLOSER DOES NOT HAVE A BAT-TERY CHARGER.

IMPORTANT: Program all protection profiles.Unused alternate profiles should be programmed withthe same settings as one of the applicable profiles.Default settings on unused alternate profiles cancause unnecessary outages if they are below normalsystem requirements.

IMPORTANT: Check minimum trip values prior tosetting or changing an alternate profile to avoid misop-eration of the control under load conditions.

TABLE 1Serial Number Break for Reclosers with Type ASensing CTs

Recloser Below Serial Number

RXE 5831

RVE 5894

WE 11199

WVE 3695

VWE 7199

VWVE27 7208

VWVE38 1204

All VSA reclosers are equipped with Type A Sensing CTs.

All VSML reclosers are equipped with Type A Sensing CTs.

All VSA12, VSA12B, VSA16, VSA20, VSA20A, and VSA20Breclosers are equipped with Type B Sensing CTs.

All VWVE38X and VWE38X reclosers are equipped withType B Sensing CTs.

Duty Cycle MonitorThe Duty Cycle Monitor provides the following duty cycleinformation:

• Measures and records duty for each individual phasein non-volatile memory.

• The recloser duty is measured and stored on thebasis of Current1.5 x Number of Operations for EachPhase (ANSI C37.61).

• Readout is based on a percentage of total duty cyclefor each phase.

• Duty record can be adjusted or reset if recloser ischanged-out, serviced, etc.

Using Table 2, select the appropriate recloser interruptingduty cycle factor and enter that value via the ProViewTM

interface software.

Control Cable

The control cable is fabricated with connectors whichmate with the female receptacle of the recloser on oneend, and the male receptacle of the control or junctionbox on the other end.

Note: The control cable must be supported along its length toprevent repeated movement due to wind or other out-side forces which can damage the cable.

Limits on control cable lengths are determined by therecloser type and the distance between the control andrecloser: See Table 3 for available Form 6 recloser con-trol Cable Lengths for Kyle reclosers.


16

WARNING: Hazardous voltage. Recloser andcontrol must be solidly grounded. Follow all

approved procedures and safety practices whengrounding this equipment. Improper grounding canresult in contact with high voltage, which will causedeath or severe personal injury. G115.1

!

IMPORTANT: All external inputs to the Form 6recloser control must be routed within 8 inches of theircorresponding ground. During a surge, a potential ofapproximately 1.5 kV per foot can develop in the con-ductors. Differences between conductor and groundpath lengths can add additional stress to the controlcomponents in the event of a power surge.

TABLE 2Duty Cycle Factor

Interrupting 100% DutyRecloser Rating CycleType (rms sym Amps) Factor*

RXE, RVE 6,000 97WE 12,000 @ 4.8 kV 257WE 10,000 @ 14.4 kV 196

VWEVWVE27 12,000 1045VWVE38X

WVE27 8,000 140

WVE38X 8,000 140

VSA12 12,000 1045VSA16 16,000 1608

VSA20VSA20A 20,000 2248VSA20B

VSO12 12,000 1045

VSO16 16,000 1608

Auxiliary-PoweredNOVA 12,500 1111

Control-PoweredNOVA 12,500 1111

*Duty Cycle Factor is Value x 105.

TABLE 3Available Form 6 Control Cable Lengths for Kyle Reclosers

Recloser Type Gauge Length (Meters) Length (Feet)

WE, WVE27, WVE38X, VWE, VWVE27, VWVE38X,Auxiliary-Powered NOVA15, Auxiliary-Powered NOVA27 18 24.4 (maximum) 80 (maximum)

16 24.7 to 38 81 to 125

14 38.4 to 61 126 to 200

VSA12, VSA12B, VSA16, VSA20,VSA20A, VSO12, VSO16 18 3.4 to 6 11 to 20

16 6.4 to 10.7 21 to 35

14 11 to 15.25 36 to 50

Control-Powered NOVA15, Control-Powered NOVA27 16 3.4 to 38 11 to 125

Mounting the Control Mount the Form 6 recloser control in a convenient,accessible location. Mounting dimensions are provided inFigure 12.

A hole and keyway in the control mounting bracketaccommodates a 15.9 mm (5/8”) bolt.

S280-70-3

17

!SAFETYFOR LIFE

WARNING: This equipment is not intended toprotect human life. Follow all locally approved

procedures and safety practices when installing oroperating this equipment. Failure to comply may resultin death, severe personal injury and equipment dam-age. G102.1

!

Figure 12.Form 6 pole mount recloser control weight and dimensions.

TRIP CLOSE


Front View

710(28.0)

310(12.25)

Vent

Bottom View

Vent

1.44 Dia. Hole forVoltage Input Connection(Caplug Installed)

Mounting Angle

Control CableReceptacle

1.44 Dia. Hole(Caplug Installed)

1.44 Dia. Hole forLow Voltage Closing

Connection(Caplug Installed)

67(2.75)

38(1.5)

67(2.75)

79(3.25)

RS-232ConnectionPort

29(1.25)

Note: Unless otherwise specified, dimen-sions shown in mm (inches).

CONTROL WEIGHT 34 kg (75 lbs)

Note: Weight of one Form 6 pole mountrecloser control.

170(6.75)

355 (14.0)

400 (15.75)

16 (.63) Dia.Mounting Holes (2)

GroundingTerminal#14 To #4Stranded

665(26.25)

Right Side View

Grounding the Control

The control cabinet must be grounded. A grounding con-nector on the underside of the cabinet will accommodateNo. 14 solid through No. 4 stranded conductors.

Suggested methods for grounding the control and reclos-er are shown in Figures 13 and 14.

Figure 13 illustrates grounding methods for 4-wire multi-grounded systems with local supply voltage transformer.

Figure 14 illustrates grounding methods for 4-wire multi-grounded systems with remote supply voltage transformer.

For effective surge protection, all control and power con-ductors for the Form 6 must be routed parallel to a corre-sponding ground path. For example, the ac power supplyfor the control should be parallel to and equal in length tothe transformer ground path. The control cable should beparallel to and routed close to the recloser ground path.


18

WARNING: Hazardous voltage. Recloser andcontrol must be solidly grounded. Follow all local-

ly approved procedures and safety practices whengrounding this equipment. Improper grounding canresult in contact with high voltage, which will causedeath or severe personal injury. G115.1

!

Installation of a Form 6 recloser control with a local sup-ply voltage transformer must include the following:

• Protection of the recloser bushings and the supplyingtransformer with lightning arresters.

• Grounding of the recloser head and tank.

• Grounding of the transformer tank.

• Grounding of the control cabinet.

• Grounding of the SCADA equipment.

4-Wire Multi-Grounded Systems

S280-70-3

19

!SAFETYFOR LIFE

SurgeArrester

RecloserHead Ground

SurgeArresterTransformer

SurgeArrester

Arrester Ground

Recloser

Pole

SupplyVoltage

PoleGround

Form 6Control

Customer Ground ConnectionAt External Lug

NE

UA

C

GNDNEUAC

InputTerminalBlock

ControlCable

AC

NEUTRAL

Form 6 ControlSupply Voltage

Transformer

ELECTRICAL CONNECTIONS Line to Neutral connected transformer

Input TerminalBlock

External Ground Lug

Figure 13.Recommended grounding method for the Form 6 recloser control installed on 4-wire multi-grounded, withlocal supply voltage transformer.


IMPORTANT: In pole-mounted applications, aground connection must be made between the reclos-er, transformer, recloser control, and SCADA equip-ment for proper protection of the equipment. The poleground must be sized per local utility practices to min-imize the impedance between the recloser and thecontrol.

Grounding with a Local Supply Voltage Transformer; 4-Wire Multi-Grounded

Installation of a Form 6 recloser control with a remotesupply voltage transformer must include the following:

• Protection of the recloser bushings and the supplyingtransformer with lightning arresters.

• Grounding of the recloser head and tank.

• Grounding of the transformer tank.

• Grounding of the control cabinet.

• Grounding of the SCADA equipment.


20

SurgeArrester

RecloserHeadGround

SupplyVoltage

PoleGround

Pole

Recloser

Pole

SurgeArrester

Transformer

ArresterGround

Form 6 Control

HOTNEUGND

NE

UA

C

Input Terminal Block

Control Cable

SurgeArrester

ArresterGround

Customer Ground Connectionat External Lug

AC

NEUTRAL

Form 6 ControlSupply Voltage

Transformer

ELECTRICAL CONNECTIONS - Remote dedicated supply transformer

InputTerminalBlock

ExternalGround Lug

Note: Distance between transformer and recloser should be one pole span or less

System

Neutral

Figure 14.Recommended grounding method for the Form 6 recloser control installed on 4-wire multi-grounded withremote supply voltage transformer.

Grounding with a Remote Supply Voltage Transformer; 4-Wire Multi-Grounded


IMPORTANT: In pole-mounted applications, aground connection must be made between the reclos-er, transformer, recloser control, and SCADA equip-ment for proper protection of the equipment. The poleground must be sized per local utility practices to min-imize the impedance between the recloser and thecontrol.

Customer Connections for ACPower

Input power to the Form 6 recloser control is connectedto terminal block TB7 for single-phase power or TB8 forthree-phase power. See Figures 17, 19, and 21. For sin-gle-phase incoming voltage supply for 120 Vac or 240Vac, connect to TB7 as shown in Figure 17. For three-phase incoming voltage supply, the user should supplyand connect to TB8 as show in Figure 19. For 240 Volt,3-wire transformer connection refer to Figure 21. Refer toAccessory section for 120 Vac or 240 Vac low voltageclosing.

Input power is required:

• To power the control

• To provide voltage and power metering

• To power the thermostatically controlled heater

• For the low voltage closing accessory

• For the convenience outlet accessory

Power Supply / Battery Charger BoardIncoming ac power is routed to the Power Supply /Battery Charger Board designed to accept either 120 Vacor 240 Vac through a selector switch located directly onthe board (Figure 15). The battery charger includes atemperature-compensated design to optimally charge thecontrol battery. The power supply / battery charger boardalso includes an auxiliary power supply for connection tocommunication equipment (radios, modems, etc.). Theauxiliary power supply is rated 28 Vdc, 65 Watts peak. Aseparate 28 Vdc to 13.8 Vdc power supply accessory isavailable for communication equipment rated for 13.8Vdc. Some additional features are as follows:

• Positive LED indicator for power supply presence.

• Selectable 120/240 Vac switch for adapting to multi-ple transformer connections. The selector switch isfactory-set based upon each customer order.

• Self-protective fuse (5 amp, 250 Vac).

• 28 Vdc whetting voltage for I/O contact inputs.

Terminal BlocksTwo terminal blocks are used for connection to the Form6 recloser control. Both terminal blocks are fit for a #6screw which can allow a maximum ring size for a #10AWG for metering.

Terminal Block TB7 provides power to the Form 6 reclos-er control and is directly connected to the power supplycircuit board. Terminal Block TB8 is used to connectsensing transformer voltage. The wiring of the transform-ers should follow the application illustrations per Figures18, 19, 20, and 21.

Default factory wiring includes connection of two wiresfrom Power Supply Terminal Block TB7 to the MeteringTerminal Block TB8. See Figure 16.

Figure 20 shows customer connections for TB8, 120 VacDelta Connection.

The wiring from TB7-3 to TB8-3 and from TB7-5 to TB8-4 connects the metering B phase to the control. If theincoming power supply voltage is different, the B phasepower supply input must be moved to the appropriatelocation. See Figure 18.

For A phase incoming power, connect to TB8-1.

For C phase incoming power, connect to TB8-5.

Note: Terminal Block positions TB7-3 and TB7-4 are factory-jumpered together.

Note: Terminal Block positions TB7-5 and TB7-6 are factory-jumpered together.

Power ConnectionsThe transformer required for power should be a minimumof 5 kVA for low-voltage ac closing reclosers and 1 kVAfor high voltage ac closing reclosers and control-poweredNOVA reclosers.

S280-70-3

21

!SAFETYFOR LIFE

Figure 15.Power Supply / Battery Charger Board.

030003KM

ACPower

Fuse

Power Supply Board

CAUTION: Equipment damage. Do not drillconnection holes into the top of the cabinet.

Connection holes in the top of the cabinet will allowmoisture to seep into the control and damage the com-ponents or cause control misoperation. Failure tocomply will void the control’s factory warranty. T249.0

!

Selector Switch

CAUTION: Equipment misoperation. Verify thatthe 120/240 Vac selector switch is correctly set

for incoming voltage. Failure to comply may causemisoperation (unintentional operation) of the controland/or equipment damage resulting in personal injury.

T278.0

!

IMPORTANT: Prior to energizing the control, theselector switch must be set as follows:

• For 120 Vac incoming power, the selector switchmust be set to the 115V position.



22

1 65432

Power Connections

TB7 120/240NEUNEU

120 (L1)

1 432 7 12111098

TB8

Voltage Sensing ConnectionsSource Load

V (1-2) V(3-4) V(5-6) V1

5 6

BØ

120(L2)

Factory Wiring for Wye Connection

Figure 16.Default factory wiring connected to B-Phase voltage metering with B-Phase incoming supply.

NEU

BØ

BØ1 65432

Power Connections

TB7120/240

NEUNEU

120 (L1)

User-SuppliedDisconnect

Switch

120(L2)

Figure 17.Single-Phase Transformer Connection, B phase input for Power and Sensing.

Note: Terminal Block positions TB7-3 andTB7-4 are factory-jumpered together.

Terminal Block positions TB7-5 andTB7-6 are factory-jumpered together.

Remove the factory jumpers betweenTB8 and TB7 for separate controlpower and sensing voltage inputs.

Note: Terminal Block positions TB7-3 and TB7-4are factory-jumpered together.

Terminal Block positions TB7-5 and TB7-6are factory-jumpered together.

S280-70-3

23

!SAFETYFOR LIFE

1 65432

Power Connections

TB7

120/240NEUNEU

120 (L1)

1 432 7 12111098

TB8


V (1-2) V(3-4) V(5-6) V1

AØ

65

AØ


Switch

120(L2)

Figure 18.Modified wiring connected to A-Phase voltage metering with A-Phase incoming supply.

NEU

CØ

BØ

AØ

AØ

BØ

CØ

1 432 7 12111098

TB8


V (1-2) V(3-4) V(5-6) V1

5 6

User-SuppliedDisconnectSwitches

Figure 19.Three-Phase Transformer Connection, Wye configuration only (TB8 Terminal Block Connection).




24

1 65432

Power Connections

TB7120/240

NEUNEU

120 (L1)

240

120

120

BØ

1 432 7 12111098

TB8


V (1-2) V(3-4) V(5-6) V1

5 6

120

Load Side

Source Side

NEU

YØ


Switch


120(L2)

Figure 21.240 Volt, 3-wire transformer connection. B phase input for Power and Sensing. *YØ for Sync Check Voltage.

Note: Terminal Block positionsTB7-3 and TB7-4 are fac-tory-jumpered together.

Terminal Block positionsTB7-5 and TB7-6 are fac-tory-jumpered together.

1 432 7 12111098

TB8


V (1-2) V(3-4) V(5-6) V1

65

CØ

BØ

AØ


Figure 20.Customer connections to TB8, 120 Vac Delta Connection.




Standard Default Supervisory InputControl and Output Status ContactsStandard customer connections TB1 and accessory cus-tomer connections are TB3 and TB4. Refer to Figures 22and 23 and Tables 4, 5, and 6. The Idea WorkbenchTM

allows customization of all the control and status points.Refer to Service Information S280-70-4 Kyle Form 6Microprocessor-Based Recloser Control ProgrammingGuide for additional information.

S280-70-3

25

!SAFETYFOR LIFE

ContactInput Voltage Rating

120 Vac 8 A

12 Vdc 8 A

24 Vdc 8 A

48 Vdc 1 A

125 Vdc 0.4 A

TABLE 5Ratings Table for Output Status Contacts CO1through CO12(Resistive Load – Pickup Time 8 ms, Dropout 15 ms)

ContactInput Voltage Rating

120 Vac 8 A

12 Vdc 8 A

24 Vdc 8 A

48 Vdc 8 A

125 Vdc 8 A

TABLE 6Ratings Table for Output Status Contact SS1(Resistive Load – Pickup Time 2 ms, Dropout 15 ms)

IMPORTANTShielding and Surge Protection ofSupervisory CablesAll supervisory operation and control monitor leads mustbe protected within shielded cables. Refer to Figure 24.

CAUTION: Equipment damage; misoperation.External leads must be shielded and the shield

must be grounded at both ends. Terminate each leadwith a 320 Vac, 160 Joules metal oxide resistor (MOV),or equivalent, at the remote end. Attach MOVs betweenthe leads and ground. Failure to properly shield and pro-tect leads can result in equipment damage and/or unin-tentional operation. G117.3

!

TB11

2

3 5 7 9 11 13 15 17 19

4 6 8 10 12 14 16 18


CI4


TB31 3 5 7 9 11 13 15 17 19 21


TB4


1 3 5 7 9 11 13CO7 CO8 CO9 CO10 CO11 CO12

2 4 6 8 10 12CO7 CO8 CO9 CO10 CO11CO12

J1 RS232 J2 IRIG-B

TTL IRIG-B

J3 RS485

2-Wire RS485


D3

F5 7

2B

4C

6E

TB6

RS232 DTE

TB2 •1 2

•3 4

•5 6

•7 8

•9 10

•11 12

•13 14

•15 16

•17 18

•19 20

I(1-2) I(3-4) I(5-6) V(1-2) V(3-4) V(5-6) V1I(SEF)

1 65432

TB5

6 5 4 3 2 178910

Power Connections

1 432 7 12111098

Mfg. No. 6A0016010XX

*Location ofModule Mfg. No.

Back of Form 6 Pole Mount Control

Module Nominal MinimumMfg. No.* Input Voltage Current Operating Time

6A00160101 12 Vdc – 48 Vdc 5 mA 5 milliseconds

6A00160102

6A00160103

6A00160104

6A00160105 48 Vdc – 125 Vdc, 5 mA 5 milliseconds

6A00160106 120 Vac

6A00160107

6A00160108

TABLE 4Operating Current Requirements forStandard and Optional Supervisory Inputs


26

SS1

TB11

2

3 5 7 9 11 13 15 17 19

4 6 8 10 12 14 16 18


CI1 CI2 CI3 CO1 CO2 CO3 CO4

CI4

TB31 3 5 7 9 11 13 15 17 19 21


TB4


1 3 5 7 9 11 13CO7 CO8 CO9 CO10 CO11 CO12

2 4 6 8 10 12CO7 CO8 CO9 CO10 CO11CO12

J1 RS232 J2 IRIG-B

TTL IRIG-B

J3 RS485

2-Wire RS485

TB5


D3

F5 7

2B

4C

6E

TB6

RS232 DTE

TB2 •1 2

•3 4

•5 6

•7 8

•9 10

•11 12

•13 14

•15 16

•17 18

•19 20

I(1-2) I(3-4) I(5-6) V(1-2) V(3-4) V(5-6) V1I(SEF)

6 5 4 3 2 178910

TB1

SS1

1

2

3 5 7 9 11 13 15 17 19

4 6 8 10 12 14 16 18



Rem

ote

Trip

and

Loc

kout

Sup

ervi

sory

Trip

and

Loc

kout

Sup

ervi

sory

Clo

se

ControlLockoutStatus(Not

Lockout)*

RecloserStatus

(RecloserOpen)*

A BHotline

TagStatus

(HotlineTag Off)*

ControlOK

Status(ControlNot OK)*

Ground TripBlockedStatus

(GRD TRIPNormal)*

Customer Wiring

Rem

ote/

Sup

ervi

sory

Com

mon

Customer-SuppliedVoltage Inputs**

**Whetting voltage is also available from the Form 6 Recloser Control on Terminal Block TB1. Refer to Figure 24.

Note: Contact output relays revert tode-energized positions as shownupon downloading new schemesor Workbench files.

*Relay Contacts shownfor Indicated Status

Figure 22.Form 6 recloser control standard default supervisory input control and output status contacts.

S280-70-3

27

!SAFETYFOR LIFE

SS1

TB1

1

2

35

79

1113

1517

19

46

810

1214

1618

CI1

CI2

CI3

SS1

CO1

CO2

CO3

CO4

CI1

CI2

CI3

CO1

CO2

CO3

CO4

CI4

TB3

13

57

911

1315

1719

21CI

5CI

6CI

7CI

8CI

9CI

10CI

11CO

5CO

6

TB4

24

68

1012

1416

1820

CI4

CI5

CI6

CI7

CI8

CI9

CI10

CI11

CO5

CO6

13

57

911

13CO

7CO

8CO

9CO

10CO

11CO

12

24

68

1012

CO7

CO8

CO9

CO10

CO11

CO12

J1 R

S232

J2 IR

IG-B

TTL

IRIG

-B

J3 R

S485

2-W

ire R

S485

TB5

RECL

OSER

INTE

RFAC

E CO

NNEC

TION

SA 1

D 3F 5

7

2 B4 C

6 E

TB6

RS23

2 DT

E

TB2

• 12

• 34

• 56

• 78

• 910

• 1112

• 1314

• 1516

• 1718

• 1920

I(1-2

)I(3

-4)

I(5-6

)V(

1-2)

V(3-

4)V(

5-6)

V1I(S

EF)

65

43

21

78

910

CI4

TB3

13

57

911

1315

1719

21

CI5

CI6

CI7

CI8

CI9

CI1

0C

I11

CO

5C

O6

TB4

24

68

1012

1416

1820

CI4

CI5

CI6

CI7

CI8

CI9

CI1

0C

I11

CO

5C

O6

13

57

911

13

CO

7C

O8

CO

9C

O10

CO

11C

O12

24

68

1012

CO

7C

O8

CO

9C

O10

CO

11C

O12

Supervisory Ground Trip Block

Supervisory Reset Targets

Supervisory Non-Reclose

Unassigned

Remote Alternate Profile 2



Non

-Rec

losi

ngS

tatu

s(N

orm

alR

eclo

se)*

Remote Normal Profile

Ala

rms

Sta

tus

(No

Ala

rms)

*

Alte

rnat

eP

rofil

e 1

Sta

tus

(Not

inA

lt 1

Pro

file)

*

Nor

mal

Pro

file

Sta

tus

(Not

inN

orm

alP

rofil

e)*

Alte

rnat

eP

rofil

e 2

Sta

tus

(Not

inA

lt 2

Pro

file)

*

Fre

quen

cyA

larm

(Fre

quen

cyN

orm

al)*

Alte

rnat

eP

rofil

e 3

Sta

tus

(Not

inA

lt 3

Pro

file)

*

Vol

tage

Ala

rm(V

olta

geN

orm

al)*

*Rel

ay C

onta

cts

show

nfo

r In

dica

ted

Sta

tus

Cus

tom

er W

iring

Remote/Supervisory Common

Cus

tom

er-S

uppl

ied

Vol

tage

Inpu

ts**

**W

hetti

ng v

olta

ge is

ava

ilabl

e fr

om th

e

For

m 6

Rec

lose

r C

ontr

ol o

n Te

rmin

al B

lock

T

B1.

Ref

er to

Fig

ure

24.

Figure 23.Form 6 recloser control Discrete Interface Board Accessory default supervisory input control and output sta-tus contacts.


28

FORM 6 RECLOSER CONTROL

REMOTEBOX

Not All RemoteConnections

Shown

SHIELD

12 CO1

3

5

7

4

6

8

CI1

CI2

CI3

CI1

CI2

CI3

RemoteTrip andLockout

SupervisoryTrip andLockout

SupervisoryClose

TB1

1

2

+

—

Whetting Voltage TerminalsCustomer Wiring

Customer Wiring

28 Vdc

11

13

CO1

RecloserStatus A*

B*

*Contacts shownwith recloser inOPEN position.

Factory-Supplied28 Vdc Whetting

Voltage

A Single common wire can be used for multiple inputsif it is jumpered at the I/O board terminals.

NOTES: Arresters to be metal oxide varistors (MOVs) 320 Vac, 160 Joules or equivalent.

Shielding for Supervisory Cables should followthe representative input control contacts andoutput status contacts as shown.

External lead resistance must not exceed 200 ohms.

Supervisory and Remote Functions aredefault functions.

Figure 24.Shielding and Surge Protection for Supervisory and Remote Cables.

Rear Panel Communication PortPin AssignmentsTables 7 and 8 indicate the pin assignments for the rearpanel RS-232 and RS-485 communication ports (Figure25). Refer to Figures 26 and 27 for pin identification.Refer to Protocols for additional information.

S280-70-3

29

!SAFETYFOR LIFE

2-Wire RS-485

J3-RS-485

5 4 3 2 1

9 8 7 6

Figure 27.Rear Panel RS-485 Communication Port PinIdentification.

Pin Number Signal Name

1 DCD . . . . . . . . . . . . . . . . . . . Carrier Detect

2 RXD . . . . . . . . . . . . . . . . . . . Receive Data

3 TXD . . . . . . . . . . . . . . . . . . . . Transmit Data

4 DTR . . . . . . . . . . . . . . . . . . . . Data Terminal Ready(Not Connected)

5 GND . . . . . . . . . . . . . . . . . . . Signal Ground

6 DSR . . . . . . . . . . . . . . . . . . . Data Set Ready(Not Connected)

7 RTS . . . . . . . . . . . . . . . . . . . . Request to Send

8 CTS . . . . . . . . . . . . . . . . . . . . Clear to Send

9 NC . . . . . . . . . . . . . . . . . . . . . Not Used

10 (Shroud) . . . . . . . . . . . . . . .Chassis Ground

TABLE 7Rear Panel RS-232 Communication PortPin Assignments

RS-232 DTE

J1-RS-232

1 2 3 4 5

6 7 8 9

Figure 26.Rear Panel RS-232 Communication Port PinIdentification.

TB11

2

3 5 7 9 11 13 15 17 19

4 6 8 10 12 14 16 18


CI4


TB31 3 5 7 9 11 13 15 17 19 21


TB4


1 3 5 7 9 11 13CO7 CO8 CO9 CO10 CO11 CO12

2 4 6 8 10 12CO7 CO8 CO9 CO10 CO11CO12

J1 RS232 J2 IRIG-B

TTL IRIG-B

J3 RS485

2-Wire RS485

TB5


D3

F5 7

2B

4C

6E

TB6

RS232 DTE

TB2 •1 2

•3 4

•5 6

•7 8

•9 10

•11 12

•13 14

•15 16

•17 18

•19 20

I(1-2) I(3-4) I(5-6) V(1-2) V(3-4) V(5-6) V1I(SEF)

6 5 4 3 2 178910

RS-232 Communication Port RS-485 Communication Port

Figure 25.Form 6 recloser control rear panel RS-232 and RS-485 communication ports.

Pin Number Signal Name

1 SGND . . . . . . . . . RS-485 Signal Ground (Same as 3)

2 GND . . . . . . . . . . Chassis Ground

3 SGND . . . . . . . . . RS-485 Signal Ground (Same as 1)

4 A . . . . . . . . . . . . . RS-485 “A” Signal (+) (Same as 8)

5 B . . . . . . . . . . . . . RS-485 “B” Signal (–) (Same as 9)



8 A . . . . . . . . . . . . . RS-485 “A” Signal (+) (Same as 4)

9 B . . . . . . . . . . . . . RS-485 “B” Signal (–) (Same as 5)

TABLE 8Rear Panel RS-485 Communication PortPin Assignments

Before Placing the Control andthe Recloser into Service

Prior to placing the control and recloser into service, thefollowing installation procedures must be properly com-pleted and verified:

1. Option Labels 1–3 changed (if applicable) on theoperating panel.

Note: Refer to Using Removable Inserts in this manual.

2. Control properly mounted for the installation.

3. Recloser installed according to all locally approvedstandards and practices.

4. AC disconnect switches installed.

5. Control and recloser properly grounded in accor-dance with guidelines in this manual and the applica-ble recloser manual.

6. Control cable properly connected and supported.

7. Verify the selector switch on the PowerSupply/Battery Charger Board is set to the correctposition based upon the incoming power supply:



8. Control battery connected and tested for properoperation.

Note: The battery test is blocked for 60 seconds uponpower-up of the control.

Test the battery as follows:

A. Press the MENU button on the front panel.

B. Using the down arrow key, navigate to the BAT-TERY menu and press ENTER.

C. Using the down arrow key, navigate to the TESTBATTERY menu and press ENTER.

D. Press the F4 button to test the battery.

Note: This message will appear on the programmingpanel LCD display: ----TESTING----

The battery test results will display in the batterymetering menu.

Note: With AC disconnected and the battery supplyingthe load, current will read -400 to -600 mAdepending on accessories connected.

9. AC power connected to the control. (Control OK LEDindicator is illuminated.)

Note: The control Power Save feature will turn off thebacklit LCD display and all LEDs if no front panelkeypad is pressed within five minutes.

10. All control programming entered and verified byappropriate personnel.

Note: Refer to Service Information S280-70-4 Kyle Form6 Microprocessor-Based Recloser ControlProgramming Guide for additional information.

11. Control clock set to the correct time.

Note: Refer to Service Information S280-70-4 Kyle Form6 Microprocessor-Based Recloser ControlProgramming Guide Clock Menu for additionalinformation.

12. Customer connections for remote and supervisoryoperation checked and completed in accordance withproper shielding and surge protection.


30



!



T278.0

!

Using Removable Inserts

The removable insert labels on the operating panel(OPTION 1, OPTION 2, and OPTION 3), can bechanged, if desired.

1. De-energize both ac and dc power.

2. Use a flathead screwdriver to unscrew the six frontpanel screws.

3. Pull the right side of the front panel out towards theleft (Figure 28).

Note: Various connecting wires will keep the panelattached to the control.

Note: It is not necessary to disconnect any wires.

4. Use tweezers to gently pull out the removable insert.

Note: The insert will slide out of the right side of the oper-ating panel (Figure 29).

Note: The insert will slide out of the top of the program-ming panel indicator section (Figure 28).

5. Change the existing label or slide in a new label withthe name of the programmed option.

An electronic label template is included on theProViewTM application software CD and can beaccessed through the following default address:

C: / Program Files / Cooper / Proview40 / Form 6 /Form 6 Inserts.doc

6. Gently push the removable insert from right to left intothe right side of the operating panel (Figure 29) ordown into the programming panel LED indicator sec-tion (Figure 28).

7. Place the front cover panel back onto the control.Using a flathead screwdriver screw the screws intothe control and tighten all hardware completely.

S280-70-3

31

!SAFETYFOR LIFE

CAUTION: Equipment damage. Always wear agrounding wrist strap to control static electricity beforehandling circuit boards. Failure to use this strap mayresult in circuit board damage. T253.1

CAUTION: Control damage. De-energize both acand dc power prior to removing or installing any inter-nal connections or circuit boards in the control. Failureto comply can result in damage to the control. T241.1

Figure 29.Labels (OPTION 1, OPTION 2, and OPTION 3) areeasily removed from and inserted into the operatingpanel.

000008KM

Figure 28.Open front panel. Labels (INDICATOR 1, INDICATOR2, AND INDICATOR 3) are easily removed from andinserted into the top of the programming panel LEDstatus indicator section.

010063KM

IMPORTANT: Laminate the removable inserts priorto installing. This will seal the ink/toner and avoiddamage to the front panel.

Removable LEDStatus Indicator Panel

These accessories are available. Contact your CooperPower Systems representative for additional information.

Low Voltage ClosingThe Low Voltage Closing Accessory utilizes 120 or 240Vac for closing power (Figures 30, 31, 32, and 33).Multiple low voltage closing accessories are available forreclosers equipped with low voltage closing. The low volt-age closing accessories available for the Form 6 reclos-er control include the appropriate receptacles and wiring

based upon the input supply voltage. Table 9 lists theavailable low voltage closing input/output receptacles forthe Form 6 recloser control.

Incoming Power ReceptaclesThe Incoming Power Receptacle allows the user to con-veniently plug the power cable into the control, eliminat-ing the need for hardwiring to the control. Various optionsare available based upon the input power voltage, andphase sensing requirements. Table 9 includes the avail-able input receptacles for the Form 6 recloser control.


32

ACCESSORIES

TB7

1

2

3

4

5

6

R2

A

B

C

R3

A

B

White

120/240 VacPower Supply

Black

1

2

FUSE 115 Amp125 Volt

1

2

4

White (neutral)

IncomingPowerReceptacle120 Vac

120 Vac

Low VoltageClosingReceptacle

Internal WiringConnections

Black

Figure 30.120 Vac low voltage closing accessory with incoming power terminal block and low voltage closing receptacle.

Description Catalog Number

120 Vac low-voltage closing 2-pin input and 2-pin outlet receptacles . . . . . . . . . . . . . . . . . . . . . KME6-1775-A

120 Vac low-voltage closing with 3-pin input and 2-pin output receptacles . . . . . . . . . . . . . . . . KME6-1775-B

120 Vac low-voltage closing with inlet hole and 2-pin outlet receptacle . . . . . . . . . . . . . . . . . . . KME6-1775-C

240 Vac low-voltage closing with 2-pin input and 2-pin outlet receptacle . . . . . . . . . . . . . . . . . . KME6-1775-D

240 Vac low-voltage closing with 3-pin input and 2-pin outlet receptacle . . . . . . . . . . . . . . . . . . KME6-1775-E

240 Vac low voltage closing, for 2-wire with inlet hole and 2-pin output receptacle . . . . . . . . . . KME6-1775-F

240 Vac low-voltage closing, for 3-wire with inlet hole and 2-pin outlet receptacle . . . . . . . . . . . KME6-1775-G

120 Vac or 240 Vac input receptacle, 2-pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KME6-1775-H

120 Vac input receptacle, 3-pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KME6-1775-J

240 Vac input receptacle, 3-pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KME6-1775-K

TABLE 9Low Voltage Closing and Input Receptacles



S280-70-3

33

!SAFETYFOR LIFE

1

TB8Input

2

TB7

1

2

3

4

5

6

R3

A

B


1

2

FUSE 115 Amp125 Volt

1

2

4

3

4

5

6

AØ

N

BØ

CØ

120 Vac

120 Vac

IncomingPowerLeads


InternalWiringConnection

120 Vac

FactoryWiring

7

Black

White (neutral)

Figure 31.Three-phase 120 Vac low voltage closing accessory with incoming power terminal block and low voltage clos-ing receptacle.

1

TB8Input

2

TB7

1

2

3

4

5

6

R3

A

B


1

2

FUSE 115 Amp125/240 Volt

1

2

4

3

4

5

6

IncomingPowerLeads


InternalWiringConnection

AØ

N

BØ

CØ

240 Vac

240 Vac

240 Vac

FactoryWiring

7

White (neutral)

Black

Figure 32.Three-phase 240 Vac low voltage closing accessory with incoming power terminal block and low voltage clos-ing receptacle.





BCT Terminal Blocks AccessoryThe BCT Terminal Blocks (Figures 34 and 35) attach tothe back of the control and provide a connection point forexternal 600:5 or 1200:5 multi-ratio bushing currenttransformers. BCT Terminal Blocks are available for boththe load or source sides and include wire for all ratios ofthe BCT. Refer to Table 10.

Auxiliary Terminal BlockAccessoryAn auxiliary terminal block and receptacle is available forthree-stage auxiliary switch wiring. Refer to Table 10.


34


BCT shorting-type terminal blockfor (Load) bushings 2, 4, 6 . . . . . . . . KME6-1773-A

BCT shorting-type terminal blockfor (Source) bushings 1, 3, 5 . . . . . . . KME6-1773-B

Terminal block and receptacle forwiring of three-stage auxiliaryswitch, KA542R3 . . . . . . . . . . . . . . . . KME6-1801-1

TABLE 10Terminal Blocks

TB7

1

2

3

4

5

6

1

2



1

2

4

1TB8

2

3

4

5

6

7

TB9

1

2

3

4

5

6

DisconnectSwitches

120V

120V

1

2


FactoryWiring

240V

120V

120V

240V

240 VacLow Voltage

Closing

Figure 33.3-wire 240 Volt transformer connection with 240 ac low voltage closing.

Note: Terminal Blockpositions TB7-3and TB7-4 arefactory-jumperedtogether.

Terminal Blockpositions TB7-5and TB7-6 arefactory-jumperedtogether.

Front Panel with Expanded LEDsAn ordering option for the front panel of the Form 6 polemount recloser control includes the availability of addi-tional configurable LEDs (Figure 36). The user is able toconfigure five additional LEDs for numerous status’,alarms, or events using the Idea WorkbenchTM feature inthe ProViewTM interface software.

Discrete Interface Board (DIF)Option AccessoryA Discrete Interface Board Option accessory provideseight configurable input control contacts and eight con-figurable output status contacts (Figure 37).

Cable Locking SleevesTo prevent detachment of the control cable from the con-trol cabinet by unauthorized personnel, a cable-lockingsleeve is available to enclose the cable plug. The plug ispassed through the sleeve and the sleeve is then fas-tened from inside the control cabinet. There is no accessto the cable receptacle without opening the locked cabi-net door and detaching the sleeve.

120 Vac GFI Duplex OutletThe GFI Duplex Outlet is available for controls poweredby 120 Vac or 240 Vac three-wire supply power. This con-venience outlet is rated for 15 Amperes and is accessiblethrough the front door in the control cabinet. The 120 VacGFI Duplex Outlet is used for many applications such aspower for the MET Tester, auxiliary measurement equip-ment, and supplemental lighting.

RS-232 CableA nine-pin RS-232 Cable is available to connect from thepersonal computer to the data port on the front panel ofthe Form 6 pole mount recloser control. The front panelRS-232 port is wired as a DCE port for direct connectionto the personal computer.

Stainless Steel CabinetA cabinet constructed from AISI 304 stainless steel isavailable as an accessory.

S280-70-3

35

!SAFETYFOR LIFE

SS1

TB11

2

3 5 7 9 11 13 15 17 19

4 6 8 10 12 14 16 18



CI4

TB31 3 5 7 9 11 13 15 17 19 21


TB4


1 3 5 7 9 11 13CO7 CO8 CO9 CO10 CO11 CO12

2 4 6 8 10 12CO7 CO8 CO9 CO10 CO11CO12

J2 IRIG-B

TTL IRIG-B

J3 RS485

2-Wire RS485

TB5


D3

F5 7

2B

4C

6E

TB6

TB2 •1 2

•3 4

•5 6

•7 8

•9 10

•11 12

•13 14

•15 16

•17 18

•19 20

I(1-2) I(3-4) I(5-6) V(1-2) V(3-4) V(5-6) V1I(SEF)

6 5 4 3 2 178910

J1 RS232

RS232 DTE

V2 V3

Figure 37.Form 6 recloser control discrete interface boardaccessory.

DIF Board Accessory

1 432 7 121110985 6

1 65432

Customer Connections

TB7

120/240NEUNEU

120 (L1)120(L2)

GROUND X5 X4 1 X3 X2 X1 GROUND X5 X4 5 X3 X2 X1

TB8

GROUND X5 X4 3 X3 X2 X1

Figure 34.Form 6 recloser control BCT terminal block acces-sory – Source Side.

1 432 7 121110985 6

1 65432

Customer Connections

TB7

120/240NEUNEU

120 (L1)120(L2)

GROUND X5 X4 2 X3 X2 X1 GROUND X5 X4 6 X3 X2 X1

TB8

GROUND X5 X4 4 X3 X2 X1

Figure 35.Form 6 recloser control BCT terminal block acces-sory – Load Side.

CONTROL POWER

CONTROL OK


RECLOSER CLOSED

A PHASE FAULT


SENSITIVE GND

ALARM


INDICATOR 3

A PHASE VOLTAGE


VOLTAGE TRIP

INDICATOR 4

INDICATOR 5INDICATOR 6INDICATOR 7

INDICATOR 8

Figure 36.Expanded status indicator LEDs.

Expanded LEDs

Fiber Optic Interface AccessoryThe fiber optic interface accessory, (Figure 38), CatalogNumber KME6-1875-1, provides a fiber-optic serial inter-face for two-way, real-time, serial communications with aremote terminal unit (RTU), telephone modem, or per-sonal computer.

Radio Mounting AccessoryThe radio mounting accessory (Figure 39) is poweredfrom a voltage regulated power supply factory-calibratedwith an output of 13.8 Vdc.

Note: This output cannot be field-calibrated.

The radio will continue to operate during the loss of acpower as long as power is supplied from the battery. Thepower supply is designed to provide up to 40 Watts(peak) and is fused to isolate any potential radio prob-lems without disturbing the protection system in therecloser control. Refer to Table 11.

Contact your Cooper Power Systems representative forany additional voltage requirements.


36

Radio-MountingBracket

24 Vdc to 13.8 VdcConverter

Customer-SuppliedPower Leads

Radio AntennaCable (onlyavailable with fullautomation accessory)

Power Cable

Antenna SurgeSuppresser andConnector (onlyavailable with fullautomation accessory)

Customer-SuppliedRadio

Figure 39.Form 6 recloser control radio mounting accessory.

TB11

2

3 5 7 9 11 13 15 17 19

4 6 8 10 12 14 16 18


CI4


TB31 3 5 7 9 11 13 15 17 19 21


TB4


1 3 5 7 9 11 13CO7 CO8 CO9 CO10 CO11 CO12

2 4 6 8 10 12CO7 CO8 CO9 CO10 CO11CO12

J1 RS232 J2 IRIG-B

TTL IRIG-B

J3 RS485

2-Wire RS485


D3

F5 7

2B

4C

6E

TB6

RS232 DTE

TB2 •1 2

•3 4

•5 6

•7 8

•9 10

•11 12

•13 14

•15 16

•17 18

•19 20

I(1-2) I(3-4) I(5-6) V(1-2) V(3-4) V(5-6) V1I(SEF)

TB5

6 5 4 3 2 178910

P3

Figure 38.KME6-1875-1 Form 6 pole mount control fiber opticinterface accessory.


Full Automation accessory12 Vdc radio provision . . . . . . . . . . . . . . . KME6-1774-3

(Radio and fiber-optic/RS232 interface not included)

Automation accessory (bracket only)12 Vdc provision . . . . . . . . . . . . . . . . . . . . KME6-1774-2

TABLE 11Radio Mounting Accessories

IMPORTANT: The KME6-1875-1 fiber optic accesso-ry kit can not be combined, installed, or used with theKME6-1801-1 auxiliary switch accessory kit.

Testing an Installed ControlThe following tests to determine initial operation of theForm 6 recloser control can be performed while connect-ed to an operating recloser.

Note: These are the only tests performed on an installed,operating control.

1. Verify operating status of all indicator lights by press-ing the LAMP TEST key on the programming panel(Figure 40).

2. Check the operational values for currents, voltages,and other metering information.

Note: Scroll through the LCD display messages by press-ing the and cursor movement arrows under-neath the LCD display on the programming panel(Figure 40).

3. Test battery operation as follows:

Note: The battery test is blocked for 60 seconds uponpower up of the control.

Note: AC power can be either connected or disconnectedfor battery test.

A. Press the MENU button on the front panel.

B. Using the down arrow key, navigate to the BAT-TERY menu, and press ENTER.

C. Using the down arrow key, navigate to the TESTBATTERY menu and press ENTER.

D. Press the F4 button to test the battery.

Note: This message will appear on the programmingpanel LCD display: ----TESTING----

The battery test results will display in the batterymetering menu.

Note: Voltage should be between 25–31 Vdc – withthe higher voltage at colder temperatures.

Under normal conditions, with AC connectedand a fully charged battery, the charging currentshould be less than 20 mA.

With AC connected and a discharged battery,the current range should be 20–450 mA.

With AC disconnected and the battery supplyingthe load, current will read -400 to -600 mAdepending on accessories connected.

4. Verify the Control OK LED is illuminated on the con-trol operator panel (Figure 41). This indicates thepresence of ac power.

Note: The control includes a Power Save feature that willturn off the backlit LCD display and all LEDs if nofront panel keypad is pressed within five minutes.Pressing any key will reactivate the display andLEDs.

All other tests described in this TESTING section requirethe Form 6 recloser control to be removed from service,connected to a bypassed recloser, or tested at a locationwhere the proper testing equipment is available.

S280-70-3

37

!SAFETYFOR LIFE

TESTING



!

IMPORTANT: The Form 6 recloser control can betaken out of service for testing and placed back intoservice without de-energizing its recloser and inter-rupting the system. However, during the time the con-trol is out of service, the recloser is inoperative.

CONTROL POWER

CONTROL OK


RECLOSER CLOSED

A PHASE FAULT


SENSITIVE GND

Control OK LED

Figure 41.Control OK LED.

METERING

RESETTARGETS

EVENTS

LAMP TEST

MENU

ENTER

+—

SETTINGS

OPERCOUNTER

ALARMS

CHANGE

F1 F2 F3 F4

Figure 40.Lamp Test button, LCD display, and cursor move-ment arrows.

LAMP TESTButton

LCD Display

Cursor Movement Arrows


38

Remove the Control fromService

1. Enable GRD TRIP BLOCKED to allow for ground tripto be disabled when re-energized.

A. Press the CHANGE button on the Operator Panelto enter the CHANGE mode.

B. Depress the GRD TRIP BLOCKED button withinten seconds after entering the CHANGE mode.

Note: If the GRD TRIP BLOCK button is notdepressed within ten seconds, the function isnot activated.

2. Disconnect the battery.

3. Remove control ac sensing and power connectionsfrom the control using a separate disconnect switch.

4. Disconnect control cable from control.

5. Remove any control input and status output wiringfrom TB1, TB3, and TB4 (Figure 42).

6. Disconnect any serial communications ports and IRIG-B timing connection from J1, J2, and J3 (Figure 42).

7. Disconnect the ground from the control.

Testing with Type MET TesterThe Kyle® Type MET electronic recloser control tester(Figure 43) is used for testing the following functions ofthe Form 6 recloser control:

• Overcurrent Timing

• Reclose Time

• Operating Sequence

• Reset Time

• Minimum Trip Current

• High Current Trip and Lockout

The MET Tester is completely self-contained, capable ofperforming all required checks and tests from a simpleverification of operation to a complete verification of alloperating parameters.

Refer to Service Information S280-76-1 Type METElectronic Recloser Control Tester Operating Instructionsfor proper setup and use of the MET Tester.

Figure 43.Kyle® Type MET electronic recloser control tester.

010028KM

SS1

TB11

2

3 5 7 9 11 13 15 17 19

4 6 8 10 12 14 16 18



CI4

TB31 3 5 7 9 11 13 15 17 19 21


TB4


1 3 5 7 9 11 13CO7 CO8 CO9 CO10 CO11 CO12

2 4 6 8 10 12CO7 CO8 CO9 CO10 CO11CO12

J2 IRIG-B

TTL IRIG-B

J3 RS485

2-Wire RS485

J1 RS232

RS232 DTE

Figure 42.Back view of Form 6 pole mount recloser control.

IMPORTANT: Disconnect switches for ac sensingand power connections are necessary to isolate theForm 6 pole mount recloser control for testing andservicing.

WARNING: Hazardous voltage. If the recloseris energized while the control cable is discon-

nected, the CT secondaries can generate high volt-ages. Contact with high voltage can cause severe per-sonal injury or death. T204.2

!

CAUTION: Hazardous Voltage. Cable conduc-tors attached to NOVA reclosers will remain at

53Vdc potential after disconnection of source power tothe recloser. Contact with any pins at the end of cablesdirectly or indirectly connected to a NOVA recloser canresult in personal injury or equipment damage. T312.0

!

Closing the Recloser DuringTestingElectrical Closing – Solenoid-OperatedReclosersLine voltage is required for automatic recloser operationduring testing of reclosers equipped with a closing sole-noid (except for reclosers equipped with the low voltageclosing accessory).

For on-line testing, bypass the recloser, open the load-side disconnects and keep the source-side disconnectsclosed. This will remove the recloser from service, but willkeep line voltage supplied to the closing solenoid (Figure44).

For shop testing, the closing solenoid voltage is sup-plied by back-feeding a transformer with a low-side ratingequal to the voltage rating of an available power source,and a high-side rating equal to the voltage rating of the

recloser (Figure 46). A 75 kA transformer of the propervoltage rating with an impedance drop of approximately3% is satisfactory. The ac source must have a compara-ble impedance drop.

A test circuit for these solenoid-closed reclosers is shownin Figure 46. The following equipment is required for therecommended shop testing setup:

Note: Solenoid-closed reclosers equipped with a 120- or 240-Vac low-voltage closing coil accessory can be tested asshown in Figure 47.

• Variable Autotransformer T1, 230 Volts, 20 Amps.

• Low-Voltage transformer T2 to simulate fault conditions.

Ratio and size will depend upon the maximum currentto be used. The recloser presents a low impedance tothe transformer, so secondary voltage must be onlyhigh enough to force the required current through thesecondary of the transformer and the recloser.

Note: An alternative method of providing the necessarycurrent through the transformer is shown inFigure 45.

• High-Voltage T3 to operate the closing solenoid.

The closing coil requirement is approximately 200kVA during the two-to-three cycle closing operation.The solenoid coil operating voltage must be main-tained at the recloser bushings during the cycle inter-val the closing coil is energized. This procedure is notused on reclosers equipped with the low-voltage clos-ing accessory.

• Ammeter with a rating based on the level of testcurrent.

• Current-actuated timer.

S280-70-3

39

!SAFETYFOR LIFE

5 6

3 4

1 2

C

B

A

BYPASS SWITCHES(CLOSED)

SOURCE SIDEDISCONNECT SWITCHES(CLOSED)

LOAD SIDEDISCONNECT SWITCHES(OPEN)

CLO

SIN

GC

OIL

LOA

DS

OU

RC

ESO

UR

CE

LOA

D

Figure 44.Closing source-side switches of a bypassed “on-line” recloser provides closing solenoid power for automaticoperation during testing.

WARNING: Hazardous voltage. The switchgearand high voltage transformer must be in a test

cage or similar protective device to prevent accidentalcontact with the high voltage parts. Solidly ground allequipment. Failure to comply can result in death,severe personal injury, and equipment damage. T221.3

!

WARNING: Hazardous voltage. Interconnectsource leads X and Y and ground solidly to the

recloser tank (Figure 46). Do not connect lead Z to anyother phase or mechanical ground. Dangerous voltagesto ground exist on the phase connected to lead Z. Solidlyground all equipment. Failure to comply can result insevere personal injury and/or equipment damage. T224.1

!

Electrical Closing – Motor-OperatedLow Voltage Closing Solenoid / NOVAReclosers

High-voltage is not required for reclosers utilizing amotor-operated closing mechanism, low voltage closing,or NOVA recloser. For information on energizing therecloser, refer to the appropriate recloser installationmanual. Low voltage supply can use either 120 or 240Vac for input power. Check the name plate on the reclos-er to verify the correct closing power requirements.

Figure 47 shows a test circuit for motor-operated, low-voltage solenoid-closing, and NOVA reclosers. Sincethese reclosers require only a low voltage source forclosing, high-voltage transformer T3 and its protectivecage is eliminated. All other equipment is the same as thetest equipment shown in Figure 46.


40

WARNING: Hazardous voltage. Solidly groundall equipment. Failure to comply can result in

death, severe personal injury, and equipment damage.T223.2

!

3

6

4

T3Y

H*

X

Z

VOLTAGE RATING OFRECLOSER CLOSINGSOLENOID COIL

SENSING CTs (3) CLOSINGSOLENOIDCONTACTOR

ROTARYSOLENOID

MAINCONTACTS (S)

G* K*

A* B*

E* F*

TO240 OR480 VACSOURCE

TO240 VACSOURCE

CLOSINGSOLENOIDCOIL

TRIPSOLENOID

CONTROLCABLE RECEPTACLE

W

FORM 6CONTROL

TOAMMETER AND RELAY TOOPERATE CYCLE COUNTEROR OTHER TIMING DEVICE

AC POWERVARIABLEAUTOTRANSFORMER240 VAC20 AMPS

T2

1 2

5

J*

T1

*Indicates control cable receptacle pin/socket designation.

Figure 46.Suggested test circuit for high voltage “shop-testing” solenoid-closing reclosers.

600:5RecloserBCT ON 600:5 Tap

Note: This test circuit can apply over 800 Amps to the recloser.

Note: Use at least 2/0 cable between bushings.

21

115Vac VariableAutotransformer (10 Amp)

Clamp-OnAmmeter

Figure 45.Alternate method of producing variable line current(substitute for T2 and W-X circuit in Figures 46 and47).

Manual Closing – Solenoid-OperatedReclosers

If high-voltage for operating the closing solenoid is notavailable, manual closing can be substituted for electricalclosing. However, not all control settings can be checkedsince manual closing is not synchronized with the closingcoil control circuit in the control.

Follow these steps to manually close the recloser:

1. Remove the closing tool port cover and gasket fromthe side of the recloser head casting.

2. Insert the tee-handled tool (available as an accesso-ry) into the port, engaging the pin on the closing shaft(Figure 48).

3. Close the recloser by placing the yellow operatinghandle (located under the sleethood) into the up orCLOSED position and turning the closing tool one-quarter turn clockwise.

4. After each trip operation, about 1/2 second elapseswhile the closing solenoid plunger is moving upwardto reset the main toggle latch.

5. After the main toggle latch resets, the recloser can beclosed again by operating the manual closing tool.

6. Replace the gasket and port cover on the recloserhead after testing has been completed.

S280-70-3

41

!SAFETYFOR LIFE

Figure 47.Suggested test circuit for motor-operated, solenoid-closing reclosers with low-voltage closing.

65

43

21

FORM 6RECLOSERCONTROL

J

G K

H

X W

120/240 VACPOWERSUPPLY

T1 T2

240 VAC

VARIABLEAUTOTRANSFORMER240 VAC-20 A

AC POWER

TO AMMETERAND RELAYTO OPERATECYCLECOUNTER OROTHER TIMINGDEVICE

SENSING CTs (3)

NOT APPLICABLE FORCONTROL-POWEREDNOVA RECLOSERS

WARNING: Explosion Hazard. ExcessiveContact Arcing. Do not use the manual closing

tool to close an oil-insulated energized recloser.Closing an energized oil-insulated recloser with amanual closing tool can cause excessive contact arc-ing, rapid build-up of gas within the equipment, andpossible explosion which can cause death, severepersonal injury, and equipment damage. T203.2

!

CAUTION: Equipment damage. Do not turn the man-ual closing tool more than one-quarter turn clockwise.Forcing the tool beyond the mechanism stop mayshear the pin on the closing shaft of the recloser. T222.0

Figure 48.Using a manual closing tool to operate the recloser.

82284KMA-F

Battery Test and ChargingProceduresTest Procedure for Installed BatteryFollow the procedure below to perform a battery test inthe Form 6 control. The values in the test procedures arebased on testing at 25˚C (77˚F).

The condition of the Form 6 control battery can be deter-mined by using the Battery Test function in the BATTERYMENU. No external current/voltage meter is necessaryfor testing.

Alarm Conditions:

• During a manual battery test a 5Ω, 55 watt resistor isplaced across the battery terminals for approximate-ly 5 seconds. The Form 6 control measures the bat-tery voltage, if the voltage drops below 22.8 Vdc forone full second, the ALARM LED (battery alarm) isilluminated.

• When the Form 6 control is disconnected from ACpower and the control battery drops below 23.5 Vdcfor 60 seconds, the ALARM LED will illuminate. If thebattery voltage continues to decay and drops below22 Vdc, the Form 6 control will shut down.

Note: The battery test is blocked for 60 seconds upon powerup of the control.

Note: AC power can be either connected or disconnected forbattery test.

1. Press the MENU button on the front panel.

2. Using the down arrow key, navigate to the BATTERYmenu and press ENTER.

3. Using the down arrow key, navigate to the TEST BAT-TERY menu and press ENTER.

4. Press the F4 button to test the battery. The batterytest results will display in the battery metering menu.

Note: Voltage should be between 25–31 Vdc with thehigher voltage at colder temperatures.

Under normal conditions, with AC connected and afully charged battery, the charging current shouldbe less than 20 mA.

With AC connected and a discharged battery thecurrent range should be 20–450 mA.

With AC disconnected and the battery supplyingthe load, current will read -400 to -600 mA depend-ing on connected accessories.

Test Procedure for UninstalledBattery

The entire process should be conducted in a clean envi-ronment, such as a repair shop.

Refer to Table 12 and follow this procedure to perform abench test on a control battery in a service shop:

1. Remove the control from service. Refer to Removethe Control from Service procedure within theTesting section of this manual.

2. Remove the battery from the control and carefullytransport it to a suitable service facility.

3. Measure battery voltage.

4. Apply test load and measure battery voltage after 5seconds of load to determine voltage drop. Refer toTable 12 for Bench Test Load Condition.

5. Remove test load.

If the battery fails the test or is at least four years old, itshould be replaced. Refer to Table 12 for battery catalogpart numbers.


42

TABLE 12Control Battery Bench Testing and Replacement Information

Bench AcceptableBattery Test Load Voltage DropCatalog Amp/ Condition at End of

Control Type Battery Part # Voltage Type Hour for 5 sec. Test LoadForm 6 Pole Mount (standard capacity) Hawker KME4-215 24v Lead 8 5Ω 3v

Cyclon Acid 55 watt or less

Form 6 Pole Mount (high capacity) Hawker KME5-134-1 24v Lead 13 5Ω 2vGenesis (two Acid 55 watt or less

12vbatteries)

CAUTION: Recloser misoperation. The controlmust be removed from service before discon-

necting the control battery. Disconnecting the controlbattery from an in-service control may cause reclosermisoperation (unintentional operation) Failure to com-ply can result in equipment damage and personalinjury. T213.4

!

Battery ChargingIf it is not possible to charge the battery with the control’sbuilt-in charger, a KA43ME7001 (120 Vac) portablebench type battery charger is available. Refer to S280-79-14 KA43ME7001 Portable Lead Acid Battery ChargerInstructions for additional information.

Charge the battery with a KA43ME7001 (120 Vac)portable charger as applicable:

• Form 6 Pole Mount Recloser Control (StandardCapacity) – Connect the battery directly to theKA43ME7001 charger. The charger continuouslymonitors the battery voltage.

• Form 6 Pole Mount Recloser Control (HighCapacity) – Use adapter KME5-325-1 to connect thetwo 12 volt batteries to the KA43ME7001 charger.

Note: A red LED indicator on the body of the charger illumi-nates when charging.

The charger senses when the battery voltage reaches2.27 volts per cell, then the charge rate reduces to main-tain a trickle charge.

The red LED flickers to indicate the battery has reacheda full charge. This process can take up to 24 hours.

Return the Control to Service

After the required work is completed, disconnect the con-trol from the test set and follow this procedure to returnthe control to service:

1. While still in service shop, appropriate personnelmust verify that all control settings are correct.

2. Reconnect the ground cable to the control.

3. Control cable properly connected and supported.

4. Plug in the control battery.

Note: The Form 6 recloser control will not power up untilac power is applied.

5. Verify the selector switch on the PowerSupply/Battery Charger Board is set to the correctposition based upon the incoming power supply:



6. Apply ac power to the control.

7. Disable GRD TRIP BLOCKED.

A. Press the CHANGE button on the Operator Panelto enter the CHANGE mode.

B. Depress the GRD TRIP BLOCKED button withinten seconds after entering the CHANGE mode.

Note: Once selected (or after ten seconds), the controlreturns to normal operation.

8. Verify the control clock is set to the current time afterac power has been reapplied.

Note: The control clock may require resetting if the oper-ating power has been disconnected for more thanthirty days. Refer to Service Information S280-70-4Kyle Form 6 Microprocessor-Based RecloserControl Programming Guide for information on set-ting the control clock.

S280-70-3

43

!SAFETYFOR LIFE



T278.0

!IMPORTANT: Never connect a single 12 volt battery tothe KA43ME7001 charger. Use adapter KME5-325-1with the battery assembly when connecting the charg-er to the two 12 volt batteries.

CAUTION: Equipment misoperation. Do notconnect this control to an energized recloser

until all control settings have been properly pro-grammed and verified. Refer to the programminginformation for this control. Failure to comply canresult in control and recloser misoperation, equipmentdamage, and personal injury. G110.3

!

IMPORTANT: Do not attempt to charge a lead acidbattery below 19 Vdc with the KA43ME7001 charger.Attempting to do so will damage the charger.

If the lead acid battery is below 19 Vdc, replace thebattery. The expired battery should be disposed of inan environmentally responsible manner. Consult localregulations for proper battery disposal.

Replacement KitsReplacement kits for the Kyle Form 6 pole mount controlare available through the factory Service Department. Toorder these kits, refer to the Replacement Parts price listfor catalog numbers and pricing. Contact your CooperPower Systems representative for additional informationand order procedures.

Factory-Authorized ServiceCentersFactory-authorized service centers are located through-out the continental United States to provide mainte-nance, repair and testing services for Kyle controls andreclosers. For further information, contact your CooperPower Systems representative.

Factory Maintenance ClassesThe factory service department offers a basic testing andtroubleshooting course for the Form 6 microprocessor-based electronic recloser control. This course, taught byexperienced service technicians, is held at the factory’sin-house training facility. For additional information, con-tact your Cooper Power Systems representative.

Type MET Recloser Control TesterA 30-minute video cassette program KSPV7 Kyle® TypeMET Electronic Recloser Control Tester Operation andTesting Procedures is available as a supplemental train-ing aid for service personnel.


©2004 Cooper Industries, Inc.Kyle® is a registered trademark of Cooper Industries, Inc.ProViewTM, Idea WorkbenchTM, Communications WorkbenchTM,and TCC EditorTM are trademarks of Cooper Industries, Inc.

KA2048-503 Rev: 06

!SAFETYFOR LIFE

KMW01/04

P.O. Box 1640Waukesha, WI 53187www.cooperpower.com

CAUTION: This equipment requires routineinspection and maintenance to ensure proper

operation. If it is not maintained, it can fail to operateproperly. Improper operation can cause equipmentdamage and possible personal injury. G105.1

!

ADDITIONAL INFORMATION

Documents

Form 6 Microprocessor-Based Service Information Pole · PDF fileDescription The Kyle® Form 6 pole mount microprocessor-based recloser control includes extensive system protection