Professional Documents
Culture Documents
Figure 1.
Form 6 Yard Mount Microprocessor-Based Recloser Control.
Cont ent s
Safety Information ..................................................... 2 Before Placing Control and Recloser into Service ... 23
Product Information .................................................. 3 Using Removable Inserts ........................................ 29
Introduction ............................................................ 3 Accessories ............................................................... 30
ANSI Standards ..................................................... 3 Low Voltage Closing ............................................... 30
Quality Standards ................................................... 3 Incoming Power Receptacles ................................. 30
Acceptance and Initial Inspection ........................... 3 Cable Locking Sleeves ........................................... 30
Handling and Storage ............................................ 3 Internal Voltage Sensing ......................................... 30
Control Power ........................................................ 3 120 VAC GFI Duplex Outlet .................................... 31
Form 6 Recloser Control Description ...................... 4 Cabinet Ordering Accessories ................................. 31
Description ............................................................. 4 BCT Terminal Blocks Accessory ............................. 31
Theory of Operation ............................................... 4 Auxiliary Terminal Block Accessory ......................... 31
Control Front Panel ................................................ 5 Discrete Interface Board Option Accessory ............ 31
Control Features ..................................................... 10 Communication Board Accessories ........................ 41
Communications .................................................... 13 Testing ........................................................................ 43
Control Information ................................................. 13 Testing an Installed Control .................................... 43
Control Back Panel ................................................ 14 Remove the Control from Service ........................... 43
Installation Procedure ............................................... 14 Testing with Type MET Tester ................................. 44
Initial Programming Prior to Installation ................... 14 Closing the Recloser During Testing ....................... 44
Control / Recloser Compatibility ............................. 14 Return the Control to Service ................................. 47
Duty Cycle Monitor ................................................. 15 Additional Information ............................................... 48
Locking the Control ................................................ 15 Replacement Kits ................................................... 48
Mounting the Control .............................................. 16 Factory-Authorized Service Centers ....................... 48
Grounding the Control ............................................ 17 Factory Testing and Troubleshooting Classes ......... 48
Customer Connections for DC Power
and AC Voltage Sensing ......................................... 18
October 2012 Supersedes 06/2005 1
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
SAFETY INFORMATION
The instructions in this manual are not intended as a sub- Safet y Inst ruct ions
stitute for proper training or adequate experience in the
safe operation of the equipment described. Only compe- Following are general caution and warning statements that
tent technicians who are familiar with this equipment should apply to this equipment. Additional statements, related to
install, operate, and service it. specific tasks and procedures, are located throughout the
manual.
A competent technician has these qualifications:
Is thoroughly familiar with these instructions.
Is trained in industry-accepted high- and low-voltage
DANGER:
Hazardous voltage. Contact with hazardous voltage will
safe operating practices and procedures. cause death or severe personal injury. Follow all locally
Is trained and authorized to energize, de-energize, approved safety procedures when working around high-
clear, and ground power distribution equipment. and low-voltage lines and equipment. G103.3
2
S280-70-2
PRODUCT INFORMATION
Int roduct ion Handling and St or age
Service Information S280-70-2 provides installation and Be careful during handling and storage of the control to
operation instructions for the Form 6 microprocessor- minimize the possibility of damage. If the control is to be
based yard mount recloser control above serial number stored for any length of time prior to installation, provide a
10,000 or beginning with CP57. clean, dry storage area. If storage is in a humid atmosphere,
make provisions to keep the control circuitry energized.
Refer to the following information as appropriate for your
version of ProView software:
Cont rol Pow er
Service Information S280-70-4 Form 6 Recloser Control
Programming Guide: ProView 4.X.X software All operating power is obtained from the substation battery
bank. There are two power supply options available for the
Service Information S280-70-21 Form 6 Recloser Form 6 recloser control. Examine the voltage decal on the
Control Programming Guide: ProView 5.X.X software back of the recloser control to verify the correct voltage
rating.
Read This Manual First
The following power supply options are available and
Read and understand the contents of this manual and configured at the factory:
follow all locally approved procedures and safety practices
before installing or operating this equipment. 24 VDC 20%
Burden 14 Watts
Addit ional Informat ion
40 VDC 140 VDC
These instructions cannot cover all details or variations in Burden 14 Watts
the equipment, procedures, or process described, nor Note: The 40 VDC 140 VDC power supply is a universal
provide directions for meeting every possible contingency power supply adaptable for either 48 VDC or 125 VDC
during installation, operation, or maintenance. When substation batteries.
additional information is desired to satisfy a problem not
covered sufficiently for the user's purpose, contact your A 120/240 VAC thermostatically controlled heater for
Cooper Power Systems sales representative. humidity control is included as standard.
Refer to the Customer Connections for DC Power and
ANSI St andards AC Voltage Sensing section of this manual for incoming
Kyle reclosers are designed and tested in accordance with power wiring illustrations for the Form 6 yard mount
the following ANSI standards: C37.60 and C37.85 and recloser control.
ANSI Guide C37.61.
Qualit y St andards
ISO 9001-Certified Quality Management System
3
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
DC POWER
SOURCE INPUT
POWER RS-232
28 VDC CONNECTIONS
IRIG-B
AUXILIARY
POWER
RECLOSER OUTPUT COMMUNICATIONS
BOARD ACCY
TRIP SOLENOID RIF RS-485
OPTICAL FIBER-OPTIC
CLOSE SOLENOID ISOLATION INTERCON- CPU ETHERNET
NECTION 3 inputs
OPTICAL
OPEN / CLOSE BOARD USER
ISOLATION
SWITCHES CONNECTIONS
OPTICAL 5 outputs
ISOLATION
A CT
B CT I/O 8 inputs
C CT USER
CONNECTIONS
8 outputs
CT COMMON MATCHING
TRANSFORMERS
AND SIGNAL
CONDITIONING FRONT
PANEL
ANALOG INPUT
AC RS-232
VOLTAGE 4 inputs (PROVIEW
SENSING PROTOCOL
CONNECTIONS ONLY)
HEATER
Figure 2.
Form 6 yard mount recloser control operational flow diagram.
4
S280-70-2
When the phase or ground current exceeds its programmed 5. If current remains above the minimum-trip level, the
minimum-trip value and associated time-current-curve (TCC) recloser will trip on TCC2 and lockout the recloser.
timing, the control initiates the programmed sequence of
recloser tripping and reclosing operations via the CPU and Cont rol Front Panel
RIF modules. If the fault is temporary, the control resets to
the start of its operating sequence after a preset time delay. The Form 6 control front panel is illustrated in Figure 3.
If the fault is permanent, the control performs its complete The front panel is separated into two clearly identified,
programmed sequence of reclose commands and locks out color-coded sections:
with the recloser open. Once locked out, the control must
The top portion of the front panel is used for programming
be closed via the operator panel or SCADA communications.
the control and providing LED status indication.
This resets the control to the start of the operating
sequence. The lower portion of the front operating panel is used
The following chain of events occurs for an operating for operating the control and recloser.
sequence of two trips to lockout (one trip on TCC1, one The control includes a Power Save feature that will turn off
trip on TCC2): the backlit LCD display and all LEDs (except Hot Line Tag)
if no front panel keypad is pressed within ten minutes.
1. The overcurrent signal is integrated with time on the
Pressing the LAMP TEST key will re-activate the display
selected curve for the first trip operation (TCC1) to
produce the signal which energizes the trip circuit. and LEDs.
Note: The Power Save feature is a ProView interface software
2. Energizing the trip circuit connects the supply to the default setting. This feature can be disabled via the
trip solenoid to open the recloser. ProView interface software.
3. Upon opening, the control starts timing on the first The control includes a Reset Menu feature that will cause
reclosing interval-delay time. the LCD display to revert to the root menu after ten minutes
4. Upon expiration of this reclosing interval-delay, a of inactivity.
closing signal is issued from the control, closing the Note: The ten minute timer and MMI Reset Menu is a ProView
recloser, and selecting the time-current characteristics interface software default setting. The menu selection
for the second trip operation (TCC2). and timer can be changed via the ProView interface
software.
RESET OPER
TARGETS COUNTER
One-Touch F1 F2 F3 F4 One-Touch
Analysis Keys EVENTS ALARMS Analysis Keys
LAMP TEST
MENU + CHANGE
Figure 3.
Form 6 recloser control front panel.
5
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
Front Panel Text Messaging SETTINGS: Displays recloser settings on the LCD display.
The LCD messages are accessed from the front panel by OPER COUNTER: Displays the total number of trip
following the Text Messages menu path. This menu operations and target counters for each A, B, and C
displays any active user-configured text messages. Phase; Ground, and Sensitive Ground on the LCD
display.
Up to fourteen user-configurable text messages can be
programmed via the Idea Workbench. Refer to Service ALARMS: Provides status information on the LCD display
Information S280-70-4 (ProView 4.X.X) or S280-70-21 for all recloser alarms.
(ProView 5.X.X) Form 6 Microprocessor-Based Recloser CHANGE: Allows the user to change the state of the
Control Programming Guide for information on program- control functions on the operator panel function keys.
ming the text messages.
Note: The CHANGE mode is a ten second period in which one
These text messages appear on the front panel LCD and function setting can be changed. If no change is made in
can be programmed to appear for alarm or other that time, the control returns to the current setting.
conditions.
LCD Display
Text messages displayed on the front panel are limited to
The LCD Display is a backlit 4-line, 20-character display
four lines of 20 characters each (including spaces). Text
that provides extensive distribution system, recloser, and
messages can also be accessed by pressing the LAMP
control status information using a minimum of eight
TEST one-touch analysis key on the front panel.
navigation keypads (Figure 4).
Programming Panel Note: The LCD display panel contrast is field-adjustable to
allow for various mounting heights and applications.
The Programming panel has the following sections: Press the MENU key and then press the (+) or () key to
One-Touch Analysis Keys increase or decrease the contrast.
There are eight analysis keys (Figure 4) that allow one- The four LCD navigation buttons are as follows:
button access to a variety of control and monitoring MENU Identifies the LCD Display menu options.
functions that appear in the LCD display. Pressing these
buttons causes the following information to display or ENTER Selects a menu option.
function to occur: + Increases value selection.
Note: When pressing a membrane pushbutton, always press Decreases value selection.
and hold for 0.5 seconds to ensure the button press is
recognized by the device. The four LCD menu function keys activate specific menu
commands. When a command appears in the LCD display
METERING: Displays the systems instantaneous metering
directly above one of the four LCD menu function keys, the
values for current and voltage on the LCD display.
user can press the key to accept/select the command.
RESET TARGETS: Resets the fault target indicators on the
The four LCD menu function keys are as follows:
operator panel.
F1 F2 F3 F4
EVENTS: Displays the last 25 events from the Sequence of
Events log. The four cursor movement arrows allow movement in the
following directions:
LAMP TEST: All operator panel LEDs are illuminated for
verification of proper connection and operating status of all Moves the cursor left.
indicator lights. All status indicators will then return to their Moves the cursor right.
previous state. While in the LAMP TEST mode, the control
response to operator panel keys is disabled, except for the Moves the cursor up one line.
TRIP (LOCKOUT), CLOSE, and HOT LINE TAG switches. Moves the cursor down one line.
METERING SETTINGS
RESET OPER
TARGETS COUNTER
F1 F2 F3 F4
EVENTS ALARMS
LAMP TEST
MENU + CHANGE
ENTER
Figure 4.
Analysis keys, LCD display, LCD menu function keys, and cursor movement arrows.
6
S280-70-2
Status Indicator LEDs In addition to the above LED blinking pattern, the red
ALARM LED will also be illuminated for these alarms:
The status indicator LEDs (Figure 5) in the Programming Failure to Trip, Failure to Close, and Interrupter
section of the Operator Panel give instant information on Malfunction.
the control and recloser status:
A PHASE FAULT, B PHASE FAULT, C PHASE FAULT: The
All of the default status indicators LEDs (except for red LEDs indicate A, B, and/or C phase current was either
CONTROL OK, CONTROL POWER, and ALARM) can be the maximum phase current or within 20% of the maximum
reconfigured via the Idea Workbench. Refer to Service when a trip signal was issued.
Information S280-70-4 (ProView 4.X.X) or S280-70-21
(ProView 5.X.X) Form 6 Microprocessor-Based Recloser GROUND FAULT, SENSITIVE GROUND FAULT: The red
Control Programming Guide for additional information. LEDs indicate that a Ground and/or Sensitive Earth Fault
tripping function was asserted at the time the trip signal
The label inserts can be user-customized. Refer to Using was asserted.
Removable Inserts section of this manual for additional
information. ALARM: The red LED indicates an alarm has been issued.
Review the alarm status and log on the LCD display for the
CONTROL OK: The green LED indicates the control is specific alarm.
operating normally and not in an alarm state.
Note: If a Battery Alarm occurs, de-select the Pole Mounted
The CONTROL OK LED will not be illuminated during these Control checkbox in the ProView application software
alarms (indicated by the red ALARM LED and displayed in Configure>System Configuration dialog box. Refer to
the alarm status log): Service Information S280-70-4 (ProView 4.X.X) or S280-
70-21 (ProView 5.X.X) Form 6 Microprocessor-Based
RAM Failure: This alarm indicates a failed RAM memo- Recloser Control Programming Guide for additional
ry test. information.
ROM Failure: This alarm indicates a failed ROM mem- ABOVE MINIMUM TRIP: The red LED indicates the current
ory test. exceeds the level set for minimum trip.
Power Supply Malf[unction]: This alarm indicates inter- FREQUENCY TRIP: Indicates the recloser tripped due to
nal control operation power was outside of its operat- an under or over frequency condition.
ing tolerance for more than 20 seconds. This alarm
resets when the internal control operation power VOLTAGE TRIP: Indicates the recloser tripped due to an
returns to operation within its normal tolerances. under or over voltage condition.
CONTROL POWER: The green LED indicates there is A PHASE VOLTAGE, B PHASE VOLTAGE, C PHASE
adequate VTC voltage to trip the recloser. This LED does VOLTAGE: The red LED indicates a presence of voltage on
not indicate the presence of AC or battery power. the respective phases. The Single-Phase Undervoltage
Pickup setting controls the voltage indication for the front
CONTROL LOCKOUT: The green LED indicates the control panel LEDs as defined in the Voltage setting dialog box for
is in a locked out state, i.e. a reclosing sequence is not in the active setting profile. Refer to Settings - Voltage in the
progress. This LED does not indicate that the recloser is Schemes section of Service Information S280-70-4
open. (ProView 4.X.X) or S280-70-21 (ProView 5.X.X) Form 6
RECLOSER OPEN: The green LED indicates the recloser Microprocessor-Based Recloser Control Programming
is in the open position. Guide.
RECLOSER CLOSED: The red LED indicates the recloser INDICATOR 1, INDICATOR 2, INDICATOR 3, INDICATOR
is in the closed position. 4, INDICATOR 5, INDICATOR 6, INDICATOR 7, INDICATOR
8: Customizable LEDs that are used with functions
Note: There are several conditions that will cause the alternate programmed through the Idea Workbench. The LED
blinking of the CONTROL LOCKOUT, RECLOSER OPEN, indicators do not have active default values. The LEDs are
and RECLOSER CLOSED LEDs: Failure to Trip, Failure to
Close, Interrupter Malfunction, and 52a/b Disagreement.
illuminated when the status configured via the Idea
Workbench is present.
The LED blinking pattern for these conditions is the
CONTROL LOCKOUT green LED and RECLOSER
CLOSED red LED alternating with the RECLOSER OPEN
green LED.
Figure 5.
Status indicator LEDs.
7
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
One-Touch Function Keys this function key is restricted to the operator panel and is
accomplished by pressing the CHANGE key and then
Quick access to frequently operated Form 6 control
pressing the SUPERVISORY OFF key. Operational data
features is provided with nine function key pushbuttons on
the control operator panel. and metering information are available while the control is
in the SUPERVISORY OFF position. The TRIP and CLOSE
The Form 6 control operator panel one-touch function keys pushbuttons and Hot Line Tag are active independent of
are illustrated in Figure 7. the SUPERVISORY OFF function.
ALTERNATE PROFILE #1, #2, and #3
GND TRIP NON SUPERVISORY The Form 6 control has four separate protection profiles; a
BLOCKED RECLOSING OFF Normal profile, and Alternate Profiles 1, 2, and 3. Each
profile changes all protection parameters for the control.
Except for the normal profile, each has an indication and
ALTERNATE ALTERNATE ALTERNATE selection key. When the operator panel display lights are
PROFILE #1 PROFILE #2 PROFILE #3 active and none of the three indicators are on, the normal
profile is active. Only one profile can be active.
To select an alternate profile, press the CHANGE key and
OPTION #1 OPTION #2 OPTION #3 then press the desired alternate profile.
To return to the normal profile, press the CHANGE key and
then press the active alternate profile to deselect it. These
Figure 7. functions can also be completed remotely via communica-
Operator panel function keys. tions interfaces.
10
S280-70-2
12
S280-70-2
TB2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
VDC Power Input
Connections
I(1-2) I(3-4) I(5-6) I(SEF) V(1-2) V(3-4) V(5-6) V1
Analog Connections
Terminal Block for
Connecting to Recloser,
Voltage Inputs
Figure 8.
Form 6 yard mount recloser control back panel.
13
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
INSTALLATION PROCEDURE
CAUTION: Equipment misoperation. Check minimum Cont rol / Recloser Compat ibilit y
trip values prior to changing an alternate profile. Failure The Form 6 yard mount recloser control is adaptable to the
to do so may cause misoperation of the recloser under following Kyle reclosers:
load conditions. T280.1
WE*, WVE27, WVE38X, VWE, VWVE27, VWVE38X, VSA12,
VSA16, VSA20, VSA12B, VSA20A, VSO12, VSO16,
IMPORTANT: Program all protection profiles. Unused Auxiliary-Powered NOVA15, Auxiliary-Powered NOVA27,
alternate profiles should be programmed with the same and Auxiliary-Powered NOVA38
settings as one of the applicable profiles. Default settings * This control is not compatible with Form 1 Type WE reclosers
on unused alternate profiles can cause unnecessary below s/n 300 and RE reclosers below s/n 400.
outages if they are below normal system requirements.
IMPORTANT: All Auxiliary-Powered NOVA reclosers
The control must be programmed with all necessary require power at the input power receptacle for tripping
operating settings, all alternate profiles, and parameters and closing.
prior to operation with an energized recloser.
Note: Initial programming of the control is the responsibility of a A control cable is required to connect the Form 6 yard
qualified technician or engineer familiar with control mount recloser control to these reclosers. Refer to Table 3
functions and programming parameters required for the in the Recloser Connections/Control Cable Section of
specific recloser installation. the Customer Connections for DC Power and AC
The control must be programmed with the Form 6 ProView Voltage Sensing section of this manual.
interface software. Refer to Service Information S280-70-4 Reclosers manufactured prior to June 1989 are equipped
(ProView 4.X.X) or S280-70-21 (ProView 5.X.X) Form 6 with Type A bushing current transformers. These reclosers
Microprocessor-Based Recloser Control Programming were designed for use with Form 2, Form 3, and Form 3A
Guide for additional information. controls. Because the Form 6 recloser control is designed
for use with reclosers equipped with Type B current-
sensing Transformers, reclosers retrofitted with Form 6
recloser controls should be retrofitted with Type B current
transformers. All reclosers manufactured since 1989 are
equipped with Type B (1000:1, 1000/500:1, or 2000:1)
sensing CTs.
14
S280-70-2
Reclosers equipped with Type B sensing CTs are compat- Dut y Cycle Monit or
ible with all Kyle recloser controls (Form 2, Form 3, Form
3A, Form 4A, Form 4C, FXA, FXB Form 5, Form 5 LS/UDP, The Duty Cycle Monitor provides the following duty cycle
and Form 6 recloser controls), and are identified with the information:
following label prominently displayed on the recloser sleet Measures and records duty for each individual phase in
hood or the front of the operator cabinet: non-volatile memory.
The recloser duty is measured and stored on the basis
of Current1.5 x Number of Operations for Each Phase
NOTICE (ANSI C37.61).
RECLOSER IS EQUIPPED WITH Readout is based on a percentage of total duty cycle
TYPE B SENSING CTs. for each phase.
RECLOSER DOES NOT HAVE A Duty record can be adjusted or reset if recloser is
BATTERY CHARGER. changed-out, serviced, etc.
Using Table 2, select the appropriate recloser interrupting
duty cycle factor and enter that value via the ProView
interface software.
The Form 6 recloser control can be used with the old-style
Type A CTs; however, the event recorder and duty cycle TABLE 2
monitor will have limited accuracy for currents above 5000 Duty Cycle Factor
Amps.
Retrofit kits with the new Type B sensing CTs are available Interrupting 100% Duty
Recloser Rating Cycle
to upgrade existing families of reclosers for operation with Type (rms sym Amps) Factor*
Form 6 recloser controls. For additional information, contact
your Cooper Power Systems representative. RXE, RVE 6,000 97
WE 12,000 @ 4.8 kV 257
For identification, Table 1 lists the serial number breaks WE 10,000 @ 14.4 kV 196
between old-style Type A and the new-style Type B sensing VWE
CTs. Below this serial number, the recloser is equipped VWVE27 12,000 1045
with the Type A CTs. VWVE38X
Note: For reclosers shipped prior to June 1989 and not listed WVE27 8,000 140
below, please contact your Cooper Power Systems WVE38X 8,000 140
representative with the recloser type and serial number VSA12 12,000 1045
for verification of type A or B bushing current transformers. VSA16 16,000 1608
VSA20
VSA20A 20,000 2248
TABLE 1 VSA20B
Serial Number Break for Reclosers with Type A VSO12 12,000 1045
Sensing CTs
VSO16 16,000 1608
Recloser Below Serial Number AC NOVA 12,500 1111
RXE 5831
*Duty Cycle Factor is Value x 105.
RVE 5894
WE 11199 Locking t he Cont rol
WVE 3695 The handles on the Form 6 control cabinet are able to
VWE 7199 accept a padlock to prevent unauthorized access. For
cabinets with the quarter-turn latch, the top handle has two
VWVE27 7208
locking holes provided depending on the diameter of the
VWVE38 1204 lock shackle being used. Refer to Figure 10.
All VSA reclosers are equipped with Type A Sensing CTs. The smaller hole should be used for shackle diameters
All VSML reclosers are equipped with Type A Sensing CTs. of .177-295.
All VSA12, VSA12B, VSA16, VSA20, VSA20A, and VSA20B The larger hole should be used for shackle diameters
reclosers are equipped with Type B Sensing CTs. of .295-.394.
All VWVE38X and VWE38X reclosers are equipped with Type B
Sensing CTs.
15
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
Mount ing t he Cont rol Mount the Form 6 yard mount recloser control in a
convenient, accessible location in a substation yard.
WARNING: This equipment is not intended to Mounting dimensions are provided in Figure 10.
protect human life. Follow all locally approved pro-
A hole and keyway in the control mounting bracket
cedures and safety practices when installing or operating
accommodates a 15.9 mm (5/8) bolt.
this equipment. Failure to comply can result in death,
severe personal injury, and equipment damage. Limits on control cable lengths are determined by the
G102.1 recloser type and the distance between the control and
recloser: See Table 3 for available Form 6 yard mount
CAUTION: Follow all locally approved safety practices recloser control cable lengths for Kyle reclosers.
when lifting and mounting the equipment. Use the lifting
lugs provided. Lift the unit smoothly and do not allow the
unit to shift. Improper lifting can result in equipment
damage. G106.2
29
(1.25)
310 16 (.63) Dia.
(12.25)
Mounting Holes (2)
CONTROL OK
CONTROL POWER
CONTROL LOCKOUT
RECLOSER OPEN
RECLOSER CLOSED
A PHASE FAULT
B PHASEFAULT
C PHASE FAULT
GROUND FAULT
SENSITI VE GND
ALARM
ABOVE MI N TRIP
I NDI CATOR 1
I NDI CATOR 2
I NDI CATOR 3
A PHASEVOLTAGE
B PHASE VOLTAGE
C PHASEVOLTAGE
FREQUENCY TRIP
VOLTAGETRIP
INDI CATOR 4
INDICATOR 5
INDI CATOR 6
INDI CATOR 7
INDI CATOR 8
RS-232 Lifting
METERING
RESET
TARGETS
SETTINGS
OPER
COUNTER
Connection Lugs
Port
F1 F2 F3 F4
EVENTS ALARMS
LAMPTEST
MENU
+ CHANGE
ENTER
RS-232 DATAPORT
665
F6 Recloser Control ON
GNDTRIP NON SUPERVISORY
BLOCKED RECLOSING OFF
TRIP CLOSE CLOSE CIRCUIT
ALTERNATIVE ALTERNATIVE ALTERNATIVE
710
DISABLE HOT LINE TAG PROFILE #1 PROFILE #2 PROFILE#3
(LOCKOUT)
(26.25)
(28.0)
(1.5) (14-pin)
67 67 79
(2.75) (2.75) (3.25) SHACKLE DIAMETER
.295-.394"
Bottom View
RS-232 Serial
Communication Port
C +
IRIG-B
RS-232 DTE
Connection
CONTROL WEIGHT 34 kg (75 lbs)
2 4 6 8 10 12 14 16 18
CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI1 1 CO5 CO6 CO7 CO8 CO9 CO10 CO11 CO12
1 3 5 7 9 11 13 15 17 19 21 1 3 5 7 9 11 13
TB3 TB4
(Accessory) 2
CI4
4
CI5
6
CI6
8
CI7
10
CI8
12 14 16 18 20
CI9 CI10 CI11 CO5 CO6
2 4 6 8 10 12
CO7 CO8 CO9 CO10 CO11 CO12
FUSE FUSE
INPUT POWER
TB5 1
+
AUXILIARYPOWER
-
RECLOSER INTERFACE CONNECTI ONS
A D F
IRIG-B Time Sync Connector
Note: Weight of one Form 6 yard-mount recloser control.
5 1 3 5 7 TB6
28 VDC 2 4 6
(10 AMP) (10 AMP) 2 4
- + B C E
TB2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12
LOW VOLTAGE 120 120/240 NEU (+) (-)
OUTPUTS L2 L1/VAC DC POWER
Figure 10.
Form 6 yard mount recloser control weight, dimensions, and pad-lock shackle diameters.
16
S280-70-2
Grounding t he Cont rol IMPORTANT: All external inputs to the Form 6 recloser
control must be routed within 8 inches of their
WARNING: Hazardous voltage. Recloser and corresponding ground. During a surge, a potential of
control must be solidly grounded. Follow all locally approximately 1.5 kV per foot can develop in the
approved procedures and safety practices when conductors. Differences between conductor and ground
grounding this equipment. Improper grounding can path lengths can add additional stress to the control
result in contact with high voltage, which will cause components in the event of a power surge.
death or severe personal injury. G115.1
NOVA Recloser
Ground
Connector
Control Cable
Receptacle
Control
Cable
Form 6
Yard Mount
Control Ground
Wire
Control
Grounding Lug
Figure 11.
Grounding connections for a Form 6 yard mount control installed in a substation.
17
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
18
S280-70-2
19
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
Source
120 Vac A
TB8
120 Vac C
1 2 3 4 5 6 7 8 9 10 11 12
Factory
Wiring
NEU
User-Supplied
Disconnect Switches
DC Voltage Required
Factory to Power Control
Wiring
User-Supplied
Disconnect Switches
TB7
Note: Terminal Block positions TB7-5 and
TB7-6 are factory-jumpered together.
Terminal Block positions TB7-7 and 1 2 3 4 5 6 7 8 9 10 11 12
TB7-8 are factory-jumpered together. LOWVOLTAGE 120 120/240 NEU (+) (-)
OUTPUTS L2 L1/VAC DC POWER
Figure 14.
Single-Phase Transformer Connection, B phase input for Voltage Sensing.
*Low Voltage Closing Accessory connects to TB7-1 and TB7-2.
20
S280-70-2
NEU
1 2 3 4 5 6 7 8 9 10 11 12 DC Voltage Required
TB8 to Power Control
Factory Wiring for Wye Connection
Figure 15.
Default factory wiring connected to B-Phase voltage metering with B-Phase incoming supply.
DANGER: Hazardous voltage. Do not connect WARNING: Hazardous voltage. Before applying
potential transformer low-voltage secondaries to power to the control, confirm that male pins of
the control through cables or other wiring until the unit is the input power receptacle are electrically insulated to
installed in the field. Transformer high-voltage primary prevent unintentional contact with 120V AC voltage.
windings will become live when 120V AC is applied to Failure to do so may result in severe personal injury or
the control from an alternate source if the transformer death. T372.0
secondary is connected. Failure to comply may result in
severe personal injury or death. T371.1
Note: Terminal Block positions TB8-1 and
TB8-6 are factory-jumpered together.
Terminal Block positions TB8-2 and
TB8-3 are factory-jumpered together.
Voltage Sensing Connections
Terminal Block positions TB8-4 and
Source Load TB8-5 are factory-jumpered together.
V (1-2) V(3-4) V(5-6) V1
C
B
1 2 3 4 5 6 7 8 9 10 11 12
TB8
User-Supplied
Disconnect
Switches
Figure 16.
Customer connections to TB8, 120 VAC Delta Connection.
21
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
DC Voltage Required
1 2 3 4 5 6 7 8 9 10 11 12 to Power Control
TB8
Factory Wiring
1 2 3 4 5 6 7 8 9 10 11 12
TB8 Factory
Wiring
NEU
Source Side
DC Voltage Required B
120
to Power Control
240
120
User-Supplied
Disconnect
Switches
1 2 3 4 5 6 7 8 9 10 11 12
Note: Terminal Block positions
TB7-5 and TB7-6 are fac-
TB7 tory-jumpered together.
Terminal Block positions
LOWVOLTAGE 120 120/240 NEU (+) (-) TB7-7 and TB7-8 are fac-
OUTPUTS L2 L1/VAC DC POWER tory-jumpered together.
Figure 18.
240 Volt, 3-wire transformer connection for voltage and sensing on B-phase. *Y for Sync Check Voltage.
22
S280-70-2
IMPORTANT
Shielding and Surge Prot ect ion of
Supervisory Cables
All supervisory operation and control monitor leads must
be protected within shielded cables. Refer to Figure 21 or
22 as appropriate.
NOTICE: External leads must be shielded and the shield
must be grounded at both ends. Terminate each lead with
a 320VAC, 150 Joules metal oxide varistor (MOV), or
equivalent, at the remote end. Attach MOVs between the
leads and ground. Failure to properly shield and protect
leads can result in equipment damage and/or unintentional
operation.
Customer-Supplied
Voltage Inputs**
Remote/Supervisory Common
Supervisory Trip and Lockout
Remote Trip and Lockout
TB1
2 4 6 8 10 12 14 16 18
Customer Wiring A B
Control Control Hotline Ground Trip
Lockout Recloser OK Tag Blocked
Status Status Status Status Status
(Not (Recloser (Control (Hotline (GRD TRIP
Lockout)* Open)* Not OK)* Tag Off)* Normal)*
Figure 19.
Form 6 yard mount recloser control Standard discrete interface board and default configurations. These default
contact input/outputs are completely configurable via the Idea Workbench.
24
**Whetting voltage is available from the IMPORTANT
Figure 20.
Form 6 Recloser Control on Terminal Block
TB5. Refer to Figure 16. Shielding and Surge Prot ect ion of
Supervisory Cables
Customer-Supplied
Voltage Inputs**
All supervisory operation and control monitor leads must
be protected within shielded cables. Refer to Figure 21 or
22 as appropriate.
NOTICE: External leads must be shielded and the shield
must be grounded at both ends. Terminate each lead with
a 320VAC, 150 Joules metal oxide varistor (MOV), or
equivalent, at the remote end. Attach MOVs between the
Not Assigned
leads and ground. Failure to properly shield and protect
leads can result in equipment damage and/or unintentional
operation.
Supervisory Non-Reclose
Remote Alternate Profile 1
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11 CO12
Form 6 recloser control discrete interface board accessory and default configurations. These default contact
S280-70-2
25
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
REMOTE
TB5 BOX
Supervisory
Trip and 8 CI3
Lockout CI3 7
Supervisory
Close 6 CI2
CI2 5
Remote
Trip and 4 CI1
CI1 3
Lockout
13
B*
Recloser 12 CO1
Status A*
*Contacts sho
with reclose 11
OPEN posit CO1
Not All Remote
Connections
TB1 Shown
NOTES: Arresters to be metal oxide varistors (MOVs) 320 VAC,
150 Joules or equivalent.
External lead resistance must not exceed 200 ohms.
A Single common wire can be used for multiple inputs
if it is jumpered at the I/O board terminals.
Shielding for Supervisory Cables should follow
the representative input control contacts and
output status contacts as shown.
Supervisory and Remote Functions are
default functions.
Figure 21.
Shielding and Surge Protection for Supervisory and Remote Cables (12-48 VDC option).
26
S280-70-2
Supervisory
Trip and 8 CI3
Lockout CI3 7
Supervisory
Close 6 CI2
CI2 5
Remote
Trip and 4 CI1
CI1 3
Lockout
13
B*
Recloser 12 CO1
Status A*
*C 11
CO1
Not All Remote
TB1 Connections
Shown
Figure 22.
Shielding and Surge Protection for Supervisory and Remote Cables (48/125 VDC, 120 VAC option).
27
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
RS-232 DTE
2 4 6 8 10 12 14 16 18
CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11 CO12
1 3 5 7 9 11 13 15 17 19 21 1 3 5 7 9 11 13
TB3 TB4
TABLE 7 2 4 6
CI4 CI5 CI6
8 10 12 14 16 18 20
CI7 CI8 CI9 CI10 CI11 CO5 CO6
2 4 6 8 10 12
CO7 CO8 CO9 CO10 CO11CO12
Rear Panel RS-232 Communication Port Pin
Assignments INPUT POWER
+
AUXILIARY POWER
-
RECLOSER INTERFACE CONNECTIONS
A D F
FUSE FUSE
TB5 1 5 1 3 5 7 TB6
RS-232 DTE
Figure 24.
Rear panel RS-232 communication port pin
identification.
28
S280-70-2
Using Removable Insert s 4. Use tweezers to gently pull out the removable insert.
Note: The insert will slide out of the right side of the
CAUTION: Control damage. De-energize both AC and operating panel (Figure 26).
DC power prior to removing or installing any internal Note: The insert will slide out of the top of the program-
connections or circuit boards in the control. Failure to ming panel indicator section (Figure 25).
comply can result in damage to the control. T241.1
5. Change the existing label or slide in a new label with the
name of the configured option.
CAUTION: Equipment damage. Always wear a An electronic label template is included on the ProView
grounding wrist strap to control static electricity before application software CD and can be accessed through
handling circuit boards. Failure to use this strap may the following default address:
result in circuit board damage. T253.1 C: / Program Files / Cooper / ProviewXX / Form 6 /
Form 6 Inserts.doc
The front panel inserts can be changed, if desired.
IMPORTANT: Laminate the removable inserts prior to
1. De-energize both AC and DC power. installing. This will seal the ink/toner and avoid damage
2. Use a flathead or 3/33" hex key screwdriver to unscrew to the front panel.
the six front panel screws.
Note: Set the screws aside for later use. 6. Gently push the removable insert from right to left into
3. Pull the right side of the front panel out towards the left the right side of the operating panel (Figure 26) or down
(Figure 25). into the programming panel LED indicator section
Note: Various connecting wires will keep the panel attached
(Figure 25).
to the control.
Note: It is not necessary to disconnect any wires.
Removable LED
Status Indicator Panel
Figure 26.
Labels are easily removed from and inserted into the
operating panel.
7. Place the front cover panel back onto the control. Use
a flathead screwdriver to screw the screws back into
the control and tighten all hardware completely.
Figure 25.
Open front panel. Labels are easily removed from and
inserted into the top of the programming panel LED
status indicator section.
29
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
ACCESSORIES
These accessories are available. Contact your Cooper Int ernal Volt age Sensing
Power Systems representative for additional information.
A four-wire cable and input receptacle accessory (Table 9)
is required for Type NOVA three-phase reclosers with the
Low Volt age Closing internal voltage sensing (IVS) option. Internal voltage sen-
The Low Voltage Closing Accessory utilizes 120 or 240 VAC sors, located on the source side, indicate voltage magni-
for closing power (Figures 29, 30, 31, 32, and 33). Multiple tude within an accuracy 2% or better and a phase degree
low voltage closing accessories are available for reclosers accuracy within 1.5 degrees (includes sensor, cable, and
equipped with low voltage closing. The low voltage closing control). The 4-pin receptacle accessory is pre-wired to the
accessories available for the Form 6 yard mount recloser voltage inputs on the control. Refer to Service Instructions
control include the appropriate receptacles and wiring S280-42-1 NOVA Three-Phase Recloser Installation and
based upon the input supply voltage. Table 8 lists the Operation Instructions for additional setting information.
available low voltage closing input/output receptacles and Note: The internal voltage sensing accessory is compatible only
cables for the Form 6 yard mount recloser control. with a Form 6 control that was purchased with the IVS
option.
Incoming Pow er Recept acles TABLE 9
The Incoming Power Receptacle allows the user to conve- Internal Voltage Sensing
niently plug the power cable into the control, eliminating
Description Catalog Number
the need for hardwiring to the control. Various options are
available based upon the input power voltage, and phase Internal Voltage Sensing input
sensing requirements. Table 8 includes the available input receptacle, 4-pin . . . . . . . . . . . . . . . . . . KME6-3799-1S
receptacles and cables for the Form 6 yard mount recloser
control. Refer to Figures 34, 35, 36, and 37. Note: Internal voltage sensing receptacle is only compatible with reclos-
ers equipped with internal voltage sensors.
Note: The internal voltage sensing cable (KA97ME) is ordered with the
Cable Locking Sleeves recloser. If a replacement cable is required, contact your Cooper Power
To prevent detachment of the control cable from the control Systems representative.
cabinet by unauthorized personnel, a cable-locking sleeve
(Catalog Number KME6-1772-1) is available to enclose the
cable plug. The plug is passed through the sleeve and the
sleeve is then fastened from inside the control cabinet.
There is no access to the cable receptacle without opening
the locked cabinet door and detaching the sleeve.
TABLE 8
Low Voltage Closing and Input Receptacles and Cables
30
S280-70-2
120 VAC GFI Duplex Out let Auxiliary Ter minal Block Accessor y
The GFI Duplex Outlet (Catalog Number KME6-1776) is An auxiliary terminal block and receptacle is available for
available for controls powered by 120 VAC or 240 VAC three-stage auxiliary switch wiring. Refer to Table 10.
three-wire supply power. This convenience outlet is rated
for 15 Amperes and is accessible through the front door in TABLE 10
the control cabinet. The 120 VAC GFI Duplex Outlet is used Terminal Blocks
for many applications such as power for the MET Tester,
auxiliary measurement equipment, and supplemental Description Catalog Number
lighting. BCT shorting-type terminal block
for (LOAD) bushings 2, 4, 6 . . . . . . . . . KME6-1773-A
Cabinet Ordering Accessories BCT shorting-type terminal block
for (SOURCE) bushings 1, 3, 5 . . . . . . . KME6-1773-B
AISI 304 stainless steel cabinet construction
Terminal block and receptacle for
Three-point door latch wiring of three-stage auxiliary
switch, KA542R3 . . . . . . . . . . . . . . . . . KME6-1801-1
BCT Terminal Block s Accessory
The BCT Terminal Blocks (Figure 27) attach to the back of Discret e Int erfac e Board (DIF)
the control and provide a connection point for external Opt ion Accessory
600:5 or 1200:5 multi-ratio bushing current transformers.
BCT Terminal Blocks are available for both the load or A Discrete Interface Board Option accessory provides
source sides and include wire for all ratios of the BCT. Refer eight configurable input control contacts and eight configu-
to Table 10. rable output status contacts (Figure 28). The ordering
options include: Standard (3 inputs / 5 outputs) or
Additional (8 inputs / 8 outputs).
RS-232 DTE
2 4 6 8 10 12 14 16 18
CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11 CO12
1 3 5 7 9 11 13 15 17 19 21 1 3 5 7 9 11 13
TB3 TB4
GROUND X5 X4 4 X3 X2 X1
2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11CO12
TB8
INPUT POWER AUXILIARY POWER RECLOSER INTERFACE CONNECTIONS
+ - A D F
FUSE FUSE
TB5 1 5 1 3 5 7 TB6
1 2 3 4 5 6 7 8 9 10 11 12
V(1-2) V(3-4) V(5-6) V1
TB2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
SOURCE LOAD 2
VOLTAGE SENSING CONNECTIONS
TB7
I(1-2) I(3-4) I(5-6) I(SEF) V(1-2) V(3-4) V(5-6) V1
1 2 3 4 5 6 7 8 9 10 11 12
LOWVOLTAGE 120 120/240 NEU (+) (-)
OUTPUTS L2 L1/VAC DC POWER
Figure 28.
Form 6 yard mount recloser control discrete interface
board accessory.
Figure 27.
Form 6 yard mount recloser control BCT terminal
block accessory.
31
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
Blac
to o er Control
21
use
2
Blac
1 2 3 4 7 8 9 10 11 12
120
TB7 LOWVOLTAGE L2 120/240 NEU (+) (-)
OUTPUTS L1/VAC DC POWER
Blac
ite
120 240 V C
ite ( )
Blac ( )
B
3
Lo Voltage
Closing ece tacle
B
2
DANGER: Hazardous voltage. Do not connect n ut
potential transformer low-voltage secondaries to ece tacle
the control through cables or other wiring until the unit is
installed in the field. Transformer high-voltage primary
windings will become live when 120V AC is applied to
the control from an alternate source if the transformer 120 240 V C
secondary is connected. Failure to comply may result in
(2- ire)
severe personal injury or death. T371.1
nco ing
WARNING: Hazardous voltage. Before applying o er
power to the control, confirm that male pins of
the input power receptacle are electrically insulated to Note: Terminal Block positions TB7-5 and
prevent unintentional contact with 120V AC voltage. TB7-6 are factory-jumpered together.
Failure to do so may result in severe personal injury or
death. T372.0
Terminal Block positions TB7-7 and
TB7-8 are factory-jumpered together.
Figure 29.
120 VAC low-voltage closing 2-pin input and 2-pin output receptacles (KME6-1838-A) and 240 VAC low-voltage
closing with 2-pin input and 2-pin output receptacle (KME6-1838-D).
32
S280-70-2
Blac
to o er Control
21
use
2
Blac
1 2 3 4 7 8 9 10 11 12
120
TB7 LOWVOLTAGE L2 120/240 NEU (+) (-)
OUTPUTS L1/VAC DC POWER
Blac
ite
120 V C
B round
3 Bloc
Braid
ed
Blac
Lo Voltage
Closing ece tacle
B C
2
n ut
DANGER: Hazardous voltage. Do not connect ece tacle
potential transformer low-voltage secondaries to
the control through cables or other wiring until the unit is
installed in the field. Transformer high-voltage primary 120 V C
windings will become live when 120V AC is applied to
nco ing
the control from an alternate source if the transformer
secondary is connected. Failure to comply may result in o er
severe personal injury or death. T371.1
Figure 30.
120 VAC low-voltage closing 3-pin input and 2-pin output receptacles (KME6-1838-B).
33
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
Blac
21 1 to o er Control
use
ed
2
2 3
use
ed
1 2 3 4 7 8 9 10 11 12
120
TB7 LOWVOLTAGE L2 120/240 NEU (+) (-)
OUTPUTS L1/VAC DCPOWER
Blac
ite
240 V C
B
3
ite
ed
Blac
Lo Voltage
Closing ece tacle
B C
2
n ut
DANGER: Hazardous voltage. Do not connect
potential transformer low-voltage secondaries to ece tacle
the control through cables or other wiring until the unit is 120 V C 120 V C
installed in the field. Transformer high-voltage primary
windings will become live when 120V AC is applied to
the control from an alternate source if the transformer 240 V C nco ing o er
secondary is connected. Failure to comply may result in
severe personal injury or death. T371.1
Figure 31.
240 VAC low-voltage closing 3-pin input and 2-pin output receptacles (KME6-1838-E).
34
S280-70-2
Blac
to o er Control
21
use
2
Blac
1 2 3 4 7 8 9 10 11 12
120
TB7 LOWVOLTAGE L2 120/240 NEU (+) (-)
OUTPUTS L1/VAC DC POWER
Blac
ite
120 240 V C
B
3
Lo Voltage
Closing ece tacle
Figure 32.
120 VAC low-voltage closing with inlet hole and 2-pin output receptacle (KME6-1838-C) and 240 VAC low-voltage
closing 2-wire with inlet hole and 2-pin output receptacle (KME6-1838-F).
35
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
Blac
21 1 to o er Control
use
ed
2
2 3
use
ed
1 2 3 4 7 8 9 10 11 12
120
TB7 LOWVOLTAGE L2 120/240 NEU (+) (-)
OUTPUTS L1/VAC DCPOWER
Blac
ite
240 V C
240 VAC 120 VAC
B L2 L1
3
Lo Voltage 120 V C
Closing ece tacle
Figure 33.
240 VAC low-voltage closing with 3-wire with inlet hole and 2-pin output receptacle (KME6-1838-G).
36
S280-70-2
1 2 3 4 7 8 9 10 11 12
120
TB7 LOWVOLTAGE L2 120/240 NEU (+) (-)
OUTPUTS L1/VAC DCPOWER
ite
Blac
Figure 34.
120 VAC or 240 VAC 2-pin input receptacle (KME6-1838-H).
37
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
1 2 3 4 7 8 9 10 11 12 eater
TB8
actor iring or e Connection
C Voltage e uired
to o er Control
1 2 3 4 7 8 9 10 11 12
120
TB7 LOWVOLTAGE L2 120/240 NEU (+) (-)
OUTPUTS L1/VAC DCPOWER
round
Bloc
ite
Braid
Blac
B C
DANGER: Hazardous voltage. Do not connect
potential transformer low-voltage secondaries to n ut
the control through cables or other wiring until the unit is ece tacle
installed in the field. Transformer high-voltage primary
windings will become live when 120V AC is applied to
the control from an alternate source if the transformer 120 V C
secondary is connected. Failure to comply may result in (3- ire)
severe personal injury or death. T371.1
nco ing
o er
WARNING: Hazardous voltage. Before applying
power to the control, confirm that male pins of
the input power receptacle are electrically insulated to Note: Terminal Block positions TB7-5 and
prevent unintentional contact with 120V AC voltage. TB7-6 are factory-jumpered together.
Failure to do so may result in severe personal injury or Terminal Block positions TB7-7 and
death. T372.0 TB7-8 are factory-jumpered together.
Figure 35.
120 VAC 3-pin input receptacle (KME6-1838-J).
38
S280-70-2
1
1
use
2
1 2 3 4 7 8 9 10 11 12 eater
TB8
actor iring or e Connection
C Voltage e uired
to o er Control
1 2 3 4 7 8 9 10 11 12
120
TB7 LOWVOLTAGE L2 120/240 NEU (+) (-)
OUTPUTS L1/VAC DCPOWER
ite
ed
Blac
B C
DANGER: Hazardous voltage. Do not connect
n ut
potential transformer low-voltage secondaries to
the control through cables or other wiring until the unit is ece tacle
installed in the field. Transformer high-voltage primary
windings will become live when 120V AC is applied to
the control from an alternate source if the transformer 240 V C (3- ire)
secondary is connected. Failure to comply may result in nco ing o er
severe personal injury or death. T371.1
Figure 36.
240 VAC 3-pin input receptacle (KME6-1838-K).
39
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
C Voltage e uired
ed to o er Control
1
2
use
2
Note: Terminal Block positions ed
TB7-5 and TB7-6 are facto-
ry-jumpered together.
Terminal Block positions
TB7-7 and TB7-8 are facto-
1 2 3 4 7 8 9 10 11 12
ry-jumpered together.
120
TB7 LOWVOLTAGE L2 120/240 NEU (+) (-)
OUTPUTS L1/VAC DCPOWER
ed
Blac
+ C
B
C o er to
au iliar - o ered
V ecloser
Custo er Connections
or C o er
DANGER: Hazardous voltage. Do not connect WARNING: Hazardous voltage. Before applying
potential transformer low-voltage secondaries to power to the control, confirm that male pins of
the control through cables or other wiring until the unit is the input power receptacle are electrically insulated to
installed in the field. Transformer high-voltage primary prevent unintentional contact with 120V AC voltage.
windings will become live when 120V AC is applied to Failure to do so may result in severe personal injury or
the control from an alternate source if the transformer death. T372.0
secondary is connected. Failure to comply may result in
severe personal injury or death. T371.1
Figure 37.
DC power for auxiliary-powered NOVA recloser (KME6-1838-M).
40
S280-70-2
Communicat ion Board Accessories A pair of industry standard ST type fiber-optic connectors
are mounted on the back of the board enabling customer
The Form 6 yard mount control is equipped with a connection to a digital communication system using fiber-
Communication Board Accessory (expansion bay) offering optic cables (customer-supplied).
versatile support for modern communication media. Six
distinct communication options (Figure 38) are available, The fiber-optic link has separate receive (RX) and transmit
providing two-way, real time digital communications with a (TX) ports operating at 820nm. Typical transmission dis-
remote terminal unit (RTU), wireless, telephone modem, tance is 2000m with 62.5/125m multi-mode fiber. Consult
Ethernet network, or other communication devices. The your Cooper Power Systems representative for availability
following options are available: of long haul solutions. Link communication speed is con-
trolled through software and can be set at: 1200, 2400,
No auxiliary communication card installed (standard) 4800, 9600, 19.2k, and 38.4k. Modbus can also be set at
RS485 (isolated) Serial communication card 57.6k.
Fiber-optic-based Serial Communication Card (ST) The fiber-optic accessory must be programmed through
the Communications Workbench for the appropriate proto-
10/100 Base-T dual Ethernet communication card col. Refer to Service Information S280-70-4 (ProView
(2*RJ-45) 4.X.X) or S280-70-21 (ProView 5.X.X) Form 6
100 Base-FX dual Ethernet communication card (2*MT- Microprocessor-Based Recloser Control Programming
RJ) Guide for additional information.
10/100 Base-T, 100 Base-FX Ethernet communication The fiber-optic based serial accessory includes TX and RX
card (RJ-45 + MT-RJ) indicating LEDs for verifying communications along with an
echo / non-echo switch for supporting ring / star fiber
The expansion bay based Communication Board Accessory
topologies.
concept offers high versatility with respect to communication
medium and protocol support. Additional accessories are When operated in a ring configuration, the toggle switch
being continuously developed. Contact your Cooper Power must be set in the ECHO position. In this mode, the fiber-
Systems representative for the latest information regarding optic card will repeat (pass through) all messages received
particular media and communication protocol support. on the RX fiber, and will respond to the Master station by
first echoing the incoming command and then sending the
RS485 Serial Communicat ion Card response. This arrangement is best suited for creation of
The RS485 serial communication card accessory provides low cost multi device fiber loops. For reliable communica-
means for establishing asynchronous link-based digital tions, the fiber loop system requires that all devices in the
communications with the Form 6 yard mount control. The loop remain powered at all times, thus enabling unob-
Galvanic isolated (1000V DC) RS485 port uses a single structed flow of information throughout the loop.
shielded twisted pair connection and can support 32 A more resilient system can be designed by using the
devices in multi-drop configuration. Communication speed fiber-optic ports in a point-to-point or multiple point-to-
is controlled through software and can be set at: 1200, point (star) configuration. For this mode, the toggle switch
2400, 4800, 9600, 19.2k, and 38.4k. Modbus can also be must be set in the NON-ECHO mode. The Form 6 yard
set at 57.6k. mount control will respond to the Master station by send-
Digital communications must be programmed through the ing a response only (total separation of Receive and
Communications Workbench to ensure proper operation of Transmit fibers). Additional hardware (fiber-optic star cou-
the RS485 communication card accessory. Refer to pler) is required to support the multiple point-to-point
Service Information S280-70-4 (ProView 4.X.X) or S280- device configurations.
70-21 (ProView 5.X.X) Form 6 Microprocessor-Based
Recloser Control Programming Guide for additional
Et hernet Communicat ion Cards
protocol support information. The Ethernet communication card accessory brings the
Ethernet network connectivity to the Form 6 yard mount
Fiber-Opt ic Based Serial Communicat ion recloser control platform. It is highly flexible, offering simul-
Card taneous support for multiple sessions, device management
The Fiber-Optic based Serial Communication Card offers (ProView over TCP/IP) and SCADA communications (DNP3
means of establishing asynchronous (RS-232 like) digital over TCP/IP).
communications through multi-mode fiber media. The use By natively supporting a set of widely accepted industry
of the fiber-optic based serial communication card standards (TCP/IP, UDP/IP, OSI) the Ethernet communica-
accessory can enhance communication reliability, and tion accessory ensures seamless interoperability with other
provides excellent electrical isolation thus protecting network devices.
transmitted data from extraneous electrical interference.
An optional fiber-optic-to-RS-232D converter with DB-9
connector (Catalog Number KME6-1875-1) is available for
interfacing between an optical signal and a hard-wired
RS-232 signal, when required. This converter is compatible
with loop (ring) and point-to-point (star) configurations.
41
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
Standard
(No Communication Option) RS-485 Communication Serial Fiber
RS-485 C + -
TX NON-ECHO RX
TX RX
#2 #1 #2 #1 #2 #1 #2 #1
J4 ETHERNET J3 J4 ETHERNET J3 J4 ETHERNET J3 J4 ETHERNET J3 Default
Primary
Ethernet
Interface
IRIG-B IRIG-B IRIG-B IRIG-B
J5 J5 J5 J5
2 1 2 1 2 1 2 1
Ethernet 10/100 Base-T Ethernet 100 Base-FX Ethernet 10/100 Base-T, Ethernet 100 Base-FX
Type 1 Type 2 100 Base-FX Type 4
Type 3
Figure 38.
Back panel Ethernet and Communication options.
The Ethernet communication card accessory is offered in 3 The Ethernet communication accessory card (Figure 38) is
physical layer configurations (twisted pair and optical-fiber equipped with two physical ports configured to act as pri-
options) as shown in Table 11. mary and standby LAN connections. Availability of the
backup communication port enables creation of highly
TABLE 11 redundant Ethernet networks thus increasing the overall
Ethernet Communication Card Configurations system reliability.
Card Output Communication Note: Under normal network conditions, all communications
Type Configurations Connectors Speed will be channeled through the primary port (#1, Figure
1 10/100 Base-T 2 * RJ-45 10 / 100MBps 38), with the standby port either logically disabled, or
(auto switching) configured for fast automatic throw-over in case of the
primary Ethernet link failure. Refer to Service Information
2 100 Base-FX 2 * MT-RJ 100MBps S280-70-4 (ProView 4.X.X) or S280-70-21 (ProView
(multi-mode fiber) (full duplex) 5.X.X) Form 6 Microprocessor-Based Recloser Control
Programming Guide for additional Ethernet accessory
3 10/100 Base-T, RJ-45 + MT-RJ 10/100MBps configuration information.
100 Base-FX and 100MBps
4 100 Base-FX, 2 * LC 100MBps
(single-mode fiber) (full duplex)
42
S280-70-2
TESTING
All other tests described in this TESTING section require
CAUTION: Equipment misoperation. Do not the Form 6 yard mount recloser control to be removed from
connect this control to an energized recloser until service, connected to a bypassed recloser, or tested at a
all control settings have been properly programmed and location where the proper testing equipment is available.
verified. Refer to the programming information for this Refer to Remove the Control from Service for the proper
control. Failure to comply can result in control and procedure to remove the control from service.
recloser misoperation, equipment damage, and personal
injury. G110.3 Remove t he Cont rol from Service
IMPORTANT: Disconnect switches for AC sensing
IMPORTANT: The Form 6 recloser control can be and power connections are necessary to isolate the
taken out of service for testing and placed back into Form 6 control for testing and servicing.
service without de-energizing its recloser and interrupting
the system. However, during the time the control is out
1.Enable GND TRIP BLOCKED to allow for ground trip to
of service, the recloser is inoperative.
be disabled when re-energized.
Test ing an Inst alled Cont rol A. Press the CHANGE button on the Operator Panel to
enter the CHANGE mode.
The following tests to determine initial operation of the
Form 6 yard mount recloser control can be performed B. Depress the GND TRIP BLOCKED button within ten
while connected to an operating recloser. seconds after entering the CHANGE mode.
Note: These are the only tests performed on an installed, oper- Note: If the GND TRIP BLOCK button is not depressed
within ten seconds, the function is not activated.
ating control.
2. Remove DC power from the control using a separate
1. Verify operating status of all indicator lights by pressing
disconnect switch.
and holding the LAMP TEST key for two seconds on
the programming panel (Figure 39). 3. Remove control AC sensing voltage from the control
using a separate disconnect switch.
2. Check the operational values for currents, voltages,
and other metering information. CAUTION: Hazardous voltage. Open CT second-
Note: Scroll through the LCD display messages by pressing aries can generate high voltages. Contact with CT
the and cursor movement arrows underneath the pins of the disconnected cable can cause electric shock
LCD display on the programming panel (Figure 39). and may result in personal injury. Open recloser contacts
and open disconnect switches before disconnecting
LCD Display
control cable. T204.3
METERING SETTINGS
RESET OPER
TARGETS COUNTER
Figure 39.
Lamp Test button, LCD display, and cursor movement 4. Disconnect control cable from the control.
arrows. 5. Remove any control input and status output wiring
from TB1, TB3, and TB4 (Figure 8).
3. Check that the CONTROL OK A PHASE FAULT 6. Disconnect any serial communications ports and IRIG-B
LED for Control CONTROL POWER B PHASE FAULT
timing connections (Figure 8).
CONTROL LOCKOUT C PHASE FAULT
OK is illuminated RECLOSER OPEN GROUND FAULT
on the control RECLOSER CLOSED SENSITIVE GND 7. Disconnect the ground from the control.
operator panel Control OK LED 8. Carefully transport the control to a suitable service
(Figure 40). This facility.
indicates the pres- Figure 40.
ence of DC power. Control OK LED.
Note: The control includes a Power Save feature that will
turn off the backlit LCD display and all LEDs if no
front panel keypad is pressed within ten minutes.
Pressing the LAMP TEST key will reactivate the
display and active LEDs.
43
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
Figure 41.
Kyle Type MET electronic recloser control tester.
44
S280-70-2
BYPASS SWITCHES
(CLOSED)
C
5 6
CLOSING
COIL
SOURCE
SOURCE
LOAD
LOAD
B
3 4
A
1 2
SOURCE SIDE LOAD SIDE
DISCONNECT SWITCHES DISCONNECT SWITCHES
(CLOSED) (OPEN)
Figure 42.
Closing source-side switches of a bypassed on-line recloser provides closing solenoid power for automatic
operation during testing.
WARNING: Hazardous voltage. The switchgear High-Voltage T3 to operate the closing solenoid.
(apparatus and control) and high-voltage trans-
former must be in a test cage or similar protected area The closing coil requirement is approximately 200 kVA
to prevent accidental contact with the high-voltage during the two-to-three cycle closing operation. The
parts. solenoid coil operating voltage must be maintained at
the recloser bushings during the cycle interval the
Solidly ground all equipment. Failure to comply can closing coil is energized. This procedure is not used on
result in death, severe personal injury, and equipment reclosers equipped with the low-voltage closing
damage. T221.5 accessory.
For shop testing, the closing solenoid voltage is supplied Ammeter with a rating based on the level of test current.
by back-feeding a transformer with a low-side rating equal Current-actuated timer.
to the voltage rating of an available power source, and a
high-side rating equal to the voltage rating of the recloser
(Figure 42). A 75 kA transformer of the proper voltage
rating with an impedance drop of approximately 3% is 115Vac Variable
Autotransformer
satisfactory. The AC source must have a comparable (10 Amp)
impedance drop. 600:5
Recloser
BCT ON 600:5 Tap
A test circuit for these solenoid-closed reclosers is shown
in Figure 44. The following equipment is required for the
recommended shop testing setup: 2 Clamp-On
1
Ammeter
Note: Solenoid-closed reclosers equipped with a 120- or 240- Note: This test circuit
VAC low-voltage closing coil accessory can be tested as can apply over
800 Amps to the
shown in Figure 45. recloser.
Variable Autotransformer T1, 230 Volts, 20 Amps. Note: Use at least 2/0
cable between
bushings.
Low-Voltage transformer T2 to simulate fault conditions.
Ratio and size will depend upon the maximum current
Figure 43.
to be used. The recloser presents a low impedance to
Alternate method of producing variable line current
the transformer, so secondary voltage must be only
(substitute for T2 and W-X circuit in Figures 44 and
high enough to force the required current through the
45).
secondary of the transformer and the recloser.
Note: An alternative method of providing the necessary
current through the transformer is shown in Figure
43.
45
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
AC POWER
Figure 45.
Suggested test circuit for motor-operated, solenoid-
closing reclosers with low-voltage closing.
Z
6
*
TO MAIN
240 OR CONTACTS (S)
4 0 VAC ROTARY
SO RCE SOLENOID
T3
Y
3 4
E* F* TRI
H* SOLENOID
CLOSING
SOLENOID
COIL
A* B*
X
2
K* G* CONTROL
TO CABLE RECE TACLE
240 VAC
SO RCE
TO
AMMETER AND RELAY TO
FORM 6 O ERATE CYCLE CO NTER
T CONTROL OR OTHER TIMING DEVICE
VARIABLE T2
AC O ER
A TOTRANSFORMER
240 VAC
20 AM S
*I s s s
Figure 44.
Suggested test circuit for high voltage shop-testing solenoid-closing reclosers.
46
S280-70-2
47
Form 6 Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
ADDITIONAL INFORMATION
Fac t ory Test ing and
CAUTION: This equipment requires routine Troubleshoot ing Classes
inspection and maintenance to ensure proper
operation. If it is not maintained, it can fail to operate The factory service department offers a basic testing and
properly. Improper operation can cause equipment troubleshooting course for the Form 6 microprocessor-
damage and possible personal injury. G105.1 based recloser control. This course, taught by experienced
service technicians, is held at the factorys in-house train-
ing facility. For additional information, contact your Cooper
Replacement Kit s Power Systems representative.
Replacement kits for the Form 6 yard mount recloser con- Type MET Recloser Cont rol Test er
trol are available through the factory Service Department.
To order these kits, refer to the Replacement Parts price list A 30-minute video program KSPV7 Kyle Type MET
for catalog numbers and pricing. Contact your Cooper Electronic Recloser Control Tester Operation and Testing
Power Systems representative for additional information Procedures is available as a supplemental training aid for
and order procedures. service personnel.
KA2048-631 Rev: 03