Professional Documents
Culture Documents
Form 6 Microprocessor-Based
Pole-Mount Recloser Control
Installation and Operation Instructions S280-70-3
For Type F6-P2A Control,
and Type F6-P2B Control,
above Serial Number 10,000
or beginning with CP57.
• F6-P2A applies to Form 6 control for
use with W, VS, and auxiliary-
powered NOVA reclosers.
• F6-P2B applies to control-powered
NOVA Form 6 control for use with
control-powered reclosers.
Figure 1.
Form 6 microprocessor-based pole-mount recloser control.
SAFETY INFORMATION
The instructions in this manual are not intended as a Safety Instructions
substitute for proper training or adequate experience in the
safe operation of the equipment described. Only competent Following are general caution and warning statements that
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
S280-70-3
Product Information
Introduction Control Battery Storage and Charging
Service Information S280-70-3 provides installation and The 24 VDC control battery in the Form 6 recloser control is
operation instructions for the Form 6 pole-mount recloser fully charged prior to shipment and is ready for use.
control above serial number 10,000 or beginning with
CP57. IMPORTANT: To maintain sufficient charge to operate
Refer to the following information as appropriate for your the control and prevent battery cell damage, the sealed
version of ProView software: lead-acid batteries should be charged after no more
than three months of storage.
• Service Information S280-70-4 Form 6 Recloser Control
Programming Guide: ProView 4.X.X software Temperature has an effect on battery life. Sealed lead acid
• Service Information S280-70-21 Form 6 Recloser batteries should be stored, fully charged, at room
Control Programming Guide: ProView 5.X.X software temperature. Never store lead acid batteries at temperatures
exceeding 47°C (117°F), as damage can result in
Read This Manual First approximately one month.
Read and understand the contents of this manual and The batteries must be tested and charged for 24 hours
follow all locally approved procedures and safety practices following every three months of storage from the last test
before installing or operating this equipment. date. A separate portable charger accessory is available.
Catalog Number KA43ME7001 provides a 120 Volt battery
Additional Information charger to power individual batteries.
These instructions cannot cover all details or variations in
the equipment, procedures, or process described, nor IMPORTANT: Connect the control battery before ac
provide directions for meeting every possible contingency power is connected to the control’s AC supply Input
during installation, operation, or maintenance. When Terminal Block. The battery must be disconnected prior
additional information is desired to satisfy a problem not to shipping or storing the control.
covered sufficiently for the user's purpose, contact your
Cooper Power Systems sales representative. Note: When shipped from the factory, the battery source is
disconnected and its output plugs are taped to the
cabinet. Connect the battery plugs into the mating
ANSI Standards connectors to complete the battery circuit.
Kyle reclosers are designed and tested in accordance with
the following ANSI standards: C37.60 and C37.85 and Control Power
ANSI Guide C37.61. The control is powered from 120 or 240 VAC. The selector
switch on the power supply board allows the user to select
Quality Standards between 120 VAC or 240 VAC.
ISO 9001-Certified Quality Management System Note: The selector switch is factory-set for each control based
upon the customer order requirement.
Acceptance and Initial Inspection
Each Form 6 recloser control is completely assembled, Battery Replacement and Disposal
tested, and inspected at the factory. It is carefully calibrated, The 24 VDC control battery has a life expectancy of four
adjusted and in good condition when accepted by the years. It is recommended that the battery be replaced after
carrier for shipment. four years or if the battery fails a battery test - whichever
Upon receipt, inspect the carton for signs of damage. occurs first.
Unpack the control and inspect it thoroughly for damage Note: Battery life is decreased at higher temperatures.
incurred during shipment. If damage is discovered, file a Dispose expired batteries in an environmentally responsible
claim with the carrier immediately. manner. Consult local regulations for proper battery
disposal.
Handling and Storage
Be careful during handling and storage of the control to
minimize the possibility of damage. If the control is to be
stored for any length of time prior to installation, provide a
clean, dry storage area. If storage is in a humid atmosphere,
make provisions to keep the control circuitry energized.
Note: To energize the control, apply AC power to the AC supply
input terminal block located in the lower right hand
corner of the back panel of the control. Refer to the
Customer Connections for AC Power section in this
manual.
3
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
4
S280-70-3
COMMUNICATIONS
RECLOSER BOARD ACCY
RIF •RS-485
TRIP SOLENOID •FIBER-OPTIC
OPTICAL •ETHERNET TB8
CLOSE SOLENOID ISOLATION INTERCON- CPU
TERMINAL
NECTION 3 inputs
OPTICAL BLOCK
OPEN / CLOSE BOARD USER
ISOLATION SENSING
SWITCHES CONNECTIONS
OPTICAL 5 outputs VOLTAGE
ISOLATION POWER INPUTS
CONNECTIONS
A Ø CT
120/240
B Ø CT I/O 8 inputs
MATCHING USER
C Ø CT TRANSFORMERS CONNECTIONS
AND SIGNAL 8 outputs
CONDITIONING
CT COMMON
ANALOG INPUT
FRONT
PANEL
RS-232
(PROVIEW
PROTOCOL
ONLY)
Figure 3.
Form 6 pole-mount recloser control operational flow diagram.
5
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
sequence after a preset time delay. If the fault is permanent, The control includes a Power Save feature that will turn off
the control performs its complete programmed sequence the backlit LCD display and all LEDs (except Hot Line Tag)
of reclose commands and locks out with the recloser open. if no front panel keypad is pressed within ten minutes.
Once locked out, the control must be closed via the Pressing the LAMP TEST key will re-activate the display
operator panel or SCADA communications. This resets the and LEDs.
control to the start of the operating sequence. Note: The Power Save feature is a ProView interface software
The following chain of events occurs for an operating default setting. This feature can be disabled via the
sequence of two trips to lockout (one trip on TCC1, one ProView interface software.
trip on TCC2): The control includes a Reset Menu feature that will cause
1. The overcurrent signal is integrated with time on the the LCD display to revert to the root menu after ten minutes
selected curve for the first trip operation (TCC1) to pro- of inactivity.
duce the signal which energizes the trip circuit. Note: The ten minute timer and MMI Reset Menu is a ProView
interface software default setting. The menu selection
2. Energizing the trip circuit connects the supply to the and timer can be changed via the ProView interface
trip solenoid to open the recloser. software.
3. Upon opening, the control starts timing on the first
reclosing interval-delay time. Front Panel Text Messaging
4. Upon expiration of this reclosing interval-delay, a clos- The LCD messages are accessed from the front panel by
ing signal is issued from the control, closing the reclos- following the Text Messages menu path. This menu
er, and selecting the time-current characteristics for the displays any active user-configured text messages.
second trip operation (TCC2). Up to fourteen user-configurable text messages can be
5. If current remains above the minimum-trip level, the programmed via the Idea Workbench. Refer to Service
recloser will trip on TCC2 and lockout the recloser. Information S280-70-4 (ProView 4.X.X) or S280-70-21
(ProView 5.X.X) Form 6 Control Programming Guide for
Control Front Panel information on programming the text messages.
The Form 6 control front panel is illustrated in Figure 4. These text messages appear on the front panel LCD and
can be programmed to appear for alarm or other
The front panel is separated into two clearly identified, conditions.
color-coded sections:
Text messages displayed on the front panel are limited to
• The top portion of the front panel is used for programming four lines of 20 characters each (including spaces). Text
the control and providing LED status indication. messages can also be accessed by pressing the LAMP
• The lower portion of the front operating panel is used TEST one-touch analysis key on the front panel.
for operating the control and recloser.
RESET OPER
TARGETS COUNTER
One-Touch F1 F2 F3 F4 One-Touch
Analysis Keys Analysis Keys
+
EVENTS ALARMS
MENU
LAMP TEST CHANGE
Figure 4.
Form 6 pole-mount control front panel.
6
S280-70-3
ALARMS: Provides status information on the LCD display Moves the cursor down one line.
for all recloser alarms.
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 one
function setting can be changed. If no change is made in
that time, the control returns to the current setting.
METERING SETTINGS
RESET OPER
TARGETS COUNTER
F1 F2 F3 F4
+
EVENTS ALARMS
MENU
LAMP TEST CHANGE
ENTER —
Figure 5.
Analysis keys, LCD display, LCD menu function keys, and cursor movement arrows.
7
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
Status Indicator LEDs RECLOSER CLOSED: The red LED indicates the recloser
The status indicator LEDs (Figure 6) in the Programming is in the closed position.
section of the Operator Panel give instant information on Note: There are several conditions that will cause the alternate
the control and recloser status: blinking of the CONTROL LOCKOUT, RECLOSER OPEN,
and RECLOSER CLOSED LEDs: Failure to Trip, Failure to
All of the default status indicators LEDs (except for Close, Interrupter Malfunction, and 52a/b Disagreement.
CONTROL OK, CONTROL POWER, and ALARM) can be
The LED blinking pattern for these conditions is the
reconfigured via the Idea Workbench. Refer to Service CONTROL LOCKOUT green LED and RECLOSER
Information S280-70-4 (ProView 4.X.X) or S280-70-21 CLOSED red LED alternating with the RECLOSER OPEN
(ProView 5.X.X) Form 6 Control Programming Guide for green LED.
additional information.
In addition to the above LED blinking pattern, the red
The label inserts can be user-customized. Refer to Using ALARM LED will also be illuminated for these alarms:
Removable Inserts section of this manual for additional Failure to Trip, Failure to Close, and Interrupter
information. Malfunction.
CONTROL OK: The green LED indicates the control is A PHASE FAULT, B PHASE FAULT, C PHASE FAULT: The
operating normally and not in an alarm state. red LEDs indicate A, B, and/or C phase current was either
the maximum phase current or within 20% of the maximum
The CONTROL OK LED will not be illuminated during these when a trip signal was issued.
alarms (indicated by the red ALARM LED and displayed in
the alarm status log): GROUND FAULT, SENSITIVE GROUND FAULT: The red
LEDs indicate that a Ground and/or Sensitive Earth Fault
• Battery Alarm: This alarm indicates battery voltage is tripping function was asserted at the time the trip signal
low or the battery failed an operator-initiated manual was asserted.
test.
ALARM: The red LED indicates an alarm has been issued.
• RAM Failure: This alarm indicates a failed RAM memo- Review the alarm status and log on the LCD display for the
ry test. specific alarm.
• 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.
• No AC Present: This alarm indicates AC power was FREQUENCY TRIP: Indicates the recloser tripped due to
unavailable for 10 continuous seconds. This alarm an under or over frequency condition.
resets when AC power is restored.
VOLTAGE TRIP: Indicates the recloser tripped due to an
• Power Supply Malf[unction]: This alarm indicates inter- under or over voltage condition.
nal control operation power was outside of its operat-
ing tolerance for more than 20 seconds. This alarm A PHASE VOLTAGE, B PHASE VOLTAGE, C PHASE
resets when the internal control operation power VOLTAGE: The red LED indicates a presence of voltage on
returns to operation within its normal tolerances. the respective phases. The Single-Phase Undervoltage
Pickup setting controls the voltage indication for the front
• RIF Comm Failure: This alarm indicates a loss of panel LEDs as defined in the Voltage setting dialog box for
communication from the RIF (Recloser Interface) circuit the active setting profile. Refer to Settings - Voltage in the
board to the main CPU circuit board. This alarm resets Schemes section of S280-70-4 (ProView 4.X.X) or S280-
if communication is re-established. 70-21 (ProView 5.X.X) Form 6 Control Programming
CONTROL POWER: The green LED indicates there is Guide.
adequate VTC voltage to trip the recloser. This LED does INDICATOR 1, INDICATOR 2, INDICATOR 3, INDICATOR
not indicate the presence of AC or battery power. 4, INDICATOR 5, INDICATOR 6, INDICATOR 7, INDICATOR
CONTROL LOCKOUT: The green LED indicates the control 8: Customizable LEDs that are used with functions
is in a locked out state, i.e. a reclosing sequence is not in programmed through the Idea Workbench. The LED
progress. This LED does not indicate that the recloser is indicators do not have active default values. The LEDs are
open. illuminated when the status configured via the Idea
Workbench is present.
RECLOSER OPEN: The green LED indicates the recloser
is in the open position.
Figure 6.
Form 6 pole-mount control status indicator LEDs.
8
S280-70-3
10
S280-70-3
11
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
The control includes an impedance-based fault locator An active Manual Close Delay can be canceled by pressing
based upon the Takagi algorithm1. Load-compensated the TRIP/LOCKOUT button.
impedance calculation is used for calculating the distance. The default setting has the feature disabled (0 seconds). A
Positive and zero sequence is configured in ohms, and the countdown on the front panel LCD screen indicates Manual
fault locator line length is configured in kilometers/miles. Close Delay is active.
13
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12
TB9
+ –
28 VDC
WHETTING VOLTAGE
AC Power Fuse
P4
P2 P3 1 2 3 4 5
1 3 1 3 1 3 24 23 22 21 20 19 18 17 16 15 14 13
1 3 1 2 3 4 5
2 4 2 4 2 4 2 4 5 12 11 10 9 8 7 6 4
5 3 2 1
120/240 VAC
Selector Switch
Customer Connection
Terminal Block TB8
1 2 3 4 5 6
Power Supply LED
Power Connections
Figure 9.
Form 6 pole-mount recloser control back panel terminal block and communication port identification.
14
S280-70-3
INSTALLATION PROCEDURE
Initial Programming Control / Recloser Compatibility
Prior to Installation The Form 6 pole-mount recloser control is adaptable to the
following Kyle reclosers:
CAUTION: Equipment misoperation. Do not
connect this control to an energized recloser until WE*, WVE27, WVE38X, VWE, VWVE27, VWVE38X, RVE,
all control settings have been properly programmed and VSA12, VSA16, VSA20, VSA12B, VSA20A, VS012, VS016,
verified. Refer to the programming information for this NOVA15**, NOVA27** and NOVA38**.
control. Failure to comply can result in control and * This control is not compatible with Form 1 Type WE reclosers
recloser misoperation, equipment damage, and per- below s/n 300 and RE reclosers below s/n 400.
sonal injury. G110.3
** Control-powered NOVA reclosers that are manufactured after
September 2004 require a Voltage Trip/Close (VTC) interface
for tripping and closing. This VTC requirement applies to three-
Caution: Equipment misoperation. Check minimum phase control-powered NOVA reclosers with a Type A or a Type
trip values prior to changing an alternate profile. Failure D mechanism and Form 5, Form 5 LS/UDP, Form 6, and Form
to do so may cause misoperation of the recloser under 6 LS controls with the control-powered interface. These
load conditions. T280.1 reclosers and controls are equipped with 19-pin control cable
receptacles. Refer to RECLOSER VTC INTERFACE and
CONTROL VTC INTERFACE sections of this manual for
IMPORTANT: Program all protection profiles. Unused additional information.
alternate profiles should be programmed with the same
settings as one of the applicable profiles. Default settings Reclosers manufactured prior to June 1989 are equipped
on unused alternate profiles can cause unnecessary out- with Type A bushing current transformers. These reclosers
ages if they are below normal system requirements. were designed for use with Form 2, Form 3, and Form 3A
controls. Because the Form 6 recloser control is designed
for use with reclosers equipped with Type B current-
The control must be programmed with all necessary sensing Transformers, reclosers retrofitted with Form 6
operating settings, all alternate profiles, and parameters recloser controls should be retrofitted with Type B current
prior to operation with an energized recloser. transformers. All reclosers manufactured since 1989 are
Note: Initial programming of the control is the responsibility of a equipped with Type B (1000:1, 1000/500:1, or 2000:1)
qualified technician or engineer familiar with control sensing CTs.
functions and programming parameters required for the
specific recloser installation. Reclosers equipped with Type B sensing CTs are compatible
with all Kyle recloser controls (Form 2, Form 3, Form 3A,
The control must be programmed with the Form 6 ProView Form 4A, Form 4C, FXA, FXB Form 5, Form 5 LS/UDP, and
interface software. Refer to Service Information S280-70-4 Form 6 recloser controls), and are identified with the
(ProView 4.X.X) or S280-70-21 (ProView 5.X.X) Form 6 following label prominently displayed on the recloser sleet
Microprocessor-Based Recloser Control Programming hood or the front of the operator cabinet:
Guide for additional information.
Note: The Pole-mounted Control checkbox in the ProView
System Configuration screen must be selected for all Form 6
pole-mount controls. This includes both pole and substation
applications. NOTICE
RECLOSER IS EQUIPPED WITH TYPE
B SENSING CTs.
RECLOSER DOES NOT HAVE A
BATTERY CHARGER.
15
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
The Form 6 recloser control can be used with the old-style Mounting the Control
Type A CTs; however, the event recorder and duty cycle
monitor will have limited accuracy for currents above 5000 WARNING: This equipment is not intended to
Amps. protect human life. Follow all locally approved pro-
Retrofit kits with the new Type B sensing CTs are cedures and safety practices when installing or operating
available to upgrade existing families of reclosers for this equipment. Failure to comply may result in death,
operation with Form 6 recloser controls. For additional severe personal injury and equipment damage. G102.1
Note: For reclosers shipped prior to June 1989 and not listed
Mount the Form 6 pole-mount recloser control in a
below, please contact your Cooper Power Systems
representative with the recloser type and serial number convenient, accessible location. Mounting dimensions are
for verification of type A or B bushing current provided in Figure 10.
transformers. Note: Unless otherwise specified, dimensions shown in mm
(inches).
TABLE 1 A hole and keyway in the control mounting bracket accom-
Serial Number Break for Reclosers with Type A modates a 15.9 mm (5/8”) bolt.
Sensing CTs
Recloser Below Serial Number Locking the Control
RXE 5831 The handles on the Form 6 control cabinet are able to
accept a padlock to prevent unauthorized access. For
RVE 5894 cabinets with the quarter-turn latch, the top handle has two
WE 11199 locking holes provided depending on the diameter of the
WVE 3695 lock shackle being used. Refer to Figure 10.
VWE 7199 • Use the smaller hole for shackle diameters of .177-
295”.
VWVE27 7208
• Use the larger hole for shackle diameters of .295-.394”.
VWVE38 1204
Note: DO NOT use a smaller shackle (.177-.295) in the
All VSA reclosers are equipped with Type A Sensing CTs. larger diameter hole as it will NOT LOCK the cabinet.
All VSML reclosers are equipped with Type A Sensing CTs. table 2
All VSA12, VSA12B, VSA16, VSA20, VSA20A, and VSA20B Duty Cycle Factor
reclosers are equipped with Type B Sensing CTs.
Interrupting 100% Duty
All VWVE38X and VWE38X reclosers are equipped with Type B Recloser Rating Cycle
Sensing CTs. Type (rms sym Amps) Factor*
RXE, RVE 6,000 97
Duty Cycle Monitor WE
WE
12,000 @ 4.8 kV
10,000 @ 14.4 kV
257
196
The Duty Cycle Monitor provides the following duty cycle VWE
information: VWVE27 12,000 1045
VWVE38X
• Measures and records duty for each individual phase in
non-volatile memory. WVE27 8,000 140
• The recloser duty is measured and stored on the basis WVE38X 8,000 140
of Current1.5 x Number of Operations for Each Phase VSA12 12,000 1045
(ANSI C37.61). VSA16 16,000 1608
VSA20
• Readout is based on a percentage of total duty cycle VSA20A 20,000 2248
for each phase. VSA20B
• Duty record can be adjusted or reset if recloser is VSO12 12,000 1045
changed-out, serviced, etc. VSO16 16,000 1608
Using Table 2, select the appropriate recloser interrupting Auxiliary-Powered
duty cycle factor and enter that value via the ProView NOVA 12,500 1111
interface software. Control-Powered
NOVA 12,500 1111
*Duty Cycle Factor is Value x 105.
16
S280-70-3
SHACKLE DIAMETER
.177-295"
SHACKLE DIAMETER
.295-.394"
CONTROL OK
CONTROL POWER
CONTROL LOCKOUT
RECLOSER OPEN
A PHASE FAULT
B PHASE FAULT
C PHASE FAULT
GROUND FAULT
ALARM
ABOVE MIN TRIP
INDICATOR 1
INDICATOR 2
A PHASE VOLTAGE
B PHASE VOLTAGE
C PHASE VOLTAGE
FREQUENCY TRIP
INDICATOR 4
INDICATOR 5
INDICATOR 6
INDICATOR 7
RS-232 Lifting
Connection
RECLOSER CLOSED SENSITIVE GND INDICATOR 3 VOLTAGE TRIP INDICATOR 8
Lugs
METERING SETTINGS
RESET OPER
TARGETS COUNTER
Port
F1 F2 F3 F4
+
EVENTS ALARMS
MENU
LAMP TEST CHANGE
ENTER —
RS-232 DATA PORT
ON
GND TRIP NON SUPERVISORY
BLOCKED RECLOSING OFF
665
TRIP CLOSE
710
CLOSE CIRCUIT
ALTERNATIVE ALTERNATIVE ALTERNATIVE
DISABLE HOT LINE TAG PROFILE #1 PROFILE #2 PROFILE #3
(LOCKOUT)
(28.0) (26.25)
Mounting Angle
1.44 Dia. Hole for
Voltage Input Connection
1.44 Dia. Hole for (Caplug Installed)
Low Voltage Closing 1.44 Dia. Hole
Connection (Caplug Installed)
(Caplug Installed)
Control Cable
38 Receptacle
(1.5) (14-pin or 19-pin)
67 67 79
(2.75) (2.75) (3.25)
Bottom View
CONTROL WEIGHT 34 kg (75 lbs)
Figure 10.
Form 6 pole-mount recloser control weight, dimensions, and pad-lock shackle diameters.
17
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
TABLE 3
Available Form 6 Control Cable Lengths for Kyle Reclosers
Recloser Type Gauge Length (Meters) Length (Feet)
18
S280-70-3
Surge
Transformer Arrester Surge
Arrester Supply Voltage
Surge Form 6 Control Input Terminal
Arrester Block
Transformer
AC
Recloser NEUTRAL
AC
Head Ground
NEU
GND
External
Ground Lug
Arrester Ground ELECTRICAL CONNECTIONS
Line to Neutral connected transformer
Supply
Voltage
Recloser
Control
Cable Pole
Form 6
Control
Pole
Ground
Input
Terminal
NEU
AC
Block
Figure 11.
Recommended grounding method for the Form 6 pole-mount recloser control installed on 4-wire multi-grounded,
with local supply voltage transformer.
19
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
Installation of a Form 6 pole-mount recloser control with a IMPORTANT: In pole-mounted applications, a ground
remote supply voltage transformer must include the connection must be made between the recloser,
following: transformer, recloser control, and SCADA equipment for
proper protection of the equipment. The pole ground
• Protection of the recloser bushings and the supplying must be sized per local utility practices to minimize the
transformer with lightning arresters. impedance between the recloser and the control.
• Grounding of the recloser head and tank.
• Grounding of the transformer tank.
IMPORTANT: All external inputs to the Form 6 recloser
• Grounding of the control cabinet. control must be routed within 8 inches of their
• Grounding of the SCADA equipment. corresponding ground. During a surge, a potential of
approximately 1.5 kV per foot can develop in the
Supply Voltage conductors. Differences between conductor and ground
Input
Form 6 Control path lengths can add additional stress to the control
Terminal
Transformer Block components in the event of a power surge.
AC
NEUTRAL
External
Ground Lug
Transformer Surge
Surge Arrester Surge
Arrester Arrester
Recloser
Head
Ground
HOT
NEU
GND
Arrester
Ground
Arrester
Ground System
Neutral
Pole
Ground Input Terminal Block
NEU
AC
Pole
Customer Ground Connection
at External Lug
Figure 12.
Recommended grounding method for the Form 6 recloser control installed on 4-wire multi-grounded with remote
supply voltage transformer.
20
S280-70-3
BØ
TB8
1 2 3 4 5 6 7 8 9 10 11 12
Figure 14.
Default factory wiring connected to B-Phase voltage metering with B-Phase incoming supply.
WARNING: Hazardous voltage. Before applying DANGER: Hazardous voltage. Do not connect
power to the control, confirm that male pins of potential transformer low-voltage secondaries to
the input power receptacle are electrically insulated to the control through cables or other wiring until the unit is
prevent unintentional contact with 120V AC voltage. installed in the field. Transformer high-voltage primary
Failure to do so may result in severe personal injury or windings will become live when 120V AC is applied to
death. T372.0 the control from an alternate source if the transformer
secondary is connected. Failure to comply may result in
Power Connections severe personal injury or death. T371.1
120 120/240 NEU Note: Terminal Block positions TB7-3 and TB7-4 are factory-
TB7 (L2) 120 (L1) NEU jumpered together.
Terminal Block positions TB7-5 and TB7-6 are factory-
jumpered together.
1 2 3 4 5 6 BØ
NEU
BØ
User-Supplied
Disconnect
Switch
Figure 15.
Single-Phase Transformer Connection, B phase input for Power and Sensing.
22
S280-70-3
AØ
1 2 3 4 5 6 7 8 9 10 11 12
TB8
User-Supplied
Disconnect
Switch
AØ
1 2 3 4 5 6
TB7
Note: Terminal Block positions TB7-3 and TB7-4
are factory-jumpered together. 120 120/240 NEU
Terminal Block positions TB7-5 and TB7-6 (L2) 120 (L1) NEU
are factory-jumpered together. Power Connections
Figure 16.
Modified wiring connected to A-Phase voltage metering with A-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
AØ
TB8
Voltage Sensing Connections
BØ
Source Load
V (1-2) V(3-4) V(5-6) V1 V2 V3
CØ
1 2 3 4 5 6 7 8 9 10 11 12
NEU
CØ
BØ
AØ
User-Supplied
Disconnect
Switches
Figure 17.
Three-Phase Transformer Connection, Wye configuration only (TB8 Terminal Block Connection).
23
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
CØ
Voltage Sensing Connections
Source Load
V (1-2) V(3-4) V(5-6) V1 V2 V3
BØ
1 2 3 4 5 6 7 8 9 10 11 12 AØ
TB8
User-Supplied
Disconnect
Switch
Voltage Sensing Connections Load Side
Source Load
V (1-2) V(3-4) V(5-6) V1 V2 V3 120
TB8
1 2 3 4 5 6 7 8 9 10 11 12
NEU
YØ
BØ
Source Side
Power Connections 120
240
120 120/240 NEU 120
Figure 19.
240 Volt, 3-wire transformer connection. B phase input for Power and Sensing. *YØ for Sync Check Voltage.
24
S280-70-3
Table 6
Ratings Table for Output Status Contact SS1
(Resistive Load – Pickup Time 2 ms, Dropout 15 ms)
Contact
Input Voltage Rating
120 VAC 8A
12 VDC 8A
24 VDC 8A
48 VDC 8A
125 VDC 8A
25
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
IMPORTANT
Shielding and Surge Protection of
Supervisory Cables
All supervisory operation and control monitor leads must
be protected within shielded cables. Refer to Figure
22.
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 MOV’s 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**
Supervisory Close
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 20.
Form 6 pole-mount recloser control standard default supervisory input control and output status contacts.
26
IMPORTANT
Shielding and Surge Protection of
Figure 21.
Supervisory Cables
All supervisory operation and control monitor leads must
be protected within shielded cables. Refer to Figure 22.
Unassigned
Remote Normal Profile
Supervisory Non-Reclose
Remote Alternate Profile 1
Remote Alternate Profile 2
Remote Alternate Profile 3
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 CO11 CO12
Form 6 pole-mount recloser control Discrete Interface Board accessory default supervisory input control and out-
27
S280-70-3
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
REMOTE
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 shown
with recloser in 11
OPEN position. CO1
Not All Remote
Connections
TB1 Shown
Figure 22.
Shielding and Surge Protection for Supervisory and Remote Cables.
28
S280-70-3
Table 7
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
9 NC . . . . . . . . . . . . . . . . . . . . . . Not Used
J1-RS-232
1 2 3 4 5
6 7 8 9
RS-232 DTE
Figure 24.
Rear panel RS-232 communication port pin
identification.
29
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
Before Placing the Control and the 8. Control battery connected and tested for proper
operation.
Recloser into Service
Note: The battery test is blocked for 30 seconds upon
power-up of the control.
CAUTION: Equipment misoperation. Do not
connect this control to an energized recloser until Test the battery as follows:
all control settings have been properly programmed and A. Press the MENU button on the front panel.
verified. Refer to the programming information for this
control. Failure to comply can result in control and B. Using the down arrow key, navigate to the BATTERY
recloser misoperation, equipment damage, and personal menu and press ENTER.
injury. G110.3
C. Using the down arrow key, navigate to the TEST
BATTERY menu and press ENTER.
Prior to placing the control and recloser into service, the D. Press the F4 button to test the battery.
following installation procedures must be properly Note: This message will appear on the programming
completed and verified: panel LCD display: ----TESTING----
1. Front panel label inserts changed (if applicable). The battery test results will display in the battery
metering menu.
Note: Refer to Using Removable Inserts in this manual.
Note: With AC disconnected and the battery supplying
2. Control properly mounted for the installation. the load, current will read -400 to -600 mA
3. Recloser installed according to all locally approved depending on accessories connected.
standards and practices. 9. AC power connected to the control. (Control OK LED
4. AC disconnect switches installed. indicator is illuminated.)
5. Control and recloser properly grounded in accordance Note: The control Power Save feature will turn off the back-
lit LCD display and all LEDs if no front panel keypad
with guidelines in this manual and the applicable
is pressed within ten minutes.
recloser manual.
10.
All control programming entered and verified by
CAUTION: Equipment misoperation. Verify that appropriate personnel.
the 120/240 VAC selector switch is correctly set Note: Refer to Service Information S280-70-4 (ProView
for incoming voltage. Failure to comply may cause 4.X.X) or S280-70-21 (ProView 5.X.X) Form 6
misoperation (unintentional operation) of the control and/ Microprocessor-Based Recloser Control
or equipment damage resulting in personal injury. Programming Guide for additional information.
T278.0 11. Control clock set to the correct time.
Note: Refer to Service Information S280-70-4 (ProView
4.X.X) or S280-70-21 (ProView 5.X.X) Form 6
6. Control cable properly connected and supported. Microprocessor-Based Recloser Control
7. Verify the selector switch on the Power Supply/Battery Programming Guide for additional information.
Charger Board is set to the correct position based 12. Customer connections for remote and supervisory
upon the incoming power supply: operation checked and completed in accordance with
• For 120 VAC incoming power, the selector switch proper shielding and surge protection (Figure 22).
must be set to the 115V position. NOTICE: External leads must be shielded and the shield
• For 240 VAC incoming power, the selector switch must be grounded at both ends. Terminate each lead with
must be set to the 230V position. a 320VAC, 150 Joules metal oxide varistor (MOV), or
equivalent, at the remote end. Attach MOV’s between the
leads and ground. Failure to properly shield and protect
leads can result in equipment damage and/or unintentional
operation.
30
S280-70-3
Using Removable Inserts 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 programming
connections or circuit boards in the control. Failure to 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 programmed 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
to the front panel.
2. Use a flathead or 3/33" hex key screwdriver to unscrew
the six front panel screws.
3. Pull the right side of the front panel out towards the left 6. Gently push the removable insert from right to left into
(Figure 25). the right side of the operating panel (Figure 26) or down
Note: Various connecting wires will keep the panel attached into the programming panel LED indicator section
to the control. (Figure 25).
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.
Figure 25.
Open front panel. Labels are easily removed from and
inserted into the top of the programming panel LED
status indicator section.
31
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
accessories
These accessories are available. Contact your Cooper Incoming Power Receptacles
Power Systems representative for additional information.
The Incoming Power Receptacle (Figures 32, 33, and 34)
allows the user to conveniently plug the power cable into
Low Voltage Closing the control, eliminating the need for hardwiring to the
The Low Voltage Closing Accessory utilizes 120 or 240 control. Various options are available based upon the input
VAC for closing power (Figures 27, 28, 29, 30, and 31). power voltage, and phase sensing requirements. Table 8
Multiple low voltage closing accessories are available for includes the available input receptacles and cables for the
reclosers equipped with low voltage closing. The low Form 6 pole-mount recloser control.
voltage closing accessories available for the Form 6
recloser control include the appropriate receptacles and Cable Locking Sleeves
wiring based upon the input supply voltage. Table 8 lists
the available low voltage closing input/output receptacles To prevent detachment of the control cable from the control
and cables for the Form 6 pole-mount recloser control. 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
Internal Voltage Sensing sleeve is then fastened from inside the control cabinet.
A four-wire cable and input receptacle accessory (Table 9) There is no access to the cable receptacle without opening
is required for Type NOVA three-phase reclosers with the the locked cabinet door and detaching the sleeve.
internal voltage sensing (IVS) option. Internal voltage sen-
sors, located on the source side, indicate voltage magni- 120 VAC GFI Duplex Outlet
tude within an accuracy 2% or better and a phase degree
accuracy within 1.5 degrees (includes sensor, cable, and The GFI Duplex Outlet (Catalog Number KME6-1776) is
control). The 4-pin receptacle accessory is pre-wired to the available for controls powered by 120 VAC or 240 VAC
voltage inputs on the control. Refer to Service Instructions three-wire supply power. This convenience outlet is rated
S280-42-1 NOVA Three-Phase Recloser Installation and for 15 Amperes and is accessible through the front door in
Operation Instructions for additional setting information. the control cabinet. The 120 VAC GFI Duplex Outlet is used
for many applications such as power for the MET Tester,
table 8 auxiliary measurement equipment, and supplemental
Low Voltage Closing and Input Receptacles and Cables lighting.
32
S280-70-3
White
Black
Voltage Sensing Connections
Source Load Ground
V (1-2) V(3-4) V(5-6) V1 V2 V3 White
BØ Black
TB8
1 2 3 4 5 6 7 8 9 10 11 12
1
Black
Fuse
Note: Terminal Block positions TB7-3 and TB7-4 are
factory-jumpered together.
Terminal Block positions TB7-5 and TB7-6 are
factory-jumpered together.
1 2 3 4 5 6
TB7 120 120/240 NEU
(L2) 120 (L1) NEU
Power Connections
Black
White
120/240 VAC
A B
R3
White
Black
Low Voltage
Closing Receptacle
A B
R2
Input
WARNING: Hazardous voltage. Before applying Receptacle
power to the control, confirm that male pins of
the input power receptacle are electrically insulated to
prevent unintentional contact with 120V AC voltage. 120/240 VAC
Failure to do so may result in severe personal injury or (2-wire)
death. T372.0
Incoming
Power
Figure 27.
120 VAC low-voltage closing 2-pin input and 2-pin output receptacles (KME6-1775-A) and 240 VAC low-voltage
closing with 2-pin input and 2-pin output receptacle (KME6-1775-D).
33
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
Black
White
Voltage Sensing Connections
Source Load Ground
V (1-2) V(3-4) V(5-6) V1 V2 V3 White
BØ Black
TB8
1 2 3 4 5 6 7 8 9 10 11 12
1
Black
Fuse
Note: Terminal Block positions TB7-3 and
TB7-4 are factory-jumpered together.
Terminal Block positions TB7-5 and
TB7-6 are factory-jumpered together.
1 2 3 4 5 6
TB7 120 120/240 NEU
(L2) 120 (L1) NEU
Power Connections
Black
White
120 VAC
A B
Braid
White
R3
Black
Low Voltage
Closing Receptacle
A C
R2
Input
Receptacle
WARNING: Hazardous voltage. Before applying
power to the control, confirm that male pins of
the input power receptacle are electrically insulated to 120 VAC
prevent unintentional contact with 120V AC voltage. Incoming
Failure to do so may result in severe personal injury or Power
death. T372.0
Figure 28.
120 VAC low-voltage closing with 3-pin input and 2-pin output receptacles (KME6-1775-B).
34
S280-70-3
1 2 4
Connections
White
Black
Voltage Sensing Connections
Source Load Ground
V (1-2) V(3-4) V(5-6) V1 V2 V3 White
BØ Black
TB8
1 2 3 4 5 6 7 8 9 10 11 12
1
Factory Wiring for Wye Connection
2
15 Amp
Black
Fuse
Note: Terminal Block positions TB7-3
and TB7-4 are factory-jump-
ered together.
Terminal Block positions TB7-5
and TB7-6 are factory-jump-
ered together. 1 2 3 4 5 6
TB7 120 120/240 NEU
(L2) 120 (L1) NEU
Power Connections
Black
White
A B
R3
Low Voltage Customer Connections for
Closing Receptacle Incoming Power
120 VAC or 240 VAC (2-wire)
Figure 29.
120 VAC low-voltage closing with inlet hole and 2-pin output receptacle ( KME6-1775-C) and 240 VAC low voltage
closing, for 2-wire with inlet hole and 2-pin output receptacle (KME6-1775-F).
35
Form 6 Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions
White
Black
Voltage Sensing Connections
Source Load
V (1-2) V(3-4) V(5-6) V1 V2 V3 White
BØ Black
1 2 3 4 5 6 7 8 9 10 11 12 2 2
TB8
1 1
Factory Wiring for Wye Connection
Red
Black
Note: Terminal Block
positions TB7-3
and TB7-4 are fac-
tory-jumpered
together.
1 2 3 4 5 6
Terminal Block
positions TB7-5 TB7 120 120/240 NEU
and TB7-6 are fac- (L2) 120 (L1) NEU
tory-jumpered
White
Black
240 VAC
White
Black
Red
A B
R3 A B C
Low Voltage R2
Closing Receptacle Input
Receptacle
WARNING: Hazardous voltage. Before applying
power to the control, confirm that male pins of 120 VAC 120 VAC
the input power receptacle are electrically insulated to
prevent unintentional contact with 120V AC voltage.
240 VAC Incoming Power
Failure to do so may result in severe personal injury or
death. T372.0
Figure 30.
240 VAC low-voltage closing with 3-pin input and 2-pin output receptacle (KME6-1775-E).
36
S280-70-3
White
Black
Voltage Sensing Connections
Source Load
V (1-2) V(3-4) V(5-6) V1 V2 V3 White
BØ Black
1 2 3 4 5 6 7 8 9 10 11 12 2 2
TB8
1 1
Factory Wiring for Wye Connection
Red
Black
Note: Terminal Block
positions TB7-3
and TB7-4 are fac-
tory-jumpered
together.
1 2 3 4 5 6
Terminal Block
positions TB7-5 TB7 120 120/240 NEU
and TB7-6 are fac- (L2) 120 (L1) NEU
tory-jumpered
White
Black
120 VAC
A B
R3
Low Voltage
Closing Receptacle
Figure 31.
240 VAC low-voltage closing, for 3-wire with inlet hole and 2-pin output receptacle (KME6-1775-G).
37
Form 6 Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions
BØ Black
TB8
1 2 3 4 5 6 7 8 9 10 11 12
White
Black
A B
R2
Input
Receptacle
2-wire
120/240 VAC
WARNING: Hazardous voltage. Before applying Incoming
power to the control, confirm that male pins of Power
the input power receptacle are electrically insulated to
prevent unintentional contact with 120V AC voltage.
Failure to do so may result in severe personal injury or
death. T372.0
Figure 32.
120 VAC or 240 VAC input receptacle, 2-pin (KME6-1775-H).
38
S280-70-3
BØ Black
TB8
1 2 3 4 5 6 7 8 9 10 11 12
Braid
White
Black
A B C
R2
Input
Receptacle
3-wire
120 VAC
WARNING: Hazardous voltage. Before applying Incoming
power to the control, confirm that male pins of Power
the input power receptacle are electrically insulated to
prevent unintentional contact with 120V AC voltage.
Failure to do so may result in severe personal injury or
death. T372.0
Figure 33.
120 VAC input receptacle, 3-pin (KME6-1775-J).
39
Form 6 Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions
BØ Black
1 2 3 4 5 6 7 8 9 10 11 12
TB8
Factory Wiring for Wye Connection
Note: Terminal Block positions TB7-3 and
TB7-4 are factory-jumpered together.
Terminal Block positions TB7-5 and
TB7-6 are factory-jumpered together.
1 2 3 4 5 6
TB7 120 120/240 NEU
(L2) 120 (L1) NEU
Power Connections
White
Black
Red
A B C
R2
Input
Receptacle
Figure 34.
240 VAC input receptacle, 3-pin (KME6-1775-K).
40
S280-70-3
GROUND X5 X4 1 X3 X2 X1 GROUND X5 X4 5 X3 X2 X1
TB8
1 2 3 4 5 6 7 8 9 10 11 12
GROUND X5 X4 3 X3 X2 X1
TB7
1 2 3 4 5 6
120 120/240 NEU
(L2)120 (L1) NEU
Customer Connections
Figure 35.
Form 6 pole-mount recloser control BCT terminal
block accessory.
41
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
IRIG-B
TB3
CI4 CI5 CI6
1 3 5
CI7 CI8 CI9 CI10 CI11 CO5
7 9 11 13 15 17 19 21
CO6 CO7 CO8 CO9 CO10 CO11 CO12
1 3 5 7 9 11 13
TB4
and is fused to isolate any potential radio problems without
disturbing the protection system in the recloser control.
Refer to Table 11.
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
TB9
Contact your Cooper Power Systems representative for
any additional voltage requirements.
+ –
28 VDC
WHETTING VOLTAGE
P1 P4
table 11
1
2
3
4
1
2
3
4
1
2
3
4
P2
1 2 3 4 5
P3
24 23 22
12 11 10
21
9
20 19
8 7
18 17
6 5
16
4
15 14
3 2
13
1
1
1
2
2
3
3
4
4
5
5
Radio Mounting Accessories
Description Catalog Number
VOLTAGE SENSING 53VDC CONTROL CABLE 28 VAC
RS-485 C + –
J1-RS-232
IRIG-B
RS-232 DTE
TB9
+ –
28 VDC
WHETTING VOLTAGE
P1 P4
Customer-Supplied
P2 P3 1 2 3 4 5
1 3 1 3 1 3 24 23 22 21 20 19 18 17 16 15 14 13
1 3 1 2 3 4 5
2 4 2 4 2 4 2 4 5 12 11 10 9 8 7 6 4
5 3 2 1
Radio
Power Cable
Radio-Mounting
Bracket
Figure 37.
Form 6 recloser control radio mounting accessory.
42
S280-70-3
43
Form 6 Microprocessor-Based Pole-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 12. mary and standby LAN connections. Availability of the
backup communication port enables creation of highly
Table 12 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
38), with the standby port either logically disabled, or
1 10/100 Base-T 2 * RJ-45 10 / 100MBps configured for fast automatic throw-over in case of the
(auto switching) primary Ethernet link failure. Refer to Service Information
S280-70-4 (ProView 4.X.X) or S280-70-21 (ProView
2 100 Base-FX 2 * MT-RJ 100MBps
(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
44
S280-70-3
testing
3. Test battery operation as follows:
CAUTION: Equipment misoperation. Do not
Note: The battery test is blocked for 30 seconds upon
connect this control to an energized recloser until
power up of the control.
all control settings have been properly programmed and
verified. Refer to the programming information for this Note: AC power can be either connected or disconnected
control. Failure to comply can result in control and for battery test.
recloser misoperation, equipment damage, and personal A. Press the MENU button on the front panel.
injury. G110.3
B. Using the down arrow key, navigate to the BATTERY
menu, and press ENTER.
IMPORTANT: The Form 6 control can be taken out of C. Using the down arrow key, navigate to the TEST
service for testing and placed back into service without BATTERY menu and press ENTER.
de-energizing its recloser and interrupting the system. D. Press the F4 button to test the battery.
However, during the time the control is out of service,
the recloser is inoperative. Note: This message will appear on the programming
panel LCD display: ----TESTING----
Testing an Installed Control The battery test results will display in the battery
metering menu.
The following tests to determine initial operation of the
Form 6 pole-mount recloser control can be performed Note: Voltage should be between 25–31 VDC – with the
while connected to an operating recloser. higher voltage at colder temperatures.
Note: These are the only tests performed on an installed, Under normal conditions, with AC connected and
operating control. a fully charged battery, the charging current
should be less than 20 mA.
1. Verify operating status of all indicator lights by pressing With AC connected and a discharged battery, the
and holding the LAMP TEST key for two seconds on current range should be 20–450 mA.
the programming panel (Figure 39).
With AC disconnected and the battery supplying
2. Check the operational values for currents, voltages, the load, current will read -400 to -600 mA
and other metering information. depending on accessories connected.
Note: Scroll through the LCD display messages by pressing 4. Verify the Control OK LED is illuminated on the control
the and cursor movement arrows underneath operator panel (Figure 40). This indicates the presence
the LCD display on the programming panel (Figure of AC power.
35).
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.
LCD Display Pressing the LAMP TEST key will reactivate the dis-
METERING SETTINGS
play and active LEDs.
RESET
TARGETS
OPER
COUNTER All other tests described in this TESTING section require
LAMP TEST Key
F1 F2 F3 F4 the Form 6 pole-mount recloser control to be removed
+ from service, connected to a bypassed recloser, or tested
EVENTS ALARMS
MENU
LAMP TEST CHANGE
at a location where the proper testing equipment is avail-
able.
Cursor Movement
ENTER —
RS-232 DATA PORT
Arrows
Figure 39.
CONTROL OK
Lamp Test button, LCD display, and cursor movement CONTROL POWER
A PHASE FAULT
B PHASE FAULT
arrows. CONTROL LOCKOUT C PHASE FAULT
RECLOSER OPEN GROUND FAULT
RECLOSER CLOSED SENSITIVE GND
Control OK LED
Figure 40.
Control OK LED.
45
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
Figure 42.
CAUTION: Equipment misoperation. Disconnect all Location of terminals TM1 and TM2 on the power
control power sources prior to disconnecting or recon- supply circuit board
necting the control cable from the control. Failure to
comply can result in recloser misoperation at the time of 2. Momentarily jumper terminals TM1 and TM2 together.
disconnection or reconnection of the control cable to the (The control will power up.)
control. T311.1
3. To power down the Form 6 control, unplug the battery
(disconnect the black/red battery connector).
3. Disconnect control cable from control. 4. Perform a battery charging cycle. Refer to Battery
4. Remove control AC sensing and power connections Charging in the Battery Test and Charging
from the control. Procedures section of these instructions.
CAUTION: Hazardous Voltage. Cable IMPORTANT: While the Form 6 control is powered in
conductors attached to controls will remain at 53 this manner, the control battery is being continuously
VDC and 120 VAC potential while connected to the discharged. When the battery voltage drops to 22V DC,
control. Contact with any pins at the end of the cable the control will automatically power down.
directly or indirectly connected to a control can result in
personal injury or equipment damage. Disconnect If the battery is left in a discharged condition, the
battery and external power sources in the control then battery(s) will sustain permanent irreversible damage.
remove control cable at control end before disconnecting Therefore, a battery charging cycle should always be
from recloser end. T312.2
performed after this procedure to bring the battery(s)
back up to full charge.
• Overcurrent Timing
CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4
7. Disconnect the
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11 CO12
• Reclose Time
1 3 5 7 9 11 13 15 17 19 21 1 3 5 7 9 11 13
TB3 TB4
trol.
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6
• Reset Time
8. Carefully transport the Figure 41.
control to a suitable Back view of top half of Form • Minimum Trip Current
service facility. 6 pole-mount recloser control. • High Current Trip and Lockout
46
S280-70-3
The MET Tester is completely self-contained, capable of WARNING: Hazardous voltage. Interconnect
performing all required checks and tests from a simple source leads X and Y and ground solidly to the
verification of operation to a complete verification of all recloser tank (Figure 46). Do not connect lead Z to any
operating parameters. other phase or mechanical ground. Dangerous voltages to
Refer to Service Information S280-76-1 Type MET Electronic ground exist on the phase connected to lead Z. Solidly
Recloser Control Tester Operating Instructions for proper ground all equipment. Failure to comply can result in severe
setup and use of the MET Tester. personal injury and/or equipment damage. T224.1
Figure 43.
Type MET electronic recloser control tester. For shop testing, the closing solenoid voltage is supplied
by back-feeding a transformer with a low-side rating equal
to the voltage rating of an available power source, and a
high-side rating equal to the voltage rating of the recloser
Closing the Recloser During (Figure 46). A 75 kA transformer of the proper voltage
Testing rating with an impedance drop of approximately 3% is
satisfactory. The AC source must have a comparable
Electrical Closing – Solenoid-Operated impedance drop.
Reclosers A test circuit for these solenoid-closed reclosers is shown
Line voltage is required for automatic recloser operation in Figure 46. The following equipment is required for the
during testing of reclosers equipped with a closing solenoid recommended shop testing setup:
(except for reclosers equipped with the low voltage closing Note: Solenoid-closed reclosers equipped with a 120- or 240-
accessory). VAC low-voltage closing coil accessory can be tested as
shown in Figure 47.
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 44.
Closing source-side switches of a bypassed “on-line” recloser provides closing solenoid power for automatic
operation during testing.
47
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
Z
5 6
J*
TO MAIN
240 OR CONTACTS (S)
480 VAC ROTARY
SOURCE SOLENOID
T3
Y
3 4
E* F* TRIP
H* SOLENOID
CLOSING
SOLENOID
COIL
A* B*
X W
1 2
K* G* CONTROL
TO CABLE RECEPTACLE
240 VAC
SOURCE
TO
AMMETER AND RELAY TO
FORM 6 OPERATE CYCLE COUNTER
T1 CONTROL OR OTHER TIMING DEVICE
VARIABLE T2
AC POWER
AUTOTRANSFORMER
240 VAC
20 AMPS
*Indicates control cable receptacle pin/socket designation.
Figure 46.
Suggested test circuit for high voltage “shop-testing” solenoid-closing reclosers.
48
S280-70-3
120/240 VAC
POWER
SUPPLY
240 VAC
TO AMMETER
T1 T2 AND RELAY
VARIABLE TO OPERATE
AUTOTRANSFORMER FORM 6 CYCLE
240 VAC-20 A RECLOSER COUNTER OR
CONTROL OTHER TIMING
DEVICE
AC POWER
Figure 47.
Suggested test circuit for motor-operated, solenoid- Figure 48.
closing reclosers with low-voltage closing. Using a manual closing tool to operate the recloser.
49
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
Battery Test and Charging 4. Press the F4 button to test the battery. The battery test
results will display in the battery metering menu.
Procedures
Note: Voltage should be between 25–31 VDC with the
Test Procedure for Installed Battery higher voltage at colder temperatures.
Under normal conditions, with AC connected and a
Follow the procedure below to perform a battery test in the fully charged battery, the charging current should be
Form 6 pole-mount control. The values in the test less than 20 mA.
procedures are based on testing at 25ºC (77ºF). With AC connected and a discharged battery, the
current range should be between 20 and less than
The condition of the Form 6 pole-mount control battery 450 mA. Current of 450 mA or greater indicates a
can be determined by using the Battery Test function in the problem with the charging circuit on the pole-mount
BATTERY MENU. No external current/voltage meter is power supply.
necessary for testing. With AC disconnected and the battery supplying the
load, current will read -400 to -600 mA depending on
Alarm Conditions: connected accessories.
• During a manual battery test a 5Ω, 55 watt resistor is Test Procedure for Uninstalled Battery
placed across the battery terminals for approximately
5 seconds. The Form 6 control measures the battery The entire process should be conducted in a clean environ-
voltage, if the voltage drops below 22.8 VDC for one ment, such as a repair shop.
full second, the ALARM LED (battery alarm) is Refer to Table 13 and follow this procedure to perform a
illuminated. bench test on a control battery in a service shop:
• When the Form 6 pole-mount control is disconnected 1. Remove the control from service. Refer to Remove the
from AC power and the control battery drops below 23.5 Control from Service procedure within the Testing
VDC for 60 seconds, the ALARM LED will illuminate. If section of this manual.
the battery voltage continues to decay and drops below
22 VDC, the Form 6 control will shut down. 2. Remove the battery from the control and carefully
transport it to a suitable service facility.
Note: The battery test is blocked for 30 seconds upon power
up of the control. 3. Measure battery voltage.
Note: AC power can be either connected or disconnected for 4. Apply test load and measure battery voltage after 5
battery test.
seconds of load to determine voltage drop. Refer to
Note: If the battery voltage drops below 19V, the battery must Table 13 for Bench Test Load Condition.
be charged by the external battery charger
KA43ME7001. 5. Remove test load.
1. Press the MENU button on the front panel. If the battery fails the test or is at least four years old, it
2. Using the down arrow key, navigate to the BATTERY should be replaced. Refer to Table 13 for battery catalog
menu and press ENTER. part numbers.
TABLE 13
Control Battery Bench Testing and Replacement Information
Bench Acceptable
Battery Test Load Voltage Drop
Catalog Amp/ Condition at End of
Control Type Part # Voltage Type Hour for 5 sec. Test Load
Form 6 Pole-mount (standard capacity) KME4-215 24v Lead 8 5Ω 3v
Acid 55 watt or less
Form 6 Pole-mount (high capacity) KME5-134-1 24v Lead 13 5Ω 2v
(two Acid 55 watt or less
12v
batteries)
50
S280-70-3
Battery Charging The charger senses when the battery voltage reaches 2.27
volts per cell, then the charge rate reduces to maintain a
If it is not possible to charge the battery with the control’s trickle charge.
built-in charger, a KME5-60-1 (120 VAC) portable bench
type battery charger kit is available, which includes the The yellow LED flickers to indicate the battery has reached
KA43ME7001 Battery Charger (Figure 49) and the KME5- a full charge. This process can take up to 24 hours.
325-1 Adapter Cable. Refer to S280-79-14 KA43ME7001 Refer to Table 14 for additional battery charging
Portable Lead Acid Battery Charger Instructions for addi- accessories.
tional information.
table 14
IMPORTANT: Do not attempt to charge a lead acid Battery Charging Accessories
battery below 2 VDC with the KA43ME7001 charger.
Description Catalog Number
The charger requires a minimal voltage to sense a
battery is connected. 120 VAC Battery Charger Accessory . . . . . . . . . KME5-60-1
If the lead acid battery is below 19 VDC for over 2 days,
replace the battery. The expired battery should be
disposed of in an environmentally responsible manner.
Consult local regulations for proper battery disposal.
Figure 49.
KA43ME7001 Battery Charger.
51
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
52
S280-70-3
TABLE 17
Catalog Numbers for Control VTC Retrofit Kits
Figure 51.
Bottom view of Form 6 recloser control showing
location of VTC label.
53
Form 6 Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions
additional information
Factory Maintenance Classes
CAUTION: This equipment requires routine
The factory service department offers a basic testing and
inspection and maintenance to ensure proper
troubleshooting course for the Form 6 microprocessor-
operation. If it is not maintained, it can fail to operate
based electronic recloser control. This course, taught by
properly. Improper operation can cause equipment
experienced service technicians, is held at the factory’s
damage and possible personal injury. G105.1
in-house training facility. For additional information, contact
your Cooper Power Systems representative.
Replacement Kits
Type MET Recloser Control Tester
Replacement kits for the Form 6 pole-mount control are
available through the factory Service Department. To order A 30-minute video program KSPV7 Kyle Type MET
these kits, refer to the Replacement Parts price list for Electronic Recloser Control Tester Operation and Testing
catalog numbers and pricing. Contact your Cooper Power Procedures is available as a supplemental training aid for
Systems representative for additional information and order service personnel.
procedures.
Factory-Authorized Service
Centers
Factory-authorized service centers are located throughout
the continental United States to provide maintenance,
repair and testing services for Cooper Power Systems
controls and reclosers. For further information, contact
your Cooper Power Systems representative.
54
S280-70-3
55
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
KA2048-630 Rev: 05