Printed in USA
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 2
Product Information . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ANSI Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Quality Standards . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Acceptance and Initial Inspection . . . . . . . . . . . . . . 3
Handling and Storage . . . . . . . . . . . . . . . . . . . . . . . 3
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . 3
Battery Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Control Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Initializing the Control . . . . . . . . . . . . . . . . . . . . . . . 4
Form 5/Triple-Single Control Description . . . . . . 5
Phase Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Ground Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sensitive Ground/Earth Fault Operation . . . . . . . . . 6
Recloser Interface (RIF) Module . . . . . . . . . . . . . . 6
Central Processing Unit (CPU) Module . . . . . . . . . 6
Discrete Interface (DIF) Module . . . . . . . . . . . . . . . 6
Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . 6
Triple-Single Control Operator Panel . . . . . . . . . . . 7
Manual Control Operation . . . . . . . . . . . . . . . . . . . 15
Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Auxiliary Power for Accessories . . . . . . . . . . . . . . 21
Recloser Interface (RIF) Module Configuration . . 21
Form 5/Triple-Single Universal Device Protection
(UDP) Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Discrete Interface (DIF) Accessory . . . . . . . . . . . . 23
Customer Connection Information . . . . . . . . . . . . . 23
Standard and UDP DIF Module 1 Inputs . . . . . . . . 26
Standard and UDP DIF Module 1 Outputs . . . . . . . 27
Standard and UDP Module 2 Inputs . . . . . . . . . . . . 28
Standard and UDP Module 2 Outputs . . . . . . . . . . 29
Input Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . 31
Initial Programming Prior to Installation . . . . . . . . . 31
Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Triple-Single Control Junction Box . . . . . . . . . . . . . 31
Mounting the Control . . . . . . . . . . . . . . . . . . . . . . . 32
Grounding the Control . . . . . . . . . . . . . . . . . . . . . . 33
Customer Connections for AC Power . . . . . . . . . . . 37
Customer Connections for Metering . . . . . . . . . . . . 37
Before Placing Control and Recloser Into Service . 41
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Testing an Installed Control . . . . . . . . . . . . . . . . . . 41
Electrical Testing of NOVA-TS Reclosers . . . . . . . 42
Remove the Control from Service . . . . . . . . . . . . . 42
Battery Test Procedure . . . . . . . . . . . . . . . . . . . . . . 43
Return the Control to Service . . . . . . . . . . . . . . . . . 44
Additional Information . . . . . . . . . . . . . . . . . . . . . . 44
1
Service Information
Reclosers
Kyle®Form 5/Triple-Single
Microprocessor-Based Recloser Control
Installation and Operation Instructions
S280-42-3
March 2003 • Supersedes 7/01
Figure 1.
Kyle®Form 5/Triple-Single microprocessor-based recloser control.
99015KM
Contents
Applicable to Serial Numbers 9416 and above.
NOTICE: This bulletin is also applicable to Kyle product
serial numbers beginning with the prefix CP57.
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
2
The instructions in this manual are not intended as a substitute for proper training or adequate experience in the
safe operation of the equipment described. Only competent technicians who are familiar with this equipment
should install, operate, and service it.
A competent technician has these qualifications:
• Is thoroughly familiar with these instructions.
• Is trained in industry-accepted high- and low-voltage
safe operating practices and procedures.
• Is trained and authorized to energize, de-energize,
clear, and ground power distribution equipment.
• Is trained in the care and use of protective equipment
such as flash clothing, safety glasses, face shield,
hard hat, rubber gloves, hotstick, etc.
Following is important safety information. For safe installation and operation of this equipment, be sure to read
and understand all cautions and warnings.
Safety Instructions
Following are general caution and warning statements
that apply to this equipment. Additional statements,
related to specific tasks and procedures, are located
throughout the manual.
SAFETY INFORMATION
WARNING: This equipment is not intended to
protect human life. Follow all locally approved
procedures and safety practices when installing or
operating this equipment. Failure to comply can result
in death, severe personal injury, and equipment damage.
G102.1
DANGER: Hazardous voltage. Contact with
hazardous voltage will cause death or severe personal injury. Follow all locally approved safety procedures when working around high- and low-voltage lines
and equipment. G103.3
WARNING: Before installing, operating, main-
taining, or testing this equipment, carefully read
and understand the contents of this manual. Improper
operation, handling or maintenance can result in death,
severe personal injury, and equipment damage. G101.0
WARNING: Power distribution equipment must
be properly selected for the intended application.
It must be installed and serviced by competent personnel who have been trained and understand proper
safety procedures. These instructions are written for
such personnel and are not a substitute for adequate
training and experience in safety procedures. Failure to
properly select, install, or maintain power distribution
equipment can result in death, severe personal injury,
and equipment damage. G122.2
SAFETY FOR LIFE
Cooper Power Systems products meet or exceed all applicable industry standards relating to product safety. We actively
promote safe practices in the use and maintenance of our products through our service literature, instructional training
programs, and the continuous efforts of all Cooper Power Systems employees involved in product design, manufacture,
marketing, and service.
We strongly urge that you always follow all locally approved safety procedures and safety instructions when working
around high voltage lines and equipment and support our “Safety For Life” mission.
This manual may contain four types of hazard
statements:
DANGER: Indicates an imminently haz-
ardous situation which, if not avoided, will
result in death or serious injury.
WARNING: Indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
CAUTION: Indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in equipment damage only.
Hazard Statement Definitions
!
SAFETY
FOR LIFE
!
SAFETY
FOR LIFE
!
!
!
!
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Introduction
Service Information S280-42-3 provides installation and
operation instructions for the Kyle®Form 5/Triple-Single
microprocessor-based electronic recloser controls. This
control is used exclusively with Kyle
®
Type NOVA-TS
reclosers. Refer to Service Information S280-42-2 Type
NOVA-TS Electronically-Controlled Recloser Installation
and Operation Instructions for additional information.
Read This Manual First
Read and understand the contents of this manual and follow all locally approved procedures and safety practices
before installing or operating this equipment.
Additional Information
These instructions cannot cover all details or variations in
the equipment, procedures, or process described, nor
provide directions for meeting every possible contingency
during installation, operation, or maintenance. When additional information is desired to satisfy a problem not covered sufficiently for the user's purpose, contact your
Cooper Power Systems sales representative.
ANSI Standards
Kyle reclosers are designed and tested in accordance
with the following ANSI standards: C37.60 and C37.85
and ANSI Guide C37.61.
Quality Standards
ISO 9001:2000 Certified Quality Management System
Acceptance and
Initial Inspection
Each Form 5/Triple-Single control is completely assembled, tested, and inspected at the factory. It is carefully
calibrated, adjusted, and in good condition when
accepted by the carrier for shipment.
Upon receipt, inspect the carton for signs of damage.
Unpack the control and inspect it thoroughly for damage
incurred during shipment. If damage is discovered, file a
claim with the carrier immediately.
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 sup-
ply input connector block TB1 located left of the
Recloser Interface (RIF) module within the control.
Refer to the Customer Connection for AC power section in this manual.
Control Battery Storage and Charging
Two 12 Vdc, 13- Amp-hour control batteries in the Form
5/Triple-Single control are fully charged prior to shipment
and is ready for use.
Note: When shipped from the factory, the battery source is dis-
connected and its output plugs are taped to the cabinet.
Connect the battery plugs into the mating connectors to
complete the battery circuit.
Temperature has an effect on battery life. Sealed lead
acid batteries should be stored, fully-charged, at room
temperature. Never store lead acid batteries at temperature exceeding 47°C (117°F), as damage can result in
approximately one month.
To keep the batteries charged, energize the control’s
built-in charger with AC power applied to the user AC supply input connector block TB1, located left of the RIF module within the control cabinet.
Battery Replacement
In a typical application, the life expectancy of a lead acid
battery is three to five years. To determine the state of the
battery, perform a bench battery test. Battery replacement
is recommended after four years for lead acid batteries or
if the battery fails the bench battery test procedure.
The
Form 5/Triple-Single control batteries have different dimensions; therefore, if the replacement battery ordered is a different brand than the original battery, a kit with mounting
hardware may be required.
Battery Disposal
Dispose expired batteries in an environmentally responsible manner. Consult local regulations for proper battery
disposal.
S280-42-3
3
!
SAFETY
FOR LIFE
PRODUCT INFORMATION
IMPORTANT: Connect the control battery when AC
power is connected to the control’s AC supply Input
Terminal Block. The battery must be disconnected
prior to shipping or storing the control.
IMPORTANT: To maintain sufficient charge to operate the control and prevent battery cell damage, the
sealed lead-acid batteries should be charged after no
more than three months of storage.
Control Power
The primary source of power is factory configured for 120
Vac or 240 Vac. Primary power is rectified to charge the
power capacitor and to power the dc/dc converter that
provides power to the control. A minimum of 500 mA of ac
current is required for heater operation, battery charging
current, and to keep all modules energized. The Kyle
®
Form 5/Triple-Single recloser control is equipped with two
dc-to-dc converters, an interface circuit, and a fully
shielded 26-pin cable.
The dc-to-dc converter boards (Figure 2) convert the control’s 24 Vdc battery supply voltage to 53 Vdc to charge
the trip/close capacitors in the NOVA mechanisms. The
output of the boards is separately fused for short circuit
protection.
The dc-to-dc converter contains voltage monitoring and
conditioning circuits which protect the battery from failure
and provides trip/close operations without AC power. The
26-pin control cable interfaces the NOVA-TS Triple-Single
recloser to the Form 5/Triple-Single control through the
junction box.
Operation Upon Loss Of AC power
The control will maintain full operation from the battery
power supply for a minimum of 32 hours at 20°C (24 hours
at -40°C). To prevent battery damage, the control shuts
down automatically upon detection of low battery voltage
below 20.5 Vdc.
Control programming settings and parameters—including
event recorder, duty monitor, and data profile metering
parameters—are stored in non-volatile memory and
retained upon loss of control power. The time/date clock
resets to 0:00:00, 1970 upon loss of control power.
The AC power LED indicator on the operator panel of the
control will turn off after 15 seconds upon loss of AC
power. The indicator will illuminate immediately upon
return of ac power.
Initializing the Control
Two methods are available to initialize the Form 5/TripleSingle control:
Method 1: Connect AC power to the input connector ter-
minal TB-1. (See the Customer Connections
for AC power section of this manual.)
Method 2: Connect the battery terminals to the control
and press the MANUAL BATTERY RECONNECT button located on the Form 5/Triple-Single power supply. See Figure 4.
Note: Method 2 powers the control off the battery
and is not intended for long term operation.
In both methods, after initialization, set the control clock
via the interface software.
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
4
Figure 2. 99007KM
Dc-to-dc converters located behind Form 5/TripleSingle operator panel (removed).
The Kyle Form 5/Triple-Single microprocessor-based
recloser control is designed for use with the Kyle NOVATS Triple-Single reclosers to provide automation of distribution feeders in line applications.
The Form 5/Triple-Single control operates three singlephase NOVA-TS reclosers representing phases A, B,
and C.
Note: Phase A, B, and C sequence positions are independent
of each other. For example, Phase A may be sequencing on TCC1 while Phase C may have sequenced to
TCC3.
The Form 5/Triple-single control uses three modes of
operation. All modes are configured through the user
interface software.
Mode A: Three-phase trip, three-phase lockout.
Mode B: Single-phase trip, three-phase lockout
Mode C: Single-phase Trip, single-phase lockout.
The Form 5/Triple-Single control includes phase and
ground current sensing as well as voltage sensing on a
per-phase basis for both source and load. The control can
compute and record current and voltage harmonics,
power, power factor, and power flow direction from current and voltage measurements.
Programming, interrogation, and operations are accomplished utilizing the interface software program (see Ser-
vice Information S280-79-2) via a personal computer. A
personal computer is temporarily connected to the control
through the operator panel RS-232 data port or remotely
through additional communication ports.
The Form 5/Triple-Single control is constructed in a modular fashion to simplify service and the addition of accessories (see Figure 4). The standard configuration
incorporates a Central Processing Unit (CPU) module,
power supply module, Recloser Interface (RIF) module,
and an operator panel.
Discrete Interface (DIF) module(s), the fiber-optic board
and the RS-232 communication interface cards may be
ordered as accessories. Mounting provisions can be
provided to add customer-supplied radio and modem
modules.
Phase Operation
In Mode A, all three phases trip and close. In Modes B and
C, each phase operates on a separate four trip sequence,
with protection parameters the same for all three phases.
In Mode B all three phases trip to lockout when one phase
sequences to lockout. In Mode C, each phase independently sequences to lockout.
Ground Operation
In Mode A, all three phases trip and close. In Modes B and
C, ground tripping is active when all three phases are
closed. Ground trip is disabled during the reclose interval
of any one phase.
For faults above the ground minimum trip value, and
below the phase minimum trip value, all three phases trip
on ground and advance to the next sequence position.
For faults above the phase and ground minimum trip
value, the control trips on the phase(s) above phase minimum trip, operating on the phase or ground TCC,
whichever is faster. Only tripped phases advance in
sequence and are counted as phase operations.
Note: Phase and ground share the same sequence position.
As position sequence advances, the phase and ground
TCCs advance.
S280-42-3
5
!
SAFETY
FOR LIFE
Figure 3.
Form 5/Triple-Single control operational flow diagram.
FORM 5/TRIPLE-SINGLE CONTROL DESCRIPTION
BATTERIES
ACTUATOR
CT
SWITCHES
TRIPLE/SINGLE
RECLOSER
RIF
OPTICAL
ISOLATION
OPTICAL
ISOLATION
OPTICAL
ISOLATION
OPTICAL
ISOLATION
MATCHING
TRANSFORMERS
AND SIGNAL
CONDITIONING
TB1 TERMINAL BLOCK
CUSTOMER P.T. INPUTS
POWER SUPPLY
CPU
RS232
Or
FIBER-OPTIC
PORT
RS232
Or
FIBER-OPTIC
PCB
OPTIONS
OPERATOR'S
PANEL
KEYBOARD
LED's
LCD
RS232 PORT
DIF#1
(OPTIONAL)
DIF#2
(OPTIONAL)
USER
CONNECTIONS
6 unlatched outputs
6 latched outputs
12 inputs
12
12
USER
CONNECTIONS
6 unlatched outputs
6 latched outputs
12 inputs
12
12
AØ
BØ
CØ
JUNCTION
BOX
26 PIN
CONNECTOR
ACTUATOR
CT
SWITCHES
ACTUATOR
CT
SWITCHES
Sensitive Ground/Earth Fault
Operation
Sensitive Ground/Earth Fault (SGF/SEF) is active when
all three phases are closed. For SGF faults, all three
phases trip at one time.
Recloser Interface (RIF) Module
The Recloser Interface (RIF) Module provides the interface between the recloser and the CPU module, as well
as the interface between the voltage sensors and the
CPU module. The RIF module provides three current
transformer inputs, three open and close circuits and
three sets of OPEN, CLOSE, and yellow operating handle
LOCKOUT status inputs (one for each phase). These signals always indicate the true state of each Form 5/TripleSingle recloser, regardless of the position of the yellow
operating handle.
One connector on the bottom of the control cabinet provides the connection for all three phases of the Kyle Type
NOVA-TS recloser.
The RIF board accepts either 12, 120, or 240 Vac voltage
inputs for metering. The factory configuration is outlined
on the module label and can be customized to user specification. See RECLOSER INTERFACE (RIF) MODULE
CONFIGURATION section of this manual.
Central Processing Unit (CPU)
Module
The CPU module is the center of the Form 5/Triple-Single
control. The CPU contains a 32-bit micro-controller, a Digital Signal Processor, RAM and EEPROM memory, and a
16-bit analog-to-digital converter. The CPU module
accepts 16 analog inputs which it routes through the digital signal processor, which samples 32 times per cycle, to
compute harmonic analysis to the 15th harmonic.
Discrete Interface (DIF) Module
The Discrete Interface (DIF) module allows users with
existing RTUs the ability to interface with the Form
5/Triple-Single control. The DIF module contains 12
inputs and 12 outputs for remote or supervisory functions.
Each Form 5/Triple-Single control can accommodate two
DIF modules. See DISCRETE INTERFACE (DIF)
ACCESSORY section of this manual.
Power Supply Module
The Power Supply module is designed to accept 100 to
134 Vac or 200 to 268 Vac user-supplied input power at
either 50 or 60 Hz.
The Power supply module (connection P9) provides
power to the auxiliary communication equipment such as
transceivers and modems. Auxiliary output provides 24
Vdc (12 Vdc is available) for user loads. The auxiliary
power supply has the capability to provide a load of up to
40 W peak (1 second) and 3 W average. The auxiliary
power is fused and current-limited to prevent user loads
from disabling the control.
If ac power is lost, the control batteries power the control
until the battery voltage drops below 20.5 V at which point
the power supply disconnects the battery from the load.
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
6
Figure 4.
Form 5/Triple-Single UDP control operating panel with interface modules and radio mounting provisions.
99015KM
Control Cable Receptacle
and Control Grounding Lug
(located beneath cabinet)
Control Batteries
Computer Processor
(CPU) Module
Recloser Interface
(RIF) Module
TB1 Connector
Block
Power
Supply
Module
DC-to-DC Converters
(located behind operator
panel)
Grounding Strap
Manual Battery
Reconnect Button
Auxiliary Power
Connection (P9)
Form 5/Triple-Single Control
Operator Panel
The Form 5/Triple-Single control operator panel (Figure 5)
allows local operation and status interrogation through
built-in operator controls and status displays. The operator panel contains LED indicators, operational pushbuttons, membrane-type functional/indication switches,
backlit LCD display, and Hot Line Tag switch with indication. An RS232 port is also provided to permit the temporary connection of a personal computer for programming
the parameters in the control.
All indicators with the exception of Hot Line Tag and
recloser status are automatically turned off after 5 minutes
of operator panel inactivity. Reactivating is accomplished
by pressing any operation switch.
LED Indicators
The operator panel LED indicators (Figure 5) give instant
information on the control and recloser status.
LED indicators include:
CONTROL OK
This green LED is illuminated when the continuous selfdiagnostics of the control have detected no CPU or memory malfunctions and indicate that the control is capable of
normal operation.
AC POWER
This green LED is illuminated when the presence of ac
input power to the control is sensed. The LED will turn off
if ac power is lost for more than 15 seconds.
ABOVE MIN TRIP
This red LED is illuminated when the control detects that
current is above the programmed minimum trip value for
Bushings 1-2, Bushings 3-4, Bushings 5-6, Ground, or
Sensitive Ground.
CHECK BATTERY
This red indicator illuminates when the control fails a battery test. A failed test can indicate any of these conditions:
• The measured battery voltage is less than 22 volts.
• The battery voltage drops more than 2 volts during the
battery test.
• A battery is not in the unit or the battery is open.
The LED will remain on until a new battery is installed or
other corrective action occurs and a successful battery
test is completed. Refer to Battery Testing and Charg-
ing Procedures in the Testing section of this manual for
more information.
RECLOSER MALFUNCTION
This red indicator is illuminated when the control detects
a failure in a trip or close operation. It turns off automatically if the recloser returns to the proper state.
REVERSE POWER FLOW
This red indicator illuminates when the control detects
power flow from the load side to the source side of the
recloser.
Note: Voltage sensor polarity must be correct for reverse
power flow to function properly.
AØ FAULT TARGET
BØ FAULT TARGET
CØ FAULT TARGET
GROUND FAULT TARGET
SENSITIVE GROUND FAULT TARGET
These red target LEDs illuminate when the control issues
an overcurrent trip signal while the respective phase current or ground current exceeds the minimum pickup
value. Reset is accomplished automatically when Auto
Reset is activated and a successful close operation is performed or manual reset is accomplished by pressing the
RESET TARGETS button on the control operator panel.
S280-42-3
7
!
SAFETY
FOR LIFE
Figure 5.
Form 5/Triple-Single control operator panel.
LCD Display
CONTROL OK
AC POWER
ABOVE MIN TRIP
CHECK BATTERY
RECLOSER MALFUNCTION
REVERSE POWER FLOW
AØ FAULT TARGET
BØ FAULT TARGET
LED Indicators
TRIP (LOCKOUT)
Pushbutton
CLOSE Pushbutton
CØ FAULT TARGET
GROUND FAULT TARGET
SENSITIVE-GROUND FAULT TARGET
AØ VOLTAGE
BØ VOLTAGE
CØ VOLTAGE
1Ø TRIP - 1Ø LOCKOUT
1Ø TRIP - 3Ø LOCKOUT
3Ø TRIP - 3Ø LOCKOUT
CLOSED
AØ
OPEN
LOCKOUT
CLOSED
BØ
OPEN
LOCKOUT
CLOSED
CØ
OPEN
LOCKOUT
SELECT PHASES TO OPERATE
TRIP
CLOSE
(LOCKOUT)
MAX CURRENT
GND TRIP
BLOCKED
COLD LOAD
PICK UP
BLOCKED
ALTERNATE
PROFILE
NO. 1
AØ
SELECTBØSELECT
HOT LINE
TAG
ON
OFF
KYLE
FORM 5/TRIPLE-SINGLE
RECLOSER CONTROL
TX 3
RX 3
BACK
RESET
TARGETS
RESET
RECLOSING
BATTERY
ALTERNATE
PROFILE
TX 2
RX 2
NEXT
CHANGE
LAMP
TEST
NON
SUPERVISORY
BLOCKED
TEST
DISABLED
ALTERNATE
PROFILE
NO. 2
SELECT
RS232
FAST
TRIPS
NO. 3
CØ
®
LCD Display
Dedicated
Function Keys
Operation
"Hot Keys"
w/LED
Indicators
Phase Select
Keys
RS232
Data Port
Hot Line Tag
AØ VOLTAGE
BØ VOLTAGE
CØ VOLTAGE
These red voltage LEDs illuminate when the control
detects the presence of voltage on the respective bushings as connected to TB1. Refer to the Customer Con-
nections for AC Power section in these instructions to
determine the appropriate power connections.
1Ø TRIP - 1Ø LOCKOUT
1Ø TRIP - 3Ø LOCKOUT
3Ø TRIP - 3Ø LOCKOUT
Indicates the Triple -Single mode of operation (Modes C,
B, A).
CLOSED, OPEN, and LOCKOUT LEDs
Each phase has its own set of status LEDs. See Figure
6. The CLOSED red indicator illuminates when the control senses the recloser mechanism is in the closed position. The OPEN green indicator illuminates when the
control senses that the recloser mechanism is in the open
position.
This green LOCKOUT indicator is illuminated when the
recloser is open and a reclosing sequence is not in
progress or when the lockout handle on the recloser
mechanism is in the down position (i.e., trip and close circuits are open).
TRIP (Lockout) Pushbutton
The TRIP pushbutton (Figure 6) provides front-panel
access to trip (lockout) the recloser. When pressed, the
TRIP push-button manually opens the recloser and locks
out the control.
CLOSE Pushbutton
When pressed, the CLOSE pushbutton (Figure 6) manually returns the control to the initial or home position, closing the recloser. The control is ready for the start of a new
trip/close sequence.
Note: Pressing the CLOSE pushbutton from the Lockout posi-
tion, will initiate Cold Load Pickup (CLPU) protection, if
the feature is first enabled from the interface software
Protection Profile screen, and the COLD LOAD PICKUP
BLOCKED LED on the operator panel is not lit.
If the recloser is closed, pushing the CLOSE pushbutton
has no effect on the control. Depressing and holding the
CLOSE pushbutton does not activate the Cold Load
Pickup feature. See Cold Load Pickup in the Control
Features section of this manual.
The Form 5/Triple-Single control has a Manual Close
Delay feature that provides an interval of time from when
the CLOSE pushbutton is depressed to the time when
manual close operation is performed. See Manual Close
Delay in the Control Features section of this manual.
Phase Selection Keys
The Form 5/Triple-Single control has phase selection
keys (Figure 7) for the user to indicate only which phase
of the NOVA-TS Triple-Single recloser will operate when
the manual TRIP (LOCKOUT) and CLOSE pushbuttons
on the operator panel are pressed. When the TRIP or
CLOSE buttons are pressed, only the phases that are
selected (LED on) will trip or close. For complete operation instructions, refer to the Manual Control Operation
section of this manual.
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
8
Figure 6.
Recloser status LEDs for each phase and manual
trip and close pushbuttons.
Figure 7.
Phase SELECT keys for operation with TRIP and
CLOSE pushbuttons.
1Ø TRIP - 1Ø LOCKOUT
1Ø TRIP - 3Ø LOCKOUT
3Ø TRIP - 3Ø LOCKOUT
CLOSED
OPEN
LOCKOUT
CLOSED
OPEN
LOCKOUT
CLOSED
OPEN
LOCKOUT
AØ
BØ
CØ
AØ
SELECT
BØ
SELECT
CØ
SELECT
SELECT PHASES TO OPERATE
TRIP
(LOCKOUT)
CLOSE
RS232 Communication Port
The standard Form 5/Triple-Single control is equipped
with an operator panel RS232 port for interface with a personal computer running the Form 5/Triple-Single interface
software program. This nine-pin female data communication equipment (DCE) Port 1 permits the uploading of all
programming information stored in the control, including
protection profiles, event recorder, data profiles, alarms,
counters, and metering information. Port 1 provides a simple means to download operating parameters from a personal computer to the control.The protocol, baud rate and
address for Port 1 are identified from the LCD display.
If a fiber-optic or RS232 accessory board is connected to
Port 2 (located on the back of the operator panel) any
external electrical connection from the operator panel will
disable the accessory board.
Note: The operator panel RS232 port is intended only for tem-
porary connection of a personal computer. Permanent
serial communications must be made via the RS232 or
fiber-optic accessory board.
LCD Display
The control operator panel has a large, backlit LCD display (Figure 8) used for viewing control parameters and
monitoring system conditions. Data is organized into
messages or “screens” of information, with each screen
containing four lines of information, with up to 20 characters per line. Access to the messages is obtained through
navigational keys which permit the user to scroll through
the menu in a timely and efficient manner.
When an overcurrent trip occurs, the control automatically
displays the fault current values as shown on the LCD display as Screen 2 (see LCD Display Messages section of
this manual).
NEXT Key
Pressing the NEXT key causes the LCD display to scroll
to the next screen of available information. Pressing and
holding the NEXT key causes the control to scroll to subsequent screens at the rate of about two screens per
second.
BACK Key
Pressing the BACK key causes the LCD display to scroll
to the previous screen of available information. Pressing
and holding the BACK key causes the control to scroll to
previous screens at a faster rate.
RESET TARGETS/RESET MAX
CURRENT Key
Pressing the RESET TARGETS/RESET MAX CURRENT
key will reset the fault target indicators on the control operator panel. The fault current values shown on Screen 1 of
the LCD display will reset to values of zero.
Pressing and holding the RESET TARGETS/RESET
MAX CURRENT key for three seconds will reset the minimum and maximum current and histogram values in LCD
Display Screens 34 through 37. This key will also reset the
Trip Failure Detection feature. See the Control Features
section of this manual.
CHANGE/LAMP TEST Key
Pressing this key for less than three seconds places the
control into a CHANGE mode for 10 seconds as indicated
by the LCD display. CHANGE mode permits the user to
change the state of the nine function/indicator switches on
the operator panel. Security is enhanced by permitting a
only one selection for each CHANGE mode period.
Pressing and holding the CHANGE/LAMP TEST key for
three seconds will cause the control to perform a frontpanel lamp test. In the Lamp Test Mode, the status indicators flash three times (one second on, one second off).
All status indicators then return to their previous state.
While in the Lamp Test Mode, the control response to
operator panel keys is disabled, except for the TRIP
(LOCKOUT), CLOSE, and HOT LINE TAG switches.
S280-42-3
9
!
SAFETY
FOR LIFE
Figure 8.
LCD display and dedicated function keys.
NEXT
RESET
TARGETS
RESET
MAX CURRENT
BACK
CHANGE
LAMP
TEST
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
10
LCD Display Screens
Every screen contains a parameter name, parameter
value, and parameter units. If the control detects that a
parameter value is invalid, the LCD display shows five
dash characters (- - - - -) in the value field of the message.
Demand metered values are indicated by (D) and instantaneous values by (I).
1 G nd ____________ A
Ph1-2 ____________ A
Ph3-4 ____________ A
Ph5-6 ____________ A
2 Gnd Fault ____________ A
Ph1-2 Fault ____________ A
Ph3-4 Fault ____________ A
Ph5-6 Fault ____________ A
3 F req Tri p____________ Hz
Time Date
Present Freq ____________ H z
4 Ph1-N VTrip ____________ V
Ph3-N VTrip ____________ V
Ph5-N VTrip ____________ V
Time Date
5 T ot ____________ k Wh
Ph1-2 ____________ k Wh
Ph3-4 ____________ k Wh
Ph5-6 ____________ k Wh
6 Instant S1 Ph-N
Ph1-N ____________ V
Ph3-N ____________ V
Ph5-N ____________ V
7 Instant S1 Ph-Ph
Ph1-3 ____________ V
Ph3-5 ____________ V
Ph5-1 ____________ V
8 Instant S2 Ph-N
Ph2-N ____________ V
Ph4-N ____________ V
Ph6-N ____________ V
9 Instant S2 Ph-Ph
Ph2-4 ____________ V
Ph4-6 ____________ V
Ph6-2 ____________ V
Screen 1 - Instantaneous Load Current
Screen 1 displays line current values present for the last
overcurrent trip operation. Values are reset to zero when
the fault targets are reset.
Screen 2 - Fault Targets
Screen 3 - Frequency Trip
Screen 4 - Voltage Trip
Screen 8 - S2 Phase-to-Neutral, Instant. Voltage
Screen 5 - Power kWh
Screen 6 - S1 Phase-to-Neutral, Instant. Voltage
Screen 9 - S2 Phase-to-Phase, Instant. Voltage
Screen 7 - S1 Phase-to-Phase, Instant. Voltage
11 Tot ____________ kW
Ph1-2 ____________ kW
Ph3-4 ____________ kW
Ph5-6 ____________ kW
Screen 11 - Real Power
10 Instant S1-S2
Ph1-2 Dif ____________ V
Ph3-4 Dif ____________ V
Ph5-6 Dif ____________ V
Screen 10 - Instantaneous Voltage
S280-42-3
11
!
SAFETY
FOR LIFE
14 Tot ____________ PF
Ph1-2 ____________ PF
Ph3-4 ____________ PF
Ph5-6 ____________ PF
15 Gnd ____________ %THDI
Ph1-2 ____________ %THDI
Ph3-4 ____________ %THDI
Ph5-6 ____________ %THDI
16 Instant S1 Ph-N
Ph1-N ____________ %THDV
Ph3-N ____________ %THDV
Ph5-N ____________ %THDV
17 Demand S1 Ph-N
Ph1-N(d) ____________ V
Ph3-N(d) ____________ V
Ph5-N(d) ____________ V
19 Demand S2 Ph-N
P h2 - N( d ) ____________ V
P h4 - N( d ) ____________ V
P h6 - N( d ) ____________ V
20 Demand S2 Ph-Ph
Ph2-4(d) ____________ V
Ph4-6(d) ____________ V
Ph6-2(d) ____________ V
13 Tot ____________ kVAr
Ph1-2 ____________ kVAr
Ph3-4 ____________ kVAr
Ph5-6 ____________ kVAr
12 Tot ____________ kVA
Ph1-2 ____________ kV A
Ph3-4 ____________ kV A
Ph5-6 ____________ kV A
Screen 17 - Demand Phase to Neutral Voltage
Screen 18 - Demand Phase-to-Phase Voltage
Screen 12 - Instantaneous kVA
Screen 19 - Demand Phase-to-Neutral Voltage
Screen 13 - Instantaneous kVAR
Screen 20 - Demand Phase-to-Phase Voltage
Screen 14 - Instantaneous Power Factor
Screen 15 - Instantaneous Total Harmonic Distortion
Current
Screen 16 - Instantaneous Total Harmonic Distortion
Voltage
21 Demand S1-S2
Ph1-2(d) ____________ V
Ph3-4(d) ____________ V
Ph5-6(d) ____________ V
Screen 21 - Demand Voltage
18 Demand S1 Ph-Ph
Ph1-3 (d) ____________ V
Ph3-5(d) ____________ V
Ph5-1(d) ____________ V
22 Gnd ____________ A
Ph1-2 (d) ____________ A
Ph3-4 (d) ____________ A
Ph5-6 (d) ____________ A
23 Tot (d) ____________ k W
Ph1-2(d) ____________ k W
Ph3-4 (d) ____________ k W
Ph5-6 (d) ____________ k W
Screen 22 - Demand Current
Screen 23 - Demand kW
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
12
24 Tot ____________ k VA
Ph1-2(d) ____________ k VA
Ph3-4(d) ____________ k VA
Ph5-6(d) ____________ k VA
25 Tot ____________ kVAr
Ph1-2(d) ____________ kVAr
Ph3-4(d) ____________ kVAr
Ph5-6(d) ____________ kVAr
26 Tot ____________ PF
Ph1-2(d) ____________ PF
Ph3-4(d) ____________ PF
Ph5-6(d) ____________ PF
27 Gnd ____________ %THDI
Ph1-2(d) ____________ %THDI
Ph3-4(d) ____________ %THDI
Ph5-6(d) ____________ %THDI
28 Demand S1 Ph-N
Ph1-N(d) ____________ %THDV
Ph3-N(d) ____________ %THDV
Ph5-N(d) ____________ %THDV
29 Gnd OC Trip ____________
Ph1-2 OC Trip ____________
Ph3-4 OCTrip ____________
Ph5-6 OC Trip ____________
30 SGF OC Trip ______
Ph1-2 Ops ______
Ph3-4 Ops ______
Ph5-6 Ops ______
31 Battery Monitor
Normal _______ V
Normal _____ mA
Test _______ V
32 – Phase MT ______ A
ALT1 MT ______ A
ALT2 MT ______ A
ALT3 MT ______ A
Screen 24 - Demand kVA
Screen 25 - Total kVAr and kVAr per Phase
Screen 26 - Demand Power Factor
Screen 27 - Demand THD Current
Screen 28 - Demand THD Voltage
Screen 29 - Number of Trips for Ground and Phase
Screen 30 - SGF Overcurrent Trip and Operations
Counter
Screen 31 - Battery Monitor
The Battery Monitor displays the battery voltage, current,
and voltage during a battery test. The Battery Monitor is
used with the Battery Test pushbutton. Refer to the Bat-
tery Test Procedure section of these instructions for
more information.
Screen 32 - Phase Minimum Trip Settings
Phase minimum trip settings are listed for the four protection profiles. Line 1 is the normal setting, ALT1 is profile
No. 1, ALT2 is profile No. 2, and ALT3 is profile No. 3.
Phase Minimum Trip Settings allow verification of trip settings before selection of an alternate profile.
35 Ph 3-4 Max ____________A
Time Date
Ph5-6 Max ____________A
Time Date
Screen 35 - Phase 3-4 Max, Phase 5-6 Max Demand
Currents
33 Gnd MT ______ A
Al t1 M T _______ A
Al t2 M T ______ A
Al t3 M T _ ______ A
34 Gnd Max ____________A
Time Date
Ph1-2 Max ____________A
Time Date
Screen 33 - Ground Minimum Trip Settings
Ground minimum trip settings are listed for the four protection profiles. Line 1 is the normal setting, ALT1 is profile No. 1, ALT2 is profile No. 2, and ALT3 is profile No. 3.
Ground Minimum Trip Settings allow verification of trip
settings before selection of an alternate profile.
Screen 34 - Ground Max, Phase 1-2 Max Demand
Currents
Operation/Indication Pushbuttons
Nine frequently-used features are provided on the control
operator panel (Figure 9).
Note: These features are activated from the keypad, control
interface software, or SCADA signal.
To initiate an operation from the operator panel, press the
CHANGE/LAMP TEST key to enter the CHANGE mode.
The operator has 10 seconds to select an operation and
modify settings. If no changes are made, the control will
return to its operational state prior to entering the
CHANGE mode. This prevents accidental changing of
settings.
Red LEDs located on each switch indicate the status of
the function, regardless of local or remote activation. For
example, if Cold Load Pickup was activated from a
SCADA signal, the red indicator would illuminate even
though it was not activated from the operator panel.
Note: Operation LEDs activated from local or remote sources
do not illuminate when the operator panel is in the power
save mode.
GND TRIP BLOCKED
Ground Trip Blocked is activated by pressing the
CHANGE/LAMP TEST key then pressing the GND TRIP
BLOCKED key. The red indicator illuminates.
NON RECLOSING
Non-Reclosing mode disables any automatic reclosing
operations. Non-reclosing does not alter the active TCC.
The feature is activated by pressing the CHANGE/LAMP
TEST key, then pressing the NON-RECLOSING key. The
red indicator illuminates.
S280-42-3
13
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SAFETY
FOR LIFE
Figure 9.
Operation/indication pushbuttons.
37 Ph3-4 Min ____________A
Time Date
Ph5-6 Min ____________A
Time Date
40 – Comm Port 2 ______
Protocol _______
Speed _______
Address _______
41 – Comm Port 3 ______
Protocol _______
Speed _______
Address _______
36 Gnd Min ____________A
Time Date
Ph1-2 Min ____________A
Time Date
38 Fault Location
Distance ____________miles
<Control Identification>
Time Date
39 CPU Firmware X.XX
Firmware FW Database X
<Control Identification>
Time Date
Screen 38 - Fault Location
Screen 36 -Ground Min, Phase 1-2 Min Demand
Currents
Screen 39 - Control Information
Screen 40 - Communication Port 2 Settings
This message displays the protocol settings (2179 or
DNP3.0), baud rate, and address for Serial Port #2.
Baud rate and address are set using the interface software, while protocol is set at the factory based on user’s
specifications.
Screen 37 - Phase 3-4 Min, Phase 5-6 Min Currents
Screen 41 - Communication Port 3 Settings
This message displays the protocol settings (2179 or
DNP3.0), baud rate, and address for Serial Port #3.
Baud rate and address are set using the interface software, while protocol is set at the factory based on user’s
specifications.
Note: Demand currents are a time integrated value and do not
reflect minimum or maximum instantaneous currents.
The demand integration time constant is set via the
interface software demand metering screen. These are
the same values displayed in the histogram screen.
Note: Pressing and holding the RESET TARGETS/RESET
MAX CURRENT key for three seconds will reset the
minimum and maximum Demand values.
GND TRIP
BLOCKED
COLD LOAD
PICKUP
BLOCKED
NON
RECLOSING
BATTERY
TEST
SUPERVISORY
BLOCKED
FAST
TRIPS
DISABLED
ALTERNATE
PROFILE
NO. 1
ALTERNATE
PROFILE
NO. 2
ALTERNATE
PROFILE
NO. 3
SUPERVISORY BLOCKED
SUPERVISORY BLOCKED disables supervisory SCADA
and interface software; remote SCADA remains active.
Operational data and metering information are available
while the control is in the SUPERVISORY BLOCKED
position. The TRIP and CLOSE pushbuttons are active
independently of the SUPERVISORY BLOCKED key.
Activation of the feature is restricted to the operator panel
keypad by pressing the CHANGE/LAMP TEST key, then
pressing the SUPERVISORY BLOCKED key.
COLD LOAD PICKUP BLOCKED
The Cold Load Pickup (CLPU) feature is blocked while the
CLOD LOAD PICKUP BLOCKED IS active. When CLPU is
not blocked, the control utilizes the Cold Load Pickup TCC,
reclose interval, operations to lockout and minimum trip settings in lieu of the normal first operation protection settings.
Note: The Cold Load Pickup Blocked key is replaced by the
SENSITIVE GROUND FAULT (SGF) key on international controls.
BATTERY TEST
Depressing the BATTERY TEST key performs a control
battery test. The red indicator illuminates and turns off
automatically when the control has finished performing the
test. Refer to Battery Testing and Charging Procedures
in the Testing section of this manual for more information.
The control performs a self-test every 12 hours or when
initiated by an external command. When a battery test is
initiated, the spurious charge is first drained to allow the
battery voltage to equalize. A 10-ohm, 55-watt resistor is
then placed across the battery terminals and a voltage
drop is calculated. If the drop from the equalized voltage
to the test voltage exceeds 2 volts, then the CHECK BATTERY LED is illuminated.
FAST TRIPS DISABLED
Fast Trips Disabled commands the control to use the programmed Fast Trips Disabled time-current curve for all
tripping operations.
ALTERNATE PROFILE Indicator/Key
The control has four separate protection profiles; a 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 selection key.
During control operation, if the three alternate profile indicator lights are not illuminated, the normal profile is active.
To select an alternate profile, press the CHANGE/LAMP
TEST key, then press the desired alternate profile. To
return to the normal profile, simply turn off the active alternate profile. These functions can also be operated
remotely via communications interfaces.
Note: The minimum trip values for each protection profile are
shown on Screens 32 and 33 of the LCD display. Check
these minimum trip values prior to changing an alternate
profile to avoid misoperation of the control under load
conditions.
Note: On Form 5/Triple-Single UDP controls, Alternate Profile
3 is replaced with SWITCH MODE. See FORM 5 LS
UNIVERSAL DEVICE PROTECTION (UDP) section of
this manual.
HOT LINE TAG ON/OFF Toggle Switch
and LED Indicator
Hot Line Tag is provided for live-line work applications. All
closing operations are disabled when the Hot Line Tag
feature is activated. While active, the control utilizes an
independent, user-selectable time-current curve for trip
operations.
The Hot Line Tag feature (Figure 10) consists of a toggle
switch and an LED indicator which illuminates when the
function is active. When active, Hot Line Tag prevents all
closing attempts and shifts protection to one trip-to-lockout on the programmed time-current curve. The Hot Line
Tag function takes precedence over Cold Load Pickup,
Non Reclosing, and Fast Trips Disabled.
Activation is accomplished by placing the operator panel
toggle switch to the ON position, or via SCADA command.
Hot Line Tag is activated from the operator panel, communication Port 2, communication Port 3, or a Discrete
Interface Module (DIF). All sources must be off to de-activate Hot Line Tag.
The Hot Line Tag feature may only be reset by the source
which initiates the function. For example, if Hot Line Tag
is activated at the operator panel, the reset function is
only possible at the operator panel, and not via SCADA
command. For SCADA, Hot Line Tag must be disabled
via the same port number where Hot Line Tag was originally enabled.
Note: Hot Line Tag automatically changes the mode of opera-
tion to 3-Phase Trip–3-Phase Lockout. If a fault occurs
while in Hot Line Tag, all three phases trip once per the
user-selectable TCC.
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
14
Figure 10.
Hot Line Tag Switch.
WARNING: Hazardous voltage. Do not use Hot
Line Tag as a substitute for a visible disconnect.
Always establish a visible disconnect prior to performing any work requiring a de-energized line. Failure to
comply may cause death, severe personal injury, or
equipment damage. T276.0
IMPORTANT: Hot Line Tag is intended solely for
live-line work applications, such as maintenance,
repairs or improvements to the distribution system, that
occur while the line remains energized.
IMPORTANT: Hot Line Tag activation does not
cause the recloser to trip open. It only prevents the
recloser from closing.
!
HOT LINE
TAG
ON
OFF
Manual Control Operation
Each single-phase unit in the NOVA-TS Triple-Single
recloser represents either A, B, or C phase. Phase selection
keys (Figure 7) are used to select a phase that will operate
when a manual TRIP or CLOSE operation is activated.
Note: Before selecting a phase for operation, press the
CHANGE/LAMP TEST key.
Manual operation of the yellow handles on the NOVA-TS
triple-single recloser is used to open and lockout the
phases, and disable the electrical and supervisory closing. The recloser mode of operation determines which
phases open and close. The Form 5/Triple-Single control
initiates the close signal.
3Ø Trip – 3Ø Lockout (Mode A) or
1Ø Trip – 3Ø Lockout (Mode B)
If the control is in Three-Phase Trip – Three-Phase Lockout (Mode A) or Single-Phase Trip – Three-Phase Lockout (Mode B), all three phases are permanently selected
and all three PHASE SELECT LEDs are illuminated.
When one phase is opened with the yellow operating handle, all three phases open and lockout The OPEN and
LOCKOUT LEDs illuminate on the control panel.
With the yellow operating handle of the appropriate phase
in the CLOSE position, press the CLOSE pushbutton on
the control operator panel. All three phases close and the
CLOSED LEDs for all three phases illuminate.
1Ø Trip – 1Ø Lockout (Mode C)
When in Single-Phase Trip – Single-Phase Lockout
(Mode C) any combination of phases can be selected and
the respective PHASE SELECT LED illuminates. Each
selected phase must be closed individually.
When the selected phase is opened with the yellow operating handle, only that phase opens and locks out. The OPEN
and LOCKOUT LEDs illuminate on the control panel.
With the yellow operating handle of the selected phase in
the CLOSE position, press the CLOSE pushbutton on the
control panel. The phase closes and the CLOSED LED for
that phase illuminates.
Control Features
The Form 5/Triple-Single recloser control offers numerous standard features and accessories that allow the user
the utmost flexibility in designing a control suitable for
their application requirements.
Under/Over Frequency Loadshedding
The Form 5/Triple-Single control includes provisions for
frequency loadshedding that trips the recloser for conditions of under or over system frequency. Access to this
feature is through frequency threshold, trip time, and
allowable voltage threshold.
With the auto-restoration feature, the Form 5/Triple-Single
control can be set to close the recloser after the system
frequency and voltage have recovered. Parameters available for setting include frequency and voltage thresholds
and time delay.
A frequency alarm is available and can be configured for
notification.
S280-42-3
15
!
SAFETY
FOR LIFE
WARNING: Hazardous Voltage. Do not rely on
the open position of the yellow operating handle;
it does not ensure that the line has been de-energized.
Always establish a visible disconnect. Failure to follow
proper safety practices can result in contact with high
voltage, which will cause death or severe personal
injury. G116.0
!
IMPORTANT: Pushing the yellow operating handle
to the CLOSE position will not close the recloser. All
close operations are initiated by the Form 5/Triple-Single control.
IMPORTANT: Pushing the yellow operating handle to
the CLOSE position will not close the recloser. All close
operations are initiated by the Form 5/Triple-Single control.
IMPORTANT: If more than 5 minutes elapses since the
last panel operation, all the LEDs, except CONTROL OK,
will turn off and all three phases will be selected. Deselect
the phases you do not want activated, and then press the
TRIP or CLOSE button.
Voltage Protection (120 Vac-based)
Voltage protection functionality is included as standard on
Form 5/Triple-Single controls. A recloser trip is issued for
under and over voltage conditions when the monitored
voltage falls outside user specified limits for a selectable
time. Response mode includes:
• any single-phase
• all three phases
• single-phase with three-phase inhibit.
Response mode facilitates protection against a single
phase condition common when a high-side fuse operates
on a distribution transformer. Parameters are also available to provide auto restoration after a trip. A voltage
alarm is available and can be configured for notification.
Protection Profiles
Four separate protection profiles are included to allow the
user to adapt overcurrent settings for varying system conditions such as load, live line work or weather. The active
profile is selected from the operator panel, the interface
software or SCADA (see Figure 11). Each profile has 14
TCC specifications plus reclose intervals, sequence coordination and reset times to maintain independent protection parameters.
Power Metering
Power metering includes single- and three-phase Watts,
VARS, KVARS, KWH measurements, and the per phase
and total system Power Factor (PF).
Power Factor Sign Metering
This feature allows a user to configure the sign that is
applied to the power factor. The user selects between the
definition of power factor (cosine of angle between current
and voltage) or the power factor sign following power flow.
Trip Failure Detection
The Trip Failure Detection feature is an internal diagnostic alarm for verifying the proper operation of circuit tripping and fault clearing of the recloser. Trip Failure
detection indicates the recloser has failed to trip all
phases following a trip signal from the control. Failure to
trip is assumed if a current of at least 10 Amps is detected
approximately 2 seconds after the trip signal is initiated.
Upon activation of the feature the following four LEDs
flash 1 second on, 1 second off (see Figure 12):
RECLOSER MALFUNCTION
RECLOSER CLOSED
RECLOSER OPEN
CONTROL LOCKOUT
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
16
Figure 12.
RECLOSER MALFUNCTION, OPEN, CLOSED, and
LOCKOUT LEDs will blink for the affected phase as
indication of Trip Failure.
Figure 11.
Interface software sample protection profile.
DANGER: Explosion. Stay clear of a recloser
that is in a trip failure mode. A recloser in trip failure mode may explode resulting in death or severe personal injury. T271.0
!
IMPORTANT: The recloser must be isolated and deenergized immediately upon detection of trip failure.
Follow proper procedures and safety practices to isolate and de-energize the recloser.
WARNING: Hazardous voltage. This device is
not a substitute for a visible disconnect. Follow all
locally approved safety practices. Failure to follow
proper safety practices can result in contact with high
voltage, which will cause death or severe personal
injury. G112.1
!
RECLOSER MALFUNCTION
REVERSE POWER FLOW
AØ FAULT TARGET
BØ FAULT TARGET
CØ FAULT TARGET
GROUND FAULT TARGET
SENSITIVE-GROUND FAULT TARGET
AØ VOLTAGE
BØ VOLTAGE
CØ VOLTAGE
1Ø TRIP - 1Ø LOCKOUT
1Ø TRIP - 3Ø LOCKOUT
3Ø TRIP - 3Ø LOCKOUT
CLOSED
AØ
OPEN
LOCKOUT
CLOSED
BØ
OPEN
LOCKOUT
CLOSED
CØ
OPEN
LOCKOUT
SELECT PHASES TO OPERATE
TRIP
CLOSE
(LOCKOUT)
The Trip Failure Detection alarm may be triggered from
many potential sources including mechanical, electrical,
control, or interrupter failure. Interrupter failure may
include loss of vacuum in a vacuum interrupter.
To clear Trip Failure Alarm, depress and hold the RESET
TARGETS/RESET MAX CURRENTS keypad for 3 seconds. This also resets targets and demand currents.
Note: There is no remote reset available with the trip failure
detection feature. It cannot be remotely turned off.
When the trip failure alarm is activated, an event is
recorded and a status alarm activated (if enabled) and
preserved during system resets.
Manual Close Delay
Manual Close Delay provides a delay from the time that
the manual CLOSE button is pushed to the time the manual close operation is performed. The CLOSED LED for
the affected phase blinks indicating the feature is active.
See Figure 13.
The delay is programmable from 0 to 60 seconds in one
second increments. A programmed delay value can be
overridden for immediate closing by pressing the CLOSE
button a second time.
An active Manual Close Delay can be canceled by pressing the TRIP/LOCKOUT button.
The default setting has the feature disabled (0 seconds).
Voltage Metering
Six voltages (3-source and 3-load) are metered as standard on the Form 5/Triple-Single control. The user selects
either line-to-neutral or line-to-line values from the control
operator panel, interface software, or serial communications. The type of value is changed by selecting “Voltage
Configuration” in the “Hardware” setup portion of the interface software.
Fast Trips Disabled
Fast Trips Disabled provides the user a quick and efficient
method for reducing momentary interruptions or “blinks”.
When activated from the front keypad (Figure 9), programmed trips to lockout will time according to the
selected time-current curve for Fast Trips Disabled. This
curve is programmable for both phase and ground on
each protection profile. A separate trips-to-lockout setting
is also provided.
Histograms
Demand metered voltages and currents can be reported
using the histogram tool. It displays the number of occurrences of a variable versus its value within user-defined
minimum and maximum limits. Date and time are
recorded for the maximum and minimum demand values.
Reverse Power Flow
Feeder load monitoring is enhanced with the inclusion of
the power flow monitoring feature. When power flow from
the load to the source side of the recloser is detected, the
control and illuminates a front-panel indicator. Response
time to a reverse power condition is one second. An alarm
is also available for remote interrogation.
Note: Voltage sensor polarity must be correct for reverse
power flow to function properly.
Harmonic Analysis
Extensive harmonic analysis is performed by the Form
5/Triple-Single control for both currents and voltages.
Analysis is performed on-line (updates every 30 seconds)
or demand integrated to user-specified time values. The
Total Harmonic Distortion (THD) for current and voltage is
available from the operator panel display (Figure 14) while
complete analysis, including graphing capabilities, is provided from the Form 5/Triple-Single interface software.
Event Recorder
The Event Recorder maintains a log of operating events
for later readout and analysis by the user. Approximately
500 events can be stored in non-volatile memory. For
each event type, time of occurrence, and other relevant
information is stored. When the event recorder has
reached capacity, the oldest event is deleted as a new
event is added.
S280-42-3
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!
SAFETY
FOR LIFE
Figure 14.
Triple-Single operator panel harmonic readout.
Figure 13.
CLOSED LED blinks for the affected phase as indication of Manual Close Delay.
CLOSED
OPEN
LOCKOUT
CLOSED
OPEN
LOCKOUT
CLOSED
OPEN
LOCKOUT
AØ
BØ
CØ
Pg14 Gnd THDI
Ph1-2 THDI
Ph3-4 THDI
Ph5-6 THDI
NEXT
RESET
TARGETS
RESET
MAX CURRENT
BACK
CHANGE
LAMP
TEST
Data Profiler
A fully-configurable data profiler is available which allows
the user to collect information by sampling demand data
at selectable intervals. These time-stamped values can
then be plotted to determine weekly load profiles, daily
harmonic disturbances or hourly voltage fluctuations. The
data profiler can provide more than 200 days of information, depending upon configuration parameters.
Cold Load Pickup
Cold Load Pickup (CLPU) must be enabled through the
interface software (Figure 15) before it can be activated
remotely or from the CLOSE pushbutton on the operator
panel. The CLPU feature provides the user with the ability to alter protection for abnormal system conditions. It is
active for a programmable time interval which begins with
each manual close. Once this time elapses, protection
reverts back to the programmed sequence. Use the Form
5/Triple-Single control interface software to program the
activation time and time-current characteristics applicable
for Cold-Load Pickup.
Note: When CLPU is active, the control utilizes the Cold Load
Pickup TCC, reclose interval, operations to lockout and
minimum trip settings in lieu of the normal protection
settings.
Alarms
Status and data alarms are available for many control
parameters such as voltage and current thresholds. Data
alarm function compares metered data to user-programmed alarm high and low limits and issues an alarm of
user-specified priority if limits are exceeded. The status
alarm function monitors status and issues an alarm of
user-defined priority when the user-programmed alarm
conditions are met. The alarms are reported via communication ports and can be configured to trigger a data profile and event record. Alarms do not affect the protection
functions of the control.
Status alarms are included for Modes A, B, and C as well
as the following status alarms for each phase of the Kyle
Type NOVA-TS Triple Single recloser:
• Open • Retry Fail
• Closed • Open Fail
• Lockout • Neither Open or Closed
• Close Retry Active • Yellow Handle Active
• Close Fail
Fault Location
Fault Location provides an approximate distance of a fault
from the the Form 5/Triple-Single control. The distance is
based on the current fault magnitude, the type of fault,
and system parameters entered by the user. The LCD display (Screen 38) identifies the estimated distance in miles
or kilometers (km) from the control.
The fault location algorithm performs an impedance calculation based on:
• Single-phase to ground fault
• Phase-to-phase fault
• Double-line to ground fault
• Three-phase fault
This information is recorded as an event in the control
Event Recorder for retrieval. The fault location algorithm
does not require voltage sensing. If the location cannot be
determined, no event is recorded and dashes are displayed on the LCD screen.
Setting the parameters for Fault Location is done through
the interface software. The user enters line impedance
parameters and system voltage information into the software via the Protection Profile menu. See Figure 16.
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
18
Figure 15.
Interface software Cold Load Pickup settings.
(Accessed from the Operations Parameters screen.
See Figure 11.)
Figure 16.
Fault Location configuration screen.
The following system parameters must be entered via the
Protection Profile menu for each profile:
• Nominal system line-to-line voltage
Note: If the Fault Location feature is not desired, the nom-
inal system voltage parameter should be set at 1.
• Source-side zero sequence and positive sequence
impedance. This includes impedance up to the location of the Form 5/Triple-Single control.
• Line-side zero sequence and positive sequence
impedance per mile or km.
• The distance units of the line impedance in miles or
km.
Refer to Service Information S280-79-2 Form 5 Micropro-
cessor-Based Recloser Control Programming Guide for
additional information.
Directional Sensitive Ground/Earth
(SGF/SEF) Fault
The Directional SGF/SEF Fault feature adds directional
capabilities to the SGF/SEF protection features. It provides a sensitive ground/earth trip if the fault is downline
of the recloser on a radial distribution system. Directional
SGF/SEF is used on ungrounded Delta systems for suppression of ground trips for faults occurring on other circuit
branches.
The user sets the parameters for Direction SGF/SEF
through the interface software via the Protection Profile
menu. See Figure 17. In addition to the normal (non-directional) SGF/SEF settings, the user enters the following
directional SGF/SEF parameters:
• Direction Enable
Note: If Direction Enable is not selected, SGF/SEF tripping
occurs through normal (non-directional) settings.
• Maximum Torque Angle (-180° to 180°, in 1° increments)
• Torque Angle Width (10° to 90°, in 1° increments)
• Zero Sequence Voltage (V
0
)
Threshold (4 to 130 V)
The Maximum Torque Angle parameter determines the
angle of maximum tripping sensitivity between the phase
angle of the zero sequence voltage and current at the time
of fault. The setting of this value depends on knowledge
of the power system. Typically a resistive fault has a value
of 0°, and a capacitive fault has a value of 90°.
Torque Angle Width parameter restricts the tripping to an
angle of plus or minus the specified width about the
Torque angle setting. For example, if the Maximum
Torque Angle is 45°, and the Torque Angle Width is set for
10°, then the control will trip at angles between 35° and
55°.
The Zero Sequence Voltage Threshold is used to set the
threshold voltage below the disabled directional SGF/SEF
tripping voltage.
Note: In most cases, a default value of 4 is adequate.
Directional SGF/SEF Fault is recorded as an event in the
control Event Recorder for retrieval. Refer to Service
Information S280-79-2 Form 5 Microprocessor-Based
Recloser Control Programming Guide for additional
information.
S280-42-3
19
!
SAFETY
FOR LIFE
IMPORTANT: Fault Location is not a protection function. Its purpose is to define a fault and provide its
approximate location relative to the Form 5/Triple-Single control detecting the fault.
Figure 17.
Directional SGF/SEF configuration screen.
Communications
Communication Ports
The Form 5/Triple-Single control has three communication ports from the CPU module. Two of the three ports
are user-accessible. Communication Port 1 is the operator panel LCD display where data is exchanged between
the CPU and the operator panel. Though not-user-configurable, Port 1 allows for flexible modifications to the front
panel for custom applications.
The operator panel RS-232 communication Port 2 provides temporary local personal computer (PC) access
when connected with a standard 9-pin cable. Port 2 provides a dual communication interface for the user. The
port includes a software switch for two external connections; the operator panel RS-232 DB-9 connector, or the
fiber-optic/RS-232 communication accessories. Local
connection to the operator panel RS-232 connection
takes precedence over the communication accessory.
Disconnecting the operator panel RS-232 communication
automatically reconnects the communication accessory
to Port 2.
Accessory Ports 2 and 3 are resident on the back of the
operator panel and can be configured to either 2179 or
DNP3.0 protocols. Port 3 provides uninterrupted communication to the RS-232 or Fiber-Optic accessory, and is
not affected by any other port or physical connection.
Figure 18 illustrates the communication configuration for
serial ports 1, 2, and 3.
Fiber-Optic and RS-232 Accessories
Two sets of receive and transmit LEDs (Figure 19) are
provided on the operator panel for fiber-optic and RS-232
communications. The TX2 and RX2 LEDs illuminate when
communicating with the operator panel RS-232 port. The
TX3 and RX3 LEDs illuminate when communicating with
either the fiber-optic or RS-232 interface accessory
boards on communication Port 3.
The RS-232 accessory board and the fiber-optic accessory boards are located behind the operator panel. Each
accessory board can be connected to either Port 2 or Port
3; no two boards can use the same port. The operator
panel LEDs indicate the status of communication on the
accessory boards. Temporary connections to the operator
panel RS-232 port disables fiber-optic or RS-232 communication at Port 2.
Port 3 provides uninterrupted communication to a remote
terminal unit (RTU). Refer to Service Information S280-
79-4 Form 5 and Form 5/Triple-Single Recloser Control
Fiber-Optic/RS-232 Serial Communications Accessory
Operation Instructions for additional information.
Protocols
Three protocols are available for the Form 5/Triple-Single
control and are configurable to serial communication
Ports 2 and 3.
The protocols are:
• Cooper Power Systems 2179
• DNP3.0, Level 3
• S-Comm Protocol accessory
Protocol DNP3.0 includes “Unsolicited Report by Exception” functionality and Protocol 2179 includes 2-bit status
functionality.
Complete documentation for Cooper Power Systems protocols are:
• Reference Data R280-90-12, Serial Communication
Protocol 2179
• Reference Data R280-90-13, Communication Point
Database for Protocol 2179
• Reference Date R280-90-14, Communication Point
Database for Protocol DNP3.0
Control Information
Control information, including firmware version and
database version, is factory installed and can not be
altered by the user. This information is accessible from
the LCD display, Screen 39.
Communication Ports 2 and 3 settings can be referenced
from the LCD display, Screen 40 and 41 respectively.
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
20
Figure 18.
Control communication port configuration.
Figure 19.
Fiber-Optic/RS-232 receive and transmit LEDs and
data port on the operator panel. The TX2 and RX2
LEDs illuminate during communication with the
operator panel RS232 port.
FRONT PANEL
DISPLAY
OPERATIONS
COMMUNICATIONS PORT 1
CONTROL
TRIPLE-SINGLE
INTERFACE
T/S RECLOSER
CLOSED
CLOSED
ALTERNATE
COMMUNICATIONS
COMMUNICATION
SYSTEM
ENGINEERING
COMMUNICATIONS PORT 2 COMMUNICATIONS PORT 3
CPU
METERING
HISTOGRAMS
PROFILES
ALARMS
TARGETS
COMMUNICATION
SYSTEM
SCADA
BATTERY
BACK-UP
AC
TX 3
RX 3
TX 2
RX 2
RS232
AUXILIARY POWER FOR
ACCESSORIES
Connection P9 (Figure 20) on the Power Supply module
provides 28Vdc (12Vdc is available) to power radio communication units, RTUs and other accessories. The auxiliary power provides 40W peak load capability. Auxiliary
power is fused at 1 Amp (F1) and current-limited to prevent user loads from disabling the control.
Customer 28V connections for auxiliary power are made
to terminals 3 and 1 and are continuously energized. Terminal 2 and 4 are not used at this time.
RECLOSER INTERFACE (RIF)
MODULE CONFIGURATION
The Recloser Interface (RIF) Module accepts either 12,
120, or 240 Vac voltage inputs for metering. The RIF Module is factory-configured at 120 Vac. The available voltages and their settings are indicated on the operator
panel of the RIF module. Two sets of dip switches, located
on the RIF operator panel, utilize different switch positions
to configure the desired voltage. See Figure 21.
Configure the RIF board by positioning the dip switches to
the desired voltage setting.
Reference the voltage table next to the switches. The
ON position is to the left; the OFF position is to the right
(Figure 21).
S280-42-3
21
!
SAFETY
FOR LIFE
CAUTION: Equipment damage. Always wear a grounding wrist strap to control static electricity before handling
circuit boards. Failure to use this strap may result in circuit board damage. T253.1
Figure 21.
Recloser Interface (RIF) Module configuration.
Figure 20.
Power Supply Module Connection P9 provides
28Vdc power to radio communication units.
MANUAL
BATTERY
RECONNECT
P
P
O
W
E
R
GDC-1A
S
U
SW (-) 4
P
28V (-) 3
P
SW (+) 2
L
28V (+) 1
Y
8
C
P
U
F1
P
9
A
U
X
P
2
P
O
W
E
R
RECLOSER
INTERFACE
MODULE
P
3
I
I
O
F
F
P
O
S7
S
I
T
I
O
N
POLARITY
DOT
C
P
U
P
4
C
P
U
P
8
V
O
L
T
A
G
E
S
E
N
S
O
R
S
VOLTAGE SENSOR
CONFIGURATION
12
120
VAC
VAC
OFF
ON
6 (Z)
ON
ON
ON
OFF
4 (Y)
ON
ON
ON
OFF
2 (X)
ON
ON
OFF
ON
5 (C)
ON
ON
ON
OFF
3 (B)
ON
ON
ON
OFF
1 (A)
ON
ON
PHASE
BUSHING
NUMBER
DIP SWITCH
POSTION
BUSHING
NUMBER
240
VAC
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
PHASE
6
5
O
N
4
3
P
2
O
S
1
6
T
5
O
4
N
3
2
1
6 (Z)•
4 (Y)•
2 (X)•
5 (C)•
3 (B)•
1 (A)•
The UDP function allows the Form 5/Triple-Single control
to become a switch control to provide indication of overcurrent trip conditions without issuing an overcurrent trip
signal. The control is in the recloser mode when the feature is in the OFF position, and in the switch mode when
the feature is ACTIVE.
While in the switch mode, all automatic open and close
operations of the recloser (including overcurrent voltage
and frequency) are blocked. Fault targeting, metering,
alarms, and event recording functions are active.
This non-tripping fault indication state is initiated via a
operator panel pushbutton (labeled SWITCH MODE) as
shown in Figure 22, digital SCADA, or discrete SCADA.
The UDP feature has local indication at the operator panel
(LED), digital indication, and remote indication via status
contacts on the Discrete Interface (DIF) module 1.
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
22
Figure 23.
Interface software Switch Mode settings.
Figure 22.
Function/Indication pushbuttons for the Form
5/Triple-Single control equipped with the UDP
accessory.
FORM 5/TRIPLE-SINGLE UNIVERSAL DEVICE PROTECTION
(UDP) CONTROL
Figure 24.
Form 5/Triple-Single UDP Operator Panel.
GND TRIP
BLOCKED
NON
RECLOSING
SUPERVISORY
BLOCKED
COLD LOAD
PICKUP
BLOCKED
ALTERNATE
PROFILE
NO. 1
AØ
SELECT
BATTERY
TEST
ALTERNATE
PROFILE
NO. 2
BØ
SELECT
FAST
TRIPS
DISABLED
SWITCH
MODE
CØ
SELECT
CONTROL OK
AC POWER
ABOVE MIN TRIP
CHECK BATTERY
RECLOSER MALFUNCTION
REVERSE POWER FLOW
AØ FAULT TARGET
BØ FAULT TARGET
CØ FAULT TARGET
GROUND FAULT TARGET
SENSITIVE-GROUND FAULT TARGET
AØ VOLTAGE
HOT LINE
TAG
GND TRIP
BLOCKED
COLD LOAD
ON
OFF
BØ VOLTAGE
CØ VOLTAGE
1Ø TRIP - 1Ø LOCKOUT
1Ø TRIP - 3Ø LOCKOUT
3Ø TRIP - 3Ø LOCKOUT
CLOSED
TRIP
AØ
BØ
CØ
CLOSE
OPEN
LOCKOUT
CLOSED
OPEN
LOCKOUT
CLOSED
OPEN
LOCKOUT
SELECT PHASES TO OPERATE
(LOCKOUT)
FORM 5/TRIPLE-SINGLE UDP
BACK
NEXT
RESET
CHANGE
TARGETS
RESET
LAMP
MAX CURRENT
TEST
NON
RECLOSING
BATTERY
PICK UP
TEST
BLOCKED
ALTERNATE
ALTERNATE
PROFILE
PROFILE
NO. 1
NO. 2
AØ
SELECTBØSELECT
TX 3
TX 2
RX 3
RX 2
KYLE
RECLOSER CONTROL
SUPERVISORY
BLOCKED
DISABLED
SELECT
RS232
SWITCH
FAST
TRIPS
MODE
CØ
®
S280-42-3
23
!
SAFETY
FOR LIFE
DISCRETE INTERFACE (DIF)
ACCESSORY
The Discrete Interface (DIF) module accessory (Figure
25) permits connection of contact-type input devices
(switches, relays) and discrete indicating devices (relays,
LEDs, lamps) to the Form 5/Triple-Single control to effect
local discrete input/output (I/O). The DIF module accessory is used for supplementing normal local controls and
status indicators for discrete SCADA functions. All DIF
inputs and outputs have been factory-set and are shown
in Figure 27.
The DIF module contains 12 inputs and 12 outputs that
are customized for a discrete SCADA function. Each
Form 5/Triple-Single control can accommodate two DIF
modules.
Whetting voltage for the DIF inputs can be supplied by the
DIF module or by the customer as shown in Figure 26.
The input voltage range is 12 to 120 Vac or Vdc. The 12
outputs are Form C relay contacts. Six of the module outputs are latching and the other six are non-latching.
Note: Latching is defined as an output that retains its status
when control power is removed.
Non-latching is defined as an output that changes its
status when control power is removed.
Note: A remote function is not controlled by the SUPERVI-
SORY BLOCKED switch.
Customer Connection
Information
Figure 26 shows the customer-supplied wiring of whetting
voltage for DIF module inputs. Connection is made from
terminal P5 on the DIF module to the respective connections on P4 inputs 1 through 12.
Figure 27 shows customer connections to the DIF outputs
at P2 and P3.
Figure 25.
Discrete Interface (DIF) Module.
Figure 26.
Customer connections for supplying whetting voltage to DIF inputs.
CAUTION: Equipment damage; misoperation.
External leads must be shielded and the shield
must be grounded at both ends. Terminate each lead
with a 320Vac, 160 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. G117.3
!
CAUTION: Equipment damage. Do not drill con-
nection holes into the top of the cabinet. Connection holes in the top of the cabinet will allow moisture to
seep into the control and damage the components or
cause control misoperation. Failure to comply will void
the control’s factory warranty.
T249.0
!
IMPORTANT: The DIF should not be used for overcurrent protection. The control gives priority to TCC
timing and issuing a trip signal rather than changing the
status of a DIF output or responding to a DIF input.
DISCRETE
INTERFACE
MODULE
ACCESSORY
INPUT COMMON
OUTPUT COMMON
12
11
10
28V (+)
9
8
7
6
5
4
3
2
1
28V (-)
12
11
10
4
3
2
1
12
6
11
10
5
9
8
4
7
6
3
5
4
2
3
2
1
1
12
11
10
9
8
7
6
9
5
4
8
3
2
7
1
12
11
10
9
8
7
6
5
4
3
2
1
P5
WHETTING
VOLTAGE
P3
UNLATCHED
OUTPUTS
P2
LATCHED
OUTPUTS
P4
INPUTS
(12 TO 120
VAC OR VDC)
WHETTING
VOLTAGE
INPUT COMMON
OUTPUT COMMON
Note: Wiring to P5-2 and P5-3 can be
reversed if necessary.
P5
4
28V (-)
3
28V (+)
2
1
To P4
Inputs 1 thru 12
Customer-Supplied
Wiring for Whetting Voltage
REMOTE
CONTACTS
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
24
Figure 27.
Customer connections to DIF module outputs with shielding and surge protection.
FORM 5 CONTROL
*28Vdc (nominal)
supplied by
DIF module for
whetting voltage.
Discrete Interface
(DIF) Module 1
INPUT COMMON
28V (-)
28V (+)
OUTPUT COMMON
SUPERVISORY BLOCK
NORMAL PROFILE
HOT LINE TAG
BATTERY TEST
NON-RECLOSING
GROUND TRIP BLOCK
PHASE C CLOSED
PHASE B CLOSED
PHASE A CLOSED
P2
P3
P5
4
3
12
11 12
910
678512 43
11 12
910
Remote Terminal Unit (RTU)
COMMON*
R
INPUT
VOLTAGE
G
R
P4
678512 43
11 12
910
678512 43
Not All Remote
Connections
Shown
PHASE C LOCKOUT
PHASE B LOCKOUT
PHASE A LOCKOUT
SUPERVISORY PHASE C CLOSE
SUPERVISORY PHASE B CLOSE
SUPERVISORY PHASE A CLOSE
SUPERVISORY PHASE C TRIP AND LOCKOUT
SUPERVISORY PHASE B TRIP AND LOCKOUT
SUPERVISORY PHASE A TRIP AND LOCKOUT
SUPERVISORY ALL PHASED CLOSE
SUPERVISORY ALL PHASES TRIP AND LOCKOUT
REMOTE HOT LINE TAG
SUPERVISORY BATTERY TEST
SUPERVISORY NON-RECLOSING
SUPERVISORY GROUND TRIP BLOCKED
S280-42-3
25
!
SAFETY
FOR LIFE
Form 5/Triple-Single and Form
5/Triple-Single UDP Controls
Form 5/Triple-Single and Form 5/Triple-Single UDP control DIF inputs and outputs are described in the following
pages.
Maximum Switching Voltage: . . . . . 135 Vac 110 Vdc
Maximum Switching Loading: . . . . 600 mA
Maximum Pickup-Release Time: . . 3 msec (does not count control response time)
Input Protection: . . . . . . . . . . . . . . . Shunting type using MOVs and capacitors
Minimum detection level: . . . . . . . . . . . . . . . . . . . . . . . . 8 Vac (50 or 60Hz) 10 Vdc
Maximum Operating Voltage: . . . . . . . . . . . . . . . . . . . . . 135 Vac (50 or 60Hz) 175 Vdc
Input Impedance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10k minimum (Inputs are current limited.)
Maximum Input Loading: . . . . . . . . . . . . . . . . . . . . . . . . 2 mA per input
Maximum Leakage Rejection: . . . . . . . . . . . . . . . . . . . . 1 mA
Maximum Pickup Time: . . . . . . . . . . . . . . . . . . . . . . . . . 10 msec (does not count control response time)
Minimum Input Pulse Time: . . . . . . . . . . . . . . . . . . . . . . 100 msec
Minimum Transition Time between Pulse Inputs: . . . . . . 200 msec
Input Protection: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shunting type using MOVs and capacitors.
Opto isolation from input to system.
Voltage Level: . . . . . 28 Vdc (nominal)
Output Current: . . . . 30 mA maximum
TABLE 1
DIF Input Ratings
TABLE 2
Whetting Voltage Source
TABLE 3
DIF Output Ratings
IMPORTANT: Each DIF contains a small, isolated
current source for use with external dry contacts. This
supply is intended for use with the DIF inputs only and
must not be used for powering external circuits. This is
considered a dry contact input for customer connection.
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
26
Form 5/Triple-Single and Form 5/Triple-Single UDP Control DIF Module 1
Inputs
The DIF inputs are factory-configured as momentary (0.25 sec. duration) or maintained functions. When Supervisory
is blocked, Supervisory signals are disabled, but Remote inputs are active. Whetting voltage for the DIF inputs is supplied by the DIF module or by the user. The input voltage range is 12 to 120 VAC or VDC.
Input Connector Function Description
1 P4-1 Supervisory Ground Trip Block Supervisory Ground Trip Block provides supervisory operation of
ground trip block by a remote momentary signal.
This input performs the same function as the GND TRIP BLOCKED
key on the operator panel. This input is inactive if the Supervisory
function is disabled.
2 P4-2 Supervisory Non-Reclosing Supervisory Non-Reclosing provides supervisory non-reclosing
input by a remote momentary signal.
This input performs the same function as the NON-RECLOSING
key on the operator panel. This input is inactive if the Supervisory
function is disabled.
3 P4-3 Supervisory Battery Test This input performs the same function as the BATTERY TEST key
on the operator panel. This input is inactive if the Supervisory function is disabled. This is a momentary function.
4 P4-4 Remote Hot Line Tag Remote Hot Line Tag performs the same functions as the HOT
LINE TAG switch on the operator panel. Remote Hot line Tag is
activated by a maintained SCADA command, a serial command,
or locally via a operator panel switch. This input is active regardless
of the state of the supervisory function.
5 P4-5 Suprv. All Phases Trip & Lockout Supervisory Trip and Lockout trips all three reclosers open and
locks out the control. The control remains locked out until closed
manually or by the supervisory close feature. A momentary signal
is required.
6 P4-6 Supervisory All Phases Close Supervisory Close initiates a closing signal to all three reclosers. A
momentary signal is required for proper operation.
7 P4-7 Suprv. Phase A Trip &Lockout
8 P4-8 Suprv. Phase B Trip & Lockout
9 P4-9 Suprv. Phase C Trip & Lockout
10 P4-10 Suprv. Phase A Close
11 P4-11 Suprv. Phase B Close
12 P4-12 Suprv. Phase C Close
Supervisory Trip and Lockout for each phase trips the recloser
open and locks out the control. The control remains locked out until
closed manually or by the supervisory close feature. A momentary
signal is required.
Supervisory Close for each phase initiates a closing signal to the
recloser. A momentary signal is required for proper operation.
S280-42-3
27
!
SAFETY
FOR LIFE
Form 5/Triple-Single and Form 5/Triple-Single UDP Control DIF Module 1
Outputs
The 12 outputs of the DIF Module are Form C relay contacts. Six of the outputs are latching and six are non-latching.
Note: Contacts shown in inactive mode.
Output Connector Function Type Description
1 P3-1 (NC) Ground Trip Blocked unlatched
P3-2 (NO)
2 P3-3 (NC) Non-Reclosing unlatched
P3-4 (NO)
3 P3-5 (NC) Battery Test unlatched
P3-6 (NO)
4 P3-7 (NC) Hot Line Tag unlatched
P3-8 (NO)
5 P3-9 (NC) Normal Profile unlatched
P3-10 (NO)
6 P3-11 (NC) Supervisory Blocked unlatched
P3-12 (NO)
7 P2-1 (NO) Phase A Lockout Latched
P2-2 (NC)
8 P2-3 (NO) Phase B Lockout Latched
P2-4 (NC)
9 P2-5 (NO) Phase C Lockout Latched
P2-6 (NC)
10 P2-7 (NO) Phase A Closed Latched
P2-8 (NC)
11 P2-9 (NO) Phase B Closed Latched
P2-10 (NC)
12 P2-11 (NO) Phase C Closed Latched
P2-12 (NC)
Normal Profile is active only when Alternate Profiles are
inactive. Normal reclosing operations will follow.
This output is active when the NON-RECLOSING indicator
in the operator panel is illuminated.
Supervisory Blocked prevents operation from supervisory
control. Programming is accessible from the operator panel.
This output is active when the SUPERVISORY BLOCKED
indicator on the operator panel is illuminated.
With Hot Line Tag active, close circuit is disabled and the
HOT LINE TAG indicator is illuminated. With Hot Line Tag
inactive, the control switched back to the previous time current curve for the active profile, close circuit is enabled and
the HOT LINE TAG indicator is off. This output is active
when the operator panel indicator is illuminated.
Ground Trip Blocked causes the control to block ground tripping operations. This output is active when the GND TRIP
BLOCKED INDICATOR on the operator panel is illuminated.
This output is active when the BATTERY TEST indicator on
the operator panel is illuminated. This is a momentary
function.
These outputs are active when the respective phase has
locked out.
These outputs are active when the respective phase has
closed.
**Note: Supervisory Alternate Profile 3 replaced by Switch
Mode on Form 5/Triple-Single UDP controls.
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
28
Form 5/Triple-Single and Form 5/Triple-Single UDP Control DIF Module 2
Inputs
The DIF inputs are factory-configured as momentary or maintained functions. When Supervisory is blocked, Supervisory signals are disabled, but Remote inputs are active. Whetting voltage for the DIF inputs is supplied by the DIF module or by the user. The input voltage range is 12 to 120 VAC or VDC.
Input Connector Function Description
1 P4-1 Remote All Phases Trip & Reclose Remote Trip and Reclose initiates a trip operation followed by a
reclose operation on all three phases. A momentary signal is
required for proper operation.
This input is active with a whetting voltage and causes the control
to perform a trip operation followed by a reclose operation. This
input is active regardless of the state of the Supervisory function.
2 P4-2 Remote All Phases Lockout All phases trip open and the control locks out. The feature can be
used for tripping from external relays and alarms. A momentary signal is required for proper operation.
3 P4-3 Remote All Phases Close All phases close upon a remote signal from the control to the
reclosers.
4 P4-4 Supervisory Normal Profile Supervisory Normal Profile requires a momentary signal for proper
operation.
This input is active with a whetting voltage and causes the control
to select Normal Protection Profile. This input is inactive if the
Supervisory function is disabled.
5 P4-5 Supervisory Alternate Profile 1
6 P4-6 Supervisory Alternate Profile 2
7 P4-7 Supervisory Alternate Profile 3*
8 P4-8 Suprv. Cold-Load Pickup Blocked This input performs the same function as the COLD LOAD PICKUP
BLOCKED key on the operator panel. This input is inactive if the
Supervisory function is disabled. A momentary signal is required
for proper operation.
9 P4-9 Supervisory Fast Trips Disabled This input performs the same function as the FAST TRIPS DISABLED
key on the operator panel and is inactive if the Supervisory function is
disabled. This is a momentary function.
10 P4-10 Supervisory SGF Blocked This input is active with a momentary whetting voltage and
causes the control to block, or unblock sensitive ground fault operations. The input is inactive if the Supervisory function is disabled.
11 P4-11 Supervisory Battery Test This input performs the same function as the BATTERY TEST key
on the operator panel. This input is inactive if the Supervisory function is disabled. This is a momentary function.
12 P4-12 Remote Hot Line Tag Remote Hot Line Tag performs the same function as the HOT LINE
TAG switch on the operator panel. Remote Hot line Tag is activated
by a maintained SCADA command, a serial command, or locally
via a operator panel switch. This input is active regardless of the
state of the supervisory function.
Supervisory Alternate Profiles provides selection of alternate programmed values for phase and ground. This feature is activated by
a remote momentary signal.
These inputs are active with a momentary whetting voltage and
cause the control to select the respective Supervisory Alternate Profile. The inputs are inactive if the Supervisory function is disabled.
Note: Supervisory Alternate Profile 3 replaced by Switch
Mode on Form 5/Triple-Single UDP controls.
S280-42-3
29
!
SAFETY
FOR LIFE
Form 5/Triple-Single and Form 5/Triple-Single UDP Control DIF Module 2
Outputs
The 12 outputs of the DIF Module are Form C relay contacts. Six of the outputs are latching and six are non-latching.
Note: Contacts shown in inactive mode.
Output Connector Function Type Description
1 P3-1 (NC) Phase A Open unlatched
P3-2 (NO)
2 P3-3 (NC) Phase B Open unlatched
P3-4 (NO)
3 P3-5 (NC) Phase C Open unlatched
P3-6 (NO)
4 P3-7 (NC) Normal Profile unlatched
P3-8 (NO)
5 P3-9 (NC) Alternate Profile 1 unlatched
P3-10 (NO)
6 P3-11 (NC) Alternate Profile 2 unlatched
P3-12 (NO)
7 P2-1 (NO) Alternate Profile 3* Latched
P2-2 (NC)
8 P2-3 (NO) Cold-Load Pickup Blocked Latched
P2-4 (NC)
9 P2-5 (NO) Fast Trips Disabled Latched
P2-6 (NC)
10 P2-7 (NO) Sensitive Ground Fault Blocked Latched
P2-8 (NC)
11 P2-9 (NO) Battery Test Latched
P2-10 (NC)
12 P2-11 (NO) Hot Line Tag Latched
P2-12 (NC)
The respective phase OPEN indicator is active when
the recloser signals the control that the respective
phase contacts are open.This output is active when the
respective PHASE OPEN indicator is illuminated.
Normal Profile is active when Alternate Profiles are
inactive. Normal reclosing will follow.
These outputs are active when the respective ALTERNATE PROFILE indicators are illuminated on the
operator panel.
This output is active when the COLD LOAD PICKUP
BLOCKED indicator on the operator panel is illuminated.
This output is active when the FAST TRIP DISABLED
indicator is illuminated.
Output is active when Sensitive Ground Fault is
blocked.
This output is active when the BATTERY TEST indicator on the operator panel is illuminated. This is a
momentary function.
With Hot Line Tag active, close circuit is disabled and
the HOT LINE TAG indicator is illuminated. With Hot
Line Tag inactive, the control switched back to the previous time current curve for the active profile, close circuit is enabled and the HOT LINE TAG indicator is off.
This output is active when the operator panel indicator
is illuminated.
Sensed Currents
Phase Current — Individual Phase Currents:
Range: 1 A to 10,000 A for 500:1 CTs
2 A to 20,000 A for 1000:1 CTs
4 A to 40,000 A for 2000:1 CTs
Accuracy:± 1 mA from 10 mA to 125 mA
0.8% from 125 mA to 1600 mA
(Control only – does not include sensor
tolerance.)
Ground Current — Vector Sum of Three-Phase
Currents:
Range: 1 A to 5,000 A for 500:1 CTs
2 A to 10,000 A for 1000:1 CTs
4 A to 20,000 A for 2000:1 CTs
Accuracy: ± 3 mA from 10 mA to 125 mA
2.4% from 125 mA to 1600 mA
(Control only – does not include sensor tolerance, but does include the phase current
summing process.)
Sensed Source Voltages
Three-phase voltages used in voltage, power and powerfactor related calculations:
Voltage measurement accuracy:
± 0.4V from 5 V to 80V
0.5% from 80 V to 135V
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
30
INPUT ACCURACY
Initial Programming Prior to
Installation
The control must be programmed with all necessary operating settings and parameters prior to operation with an
energized recloser.
Note: Program all protection profiles. Unused alternate pro-
files should be programmed with the same settings as
one of the applicable profiles. Default settings on
unused alternate profiles can cause unnecessary outages if they are below normal system requirements.
Initial programming of the control is the responsibility of a
qualified technician or engineer familiar with control functions and programming parameters required for the specific recloser installation.
The control must be programmed with the Form 5/TripleSingle interface software.
Control Cable
The control cable is fabricated with connectors on both
ends.
Note: The control cable must be supported along its length to
prevent repeated movement due to wind or other outside forces which can damage the cable.
Triple-Single Control Junction
Box
The Type NOVA-TS Triple-Single recloser is connected to
the Form 5/Triple-Single recloser control at a junction box.
See Figure 28.
• In a pole-mounting application, the junction box is
mounted on the mounting frame.
• For substation applications, mount the junction box on
the frame in a location between the Type NOVA-TS
Triple-Single recloser and the Form 5/Triple-Single
control.
S280-42-3
31
!
SAFETY
FOR LIFE
INSTALLATION PROCEDURE
CAUTION: Equipment misoperation. Do not
connect this control to an energized recloser until
all control settings have been properly programmed
and verified. Refer to the programming information for
this control. Failure to comply can result in control and
recloser misoperation, equipment damage, and personal injury. G110.3
!
IMPORTANT: The triple-single recloser junction box
is mounted with all cable connections made at the bottom of the box.
Figure 28.
NOVA-TS Triple-Single reclosers are connected to
the Form 5/Triple-Single control through a junction
box.
NOVA-TS
Pole-mounting
or Substation
mounting frame
Junction Box
BØ
AØ
CØ
Form 5/Triple-Single
(3) Triple-Single
Recloser Cables
Control Cable
Mounting the Control
Mount the Form 5/Triple-Single recloser control in a convenient, accessible location. Mounting dimensions are
provided in Figure 29.
For pole-mounted installation, a hole and keyway in the
control mounting bracket accommodates a 5/8” bolt.
Limits on control cable length are determined by the maximum distance between the control, junction box, and
NOVA-TS Triple-Single recloser:
• Up to 312 m (95* ft) for NOVA-TS Triple-Single
recloser.
* This length is based on standard control cables. Consult
your Cooper Power Systems representative if longer
cable lengths are required.
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
32
Figure 29.
Control cabinet mounting dimensions.
20 (3/4) Dia. Hole
for Locking Handle
Female Receptacle
For Control
35mm (1-7/16") Dia. Hole
For User 120Vac
Input Connection
(Cap-Plug Installed)
110mm
(4-1/4")
40mm
(1-1/2")
30mm (1-1/8") Hole
In Lifting Lug
Cable
Vent
190mm
(7-3/8")
200mm
(7-7/8")
380mm
(15")
130mm
(5-1/8")
160mm
(6-3/8")
C
L
C
L
120mm (4-3/4")
45mm (1-3/4") Dia. Hole
For Automation Accessory
(Cap-Plug Installed)
Mtg Hole For
15mm (5/8") Max
Bolt Dia.*
* USER-PROVIDED HARDWARE
40mm (1-1/2")
76mm
(3")
480mm
(19")
240mm
(9-1/2")
685mm
(27")
Male Receptacle
For Control Cable
30mm
(1-1/8")
CONTROL WEIGHT
350mm
(13-13/16")
410
(16-15/64)
52 kg (115 LBS)
110mm
(4-3/8")
165mm
(6-1/2")
16 (5/8) Dia. Hole
for User-Provided Lock
580mm (23")
640mm (25-1/4")
Grounding Terminal
One Internal and
One External
Use No. 14 To No. 4
Stranded Wire
Grounding the Control
The control cabinet must be grounded. A grounding connector on the underside of the cabinet will accommodate
No. 14 solid through No. 4 stranded conductors.
Suggested methods for grounding the control and
recloser are shown in Figures 30, 31, and 32.
Figure 30 illustrates grounding methods for 3-wire
ungrounded and 4-wire multi-grounded systems with local
supply voltage transformer.
Figure 31 illustrates grounding methods for 3-wire
ungrounded and 4-wire multi-grounded systems with
remote supply voltage transformer.
Figure 32 illustrates grounding on a 3-wire uni-grounded
system.
For effective surge protection all control and power conductors for the Form 5/Triple-Single control must be
routed parallel to a corresponding ground path. For example, the AC power supply for the control should be parallel to and equal in length to the transformer ground path.
The control cable should be parallel to and routed close to
the recloser ground path.
S280-42-3
33
!
SAFETY
FOR LIFE
WARNING: Hazardous voltage. Recloser and
control must be solidly grounded. Follow all
locally approved procedures and safety practices when
grounding this equipment. Improper grounding can
result in contact with high voltage, which will cause
death or severe personal injury. G115.1
!
Installation of the Form 5/Triple-Single control must
include the following:
• Protection of the recloser bushings and the supplying
transformer with lightning arresters.
• Grounding of the recloser head and tank.
• Grounding of the transformer tank.
• Grounding of the control cabinet.
• Grounding of the SCADA equipment
4-Wire Multi-Grounded Systems
3-Wire Ungrounded and Impedance Grounded Systems
The use of a grounding mat may be required depending
upon the local safety regulations defining the permissible
step and touch potential levels. Consult local regulations
for proper grounding procedures.
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
34
IMPORTANT: In pole-mounted applications, a
ground connection must be made between the
recloser, transformer, recloser control, and SCADA
equipment for proper protection of the equipment. The
pole ground must be sized per local utility practices to
minimize the impedance between the recloser and the
control.
IMPORTANT: All external inputs to the Form 5 control must be routed within 8 inches of their corresponding ground. During a surge, a potential of approximately
1.5 kV per foot can develop in the conductors. Differences between conductor and ground path lengths can
add additional stress to the control components in the
event of a power surge.
Grounding with a Local Supply Voltage Transformer; 4-Wire Multi-Grounded,
3-Wire Ungrounded, or Impedance-Grounded
Figure 30.
Recommended grounding method for the Form 5/Triple-Single control installed on 4-wire multi-grounded, 3wire ungrounded, or impedance-grounded systems with local supply voltage.
Surge
Arrester
Supply
Voltage
Transformer
Typical transformer mounting is
180° to the recloser.
AC
NEU
GND
Surge
Arrester
NOVA-TS
Triple-Single
Recloser
Pole Ground
Recloser
Head
Ground
Junction Box
CLOSED
Surge
Arrester
Pole
CLOSED
Control
Cable
NEU
AC
Surge
Arrester
Arrester
Ground
Recloser
Head
Ground
Pole Mounting
Accessory
Form 5/Triple-Single
Control
Input Terminal
Block
Customer Ground Connection
At External Lug
Input Terminal
Block
Supply Voltage
Transformer
ELECTRICAL CONNECTIONS
Line to Neutral connected transformer
Form 5 Control
AC
NEUTRAL
ELECTRICAL CONNECTIONS
Line to Line connected transformer
Form 5 Control
AC
NEUTRAL
Supply Voltage
Transformer
External
Ground Lug
Input Terminal
Block
External
Ground Lug
Line
to
Line
Voltage
Installation of a Form 5/Triple-Single control with a remote
supply voltage transformer must include the following:
• Protection of the recloser bushings and the supplying
transformer with lightning arresters.
• Grounding of the recloser head and tank.
• Grounding of the transformer tank.
• Grounding of the control cabinet.
• Grounding of the SCADA equipment.
S280-42-3
35
!
SAFETY
FOR LIFE
Figure 31.
Recommended grounding method for the Form 5/Triple-Single Control installed on 4-wire multi-grounded, 3wire ungrounded, or impedance-grounded systems with remote supply voltage transformer.
IMPORTANT: All external inputs to the Form
5/Triple-Single control must be routed within 8 inches
of their corresponding ground. During a surge, a
potential of approximately 1.5 kV per foot can develop
in the conductors. Differences between conductor and
ground path lengths can add additional stress to the
control components in the event of a power surge.
IMPORTANT: In pole-mounted applications, a
ground connection must be made between the
recloser, transformer, recloser control, and SCADA
equipment for proper protection of the equipment. The
pole ground must be sized per local utility practices to
minimize the impedance between the recloser and the
control.
Grounding with a Remote Supply Voltage Transformer; 4-wire Multi-Grounded,
3-Wire Ungrounded, or Impedance-Grounded
Supply Voltage
Transformer
ELECTRICAL CONNECTIONS - Remote dedicated
Form 5/Triple-Single
Control
AC
NEUTRAL
External
Ground Lug
supply transformer
Input
Terminal
Block
Low Voltage Distribution Network
Input
Form 5/Triple-Single
Terminal
Control
Block
AC
NEUTRAL
External
Ground Lug
ELECTRICAL CONNECTIONS - using isolation transformer
115 Vac
Supply Voltage
Local Isolation
Transformer
Customer
Supplied
Low Voltage
Low Voltage
Arrester
Pole
Transformer
Surge
Arrester
AC
NEU
GND
Note: Distance between
transformer and
recloser should be
one pole span or less
Pole Ground
NOVA-TS
Triple-Single
Recloser
Supply
Voltage
Pole Ground
Surge
Arrester
Junction Box
Surge
Arrester
CLOSED
Pole
CLOSED
Control
Cable
NEU
AC
Surge
Arrester
Recloser
Head
Ground
Pole Mounting
Accessory
Form 5/Triple-Single
Control
Input Terminal
Block
Customer Ground Connection
At External Lug
Arrester
Ground
System
Neutral
Installation of a Form 5/Triple-Single control on a 3-wire
uni-ground system must include the following:
• Protection of the recloser bushings and the supplying
transformer with lightning arresters.
• Grounding of the recloser head and tank.
• Grounding of the transformer tank.
• Grounding of the control cabinet.
• Grounding of the SCADA equipment.
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
36
Figure 32.
Recommended grounding method for the Form
5/Triple-Single Control installed on a 3-wire unigrounded system.
IMPORTANT: All external inputs to the Form 5/TripleSingle control must be routed within 8 inches of their
corresponding ground. During a surge, a potential of
approximately 1.5 kV per foot can develop in the conductors. Differences between conductor and ground
path lengths can add additional stress to the control
components in the event of a power surge.
IMPORTANT: In pole-mounted applications, a
ground connection must be made between the
recloser, transformer, recloser control, and SCADA
equipment for proper protection of the equipment. The
pole ground must be sized per local utility practices to
minimize the impedance between the recloser and the
control.
WARNING: Hazardous Voltage. Use locally
approved operator safety procedures for proper
insulation when maintaining this equipment. High Voltage step and touch potential is characteristic in uniground systems. Failure to comply can cause death or
severe personal injury. T262.0
!
CAUTION: Exported Potential. Do not make
direct electrical connections to remote devices.
All SCADA equipment must be mounted locally or connected using the fiber-optic or radio communication
accessory. Direct connections to remote devices can
produce exported potential causing equipment damage or personal injury. T263.0
!
CAUTION: Hazardous Voltage. Do not use a
shared low voltage network to power the recloser
control unless the network is specifically designed to
withstand maximum ground potential rise. Ground
faults on a high voltage network can create a rise in
ground potential. T264.0
!
Grounding on a 3-Wire Uni-grounded System
Surge
Arrester
Supply
Voltage
Supply Voltage
Transformer
ELECTRICAL CONNECTIONS
Line to Neutral connected transformer
AC
NEU
GND
Triple-Single
Form 5 Control
AC
NEUTRAL
Transformer
Typical transformer mounting is
180° to the recloser.
NOVA-TS
Recloser
Junction Box
Surge
Arrester
Input Terminal
Block
External
Ground Lug
CLOSED
Pole
Surge
Arrester
Arrester
Recloser
Head
Ground
Ground
CLOSED
Pole
Mounting
Accessory
Form 5/Triple-Single
Control
Input Terminal
Block
AC
NEU
Customer Ground
Connection
At External Lug
Control Height must be
3 meters (10 feet)
minimum above earth
Control
Cable
Pole
Ground
Customer Connections for AC
Power
Input power to the Form 5/Triple-Single control is connected to terminal block TB1. (Located behind the operator panel, on the left side of the control. See Figure 34).
Input power is required:
• To power the control
• To provide voltage and power metering
Power Supply Verification
Incoming power is routed to the Power Supply module
which is factory-configured for either 120 or 240 volt
operation. The power supply module is factory-wired to
TB-1 and protected by the 3.15 Amp fuse labeled F2 on
the power supply operator panel. A label on the Power
Supply module indicates the proper voltage rating. See
Figure 33.
Inserting and Releasing Wire
Connections
In Terminal Block TB1, each terminal has a wire locking
clamp that has to be opened to accept and secure the
wire. A 3/32 inch flat-blade screwdriver is inserted into
each terminal hole to open the locking clamp. Figure 35
provides the procedure for opening and securing the wire
connections.
The wire is inserted into the terminal connection hole
while the screwdriver is placed into the wire release and
locking hole.
Follow the same procedure to release wire connections.
Power Connections
Customer connections to TB1 vary upon application. TB1
connections provide power and metering inputs to the
control. Figures 35 through 40 show the customer connections for 120 Vac and 240 Vac low voltage closing.
Figures 35 through 38 illustrate customer connections for
single- and three-phase transformers. Figure 35 shows
standard wiring with BØ transformer connected to TB1-2
location. Other phases should be connected from the single-phase transformer by wiring the BLACK wire from the
Power Supply module to the terminal of the respective
phase as shown in Figures 39 and 40. For example, Figure 40 shows connection from the Power Supply module
to an AØ transformer.
The transformer required for power should be 1kVA.
Note: The Form 5/Triple-Single or Form 5/Triple-Single UDP
control (for either Wye or Delta) can be powered by connecting an appropriate power source to TB1-2 (hot) and
TB1-4 (neutral).
Customer Connections for
Metering
Customer voltage inputs for metering are field configurable on the RIF module to accept 12, 120, or 240 Vac.
The incoming power supply must match the indication for
incoming power on the RIF module. The factory-configured settings for the RIF are displayed on the module
panel. See Figure 21.
See RIF Module Configuration section of this manual.
S280-42-3
37
!
SAFETY
FOR LIFE
CAUTION: Equipment damage. Do not drill con-
nection holes into the top of the cabinet. Connection holes in the top of the cabinet will allow moisture to
seep into the control and damage the components or
cause control misoperation. Failure to comply will void
the control’s factory warranty. T249.0
!
Figure 34. 99003KM
Terminal Connector Block TB1.
Y
Figure 33.
Label on Power Supply module indicates factoryconfigured voltage rating (120Vac).
M
O
D
U
L
E
GDC-3.15A
F2
CONFIGURED
FOR
120
VAC
240
VAC
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
38
Figure 35.
Form 5/Triple-Single and Form 5/Triple-Single UDP Power customer connections to terminal block TB1
(120Vac/240Vac Wye Connection).
Figure 36.
Form 5/Triple-Single and Form 5/Triple-Single UDP Power customer connections to terminal block TB1
(120Vac/240Vac Delta Connection).
To insert wire:
1. Insert 3/32 inch flat-
blade screwdriver into
Wire Release and
Locking hole.
2. Carefully insert the
screwdriver along side
the locking clamp.
3. Pull toward the center
of terminal block TB1
until the locking clamp
opens.
4. Insert wire into Terminal
Connection hole.
5. Release screwdriver.
6. Carefully pull wire to be
sure it is secure.
Wire Release
and Locking Hole
Terminal
Connection Hole
Connection
Wire
TB1
16
15
14
13
12
11
10
9
TB1
(Top View)
Note: Only slight pressure is
required to open the
locking clamp. Excessive
pressure can damage
the terminal block.
3/32 inch
Flat-Blade
Screwdriver
240Vac CLOSING
OPTION
CLOSING
VOLTAGE
AC
CUSTOMER
CONNECTIONS
POWER
SOURCE
OUTPUT
AC
CUSTOMER
CONNECTIONS
*REQUIRED FOR
CONTROL OPERATION
Y' VOLTAGE
B' VOLTAGE
NEUTRAL
SOURCE 2
NEUTRAL
SOURCE 1
NEUTRAL
SOURCE 2
POWER
OUTPUT
VOLTAGE
NEUTRAL
*NEUTRAL
SOURCE 1
POWER
120Vac
120Vac
*BØ
TB1
16
15
14
13
12
11
10
9
ZØ
YØ
8
XØ
7
6
5
NEU
4
CØ
AØ
CØ
3
BØ
2
AØ
1
AØ
BØ
CØ
240V CLOSING
OPTION
AC
CUSTOMER
CONNECTIONS
POWER
SOURCE
OUTPUT
AC
CUSTOMER
CONNECTIONS
*REQUIRED FOR
CONTROL OPERATION
SEE POWER SUPPLY
MODULE FOR
CORRECT VOLTAGE
SOURCE 2
POWER
OUTPUT
VOLTAGE
OUTPUT
VOLTAGE
SOURCE 1
POWER
*CØ
*AØ
TB1
16
15
14
13
12
11
10
ZØ
9
YØ
XØ
8
7
6
5
CØ
4
BØ
3
BØ
AØ
2
1
AØ
BØ
CØ
S280-42-3
39
!
SAFETY
FOR LIFE
Figure 37.
Form 5/Triple-Single and Form 5/Triple-Single UDP Power customer connections to terminal block TB1
(120Vac/240Vac, Open-Delta Connection).
Figure 38.
Form 5/Triple-Single and Form 5/Triple-Single UDP Power customer connections to terminal block TB1 (3-Wire,
240Vac Connection).
240V CLOSING
OPTION
AC
CUSTOMER
CONNECTIONS
POWER
SOURCE
OUTPUT
AC
CUSTOMER
CONNECTIONS
*REQUIRED FOR
CONTROL OPERATION
SEE POWER SUPPLY
MODULE FOR
CORRECT VOLTAGE
SOURCE 2
POWER
OUTPUT
VOLTAGE
OUTPUT
VOLTAGE
SOURCE 1
POWER
ZØ
XØ
*CØ
*AØ
TB1
16
15
14
13
12
11
10
9
YØ
8
7
6
5
CØ
4
BØ
3
BØ
AØ
2
1
AØ
BØ
CØ
240V CLOSING
OPTION
CLOSING
VOLTAGE
AC
CUSTOMER
CONNECTIONS
POWER
SOURCE
OUTPUT
AC
CUSTOMER
CONNECTIONS
*REQUIRED FOR
CONTROL OPERATION
Y' VOLTAGE
B' VOLTAGE
NEUTRAL
SOURCE 2
NEUTRAL
SOURCE 1
NEUTRAL
SOURCE 2
POWER
OUTPUT
VOLTAGE
OUTPUT
VOLTAGE
*NEUTRAL
SOURCE 1
POWER
120Vac
120Vac
ZØ
YØ
XØ
CØ
*BØ
AØ
TB1
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
120Vac
Neutral
120Vac
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
40
Figure 39.
Form 5/Triple-Single and Form 5/Triple-Single UDP Power and Low Voltage Closing customer connections to
terminal block TB1 (Single-Phase Connection, Standard BØ Input).
Figure 40.
Form 5/Triple-Single and Form 5/Triple-Single UDP Power and Low Voltage Closing customer connections to
terminal block TB1 (Single-Phase Connection, AØ Input).
P
WHT
O
W
E
R
S
U
P
P
L
Y
M
O
D
U
L
E
GDC-3.15A
F2
CONFIGURED
BLK
P
9
A
U
X
FOR
120
VAC
240
VAC
NEU
BØ
240Vac CLOSING
CLOSING
VOLTAGE
AC
CUSTOMER
CONNECTIONS
POWER
SOURCE
OUTPUT
AC
CUSTOMER
CONNECTIONS
OPTION
SOURCE 2
POWER
YØ VOLTAGE
120Vac
BØ VOLTAGE
120Vac
NEUTRAL
SOURCE 2
NEUTRAL
SOURCE 1
NEUTRAL
OUTPUT
VOLTAGE
NEUTRAL
*NEUTRAL
SOURCE 1
POWER
*BØ
TB1
16
15
14
13
12
11
10
9
ZØ
YØ
8
XØ
7
6
5
4
CØ
3
2
AØ
1
BØ
*REQUIRED FOR
CONTROL OPERATION
P
WHT
O
W
E
R
S
U
P
P
L
Y
M
O
D
U
L
E
GDC-3.15A
BLK
F2
CONFIGURED
FOR
120
VAC
240
VAC
NEU
P
9
A
U
X
AØ
AØ
240Vac CLOSING
CLOSING
VOLTAGE
AC
CUSTOMER
CONNECTIONS
POWER
SOURCE
OUTPUT
AC
CUSTOMER
CONNECTIONS
OPTION
SOURCE 2
POWER
SOURCE 1
POWER
Y' VOLTAGE
120Vac
B' VOLTAGE
120Vac
NEUTRAL
SOURCE 2
NEUTRAL
SOURCE 1
NEUTRAL
OUTPUT
VOLTAGE
NEUTRAL
*NEUTRAL
*BØ
TB1
16
15
14
13
12
11
10
9
ZØ
YØ
8
XØ
7
6
5
4
CØ
3
2
AØ
1
*REQUIRED FOR
CONTROL OPERATION
Before Placing the Control and
the Recloser into Service
Prior to placing the control and recloser into service, the
following installation procedures must be properly completed and verified:
1. Control properly mounted for the installation.
2. Recloser installed according to all locally approved
standards and practices.
3. Control and recloser properly grounded in accordance
with guidelines in this manual.
4. Control cable properly connected and supported.
5. Control battery connected and tested for proper
operation.
6. AC power connected to the control. (AC power LED
indicator is ON.)
7. All control programming entered and verified by
appropriate personnel.
8. Control clock set to the correct time.
9. Customer connections for remote and supervisory
operation checked and completed in accordance with
proper shielding and surge protection.
TESTING
Testing an Installed Control
The following tests to determine initial operation of the
Form 5/Triple-Single control can be performed while connected to an operating recloser. This is the only test performed on an installed, operating control. The Electrical
Testing of NOVA-TS Triple-Single Reclosers test
described in this section requires the Form 5/Triple-Single
control to be removed from service, connected to a
bypassed recloser or tested at a location where the proper
testing equipment is available.
1. Turn on the operator panel display by pressing the
CHANGE/LAMP TEST button on the control operator
panel.
2. Scroll through the LCD display messages as
described in the LCD Display Messages section of
these instructions. See Form 5/Triple-Single Control
Operator Panel section of this manual.
Check the operational values for currents, voltages,
and other metering information.
3. Check that the LED for AC power is illuminated on the
control operator panel. This indicates the presence of
AC power.
4. Test battery operation, using the procedures
described in the Battery Test Procedure section of
these instructions.
S280-42-3
41
!
SAFETY
FOR LIFE
CAUTION: Equipment misoperation. Do not
connect this control to an energized recloser
until all control settings have been properly programmed and verified. Refer to the programming
information for this control. Failure to comply can
result in control and recloser misoperation, equipment damage, and personal injury. G110.3
!
WARNING: Hazardous voltage. Recloser and
control must be solidly grounded. Follow all
locally approved procedures and safety practices when
grounding this equipment. Improper grounding can
result in contact with high voltage, which will cause
death or severe personal injury. G115.1
!
IMPORTANT: The Form 5/Triple-Single recloser control can be taken out of service for testing and placed
back into service without de-energizing its recloser and
interrupting the system. However, during the time the
control is out of service, the recloser is inoperative.
CAUTION: Equipment misoperation. Do not
connect this control to an energized recloser
until all control settings have been properly programmed and verified. Refer to the programming
information for this control. Failure to comply can
result in control and recloser misoperation, equipment damage, and personal injury. G110.3
!
Check CPU Status
Check the operating status CPU module. Open the cabinet door and locate the LED indicator (see Figure 41).
The LED indicator on the CPU module should flash at a
rate of one flash per second for normal operation.
Electrical Testing of NOVA-TS
Triple-Single Reclosers
Each unit in the Type NOVA-TS Triple-Single recloser utilize an interface circuit located in its mechanism housing.
The electronic interface circuit controls the opening and
closing signals to the magnetic actuator.
Figure 42 shows a test circuit for NOVA-TS reclosers with
the Form 5/Triple-Single control.
Use this circuit to simulate load current and for testing
minimum trip operation and sequencing the mechanism
with the Form 5/Triple-Single control for each phase.
Remove the Control from
Service
1. Enable GND TRIP BLOCKED to allow for ground trip
to be disabled when re-energized.
A. Press the CHANGE/LAMP TEST key on the Oper-
ator Panel to enter the CHANGE mode.
Note: The LCD Display Screen will indicate the amount
of time available in CHANGE mode to make a
change.
B. Depress the GND TRIP BLOCKED key.
Note: After the GND TRIP BLOCKED key is
depressed, the red LED indicator will illuminate
to indicate GROUND TRIP BLOCKED is active.
2. Unplug the control battery.
3. Remove control ac sensing and power connections
from the control using a separate disconnect switch.
4. Disconnect control cable from the control.
5. Disconnect the ground from the control.
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
42
WARNING: Hazardous voltage. Solidly ground
all equipment. Failure to comply can result in
death, severe personal injury, and equipment damage.
T223.2
!
Figure 42.
Suggested test circuit for NOVA-TS Triple-Single
reclosers with Form 5/Triple-Single control.
Figure 41.
Form 5/Triple-Single control CPU module.
99016KM
CPU Module
(Central Processing Unit)
CPU Module LED Indicator
IMPORTANT: Disconnect switches for ac sensing
and power connections are necessary to isolate the
Form 5/Triple-Single Recloser Control for testing and
servicing.
WARNING: Hazardous voltage. If the recloser
is energized while the control cable is discon-
nected, the CT secondaries can generate high voltages. Contact with high voltage can cause severe
personal injury or death. T204.2
!
Source
Form 5/
Triple-Single
Control
Variable
Autotransformer
(10 Amp)
600:5
Recloser
BCT ON 600:5 Tap
2
115Vac
Use 2/0 cable or larger
6
5
4
Triple-Single
Junction Box
2
Load
3
1
Clamp-On
Ammeter
Battery Test Procedure
The condition of the control battery is tested by depressing the BATTERY TEST key on the operator panel. No
external current/voltage meter is necessary for testing.
The control performs a self-test every 12 hours or when initiated by an external command. When a battery test is initiated,
the spurious charge is first drained to allow the battery voltage
to equalize. A 10-ohm, 55-watt resistor is then placed across
the battery terminals and a voltage drop is calculated. If the
drop from the equalized voltage to the test voltage exceeds 2
volts, then the CHECK BATTERY LED is illuminated.
To perform a battery test:
1. Using the NEXT and BACK keys, scroll through the
LCD display to Screen 31, the Battery Monitor screen.
2. Record the NORMAL VOLTS and NORMAL CUR-
RENT readings from the screen.
Note: Voltage should be between 25 to 31 volts with
higher readings at colder temperatures. Under normal conditions with ac connected and the battery
trickle charging, the current should read less than
20 mA. With ac connected and in bulk charging
mode, current will range from 12 to 600 mA. With ac
disconnected and the battery supplying the load,
current will read -180 mA to -600 mA depending on
accessories connected.
3. Momentarily, press the CHANGE/LAMP TEST key,
then BATTERY TEST key.
Note: AC power can be either connected or disconnected.
4. Record the TEST VOLTS reading from the LCD and
the status of the CHECK BATTERY LED. Service the
battery if the CHECK BATTERY LED is illuminated.
Testing Procedure for Uninstalled
Battery
The entire process should be conducted in a clean environment, such as a repair shop.
Refer to Table 4 and follow this procedure to perform a
bench test on a control battery in a service shop:
1. Remove the control from service. Refer to Remove
the Control from Service procedure within the Testing section of this manual.
2. Remove the battery from the control and carefully
transport it to a suitable service facility.
3. Measure battery voltage.
4. Apply test load and measure battery voltage after 5 sec-
onds of load to determine voltage drop. Refer to Table
4 for Bench Test Load Condition.
5. Remove test load.
If the battery fails the test or is at least four years old, it
should be replaced. Refer to Table 4 for battery catalog part
numbers.
Battery Charging
If it is not possible to charge the battery with the control’s
built-in charger, a KA43ME7001 (120 Vac) portable bench
type battery charger is available. Refer to Service Infor-
mation S280-79-14 KA43ME7001 Portable Lead Acid
Battery Charger Instructions for additional information.
Use adapter KME5-325-1 to connect the two 12 volt batteries to the KA43ME7001 charger. Charge the battery
with a KA43ME7001 (120 Vac) portable charger.
Note: A red LED indicator on the body of the charger illumi-
nates when charging.
The charger senses when the battery voltage reaches
2.27 volts per cell, then the charge rate reduces to maintain a trickle charge.
The red LED flickers to indicate the battery has reached a
full charge. This process can take up to 24 hours.
S280-42-3
43
!
SAFETY
FOR LIFE
TABLE 4
Battery Bench Testing and Replacement Information
The Form 5/Triple-Single control batteries have different dimensions; therefore, if the replacement battery ordered is a different brand
than the original battery, a kit with mounting hardware may be required to accommodate the replacement battery size.
Bench Acceptable
Battery Test Load Voltage Drop Battery
Control Catalog Amp/ Condition at end of Battery Replacement
Type Battery Part # Voltage Type Hour for 5 sec. Test Load Tester Kit
Form 5/ Hawker KME5-134-1 24v Lead 13 5
Ω,
2v BATTERY KME5-709-17
Triple- Genesis or (two Acid 55 watt or less TEST or
Single Sonnenschein KME5-134-2 12v 18 hot key on KME5-709-12
high or batteries) control panel or
capacity Yuasa KME5-134-3 12 KME5-709-13
CAUTION:
Recloser misoperation. The control
must be removed from service before disconnecting
the control battery. Disconnecting the control battery from an
in-service control may cause recloser misoperation (unintentional operation). Failure to comply can result in equipment
damage or personal injury. T213.4
IMPORTANT: Never connect a single 12 volt battery to
the KA43ME7001 charger. Use adapter KME5-325-1
with the battery assembly when connecting the charger
to the two 12 volt batteries.
IMPORTANT: Do not attempt to charge a lead acid
battery below 19 Vdc with the KA43ME7001 charger.
Attempting to do so will damage the charger.
!
Return the Control to Service
Follow this procedure to return the control to service:
1. Connect cable to de-energized control and recloser.
2. Plug in the control battery.
3. Apply ac power to the control.
4. Verify that all control settings are correct.
5. Disable GND TRIP BLOCKED.
A. Press the CHANGE/LAMP TEST key on the Oper-
ator Panel to enter the CHANGE mode.
Note: The LCD Display Screen will indicate the amount
of time available in CHANGE mode to make a
change.
B. Depress the GND TRIP BLOCKED key.
Note: After the GND TRIP BLOCKED key is
depressed, the red LED indicator will not be illuminated indicating GROUND TRIP BLOCKED is
not active.
6. Reset the control clock after AC power has been reapplied. (Refer Setting The Control Clock in Service
Information S280-79-2, Form 5 MicroprocessorBased Recloser Control Programming Guide.)
Replacement Kits
Replacement kits for the Kyle®Form 5/Triple-Single Control are available through the factory Service Department.
To order these kits, refer to the Replacement Parts price
list for catalog numbers and pricing. Contact your Cooper
Power Systems representative for additional information
and ordering procedures.
Factory-Authorized Service
Centers
Factory-authorized service centers are located throughout the continental United States to provide maintenance,
repair and testing services for Kyle controls and reclosers.
For further information, contact your Cooper Power Systems representative.
Factory Maintenance Classes
The factory service department offers a basic testing and
troubleshooting course for the Form 5/Triple-Single Microprocessor-Based Electronic Recloser Control and NOVATS Recloser. This course, taught by experienced service
technicians, is held at the factory’s in-house training facility. For additional information, contact your Cooper Power
Systems representative.
Kyle Form 5/Triple-Single Microprocessor-Based Recloser Control Installation and Operation Instructions
44
KDL
6/05
1045 Hickory Street
Pewaukee, WI 53072 USA
www.cooperpower.com
©2004 Cooper Power Systems or its affiliates.
Kyle
®
is a registered trademark of Cooper Power Systems or its affiliates.
KA2048-477 Rev: 02
ADDITIONAL INFORMATION
CAUTION: This equipment requires routine
inspection and maintenance to ensure proper
operation. If it is not maintained, it can fail to operate
properly. Improper operation can cause equipment
damage and possible personal injury. G105.1
!
CAUTION: Equipment misoperation. Do not
connect this control to an energized recloser
until all control settings have been properly programmed and verified. Refer to the programming
information for this control. Failure to comply can
result in control and recloser misoperation, equipment damage, and personal injury.
G110.3
!
!
SAFETY
FOR LIFE
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