Cooper Kyle Form 6 Disassembly And Reassembly
1
Form 6 Recloser Control Disassembly,
Reassembly, and Testing Instructions
Reclosers
Service Information
Safety Information ..................................................... 2
Hazard Statement Definitions ................................ 2
Safety Instructions .................................................. 2
Product Information .................................................. 3
Introduction ............................................................ 3
ANSI Standards ..................................................... 3
Quality Standards ................................................... 3
Acceptance and Initial Inspection .......................... 3
Handling and Storage ............................................ 3
Description ............................................................. 3
Disassembly .............................................................. 4
Disassembly Instructions ....................................... 4
Open the Module ................................................... 5
Remove/Replace CPU Board ................................ 5
Remove/Replace Comms. Accsy. Board Only ....... 6
Remove/Replace I/O Board ................................... 7
Remove/Replace Power Supply or RIF Board ...... 7
Remove/Replace Analog Board ............................. 8
Reassembly ............................................................... 8
Reassembly Instructions ........................................ 8
Place Module in Control ......................................... 8
Before Placing the Control Into Service ................. 9
Installation ................................................................. 9
Initial Programming Prior to Installation ................. 9
Testing ........................................................................10
Testing Instructions ................................................10
Communication Ports .............................................10
Contact Inputs/Outputs ..........................................10
Testing with Type MET Tester ................................11
Additional Information ..............................................12
Replacement Kits ...................................................12
Factory-Authorized Service Centers ......................12
Factory Testing and Troubleshooting Classes .......12
Contents
S280-70-11
Printed in USA
1
August 2005 • Supersedes 6/04
Figure 1.
Kyle®Form 6 Pole Mount, Yard Mount, and Rack Mount recloser controls.
Form 6 Recloser Control Disassembly, Reassembly, and Testing 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
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 hazardous 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
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
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SAFETY
FOR LIFE
!
SAFETY
FOR LIFE
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Introduction
Service Information S280-70-11 provides disassembly,
reassembly, and testing instructions for the Kyle
®
Form 6
recloser control.
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. For
additional information, 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 unit is in good condition at the factory and when
accepted by the carrier for shipment.
Upon receipt, inspect the carton for signs of damage.
Unpack the unit(s) 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 unit to minimize the possibility of damage. If the unit is to be stored
for any length of time prior to installation, provide a clean,
dry storage area.
Description
Service Information S280-70-11 provides disassembly,
reassembly, and testing instructions for the Form 6 Rack
Mount, Yard Mount, Pole Mount, and Triple-Single Pole
Mount recloser controls.
For additional information on installing the control,
removing the control from service, and control testing
procedures, refer to the appropriate instructions:
• Service Information S280-70-1 Form 6 Rack Mount
Recloser Control Installation and Operation
Instructions
• Service Information S280-70-2 Form 6 Yard Mount
Recloser Control Installation and Operation
Instructions
• Service Information S280-70-3 Form 6 Pole Mount
Recloser Control installation and Operation
Instructions
• Service Information S280-70-7 Form 6 Triple-Single
Pole Mount Recloser Control Installation and
Operation Instructions
S280-70-11
3
!
PRODUCT INFORMATION
SAFETY
FOR LIFE
Form 6 Recloser Control
Disassembly Instructions
These instructions describe the disassembly of the Form
6 recloser control.
1. Remove the Form 6 Control from Service. Refer to
appropriate Service Information Instructions:
• Service Information S280-70-1 Form 6 Rack Mount
Control Installation and Operation Instructions
Remove the Control from Service section
• Service Information S280-70-2 Form 6 Yard Mount
Control Installation and Operation Instructions
Remove the Control from Service section
• Service Information S280-70-3 Form 6 Pole Mount
Control Installation and Operation Instructions
Remove the Control from Service section
• Service Information S280-70-7 Form 6 Triple
Single Pole Mount Control Installation and
Operation Instructions Remove the Control from
Service section
2. Carefully transport the recloser control to a suitable
service facility.
Note: The entire disassembly, reassembly, and testing
process should be conducted in a clean environment, such as a repair shop.
This step applies to Form 6 Pole and Yard mount controls.
3. Remove module from cabinet as applicable.
A. For complete scheme structure and verification
refer to appropriate instructions:
• Service Information S280-70-4 Form 6 Control
Schemes section
• Service Information S280-70-9 Form 6-TS
Control Schemes section
B. Disconnect SCADA communications to the Form 6
control.
C. Remove all applicable connecting wires from
module.
D. Remove the 7/16 inch grounding nut and lock-
washers located on the bottom of the control module (Figure 2).
E. Remove the four mounting nuts that secure the
front of the module to the cabinet (Figure 3).
Form 6 Recloser Control Disassembly, Reassembly, and Testing Instructions
4
DISASSEMBLY
CAUTION: Recloser misoperation. The control must
be removed from service prior to performing any maintenance, testing, or programming changes. Failure to
comply can result in misoperation (unintentional operation) of the recloser. T216.2
IMPORTANT: Isolate all power connections to the
Form 6 recloser control, i.e., AC voltage sensing and
SCADA, before removing control from service.
IMPORTANT: Make sure the power is turned off and
the battery is disconnected.
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 2.
Location of grounding nut and lockwashers on the
rear panel of the Form 6 pole mount control (below
SN 10000).
CAUTION: Recloser misoperation. Before
downloading configuration files or settings to the
equipment, verify that the files and settings are correct
for the location and application. Downloading configuration files or settings designed for a different location
or application can result in severe personal injury and
equipment damage. G133.0
Figure 3.
Location of the four mounting nuts on the front of
the Form 6 pole mount control.
Hex Nuts
CO4
CI1
CI2 CI3 SS1 CO1
123 5 7 9 11 13 15 17 19
TB1
4681012141618
CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4
CI4
CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6
135 7 91113151719 21
TB3
2
4681012141618
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5
•12•34•56•78•
TB2
I(1-2)
I(3-4) I(5-6) V(1-2)
CO2 CO3
20
CO6
TB5
432
9
10
1
7
5
8
6
910•11 12•13 14•15 16•17 18
I(SEF)
J1 RS232
RS232 DTE
CO7 CO8
135791113
2
CO7 CO8 CO9 CO10 CO11CO12
RECLOSER INTERFACE CONNECTIONS
A
1
2B4C6
V(3-4) V(5-6) V1
J2 IRIG-B
J3 RS485
TTL IRIG-B
2-Wire RS485
CO9 CO10 CO11
4681012
D
F
3
TB6
57
E
19
CO12
TB4
•
20
Grounding Nut
and Lockwashers
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