Cooper Lighting S280-79-10 User Manual

Download

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

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

Initializing the Control . . . . . . . . . . . . . . . . . . . . . . . 4

Form 5 Control Description . . . . . . . . . . . . . . . . . . 5

Recloser Interface (RIF) Module . . . . . . . . . . . . . . 6

Central Processing Unit (CPU) Module . . . . . . . . . 6

Discrete Interface (DIF) Module . . . . . . . . . . . . . . . 6

Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . 6

Form 5 Control Operator Panel . . . . . . . . . . . . . . . 7

Battery Test Procedure . . . . . . . . . . . . . . . . . . . . . . 14

Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Auxiliary Power for Accessories . . . . . . . . . . . . . . 20

Recloser Interface (RIF) Module Configuration . . 20 Form 5 Universal Device Protection (UDP)

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Form 5 DC NOVA 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 . . . . . . . 28

Standard and UDP Module 2 Inputs . . . . . . . . . . . . 29

Standard and UDP Module 2 Outputs . . . . . . . . . . 30

Input Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Installation Procedure . . . . . . . . . . . . . . . . . . . . . . 32

Initial Programming Prior to Installation . . . . . . . . . 32

Control / Recloser Compatibility . . . . . . . . . . . . . . . 32

Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Mounting the Control . . . . . . . . . . . . . . . . . . . . . . . 33

Grounding the Control . . . . . . . . . . . . . . . . . . . . . . 34

Customer Connections for AC Power . . . . . . . . . . . 38

Customer Connections for Metering . . . . . . . . . . . . 38

Before Placing Control and Recloser into Service . 42

Testing and Troubleshooting . . . . . . . . . . . . . . . . 43

Testing an Installed Control . . . . . . . . . . . . . . . . . . 43

Testing with Type MET Tester . . . . . . . . . . . . . . . . 43

Closing the Recloser During Testing . . . . . . . . . . . 44

Form 5 Control Default Test Procedure . . . . . . . . 47

Remove the Control from Service . . . . . . . . . . . . . 55

Return the Control to Service . . . . . . . . . . . . . . . . 55

Additional Information . . . . . . . . . . . . . . . . . . . . . . 56

Service Information

Reclosers

Kyle®Form 5, Form 5 UDP, Form 5 DC NOVA Microprocessor-Based Recloser Controls Installation and Operation Instructions

S280-79-10

November 2001 • Supersedes 1/01

Figure 1. Kyle®Form 5/UDP microprocessor-based recloser control.

99001KM

Contents

Applicable to serial numbers above 3000 or beginning with CP57.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

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.

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 haz-

ardous 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

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: 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

SAFETY

FOR LIFE

Introduction

Service Information S280-79-10 provides installation and operation instructions for the Kyle Form 5 and Form 5 UDP microprocessor-based electronic recloser controls.

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, please 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 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

The 24 Vdc control battery in the Form 5 control is fully charged prior to shipment and is ready for use. In order to maintain sufficient charge to operate the control, the sealed lead acid battery should be charged after no more than three months of storage.

Note: Two 12 Vdc, 13 amp-hour batteries are available for

use with the Form 5 Distribution Automation upgrade accessory.

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 battery charged, energize the control’s builtin charger with AC power applied to the user AC supply input connector block TB1, located left of the RIF module within the control cabinet.

Note: When shipped from the factory, the battery source is

disconnected and its output plugs are taped to the cabinet. Connect the battery plugs into the mating connectors to complete the battery circuit.

Battery Replacement

The 24 Vdc control battery has a life expectancy of 4 to 6 years. It is recommended that the battery be replaced after 4 years.

Control Power

The primary source of power is factory configured for 120 Vac or 240 Vac. The 240 Vac version is available as an option at time of order entry. 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.

S280-79-10

PRODUCT INFORMATION

IMPORTANT: Connect the control battery when AC

power is connected to the control’s AC supply Input Ter-

minal Block. The battery must be disconnected prior to

shipping or storing the control.

IMPORTANT: To maintain sufficient charge to oper-

ate the control and prevent battery cell damage, the

sealed lead-acid batteries should be charged after no

more than three months of storage.

SAFETY

FOR LIFE

AC Reclosers

Power to operate the tripping and closing solenoids in the recloser is provided by the power capacitor located behind the operator panel of the control. A sealed, 24-volt, lead acid battery is located in the lower portion of the control cabinet and is utilized to provide operating and tripping energy when AC power is temporarily lost. The control is equipped with an ac-powered, temperaturecompensated battery charger.

Operation Upon Loss Of AC Power

If the control is equipped with the standard 24 Vdc leadacid battery, the control maintains 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 22.7 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 control.

Method 1: Connect AC power to the input connector ter-

minal TB-1. Refer to the Customer Connec- tions for AC Power section of this manual.

Method 2: Connect the battery terminal on the control

and press the MANUAL BATTERY RECONNECT button located on the Form 5 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, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

Figure 2. 99005KM Form 5 recloser control operator panel.

LCD Display

LED Indicators

CLOSE Pushbutton

TRIP (LOCKOUT)

Pushbutton

CONTROL OK

AC POWER

ABOVE MIN TRIP

CHECK BATTERY

RECLOSER MALFUNCTION

REVERSE POWER FLOW

BUSHINGS 1-2 FAULT TARGET

BUSHINGS 3-4 FAULT TARGET

BUSHINGS 5-6 FAULT TARGET

GROUND FAULT TARGET

SENSITIVE-GROUND FAULT TARGET

BUSHINGS 1-2 VOLTAGE

BUSHINGS 3-4 VOLTAGE

BUSHINGS 5-6 VOLTAGE

RECLOSER CLOSED

RECLOSER OPEN

CONTROL LOCKOUT

HOT LINE

TAG

GND TRIP BLOCKED

COLD LOAD

BLOCKED

OFF

PICK UP

ALTERNATE

PROFILE

NO. 1

TX 3

RX 3

BACK

RESET

TARGETS

RESET

MAX CURRENT

RECLOSING

TX 2

RX 2

NON

BATTERY

TEST

ALTERNATE

PROFILE

NO. 2

CHANGE

LAMP TEST

RS232

SUPERVISORY

BLOCKED

FAST TRIPS

DISABLED

ALTERNATE

PROFILE

NO. 3

LCD Display Dedicated Function Keys

Operation "Hot Keys"

RS232 Data Port

TRIP

(LOCKOUT)

KYLE

FORM 5

Hot Line Tag

RECLOSER CONTROL

Current sensing is provided by three current transformers located in the recloser and interfaced to the Form 5 control via the control cable. This cable also supplies Trip, Close, and Recloser status, and connects to the Recloser Interface (RIF) module to provide isolation for reliable operation. Voltages for metering are also connected to the RIF module via the connector terminal block, TB-1 (Figure 3).

A functional block diagram of the Form 5 control is shown in Figure 3. Line current flowing through the recloser is converted by the CPU module to a digital signal suitable for metering and fault current calculations. Data sampling occurs at a rate 32 times per cycle. The CPU contains a data acquisition section that uses the acquired samples to compute the fundamental currents and voltage for use in overcurrent, under/over voltage and under/over frequency protection, as well as currents and voltages for metering functions. The current for overcurrent protection is calculated on a sub-cycle basis; it includes only the fundamental and DC component. For metering, the fundamental and harmonic current and voltages are determined.

When the phase or ground current exceeds its programmed minimum-trip value and associated time-current curve (TCC) timing, the control initiates the programmed sequence of recloser tripping and reclosing operations via the CPU and RIF modules. If the fault is temporary, the control ceases to command recloser operations after a successful reclose, and the control resets to the start of its operating sequence after a preset time delay. If the fault is permanent, the control performs its complete programmed sequence of reclose commands and locks out with the recloser open. Once locked out, the control must be closed via the operator panel or SCADA communications. This resets the control to the start of the operating sequence.

The following chain of events occurs for an operating sequence of two trips to lockout:

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

2. Energizing the trip circuit connects the battery and capacitor to the trip solenoid to open the recloser.

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

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

5. If current remains above the minimum-trip level, the tripping and reclosing sequence is repeated.

6. The control begins the reset-delay timer if the overcurrent is cleared before the operating sequence reaches lockout indicated by a closed recloser and current below minimum trip.

7. When the reset-delay times out, the control is reset to the home state and is ready for another programmed operating sequence. If current rises above minimum trip prior to the reset-delay timing out, the timer is halted and the control resumes the operating sequence while the accumulated reset-delay timing is restarted.

S280-79-10

Figure 3. Form 5 control operational flow diagram.

FORM 5 CONTROL DESCRIPTION

SAFETY

FOR LIFE

TB1 TERMINAL BLOCK

CUSTOMER P.T. INPUTS

RECLOSER

TRIP SOLENOID

CLOSE SOLENOID

OPEN / CLOSE

SWITCHES

A Ø CT

B Ø CT

C Ø CT

CT COMMON

RIF

OPTICAL

ISOLATION

OPTICAL

ISOLATION

OPTICAL

ISOLATION

MATCHING

TRANSFORMERS

AND SIGNAL

CONDITIONING

POWER SUPPLY

CPU

OPTIONS

OPERATOR'S

PANEL

KEYBOARD

LED's

LCD

RS232 PORT

RS232

FIBER-OPTIC

PORT

RS232

FIBER-OPTIC

PCB

BATTERY

DIF#1

(OPTIONAL)

CONNECTIONS

6 unlatched outputs

6 latched outputs

USER

12 inputs

DIF#2

(OPTIONAL)

CONNECTIONS

6 unlatched outputs

6 latched outputs

USER

12 inputs

The Form 5 control is constructed in a modular fashion to simplify service and the addition of accessories (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.

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 is designed to interface with the following reclosers: WE/WVE group, NOVA group, VSA/VSO group, and KFME/KFVME (50Hz) group.

The recloser connector includes three current-transformer inputs, Open and Closed status sensing, and Trip and Close controls. The voltage sensor connector accepts six voltage inputs; three for source-side, and three for load-side voltage. Two sets of dip switches, located on the RIF front panel, utilize different switch positions to configure the desired voltage. See Figure 17.

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 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 control. The DIF module contains 12 inputs and 12 outputs can be customized for a remote or supervisory function. One Form 5 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 auxiliary power to radio communications units, RTUs and other accessories. The 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.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

Figure 4. Form 5 UDP control operating panel with interface modules and radio mounting provisions.

99001KM

Control Cable Receptacle

and Control Grounding Lug

(located beneath cabinet)

Control Battery

Central Processing Unit (CPU) Module

Recloser Interface

(RIF) Module

TB1 Connector

Block

Power

Supply

Module

Power Capacitor

(Located behind operator panel)

Grounding Strap

Manual Battery

Reconnect Button

Auxiliary Power

Connection (P9)

Form 5 Control Operator Panel

The Form 5 control operator panel (Figure 8) 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 RS-232 port is also provided to permit the temporary connection of a PC 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. The LCD messages will remain while in this power-saving mode, although the illuminating backlight will shut off.

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 10 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 for two conditions:

1. Battery voltage is below 20 Vdc or drops 2Vdc or more during battery test.

2. The control fails a manual battery test. The LED will remain on until a successful battery test is completed.

Refer to the Battery Test Procedure in 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 and phase must be correct for

reverse power flow to function properly.

BUSHINGS 1-2 FAULT TARGET

BUSHINGS 3-4 FAULT TARGET

BUSHINGS 5-6 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.

BUSHINGS 1-2 VOLTAGE

BUSHINGS 3-4 VOLTAGE

BUSHINGS 5-6 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.

RECLOSER CLOSED

This red indicator is illuminated when the control senses that the recloser mechanism is in the closed position.

S280-79-10

Figure 5. Form 5 control operator panel.

SAFETY

FOR LIFE

CONTROL OK

AC POWER

ABOVE MIN TRIP

CHECK BATTERY

RECLOSER MALFUNCTION

REVERSE POWER FLOW

BACK

MAX CURRENT

NO. 1

TX 3

RX 3

RESET

TARGETS

RESET

NON

RECLOSING

BATTERY

TEST

ALTERNATE

PROFILE

NO. 2

TX 2

RX 2

FORM 5

CHANGE

LAMP TEST

RS232

SUPERVISORY

BLOCKED

FAST TRIPS

DISABLED

ALTERNATE

PROFILE

NO. 3

BUSHINGS 1-2 FAULT TARGET

BUSHINGS 3-4 FAULT TARGET

BUSHINGS 5-6 FAULT TARGET

GROUND FAULT TARGET

SENSITIVE-GROUND FAULT TARGET

BUSHINGS 1-2 VOLTAGE

BUSHINGS 3-4 VOLTAGE

BUSHINGS 5-6 VOLTAGE

RECLOSER CLOSED

RECLOSER OPEN

CONTROL LOCKOUT

TRIP

(LOCKOUT)

HOT LINE

TAG

GND TRIP BLOCKED

COLD LOAD

PICK UP

BLOCKED

ALTERNATE

PROFILE

OFF

KYLE

RECLOSER CONTROL

RECLOSER OPEN

This green indicator is illuminated when the control senses that the recloser mechanism is in the open position.

CONTROL LOCKOUT

This green 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.

Note: The RECLOSER MALFUNCTION, RECLOSER OPEN,

RECLOSER CLOSED, and RECLOSER LOCKOUT LEDs will flash upon detection of a trip failure. See the Control Features section of this manual.

TRIP (Lockout) Pushbutton

The TRIP pushbutton (Figure 2) provides front-panel access to trip (lockout) the recloser. When pressed, the TRIP push-button opens the recloser and locks out the control.

CLOSE Pushbutton

When pressed, the CLOSE pushbutton (Figure 2) 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 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.

LCD Display

The control operator panel has a large, backlit LCD display (Figure 6) used for viewing control parameters and monitoring system conditions. Data is organized into screens of information, with each display containing four lines of information, with up to 20 characters per line. Access to the screens 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 1. Refer to LCD Display Screens 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 screen.

RESET TARGETS/RESET MAX CURRENT Key

Pressing the RESET TARGETS/RESET MAX CURRENT key resets the fault target indicators on the control operator panel. The fault current values shown on Screen 2 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.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

Figure 6. LCD display and dedicated function keys.

RESET

TARGETS

RESET

MAX CURRENT

BACK

CHANGE

LAMP TEST

LCD Display Screens

Every LCD display 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 screen. Demand metered values are indicated by (D) and instantaneous values by (I).

S280-79-10

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 Freq Trip____________ H z

Time Date

Present Freq ____________ Hz

4 Ph1-N VTrip ____________ V

Ph3-N VTrip ____________ V

Ph5-N VTrip ____________ V

Time Date

5 T ot ____________ kW h

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 ____________ k W

Ph3-4 ____________ k W

Ph5-6 ____________ k W

Screen 11 – Real Power

10 Instant S1-S2

Ph1-2 Dif ____________ V

Ph3-4 Dif ____________ V

Ph5-6 Dif ____________ V

Screen 10 – Instantaneous Voltage

12 Tot ____________ kV A

Ph1-2 ____________ k VA

Ph3-4 ____________ k VA

Ph5-6 ____________ k VA

Screen 12 – Instantaneous kVA

SAFETY

FOR LIFE

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

14 Tot ____________ PF

Ph1-2 ____________ P F

Ph3-4 ____________ P F

Ph5-6 ____________ P F

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

Ph2-N(d) ____________ V

Ph4-N(d) ____________ V

Ph6-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

Screen 17 – Demand Phase to Neutral Voltage

Screen 18 – Demand Phase-to-Phase Voltage

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) ____________ kW

Ph3-4 (d) ____________ k W

Ph5-6 (d) ____________ k W

24 Tot ____________ k VA

Ph1-2(d) ____________ kV A

Ph3-4(d) ____________ kV A

Ph5-6(d) ____________ kV A

Screen 22 – Demand Current

Screen 23 – Demand kW

Screen 24 – Demand kVA

S280-79-10

25 Tot ____________ kVAr

Ph1-2(d) ____________ kVAr

Ph3-4(d) ____________ kVAr

Ph5-6(d) ____________ kVAr

26 Tot ____________ PF

Ph1-2(d) ____________ P F

Ph3-4(d) ____________ P F

Ph5-6(d) ____________ P F

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 ______

Operations ______

31 Battery Monitor

Normal _______ V

Normal _____ mA

Test _______ V

32 – Phase MT ______ A

ALT1 MT ______ A

ALT2 MT ______ A

ALT3 MT ______ A

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 – Number of SGF Trips and Total Trip

Operations

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.

33 Gnd MT ______ A

Alt1 MT _______ A

Alt2 MT ______ A

Alt3 MT _______ A

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.

34 Gnd Max ____________A

Time Date

Ph1-2 Max ____________A

Time Date

Screen 34 – Ground Max, Phase 1-2 Max Demand

Currents

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

SAFETY

FOR LIFE

Operation/Indication Pushbuttons

Nine frequently used features are provided on the control operator panel (Figure 7).

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 front panel is in the powersave 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.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

Figure 7. 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 _______

38 Fault Location

Distance ____________miles

Time Date

39 CPU Firmware X.XX

Firmware FW Database X

Time Date

Screen 38 – Fault Location

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: Pressing and holding the RESET TARGETS/RESET

MAX CURRENT key for three seconds will reset the minimum and maximum Demand values.

36 Gnd Min ____________A

Time Date

Ph1-2 Min ____________A

Time Date

Screen 36 – Ground Min, Phase 1-2 Min Demand

Currents

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.

GND TRIP BLOCKED

COLD LOAD

PICKUP

BLOCKED

ALTERNATE

PROFILE

NO. 1

NON

RECLOSING

BATTERY

TEST

ALTERNATE

PROFILE

NO. 2

SUPERVISORY

BLOCKED

FAST

TRIPS

DISABLED

ALTERNATE

PROFILE

NO. 3

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.

SUPERVISORY BLOCKED

Supervisory Blocked disables supervisory SCADA and the 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 function.

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 feature is blocked while the COLD 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 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 the Battery Test Procedure section of these instructions for further details on testing the control battery.

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: Program all protection profiles. Program unused alter-

nate profiles should be programmed with the same setting as one of the applicable profiles. Default settings on unused alternate profiles can cause unnecessary outages if they are below normal system requirements.

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 UDP controls, Alternate Profile 3 is replaced

with SWITCH MODE.

HOT LINE TAG Switch

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 8) 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, resetting the 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.

S280-79-10

Figure 8. 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.

SAFETY

FOR LIFE

HOT LINE

TAG

OFF

RS-232 Communication Port

The standard Form 5 control is equipped with a operator panel RS-232 port for interface with a personal computer running the Form 5 interface software program. This ninepin 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 RS-232 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 RS-232 port is intended only for

temporary connection of a personal computer. Permanent serial communications must be made via the RS232 or fiber-optic accessory board.

Battery Test Procedure

The condition of the control battery is tested by depressing the BATTERY TEST hot 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 -600mA 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

for Step 3.

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.

Control Features

The Form 5 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 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 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.

Voltage Protection (120 Vac-based)

Voltage protection functionality is included as standard on all Form 5 controls. A recloser trip will be 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, and single-phase with three-phase inhibit. Response mode facilitates protecting 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 or with the interface software or SCADA (Figure 9). Each profile has 14 TCC specifications plus reclose intervals, sequence coordination and reset times to maintain independent protection parameters.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

Figure 9. Interface software sample protection profile.

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 may select between the standard definition of power factor (cosine of angle between current and voltage) or the Cooper Power Systems default of the power factor sign following power flow.

Voltage Metering

Six voltages (3-source and 3-load) are metered as standard on the Form 5 control. The user selects either phaseto-phase or phase-to-ground values from the control operator panel, interface software, or serial communications. This reference is changed by selecting the voltage sensor correction 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, 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. See Figure 9.

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, these four LEDs flash 1 second on, 1 second off (Figure 10):

• RECLOSER MALFUNCTION

• RECLOSER CLOSED

• RECLOSER OPEN

• CONTROL 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.

To test the Trip Failure Detection feature, see Testing

With Type MET Tester in the TESTING AND TROUBLESHOOTING section of this manual.

S280-79-10

Figure 10. RECLOSER MALFUNCTION, RECLOSER CLOSED, RECLOSER OPEN and CONTROL LOCKOUT LEDs will blink for the affected phase as indication of Trip Failure.

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

SAFETY

FOR LIFE

AC POWER

ABOVE MIN TRIP

CHECK BATTERY

RECLOSER MALFUNCTION

REVERSE POWER FLOW

BUSHINGS 1-2 FAULT TARGET

BUSHINGS 3-4 FAULT TARGET

BUSHINGS 5-6 FAULT TARGET

GROUND FAULT TARGET

SENSITIVE-GROUND FAULT TARGET

BUSHINGS 1-2 VOLTAGE

BUSHINGS 3-4 VOLTAGE

BUSHINGS 5-6 VOLTAGE

RECLOSER CLOSED

RECLOSER OPEN

CONTROL LOCKOUT

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 delay is programmable from 0 to 60 seconds in 1 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). The RECLOSER CLOSED LED indicates the status of the feature. See Figure 11.

Harmonic Analysis

Extensive harmonic analysis is performed by the Form 5 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 12) while complete analysis, including graphing capabilities, is provided from the Form 5 interface software.

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 illuminates an operator-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.

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 is capacity, the oldest event is deleted as a new event is added.

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 in between userdefined minimum and maximum limits. Date and time are recorded for the maximum and minimum demand values.

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 13) 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 control interface software to program the activation time and time-current characteristics applicable to 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.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

Figure 13. Interface software Cold Load Pickup settings.

Figure 12. Form 5 operator panel harmonic readout.

Figure 11. The blinking of the RECLOSER CLOSED LED indicates Manual Close Delay is active.

RECLOSER CLOSED

RECLOSER OPEN

CONTROL LOCKOUT

Pg14 Gnd %THDI Ph1-2 %THDI Ph3-4 %THDI Ph5-6 %THDI

BACK

RESET

TARGETS

RESET

MAX CURRENT

CHANGE

LAMP TEST

Alarms

Status and data alarms are available for many control parameters such as voltage, currents, 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.

Fault Location

Fault Location provides an approximate distance of a fault from the the Form 5 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 14.

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 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.

S280-79-10

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 control detecting the fault.

Figure 14. Fault Location configuration screen.

SAFETY

FOR LIFE

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 15. 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

)

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 Infor-

mation S280-79-2 Form 5 Microprocessor-Based Recloser Control Programming Guide for additional information.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

Figure 15. Directional SGF/SEF configuration screen.

Communications

Communication Ports

The Form 5 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 16 illustrates the communication configuration for serial ports1, 2, and 3.

Fiber-Optic/RS-232 Accessory

Two sets of receive and transmit LEDs (Figure 17) 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 S280-79-4 Form 5

Serial communications Accessory Operation Instructions for additional information.

Protocols

Three protocols are available for the Form 5 control and are factory-configurable to 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, Screens 40 and 41 respectively. (Port 1 shares the same settings as Port 2.)

S280-79-10

Figure 16. Control communication port configuration.

Figure 17. 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 RS-232 port.

SAFETY

FOR LIFE

TEMPORARY

OPERATIONS

OPERATOR PANEL

DISPLAY AND

KEYPAD

ENGINEERING

COMMUNICATIONS

PORT 1

(Internal Use Only)

(Local PC)

OPERATOR

PANEL RS-232

(Metering, Histograms Profiles, Alarms, Targets)

ENGINEERING

(Radio, Fiber-Optic, Modem)

RS-232 or

FIBER-OPTIC

ACCY

AUTO TRANSFER SWITCH (Operator Panel Connection Disables Accessory)

COMMUNICATIONS PORT 2 (Shared)

CPU

COMMUNICATIONS

SCADA SYSYEM

(Radio, Fiber-Optic, Modem)

FIBER-OPTIC

PORT 3

(Dedicated)

RS-232 or

ACCY

TX 3

RX 3

TX 2

RX 2

RS232

AUXILIARY POWER FOR

ACCESSORIES

Connection P9 (Figure 18) on the Power Supply module provides 24Vdc (12Vdc is available) to power radio communication units, RTUs and other accessories. The auxiliary power provides 40W peak load capability. Auxiliary power is fused 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 continually energized. Terminal 2 and 4 are not used at this time.

RECLOSER INTERFACE (RIF)

MODULE CONFIGURATION

The Recloser Interface (RIF) Module is factory-configured at 120Vac. For operating voltages other than 120Vac, the RIF module must be removed from the control cabinet for configuration.

To remove the RIF Module for configuration:

1. Disconnect the control battery.

2. Remove the four connectors from the front of the RIF

Module.

3. Remove the nut and disconnect the grounding strap to

the operator panel. See Figure 4.

4. Disconnect the wiring harness connectors from the

bottom of the RIF Module.

Note: Press the locking tabs to release the harness con-

nectors.

5. Remove the four 11mm (.437 in) screws securing the

board to the mounting bracket.

6. Pull the module out of the cabinet.

The dip switches are located on the side of the module.

7. Configure the RIF board as shown in Figure 19.

8. After configuration, place the module back into posi-

tion in the control cabinet and secure to the mounting bracket with screws previously removed.

9. Replace nut securing the RIF Module grounding strap

10. Replace all connectors on the front and bottom of the

RIF Module.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

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 19. Recloser Interface (RIF) Module indicates the factory-configured metering voltage (120Vac).

Figure 18. Power Supply Module Connection P9 provides 24Vdc power to radio communication units.

IMPORTANT: The Form 5 control must be completely de-energized prior to removing and configuring the RIF board.

GDC-1A

SW (-) 4

28V (-) 3

SW (+) 2

28V (+) 1

C P U

P 9

A U X

Example shown for 120Vac operation:

SENSOR

VOLTAGE POLE1 POLE2

12Vac OFF OFF

120Vac* OFF ON

240Vac ON ON

*120Vac is factory-set configuration

INPUT VOLTAGE

SELECTION

OFF

SELECTION

POLE 1 POLE 2 POLE 1 POLE 2

POLE 1 POLE 2

POLE 1 POLE 2 POLE 1 POLE 2

POLE 1 POLE 2

BUSHING 2 (XØ)

BUSHING 4 (YØ)

BUSHING 6 (ZØ)

INPUT VOLTAGE

OFF

BUSHING 1 (AØ)

BUSHING 3 (BØ)

BUSHING 5 (CØ)

The UDP function allows the Form 5 control to become a switch control to provide indication of overcurrent trip conditions without issuing an overcurrent trip signal. The con- trol 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), 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.

S280-79-10

Figure 21. Interface software Switch Mode settings.

Figure 20. Function/Indication pushbuttons for the Form 5 equipped with the UDP accessory.

FORM 5 UNIVERSAL DEVICE PROTECTION (UDP) CONTROL

Figure 22. Form 5/UDP Operator Panel.

SAFETY

FOR LIFE

GND TRIP BLOCKED

COLD LOAD

PICKUP

BLOCKED

ALTERNATE

PROFILE

NO. 1

NON

RECLOSING

BATTERY

TEST

ALTERNATE

PROFILE

NO. 2

SUPERVISORY

BLOCKED

FAST

TRIPS

DISABLED

SWITCH

MODE

CONTROL OK

AC POWER

ABOVE MIN TRIP

CHECK BATTERY

RECLOSER MALFUNCTION

REVERSE POWER FLOW

BUSHINGS 1-2 FAULT TARGET

BUSHINGS 3-4 FAULT TARGET

BUSHINGS 5-6 FAULT TARGET

GROUND FAULT TARGET

HOT LINE

TAG

GND TRIP BLOCKED

COLD LOAD

BLOCKED

OFF

PICK UP

ALTERNATE

PROFILE

NO. 1

TX 3

RX 3

SENSITIVE-GROUND FAULT TARGET

AØ

SOURCE

BØ

VOLTAGE

CØ

XØ

LOAD

YØ

VOLTAGE

ZØ

RECLOSER CLOSED

RECLOSER OPEN

CONTROL LOCKOUT

BACK

RESET

TARGETS

RESET

MAX CURRENT

RECLOSING

TX 2

RX 2

NON

BATTERY

TEST

ALTERNATE

PROFILE

NO. 2

CHANGE

LAMP TEST

RS232

SUPERVISORY

BLOCKED

FAST

TRIPS

DISABLED

SWITCH

MODE

TRIP

(LOCKOUT)

RECLOSER CONTROL

KYLE

FORM 5/UDP

The Kyle Form 5 recloser control can be equipped with a dc-to-dc converter, interface circuit, and a fully shielded 19-pin cable for use with a Type DC NOVA recloser. See Figure 23.

The dc-to-dc converter board (Figure 24) converts the control’s 24 Vdc battery supply voltage to 53 Vdc to drive the trip/close capacitors in the NOVA mechanism. The output of the board is separately fused for operator indication.

The dc-to-dc converter houses voltage monitoring and conditioning circuits which protect the battery from failure and provides trip/close operations without AC power. The 19-pin control cable interfaces the NOVA dc recloser to the Form 5 control through the interface circuit. The cable also provides AC power from the control to the recloser mechanism heater.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

FORM 5 DC NOVA CONTROL

Figure 23. Connections of a Form 5 control with dc NOVA accessory to a dc NOVA recloser.

Figure 24. 99007KM Dc-to-dc converter located behind Form 5 operator panel (removed).

dc NOVA

Potential Transformer (120/240Vac)

19 Pin

Control Cable

Form 5 Control

O P E

120Vac/240Vac

Power Cable

S280-79-10

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 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 factory-set inputs and outputs for discrete SCADA functions. Each Form 5 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.

Note: 28 Vdc (nominal) is provided from the DIF module via

connector P5 for use as whetting voltage for inputs to P4. As an alternative, the user can supply whetting voltage from an auxiliary source, such as a RTU.

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 25 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 320 Vac, 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: Do not use DIF module for overcurrent protection. Digital SCADA can be used for this application. 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.

SAFETY

FOR LIFE

DISCRETE

INTERFACE

MODULE

ACCESSORY

INPUT COMMON

OUTPUT COMMON

9 8 7 6 5 4 3 2 1

28V (–) 28V (+)

4 3

12 11 10

9 8 7 6 5 4 3 2 1

12 11 10

9 8 7 6 5 4 3 2 1

12 11 10

9 8 7 6 5 4 3 2 1

WHETTING VOLTAGE

UNLATCHED OUTPUTS

LATCHED OUTPUTS

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.

28V (-)

28V (+)

4 3

Customer-Supplied Wiring for Whetting Voltage

REMOTE CONTACTS

To P4

Inputs 1 thru 12

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

Figure 27. Customer connections to DIF module outputs with shielding and surge protection.

FORM 5 CONTROL

*28 Vdc (nominal)

supplied by

DIF module for

whetting voltage.

Discrete Interface

Module (DIF)

INPUT COMMON

*28V (–)

*28V (+)

OUTPUT COMMON

CONTROL OK

AC POWER

SUPERVISORY BLOCKED

COLD LOAD PICKUP BLOCKED

NON-RECLOSING

NORMAL PROFILE

ALTERNATE PROFILE 3

ALTERNATE PROFILE 2

ALTERNATE PROFILE 1

11 12

910

67 8512 43

11 12

910

Remote Terminal Unit (RTU)

COMMON

INPUT VOLTAGE

GROUND TRIP BLOCKED

HOT LINE TAG

RECLOSER OPEN

67 8512 43

REMOTE TRIP AND LOCKOUT

REMOTE TRIP AND RECLOSE

SUPERVISORY COLD LOAD PICKUP BLOCKED

SUPERVISORY NON-RECLOSING

SUPERVISORY NORMAL PROFILE

SUPERVISORY ALTERNATE PROFILE 3*

SUPERVISORY ALTERNATE PROFILE 2

SUPERVISORY ALTERNATE PROFILE 1

SUPERVISORY GROUND TRIP BLOCKED

(*SWITCH MODE ON FORM 5 UDP)

REMOTE HOT LINE TAG

SUPV. CLOSE

SUPV. TRIP & L.O.

11 12

910

67 8512 43

Not All Remote

Connections

Shown

S280-79-10

Standard and UDP Controls

Standard and UDP Form 5 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: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 k 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 (Supplied by Internal Voltage Source of DIF Module)

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.

SAFETY

FOR LIFE

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

Note: Supervisory Alternate Profile 3 replaced by Switch

Mode on UDP controls.

Standard and UDP Control DIF Module 1

Inputs

The DIF inputs are factory-configured as momentary (0.25 sec. duration) or maintained functions. Supervisory signals do not have any effect when supervisory blocked is active. Remote inputs function when supervisory is blocked.

Input Connector Function Description

1 P4-1 Supervisory Trip and Lockout Supervisory Trip and Lockout 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.

2 P4-2 Supervisory Close Supervisory Close initiates a closing signal to the recloser. A

momentary signal is required for proper operation.

3 P4-3 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.

4 P4-4 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.

5 P4-5 Supervisory Alternate Profile 1 6 P4-6 Supervisory Alternate Profile 2 7 P4-7 Supervisory Alternate Profile 3*

8 P4-8 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.

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.

S280-79-10

Standard and UDP Control DIF Module 1

Inputs (cont’d)

Input Connector Function Description

9 P4-9 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.

10 P4-10 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.

11 P4-11 Remote Trip and Reclose Remote Trip and Reclose initiates a trip operation followed by a

reclose operation. 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.

12 P4-12 Remote Trip and Lockout Remote Trip and Lockout trips the recloser open and locks out the

control. It can be used for tripping from external relays and alarms. A momentary signal is required for proper operation. This input performs the same function as the TRIP (LOCKOUT)

switch on the operator panel and is active regardless of the state of the Supervisory function.

SAFETY

FOR LIFE

*Note: Supervisory Alternate Profile 3 replaced by Switch

Mode on UDP controls.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

Standard and 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 Normal Profile Non-Latched

P3-2 NO

2 P3-3 NC Non-Reclosing Non-Latched

P3-4 NO

3 P3-5 NC Cold-Load Pickup Blocked Non-Latched

P3-6 NO

4 P3-7 NC Supervisory Blocked Non-Latched

P3-8 NO

5 P3-9 NC AC power Non-Latched

P3-10 NO

6 P3-11 NC Control OK Non-Latched

P3-12 NO

7 P2-1 NO Recloser Open Latched

P2-2 NC

8 P2-3 NO Hot Line Tag Latched

P2-4 NC

9 P2-5 NO Ground Trip Blocked Latched

P2-6 NC

10 P2-7 NO Alternate Profile 1 Latched

P2-8 NC

11 P2-9 NO Alternate Profile 2 Latched

P2-10 NC

12 P2-11 NO Alternate Profile 3* 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.

This output is active when the COLD LOAD PICKUP BLOCKED indicator on 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.

AC power indicator is active when the control detects the presence of AC power. This output is active when the AC power indicator on the operator panel is illuminated.

Control OK indicator is active when the control is able to perform protection operations. This output is active when the CONTROL OK indicator on the operator panel is illuminated.

Recloser Open indicator is active when the recloser signals the control that the recloser contacts are open. This output is active when the RECLOSER OPEN indicator is illuminated.

These outputs are active when the respective ALTERNATE PROFILE indicators 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.

S280-79-10

Standard and UDP Control DIF Module 2

Inputs

The DIF inputs are factory-configured as momentary or maintained functions. 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 Fast Trips Disabled This input performs the same function as the FAST TRIPS DIS-

ABLED key on the operator panel and is inactive if the Supervisory function is disabled. This is a momentary function.

2 P4-2 Supervisory Reset Targets This input performs the same function as the RESET

TARGETS/RESET MAX CURRENT key on the operator panel. This input is inactive if the Supervisory function is disabled. This is a momentary function.

3 P4-3 Supervisory Operation Counter OFF The operation counter is disabled when this input is active with a

maintained whetting voltage. This input is inactive if the Supervisory function is disabled.

4 P4-4 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.

5 P4-5 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.

SAFETY

FOR LIFE

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

Standard and 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) Control Lockout Non-Latched

P3-2 (NO)

2 P3-3 (NC) Check Battery Non-Latched

P3-4 (NO)

3 P3-5 (NC) Reverse Power Flow Non-Latched

P3-6 (NO)

4 P3-7 (NC) Fast Trips Disabled Non-Latched

P3-8 (NO)

5 P3-9 (NC) Operation Counter Non-Latched

P3-10 (NO)

6 P3-11 (NC) Recloser Malfunction Non-Latched

P3-12 (NO)

7 P2-1 (NO) Bushings 1-2 Fault Target Latched

P2-2 (NC)

8 P2-3 (NO) Bushings 3-4 Fault Target Latched

P2-4 (NC)

9 P2-5 (NO) Bushings 5-6 Fault Target Latched

P2-6 (NC)

10 P2-7 (NO) Ground Fault Target Latched

P2-8 (NC)

11 P2-9 (NO) Sensitive Ground Fault Target Latched

P2-10 (NC)

12 P2-11 (NO) Sensitive Ground Fault Blocked Latched

P2-12 (NC)

This output is active when the CONTROL LOCKOUT indicator is illuminated.

This output is active when the CHECK BATTERY indicator is illuminated.

This output is active when the REVERSE POWER FLOW indicator is illuminated.

This output is active when the FAST TRIPS DISABLED indicator is illuminated.

If the Supervisory function is enabled, this output is active when the OPERATION COUNTER OFF inputs from Comm Port 1-DIF2, Comm Port 2 and Comm Port 3 are not active.

This output is active when the RECLOSER MALFUNCTION indicator is illuminated.

This output is active when the BUSHINGS 1-2 FAULT TARGET indicator is illuminated.

This output is active when the BUSHINGS 3-4 FAULT TARGET indicator is illuminated.

This output is active when the BUSHINGS 5-6 FAULT TARGET indicator is illuminated.

Output is active when the GROUND FAULT TARGET indicator is illuminated.

Output is active when the SENSITIVE GROUND FAULT TARGET indicator is illuminated.

Output is active when Sensitive Ground Fault is blocked.

Sensed Currents

Note: Control only, does not include sensor tolerance, but

does include the phase current summing process.

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

Sensed Source Voltages

Three-phase voltages used in voltage, power and powerfactor related calculations:

Voltage measurement accuracy:

± 0.4V from 5V to 80V

0.5% from 80V to 135V

S280-79-10

INPUT ACCURACY

SAFETY

FOR LIFE

Initial Programming Prior to Installation

The control must be programmed with all necessary operating settings, all alternate profiles, 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 interface software.

Control / Recloser Compatibility

Reclosers manufactured prior to June 1989 are equipped with Type A bushing current transformers. These reclosers were designed for use with Form 2, Form 3, and Form 3A controls. Because the Form 5 control is designed for use with reclosers equipped with Type B current-sensing Transformers, reclosers retrofitted with Form 5 controls should be retrofitted with Type B current transformers. All reclosers manufactured since 1989 are equipped with Type B (1000:1, 1000/500:1, or 2000:1) sensing CTs.

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

The Form 5 control can be used with the old-style Type A CTs; however, the event recorder, data profiler and duty cycle monitor will have limited accuracy for currents above 5000 Amps.

Retrofit kits with the new Type B sensing CTs are available to upgrade existing families of reclosers for operation with Form 5 controls. For additional information, contact your Cooper Power Systems representative.

For identification, Table 4 lists the serial number breaks between old-style Type A and the new-style Type B sensing CTs. Below this serial number, the recloser is equipped with the Type A CTs.

Note: For reclosers shipped prior to June 1989 and not listed

below, please contact your Cooper Power Systems representative with the recloser type and serial number for verification of Type A or B bushing current transformers.

Control Cable

The control cable is fabricated with connectors which mate with the female receptacle of the recloser on one end and the male receptacle of the control on the other end.

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.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

TABLE 4 Serial Number Break for Reclosers with Type A Sensing CTs

Recloser Below Serial Number

RXE 5831

RVE 5894

WE 11199

WVE 3695

VWE 7199

VWVE27 7208

VWVE38 1204

NOTICE

RECLOSER IS EQUIPPED WITH TYPE B SENSING CTs.

RECLOSER DOES NOT HAVE A BATTERY CHARGER.

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

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: 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.

Mounting the Control

Mount the Form 5 recloser control in a convenient, accessible location. Mounting dimensions are provided in Figure 28.

• For pole-mounted installation, a hole and keyway in the control mounting bracket accommodates a 5/8” bolt.

• For substation installation, brackets are available as an accessory for mounting the control to a substation frame.

Limits on control cable length are determined by the maximum distance between the control and recloser:

• Up to 410 m (125* ft) for solenoid-operated reclosers

(VWE, VWVE27, VWVE38X, WE, WVE27, WVE38X, and NOVA).

• Up to 10,7 m (35* ft) for motor-operated reclosers

(VSA12, VSA12B, VSA16, VSA20, VSA20A, VSO12, VSO16).

Up to 41 m (135* ft) for NOVA DC.

* These lengths are based on standard control cables.

Consult your Cooper Power Systems representative if longer cable lengths are required.

S280-79-10

Figure 28. Control cabinet mounting dimensions.

SAFETY

FOR LIFE

Female Receptacle

For Control

Cable

Vent

35mm (1-7/16") Dia. Hole

For User 120Vac Input Connection

(Cap-Plug Installed)

110mm (4-1/4")

120mm (4-3/4")

40mm

(1-1/2")

30mm (1-1/8") Hole

In Lifting Lug

Male Receptacle

For Control Cable

685mm

(27")

380mm

(15")

190mm (7-3/8")

200mm (7-7/8")

130mm

(5-1/8")

160mm (6-3/8")

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")

580mm (23")

640mm (25-1/4")

76mm

(3")

480mm

(19")

240mm (9-1/2")

Die-cast-zinc latchable Handle For UserProvided Utility-Grade Padlock

30mm

(1-1/8")

CONTROL WEIGHT

350mm

(13-13/16")

52 kg (115 LBS)

110mm (4-3/8")

165mm (6-1/2")

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 29, 30, and 31.

Figure 29 illustrates grounding methods for 3-wire ungrounded and 4-wire multi-grounded systems with local supply voltage transformer.

Figure 30 illustrates grounding methods for 3-wire ungrounded and 4-wire multi-grounded systems with remote supply voltage transformer.

Figure 31 illustrates grounding on a 3-wire uni-grounded system.

For effective surge protection all control and power conductors for the Form 5 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.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

WARNING: Hazardous Voltage. The 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, severe personal injury. G115.1

Installation of a Form 5 control with a local 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.

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.

S280-79-10

Figure 29. Recommended grounding method for the Form 5 Control installed on 4-wire multi-grounded, 3-wire ungrounded, or impedance-grounded systems with local supply voltage transformer.

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

SAFETY

FOR LIFE

GND

NEU

Surge

Arrester

Surge Arrester

Recloser Head Ground

Transformer

Surge

Arrester

Supply Voltage

Transformer

Form 5 LS Control

NEUTRAL

Input Terminal Block

External Ground Lug

Supply

Voltage

Control

Pole

Ground

Cable

Arrester Ground

Recloser

Pole

Form 5 LS Control

Input

NEU

Terminal Block

Customer Ground Connection At External Lug

Input Terminal

Block

ELECTRICAL CONNECTIONS

Line to Neutral connected transformer

Form 5 LS Control

NEUTRAL

ELECTRICAL CONNECTIONS

Line to Line connected transformer

Supply Voltage

Transformer

External Ground Lug

Line to Line Voltage

Installation of a Form 5 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

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

Figure 30. Recommended grounding method for the Form 5 Control installed on 4-wire multi-grounded, 3-wire ungrounded, or impedance-grounded systems with remote supply voltage transformer.

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 1.5kV 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 Remote Supply Voltage Transformer; 4-Wire Multi-Grounded, 3-Wire Ungrounded, or Impedance-Grounded

Supply Voltage

Transformer

ELECTRICAL CONNECTIONS - Remote dedicated

Form 5 LS Control

NEUTRAL

supply transformer

Input Terminal Block

External Ground Lug

Low Voltage Distribution Network

Input

Terminal

Block

ELECTRICAL CONNECTIONS - using isolation transformer

Form 5 LS Control

NEUTRAL

External

Ground Lug

115 Vac Supply Voltage

Local Isolation Transformer

Customer Supplied Low Voltage

Low Voltage Arrester

Pole

Transformer

HOT NEU GND

Note: Distance between

transformer and recloser should be one pole span or less

Supply

Voltage

Pole

Ground

Surge Arrester

Arrester

Ground

Surge Arrester

Recloser

Control Cable

Pole

Form 5 LS Control

Input Terminal Block

NEU

Customer Ground Connection at External Lug

Surge Arrester

Recloser Head Ground

Arrester Ground

System

Neutral

Installation of a Form 5 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.

S280-79-10

Figure 31. Recommended grounding method for the Form 5 Control installed on a 3-wire uni-grounded system.

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 1.5kV 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.

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

SAFETY

FOR LIFE

Supply Voltage

Line to Line Voltage

Transformer

ELECTRICAL CONNECTIONS - Dedicated Supply

Surge

Arrester

Supply

Voltage

Form 5 LS

Control

Input Terminal Block

Form 5 LS Control

Transformer

HOT NEU

GND

NEU

Neutral

Surge

Arrester

Input Terminal Block

External Ground Lug

Surge Arrester

Recloser Head Ground

Arrester Ground

Recloser

Control Cable

Customer Ground

Connection

at External Lug

Control Height must be

3 Meters (10 feet)

minimum above earth

Pole Ground

Customer Connections for AC Power

Input power to the Form 5 control is connected to terminal block TB1 (located behind the operator panel, on the left side of the control). See Figure 33.

Input power is required:

• To power the control

• To provide voltage and power metering

• For voltage detection for loop scheme accessory

• For the low voltage closing accessory

• For the convenience outlet accessory

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

32.

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 34 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 34 through 39 show the customer connections for 120 Vac and 240 Vac low voltage closing.

Figures 34 through 37 illustrate customer connections for single-phase transformers. Figure 34 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 Figure 38 and 39. For example, Figure 39 shows connection from the Power Supply module to an AØ transformer.

The transformer required for power should be a minimum of 5kVA for low-voltage ac closing reclosers and 1kVA for dc closing reclosers.

Note: An out-of-service Form 5 or Form 5 UDP control (for

either Wye or Delta) can be powered by connecting to TB1-2 (hot) and TB1-4 (neutral) to an appropriate power source.

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 19.

See RIF Module Configuration section of this manual.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

CAUTION: Equipment damage. Do not drill con-

Figure 33. 99003KM Terminal Connector Block TB1.

IMPORTANT: Delta connections are not used on any Form 5 control accessory that utilizes the low voltage transfer relay.

Figure 32. Label on Power Supply module indicates factoryconfigured voltage rating (120Vac).

O D U

GDC-3.15A

CONFIGURED

FOR

120

VAC

240

VAC

S280-79-10

Figure 34. Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1 (120Vac or 240Vac Wye Connection).

Figure 35. Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1 (120Vac or 240Vac Delta Connection).

SAFETY

FOR LIFE

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

TB1

(Top View)

Note: Only slight pressure is

3/32 inch

Flat-Blade

Screwdriver

required to open the locking clamp. Excessive pressure can damage the terminal block.

240Vac CLOSING

OPTION

CLOSING VOLTAGE

CUSTOMER

CONNECTIONS

POWER

SOURCE

OUTPUT

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

*BØ

TB1

ZØ

YØ

XØ

HOT (LV Closing Output)

NEU (LV Closing Output)

NEU

CØ

AØ

CØ

BØ

AØ

BØ

CØ

240V CLOSING

OPTION

CUSTOMER

CONNECTIONS

POWER

SOURCE

OUTPUT

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

ZØ

YØ

XØ

HOT (LV Closing Output)

CØ

BØ

AØ

BØ

CØ

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

Figure 36. Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1 (120Vac or 240Vac Open-Delta Connection).

Figure 37. Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1 (3-wire, 240Vac Connection).

240V CLOSING

OPTION

CUSTOMER

CONNECTIONS

POWER

SOURCE

OUTPUT

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

ZØ

YØ

XØ

HOT (LV Closing Output)

CØ

BØ

AØ

BØ

CØ

240V CLOSING

OPTION

CLOSING

VOLTAGE

CUSTOMER

CONNECTIONS

POWER

SOURCE

OUTPUT

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

ZØ

YØ

XØ

CØ

*BØ

AØ

TB1

HOT (240Vac LV Closing Output)†

HOT (120Vac LV Closing Output)

NEU (120Vac LV Closing Output)

† For use with accessories:

3-Wire Low-Voltage Closing with receptacle

3-Wire Low-Voltage Closing with inlet hole for hardwiring

120Vac

Neutral

120Vac

S280-79-10

Figure 38. Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1 (SinglePhase Connection, Standard BØ Input).

Figure 39. Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1 (SinglePhase Connection, AØ Input).

SAFETY

FOR LIFE

240Vac CLOSING

CLOSING VOLTAGE

CUSTOMER

CONNECTIONS

POWER

SOURCE

OUTPUT

CUSTOMER

CONNECTIONS

OPTION

YØ VOLTAGE

120Vac

BØ VOLTAGE

120Vac

NEUTRAL

SOURCE 2

NEUTRAL

SOURCE 1

NEUTRAL

SOURCE 2 POWER

OUTPUT

VOLTAGE

NEUTRAL

*NEUTRAL

SOURCE 1 POWER

ZØ

YØ

XØ

CØ

*BØ

AØ

TB1

HOT (LV Closing Output)

NEU (LV Closing Output)

Jumper**

WHT

P O W

M O

GDC-3.15A

CONFIGURED

BLK

P 9

A U X

FOR

120

VAC

240

VAC

NEU

BØ

*REQUIRED FOR CONTROL OPERATION

**Jumper necessary for use with Low-Voltage Closing Accessory

WHT

GDC-3.15A

BLK

CONFIGURED

FOR

120 VAC

240 VAC

NEU

A U X

AØ

240Vac CLOSING

CLOSING VOLTAGE

CUSTOMER

CONNECTIONS

POWER

SOURCE

OUTPUT

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

ZØ

YØ

XØ

HOT (LV Closing Output)

NEU (LV Closing Output)

CØ

AØ

Jumper**

*REQUIRED FOR CONTROL OPERATION

**Jumper necessary for use with Low-Voltage Closing Accessory

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. AC power connected to the control. (AC power LED

indicator is illuminated.)

5. Control battery connected and tested for proper

operation.

6. All control programming entered and verified by

appropriate personnel.

7. Control clock set to the correct time.

8. Customer connections for remote and supervisory

operation checked and completed in accordance with proper shielding and surge protection.

9. Control cable properly connected and supported.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

CAUTION: Equipment misoperation. Do not

WARNING: Hazardous voltage. Recloser and

Testing an Installed Control

The following tests to determine initial operation of the Form 5 control can be performed while connected to an operating recloser. These are the only tests performed on an installed, operating control. All other tests described in this Testing and Troubleshooting section require the Form 5 control to be removed from service, connected to a bypassed recloser, or tested at a location where the proper testing equipment is available.

1. Wake-up 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. Refer to Form 5 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.

Check CPU Status

Check the operating status of the CPU module. Open the cabinet door and locate the LED indicator (Figure 40).

The LED indicator on the CPU module should flash at a rate of one flash per second for normal 60 Hz operation (slightly faster for 50Hz).

Testing With Type MET Tester

The Kyle Type MET Electronic Recloser Control Tester (Figure 41) is used for testing the Form 5 control.

The MET Tester is completely self-contained, includes all necessary metering and interconnecting cables, and is capable of performing all required checks and tests from a simple verification of operation to a complete verification

of all operating parameters. Refer to Service Information

S280-76-1 Type MET Electronic Recloser Control Tester Operator Instructions for proper setup and use of the MET

tester. Refer to Form 5 Control Default Test Procedure section of this manual for specific tests requiring the KMET Tester.

S280-79-10

IMPORTANT: The Form 5 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

Figure 40. Form 5 control CPU module.

99002KM

CPU Module (Central Processing Unit)

CPU Module LED Indicator

Figure 41. Kyle Type MET electronic recloser control tester.

010028KM

IMPORTANT: The Form 5 DC NOVA control cannot be tested with the standard Kyle MET Tester. A junction box accessory for the MET tester is available for testing the Form 5 DC NOVA control.

TESTING AND TROUBLESHOOTING

IMPORTANT: When the control is open and current

is present, the Trip Fail detection circuit in the Form 5 control will activate when the Kyle Type MET tester CALIBRATE switch is ON. Depress and hold the RESET TARGET keypad on the control for 3 seconds to reset the condition.

SAFETY

FOR LIFE

Closing the Recloser During Testing

Electrical Closing—Solenoid-Operated Reclosers

Line voltage is required for automatic recloser operation during testing of reclosers equipped with a closing solenoid (except for reclosers equipped with the low voltage closing accessory).

For on-line testing, bypass the recloser, open the loadside disconnects and keep the source-side disconnects closed. This will remove the recloser from service, but will keep line voltage supplied to the closing solenoid (Figure

44).

For shop testing, the closing solenoid voltage is supplied by back-feeding a transformer with a low-side rating equal to the voltage rating of an available power source, and a high-side rating equal to the voltage rating of the recloser (Figure 45). A 75kVA transformer of the proper voltage rating with an impedance drop of approximately 3% is satisfactory. The ac source must have a comparable impedance drop.

The closing coil requirement is approximately 200kVA during the two-to-three cycle closing operation. The solenoid coil operating voltage must be maintained at the recloser bushings during the cycle interval the closing coil is energized. This procedure is not used on reclosers equipped with the low-voltage closing accessory.

Electrical Closing—Motor-Operated Reclosers

High-voltage is not required for reclosers utilizing a motoroperated closing mechanism energized from a 230VAC power source. For information on energizing the recloser, refer to the appropriate motor-operated recloser installation manual.

Figure 43 shows a test circuit for motor-operated and solenoid-closing reclosers with low-voltage closing. Since these reclosers require only a 240 Vac source for closing, high-voltage transformer T3 and its protective cage is eliminated. All other equipment is the same as the test equipment shown in Figure 42.

Electrical Closing—NOVA Reclosers

Type NOVA 3-phase reclosers utilize an interface circuit located in the mechanism housing. The electronic interface circuit controls the opening and closing signals to the magnetic actuator.

The Dc NOVA Recloser is tested with the dc-to-dc converter and 19-pin cable connected to the dc power supply.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

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

death, severe personal injury, and equipment damage.

T223.2

Figure 43. Suggested test circuit for motor-operated, solenoidclosing reclosers with low-voltage closing.

WARNING: Hazardous voltage. Interconnect

source leads X and Y and ground solidly to the recloser tank (Figure 45). Do not connect lead Z to any other phase or mechanical ground. Dangerous voltages to ground exist on the phase connected to lead Z. Solidly ground all equipment. Failure to comply can result in severe personal injury and/or equipment damage. T224.1

Figure 42. Alternate method of producing variable line current (substitute for T2 and W-X circuit in Figures 43 and

45).

WARNING: Hazardous voltage. The switchgear

and high voltage transformer must be in a test cage or similar protective device to prevent accidental contact with the high voltage parts. Solidly ground all equipment. Failure to comply can result in death, severe personal injury, and equipment damage. T221.3

Sensing CTs (3)

240 Vac

Closing

Motor

T1 T2

Variable Autotransformer 240 Vac-20 A

Electronic Control

240 Vac Power Supply

To Ammeter and Relay to operate cycle counter or other timing device

115Vac

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

Variable Autotransformer (10 Amp)

600:5 Recloser BCT ON 600:5 Tap

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

Clamp-On Ammeter

120 Vac

S280-79-10

Figure 45. Suggested test circuit for “shop-testing” solenoid-closing reclosers.

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

SAFETY

FOR LIFE

BYPASS SWITCHES

(CLOSED)

SOURCE

SOURCE SIDE DISCONNECT SWITCHES (CLOSED)

CLOSING

5 6

COIL

SOURCE

1 2

LOAD

LOAD SIDE DISCONNECT SWITCHES (OPEN)

LOAD

VOLTAGE RATING OF RECLOSER CLOSING SOLENOID COIL

TO 240 OR 480 VAC SOURCE

SENSING CTs (3)

CLOSING SOLENOID COIL

CLOSING SOLENOID CONTACTOR

ROTARY SOLENOID

MAIN CONTACTS (S)

TRIP SOLENOID

TO 240 VAC SOURCE

VARIABLE AUTOTRANSFORMER 240 VAC 20 AMPS

CONTROL CABLE RECEPTACLE

ELECTRONIC CONTROL

AMMETER AND RELAY TO OPERATE CYCLE COUNTER OR OTHER TIMING DEVICE

120 VAC

Manual Closing—Solenoid-Operated Reclosers

If high-voltage for operating the closing solenoid is not available, manual closing can be substituted for electrical closing. However, not all control settings can be checked since manual closing is not synchronized with the closing coil control circuit in the control.

To manually close the recloser:

1. Remove the closing tool port cover and gasket from

the side of the recloser head casting.

2. Insert the tee-handled tool (available as an accessory)

into the port, engaging the pin on the closing shaft (Figure 46).

3. Close the recloser by placing the yellow operating

handle (located under the sleethood) into the up or CLOSED position and turning the closing tool onequarter turn clockwise.

4. After each trip operation, about 1/2 second elapses

while the closing solenoid plunger is moving upward to reset the main toggle latch.

5. After the main toggle latch resets, the recloser can be

closed again by operating the manual closing tool.

6. Replace the gasket and port cover on the recloser

head after testing has been completed.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

WARNING: Explosion Hazard. Excessive Con-

tact Arcing. Do not use the manual closing tool to close an oil-insulated, energized recloser. Closing an energized oil-insulated recloser with a manual closing tool can cause excessive contact arcing, rapid build-up of gas within the equipment, and possible explosion that can cause death, severe personal injury, and equipment damage. T203.2

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

Figure 46. Using a manual closing tool to operate the recloser.

82284KMA-F

Use this procedure to test the Form 5 control with factory default control settings. Follow all cautions and warnings in these service instructions.

Before installation on an active feeder, the Form 5 control’s final control settings must be fully tested using an appropriate test procedure. The Form 5 Control Default Test Sheet follows these instructions. The Form 5 Control Default Test Sheet Optimal Values gives the optimal values for the test results.

When performing these tests, change the Form 5 panel settings by first pressing the CHANGE button and then pressing the button of the function to be changed.

Initial Settings

1. Apply 120 (240) Vac to the control phase B and neu-

tral for standard controls.

2. Plug in battery.

3. Verify control is programmed for all default settings.

• Phase Minimum Trip is set to 100 amps.

• Ground Minimum Trip is set to 50 amps.

4. Disable Sequence Coordination in normal profile

using personal computer (PC).

5. Activate COLD LOAD PICKUP BLOCKED (LED is on)

on Form 5 display panel.

6. Activate GROUND TRIP BLOCK (LED is on) on Form

5 display panel.

Test Battery Circuitry

1. Press BACK button on display panel until Battery Test

Screen 31 appears.

2. Record values for all settings.

3. Press CHANGE button on the display panel.

4. Press BATTERY TEST button on display panel.

5. Record values for all readings.

Test Phase Minimum Trip Values

1. Verify Ground Trip Block LED is on.

2. Set KMET Phase Selector S5 to A.

3. Set KMET switch S4 to 300 milliampere range.

4. Set KMET Variac TR1 to zero.

5. Set KMET switch S2 to test fault current position.

6. Press the TRIP button on the display panel.

7. Press the CLOSE button on the display panel.

8. Slowly raise TR1 until Above Minimum Trip LED is on,

on display panel. Control should trip out quickly for load currents above 105 milliamperes. Record value.

9. Repeat steps 4 – 8 for phases B and C (move KMET

S5 to B, then C).

10. Change Form 5 control from Normal Profile to Alter-

nate Profile 1.

11. Verify Cold Load Pickup Blocked (LED is on) on the

display panel.

12. Repeat steps 2 – 9 for Form 5 Alternate Profiles 1, 2,

and 3. The control is programmed to trip out at 200 milliamperes on the Alternate 1, 2, and 3 Profiles.

Note: If Cold Load Pickup LED is off, the control will trip on a

time delayed Time Current Curve with two trips to lockout for 30 seconds after closing in the control, per the default Cold Load Pickup control settings.

Note: If Alternate Profiles 1, 2, and 3 have the sequence coor-

dination function enabled while testing the Form 5 control minimum trip values, it may result in the control skipping past the fast TCC curves during the test for minimum trip. The control will then lock out on the delayed TCC curves.

Note: If the Form 5 control has Switch Mode rather than Pro-

file 3, the control will indicate current Above Minimum Trip, but will not trip out.

S280-79-10

CAUTION: Equipment misoperation. Do not con-

nect 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 Form 5 DC NOVA control can not be tested with the standard Kyle MET Tester. A junction box accessory for the MET tester is availble for testing the Form 5 DC NOVA control.

FORM 5 CONTROL DEFAULT TEST PROCEDURE

IMPORTANT: The Battery Test procedure requires

large current drain. Overuse of this procedure will drain the battery.

SAFETY

FOR LIFE

Test Ground Minimum Trip Values

1. Change the Form 5 control from an Alternate Profile to

the Normal Profile (all three Profile LEDs are off). Disable Ground Trip Block (LED off).

2. Set KMET switch S4 to 100 milliampere range.

3. Set KMET Variac TR1 to zero.

4. Set KMET switch S2 to test fault position.

5. Verify the Form 5 phase minimum trip values are

higher than the ground trip values.

6. Set KMET Phase Selector S5 to A.

7. Press the TRIP button on the display panel.

8. Press the CLOSE button on the display panel.

9. Slowly raise TR1 until Above Minimum Trip shows on

Form 5 control. Control should trip out for load currents above 50 milliamperes. Record values.

10. Repeat steps 4 – 9 for the Form 5 Alternate Profiles 1,

2, and 3. The control is programmed to trip out at 100 milliamperes on the Alternate 1, 2, and 3 Profiles.

Note: If Cold Load Pickup is activated (LED off), the control will

trip on a time delayed TCC with two trips to lockout for 30 seconds after closing in the control, per the default Cold Load Pickup control settings.

Test Phase Timing

1. Set the Form 5 control to Normal profile (all Alternate

Profile LEDs off).

2. Activate GROUND TRIP BLOCK (LED on). Ground

Trip is blocked.

3. Set KMET Phase Selector S5 to phase A.

4. Set KMET switch S4 to 300 milliampere range.

5. Press the Form 5 trip switch once to lock out the Form

5 control.

6. Set KMET phase selector S3 to Control Response.

7. While holding the KMET Test Fault Current Switch S2

in the Calibrate position, adjust the fault current to 200 percent fault (100 X 2 or 200 milliamperes).

Note: On newer controls, applying fault current while the

control is locked out will set the Recloser Malfunction LED. This will not affect testing. To clear, press the Reset Targets button after all tests are complete.

8. Press the TRIP button on the display panel.

9. Press the CLOSE button on the display panel.

10. Set KMET Fault Switch S2 to test fault current posi-

tion. Record timing readings from the KMET time clock for all trips on the A 2X___ test sheet location.

11. Set KMET Test Set switch S4 to the 1A position.

12. Set KMET Phase Selector S5 to phase B.

13. Calibrate KMET fault current to 500 percent (100 X 5

or 500 milliamperes) using the KMET 1A range.

14. Press the TRIP button on the display panel.

15. Press the CLOSE button on the display panel.

16. Set KMET test set Fault Current Switch S2 to test fault

current position. Record timings from the KMET test set for all trips on the B 5X ___ locations on the test sheet.

17. Set KMET Phase Selector S5 to phase C.

18. Calibrate KMET Phase Selector S5 to 1000% of fault

(1000 milliamperes).

19. Press the TRIP button on the display panel.

20. Press the CLOSE button on the display panel.

21. Set KMET test set Fault Current Switch S2 to test fault

current position. Record timings from the KMET test set for all trips on the C 10X ___ locations on the test sheet.

22. Repeat steps 2 – 21 for Alternate Profiles 1, 2, and 3.

Note that the Phase minimum trip for the Alternate Profiles is 200 amps. The 200% fault will then be 400 milliamperes or .4 amp, the 500% fault will then be 1000 milliamperes or 1 amp, and the 1000% fault will then be 2000 milliamperes or 2 amps.

Test Ground Timing

1. Verify control is programmed for all default settings.

2. Disable GROUND TRIP BLOCK (LED off). Ground

Trip is active.

3. Activate the Normal Profile (Alternate Profile LEDs

off).

Note: When testing the ground trip timing circuit, the KMET

test set applies a phase to ground fault to the Form 5 control. If the applied fault current exceeds the phase minimum trip value, the control may time out on the phase time current curve, which may be shorter than the proper ground time current curve. For this reason, the Form 5 phase minimum trip value should be increased to a higher value while testing Form 5 ground trip time current curves.

4. Increase the Form 5 phase minimum trip value to

1600 amperes.

5. Set KMET Test Set switch S4 to the 300 milliampere

position.

6. While holding the Fault Current Switch S2 in the Cali-

brate position, adjust the fault current to 200 percent fault (50 X 2 or 60 milliamperes).

7. Press the TRIP button on the display panel.

8. Press the CLOSE button on the display panel.

9. Set KMET test set Fault Current switch S2 in the test

fault current position. Record timings from the KMET test set for all trips on the G 2X ___ locations on the test sheet.

10. Calibrate KMET fault current to 500 percent, (50 X 5

or 250 milliamperes).

11. Press the TRIP button on the display panel.

12. Press the CLOSE button on the display panel.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

13. Set KMET test set Fault Current switch S2 in the test

fault current position. Record timings from the KMET test set for all trips on the G 5X ___ locations on the test sheet.

14. Set KMET Test Set switch S4 to the 1A position.

15. Calibrate KMET fault current to 1000 percent, (50 X 10

or 500 milliamperes).

16. Press the TRIP button on the display panel.

17. Press the CLOSE button on the display panel.

18. Set KMET test set Fault Current switch S2 in the test

fault current position. Record timings from the KMET test set for all trips on the G 10X ___ locations on the test sheet.

19. Repeat steps 4 – 18 for Alternate Profiles 1, 2, and 3.

Note that the ground minimum trip for the Alternate Profiles is 100 amps. The 200% fault will then be 200 milliamperes, the 500% fault will then be 500 milliamperes, and the 1000% fault will then be 1000 milliamperes or 1 amps.

20. Return the Normal Profile Phase Minimum Trip Value

to the pretest value, 100 amps.

Test Non-Reclose

1. Activate NON-RECLOSING (LED on).

2. Activate GROUND TRIP BLOCK (LED on).

3. Set KMET Phase Selector switch S5 to phase A.

4. Set Form 5 control to Normal Profile (all Alternate Pro-

file LEDs off).

5. Adjust fault current to 200 percent or 200 mil-

liamperes.

6. Press the TRIP button on the display panel.

7. Press the CLOSE button on the display panel.

8. Set KMET test set Fault Current Switch S2 to fault

position.

9. Control should trip once, then indicate open and lock-

out. Record time value.

10. Disable NON-RECLOSE (LED off).

11. Repeat steps 5 – 8, to lockout. Record time value.

Test Cold Load Pickup Blocked

1. Disable COLD LOAD PICKUP BLOCKED (LED off).

2. CLOSE the Form 5 control.

3. Adjust fault current to 200 percent or 200 mil-

liamperes.

4. Within 30 seconds of Step 3, set KMET test set Fault

Current Switch S2 to fault position.

5. Control should trip twice on slow TCC curve, then indi-

cate open and lockout. Record timing value.

6. Activate COLD LOAD PICKUP BLOCKED (LED on).

7. Repeat steps 2 – 4. Record value.

Test Fast Trips Disabled

1. Activate FAST TRIPS DISABLED (LED on).

2. CLOSE the Form 5 control.

3. Adjust fault current to 200 percent or 200 mil-

liamperes.

4. Set KMET test set Fault Current Switch S2 to fault

position.

5. Control should trip two times to lockout, on all slow

TCCs, then indicate OPEN and lockout. Record value.

6. Deactivate Fast Trips Disabled (LED off).

7. Repeat steps 2 -4. Control should trip on two fast, two

slow TCCs. Record values.

Test Hot Line Tag

1. CLOSE the Form 5 control.

2. Activate HOT LINE TAG (LED on).

3. Adjust fault current to 200 percent or 200 mil-

liamperes.

4. Set KMET test set Fault Current Switch S2 to fault

position.

5. Control should trip out once on the 101 TCC curve,

then indicate open and lockout. Record value.

6. Verify that it is not possible to close the Form 5 control.

7. Deactivate HOT LINE TAG (LED off).

8. Verify that you can CLOSE the Form 5 control.

Test Reclose

1. Set KMET selector switch S3 to Control Reclose

Reset.

2. Reset the KMET Time Clock if required.

3. Adjust fault current to 200 percent or 200 mil-

liamperes.

4. Set KMET test set Fault Current Switch S2 to fault

position.

5. After trip, turn fault switch S2 off.

6. Record reclose time.

7. Repeat steps 2 – 6 until control locks out.

S280-79-10

SAFETY

FOR LIFE

Test Close Circuit Disable Fuse

This test is only applicable to Form 5 LS controls and standard Form 5 controls below Serial Number 3000.

1. Set KMET Fault Switch S2 to OFF.

2. CLOSE the Form 5 control.

3. Remove Close Circuit Disable fuse.

4. Adjust fault current to 200 percent or 200 mil-

liamperes.

5. Set KMET test set Fault Current Switch S2 to fault

position. The control will trip once.

6. Verify that it is not possible to close the Form 5 control.

7. Replace Close Circuit Disable fuse.

8. Verify it is now possible to CLOSE the Form 5 control.

Verify Instantaneous Demand Metering

1. Enable GROUND TRIP BLOCK (LED on).

2. Set KMET switch S2 to OFF.

3. Set KMET Phase Selector S5 to A.

4. Set KMET Variac to zero.

5. Set KMET switch S4 to the 100 milliampere range.

6. CLOSE Form 5 control.

7. Set KMET switch S2 to ON.

8. Set KMET Variac to read 80 milliamperes.

9. Scroll the Form 5 LCD screen to screen 1.

10. Verify Instantaneous metering on Phase A and

Ground reads 80 milliamperes.

11. Set KMET Phase Selector S5 to B.

12. Verify Instantaneous metering on Phase B and

Ground reads 80 milliamperes.

13. Set KMET Phase Selector S5 to C.

14. Verify Instantaneous metering on Phase C and

Ground reads 80 milliamperes.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

S280-79-10

Form 5 Control Default Test Optimal Values

2. Volts 28.0 2.6 Volts 28.0

Battery Circuitry MA 35 2.6 MA 550

Volts 27.0 2.6 volts 24.2

3. Normal Profile Phase A Amps Phase B Amps Phase C Amps

100.5 100.3 100.7

Phase Profile #1 Phase A Amps Phase B Amps Phase C Amps

Minimum Trip 200.9 200.2 200.5

Profile #2 Phase A Amps Phase B Amps Phase C Amps

200.9 200.2 200.5

Profile #3 Phase A Amps Phase B Amps Phase C Amps

200.9 200.2 200.5

4. Normal Ground Amps 50.1

Ground Profile #1 Ground Amps 100.3

Minimum Trip Profile #2 Ground Amps 100.3

Profile #3 Ground Amps 100.3

5. Trip to Lockout Sequence 1st 2nd 3rd 4th

Phase Timing Normal Phase A 2X 0.161 0.164 1.416 1.421

Phase B 5X 0.018 0.017 0.278 0.280

Phase C 10X 0.016 0.014 0.088 0.086

Profile #1 Phase A 2X 0.153 0.154 1.443 1.441

Phase B 5X 0.015 0.014 0.273 0.275

Phase C 10X 0.011 0.009 0.087 0.087

Profile #2 Phase A 2X 0.153 0.154 1.443 1.441

Phase B 5X 0.015 0.014 0.273 0.275

Phase C 10X 0.011 0.009 0.087 0.087

Profile #3 Phase A 2X 0.153 0.154 1.443 1.441

Phase B 5X 0.015 0.014 0.273 0.275

Phase C 10X 0.011 0.009 0.087 0.087

SAFETY

FOR LIFE

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

Form 5 Control Default Test Optimal Values

6. Trip Sequence 1st 2nd 3rd 4th

Ground Timing Normal Ground 2X 0.214 0.212 3.894 3.896

Ground 5X 0.012 0.016 1.097 1.099

Ground 10X 0.008 0.014 0.652 0.653

Profile #1 Ground 2X 0.214 0.212 3.894 3.896

Ground 5X 0.012 0.016 0.952* 0.954*

Ground 10X 0.008 0.014 0.280* 0.276*

Profile #2 Ground 2X 0.214 0.212 3.984 3.896

Ground 5X 0.012 0.016 0.952* 0.954*

Ground 10X 0.008 0.014 0.280* 0.276*

Profile #3 Ground 2X 0.214 0.212 3.894 3.896

Ground 5X 0.012 0.016 0.952* 0.954*

Ground 10X 0.008 0.014 0.280* 0.276*

7. Enabled Phase 2X 0.153 lockout lockout lockout

Non-Reclose Disabled Phase 2X 0.152 0.153 1.420 1.433

8. Cold Load Block Off Phase 2X 1.420 1.433 lockout lockout

PickUp Blocked Block On 0.158 0.154 1.420 1.433

9. Fast Trips Enabled Phase 2X 1.419 1.422 lockout lockout

Disabled Phase 2X 0.155 0.156 1.418 1.424

10. No Reclose Phase 2X 0.014 lockout lockout lockout

Hot Line Tag Enabled Phase 2X 0.155 0.156 1.148 1.424

11. Reclose Sequence 1st 2nd 3rd 4th

Test Reclose Reclose Times 1.975 1.974 4.968 lockout

12. Fuse Out Can’t Close? Yes No

Close Circuit XXX

Disable Fuse Fuse In Can Close? Yes No

XXX

13. Instantaneous Phase A Phase B Phase C

Demand Metering Amps 80 Amps 81 Amps 80

*Refer to the Test Ground Timing section of this manual.

S280-79-10

Form 5 Control Default Test Sheet

Date: Serial No:

2. Volts 2.6 Volts

Battery Circuitry MA 2.6 MA

Volts 2.6 volts

3. Normal Profile Phase A Amps Phase B Amps Phase C Amps

Phase Profile #1 Phase A Amps Phase B Amps Phase C Amps

Minimum Trip

Profile #2 Phase A Amps Phase B Amps Phase C Amps

Profile #3 Phase A Amps Phase B Amps Phase C Amps

4. Normal Ground Amps

Ground Profile #1 Ground Amps

Minimum Trip Profile #2 Ground Amps

Profile #3 Ground Amps

5. Trip to Lockout Sequence 1st 2nd 3rd 4th

Phase Timing Normal Phase A 2X

Phase B 5X

Phase C 10X

Profile #1 Phase A 2X

Phase B 5X

Phase C 10X

Profile #2 Phase A 2X

Phase B 5X

Phase C 10X

Profile #3 Phase A 2X

Phase B 5X

Phase C 10X

SAFETY

FOR LIFE

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

Form 5 Control Default Test Sheet

6. Trip Sequence 1st 2nd 3rd 4th

Ground Timing Normal Ground 2X

Ground 5X

Ground 10X

Profile #1 Ground 2X

Ground 5X

Ground 10X

Profile #2 Ground 2X

Ground 5X

Ground 10X

Profile #3 Ground 2X

Ground 5X

Ground 10X

7. Enabled Phase 2X lockout lockout lockout

Non-Reclose Disabled Phase 2X

8. Cold Load Block Off Phase 2X lockout lockout

PickUp Blocked Block On

9. Fast Trips Enabled Phase 2X lockout lockout

Disabled Phase 2X

10. No Reclose Phase 2X

Hot Line Tag Enabled Phase 2X

11. Reclose Sequence 1st 2nd 3rd 4th

Test Reclose Reclose Times

12. Fuse Out Can’t Close? Yes No

Close Circuit

Disable Fuse Fuse In Can Close? Yes No

13.Instantaneous Phase A Phase B Phase C

Demand Metering Amps Amps Amps

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. Disconnect control cable from the control.

3. De-energize ac power from the control.

4. Unplug the control battery.

RETURN THE CONTROL TO SERVICE

After the required work is completed, disconnect the control from the test set and follow this procedure to return the control to service:

1. Plug in the control battery.

2. Apply ac power to the control.

3. Verify that all control settings are correct.

4. Reconnect the control cable to the control.

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 to Setting the Control Clock in Service

Information S280-79-2 Form 5 Microprocessor-Based Recloser Control Programming Guide.

S280-79-10

IMPORTANT: Disconnect switches for ac sensing and power connections are necessary to isolate the Form 5 Recloser Control for testing and servicing.

WARNING: Hazardous voltage. If the recloser

is energized while the control cable is disconnected, the CT secondaries can generate high voltages. Contact with high voltage can cause severe personal injury or death. T204.2

CAUTION: Equipment misoperation. Do not

G110.3

SAFETY

FOR LIFE

Replacement Kits

Replacement kits for the Kyle Form 5 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 MicroprocessorBased Electronic Recloser Control and Reclosers. 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.

Type MET Recloser Control Tester

A 30-minute video cassette program, KSPV7 Kyle®Type MET Electronic Recloser Control Tester Operation and Testing Procedures is available as a supplemental train-

ing aid for service personnel.

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions

KDL

5/05

1045 Hickory Street Pewaukee, WI 53072 www.cooperpower.com

is a registered trademark of Cooper Power Systems or its affiliates.

KA2048-476 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

SAFETY

FOR LIFE

Cooper Lighting S280-79-10 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual