Manual Book F6

Reclosers
Form 6 Microprocessor-Based Pole Mount Control Service Information

for NOVA® i and Control-Powered NOVA® Reclosers
Installation and Operation Instructions S280-70-18
For Type F6-P2B Control
above Serial Number CP58F600001.
030036KM
Figure 1.
Kyle® Form 6 microprocessor-based pole mount recloser control.
Contents
Safety Information ..................................................... 2 Control Cable .........................................................18
Product Information .................................................. 3 Grounding the Control ............................................18
Introduction ............................................................ 3 Customer Connections for AC Power ....................21
Industry Standards ................................................. 3 Before Placing Control and Recloser into Service ...31
Quality Standards ................................................... 3 Using Removable Inserts .......................................32
Acceptance and Initial Inspection .......................... 3 Accessories ...............................................................33
Handling and Storage ............................................ 3 Incoming Power Receptacles ................................33
Control Power ........................................................ 3 Internal Voltage Sensing Receptacle .....................33
Battery Replacement and Disposal ........................ 3 Cable Locking Sleeves ..........................................33
Control VTC Interface ............................................ 4 120 Vac GFI Duplex Outlet ....................................33
Recloser VTC Interface .......................................... 4 Cabinet Ordering Accessories ...............................33
Operation Upon Loss of AC Power ........................ 5 Discrete Interface Board Option Accessory ...........34
Form 6 Recloser Control Description ..................... 6 Radio Mounting Accessory ....................................34
Description ............................................................. 6 Communication Board Accessories .......................35
Theory of Operation ............................................... 6 Testing ........................................................................37
Control Front Panel ................................................ 7 Testing an Installed Control ....................................37
Control Features ....................................................12 Remove the Control from Service ..........................38
Communications ....................................................15 Testing with Type MET Tester ................................38
Control Information .................................................15 Closing the Recloser During Testing ......................39
Control Back Panel ................................................15 Battery Test and Charging Procedures ..................40
Installation Procedure ..............................................16 Return the Control to Service ................................42
Initial Programming Prior to Installation .................16 Additional Information ..............................................43
Duty Cycle Monitor .................................................16 Replacement Kits ...................................................43
Mounting the Control ..............................................17 Maintenance Classes .............................................43
May 2007 • New Issue 1

Form 6 Pole Mount Control for NOVA® i and Control-Powered NOVA® Reclosers Instructions
!
SAFETY
!
SAFETY
FOR LIFE
SAFETY FOR LIFE 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.
SAFETY INFORMATION
The instructions in this manual are not intended as a sub- Safety Instructions
stitute for proper training or adequate experience in the
safe operation of the equipment described. Only compe- Following are general caution and warning statements
tent technicians who are familiar with this equipment that apply to this equipment. Additional statements, relat-
should install, operate, and service it. ed to specific tasks and procedures, are located through-
out the manual.
A competent technician has these qualifications:
• Is thoroughly familiar with these instructions.
DANGER: Hazardous voltage. Contact with
• Is trained in industry-accepted high- and low-voltage ! hazardous voltage will cause death or severe
safe operating practices and procedures. personal injury. Follow all locally approved safety pro-
• Is trained and authorized to energize, de-energize, cedures when working around high- and low-voltage
clear, and ground power distribution equipment. lines and equipment. G103.3
• Is trained in the care and use of protective equipment

such as flash clothing, safety glasses, face shield,
hard hat, rubber gloves, hotstick, etc. WARNING: Before installing, operating, main-
Following is important safety information. For safe instal-
! taining, or testing this equipment, carefully read
lation and operation of this equipment, be sure to read and understand the contents of this manual. Improper
and understand all cautions and warnings. operation, handling or maintenance can result in
death, severe personal injury, and equipment damage.
G101.0
Hazard Statement Definitions

This manual may contain four types of hazard WARNING: This equipment is not intended to
statements: ! protect human life. Follow all locally approved
procedures and safety practices when installing or
DANGER: Indicates an imminently haz-
! ardous situation which, if not avoided, will
operating this equipment. Failure to comply can
result in death, severe personal injury, and equip-
result in death or serious injury. ment damage. G102.1
WARNING: Indicates a potentially hazardous

! situation which, if not avoided, could result in WARNING: Power distribution and transmission
death or serious injury. ! equipment must be properly selected for the
intended application. It must be installed and serviced
CAUTION: Indicates a potentially hazardous by competent personnel who have been trained and
! situation which, if not avoided, may result in understand proper safety procedures. These instruc-
minor or moderate injury. tions are written for such personnel and are not a sub-
stitute for adequate training and experience in safety
CAUTION: Indicates a potentially hazardous situ- procedures. Failure to properly select, install, or main-
ation which, if not avoided, may result in equip- tain power distribution and transmission equipment can
ment damage only. result in death, severe personal injury, and equipment
damage. G122.3
2
!
SAFETY
FOR LIFE
S280-70-18
PRODUCT INFORMATION
Introduction Handling and Storage
Service Information S280-70-18 provides installation and Be careful during handling and storage of the control to min-
operation instructions for the Kyle® Form 6 pole mount imize the possibility of damage. If the control is to be stored
control above serial number CP58F600001. This control for any length of time prior to installation, provide a clean,
is intended for NOVA® i and control-powered NOVA® dry storage area. If storage is in a humid atmosphere, make
reclosers. provisions to keep the control circuitry energized.
Refer to the appropriate Service Information for addition- Note: To energize the control, apply ac power to the ac sup-
al information: ply input terminal block located in the lower right hand
corner of the back panel of the control. Refer to the
• S280-43-1 NOVA i Three-Phase Microprocessor- Customer Connections for AC Power section in this
Controlled Recloser Installation and Operation manual.
Instructions Control Battery Storage and Charging
• S280-42-1 NOVA Three-Phase Microprocessor- The 24 Vdc control battery in the Form 6 recloser control
Controlled Recloser Installation and Operation is fully charged prior to shipment and is ready for use.
Instructions
• S280-70-4 Form 6 Microprocessor-Based Recloser IMPORTANT: To maintain sufficient charge to oper-
Control Programming Guide ate the control and prevent battery cell damage, the
sealed lead-acid batteries should be charged after no
Read This Manual First more than three months of storage.
Read and understand the contents of this manual and fol- Temperature has an effect on battery life. Sealed lead
low all locally approved procedures and safety practices acid batteries should be stored, fully charged, at room
before installing or operating this equipment. temperature. Never store lead acid batteries at tempera-
tures exceeding 47°C (117°F), as damage can result in
Additional Information approximately one month.
These instructions cannot cover all details or variations in To keep the battery charged, energize the control’s built-
the equipment, procedures, or process described, nor in charger with ac power applied to the user ac supply
provide directions for meeting every possible contingency input connector block TB1. See Customer Connections
during installation, operation, or maintenance. When addi- for AC Power. In addition, if power to the control is not
tional information is desired to satisfy a problem not cov- possible a separate portable charger accessory is avail-
ered sufficiently for the user's purpose, contact your able. Catalog Number KA43ME7001 provides a 120 Volt
Cooper Power Systems sales representative. battery charger to power individual batteries.
Industry Standards IMPORTANT: Connect the control battery before ac
Cooper Power Systems reclosers are designed and test- power is connected to the control’s ac supply Input
ed in accordance with ANSI standard C37.60 and appro- Terminal Block. The battery must be disconnected
priate IEC standards. prior to shipping or storing the control.
Note: When shipped from the factory, the battery source is

Quality Standards disconnected and its output plugs are taped to the cab-
The quality system of the manufacturing facility shall be inet. Connect the battery plugs into the mating connec-
tors to complete the battery circuit.
independently certified to meet the following standards:
ISO 9001 (International Standards), ANSI/ISO/ASQC
Q9001 (American National Standards) and BS EN ISO Control Power
9001 (European Standards). The control is powered from 120 or 240 Vac. The selec-
tor switch on the power supply board allows the user to
Acceptance and Initial Inspection select between 120 Vac or 240 Vac.
Each Form 6 recloser control is completely assembled, Note: The selector switch is factory-set for each control
tested, and inspected at the factory. It is carefully cali- based upon the customer order requirement.
brated, adjusted and in good condition when accepted by
the carrier for shipment. Battery Replacement and
Upon receipt, inspect the carton for signs of damage. Disposal
Unpack the control and inspect it thoroughly for damage The 24 Vdc control battery has a life expectancy of four
incurred during shipment. If damage is discovered, file a to six years. It is recommended that the battery be
claim with the carrier immediately. replaced after four years.
Dispose expired batteries in an environmentally respon-
sible manner. Consult local regulations for proper battery
disposal.
3
Control VTC Interface Recloser VTC Interface

The Kyle Form 6 recloser control for the NOVA i and
®
The Form 6 control is applicable to NOVA i reclosers and
control-powered NOVA recloser is VTC-ready. The VTC- all control-powered NOVA reclosers (VTC and non-VTC
interface mechanism adds DC voltage input power on mechanism interfaces). A label is provided on the control
NOVA reclosers. to indicate that the control is “VTC READY” and will pro-
Note: These controls have a 19-pin control cable recep- vide compatibility with the NOVA i and legacy NOVA
tacle and can be identified by the following label reclosers.
displayed on the bottom of the control cabinet, as The control-powered NOVA i recloser does not include
shown in Figure 2. the VTC mechanism interface and does not include a
“VTC” label on the mechanism housing.
Control-Powered Type NOVA reclosers with serial num-
bers 100,000 and above, as listed in Table 1, require a
VTC-ready control. They are equipped with a 19-pin con-
trol cable receptacle and can be identified by labels
prominently displayed on the bottom of the recloser tank
and on the side near the 19-pin receptacle, as shown in
Figure 3 below.
For more information on the Control-Powered NOVA
Interface, refer to Service Information S280-42-1.
CAUTION: Equipment misoperation. The con-

! trol-powered NOVA reclosers that require a VTC
interface must be used with VTC-ready controls.
Failure to use a VTC-ready control will result in failure
to trip or close. G144.0
TABLE 1
Serial Number Break for Control-Powered NOVA
Reclosers with VTC
Control-Powered NOVA Serial No.

NOVA15 100,000
NOVA27 100,000
NOVA38 100,000
Note: Control-powered NOVA reclosers with serial numbers
below those listed in Table 1 do not require a VTC-
ready control. Refer to the recloser nameplate for the
serial number.
Figure 2.
Bottom view of Form 6 recloser control showing
location of VTC label.
Figure 3.
Receptacle side view and bottom view of control-
powered NOVA recloser tank, showing placement
of VTC label.
4
!
SAFETY
FOR LIFE
S280-70-18
Operation Upon Loss of AC

Power
The control is equipped with either an 8 Amp-Hour or 13
Amp-Hour 24 Vdc lead acid battery for operation upon
loss of ac power. The control maintains full operation
from the battery for a period of time dependent upon the
battery size:
• 8 Amp-Hour — 15 hour maximum (20°C)
• 13 Amp-Hour — 25 hour maximum (20°C)
In the event that the ac power has not returned within the
times listed above, the control will disconnect the battery
from the circuit.
Note: The control continuously monitors the battery voltage.
To prevent battery damage, the control shuts down
automatically upon detection of low battery voltage
(below 22 Vdc) for 60 seconds.
Control programming settings and parameters—includ-
ing event recorder—are stored in non-volatile memory
030034KM
and retained upon loss of control power. The time/date Figure 4.
clock will continue to operate for approximately 30 days Form 6 pole mount recloser control is accessible
after loss of control power. from both the front and back of the cabinet.
Phase B (Ø) is the factory default phase. Unless changed
by the user, the B PHASE VOLTAGE red LED illuminates The control clock may require resetting if the operating
indicating ac is the operating power. If BØ (or the user- power has been disconnected for more than thirty days.
indicated phase) loses ac power, the ALARM red indica- Refer to Service Information S280-70-4 Kyle Form 6
tor LED will illuminate. The ALARM log on the LCD Microprocessor-Based Recloser Control Programming
Display will indicate NO AC PRESENT and the CON- Guide for information on setting the control clock.
TROL OK LED will not be illuminated. Note: When ac power is present, the control will operate
regardless of back-up battery presence.
IMPORTANT: If the the control shuts down due to

low battery voltage before ac power is restored, and
the connected energized recloser is CLOSED; it will
only TRIP and LOCKOUT via front panel pushbutton
command.
A control that has shut down due to low battery voltage
before ac power is restored will have a blank LCD dis-
play (no text message shown).
5
FORM 6 RECLOSER CONTROL DESCRIPTION

Description The control can be configured, by the factory or by the
user, for a wide variety of applications. If user require-
The Kyle® Form 6 pole mount microprocessor-based ments change, the control functions can be modified to
recloser control includes extensive system protection meet the new requirements.
functionality, including phase, ground, and negative
sequence overcurrent protection, over/underfrequency, The control is accessible from both the front and back of
and voltage protection, directionality, sensitive ground the cabinet (Figure 4).
fault, and sync check.
Analysis tools include fault locating, event recording,
Theory of Operation
TCC EditorTM II, Idea WorkbenchTM, Data Profiler, and A functional block diagram of the Form 6 recloser control
oscillography functions, including oscillography replay. is shown in Figure 5. Current sensing is provided by three
current transformers located in the recloser and inter-
Metering functions include demand and instantaneous
faced to the Form 6 recloser control via the control cable.
current on a per-phase basis, instantaneous voltage and
This cable also supplies Trip, Close, and Recloser status,
power factor on a per-phase basis, and power (real, reac-
and connects to the Recloser Interface (RIF) module to
tive, apparent) on a per phase or total basis. Symmetrical
provide isolation for reliable operation. Voltages for
components for both voltage and current are displayed
metering are connected to the analog input module
along with kilowatt-hours for energy metering. Harmonics
through terminal block TB8.
from the 2nd to the 15th harmonic are also included.
Line current flowing through the recloser is converted by
The front panel LCD display is used to configure the
the CPU module to a digital signal suitable for metering
operating settings for the control. It is also used to display
and fault current calculations. Data sampling occurs at a
metering, counter information, control parameters, reset
rate of 64 times per cycle. The CPU contains a data
alarms, and provide diagnostic information.
acquisition section that uses the acquired samples to
Control parameters can also be programmed via a per- compute the fundamental currents and voltage for use in
sonal computer connected to the control through the front overcurrent, under/overvoltage, and under/overfrequen-
panel RS-232 port. Control programming, interrogation, cy protection, as well as currents and voltages for meter-
and operations are performed with Form 6 ProViewTM ing functions. The current for overcurrent protection is
interface software on a personal computer. calculated on a sub-cycle basis; it includes only the fun-
ProViewTM interface program software includes additional damental and DC component.
functions used to create and graphically display Time When the phase or ground current exceeds its pro-
Current Curves and provides the Idea WorkbenchTM for grammed minimum-trip value and associated time-cur-
configuring user-selected inputs and outputs, config- rent-curve (TCC) timing, the control initiates the pro-
urable event and alarm data, and selectable communica- grammed sequence of recloser tripping and reclosing
tion points for serial communication. operations via the CPU and RIF modules. If the fault is
The control operates on 50 and 60 Hz systems. temporary, the control ceases to command recloser oper-
ations after a successful reclose, and the control resets
120/VAC
TB7 OUTLET
TERMINAL DUPLEX
RS-232
POWER BLOCK ACCESSORY
BATTERY IRIG-B
COMMUNICATIONS
RECLOSER BOARD ACCY
RIF •RS-485
TRIP SOLENOID •FIBER-OPTIC
OPTICAL •ETHERNET TB8
CLOSE SOLENOID ISOLATION INTERCON- CPU
TERMINAL
NECTION 3 inputs
OPTICAL BLOCK
OPEN / CLOSE BOARD USER
ISOLATION SENSING
SWITCHES CONNECTIONS
OPTICAL 5 outputs VOLTAGE
ISOLATION POWER INPUTS
CONNECTIONS
A Ø CT
120/240
B Ø CT I/O 8 inputs
MATCHING USER
C Ø CT TRANSFORMERS CONNECTIONS
AND SIGNAL 8 outputs
CONDITIONING
CT COMMON
ANALOG INPUT
FRONT
PANEL
RS-232
(PROVIEW
PROTOCOL
ONLY)
Figure 5.
Form 6 pole mount recloser control operational flow diagram.
6
!
SAFETY
FOR LIFE
S280-70-18
to the start of its operating sequence after a preset time The control includes a Power Save feature that will turn
delay. If the fault is permanent, the control performs its off the backlit LCD display and all LEDs (except Hot Line
complete programmed sequence of reclose commands Tag) if no front panel keypad is pressed within ten min-
and locks out with the recloser open. Once locked out, utes. Pressing the LAMP TEST key will re-activate the
the control must be closed via the operator panel or display and LEDs.
SCADA communications. This resets the control to the Note: The Power Save feature is a ProView interface soft-
start of the operating sequence. ware default setting. This feature can be disabled via
The following chain of events occurs for an operating the ProView interface software.
sequence of two trips to lockout (one trip on TCC1, one The control includes a Reset Menu feature that will cause
trip on TCC2): the LCD display to revert to the root menu after ten min-
1. The overcurrent signal is integrated with time on the utes of inactivity.
selected curve for the first trip operation (TCC1) to Note: The ten minute timer and MMI Reset Menu is a
produce the signal which energizes the trip circuit. ProView interface software default setting. The menu
selection and timer can be changed via the ProView
2. Energizing the trip circuit connects the supply to the interface software.
trip solenoid to open the recloser.
3. Upon opening, the control starts timing on the first Front Panel Text Messaging
reclosing interval-delay time. The LCD messages are accessed from the front panel by
4. Upon expiration of this reclosing interval-delay, a following the Text Messages menu path. This menu dis-
closing signal is issued from the control, closing the plays any active user-configured text messages.
recloser, and selecting the time-current characteris- Up to fourteen user-configurable text messages can be
tics for the second trip operation (TCC2). programmed via the Idea Workbench. Refer to Service
5. If current remains above the minimum-trip level, the Information S280-70-4 Form 6 Control Programming
recloser will trip on TCC2 and lockout the recloser. Guide for information on programming the text messages.
These text messages appear on the front panel LCD
Control Front Panel and can be programmed to appear for alarm or other
conditions.
The Form 6 control front panel is illustrated in Figure 6.
Text messages displayed on the front panel are limited to
The front panel is separated into two clearly identified,
four lines of 20 characters each (including spaces). Text
color-coded sections:
messages can also be accessed by pressing the LAMP
• The top portion of the front panel is used for program- TEST one-touch analysis key on the front panel.
ming the control and providing LED status indication.
• The lower portion of the front operating panel is used
for operating the control and recloser.
CONTROL OK A PHASE FAULT ALARM A PHASE VOLTAGE INDICATOR 4

CONTROL POWER B PHASE FAULT ABOVE MIN TRIP B PHASE VOLTAGE INDICATOR 5
LED Indicators CONTROL LOCKOUT C PHASE FAULT INDICATOR 1 C PHASE VOLTAGE INDICATOR 6
RECLOSER OPEN GROUND FAULT INDICATOR 2 FREQUENCY TRIP INDICATOR 7
RECLOSER CLOSED SENSITIVE GND INDICATOR 3 VOLTAGE TRIP INDICATOR 8
LCD Display
LCD Menu Function Keys
METERING SETTINGS
RESET OPER
TARGETS COUNTER
One-Touch F1 F2 F3 F4 One-Touch
Analysis Keys EVENTS ALARMS Analysis Keys
LAMP TEST
MENU + CHANGE
Cursor Movement Arrows

LCD Display
ENTER — LCD Display
Dedicated
RS-232 DATA PORT
Function Keys
Dedicated
Function Keys KYLE® F6 Recloser Control ON
GND TRIP NON SUPERVISORY
BLOCKED RECLOSING OFF
RS-232
TRIP CLOSE CLOSE CIRCUIT Configuration
ALTERNATE ALTERNATE ALTERNATE
DISABLE HOT LINE TAG PROFILE #1 PROFILE #2 PROFILE #3
Data Port
OPTION #1 OPTION #2 OPTION #3 One-Touch
Function Keys
(LOCKOUT)
Hot Line Tag Toggle Switch and

TRIP (LOCKOUT) Close Circuit
CLOSE Pushbutton Three-Segment LED Indication
Pushbutton Disable Fuse
(Hardwire Connected) and Fuseholder
Figure 6.
Form 6 pole mount control front panel.
7
Programming Panel LCD Display

The Programming panel has the following sections: The LCD Display is a backlit 4-line, 20-character display
that provides extensive distribution system, recloser, and
One-Touch Analysis Keys control status information using a minimum of eight nav-
There are eight analysis keys (Figure 7) that allow one- igation keypads (Figure 7).
button access to a variety of control and monitoring func- Note: The LCD display panel contrast is field-adjustable to allow
tions that appear in the LCD display. Pressing these but- for various mounting heights and applications. Press the
tons causes the following information to display or func- MENU key and then press the (+) or (–) key to increase
tion to occur: or decrease the contrast.
METERING: Displays the systems instantaneous meter- The four LCD navigation buttons are as follows:
ing values for current and voltage on the LCD display.
MENU: Identifies the LCD Display menu options.
RESET TARGETS: Resets the fault target indicators on
ENTER: Selects a menu option.
the operator panel.
+: Increases value selection.
EVENTS: Displays the last 25 events from the Sequence
of Events log. –: Decreases value selection.
LAMP TEST: All operator panel LEDs are illuminated for The four LCD menu function keys activate specific menu
verification of proper connection and operating status of commands. When a command appears in the LCD dis-
all indicator lights. All status indicators will then return to play directly above one of the four LCD menu function
their previous state. While in the LAMP TEST mode, the keys, the user can press the key to accept/select the
control response to operator panel keys is disabled, command.
except for the TRIP (LOCKOUT), CLOSE, and HOT The four LCD menu function keys are as follows:
LINE TAG switches.
F1 F2 F3 F4
SETTINGS: Displays recloser settings on the LCD display.
The four cursor movement arrows allow movement in the
OPER COUNTER: Displays the total number of trip oper- following directions:
ations and target counters for each A, B, and C Phase;
Ground, and Sensitive Ground on the LCD display. Moves the cursor left.
ALARMS: Provides status information on the LCD dis- Moves the cursor right.
play for all recloser alarms. Moves the cursor up one line.
CHANGE: Allows the user to change the state of the con- Moves the cursor down one line.
trol functions on the operator panel function keys.
Note: The CHANGE mode is a ten second period in which one
function setting can be changed. If no change is made
in that time, the control returns to the current setting.
METERING SETTINGS
RESET OPER
TARGETS COUNTER
F1 F2 F3 F4
EVENTS ALARMS
LAMP TEST
MENU + CHANGE
ENTER —
Figure 7.
Analysis keys, LCD display, LCD menu function keys, and cursor movement arrows.
8
!
SAFETY
FOR LIFE
S280-70-18
Status Indicator LEDs RECLOSER CLOSED: The red LED indicates the reclos-
The status indicator LEDs (Figure 8) in the Programming er is in the closed position.
section of the Operator Panel give instant information on Note: There are several conditions that will cause the alter-
the control and recloser status: nate blinking of the CONTROL LOCKOUT, RECLOSER
OPEN, and RECLOSER CLOSED LEDs: Failure to
All of the default status indicators LEDs (except for CON- Trip, Failure to Close, Interrupter Malfunction, and
TROL OK, CONTROL POWER, and ALARM) can be 52a/b Disagreement.
reconfigured via the Idea Workbench. Refer to Service
The LED blinking pattern for these conditions is the
Information S280-70-4 Form 6 Control Programming CONTROL LOCKOUT green LED and RECLOSER
Guide for additional information. CLOSED red LED alternating with the RECLOSER
The label inserts can be user-customized. Refer to Using OPEN green LED.
Removable Inserts section of this manual for additional In addition to the above LED blinking pattern, the red
information. ALARM LED will also be illuminated for these alarms:
Failure to Trip, Failure to Close, and Interrupter
CONTROL OK: The green LED indicates the control is Malfunction.
operating normally and not in an alarm state.
A PHASE FAULT, B PHASE FAULT, C PHASE FAULT:
The CONTROL OK LED will not be illuminated during The red LEDs indicate A, B, and/or C phase current was
these alarms (indicated by the red ALARM LED and dis- either the maximum phase current or within 80% of the
played in the alarm status log): maximum when a trip signal was issued.
• Battery Alarm: This alarm indicates battery voltage is GROUND FAULT, SENSITIVE GROUND FAULT: The red
low or the battery failed an operator-initiated manual LEDs indicate that a Ground and/or Sensitive Earth Fault
test. tripping function was asserted at the time the trip signal
• Memory Test: This alarm indicates a failed ROM or was asserted.
RAM memory test. ALARM: The red LED indicates an alarm has been
• No AC Power: This alarm indicates AC power was issued. Review the alarm status and log on the LCD dis-
unavailable for 10 continuous seconds. This alarm play for the specific alarm.
resets when AC power is restored. ABOVE MINIMUM TRIP: The red LED indicates the cur-
• Internal Power Failure: This alarm indicates internal rent exceeds the level set for minimum trip.
control operation power was outside of its operating FREQUENCY TRIP: Indicates the recloser tripped due to
tolerance for more than 20 seconds. This alarm a frequency trip.
resets when the internal control operation power
returns to operation within its normal tolerances. VOLTAGE TRIP: Indicates the recloser tripped due to a
voltage trip.
• RIF Comms Failure: This alarm indicates a loss of
communication from the RIF (Recloser Interface) cir- A PHASE VOLTAGE, B PHASE VOLTAGE, C PHASE
cuit board to the main CPU circuit board. This alarm VOLTAGE: The red LED indicates a presence of voltage
resets if communication is re-established. on the respective phases. The Single-Phase
Undervoltage Pickup setting controls the voltage indica-
CONTROL POWER: The green LED indicates there is tion for the front panel LEDs as defined in the Voltage
adequate charge (voltage) on the trip circuit capacitor to setting dialog box for the active setting profile. Refer to
trip or close the recloser. This LED does not indicate the Settings - Voltage in the Schemes section of S280-70-
presence of AC or battery power. 4 Form 6 Control Programming Guide.
CONTROL LOCKOUT: The green LED indicates the con- INDICATOR 1, INDICATOR 2, INDICATOR 3, INDICA-
trol is in a locked out state, i.e. a reclosing sequence is TOR 4, INDICATOR 5, INDICATOR 6, INDICATOR 7,
not in progress. This LED does not indicate that the INDICATOR 8: Customizable LEDs that are used with
recloser is open. functions programmed through the Idea WorkbenchTM.
RECLOSER OPEN: The green LED indicates the reclos- The LED indicators do not have active default values.
er is in the open position. The LEDs are illuminated when the status configured via
the Idea WorkbenchTM is present.
CONTROL OK A PHASE FAULT ALARM A PHASE VOLTAGE INDICATOR 4

CONTROL POWER B PHASE FAULT ABOVE MIN TRIP B PHASE VOLTAGE INDICATOR 5
CONTROL LOCKOUT C PHASE FAULT INDICATOR 1 C PHASE VOLTAGE INDICATOR 6
RECLOSER OPEN GROUND FAULT INDICATOR 2 FREQUENCY TRIP INDICATOR 7
RECLOSER CLOSED SENSITIVE GND INDICATOR 3 VOLTAGE TRIP INDICATOR 8
Figure 8.
Form 6 pole mount control status indicator LEDs.
9
Operating Panel CLOSE CIRCUIT DISABLE

RS-232 Configuration Data Port Close Circuit Disable (Figure 9) is a removable fuse that,
when removed from the front operating panel, disables
The RS-232 connector (shown in Figure 6) on the front the close circuit from the control to the recloser.
operating panel allows direct connection to a personal Removing the fuse from the control disables all electrical
computer without any special cables or connectors. This closing of the recloser and provides a physical discon-
port is used only for configuring the control with ProView nect to the recloser closing circuit. As a result, the control
application software. All settings, metering, events, and cannot perform a close operation. This disconnect over-
oscillography data are available from this port. The port is rides all close functions and makes a remote or manual
Data Communication Equipment (DCE) wired for direct close operation impossible.
connection to a personal computer.
Note: When the Close Circuit Disable fuse is removed, the
A 9-pin RS-232 cable (Catalog Number KME5-66) to trip circuit remains active and will trip per the pro-
connect from the PC to the RS-232 data port is available grammed time current curve for a faulted condition.
as an accessory.
IMPORTANT: If the CLOSE button is pressed after
HOT LINE TAG ON/OFF Toggle Switch and LED the Close Circuit Disable fuse is removed, do not rein-
Indicator stall the fuse until after the ALARM LED illuminates
(within approximately five seconds) to indicate CLOSE
WARNING: Hazardous voltage. Do not use Hot
!Line Tag as a substitute for a visible disconnect.
MALFUNCTION. Re-installing the Close Circuit Disable
fuse prior to the CLOSE MALFUNCTION ALARM indi-
Always establish a visible disconnect prior to perform-
cation will cause the control to close the recloser.
ing any work requiring a de-energized line. Failure to
comply may cause death, severe personal injury, or TRIP (Lockout) Pushbutton
equipment damage. T276.0
The TRIP pushbutton (Figure 9) provides front-panel
access to trip (lockout) the recloser. When pressed, the
Hot Line Tag is provided for live-line work applications. All TRIP pushbutton opens the recloser and locks out the
closing operations are disabled when the Hot Line Tag control.
feature is activated.
Note: In the event of main microprocessor failure, the trip circuit
IMPORTANT: Hot Line Tag activation does not cause can operate independent of the main microprocessor.
the recloser to trip open. It only prevents the recloser CLOSE Pushbutton
from closing.
When pressed, the CLOSE pushbutton (Figure 9) returns
the control to the initial or home sequence position, clos-
IMPORTANT: Hot Line Tag is intended solely for live- ing the recloser. The control is ready for the start of a new
line work applications, such as maintenance, repairs or trip/close sequence.
improvements to the distribution system, that occur
while the line remains energized. Note: Pressing the CLOSE pushbutton from the Lockout posi-
tion initiates Cold Load Pickup (CLPU) protection, if the
Hot Line Tag prevents all closing attempts from the con- feature is enabled.
trol and shifts protection to one trip-to-lockout on the com- The user does have the ability to block COLD LOAD
posite curve of the Hot Line Tag definite time and the PICKUP through the LCD menu or by configuring one
of the Option one-touch function keys via the Idea
TCC1 curve (whichever is faster). Hot Line Tag takes Workbench feature in ProView.
precedence over Cold Load Pickup, Non-Reclosing, and If the recloser is closed, pushing and holding the
Fast Trips Disabled. CLOSE pushbutton does not activate the Cold Load
Pickup feature. See Cold Load Pickup in the Control
Hot Line Tag is activated from either the operator panel Features section of this manual.
toggle switch, serial communications, or a discrete
SCADA function. All sources must be off to de-activate
Hot Line Tag.
To activate the function from the operator panel, flip tog-
gle switch up to the ON position. See Figure 9. The LED KYLE® F6 RECLOSER CONTROL
indicator illuminates when the function is active. ON
The Hot Line Tag function may only be reset by the source TRIP CLOSE CLOSE
CIRCUIT
which initiates it. For example, if Hot Line Tag is activated DISABLE HOT LINE TAG
at the operator panel, the reset function is only possible at
the operator panel, and not via SCADA command.
(LOCKOUT)
IMPORTANT: If the power save feature is enabled

(default), and more than ten minutes elapses since the
last panel operation, all the LEDs, except HOT LINE Figure 9.
TAG (if active), will turn off. TRIP (Lockout) pushbutton; CLOSE pushbutton; Hot
Line Tag switch and Hot Line Tag red indicator LEDs.
10
!
SAFETY
FOR LIFE
S280-70-18
One-Touch Function Keys SUPERVISORY OFF

Quick access to frequently operated Form 6 control fea- When the SUPERVISORY OFF red indicator is illuminat-
tures is provided with nine function key pushbuttons on ed, supervisory commands are blocked. Supervisory
the control operator panel. functions through the back panel serial communication
The Form 6 control operator panel one-touch function ports and the discrete I/O are blocked. Serial communi-
keys are illustrated in Figure 10. cations through the front panel RS-232 port remain active
independent of the status of the SUPERVISORY OFF
switch. Activation of this function key is restricted to the
GND TRIP NON SUPERVISORY operator panel and is accomplished by pressing the
CHANGE key and then pressing the SUPERVISORY
OFF key. Operational data and metering information are
ALTERNATE ALTERNATE ALTERNATE available while the control is in the SUPERVISORY OFF
PROFILE #1 PROFILE #2 PROFILE #3 position. The TRIP and CLOSE pushbuttons and Hot
Line Tag are active independent of the SUPERVISORY
OFF function.
OPTION #1 OPTION #2 OPTION #3
ALTERNATE PROFILE #1, #2, and #3
Figure 10. The Form 6 control has four separate protection profiles;
Form 6 pole mount control operator panel one-touch a normal profile, and Alternate Profiles 1, 2, and 3. Each
function keys. profile changes all protection parameters for the control.
Except for the normal profile, each has an indication and
Red LEDs located on each function key indicate the sta- selection key. When the operator panel display lights are
tus of the function, regardless of local or remote activa- active and none of the three indicators are on, the normal
tion. For example, if Ground Trip Blocked is activated profile is active. Only one profile can be active.
from a SCADA signal, the red indicator will illuminate
To select an alternate profile, press the CHANGE key
even though it was not activated from the operator panel.
and then press the desired alternate profile.
Operator panel function key activation or de-activa-
To return to the normal profile, press the CHANGE key
tion requires the operator to first press the CHANGE key
and then press the active alternate profile to deselect it.
to enter the CHANGE mode. A function must then be
These functions can also be completed remotely via
selected or de-selected within ten seconds to activate or
communications interfaces.
de-activate the function. Once selected, the control
returns to normal operation until prompted for another
change request. This prevents accidental changing of IMPORTANT: Unused alternate profiles should be
functions or features. programmed with the same settings as one of the
applicable profiles. Default settings on unused alter-
Note: Only one function can be changed per each CHANGE nate profiles can cause unnecessary outages if they
mode activation. are below normal system requirements and activated.
GND TRIP BLOCKED
The Ground Trip Blocked function blocks all ground sens- IMPORTANT: Check minimum trip values prior to
ing in the control for the active profile. This red indicator changing an alternate profile to avoid misoperation of
is illuminated when Ground Trip Block is activated from the control under load conditions.
the serial port, I/O, the interface software, or locally (via
the front panel) causing the control to block all ground
sensing. OPTION #1, OPTION #2, AND OPTION #3
NON RECLOSING The OPTION #1, OPTION #2, and OPTION #3 function
keys must be programmed via the ProViewTM Idea
The control is operating in a non-reclosing mode when WorkbenchTM software.
the NON RECLOSING red indicator is illuminated. Non-
reclosing mode disables any automatic reclosing opera- The OPTION LEDs are illuminated when the options con-
tions. Non-reclosing does not alter the active TCC. figured via the Idea Workbench are selected. Refer to
Activation is possible from the SCADA port, I/O, the inter- Service Information S280-70-4 Form 6 Control
face software, or locally (via the front panel). Programming Guide for additional information.
These OPTION keys provide a momentary signal. For
instance, these keys can be programmed to toggle con-
trol status, protective functions, or a momentary input
pulse.
The OPTION #1, OPTION #2, and OPTION #3 function
keys are intentionally not defaulted to any function. The
functions are assigned to each OPTION key via the Idea
WorkbenchTM application.
11
Control Features Sequence Coordination

The Form 6 pole mount recloser control offers numerous Sequence Coordination eliminates nuisance tripping
standard features and accessories that allow the user the through trip coordination. It allows the control to step
utmost flexibility applying the recloser control. through selected operations in the operating sequence
without tripping. The number of Sequence Coordination
Control Security advances is programmable from one to three operations
The Form 6 pole mount recloser control has multiple cus- to provide trip coordination with a downline recloser. This
tomer-programmable security codes to limit control pro- feature is independently selectable for each protection
gramming and viewing function access to authorized per- profile.
sonnel. The front panel Man-Machine Interface (MMI) Cold Load Pickup
includes a user-selected security code to access the set-
tings. Plus, the ProViewTM interface software has it’s own The control includes a Cold Load Pickup feature to pre-
security levels for multiple-user access. vent the control from tripping while energizing non-fault
system loads. This feature has independently program-
Refer to Service Information S280-70-4 Form 6 mable minimum trip value time-current curve, reclose
Microprocessor-Based Recloser Control Programming interval, and number of independent operations to lock-
Guide for additional information. out for each protection profile. Cold Load Pickup also
Protection Profiles includes TCC Multipliers, TCC Adders, Minimum
Response Time, Time Dial Reset, and High Current
Four protection profiles capable of fully specifying control Lockout. Also, direct values, not multiples of minimum
operation are standard in the control. Each protection trip, are provided for high current lockout.
profile includes the following as a minimum:
• Overcurrent Protection
Fast Trips Disabled
The control includes a Fast Trips Disabled feature to
• Over/Undervoltage Protection
modify protection, so that all trip operations use the pro-
• Over/Underfrequency Protection grammed TCC2. This feature is independently selectable
• Directional Protection for each protection profile. All trip operations will time on
TCC2. Typically, TCC1 is fast and TCC2 is delayed. So,
• Hot Line Tag Functionality as an example, the control will change it’s sequence from
• Sync Check 2 fast and 2 delayed operations to 2 operations on TCC2
when Fast Trips Disabled is active.
• Sensitive Earth Fault Protection
• Sequence Coordination High Current Lockout
• Operation Settings The High Current Lockout feature will automatically lock-
out the control on the selected operation when current
Time Current Curves exceeds a programmable level. The active trip numbers
for the lockout is selectable for phase, ground, and neg-
Time-current curves are available for numerous functions, ative sequence. This feature is independently selectable
including fast and delayed operations for phase, ground, for each protection profile.
and negative sequence protection. Each time-current is
selected from a defined fifty curves which can be further Sensitive Ground/Earth Fault
customized by the user. The time-current curves are also Operation
selected from a graphical TCC EditorTM II to visualize any
modifications prior to configuring the control. The control has a Sensitive Ground/Earth Fault Trip fea-
ture that provides tripping of the recloser after a pro-
The time-current curves include the following modifications grammable, definite time for ground currents below nor-
for phase, ground, and negative sequence protection: mal ground minimum trip levels. The feature has pro-
• Time Multiplier with a range of 0.1 to 25 in .1 increments. grammable operations to lockout and reclose intervals
independent of the ground settings. This feature is inde-
• Time Adder with a range of 0 to 30 seconds in .01 pendently selectable for each protection profile.
second increments.
• Minimum Response Time with a range of 0.01 to 1 Thermostatically Controlled Heater
seconds in .001 second increments. The control has a standard 15 Watt thermostatically con-
• High Current Trip multiplier with a range of 1 to 32 trolled heater (ON 70°F, OFF 85°F) for humidity control
multipliers in increments of 0.1. and voltage input independent. The heater is powered
from the power supply board.
• High Current Trip Time Delay with a range of 0.01 to
.150 second in .001 second increments.
• Time Dial Reset co-efficient with a range of .1 to 30
seconds in 1 second increments.
12
!
SAFETY
FOR LIFE
S280-70-18
Metering The control also provides a minimum of three config-

urable input control contacts. Each control contact is con-
The control provides instantaneous and/or demand figurable using a graphical interface software. Contacts
metering with programmable integration intervals for the accept a whetting voltage range of 12–250 Vdc, 120/240
following functions: Vac. Each digital input is configured for either a momen-
• Real and reactive power for each phase and total, tary, maintained, or maintained with precedence contact.
including directional, on an individual phase basis. Default input control contacts are: Supervisory Trip and
Lockout, Supervisory Close, and Remote Trip and
• Demand currents on a per phase basis.
Lockout.
• Instantaneous currents, including ground current.
A Discrete Interface Board is also available as an acces-
• Instantaneous voltage on a per phase basis. sory to provide an additional eight output status contacts
• Instantaneous frequency. and eight input control contacts. The expansion I/O board
is completely user-configurable.
• Positive, negative, and zero sequence voltages.
• Instantaneous power factor on a per phase basis.
TCC EditorTM II
Coordination and actual time current modifications are
• Metering settings to include demand interval, and
available with a graphic interactive TCC EditorTM or simi-
alarm thresholds for current, single-phase kW, three-
lar graphical software.
phase kW, single-phase kvar, and three-phase kvar.
The TCC EditorTM II includes a complete database of
Event Recorder standard recloser industry time current curves (TCC),
The Form 6 control contains capabilities to perform both ANSI and IEC types, along with the ability to cus-
Sequence of Events time-stamping for up to 33 event tomize the TCCs with multipliers, constant time adders,
types. Sixteen additional inputs can be user-defined or minimum response time adders. Also, the user is able
through the Idea WorkbenchTM. to derive their own specific TCC through data point entry.
Each modified time current curve can be identified with a
Factory-defined event types include: user-customized name and is selectable for configuring
• Overcurrent Protection Trip the control. The grid and format for presenting the TCCs
has a user-adjustable scale, including the option of pre-
• External Trip senting multiple TCCs in various user-configured colors.
• Non-Reclose Trip
Oscillography
• External Close
Oscillography is provided to present current and voltage
• Lockout waveforms, along with protection element and recloser
• Reset response status changes. Filtered and unfiltered data are
provided for viewing.
The Event Recorder maintains a minimum of 90 event
records. The last 25 events are viewable on the front The recorded values are super-imposed on the protec-
panel LCD display. Refer to S280-70-4 Form 6 Control tion scheme, and the state or value at any point in the
Programming Guide for additional information. scheme is displayed. The user has the capability to move
through the event and watch the response of every func-
Recloser Duty Monitor tion. All analog signals, digital inputs, and contact outputs
are monitored. Analog oscillography is displayed at 16
The Form 6 recloser control software is equipped with a
samples per cycle.
Recloser Interrupting Duty Monitor. The Duty Monitor
accumulates the summation of I1.5 for all interrupted cur- Oscillographic data is recorded to analyze multiple
rents on each interrupter. This feature permits program- events during a permanent fault or other event type. The
mable entries to preset the duty of an existing recloser. oscillographic data shows two cycles before the trigger
The recloser duty monitor displays interrupting duty in point and eight cycles after the trigger point (default).
percent of duty used. If the duty cycle monitor exceeds Note: The configuration settings are programmable.
100%, the recloser should be examined for maintenance.
Oscillography automatically initiates trigger points for the
Discrete SCADA Communications following functions:
The control provides five configurable output status con- • Above Minimum Trip for Phase, Ground, and
tacts and three configurable input control contacts as Sensitive Ground Fault
standard. Each status contact is configurable using • Single- and Three-Phase Overvoltage
graphical interface software to combine status functional-
ity along with Boolean algebra. Default output status con- • Single- and Three-Phase Undervoltage
tacts are: Lockout, Recloser Open, Recloser Closed, • Over- and Underfrequency
Ground Trip Block, and Hot Line Tag. One output status
contact is a solid state output (SS1) with a pickup time no • Trip Signal Issued
longer than two milliseconds. • Close Signal Issued
13
Removable Inserts 1
T. Takagi, Y. Yamakoshi, J. Baba, K. Uemura, T. Sakaguchi, "A New
Algorithm of an Accurate Fault Location for EHV/UHV Transmission
Removable inserts are included with the control design Lines: Part I - Fourier Transformation Method", IEEE Trans. on PAS,
for customization of specific protection requirements. Vol. PAS-100, No. 3, March 1981, pp 1316-1323.
Inserts are available for the status indicator LEDs, the
operator panel function keys, and the analysis keys. The Sync Check
removable inserts are designed for use without adhe- Sync Check is a permissive system used to qualify any
sives, labelmakers, or temporary labels. Refer to Using close signal to the mechanism when enabled via the sync
Removable Inserts for more information. check settings. Sync check allows for closing for any
An electronic label template is included on the ProViewTM combination of dead/live bus/line, and to perform antici-
application software CD and can be accessed through patory closing for a live bus/live line condition by calcu-
the following default address: C: \ Program Files \ Cooper lating slip and anticipating the mechanism closing delay.
\ Proview401 \ Form 6 \ Form 6 Inserts.doc In addition to the anticipatory close calculation, the sync
check system performs verification of line and bus volt-
Idea WorkbenchTM age magnitudes and frequencies to determine that they
are within pre-determined ranges, and that the angular
The Idea WorkbenchTM provides access to various inputs, difference between the two systems is also within the
intermediate variables, and internal Form 6 alarms, sta- pre-determined range. For a live/live close, where there
tus, and targets to allow user-customization of the Form is no slip between the systems, the sync check system
6 recloser control to meet specific and unique applica- allows permissive closing after the two systems are with-
tions. The Idea WorkbenchTM also gives the user the abil- in frequency and voltage limits, and the angular differ-
ity to perform logical functions with these variables by ence between the systems has been within the allowable
using a simple graphical user interface. Use of the Idea limits for a pre-determined time.
WorkbenchTM is not a requirement for operation.
Sync Check functionality includes the following applica-
Refer to Service Information S280-70-4 Form 6 tions: Hot Line/Hot Bus Closing; Dead Line/Hot Bus
Microprocessor-Based Recloser Control Programming Closing; Hot Line/Dead Bus Closing; and Dead
Guide for additional Idea WorkbenchTM information. Line/Dead Bus Closing.
Over/Underfrequency Protection Sync Check Parameters include the following config-
urable settings: Voltage Angle; Mechanism Operating
The control includes two-stage operation for both under-
Delay; Static Angle Delay; Dead Threshold; Live
frequency and overfrequency protection. A fixed time
Threshold; Positive Sequence Dead Threshold; Upper
delay ranging from 0 to 100 seconds in .001 second
Voltage Limit; Lower Voltage Limit; Lower Frequency
increments is available for both over and underfrequen-
Limit; Upper Frequency Limit; and Fail to Close Timer.
cy. A frequency restoration function, enabled or disabled
by the user, is provided to allow the recloser to automat- Data Profiler
ically close should frequency return to within configured
settings for a user-settable time. Over/Underfrequency A fully-configurable data profiler is available which allows
Protection is included as part of each protection profile. the user to collect information by sampling data at selec-
table intervals. These time-stamped values can then be
Over/Undervoltage Protection viewed to determine weekly load profiles, daily harmonic
disturbances or hourly voltage fluctuations. The number
The control includes single-phase and three-phase under
of days of information the data profiler can provide
voltage tripping. The control also includes three-phase
depends upon configuration parameters.
overvoltage tripping. Both over and undervoltage func-
tions include a single-phase and three-phase pick-up set- Refer to Service Information S280-70-4 Form 6
ting; a single-phase and three-phase time delay setting Microprocessor-Based Recloser Control Programming
ranging from 0 to 100 seconds. Guide for additional information.
Directional Manual Close Delay

Directional functionality is included to maintain system Manual Close Delay provides a delay from the time that
coordination from multiple sources, as well as circuit the manual CLOSE button is pushed to the time the man-
reconfiguration for each profile. Directional applies to ual close operation is performed.
phase, ground, and negative sequence protection, The delay is programmable from 0 to 60 seconds in 1
selected independently. A maximum torque angle has a second increments. A programmed delay value can be
range of 0 - 90 degrees. overridden for immediate closing by pressing the CLOSE
Fault Location button a second time.
The control includes an impedance-based fault locator An active Manual Close Delay can be canceled by press-
based upon the Takagi algorithm1. Load-compensated ing the TRIP/LOCKOUT button.
impedance calculation is used for calculating the dis- The default setting has the feature disabled (0 seconds).
tance. Positive and zero sequence is configured in A countdown on the front panel LCD screen indicates
ohms, and the fault locator line length is configured in Manual Close Delay is active.
kilometers/miles.
14
!
SAFETY
FOR LIFE
S280-70-18
Communications Ethernet configuration is accomplished via ProView inter-

face software. Refer to S280-70-4 Form 6 Control
Communication Ports Programming Guide, Section 4: Schemes,
Communicating with the Form 6 Control, for Ethernet
The Form 6 control has two back panel communication
Configuration information.
ports and a front panel configuration data port.
When a communication protocol is selected for the option-
The front panel configuration data port is described in the
al communication boards (serial fiber or the RS-485 seri-
Operating Panel section of this manual.
al port), the RS-232 serial port is defaulted to ProViewTM
There is one standard 9-pin RS-232 and one optional com- interface software protocol.
munication port (RS-485, serial fiber, Ethernet wire or fiber
DNP3 is factory-defaulted to the RS-232 port.
or both) on the back operator panel, as well as a standard
IRIG-B port for user time-syncing. See Figure 11. When a communication protocol is selected for the RS-
232 serial port, the optional RS-485 or serial fiber optic
Communication Protocols board is not active.
Four communication protocols are available for the Form The RS-485 or fiber optic serial ports do not support
6 recloser control: ProViewTM interface software protocol.
• Modbus The user can simultaneously communicate to the Form 6
• DNP3 control using both the front panel data port and the
appropriate back panel serial communication port (pro-
• 2179 vided the back panel RS-232 port or the Ethernet option-
• IEC870-5-101 al communications board is not configured to be ProView
protocol).
One communication protocol can be selected for either the
back panel RS-232 or the optional communication port.
Control Information
All four protocols are selected and configured by the user
Control information includes firmware identification by
with the ProViewTM Communications WorkbenchTM appli-
catalog number and name, date code, and ProView
cation software.
release number. Control information is available through
Ethernet Communications the Settings menu on the front panel (Figure 6).
• ProView over TCP/IP Control Back Panel
• DNP3 over TCP/IP The control back panel is easily accessible through the
Ethernet connection allows for network application of the back door of the control cabinet (Figure 4) with readily
Form 6 pole mount control for both DNP3 and ProView identifiable serial ports and connections (Figure 11).
protocols. In addition, the front panel data port can simul-
taneously communicate ProView to the PC.
RS-232 Serial Communication Port

Discrete Interface
Board (Accessory) TB1
1
CI1
3
CI2
5
CI3 SS1
7 9
CO1 CO2 CO3 CO4
11 13 15 17 19 J1-RS-232
RS-485
C + –
RS-485 Serial Communication Port (optional)

2 4 6
CI1 CI2
8 10 12 14 16 18
CI3 SS1 CO1 CO2 CO3 CO4
RS-232 DTE
IRIG-B
Fiber Optic port, "ST" Type Connector (optional),
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11 CO12
TB3
1 3 5 7 9 11 13 15 17 19 21 1 3 5 7 9 11 13
TB4
Ethernet Port, "MT-RJ" Fiber RJ45 Connector (optional)
2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11CO12
TB9
IRIG-B Time Sync Connector
+ –
28 VDC
WHETTING VOLTAGE
Power Supply Board

P1 P4
AC Power Fuse 1
2
3
4
VOLTAGE SENSING
1
2
3
4
1
2
3
4
P2
1 2 3
53VDC
4 5
P3
24 23 22
12 11 10
21
9
CONTROL CABLE
20 19
8 7
18 17
6 5
16
4
15 14
3 2
13
1
1
1
2
2
3
28 VAC
4
4
5
120/240 Vac
Selector Switch
Battery Connector (2-position)

Voltage Sensing 1 2 3 4 7 8 9 10 11 12
Customer Connection
Terminal Block TB8
1 2 3 4 5 6
Power Supply LED
Power Connections
Grounding Terminal, One

AC Customer Connection
External & One Internal
Terminal Block TB7
(#14 to #4 Stranded)
Figure 11.
Form 6 pole mount recloser control back panel terminal block and communication port identification.
15
INSTALLATION PROCEDURE
Initial Programming Duty Cycle Monitor
Prior to Installation The Duty Cycle Monitor provides the following duty cycle
information:
CAUTION: Equipment misoperation. Do not
! connect this control to an energized recloser until • Measures and records duty for each individual phase
in non-volatile memory.
all control settings have been properly programmed
and verified. Refer to the programming information for • The recloser duty is measured and stored on the
this control. Failure to comply can result in control and basis of Current1.5 x Number of Operations for Each
recloser misoperation, equipment damage, and per- Phase (ANSI C37.61).
sonal injury. G110.3
• Readout is based on a percentage of total duty cycle
for each phase.
CAUTION: Equipment misoperation. Check mini-
• Duty record can be adjusted or reset if recloser is
mum trip values prior to changing an alternate profile.
changed-out, serviced, etc.
Failure to do so may cause misoperation of the reclos-
er under load conditions. T280.1 Using Table 2, select the appropriate recloser interrupting
duty cycle factor and enter that value via the ProViewTM
interface software.
IMPORTANT: Program all protection profiles.
Unused alternate profiles should be programmed with
the same settings as one of the applicable profiles. TABLE 2
Default settings on unused alternate profiles can Duty Cycle Factor
cause unnecessary outages if they are below normal
system requirements. Interrupting 100% Duty
Recloser Rating Cycle
Type (rms sym Amps) Factor*
The control must be programmed with all necessary Control-Powered 12,500 1111
operating settings, all alternate profiles, and parameters NOVA i 16,000 1608
prior to operation with an energized recloser. Control-Powered 12,500 1111
Note: Initial programming of the control is the responsibility of NOVA 16,000 1608
a qualified technician or engineer familiar with control
functions and programming parameters required for the *Duty Cycle Factor is Value x 105.
specific recloser installation.
The control must be programmed with the Form 6
ProView interface software. Refer to Service Information
S280-70-4 Form 6 Microprocessor-Based Recloser
Control Programming Guide for additional information.
Note: The Pole Mounted Control checkbox in the ProView
System Configuration screen must be selected for all
Form 6 pole mount controls. This includes both pole
and substation applications.
16
!
SAFETY
FOR LIFE
S280-70-18
Mounting the Control Mount the Form 6 pole mount recloser control in a con-
venient, accessible location. Mounting dimensions are
provided in Figure 12.
WARNING: This equipment is not intended to
! protect human life. Follow all locally approved
Note: Unless otherwise specified, dimensions shown in mm
(inches).
procedures and safety practices when installing or
operating this equipment. Failure to comply may result A hole and keyway in the control mounting bracket
in death, severe personal injury and equipment dam- accommodates a 15.9 mm (5/8”) bolt.
age. G102.1
29
(1.25)
310
(12.25) 16 (.63) Dia.
Mounting Holes (2)
CONTROL OK
CONTROL POWER
CONTROL LOCKOUT
RECLOSER OPEN
RECLOSER CLOSED
A PHASE FAULT
B PHASE FAULT
C PHASE FAULT
GROUND FAULT
SENSITIVE GND
ALARM
ABOVE MIN TRIP
INDICATOR 1
INDICATOR 2
INDICATOR 3
A PHASE VOLTAGE
B PHASE VOLTAGE
C PHASE VOLTAGE
FREQUENCY TRIP
VOLTAGE TRIP
INDICATOR 4
INDICATOR 5
INDICATOR 6
INDICATOR 7
INDICATOR 8
RS-232
METERING
RESET
TARGETS
SETTINGS
OPER
COUNTER
Connection
Port
F1 F2 F3 F4
EVENTS ALARMS
LAMP TEST
MENU + CHANGE
ENTER —
RS-232 DATA PORT
KYLE F6 Recloser Control ON

GND TRIP NON SUPERVISORY
TRIP CLOSE
665
CLOSE CIRCUIT
ALTERNATIVE ALTERNATIVE ALTERNATIVE
DISABLE HOT LINE TAG
710
PROFILE #1 PROFILE #2 PROFILE #3
OPTION #1 OPTION #2 OPTION #3
(LOCKOUT)
(28.0) (26.25)
Front View 170

(6.75)
355 (14.0) Grounding
400 (15.75) Terminal
#14 To #4
Right Side View Stranded
Vent Vent
Mounting Angle
1.44 Dia. Hole for
Voltage Input Connection
Customer Use (Caplug Installed)
1.44 Dia. Hole
(Caplug Installed)
Control Cable
38 Receptacle
(1.5) (19-pin)
67 67 79
(2.75) (2.75) (3.25)
Bottom View
CONTROL WEIGHT 34 kg (75 lbs)
Figure 12.
Form 6 pole mount recloser control weight and dimensions.
17
Control Cable Grounding the Control
WARNING: Hazardous voltage. Recloser and WARNING: Hazardous voltage. Recloser and
! control must be solidly grounded. Follow all ! control must be solidly grounded. Follow all
approved procedures and safety practices when locally approved procedures and safety practices
grounding this equipment. Improper grounding can when grounding this equipment. Improper grounding
result in contact with high voltage, which will cause can result in contact with high voltage, which will cause
death or severe personal injury. G115.1
death or severe personal injury. G115.1
The control cable is fabricated with connectors which

mate with the female receptacle of the recloser on one The control cabinet must be grounded. A grounding con-
end, and the male receptacle of the control or junction nector on the underside of the cabinet will accommodate
box on the other end. No. 14 solid through No. 4 stranded conductors.
Note: The control cable must be supported along its length to Suggested methods for grounding the control and reclos-
prevent repeated movement due to wind or other out- er are shown in Figures 13, 14 and 15.
side forces which can damage the cable.
Figure 13 illustrates grounding methods for NOVA i
reclosers with a Form 6 pole mount control and local sup-
IMPORTANT: All external inputs to the Form 6 ply voltage transformer.
recloser control must be routed within 8 inches of their
corresponding ground. During a surge, a potential of Figure 14 illustrates grounding methods for NOVA i
approximately 1.5 kV per foot can develop in the con- reclosers with a Form 6 pole mount control and remote
ductors. Differences between conductor and ground supply voltage transformer.
path lengths can add additional stress to the control Figure 15 illustrates grounding methods for NOVA i
components in the event of a power surge. reclosers with a Form 6 pole mount control on a 3-wire
uni-grounded system.
Limits on control cable lengths are determined by the For effective surge protection, all control and power con-
recloser type and the distance between the control and ductors for the Form 6 control must be routed parallel to
recloser: See Table 3 for available Form 6 recloser con- a corresponding ground path. For example, the ac power
trol cable lengths. 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.
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.
TABLE 3
Available Form 6 Control Cable Lengths
Recloser Type Gauge Length (Meters) Length (Feet)
Control-Powered NOVA and NOVA i reclosers 16 3.4 to 38 11 to 125
18
!
SAFETY
FOR LIFE
S280-70-18
Grounding with a Local Supply Grounding with a Remote Supply

Voltage Transformer: 4-Wire Multi- Voltage Transformer: 4-Wire Multi-
Grounded, 3-Wire Ungrounded, or Grounded, 3-Wire Ungrounded, or
Impedance-Grounded Impedance-Grounded
Installation with a local supply voltage transformer must Installation with a remote supply voltage transformer
include the following (refer to Figure 13): must include the following (refer to Figure 14):
• Protection of the recloser bushings and the supplying • Protection of the recloser bushings and the supplying
transformer with lightning arresters. transformer with lightning arresters.
• Grounding of the recloser head and tank. • Grounding of the recloser head and tank.
• Grounding of the transformer tank. • Grounding of the transformer tank.
• Grounding of the control cabinet. • Grounding of the control cabinet.
• Grounding of the SCADA equipment. • Grounding of the SCADA equipment.
Figure 14.
Figure 13. Recommended grounding method for NOVA i
Recommended grounding method for NOVA i recloser with microprocessor-based control and
recloser with microprocessor-based control and remote supply voltage transformer.
local supply voltage transformer.
19
Grounding on a 3-Wire Uni-Grounded CAUTION: Hazardous Voltage. Do not use

System ! a shared low-voltage network to power the
Installation on a 3-wire uni-grounded system must recloser control unless the network is specifically
include the following (refer to Figure 15): designed to withstand maximum ground potential rise.
Ground faults on a high-voltage network can create a
• Protection of the recloser bushings and the supplying rise in ground potential. T264.0
transformer with lightning arresters.
• Grounding of the recloser head and tank.
• Grounding of the transformer tank. IMPORTANT: In pole-mounted applications, a
• Grounding of the control cabinet. ground connection must be made between the reclos-
er, transformer, recloser control, and SCADA equip-
• Grounding of the SCADA equipment.
ment for proper protection of the equipment. It is rec-
ommended to use a minimum of 50 sq mm copper
WARNING: Hazardous Voltage. Use locally
! approved operator safety procedures for proper
wire for the pole ground connection to the recloser.
insulation when maintaining this equipment. High volt-
age step and touch potential is characteristic in uni-
ground systems. Failure to comply can cause death or IMPORTANT: All external inputs to the control must
severe personal injury. T262.0
be routed within 203 mm of their corresponding
ground. During a surge, a potential of approximately
1.5 kV per foot can develop in the conductors.
CAUTION: Exported Potential. Do not make Differences between conductor and ground path
! direct electrical connections to remote devices. lengths can add additional stress to the control com-
All SCADA equipment must be mounted locally or con- ponents in the event of a power surge.
nected using the fiber-optic or radio communication
accessory. Direct connections to remote devices can
produce exported potential causing equipment dam-
age or personal injury. T263.0
Figure 15.
Recommended grounding method for NOVA i reclosers with microprocessor-based control on a 3-wire uni-
grounded system.
20
!
SAFETY
FOR LIFE
S280-70-18
Customer Connections for AC CAUTION: Equipment misoperation. Verify

Power ! that the 120/240 Vac selector switch is correctly
set for incoming voltage. Failure to comply may cause
CAUTION: Equipment damage. Do not drill misoperation (unintentional operation) of the control
! connection holes into the top of the cabinet. and/or equipment damage resulting in personal injury.
Connection holes in the top of the cabinet will allow T278.0
moisture to seep into the control and damage the com-

ponents or cause control misoperation. Failure to AC
comply will void the control’s factory warranty. T249.0 Power
Fuse
Input power to the Form 6 pole mount recloser control is
connected to terminal block TB7 for single-phase power
or TB8 for three-phase power. For single-phase incoming
voltage supply for 120 Vac or 240 Vac, connect to TB7 as
shown in Figure 17. For three-phase incoming voltage
supply, the user should supply and connect to TB8 as Selector Switch Power Supply Board
show in Figures 20 and 21. For 240 Volt, 3-wire trans-
former connection refer to Figure 22. 030003KM
Figure 16.
Input power is required: Power Supply / Battery Charger Board.
• To power the control
• To provide voltage and power metering Terminal Blocks
• To power the thermostatically controlled heater Two terminal blocks are used for connection to the Form
6 recloser control. Both terminal blocks are fit for a #6
• For the convenience outlet accessory screw which can allow a maximum ring size for a #10
AWG for metering.
Power Supply / Battery Charger Board
Default factory wiring includes connection of two wires
Incoming ac power is routed to the Power Supply / from Power Supply Terminal Block TB7 to the Metering
Battery Charger Board designed to accept either 120 Vac Terminal Block TB8. See Figure 17.
or 240 Vac through a selector switch located directly on
the board (Figure 16). The battery charger includes a The wiring from TB7-3 to TB8-3 and from TB7-5 to TB8-
temperature-compensated design to optimally charge the 4 connects the metering B phase to the control. If the
control battery. The power supply / battery charger board incoming power supply voltage is different, the B phase
also includes an auxiliary power supply for connection to power supply input must be moved to the appropriate
communication equipment (radios, modems, etc.). The location. See Figure 18.
auxiliary power supply is rated 28 Vdc, 65 Watts peak. A For A phase incoming power, connect to TB8-1.
separate 28 Vdc to 13.8 Vdc power supply accessory is
available for communication equipment rated for 13.8 For C phase incoming power, connect to TB8-5.
Vdc. Some additional features are as follows: Note: Terminal Block positions TB7-3 and TB7-4 are factory-
jumpered together.
• Positive LED indicator for power supply presence.
Note: Terminal Block positions TB7-5 and TB7-6 are factory-
• Selectable 120/240 Vac switch for adapting to multi- jumpered together.
ple transformer connections. The selector switch is
factory-set based upon each customer order. Power Connections
• Self-protective fuse (5 amp, 250 Vac). The transformer required for power should be a minimum
• 28 Vdc whetting voltage for I/O contact inputs. of 1 kVA for NOVA i and control-powered NOVA
reclosers.
IMPORTANT: Prior to energizing the control, the

selector switch must be set as follows:
• For 120 Vac incoming power, the selector switch
must be set to the 115V position.
21
Voltage Sensing Connections

Source Load
V (1-2) V(3-4) V(5-6) V1 V2 V3
BØ
TB8
1 2 3 4 5 6 7 8 9 10 11 12
Factory Wiring for Wye Connection
Note: Terminal Block positions TB7-3 and

TB7-4 are factory-jumpered together.
Terminal Block positions TB7-5 and 1 2 3 4 5 6
TB7-6 are factory-jumpered together. 120 120/240 NEU
Remove the factory jumpers between
TB7
(L2)120 (L1) NEU
TB8 and TB7 for separate control
power and sensing voltage inputs. Power Connections
Figure 17.
Default factory wiring connected to B-Phase voltage metering with B-Phase incoming supply (no internal volt-
age sensors).

Source Load
V (1-2) V(3-4) V(5-6) V1 V2 V3
AØ
1 2 3 4 5 6 7 8 9 10 11 12
TB8
User-Supplied
Disconnect
Switch
AØ
1 2 3 4 5 6
TB7
Note: Terminal Block positions TB7-3 and TB7-4
are factory-jumpered together. 120 120/240 NEU
Terminal Block positions TB7-5 and TB7-6 (L2) 120 (L1) NEU
are factory-jumpered together. Power Connections
Figure 18.
Modified wiring connected to A-Phase voltage metering with A-Phase incoming supply.
22
!
SAFETY
FOR LIFE
S280-70-18
Internal Voltage
Sensor (IVS)
Receptacle
BØ
C
D
A
B
NEU
BØ
User-Supplied
Disconnect
Switch
12
V3
11
Factory Wiring for Wye Connection

Load
10
6
(L2) 120 (L1) NEU
120 120/240 NEU
V2
Power Connections
5
9
4
8
V1
3
7
2
V (1-2) V(3-4) V(5-6)
1
5
TB7
Source
4
3
2
1
Note: Terminal Block positions TB7-3 and

TB8
Terminal Block positions TB7-5 and

Figure 19.
Single-Phase Transformer Connection, B phase input for Power (with internal voltage sensors).
23
AØ
TB8
BØ
Source Load
V (1-2) V(3-4) V(5-6) V1 V2 V3
CØ
1 2 3 4 5 6 7 8 9 10 11 12
NEU
CØ
BØ
AØ
User-Supplied
Disconnect
Switches
Figure 20.
Three-Phase Transformer Connection, Wye configuration only (TB8 Terminal Block Connection).

Source Load
V (1-2) V(3-4) V(5-6) V1 V2 V3
CØ
BØ
1 2 3 4 5 6 7 8 9 10 11 12
TB8
AØ
User-Supplied
Disconnect
Switches
Note: Terminal Block positions TB8-1 and TB8-6 are fac-

tory-jumpered together for Delta connection only.
Terminal Block positions TB8-2 and TB8-3 are fac-
Terminal Block positions TB8-4 and TB8-5 are fac-
Remove factory jumpers for Wye application.
Figure 21.
Customer connections to TB8, 120 or 240 Vac Delta Connection.
24
!
SAFETY
FOR LIFE
S280-70-18
Source Side
Power Connections 120
240
120 120/240 NEU 120
TB7 (L2) 120 (L1) NEU

User-Supplied
Disconnect
Switches
1 2 3 4 5 6 Note: Terminal Block positions TB7-3 and

Terminal Block positions TB7-5 and
Figure 22
240 Volt, 3-wire transformer connection.
User-Supplied
Disconnect
Switch
Voltage Sensing Connections Load Side
Source Load 120 or
V (1-2) V(3-4) V(5-6) V1 V2 V3 240 Vac
TB8
1 2 3 4 5 6 7 8 9 10 11 12
NEU
YØ
Note: Sync Check must be applied to V1.
Figure 23.
Customer connections for single-phase sync check.
25
Standard Default Supervisory Input TABLE 4

Control and Output Status Contacts Operating Current Requirements for Standard and
Optional Supervisory Inputs
Standard customer connections TB1 and accessory cus-
tomer connections are TB3 and TB4. Refer to Figures 24 Nominal Minimum
and 25 and Tables 4, 5, and 6. The Idea WorkbenchTM Input Voltage Current Operating Time
allows customization of all the control and status points.
Refer to Service Information S280-70-4 Form 6 12 Vdc – 250 Vdc,
Microprocessor-Based Recloser Control Programming 120/240 Vac 2.5 mA 5 milliseconds
Guide for additional information.
IMPORTANT TABLE 5
Ratings Table for Output Status Contacts CO1
Shielding and Surge Protection of through CO12
Supervisory Cables (Resistive Load – Pickup Time 8 ms, Dropout 15 ms)
All supervisory operation and control monitor leads must Contact
be protected within shielded cables. Refer to Figure 26. Input Voltage Rating
120 Vac 8A
CAUTION: Equipment damage; misoperation.
External leads must be shielded and the shield must be 12 Vdc 8A
grounded at both ends. Terminate each lead with a 320
Vac, 160 Joules metal oxide resistor (MOV), or equiva- 24 Vdc 8A
lent, at the remote end. Attach MOVs between the leads
48 Vdc 1A
and ground. Failure to properly shield and protect leads
can result in equipment damage and/or unintentional 125 Vdc 0.4 A
operation. G117.3
240 Vac 0.2 A
TABLE 6
Ratings Table for Output Status Contact SS1
(Resistive Load – Pickup Time 2 ms, Dropout 15 ms)
Contact
Input Voltage Rating
120 Vac 8A
12 Vdc 8A
24 Vdc 8A
48 Vdc 8A
125 Vdc 8A
240 Vac 8A
26
!
SAFETY
FOR LIFE
S280-70-18
IMPORTANT
Shielding and Surge Protection of
Supervisory Cables
All supervisory operation and control monitor leads must
be protected within shielded cables. Refer to Figure 26.
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 resistor (MOV), or equiva-
and ground. Failure to properly shield and protect leads
can result in equipment damage and/or unintentional
operation. G117.3
Customer-Supplied
Voltage Inputs**
Supervisory Close
Remote/Supervisory Common
Supervisory Trip and Lockout
Remote Trip and Lockout
**Whetting voltage is also available from

the Form 6 Recloser Control on
Terminal Block TB9. Refer to Figure 26.
Note: Contact output relays revert to

de-energized positions as shown
upon downloading new schemes
or Workbench files.
CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4

1 3 5 7 9 11 13 15 17 19
TB1
2 4 6 8 10 12 14 16 18
Customer Wiring A B
Control Control Hotline Ground Trip
Lockout Recloser OK Tag Blocked
Status Status Status Status Status
(Not (Recloser (Control (Hotline (GRD TRIP
Lockout)* Open)* Not OK)* Tag Off)* Normal)*
*Relay Contacts shown

for Indicated Status
Figure 24.
Form 6 pole mount recloser control standard default supervisory input control and output status contacts.
27
28
IMPORTANT
Shielding and Surge Protection of
Figure 25.
Supervisory Cables
All supervisory operation and control monitor leads must
be protected within shielded cables. Refer to Figure 26.
**Whetting voltage is available from the CAUTION: Equipment damage; misoperation. exter-
nal leads must be shielded and the shield must be
output status contacts.

Form 6 Recloser Control on Terminal Block
TB9. Refer to Figure 26. grounded at both ends. Terminate each lead with a 320
Customer-Supplied and ground. Failure to properly shield and protect leads
Voltage Inputs** can result in equipment damage and/or unintentional
operation. G117.3
Unassigned
Remote Normal Profile
Supervisory Non-Reclose
Remote Alternate Profile 1
Supervisory Reset Targets

Remote/Supervisory Common
Supervisory Ground Trip Block

CI4 CI9 CO7 CO8 CO9 CO10 CO11 CO12
TB4
CI5 CI6 CI7 CI8 CI10 CI11 CO5 CO6
TB3
1 3 5 7 9 11 13 15 17 19 21 1 3 5 7 9 11 13
2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12
Customer Wiring Non-Reclosing

Status Normal Alternate Alternate Alternate Frequency
(Normal Profile Profile 1 Profile 2 Profile 3 Alarm
Voltage
Reclose)* Alarms Status Status Status Status (Frequency
Alarm
Status (Not in (Not in (Not in (Not in Normal)*
(Voltage
(No Alarms)* Normal Alt 1 Alt 2 Alt 3
Normal)*
Profile)* Profile)* Profile)* Profile)*
*Relay Contacts shown
for Indicated Status
Form 6 pole mount recloser control Discrete Interface Board accessory default supervisory input control and
!
SAFETY
FOR LIFE
S280-70-18
FORM 6 POLE MOUNT

RECLOSER CONTROL
TB9 SHIELD
1 + Customer Wiring 28 Vdc Whetting Voltage Terminals

Factory-Supplied
28 Vdc Whetting
Voltage
2 — Customer Wiring
REMOTE
BOX
Supervisory
Trip and 8 CI3
Lockout CI3 7
Supervisory
Close 6 CI2
CI2 5
Remote
Trip and 4 CI1
CI1 3
Lockout
13
B*
Recloser 12 CO1
Status A*
*Contacts shown
with recloser in 11
OPEN position. CO1
Not All Remote
Connections
TB1 Shown
NOTES: Arresters to be metal oxide varistors (MOVs) 320 Vac,

160 Joules or equivalent.
External lead resistance must not exceed 200 ohms.
A Single common wire can be used for multiple inputs
if it is jumpered at the I/O board terminals.
Shielding for Supervisory Cables should follow
the representative input control contacts and
output status contacts as shown.
Supervisory and Remote Functions are
default functions.
Figure 26.
Shielding and Surge Protection for Supervisory and Remote Cables.
29
Rear Panel RS-232 Communication

Port Pin Assignments RS-232 Serial IRIG-B Time
Communication Port Sync Connector
Table 7 indicates the pin assignments for the rear panel
RS-232 communication port (Figure 28). Refer to Figure
27 for pin identification. Refer to Protocols for additional
information.
1 3 5 7 9 11 13 15 17 19
Refer to the Accessories section of this manual for addi- TB1
J1-RS-232
tional communication options. 2 4 6 8 10 12 14 16 18

RS-232 DTE
IRIG-B
TABLE 7 TB3
CI4 CI5 CI6
1 3 5
CI7 CI8 CI9 CI10 CI11 CO5
7 9 11 13 15 17 19 21
CO6 CO7 CO8 CO9 CO10 CO11 CO12
1 3 5 7 9 11 13
TB4
Rear Panel RS-232 Communication Port Pin
Assignments 2 4 6
CI4 CI5 CI6
8 10 12 14 16 18 20
CI7 CI8 CI9 CI10 CI11 CO5 CO6
2 4 6 8 10 12
CO7 CO8 CO9 CO10 CO11CO12
Pin Number Signal Name TB9
1 DCD . . . . . . . . . . . . . . . . . . . Carrier Detect

+ –
28 VDC
2 RXD . . . . . . . . . . . . . . . . . . . Receive Data WHETTING VOLTAGE
3 TXD . . . . . . . . . . . . . . . . . . . . Transmit Data P1 P4

P2 P3 1 2 3 4 5
1 3 1 3 1 3 24 23 22 21 20 19 18 17 16 15 14 13
4 DTR . . . . . . . . . . . . . . . . . . . . Data Terminal Ready 1 3 1 2 3 4 5

2 4 2 4 2 4 2 4 5 12 11 10 9 8 7 6 4
5 3 2 1
VOLTAGE SENSING 53VDC CONTROL CABLE 28 VAC

(Not Connected)
5 GND . . . . . . . . . . . . . . . . . . . Signal Ground
6 DSR . . . . . . . . . . . . . . . . . . . Data Set Ready

(Not Connected)
Figure 28.
7 RTS . . . . . . . . . . . . . . . . . . . . Request to Send Form 6 pole mount recloser control rear panel RS-
232 communication ports (standard configuration).
8 CTS . . . . . . . . . . . . . . . . . . . . Clear to Send
9 NC . . . . . . . . . . . . . . . . . . . . . Not Used
10 (Shroud) . . . . . . . . . . . . . . . .Chassis Ground
J1-RS-232
1 2 3 4 5
6 7 8 9
RS-232 DTE
Figure 27.
Rear panel RS-232 communication port pin
identification.
30
!
SAFETY
FOR LIFE
S280-70-18
Before Placing the Control and 8. Control battery connected and tested for proper
operation.
the Recloser into Service
Note: The battery test is blocked for 30 seconds upon
power-up of the control.
! connect this control to an energized recloser until Test the battery as follows:
all control settings have been properly programmed A. Press the MENU button on the front panel.
and verified. Refer to the programming information for
this control. Failure to comply can result in control and B. Using the down arrow key, navigate to the BAT-
recloser misoperation, equipment damage, and per- TERY menu and press ENTER.
C. Using the down arrow key, navigate to the TEST
BATTERY menu and press ENTER.
Prior to placing the control and recloser into service, the
following installation procedures must be properly com- D. Press the F4 button to test the battery.
pleted and verified: Note: This message will appear on the programming
panel LCD display: ----TESTING----
1. Front panel label inserts changed (if applicable).
The battery test results will display in the battery
Note: Refer to Using Removable Inserts in this manual.
metering menu.
2. Control properly mounted for the installation. Note: With AC disconnected and the battery supplying
3. Recloser installed according to all locally approved the load, current will read -400 to -600 mA
standards and practices. depending on accessories connected.
4. AC disconnect switches installed. 9. AC power connected to the control. (Control OK LED

indicator is illuminated.)
5. Control and recloser properly grounded in accor-
dance with guidelines in this manual and the applica- Note: The control Power Save feature will turn off the
backlit LCD display and all LEDs if no front panel
ble recloser manual.
keypad is pressed within ten minutes.
6. Control cable properly connected and supported.
10. All control programming entered and verified by
appropriate personnel.
CAUTION: Equipment misoperation. Verify that
! the 120/240 Vac selector switch is correctly set Note: Refer to Service Information S280-70-4 Kyle Form
6 Microprocessor-Based Recloser Control
for incoming voltage. Failure to comply may cause Programming Guide for additional information.
misoperation (unintentional operation) of the control
and/or equipment damage resulting in personal injury. 11. Control clock set to the correct time.
T278.0
Note: Refer to Service Information S280-70-4 Kyle Form
6 Microprocessor-Based Recloser Control
7. Verify the selector switch on the Power Programming Guide Clock Menu for additional
Supply/Battery Charger Board is set to the correct information.
position based upon the incoming power supply: CAUTION: Equipment damage; misoperation.
• For 120 Vac incoming power, the selector switch External leads must be shielded and the shield must be
must be set to the 115V position. grounded at both ends. Terminate each lead with a 320
lent, 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 uninten-
tional operation. G117.3
12. Customer connections for remote and supervisory

operation checked and completed in accordance with
proper shielding and surge protection (Figure 26).
31
Using Removable Inserts 4. Use tweezers to gently pull out the removable insert.
Note: The insert will slide out of the right side of the oper-
CAUTION: Control damage. De-energize both ac ating panel (Figure 30).
and dc power prior to removing or installing any inter-
Note: The insert will slide out of the top of the program-
nal connections or circuit boards in the control. Failure ming panel indicator section (Figure 29).
to comply can result in damage to the control. T241.1
5. Change the existing label or slide in a new label with
the name of the programmed option.
CAUTION: Equipment damage. Always wear a An electronic label template is included on the
grounding wrist strap to control static electricity before ProViewTM application software CD and can be
handling circuit boards. Failure to use this strap may accessed through the following default address:
result in circuit board damage. T253.1
C: \ Program Files \ Cooper \ Proview401 \ Form 6 \
Form 6 Inserts.doc
The front panel inserts can be changed, if desired.
1. De-energize both ac and dc power. IMPORTANT: Laminate the removable inserts prior
to installing. This will seal the ink/toner and avoid dam-
2. Use a flathead screwdriver to unscrew the six front
age to the front panel.
panel screws.
3. Pull the right side of the front panel out towards the 6. Gently push the removable insert from right to left into
left (Figure 29). the right side of the operating panel (Figure 30) or
Note: Various connecting wires will keep the panel down into the programming panel LED indicator sec-
attached to the control. tion (Figure 29).
Note: It is not necessary to disconnect any wires.
Removable LED
Status Indicator Panel
000008KM
Figure 30.
Labels are easily removed from and inserted into
the operating panel.
7. Place the front cover panel back onto the control.

Using a flathead screwdriver screw the screws into
the control and tighten all hardware completely.
030038KM
Figure 29.
Open front panel. Labels are easily removed from
and inserted into the top of the programming panel
LED status indicator section.
32
!
SAFETY
FOR LIFE
S280-70-18
ACCESSORIES
These accessories are available. Contact your Cooper Cable Locking Sleeves
Power Systems representative for additional information.
To prevent detachment of the control cable from the con-
trol cabinet by unauthorized personnel, a cable-locking
Incoming Power Receptacles sleeve (Catalog Number KME6-1772-1) is available to
The Incoming Power Receptacle allows the user to con- enclose the cable plug. The plug is passed through the
veniently plug the power cable into the control, eliminat- sleeve and the sleeve is then fastened from inside the
ing the need for hardwiring to the control. Various options control cabinet. There is no access to the cable recepta-
are available based upon the input power voltage, and cle without opening the locked cabinet door and detach-
phase sensing requirements. Table 8 includes the avail- ing the sleeve.
able input receptacles and cables for the Form 6 pole
mount recloser control. 120 Vac GFI Duplex Outlet
The GFI Duplex Outlet (Catalog Number KME6-1776) is
Internal Voltage Sensing available for controls powered by 120 Vac or 240 Vac
Receptacle three-wire supply power. This convenience outlet is rated
The internal voltage sensing receptacle allows connec- for 15 Amperes and is accessible through the front door
tion from the internal voltage sensor accessory on the in the control cabinet. The 120 Vac GFI Duplex Outlet is
control-powered NOVA and NOVA i recloser to the con- used for many applications such as power for the MET
trol. The 4-pin receptacle on the Form 6 control is wired Tester, auxiliary measurement equipment, and supple-
to terminal block TB-8 for three voltage sensing inputs. mental lighting.
Refer to Figure 19.
Cabinet Ordering Accessories
• AISI 304 stainless steel cabinet construction
• Three-point door latch
TABLE 8
Input Receptacles and Cables
Description Catalog Number
120 Vac or 240 Vac input receptacle, 2-pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KME6-1775-H
120 Vac input receptacle, 3-pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KME6-1775-J
240 Vac input receptacle, 3-pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KME6-1775-K
AC Input Cable, 120 or 240 Vac, 2-wire for 2-pin input for use with KME6-1775-A, KME6-1775-D, or
KME6-1775-H receptacles. Replace X with desired length. Select from 10 to 80 feet. . . . . . . . . . . . . . . . . . . . . . . KA11ME1-X
AC Input Cable, 240 Vac, 3-wire for 3-pin input for use with KME6-1775-E or KME6-1775-K receptacles.
Replace X with desired length. Select from 10 to 80 feet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KME4-67-2-X
AC Input Cable, 120 Vac, 3-wire for 3-pin input for use with KME6-1775-B and KME6-1775-J receptacles.
Replace X with desired length. Select from 10 to 80 feet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KME4-67-3-X
Internal Voltage Sensing Cable, 4-wire for use with standard front panel with or without sensitive ground fault.
Replace X with desired length. Select from 5 to 35 feet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KA97ME-X
33
Discrete Interface Board (DIF) Radio Mounting Accessory

Option Accessory The radio mounting accessory (Figure 32) is powered
A Discrete Interface Board Option accessory provides from a voltage regulated power supply factory-calibrated
eight configurable input control contacts and eight con- with an output of 13.8 Vdc.
figurable output status contacts (Figure 31). The ordering Note: This output cannot be field-calibrated.
options include: Standard (3 inputs / 5 outputs) or
Additional (8 inputs / 8 outputs). The radio will continue to operate during the loss of ac
power as long as power is supplied from the battery. The
DIF Board Accessory power supply is designed to provide up to 40 Watts
(peak) and is fused to isolate any potential radio prob-
lems without disturbing the protection system in the
RS-485 C + –
recloser control. Refer to Table 9.
1 3 5 7 9 11 13 15 17 19 J1-RS-232
TB1
IRIG-B
Contact your Cooper Power Systems representative for
RS-232 DTE
2 4 6
CI1 CI2
8 10 12 14 16 18
CI3 SS1 CO1 CO2 CO3 CO4 any additional voltage requirements.
1 3 5 7 9 11 13 15 17 19 21 1 3 5 7 9 11 13
TB3 TB4
TABLE 9
2 4 6
CI4 CI5 CI6
8 10 12 14 16 18 20
CI7 CI8 CI9 CI10 CI11 CO5 CO6
2 4 6 8 10 12
CO7 CO8 CO9 CO10 CO11CO12
Communication Accessories
TB9 Description Catalog Number
+ – Full Automation accessory

28 VDC
WHETTING VOLTAGE 12 Vdc radio provision . . . . . . . . . . . . . . . KME6-1774-3
P1 P4 (Radio and fiber-optic/RS232 interface not included)
P2 P3 1 2 3 4 5
1 3 1 3 1 3 24 23 22 21 20 19 18 17 16 15 14 13
1 2 3 4 5
Automation accessory (bracket only)

2 4 2 4 2 4 1 2 3 4 5 12 9
11 10 8 7 6 5 4 3 2 1
12 Vdc provision . . . . . . . . . . . . . . . . . . . . KME6-1774-2

Figure 31. DB9 to DB25 Radio Cable, 1-ft. Length . . . . KME5-347-5
Form 6 recloser control discrete interface board
accessory. DB9 to DB25 Radio Cable, 6-ft. Length . . . . KP2412A3
RS-485 C + –
J1-RS-232
IRIG-B
RS-232 DTE
TB9
+ –
28 VDC
WHETTING VOLTAGE
P1 P4
P2 P3
Customer-Supplied
1 2 3 4 5
1 3 1 3 1 3 24 23 22 21 20 19 18 17 16 15 14 13
1 3 1 2 3 4 5
2 4 2 4 2 4 2 4 5 12 11 10 9 8 7 6 4
5 3 2 1
Radio
Power Cable
Radio-Mounting
Bracket
24 Vdc to 13.8 Vdc

Converter
Customer-Supplied
Power Leads
Radio Antenna
Cable (only
available with full
automation accessory)
Antenna Surge
Suppresser and
Connector (only
available with full
automation accessory)
Figure 32.
Form 6 recloser control radio mounting accessory.
34
!
SAFETY
FOR LIFE
S280-70-18
Communication Board A pair of industry standard ST type fiber-optic connectors

are mounted on the back of the board enabling customer
Accessories connection to a digital communication system using fiber-
The Form 6 pole mount control is equipped with a optic cables (customer-supplied).
Communication Board Accessory (expansion bay) offer-
The fiber-optic link has separate receive (RX) and trans-
ing versatile support for modern communication media.
mit (TX) ports operating at 820nm. Typical transmission
Six distinct communication options (Figure 33) are avail-
distance is 2000m with 62.5/125µm multi-mode fiber.
able, providing two-way, real time digital communications
Consult your Cooper Power Systems representative for
with a remote terminal unit (RTU), wireless, telephone
availability of long haul and single mode fiber solutions.
modem, Ethernet network, or other communication
Link communication speed is controlled through software
devices. The following options are available:
and can be set at: 1200, 2400, 4800, 9600, 19.2k, 38.4k,
• No auxiliary communication card installed (standard) 57.6k, and 115kBPS.
• RS485 (isolated) Serial communication card The fiber-optic accessory must be programmed through
• Fiber-optic-based Serial Communication Card (ST) the Communications Workbench for the appropriate pro-
tocol. Refer to S280-70-4 Form 6 Control Programming
• 10/100 Base-T dual Ethernet communication card Guide for additional information.
(2*RJ-45)
The fiber-optic based serial accessory includes TX and
• 100 Base-FX dual Ethernet communication card RX indicating LEDs for verifying communications along
(2*MT-RJ) with an echo / non echo switch for supporting ring / star
• 10/100 Base-T, 100 Base-FX Ethernet communica- fiber topologies.
tion card (RJ-45 + MT-RJ) When operated in a ring configuration, the toggle switch
The expansion bay based Communication Board must be set in the ECHO position. In this mode, the fiber-
Accessory concept offers high versatility with respect to optic card will repeat (pass through) all messages
communication medium and protocol support. Additional received on the RX fiber, and will respond to the Master
accessories are being continuously developed. Contact station by first echoing the incoming command and then
your Cooper Power Systems representative for the latest sending the response. This arrangement is best suited
information regarding particular media and communica- for creation of low cost multi device fiber loops. For reli-
tion protocol support. able communications, the fiber loop system requires that
all devices in the loop remain powered at all times, thus
RS485 Serial Communication Card enabling unobstructed flow of information throughout the
loop.
The RS485 serial communication card accessory pro-
vides means for establishing asynchronous link-based A more resilient system can be designed by using the
digital communications with the Form 6 pole mount con- fiber-optic ports in a point-to-point or multiple point-to-
trol. The Galvanic isolated (1000V DC) RS485 port uses point (star) configuration. For this mode, the toggle
a single shielded twisted pair connection and can support switch must be set in the NON-ECHO mode. The Form
16 devices in multi-drop configuration. Communication 6 pole mount control will respond to the Master station
speed is controlled through software and can be set at: by sending a response only (total separation of Receive
1200, 2400, 4800, 9600, 19.2k, 38.4k, 57.6k, and and Transmit fibers). Additional hardware (fiber-optic
115kBPS. star coupler) is required to support the multiple point-to-
point device configurations.
Digital communications must be programmed through
the Communications Workbench to ensure proper opera- Ethernet Communication Cards
tion of the RS485 communication card accessory. Refer
to S280-70-4 Form 6 Control Programming Guide for The Ethernet communication card accessory brings the
additional protocol support information. Ethernet network connectivity to the Form 6 pole mount
recloser control platform. It is highly flexible, offering
Fiber-Optic Based Serial simultaneous support for multiple sessions, device man-
Communication Card agement (ProView over TCP/IP) and SCADA communi-
cations (DNP3 over TCP/IP).
The Fiber-Optic based Serial Communication Card offers
means of establishing asynchronous (RS-232 like) digital By natively supporting a set of widely accepted industry
communications through multi-mode fiber media. The standards (TCP/IP, UDP/IP, OSI) the Ethernet communi-
use of the fiber-optic based serial communication card cation accessory ensures seamless interoperability with
accessory can enhance communication reliability, and other network devices.
provides excellent electrical isolation thus protecting
transmitted data from extraneous electrical interference.
35
Standard
(No Communication Option) RS-485 Communication Serial Fiber
RS-485 C + -
TX NON-ECHO RX
TX RX
IRIG-B IRIG-B IRIG-B

J5 J5 J5
#2 #1 #2 #1 #2 #1 #2 #1
J4 – ETHERNET – J3 J4 – ETHERNET – J3 J4 – ETHERNET – J3 J4 – ETHERNET – J3 Default
Primary
Ethernet
Interface
IRIG-B IRIG-B IRIG-B IRIG-B
J5 J5 J5 J5
2 1 2 1 2 1 2 1
Ethernet 10/100 Base-T Ethernet 100 Base-FX Ethernet 10/100 Base-T, Ethernet 100 Base-FX
Type 1 Type 2 100 Base-FX Type 4
Type 3
Figure 33.
Back panel Ethernet and Communication options.
The Ethernet communication card accessory is offered in The Ethernet communication accessory card (Figure 33)
3 physical layer configurations (twisted pair and optical- is equipped with two physical ports configured to act as
fiber options) as shown in Table 10. primary and standby LAN connections. Availability of the
backup communication port enables creation of highly
TABLE 10 redundant Ethernet networks thus increasing the overall
Ethernet Communication Card Configurations system reliability.
Card Output Communication Note: Under normal network conditions, all communications
Type Configurations Connectors Speed will be channeled through the primary port (#1, Figure
33), with the standby port either logically disabled, or
1 10/100 Base-T 2 * RJ-45 10/100MBps configured for fast automatic throw-over in case of the
(auto switching) primary Ethernet link failure. Refer to S280-70-4 Form
6 Control Programming Guide for additional Ethernet
2 100 Base-FX 2 * MT-RJ 100MBps accessory configuration information.
(multi-mode fiber) (full duplex)
3 10/100 Base-T, RJ-45 + MT-RJ 10/100MBps

100 Base-FX and 100MBps
4 100 Base-FX 2 * LC 100MBps

(single-mode fiber) (full duplex)
Maximum link length is determined by the use of the par-

ticular physical layer implementation, and can be further
constrained by the actual network configuration. In case
of the 100Base-FX MT-RJ connector based implementa-
tion, maximum link length in excess of 2000m can be
achieved with 62.5/125µm multi mode fiber. The fiber-
optic link uses 1300nm wavelength, and can easily be
interfaced to other 100Base-FX solutions (ST connector
patch cord solution).
36
!
SAFETY
FOR LIFE
S280-70-18
TESTING
3. Test battery operation as follows:
! connect this control to an energized recloser until
Note: The battery test is blocked for 30 seconds upon
power up of the control.
all control settings have been properly programmed
and verified. Refer to the programming information for Note: AC power can be either connected or disconnected
for battery test.
this control. Failure to comply can result in control and
recloser misoperation, equipment damage, and per- A. Press the MENU button on the front panel.
B. Using the down arrow key, navigate to the BAT-
TERY menu, and press ENTER.
IMPORTANT: The Form 6 control can be taken out C. Using the down arrow key, navigate to the TEST
of service for testing and placed back into service with- BATTERY menu and press ENTER.
out de-energizing its recloser and interrupting the sys- D. Press the F4 button to test the battery.
tem. However, during the time the control is out of ser-
vice, the recloser is inoperative. Note: This message will appear on the programming
panel LCD display: ----TESTING----
Testing an Installed Control The battery test results will display in the battery
metering menu.
The following tests to determine initial operation of the
Form 6 pole mount recloser control can be performed Note: Voltage should be between 25–31 Vdc – with
while connected to an operating recloser. the higher voltage at colder temperatures.
Note: These are the only tests performed on an installed, Under normal conditions, with AC connected
operating control. and a fully charged battery, the charging current
should be less than 20 mA.
1. Verify operating status of all indicator lights by press- With AC connected and a discharged battery,
ing and holding the LAMP TEST key for two seconds the current range should be 20–450 mA.
on the programming panel (Figure 34).
With AC disconnected and the battery supplying
2. Check the operational values for currents, voltages, the load, current will read -400 to -600 mA
and other metering information. depending on accessories connected.
Note: Scroll through the LCD display messages by press- 4. Verify the Control OK LED is illuminated on the con-
ing the and cursor movement arrows under- trol operator panel (Figure 35). This indicates the
neath the LCD display on the programming panel presence of ac power.
(Figure 34).
Note: The control includes a Power Save feature that will
turn off the backlit LCD display and all LEDs if no
front panel keypad is pressed within ten minutes.
LCD Display Pressing the LAMP TEST key will reactivate the
METERING SETTINGS
display and active LEDs.
RESET
TARGETS
OPER
COUNTER All other tests described in this TESTING section require
LAMP TEST Key
F1 F2 F3 F4 the Form 6 pole mount recloser control to be removed
EVENTS ALARMS
from service, connected to a bypassed recloser, or test-
LAMP TEST
MENU + CHANGE
ed at a location where the proper testing equipment is
Cursor Movement available.
Arrows ENTER —
RS-232 DATA PORT
Figure 34.
CONTROL OK A PHASE FAULT
Lamp Test button, LCD display, and cursor move-
CONTROL POWER B PHASE FAULT
ment arrows. CONTROL LOCKOUT C PHASE FAULT
RECLOSER OPEN GROUND FAULT
RECLOSER CLOSED SENSITIVE GND
Control OK LED
Figure 35.
Control OK LED.
37
Remove the Control from Testing with Type MET Tester

Service The Kyle® Type MET electronic recloser control tester
(Figure 37) is used for testing the following functions of
IMPORTANT: Disconnect switches for ac sensing the Form 6 recloser control:
and power connections are necessary to isolate the • Overcurrent Timing
Form 6 control for testing and servicing.
• Reclose Time
1. Enable GND TRIP BLOCKED to allow for ground trip • Operating Sequence
to be disabled when re-energized.
• Reset Time
A. Press the CHANGE button on the Operator Panel
• Minimum Trip Current
to enter the CHANGE mode.
• High Current Trip and Lockout
B. Depress the GND TRIP BLOCKED button within
ten seconds after entering the CHANGE mode. The MET Tester is completely self-contained, capable of
Note: If the GND TRIP BLOCK button is not pressed performing all required checks and tests from a simple
within ten seconds, the function is not activated. verification of operation to a complete verification of all
operating parameters.
2. Disconnect the battery.
Note: The Control-Powered NOVA Test Adapter Junction Box
3. Remove control ac sensing and power connections Accessory (Catalog Number KNOVA3058-15) is
from the control using a separate disconnect switch. required when using the MET tester to test the control-
powered NOVA recloser.
WARNING: Hazardous voltage. If the recloser Refer to Service Information S280-76-1 Type MET
!is energized while the control cable is discon- Electronic Recloser Control Tester Operating Instructions
nected, the CT secondaries can generate high volt- for proper setup and use of the MET Tester.
ages. Contact with high voltage can cause severe per-
sonal injury or death. T204.2
4. Disconnect control cable from control.
CAUTION: Hazardous voltage. Cable conduc-

! tors attached to NOVA reclosers will remain at
53Vdc potential after disconnection of source power to
the recloser. Contact with any pins at the end of cables
directly or indirectly connected to a NOVA recloser can
result in personal injury or equipment damage. T312.0
5. Remove any control input and status output wiring

from TB1, TB3, and TB4 (Figure 36).
6. Disconnect any serial communications ports and IRIG-
B timing connections (Figure 36).
7. Disconnect the ground from the control.
8. Carefully transport the control to a suitable service
facility.
RS-485 C + –
1 3 5 7 9 11 13 15 17 19 J1-RS-232
010028KM
TB1
Figure 34.
2 4 6 8 10 12 14 16 18
RS-232 DTE
IRIG-B
Kyle Type MET electronic recloser control tester.
®
1 3 5 7 9 11 13 15 17 19 21 1 3 5 7 9 11 13
TB3 TB4
2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11CO12
Figure 36.
Back view of top half of Form 6 pole mount recloser
control.
38
!
SAFETY
FOR LIFE
S280-70-18
Closing the Recloser During

Testing
For on-line testing, bypass the recloser, open the load-
side 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
38).
BYPASS SWITCHES
(CLOSED)
SOURCE LOAD
C
5 6
SOURCE
LOAD
B
3 4
A
1 2
SOURCE SIDE LOAD SIDE

DISCONNECT SWITCHES DISCONNECT SWITCHES
(CLOSED) (OPEN)
Figure 38.
Closing source-side switches of a bypassed “on-line” recloser provides closing solenoid power for automatic
operation during testing.
39
Battery Test and Charging Test Procedure for Uninstalled

Procedures Battery
Test Procedure for Installed Battery
CAUTION: Recloser misoperation. The control
Follow the procedure below to perform a battery test in ! must be removed from service before discon-
the Form 6 pole mount control. The values in the test pro- necting the control battery. Disconnecting the control
cedures are based on testing at 25˚C (77˚F). battery from an in-service control may cause recloser
The condition of the Form 6 pole mount control battery misoperation (unintentional operation) Failure to com-
can be determined by using the Battery Test function in ply can result in equipment damage and personal
the BATTERY MENU. No external current/voltage meter injury. T213.4
is necessary for testing.

Alarm Conditions: The entire process should be conducted in a clean envi-
ronment, such as a repair shop.
• During a manual battery test a 5Ω, 55 watt resistor is
placed across the battery terminals for approximate- Refer to Table 11 and follow this procedure to perform a
ly 5 seconds. The Form 6 control measures the bat- bench test on a control battery in a service shop:
tery voltage, if the voltage drops below 22.8 Vdc for 1. Remove the control from service. Refer to Remove
one full second, the ALARM LED (battery alarm) is the Control from Service procedure within the
illuminated. Testing section of this manual.
• When the Form 6 pole mount control is disconnected 2. Remove the battery from the control and carefully
from AC power and the control battery drops below transport it to a suitable service facility.
23.5 Vdc for 60 seconds, the ALARM LED will illumi-
nate. If the battery voltage continues to decay and 3. Measure battery voltage.
drops below 22 Vdc, the Form 6 control will shut down. 4. Apply test load and measure battery voltage after 5
Note: The battery test is blocked for 30 seconds upon power seconds of load to determine voltage drop. Refer to
up of the control. Table 11 for Bench Test Load Condition.
Note: AC power can be either connected or disconnected for
battery test. 5. Remove test load.
1. Press the MENU button on the front panel. If the battery fails the test or is at least four years old, it
should be replaced. Refer to Table 11 for battery catalog
2. Using the down arrow key, navigate to the BATTERY part numbers.
menu and press ENTER.
3. Using the down arrow key, navigate to the TEST BAT-
TERY menu and press ENTER.
4. Press the F4 button to test the battery. The battery
test results will display in the battery metering menu.
Note: Voltage should be between 25–31 Vdc with the
higher voltage at colder temperatures.
Under normal conditions, with AC connected and a
fully charged battery, the charging current should
be less than 20 mA.
With AC connected and a discharged battery the
current range should be between 20 and less than
450 mA. Current of 450 mA or greater indicates a
problem with the charging circuit on the pole mount
power supply.
With AC disconnected and the battery supplying
the load, current will read -400 to -600 mA depend-
ing on connected accessories.
TABLE 11
Control Battery Bench Testing and Replacement Information
Bench Acceptable
Battery Test Load Voltage Drop
Catalog Amp/ Condition at End of
Control Type Battery Part # Voltage Type Hour for 5 sec. Test Load
Form 6 Pole Mount (standard capacity) Hawker KME4-215 24v Lead 8 5Ω 3v
Cyclon Acid 55 watt or less
Form 6 Pole Mount (high capacity) Hawker KME5-134-1 24v Lead 13 5Ω 2v
Genesis (two Acid 55 watt or less
12v
batteries)
40
!
SAFETY
FOR LIFE
S280-70-18
Battery Charging The charger senses when the battery voltage reaches
2.27 volts per cell, then the charge rate reduces to main-
If it is not possible to charge the battery with the control’s tain a trickle charge.
built-in charger, a KA43ME7001 (120 Vac) portable
bench type battery charger is available. Refer to S280- The red LED flickers to indicate the battery has reached
79-14 KA43ME7001 Portable Lead Acid Battery Charger a full charge. This process can take up to 24 hours.
Instructions for additional information. Refer to Table 12 for additional battery charging
accessories.
IMPORTANT: Do not attempt to charge a lead acid
battery below 19 Vdc with the KA43ME7001 charger. TABLE 12
Attempting to do so will damage the charger. Battery Charging Accessories
If the lead acid battery is below 19 Vdc, replace the Description Catalog Number
battery. The expired battery should be disposed of in 120 Vac Battery Charger Accessory . . . . . . . . KA43ME7001
an environmentally responsible manner. Consult local
regulations for proper battery disposal.
Charge the battery with a KA43ME7001 (120 Vac)

portable charger as applicable:
• Form 6 Pole Mount Recloser Control (Standard
Capacity) – Connect the battery directly to the
KA43ME7001 charger. The charger continuously
monitors the battery voltage.
• Form 6 Pole Mount Recloser Control (High
Capacity) – Use adapter KME5-325-1 to connect the
two 12 volt batteries to the KA43ME7001 charger.
IMPORTANT: Never connect a single 12 volt battery to

the KA43ME7001 charger. Use adapter KME5-325-1
with the battery assembly when connecting the charg-
er to the two 12 volt batteries.
Note: A red LED indicator on the body of the charger illumi-

nates when charging.
41
Return the Control to Service 6. Apply ac power to the control.

7. Disable GND TRIP BLOCKED.
! connect this control to an energized recloser
A. Press the CHANGE button on the Operator Panel
to enter the CHANGE mode.
until all control settings have been properly pro-
grammed and verified. Refer to the programming B. Depress the GND TRIP BLOCKED button within
information for this control. Failure to comply can ten seconds after entering the CHANGE mode.
result in control and recloser misoperation, equipment Note: Once selected (or after ten seconds), the control
damage, and personal injury. G110.3 returns to normal operation.
8. Verify the control clock is set to the current time after
After the required work is completed, disconnect the con- ac power has been reapplied.
trol from the test set and follow this procedure to return
the control to service: Note: The control clock may require resetting if the oper-
ating power has been disconnected for more than
1. While still in service shop, appropriate personnel thirty days. Refer to Service Information S280-70-4
must verify that all control settings are correct. Kyle Form 6 Microprocessor-Based Recloser
Control Programming Guide for information on set-
2. Reconnect the ground cable to the control. ting the control clock.
3. Control cable properly connected and supported.
4. Plug in the control battery.
Note: The Form 6 pole mount recloser control will not
power up until ac power is applied.
CAUTION: Equipment misoperation. Verify that

! the 120/240 Vac selector switch is correctly set
for incoming voltage. Failure to comply may cause
misoperation (unintentional operation) of the control
and/or equipment damage resulting in personal injury.
T278.0
5. Verify the selector switch on the Power

Supply/Battery Charger Board is set to the correct
position based upon the incoming power supply:
42
!
SAFETY
FOR LIFE
S280-70-18
ADDITIONAL INFORMATION
Maintenance Classes
CAUTION: This equipment requires routine
! inspection and maintenance to ensure proper Cooper Power Systems offers a basic testing and trou-
bleshooting course for the Form 6 microprocessor-based
operation. If it is not maintained, it can fail to operate
properly. Improper operation can cause equipment electronic recloser control. This course is taught by expe-
damage and possible personal injury. G105.1
rienced service technicians. For additional information,
contact your Cooper Power Systems representative.
Replacement Kits Type MET Recloser Control Tester

Replacement kits for the Kyle Form 6 pole mount control A 30-minute video cassette program KSPV7 Kyle® Type
are available from Cooper Power Systems. To order MET Electronic Recloser Control Tester Operation and
these kits, refer to the Replacement Parts price list for Testing Procedures is available as a supplemental train-
catalog numbers and pricing. Contact your Cooper ing aid for service personnel.
Power Systems representative for additional information
and order procedures.
43
!
SAFETY
FOR LIFE
©2007 Cooper Power Systems, Inc., or its affiliates.

Kyle® and NOVA® are registered trademarks of Cooper Power Systems, Inc.,
or its affiliates.
ProViewTM, Idea WorkbenchTM, Communications WorkbenchTM, and TCC EditorTM 1045 Hickory Street
are trademarks of Cooper Power Systems, Inc., or its affiliates. Pewaukee, WI 53072
IEEE is a trademark of the Institute of Electrical and Electronics Engineers, Inc. www.cooperpower.com
KA2048-691 Rev: 00

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Reclosers

Form 6 Microprocessor-Based Pole Mount Control Service Information

May 2007 • New Issue 1

• Is trained in the care and use of protective equipment

Hazard Statement Definitions

WARNING: Indicates a potentially hazardous

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

Control VTC Interface Recloser VTC Interface

CAUTION: Equipment misoperation. The con-

Control-Powered NOVA Serial No.

Operation Upon Loss of AC

IMPORTANT: If the the control shuts down due to

FORM 6 RECLOSER CONTROL DESCRIPTION

CONTROL OK A PHASE FAULT ALARM A PHASE VOLTAGE INDICATOR 4

Cursor Movement Arrows

Hot Line Tag Toggle Switch and

Programming Panel LCD Display

CONTROL OK A PHASE FAULT ALARM A PHASE VOLTAGE INDICATOR 4

Operating Panel CLOSE CIRCUIT DISABLE

IMPORTANT: If the power save feature is enabled

One-Touch Function Keys SUPERVISORY OFF

Control Features Sequence Coordination

Metering The control also provides a minimum of three config-

Directional Manual Close Delay

Communications Ethernet configuration is accomplished via ProView inter-

RS-232 Serial Communication Port

RS-485 Serial Communication Port (optional)

Power Supply Board

Battery Connector (2-position)

Grounding Terminal, One

KYLE F6 Recloser Control ON

OPTION #1 OPTION #2 OPTION #3

Front View 170

Control Cable Grounding the Control

The control cable is fabricated with connectors which

Control-Powered NOVA and NOVA i reclosers 16 3.4 to 38 11 to 125

Grounding with a Local Supply Grounding with a Remote Supply

Grounding on a 3-Wire Uni-Grounded CAUTION: Hazardous Voltage. Do not use

Customer Connections for AC CAUTION: Equipment misoperation. Verify

moisture to seep into the control and damage the com-

IMPORTANT: Prior to energizing the control, the

Voltage Sensing Connections

Factory Wiring for Wye Connection

Note: Terminal Block positions TB7-3 and

Voltage Sensing Connections

Factory Wiring for Wye Connection

Note: Terminal Block positions TB7-3 and

Terminal Block positions TB7-5 and

Voltage Sensing Connections

Note: Terminal Block positions TB8-1 and TB8-6 are fac-

TB7 (L2) 120 (L1) NEU

1 2 3 4 5 6 Note: Terminal Block positions TB7-3 and

Note: Sync Check must be applied to V1.

Standard Default Supervisory Input TABLE 4

CAUTION: Equipment damage; misoperation.

**Whetting voltage is also available from

Note: Contact output relays revert to

CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4

CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4

*Relay Contacts shown