Reclosers: Form 6 Triple-Single Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
Reclosers: Form 6 Triple-Single Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
Reclosers: Form 6 Triple-Single Microprocessor-Based Yard Mount Recloser Control Installation and Operation Instructions
Figure 1.
Kyle® Form 6 triple-single yard mount microprocessor-based recloser control.
Contents
Safety Information ..................................................... 2 Mounting the Control ..............................................18
Product Information .................................................. 3 Grounding the Control ............................................19
Introduction ............................................................ 3 Customer Connections for DC Power
ANSI Standards ..................................................... 3 and AC Voltage Sensing ........................................20
Quality Standards ................................................... 3 Before Placing Control and Recloser into Service .25
Form 6-TS Recloser Control Description ............... 4 Incoming Power Receptacles ................................32
Initial Programming Prior to Installation .................16 Return the Control to Service ................................37
!
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
2
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S280-70-15
PRODUCT INFORMATION
Introduction Handling and Storage
Service Information S280-70-15 provides installation and Be careful during handling and storage of the control to
operation instructions for the Kyle® Form 6 Triple-Single minimize the possibility of damage. If the control is to be
yard mount recloser control. stored for any length of time prior to installation, provide
a clean, dry storage area. If storage is in a humid atmos-
Refer to Service Information S280-70-9 Form 6-TS
phere, make provisions to keep the control circuitry
Control Programming Guide for additional information.
energized.
The Form 6 Triple-Single (TS) control is designed for use
with three Kyle® NOVA-TS Triple-Single reclosers. Refer Control Power
to Service Information S280-42-2 NOVA-TS Recloser
Installation and Operation Instructions. All operating power is obtained from the substation bat-
tery bank. There are two power supply options available
Read This Manual First for the Form 6-TS yard mount recloser control. Examine
the voltage decal on the back of the recloser control to
Read and understand the contents of this manual and fol- verify the correct voltage rating.
low all locally approved procedures and safety practices
before installing or operating this equipment. The following power supply option is available and con-
figured at the factory:
Additional Information • 40 VDC –140 VDC
These instructions cannot cover all details or variations in Burden 14 Watts
the equipment, procedures, or process described, nor Note: The 40 VDC – 140 VDC power supply is a universal
provide directions for meeting every possible contingency power supply adaptable for either 48 VDC or 125 VDC
during installation, operation, or maintenance. When addi- substation batteries.
tional information is desired to satisfy a problem not cov-
ered sufficiently for the user's purpose, contact your A 120/240 VAC thermostatically controlled heater for
Cooper Power Systems sales representative. humidity control is included as standard.
Refer to the Customer Connections for DC Power and
ANSI Standards AC Voltage Sensing section of this manual for incoming
power wiring illustrations for the Form 6-TS yard mount
Kyle reclosers are designed and tested in accordance
recloser control.
with the following ANSI standards: C37.60 and C37.85
and ANSI Guide C37.61.
Quality Standards
ISO 9001:2000-Certified Quality Management System
3
Form 6 Triple-Single Yard Mount Recloser Control Installation and Operation Instructions
CT
MATCHING I/O 8 inputs
TRANSFORMERS USER
CONNECTIONS
CØ AND SIGNAL
8 outputs
CONDITIONING
ACTUATOR TB8
FRONT TERMINAL
SWITCHES ANALOG INPUT PANEL BLOCK
CT RS-232 SENSING
(PROVIEW VOLTAGE
POWER INPUTS
PROTOCOL CONNECTIONS
ONLY) 120/240 VAC
Figure 2.
Form 6-TS yard mount recloser control operational flow diagram.
4
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SAFETY
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S280-70-15
5
Form 6 Triple-Single Yard Mount Recloser Control Installation and Operation Instructions
RESET OPER
TARGETS COUNTER
One-Touch F1 F2 F3 F4 One-Touch
Analysis Keys EVENTS ALARMS Analysis Keys
LAMP TEST
MENU + CHANGE
Figure 3.
Form 6-TS yard mount recloser control front panel.
6
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SAFETY
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S280-70-15
Programming Panel CHANGE: Allows the user to change the state of the con-
trol functions on the operator panel function keys.
The Programming panel has the following sections:
Note: The CHANGE mode is a ten second period in which one
One-Touch Analysis Keys function setting can be changed. If no change is made
There are eight analysis keys (Figure 4) that allow one- in that time, the control returns to the current setting.
button access to a variety of control and monitoring func- LCD Display
tions that appear in the LCD display.
The LCD Display is a backlit 4-line, 20-character display
Note: The label inserts can be customized, but the analysis that provides extensive distribution system, recloser, and
key functions remain the same. control status information via the navigation keypads
Pressing these buttons causes the following information (Figure 4).
to display or function to occur: Note: The LCD display panel contrast is field-adjustable to allow
METERING: Displays the systems instantaneous meter- for various mounting heights and applications. Press the
ing values for current and voltage on the LCD display. MENU key and then press the (+) or (–) key to increase
or decrease the contrast.
RESET TARGETS: Resets the fault target indicators on
The four LCD navigation buttons are as follows:
the operator panel.
MENU: Identifies the LCD Display menu options.
EVENTS: Displays the last 25 events from the Sequence
of Events log. ENTER: Selects a menu option.
LAMP TEST: This button functions two ways: +: Increases value selection.
• Press and immediately release this button to display –: Decreases value selection.
the front panel LED status. The four LCD menu function keys activate specific menu
• Press and hold the LAMP TEST button for two sec- commands. When a command appears in the LCD dis-
onds to enable the actual LAMP TEST feature. All play directly above one of the four LCD menu function
operator panel LEDs are illuminated for verification of keys, the user can press the key to accept/select the
proper connection and operating status of all indica- command.
tor lights. All status indicators will then return to their The four LCD menu function keys are as follows:
previous state. While in the LAMP TEST mode, the
control response to operator panel keys is disabled, F1 F2 F3 F4
except for the TRIP (LOCKOUT), CLOSE, and HOT The four cursor movement arrows allow movement in the
LINE TAG switches. following directions:
SETTINGS: Displays recloser settings on the LCD display. Moves the cursor left.
OPER COUNTER: Displays the total number of trip oper- Moves the cursor right.
ations and target counters for each A, B, and C Phase;
Ground, and Sensitive Ground on the LCD display. Moves the cursor up one line.
ALARMS: Provides status information on the LCD dis- Moves the cursor down one line.
play for all recloser alarms.
METERING SETTINGS
RESET OPER
TARGETS COUNTER
F1 F2 F3 F4
EVENTS ALARMS
LAMP TEST
MENU + CHANGE
ENTER —
Figure 4.
Analysis keys, LCD display, LCD menu function keys, and cursor movement arrows.
7
Form 6 Triple-Single Yard Mount Recloser Control Installation and Operation Instructions
Status Indicator LEDs RECLOSER CLOSED: The steady red LED indicates all
The status indicator LEDs (Figure 5) in the Programming three reclosers are in the closed position. The blinking
section of the Operator Panel give instant information on red LED indicates one or two reclosers are in the closed
the control and recloser status: position.
Note: There are several conditions that will cause the alter-
All of the default status indicators LEDs (except for CON- nate blinking of the CONTROL LOCKOUT, RECLOSER
TROL OK, CONTROL POWER, and ALARM) can be OPEN, and RECLOSER CLOSED LEDs: Failure to
reconfigured via the Idea Workbench. Refer to Service Trip, Failure to Close, Interrupter Malfunction, and
Information S280-70-9 Form 6 -TS Control Programming 52a/b Disagreement.
Guide for additional information.
The LED blinking pattern for these conditions is the
The label inserts can be user-customized. Refer to Using CONTROL LOCKOUT green LED and RECLOSER
Removable Inserts section of this manual for additional CLOSED red LED alternating with the RECLOSER
information. OPEN green LED. The red ALARM LED will also be
illuminated.
CONTROL OK: The green LED indicates the control is
This LED blinking pattern is different than the continu-
operating normally and not in an alarm state.
ous blinking of all three LEDs that occurs when all three
The CONTROL OK LED will not be illuminated during reclosers do not have the same status, i.e. OPEN or
these alarms (indicated by the red ALARM LED and dis- CLOSED. To determine the actual status of each
played in the alarm status log): recloser (phase), refer to the Form 6-TS control front
panel MMI RECLOSER STATUS menu display.
• Memory Test: This alarm indicates a failed ROM or
RAM memory test. A PHASE FAULT, B PHASE FAULT, C PHASE FAULT:
The red LEDs indicate A, B, and/or C phase current was
• No AC Power: This alarm indicates AC power was either the maximum phase current or within 80% of the
unavailable for 10 continuous seconds. This alarm maximum when a trip signal was issued.
resets when AC power is restored.
GROUND FAULT, SENSITIVE GROUND FAULT: The red
• Internal Power Failure: This alarm indicates internal LEDs indicate that a Ground and/or Sensitive Earth Fault
control operation power was outside of its operating tripping function was asserted at the time the trip signal
tolerance for more than 20 seconds. This alarm was asserted.
resets when the internal control operation power
returns to operation within its normal tolerances. ALARM: The red LED indicates an alarm has been
issued. Review the alarm status and log on the LCD dis-
CONTROL POWER: The green LED indicates there is play for the specific alarm.
adequate charge (voltage) on the trip circuit capacitor to
Note: If a Battery Alarm occurs, de-select the Pole Mounted
trip or close the recloser. This LED does not indicate the
Control checkbox in the ProView application software
presence of AC power. Configure>System Configuration dialog box. Refer to
CONTROL LOCKOUT: The steady green LED indicates S280-70-9 Form 6-TS Control Programming Guide for
the control for all three reclosers is in a locked out state, additional information.
i.e. a reclosing sequence is not in progress on any reclos- ABOVE MINIMUM TRIP: The red LED indicates the cur-
er. The blinking green LED may indicate that the control rent exceeds the level set for minimum trip.
for one or two reclosers is in a locked-out state, i.e. a
reclosing sequence is not in progress on those one or A PHASE VOLTAGE, B PHASE VOLTAGE, C PHASE
two reclosers. This LED (blinking or steady) does not VOLTAGE: Indicates a presence of voltage on the
indicate that any recloser is open. respective phases. The Single-Phase Undervoltage
Pickup setting controls the voltage indication for the front
RECLOSER OPEN: The steady green LED indicates all panel LEDs as defined in the Voltage setting dialog box
three reclosers are in the open position. The blinking for the active setting profile. Refer to Settings - Voltage
green LED indicates one or two reclosers are in the open in Schemes section of S280-70-9 Form 6-TS Control
position. Programming Guide.
FREQUENCY TRIP: Indicates the recloser tripped due to
a frequency trip.
VOLTAGE TRIP: Indicates the recloser tripped due to a
voltage trip.
Figure 5.
Status indicator LEDs.
8
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S280-70-15
INDICATOR 1, INDICATOR 2, INDICATOR 3, INDICA- To activate the function from the operator panel, flip tog-
TOR 4, INDICATOR 5, INDICATOR 6, INDICATOR 7, gle switch up to the ON position. See Figure 6. The LED
INDICATOR 8: Customizable LEDs that are used with indicator illuminates when the function is active.
functions programmed through the Idea WorkbenchTM.
The Hot Line Tag function may only be reset by the source
The LED indicators do not have active default values.
which initiates it. For example, if Hot Line Tag is activated
The LEDs are illuminated when the status configured via
at the operator panel, the reset function is only possible at
the Idea WorkbenchTM is present.
the operator panel, and not via SCADA command.
Operating Panel
IMPORTANT: If the power save feature is enabled
The Operating section includes the following sections: (default), and more than ten minutes elapses since the
RS-232 Configuration Data Port last panel operation, all the LEDs, except HOT LINE
TAG (if active), will turn off.
The RS-232 connector (shown in Figure 3) on the front
operating panel allows direct connection to a personal
computer without any special cables or connectors. This TRIP (Lockout) Pushbutton
port is used only for configuring the control with ProView The TRIP pushbutton (Figure 6) provides front-panel
application software. All settings, metering, events, and access to trip (lockout) the recloser. When pressed, the
oscillography data are available from this port. The port is TRIP pushbutton opens the recloser and locks out the
Data Communication Equipment (DCE) wired for direct control. The TRIP pushbutton operates independent of
connection to a personal computer. the microprocessor.
A 9-pin RS-232 cable (Catalog Number KME5-66) to Note: In the event of main microprocessor failure, the
connect from the PC to the RS-232 data port is available trip circuit can operate independent of the main
as an accessory. microprocessor.
HOT LINE TAG ON/OFF Toggle Switch and LED CLOSE Pushbutton
Indicator When pressed, the CLOSE pushbutton (Figure 6) returns
the control to the initial or home sequence position, clos-
WARNING: Hazardous voltage. Do not use Hot ing the recloser. The control is ready for the start of a new
! Line Tag as a substitute for a visible disconnect. trip/close sequence.
Always establish a visible disconnect prior to perform- Note: Pressing the CLOSE pushbutton from the Lockout posi-
ing any work requiring a de-energized line. Failure to tion initiates Cold Load Pickup (CLPU) protection, if the
comply may cause death, severe personal injury, or feature is enabled.
equipment damage. T276.0
The user does have the ability to block COLD LOAD
PICKUP through the LCD menu or by configuring one
Hot Line Tag is provided for live-line work applications. All of the Option one-touch function keys via the Idea
closing operations are disabled when the Hot Line Tag Workbench feature in ProView.
feature is activated. While active, the control may also If the recloser is closed, pushing and holding the
utilize an independent, user-selectable time-current CLOSE pushbutton does not activate the Cold Load
curve for trip operations. Pickup feature. See Cold Load Pickup in the Control
Features section of this manual.
IMPORTANT: Hot Line Tag activation does not
cause the recloser to trip open. It only prevents the
recloser from closing.
KYLE F6 Recloser Control ON
IMPORTANT: Hot Line Tag is intended solely for live-
line work applications, such as maintenance, repairs or TRIP CLOSE
improvements to the distribution system, that occur OFF
while the line remains energized. HOT LINE TAG
Hot Line Tag prevents all closing attempts from the con- (LOCKOUT)
trol and shifts protection to one trip-to-lockout on the
composite curve of the Hot Line Tag definite time and the
TCC1 curve (whichever is faster). Hot Line Tag takes Figure 6.
precedence over Cold Load Pickup, Non-Reclosing, and TRIP (Lockout) pushbutton; CLOSE pushbutton; Hot
Fast Trips Disabled. Line Tag switch and Hot Line Tag red indicator LEDs.
Hot Line Tag is activated from either the operator panel
toggle switch, serial communications, or a discrete
SCADA function. All sources must be off to de-activate
Hot Line Tag.
9
Form 6 Triple-Single Yard Mount Recloser Control Installation and Operation Instructions
10
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SAFETY
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S280-70-15
Three-Phase Trip – Three-Phase Lockout (ganged) OPTION #1, OPTION #2, AND OPTION #3
or The OPTION #1, OPTION #2, and OPTION #3 function
Single-Phase Trip – Three-Phase Lockout keys must be programmed via the ProViewTM Idea
WorkbenchTM software.
If the control is in Three-Phase Trip – Three-Phase
The OPTION LEDs are illuminated when the options con-
Lockout (ganged) mode or Single-Phase Trip – Three-
figured via the Idea Workbench are selected. Refer to
Phase Lockout mode, all three phases are permanently
Service Information S280-70-9 Form 6-TS Control
selected and the A PHASE SELECT, B PHASE SELECT,
Programming Guide for additional information.
and C PHASE SELECT LEDs are illuminated.
These OPTION keys provide a momentary signal. For
When one phase is opened with the yellow operating
instance, these keys can be programmed to toggle con-
handle, all three phases open and lockout. The
trol status, protective functions, or a momentary input
RECLOSER OPEN and CONTROL LOCKOUT indicator
pulse.
LEDs illuminate on the control panel.
The OPTION #1, OPTION #2, and OPTION #3 function
With the yellow operating handle of the appropriate
keys are intentionally not defaulted to any function. The
phase in the CLOSE position, press the CLOSE push-
functions are assigned to each OPTION key via the Idea
button on the control operator panel. All three phases
WorkbenchTM application.
close and the RECLOSER CLOSED LED illuminates.
Single-Phase Trip – Single-Phase Lockout
When in Single-Phase Trip – Single-Phase Lockout
mode any combination of phases can be selected and
the respective PHASE SELECT LED illuminates. Each
selected phase must be closed individually.
When the selected phase is opened with the yellow oper-
ating handle, only that phase opens and locks out. The
RECLOSER OPEN, RECLOSER CLOSED, and CON-
TROL LOCKOUT indicator LEDs blink on the control
panel.
The default text message on the LCD displays the mode
of the triple-single configuration and the status of each
phase.
With the yellow operating handle of the selected phase in
the CLOSE position, press the CLOSE pushbutton on the
control panel. The phase closes and the RECLOSER
CLOSED LED illuminates.
11
Form 6 Triple-Single Yard Mount Recloser Control Installation and Operation Instructions
12
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S280-70-15
13
Form 6 Triple-Single Yard Mount Recloser Control Installation and Operation Instructions
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. close signal to the mechanism when enabled via the sync
An electronic label template is included on the ProViewTM check settings. Sync check allows for closing for any
application software CD and can be accessed through combination of dead/live bus/line, and to perform antici-
the following default address: C: \ Program Files \ patory closing for a live bus/live line condition by calcu-
Cooper \ Proview40 \ Form 6 \ Form 6 Inserts.doc lating slip and anticipating the mechanism closing delay.
In addition to the anticipatory close calculation, the sync
Refer to Using Removable Inserts for more information. check system performs verification of line and bus volt-
age magnitudes and frequencies to determine that they
Idea WorkbenchTM 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. Idea WorkbenchTM also gives the user the ability to in frequency and voltage limits, and the angular differ-
perform logical functions with these variables by using a ence between the systems has been within the allowable
simple graphical user interface. Use of Idea WorkbenchTM limits for a pre-determined time.
is not a requirement for operation. Sync Check functionality includes the following applica-
Refer to Service Information S280-70-9 Form 6-TS tions: Hot Line/Hot Bus Closing; Dead Line/Hot Bus
Control Programming Guide for additional Idea Closing; Hot Line/Dead Bus Closing; and Dead
WorkbenchTM information. Line/Dead Bus Closing.
Sync Check Parameters include the following config-
Over/Underfrequency Protection 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 A fully-configurable data profiler is available which allows
settings for a user-settable time. Over/Underfrequency the user to collect information by sampling data at selec-
protection is included as part of each protection profile. table intervals. These time-stamped values can then be
viewed to determine weekly load profiles, daily harmonic
Over/Undervoltage Protection disturbances or hourly voltage fluctuations. The number
The control includes single-phase and three-phase of days of information the data profiler can provide
undervoltage tripping. The control also includes three- depends upon configuration parameters.
phase overvoltage tripping. Both over and undervoltage
Refer to Service Information S280-70-9 Form 6-TS
functions include a single-phase and three-phase pick-up
Control Programming Guide for additional information.
setting; a single-phase and three-phase time delay set-
ting ranging from 0 to 100 seconds. Manual Close Delay
Directional Manual Close Delay provides a delay from the time that
the manual CLOSE button is pushed to the time the man-
Directional functionality is included to maintain system
ual close operation is performed.
coordination from multiple sources, as well as circuit
reconfiguration for each profile. Directional applies to The delay is programmable from 0 to 60 seconds in 1
phase, ground, and negative sequence protection, second increments. A programmed delay value can be
selected independently. A maximum torque angle has a overridden for immediate closing by pressing the CLOSE
range of 0 – 90 degrees. button a second time.
Eight Control Inputs CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4
C + – RS-485 Serial Communication Port (optional)
J1-RS-232
Outputs (Accessory)
CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4
TB3
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6
1 3 5 7 9 11 13 15 17 19 21
CO7 CO8 CO9 CO10 CO11 CO12
1 3 5 7 9 11 13
TB4 Ethernet Port, "MT-RJ" Fiber
2 4 6 8 10 12 14 16 18 20
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6
– +
Customer Connection 1 2 3 4 5 6 7 8 9 10 11 12
TB7
1 2 3 4 5 6 7 8 9 10 11 12
LOW VOLTAGE 120 120/240 NEU (+) (-)
OUTPUTS L2 L1/VAC VDC
Figure 8.
Form 6-TS yard mount recloser control back panel.
15
Form 6 Triple-Single Yard Mount Recloser Control Installation and Operation Instructions
Control Information
Control information includes firmware identification by
catalog number and name, date code, and ProView
release number. Control information is available through
the Settings menu on the front panel (Figure 3).
INSTALLATION PROCEDURE
16
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SAFETY
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S280-70-15
17
Form 6 Triple-Single Yard Mount Recloser Control Installation and Operation Instructions
Mounting the Control Mount the Form 6-TS yard mount recloser control in a
convenient, accessible location in a substation yard.
Mounting dimensions are provided in Figure 11.
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 can 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
The weight of one Form 6-TS yard mount control is
approximately 34 kg (75 lbs).
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
665
BLOCKED RECLOSING
TRIP CLOSE
A PHASE B PHASE C PHASE
710
OFF SELECT SELECT SELECT
HOT LINE TAG
(LOCKOUT)
(28.0) (26.25)
Control Cable
38 Receptacle 1.81 Dia.
(1.5) (26-pin)
67 67 79
(2.75) (2.75) (3.25)
Bottom View
Figure 11.
Form 6-TS yard mount recloser control dimensions.
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S280-70-15
Recloser
Recloser Recloser Head
Head Head Ground
Ground Ground
CLOSED
CLOSED
CLOSED
Form 6-TS
Junction Yard
Box Mount
Control
Control
Cable Control
Ground Grounding
Wire Lug
Figure 12.
Grounding connections for a Form 6-TS yard mount control installed in a substation.
19
Form 6 Triple-Single Yard Mount Recloser Control Installation and Operation Instructions
AC Power Requirements
6 7 8 9 10 11 12 The transformer required for power is a minimum of 1 kVA.
5-6) V1 V2 V3
LOAD
2 Note: AC voltage is required for the internal cabinet heater
SENSING CONNECTIONS and the 120 VAC GFI Duplex Outlet accessory.
TB7 The following are not functional for single phase AC
1 2 3 4 5 6 7 8 9 10 11 12 voltage input:
LOW VOLTAGE 120 120/240 NEU (+) (-)
OUTPUTS L2 L1/VAC VDC
• Directional Protection
• Single-Phase Voltage Protection
Figure 13. • True Three-Phase Metering
Note: Phantom Phase can generate missing phases for
Power connections Terminal Block TB7. three-phase metering estimates.
20
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SAFETY
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S280-70-15
Load
120 Vac XØ
TB8
120 Vac ZØ
1 2 3 4 5 6 7 8 9 10 11 12
Factory
Wiring
NEU
ZØ
YØ
XØ
User-Supplied
Disconnect Switches
Source
120 Vac AØ
120 Vac BØ
120 Vac CØ
NEU
CØ
BØ
AØ
User-Supplied
Disconnect Switches DC Voltage
Factory Required
Wiring to Power Control
User-Supplied
Disconnect Switches
TB7
Figure 14.
Three-Phase Transformer Connection for Voltage Sensing and Heater, Wye configuration only (TB8 Terminal
Block Connection).
21
Form 6 Triple-Single Yard Mount Recloser Control Installation and Operation Instructions
TB7
DC Voltage Required
1 2 3 4 5 6 7 8 9 10 11 12
to Power Control
LOW VOLTAGE 120 120/240 NEU (+) (-)
OUTPUTS L2 L1/VAC VDC
BØ
User-Supplied
Disconnect
Switches
NEU
1 2 3 4 5 6 7 8 9 10 11 12 Factory
Wiring
NEU
YØ
DC Voltage Required
to Power Control
TB7
1 2 3 4 5 6 7 8 9 10 11 12
LOW VOLTAGE 120 120/240 NEU (+) (-)
Note: Terminal Block positions OUTPUTS L2 L1/VAC VDC BØ
Source Side
TB7-5 and TB7-6 are fac- 120
Figure 16.
240 Volt, 3-wire transformer connection for voltage and sensing on B-phase. YØ for Sync Check Voltage.
22
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S280-70-15
1 2 3 4 5 6 7 8 9 10 11 12 DC Voltage Required
Factory Wiring to Power Control
for Wye Connection
Figure 17.
Default factory wiring connected to B-Phase voltage metering with B-Phase incoming supply.
DC Voltage Required
1 2 3 4 5 6 7 8 9 10 11 12 to Power Control
Factory
Wiring
Figure 18.
Modified wiring connected to A-Phase voltage metering with A-Phase incoming supply. Also, supplies heater
and convenience outlet accessory power.
23
Form 6 Triple-Single Yard Mount Recloser Control Installation and Operation Instructions
BØ
1 2 3 4 5 6 7 8 9 10 11 12
AØ
User-Supplied
Disconnect
Switches
Figure 19.
Customer connections to TB8, 120 VAC Delta Connection.
24
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SAFETY
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S280-70-15
IMPORTANT
Shielding and Surge Protection of
Supervisory Cables
All supervisory operation and control monitor leads must
be protected within shielded cables. Refer to Figure 22 or
23 as appropriate.
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-
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 unintentional
operation. G117.3
Remote/Supervisory Common
TB1
2 4 6 8 10 12 14 16 18
Customer Wiring A B
AØ Control Control Hotline Ground Trip
Lockout AØ Recloser OK Tag Blocked
Status Status Status Status Status
(Not (Recloser (Control (Hotline (GRD TRIP
Lockout)* Open)* Not OK)* Tag Off)* Normal)*
Figure 20.
Form 6-TS yard mount recloser control Standard discrete interface board and default configurations. These
default contact input/outputs are completely configurable via the Idea WorkbenchTM.
26
SAFETY
!
FOR LIFE
IMPORTANT
Figure 21.
Shielding and Surge Protection of
Supervisory Cables
All supervisory operation and control monitor leads must
be protected within shielded cables. Refer to Figure 22 or
23 as appropriate.
Unassigned
Remote Normal Profile
Supervisory Non-Reclose
Remote Alternate Profile 2
Remote Alternate Profile 3
default contact input/outputs are completely configurable via the Idea WorkbenchTM.
2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11 CO12
Form 6-TS yard mount recloser control discrete interface board accessory and default configurations. These
27
S280-70-15
Form 6 Triple-Single Yard Mount Recloser Control Installation and Operation Instructions
REMOTE
TB9 BOX
Three-Phase
Supervisory 8 CI3
Trip and
Lockout
CI3 7
Three-Phase
Supervisory 6 CI2
Close CI2 5
Three-Phase
Remote 4 CI1
CI1 3
Trip and
Lockout
13
A Phase B*
Recloser
Status 12 CO1
A*
*Contacts shown
with recloser in 11
OPEN position. CO1
Not All Remote
Connections
TB1 Shown
Figure 22.
Shielding and Surge Protection for Supervisory and Remote Cables (factory-supplied whetting voltage).
28
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SAFETY
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S280-70-15
Three-Phase
Supervisory
Trip and 8 CI3
Lockout CI3 7
Three-Phase
Supervisory
Close 6 CI2
CI2 5
Three-Phase
Remote
Trip and 4 CI1
CI1 3
Lockout
13
A Phase
Recloser B*
Status
12 CO1
A*
*Contacts shown 11
with recloser in CO1
Not All Remote
OPEN position. TB1 Connections
Shown
Figure 23.
Shielding and Surge Protection for Supervisory and Remote Cables (customer-supplied whetting voltage).
29
Form 6 Triple-Single Yard Mount Recloser Control Installation and Operation Instructions
information. TB3
1 3
CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6
5 7 9 11 13 15 17 19 21
CO7 CO8 CO9 CO10 CO11 CO12
1 3 5 7 9 11 13
TB4
2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12
Refer to the Accessories section of this manual for addi- CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6
FUSE
INPUT POWER AUXILIARY POWER TB9
FUSE TB5 +
1
-
5
CO7 CO8 CO9 CO10 CO11 CO12
P1 P4
P2 P3
TABLE 5
Rear Panel RS-232 Communication Port Pin
Assignments
Pin Number Signal Name
1
1 2 3 4 5 6 7 8 9 10 11 12
TB7
RS-232 DTE
Figure 25.
Rear panel RS-232 communication port pin
identification.
30
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SAFETY
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S280-70-15
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
operating panel (Figure 27).
CAUTION: Control damage. De-energize both ac
and dc power prior to removing or installing any inter- Note: The insert will slide out of the top of the pro-
nal connections or circuit boards in the control. Failure gramming panel indicator section (Figure 26).
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 configured option.
An electronic label template is included on the
CAUTION: Equipment damage. Always wear a ProViewTM application software CD and can be
grounding wrist strap to control static electricity before accessed through the following default address:
handling circuit boards. Failure to use this strap may
result in circuit board damage. T253.1
C: \ Program Files \ Cooper \ Proview40 \ 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
2. Use a flathead screwdriver to unscrew the six front damage to the front panel.
panel screws.
Note: Set the screws aside for later use. 6. Gently push the removable insert from right to left into
3. Pull the right side of the front panel out towards the the right side of the operating panel (Figure 26) or
left (Figure 26). down into the programming panel LED indicator sec-
Note: Various connecting wires will keep the panel
tion (Figure 26).
attached to the control.
Note: It is not necessary to disconnect any wires.
Removable LED
Status Indicator Panel
000008KM
Figure 27.
Labels are easily removed from and inserted into
the operating panel.
Figure 26.
Open front panel. Labels are easily removed from
and inserted into the top of the programming panel
LED status indicator section.
31
Form 6 Triple-Single Yard Mount Recloser Control Installation and Operation Instructions
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, cable-locking
120 VAC GFI Duplex Outlet sleeves (Catalog Number KME6-1772-X) are available to
The GFI Duplex Outlet (Catalog Number KME6-1820) is enclose the cable plug.
available for controls powered by 120 VAC VAC three- Note: Replace X with the desired number of cable sleeves (1,
wire supply power. This convenience outlet is rated for 15 2, 3, 4, or 5).
Amperes and is accessible through the front door in the
control cabinet. The 120 VAC GFI Duplex Outlet is used The plug is passed through the sleeve and the sleeve is
for many applications such as power for the MET Tester, then fastened from inside the control cabinet. There is no
auxiliary measurement equipment, and supplemental access to the cable receptacle without opening the
lighting. locked cabinet door and detaching the sleeve.
TABLE 6
Input Receptacles and Cables
Description Catalog Number
120 VAC or 240 VAC input receptacle, 2-pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KME6-1838-H
120 VAC input receptacle, 3-pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KME6-1838-J
240 VAC input receptacle, 3-pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KME6-1838-K
AC Input Cable, 120 or 240 VAC, 2-wire for 2-pin input for use with KME6-1838-H receptacle.
Replace X with desired length. Select from 10 to 80 feet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KMA11ME1-X
AC Input Cable, 240 VAC, 3-wire for 3-pin input for use with KME6-1838-K receptacle.
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 KME6-1838-J receptacle.
Replace X with desired length. Select from 10 to 80 feet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KME4-67-3-X
Option Accessory
RS-232 DTE
2 4 6 8 10 12 14 16 18
Outputs (Accessory)
CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11 CO12
1 3 5 7 9 11 13 15 17 19 21 1 3 5 7 9 11 13
TB3 TB4
2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12
A Discrete Interface Board Option accessory provides CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6
FUSE
INPUT POWER AUXILIARY POWER TB9
FUSE TB5 +
1
-
5
CO7 CO8 CO9 CO10 CO11 CO12
eight configurable input control contacts and eight con- (10 AMP) (10 AMP) 2 4 28 VDC
– +
28 VDC
WHETTING VOLTAGE
- +
options include: Standard (3 inputs / 5 outputs) or VOLTAGE SENSING 53VDC CONTROL CABLE 28 VAC
TB8
1 2 3 4 5 6 7 8 9 10 11 12
V(1-2) V(3-4) V(5-6) V1 V2 V3
2
SOURCE LOAD
VOLTAGE SENSING CONNECTIONS
TB7
1 2 3 4 5 6 7 8 9 10 11 12
LOW VOLTAGE 120 120/240 NEU (+) (-)
OUTPUTS L2 L1/VAC VDC
Figure 28.
Form 6-TS yard mount recloser control discrete
interface board accessory.
32
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SAFETY
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S280-70-15
33
Form 6 Triple-Single Yard Mount Recloser Control Installation and Operation Instructions
Standard
(No Communication Option) RS-485 Communication Serial Fiber
RS-485 C + -
TX NON-ECHO RX
TX RX
#2 #1 #2 #1 #2 #1 Default Primary
ETHERNET ETHERNET ETHERNET Ethernet Interface
The Ethernet communication card accessory is offered in The Ethernet communication accessory card (Figure 29)
3 physical layer configurations (twisted pair and optical- is equipped with two physical ports configured to act as
fiber options) as shown in Table 7. primary and standby LAN connections. Availability of the
backup communication port enables creation of highly
TABLE 7 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
29), with the standby port either logically disabled, or
1 10/100 Base-T 2 * RJ-45 10 / 100MBps configured for fast automatic throw-over in case of the
(auto switching) primary Ethernet link failure. Refer to Service
Information S280-70-9 Form 6-TS Control
2 100 Base-FX 2 * MT-RJ 100MBps
(fiber) (full duplex) Programming Guide for additional Ethernet accessory
configuration information.
3 10/100 Base-T, RJ-45 + MT-RJ 10/100MBps
100 Base-FX and 100MBps
34
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S280-70-15
TESTING
and verified. Refer to the programming information for RECLOSER CLOSED SENSITIVE GND
this control. Failure to comply can result in control and Control OK LED
recloser misoperation, equipment damage, and per- Figure 31.
sonal injury. G110.3
Control OK LED.
LCD Display
2. Remove DC power from the control using a separate
disconnect switch.
METERING SETTINGS
RESET
TARGETS
OPER
COUNTER
3. Remove control AC sensing voltage from the control
LAMP TEST Key using a separate disconnect switch.
F1 F2 F3 F4
EVENTS ALARMS
LAMP TEST
MENU + CHANGE
! WARNING: Hazardous voltage. If the recloser
is energized while the control cable is discon-
Cursor Movement
nected, the CT secondaries can generate high volt-
Arrows ENTER — ages. Contact with high voltage can cause severe per-
RS-232 DATA PORT
Figure 30.
Lamp Test button, LCD display, and cursor move-
4. Disconnect control cable from the control.
ment arrows.
Note: Do not disconnect any of the three recloser cables
from the reclosers or junction box unless all of the
3. Check that the LED for Control OK is illuminated on above steps have been completed. Refer to
the control operator panel (Figure 31). This indicates Service Information S280-42-2 NOVA-TS Recloser
the presence of DC power. Installation and Operation Instructions.
Note: The control includes a Power Save feature that will 5. Remove any control input and status output wiring
turn off the backlit LCD display and all LEDs if no from TB1, TB3, and TB4 (Figure 8).
front panel keypad is pressed within ten minutes.
Pressing the LAMP TEST key will reactivate the 6. Disconnect any serial communications ports and IRIG-
display and active LEDs. B timing connections (Figure 8).
7. Disconnect the ground from the control.
8. Carefully transport the control to a suitable service
facility.
35
Form 6 Triple-Single Yard Mount Recloser Control Installation and Operation Instructions
T223.2 Source
5 3 1
36
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S280-70-15
37
Form 6 Triple-Single Yard Mount Recloser Control Installation and Operation Instructions
ADDITIONAL INFORMATION
Factory-Authorized Service
CAUTION: This equipment requires routine Centers
!inspection and maintenance to ensure proper
operation. If it is not maintained, it can fail to operate Factory-authorized service centers are located through-
properly. Improper operation can cause equipment out the continental United States to provide mainte-
damage and possible personal injury. G105.1 nance, repair and testing services for Kyle controls and
reclosers. For further information, contact your Cooper
Power Systems representative.
Replacement Kits
Replacement kits for the Kyle Form 6-TS yard mount Factory Testing and
recloser control are available through the factory Service Troubleshooting Classes
Department. To order these kits, refer to the
Replacement Parts price list for catalog numbers and The factory service department offers a basic testing and
pricing. Contact your Cooper Power Systems represen- troubleshooting course for the Form 6 microprocessor-
tative for additional information and order procedures. based recloser control. This course, taught by experi-
enced service technicians, is held at the factory’s in-
house training facility. For additional information, contact
your Cooper Power Systems representative.
38
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SAFETY
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S280-70-15
39
Form 6 Triple-Single Yard Mount Recloser Control Installation and Operation Instructions
!
SAFETY
FOR LIFE