Cooper Lighting Power Supply S280 79 10 User Manual

Reclosers

Service Information

Kyle Form 5, Form 5 UDP, Form 5 DC NOVA

Microprocessor-Based Recloser Controls

Installation and Operation Instructions

S280-79-10

Applicable to serial numbers above 3000 or beginning with CP57.

99001KM

Figure 1.

Kyle Form 5/UDP microprocessor-based recloser control.

Contents

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 2

Product Information . . . . . . . . . . . . . . . . . . . . . . . . 3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

ANSI Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Quality Standards . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Acceptance and Initial Inspection . . . . . . . . . . . . . . 3

Handling and Storage . . . . . . . . . . . . . . . . . . . . . . . 3

Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . 3

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

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

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

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

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

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

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

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

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

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

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

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

Recloser Interface (RIF) Module Configuration . . 20

Discrete Interface (DIF) Accessory . . . . . . . . . . . . 23

Customer Connection Information . . . . . . . . . . . . . 23

Standard and UDP DIF Module 1 Inputs . . . . . . . . 26

Standard and UDP DIF Module 1 Outputs . . . . . . . 28

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

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

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

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

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

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

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

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

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

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

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

Before Placing Control and Recloser into Service . 42

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

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

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

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

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

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

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

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

Form 5 Universal Device Protection (UDP)

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

Form 5 DC NOVA Control . . . . . . . . . . . . . . . . . . . 22

November 2001 • Supersedes 1/01

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Printed in USA

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S280-79-10

PRODUCT INFORMATION

Control Battery Storage and Charging

Introduction

Service Information S280-79-10 provides installation and

operation instructions for the Kyle Form 5 and Form 5

UDP microprocessor-based electronic recloser controls.

The 24 Vdc control battery in the Form 5 control is fully

charged prior to shipment and is ready for use. In order to

maintain sufficient charge to operate the control, the

sealed lead acid battery should be charged after no more

than three months of storage.

Read This Manual First

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

use with the Form 5 Distribution Automation upgrade

accessory.

Read and understand the contents of this manual and fol-

low all locally approved procedures and safety practices

before installing or operating this equipment.

Temperature has an effect on battery life. Sealed lead

acid batteries should be stored, fully charged, at room

temperature. Never store lead acid batteries at tempera-

ture exceeding 47°C (117°F), as damage can result in

approximately one month.

Additional Information

These instructions cannot cover all details or variations in

the equipment, procedures, or process described, nor

provide directions for meeting every possible contingency

during installation, operation, or maintenance. When

additional information is desired to satisfy a problem not

covered sufficiently for the user's purpose, please contact

your Cooper Power Systems sales representative.

IMPORTANT: To maintain sufficient charge to oper-

ate the control and prevent battery cell damage, the

sealed lead-acid batteries should be charged after no

more than three months of storage.

ANSI Standards

Kyle reclosers are designed and tested in accordance

with the following ANSI standards: C37.60 and C37.85

and ANSI Guide C37.61.

To keep the battery charged, energize the control’s built-

in charger with AC power applied to the user AC supply

input connector block TB1, located left of the RIF module

within the control cabinet.

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

disconnected and its output plugs are taped to the cab-

inet. Connect the battery plugs into the mating connec-

tors to complete the battery circuit.

Quality Standards

ISO 9001:2000-Certified Quality Management System

Acceptance and

Initial Inspection

Each Form 5 control is completely assembled, tested, and

inspected at the factory. It is carefully calibrated, adjusted

and in good condition when accepted by the carrier for

shipment.

IMPORTANT: Connect the control battery when AC

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

minal Block. The battery must be disconnected prior to

shipping or storing the control.

Upon receipt, inspect the carton for signs of damage.

Unpack the control and inspect it thoroughly for damage

incurred during shipment. If damage is discovered, file a

claim with the carrier immediately.

Battery Replacement

The 24 Vdc control battery has a life expectancy of 4 to 6

years. It is recommended that the battery be replaced

after 4 years.

Handling and Storage

Control Power

Be careful during handling and storage of the control to min-

imize the possibility of damage. If the control is to be stored

for any length of time prior to installation, provide a clean,

dry storage area. If storage is in a humid atmosphere, make

provisions to keep the control circuitry energized.

The primary source of power is factory configured for 120 Vac

or 240 Vac. The 240 Vac version is available as an option

at time of order entry. Primary power is rectified to charge

the power capacitor and to power the dc/dc converter that

provides power to the control. A minimum of 500 mA of ac

current is required for heater operation, battery charging

current, and to keep all modules energized.

Note: To energize the control, apply AC power to the AC sup-

ply input connector block TB1 located left of the

Recloser Interface (RIF) module within the control.

Refer to the Customer Connection for AC power sec-

tion in this manual.

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

The AC power LED indicator on the operator panel of the

AC Reclosers

control will turn off after 15 seconds upon loss of AC

power. The indicator will illuminate immediately upon

return of ac power.

Power to operate the tripping and closing solenoids in the

recloser is provided by the power capacitor located

behind the operator panel of the control. A sealed, 24-volt,

lead acid battery is located in the lower portion of the con-

trol cabinet and is utilized to provide operating and trip-

ping energy when AC power is temporarily lost. The

control is equipped with an ac-powered, temperature-

compensated battery charger.

Initializing the Control

Two methods are available to initialize the Form 5 control.

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

minal TB-1. Refer to the Customer Connec-

tions for AC Power section of this manual.

Operation Upon Loss Of AC Power

Method 2: Connect the battery terminal on the control

and press the MANUAL BATTERY RECON-

NECT button located on the Form 5 power

supply. See Figure 4.

If the control is equipped with the standard 24 Vdc lead-

acid battery, the control maintains full operation from the

battery power supply for a minimum of 32 hours at 20°C

(24 hours at -40°C). To prevent battery damage, the con-

trol shuts down automatically upon detection of low bat-

tery voltage below 22.7 Vdc.

Note: Method 2 powers the control off the battery

and is not intended for long term operation.

In both methods, after initialization, set the control clock

via the interface software.

Control programming settings and parameters—including

event recorder, duty monitor, and data profile metering

parameters—are stored in non-volatile memory and

retained upon loss of control power. The time/date clock

resets to 0:00:00, 1970 upon loss of control power.

LCD Display

CONTROL OK

AC POWER

ABOVE MIN TRIP

CHECK BATTERY

RECLOSER MALFUNCTION

REVERSE POWER FLOW

BACK

BUSHINGS 1-2 FAULT TARGET

LED Indicators

RESET

TARGETS

BUSHINGS 3-4 FAULT TARGET

CHANGE

RESET

MAX CURRENT

LAMP

TEST

BUSHINGS 5-6 FAULT TARGET

GROUND FAULT TARGET

LCD Display Dedicated

Function Keys

NON

RECLOSING

GND TRIP

BLOCKED

SUPERVISORY

BLOCKED

SENSITIVE-GROUND FAULT TARGET

COLD LOAD

PICK UP

FAST

TRIPS

DISABLED

BUSHINGS 1-2 VOLTAGE

BUSHINGS 3-4 VOLTAGE

BUSHINGS 5-6 VOLTAGE

BATTERY

TEST

BLOCKED

ALTERNATE

PROFILE

ALTERNATE

PROFILE

ALTERNATE

PROFILE

NO.

Operation "Hot Keys"

TX 2

TX 3

HOT LINE

TAG

RECLOSER CLOSED

RECLOSER OPEN

OFF RX 3

CLOSE Pushbutton

RS232

RX 2

CONTROL LOCKOUT

RS232 Data Port

Hot Line Tag

TRIP (LOCKOUT)

Pushbutton

TRIP

(LOCKOUT)

KYLE

FORM 5

RECLOSER CONTROL

Figure 2.

Form 5 recloser control operator panel.

99005KM

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FORM 5 CONTROL DESCRIPTION

Current sensing is provided by three current transformers

located in the recloser and interfaced to the Form 5 control

via the control cable. This cable also supplies Trip, Close,

and Recloser status, and connects to the Recloser Inter-

face (RIF) module to provide isolation for reliable opera-

tion. Voltages for metering are also connected to the RIF

module via the connector terminal block, TB-1 (Figure 3).

The following chain of events occurs for an operating

sequence of two trips to lockout:

1. The overcurrent signal is integrated with time on the

selected curve for the first trip operation (TCC1) to

produce the signal which energizes the trip circuit.

2. Energizing the trip circuit connects the battery and

capacitor to the trip solenoid to open the recloser.

A functional block diagram of the Form 5 control is shown

in Figure 3. Line current flowing through the recloser is

converted by the CPU module to a digital signal suitable

for metering and fault current calculations. Data sampling

occurs at a rate 32 times per cycle. The CPU contains a

data acquisition section that uses the acquired samples to

compute the fundamental currents and voltage for use in

overcurrent, under/over voltage and under/over frequency

protection, as well as currents and voltages for metering

functions. The current for overcurrent protection is calcu-

lated on a sub-cycle basis; it includes only the fundamen-

tal and DC component. For metering, the fundamental and

harmonic current and voltages are determined.

3. Upon opening, the control starts timing on the first

reclosing interval-delay time.

4. Upon expiration of this reclosing interval-delay, a clos-

ing signal is issued from the control, closing the

recloser and selecting the time-current characteristics

for the second trip operation (TCC2).

5. If current remains above the minimum-trip level, the

tripping and reclosing sequence is repeated.

6. The control begins the reset-delay timer if the over-

current is cleared before the operating sequence

reaches lockout indicated by a closed recloser and

current below minimum trip.

When the phase or ground current exceeds its pro-

grammed minimum-trip value and associated time-cur-

rent curve (TCC) timing, the control initiates the

programmed sequence of recloser tripping and reclosing

operations via the CPU and RIF modules. If the fault is

temporary, the control ceases to command recloser oper-

ations after a successful reclose, and the control resets to

the start of its operating sequence after a preset time

delay. If the fault is permanent, the control performs its

complete programmed sequence of reclose commands

and locks out with the recloser open. Once locked out, the

control must be closed via the operator panel or SCADA

communications. This resets the control to the start of the

operating sequence.

7. When the reset-delay times out, the control is reset to

the home state and is ready for another programmed

operating sequence. If current rises above minimum

trip prior to the reset-delay timing out, the timer is

halted and the control resumes the operating

sequence while the accumulated reset-delay timing is

restarted.

TB1 TERMINAL BLOCK

POWER SUPPLY

BATTERY

CUSTOMER P.T. INPUTS

RECLOSER

RIF

OPTICAL

ISOLATION

OPERATOR'S

PANEL

DIF#2

(OPTIONAL)

TRIP SOLENOID

DIF#1

(OPTIONAL)

CPU

OPTICAL

ISOLATION

CLOSE SOLENOID

KEYBOARD

LED's

OPEN / CLOSE

SWITCHES

OPTICAL

ISOLATION

LCD

RS232 PORT

A Ø CT

B Ø CT

C Ø CT

MATCHING

TRANSFORMERS

AND SIGNAL

CONDITIONING

RS232

FIBER-OPTIC

PORT

USER

CT COMMON

CONNECTIONS

6 unlatched outputs

6 latched outputs

12 inputs

CONNECTIONS

6 unlatched outputs

6 latched outputs

12 inputs

OPTIONS

RS232

FIBER-OPTIC

PCB

Figure 3.

Form 5 control operational flow diagram.

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

The Form 5 control is constructed in a modular fashion to

Central Processing Unit (CPU)

simplify service and the addition of accessories (Figure

4). The standard configuration incorporates a Central

Processing Unit (CPU) module, power supply module,

Recloser Interface (RIF) module, and an operator panel.

Module

The CPU module is the center of the Form 5 control. The

CPU contains a 32-bit micro-controller, a Digital Signal

Processor, RAM and EEPROM memory, and a 16-bit

analog-to-digital converter. The CPU module accepts 16

analog inputs which it routes through the digital signal

processor, which samples 32 times per cycle, to compute

harmonic analysis to the 15th harmonic.

Discrete Interface (DIF) module(s), the fiber-optic board

and the RS-232 communication interface cards may be

ordered as accessories. Mounting provisions can be

provided to add customer-supplied radio and modem

modules.

Discrete Interface (DIF) Module

Recloser Interface (RIF) Module

The Discrete Interface (DIF) module allows users with

existing RTUs the ability to interface with the Form 5 con-

trol. The DIF module contains 12 inputs and 12 outputs

can be customized for a remote or supervisory function.

One Form 5 control can accommodate two DIF modules.

See DISCRETE INTERFACE (DIF) ACCESSORY sec-

tion of this manual.

The Recloser Interface (RIF) Module provides the inter-

face between the recloser and the CPU module, as well

as the interface between the voltage sensors and the

CPU module. The RIF is designed to interface with the fol-

lowing reclosers: WE/WVE group, NOVA group,

VSA/VSO group, and KFME/KFVME (50Hz) group.

The recloser connector includes three current-trans-

former inputs, Open and Closed status sensing, and Trip

and Close controls. The voltage sensor connector

accepts six voltage inputs; three for source-side, and

three for load-side voltage. Two sets of dip switches,

located on the RIF front panel, utilize different switch posi-

tions to configure the desired voltage. See Figure 17.

Power Supply Module

The Power Supply module is designed to accept 100 to

134 Vac or 200 to 268 Vac user-supplied input power at

either 50 or 60 Hz.

The Power supply module (connection P9) provides aux-

iliary power to radio communications units, RTUs and

other accessories. The auxiliary output provides 24 Vdc

(12 Vdc is available) for user loads. The auxiliary power

supply has the capability to provide a load of up to 40 W

peak (1 second) and 3 W average. The auxiliary power is

fused and current-limited to prevent user loads from dis-

abling the control.

The RIF board accepts either 12, 120, or 240 Vac voltage

inputs for metering. The factory configuration is outlined

on the module label and can be customized to user spec-

ification. See RECLOSER INTERFACE (RIF) MODULE

CONFIGURATION section of this manual.

Recloser Interface

(RIF) Module

Manual Battery

Reconnect Button

Auxiliary Power

Connection (P9)

Grounding Strap

Power Capacitor

Central Processing

Unit (CPU) Module

Power

Supply

Module

(Located behind operator

panel)

TB1 Connector

Block

Control Cable Receptacle

and Control Grounding Lug

(located beneath cabinet)

Control Battery

99001KM

Figure 4.

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

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S280-79-10

AC POWER

Form 5 Control Operator Panel

This green LED is illuminated when the presence of ac

input power to the control is sensed. The LED will turn off

if ac power is lost for more than 10 seconds.

The Form 5 control operator panel (Figure 8) allows local

operation and status interrogation through built-in operator

controls and status displays. The operator panel contains

LED indicators, operational pushbuttons, membrane-type

functional/indication switches, backlit LCD display, and

Hot Line Tag switch with indication. An RS-232 port is also

provided to permit the temporary connection of a PC for

programming the parameters in the control.

ABOVE MIN TRIP

This red LED is illuminated when the control detects that

current is above the programmed minimum trip value for

Bushings 1-2, Bushings 3-4, Bushings 5-6, Ground, or

Sensitive Ground.

All indicators with the exception of Hot Line Tag and

recloser status are automatically turned off after 5 minutes

of operator panel inactivity.

CHECK BATTERY

This red indicator illuminates for two conditions:

Reactivating is accomplished by pressing any operation

switch. The LCD messages will remain while in this

power-saving mode, although the illuminating backlight

will shut off.

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

during battery test.

2. The control fails a manual battery test. The LED will

remain on until a successful battery test is completed.

Refer to the Battery Test Procedure in this manual for

more information.

CONTROL OK

AC POWER

ABOVE MIN TRIP

RECLOSER MALFUNCTION

This red indicator is illuminated when the control detects

a failure in a trip or close operation. It turns off automati-

cally if the recloser returns to the proper state.

CHECK BATTERY

RECLOSER MALFUNCTION

REVERSE POWER FLOW

BACK

BUSHINGS 1-2 FAULT TARGET

REVERSE POWER FLOW

RESET

TARGETS

BUSHINGS 3-4 FAULT TARGET

BUSHINGS 5-6 FAULT TARGET

GROUND FAULT TARGET

CHANGE

RESET

MAX CURRENT

LAMP

TEST

This red indicator illuminates when the control detects

power flow from the load side to the source side of the

recloser.

NON

GND TRIP

BLOCKED

SENSITIVE-GROUND FAULT TARGET

SUPERVISORY

BLOCKED

RECLOSING

Note: Voltage sensor polarity and phase must be correct for

COLD LOAD

PICK UP

FAST

TRIPS

DISABLED

BUSHINGS 1-2 VOLTAGE

BUSHINGS 3-4 VOLTAGE

BUSHINGS 5-6 VOLTAGE

BATTERY

TEST

BLOCKED

reverse power flow to function properly.

ALTERNATE

PROFILE

ALTERNATE

PROFILE

ALTERNATE

PROFILE

NO.

BUSHINGS 1-2 FAULT TARGET

BUSHINGS 3-4 FAULT TARGET

BUSHINGS 5-6 FAULT TARGET

GROUND FAULT TARGET

TX 2

TX 3

HOT LINE

TAG

RECLOSER CLOSED

RECLOSER OPEN

OFF RX 3 RX 2

RS232

CONTROL LOCKOUT

SENSITIVE GROUND FAULT TARGET

These red target LEDs illuminate when the control issues

an overcurrent trip signal while the respective phase cur-

rent or ground current exceeds the minimum pickup

value. Reset is accomplished automatically when Auto

Reset is activated and a successful close operation is per-

formed or manual reset is accomplished by pressing the

RESET TARGETS button on the control operator panel.

TRIP

(LOCKOUT)

KYLE

FORM 5

RECLOSER CONTROL

Figure 5.

BUSHINGS 1-2 VOLTAGE

BUSHINGS 3-4 VOLTAGE

BUSHINGS 5-6 VOLTAGE

Form 5 control operator panel.

LED Indicators

These red voltage LEDs illuminate when the control

detects the presence of voltage on the respective bush-

ings as connected to TB1. Refer to the Customer Con-

nections for AC Power section in these instructions to

determine the appropriate power connections.

The operator panel LED indicators (Figure 5) give instant

information on the control and recloser status.

LED indicators include:

CONTROL OK

RECLOSER CLOSED

This green LED is illuminated when the continuous self-

diagnostics of the control have detected no CPU or mem-

ory malfunctions and indicate that the control is capable of

normal operation.

This red indicator is illuminated when the control senses

that the recloser mechanism is in the closed position.

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

RECLOSER OPEN

This green indicator is illuminated when the control senses

that the recloser mechanism is in the open position.

CONTROL LOCKOUT

This green indicator is illuminated when the recloser is

open and a reclosing sequence is not in progress or when

the lockout handle on the recloser mechanism is in the

BACK

down position; i.e., trip and close circuits are open.

RESET

TARGETS

Note: The RECLOSER MALFUNCTION, RECLOSER OPEN,

RECLOSER CLOSED, and RECLOSER LOCKOUT

LEDs will flash upon detection of a trip failure. See the

Control Features section of this manual.

CHANGE

RESET

MAX CURRENT

LAMP

TEST

Figure 6.

TRIP (Lockout) Pushbutton

LCD display and dedicated function keys.

The TRIP pushbutton (Figure 2) provides front-panel

access to trip (lockout) the recloser. When pressed, the

TRIP push-button opens the recloser and locks out the

control.

BACK Key

Pressing the BACK key causes the LCD display to scroll

to the previous screen of available information. Pressing

and holding the BACK key causes the control to scroll to

previous screen.

CLOSE Pushbutton

When pressed, the CLOSE pushbutton (Figure 2) returns

the control to the initial or home position, closing the

recloser. The control is ready for the start of a new

trip/close sequence.

RESET TARGETS/RESET MAX

CURRENT Key

Pressing the RESET TARGETS/RESET MAX CURRENT

key resets the fault target indicators on the control opera-

tor panel. The fault current values shown on Screen 2 of

the LCD display will reset to values of zero.

Note: Pressing the CLOSE pushbutton from the Lockout posi-

tion, will initiate Cold Load Pickup (CLPU) protection, if

the feature is first enabled from the interface software

Protection Profile screen, and the COLD LOAD PICKUP

BLOCKED LED on the operator panel is not lit.

Pressing and holding the RESET TARGETS/RESET

MAX CURRENT key for three seconds will reset the min-

imum and maximum current and histogram values in LCD

Display screens 34 through 37. This key will also reset the

Trip Failure Detection feature. See the Control Features

section of this manual.

If the recloser is closed, pushing the CLOSE pushbutton

has no effect on the control. Depressing and holding the

CLOSE pushbutton does not activate the Cold Load

Pickup feature. See Cold Load Pickup in the Control

Features section of this manual.

The Form 5 control has a Manual Close Delay feature that

provides an interval of time from when the CLOSE push-

button is depressed to the time when manual close oper-

ation is performed. See Manual Close Delay in the

Control Features section of this manual.

CHANGE/LAMP TEST Key

Pressing this key for less than three seconds places the

control into a CHANGE mode for 10 seconds as indicated

by the LCD display. CHANGE mode permits the user to

change the state of the nine function/indicator switches on

the operator panel. Security is enhanced by permitting a

only one selection for each CHANGE mode period.

LCD Display

The control operator panel has a large, backlit LCD dis-

play (Figure 6) used for viewing control parameters and

monitoring system conditions. Data is organized into

screens of information, with each display containing four

lines of information, with up to 20 characters per line.

Access to the screens is obtained through navigational

keys which permit the user to scroll through the menu in a

timely and efficient manner.

Pressing and holding the CHANGE/LAMP TEST key for

three seconds will cause the control to perform a front-

panel lamp test. In the Lamp Test Mode, the status indi-

cators flash three times (one second on, one second off).

All status indicators then return to their previous state.

While in the Lamp Test Mode, the control response to

operator panel keys is disabled, except for the TRIP

(LOCKOUT), CLOSE, and HOT LINE TAG switches.

When an overcurrent trip occurs, the control automatically

displays the fault current values as shown on the LCD dis-

play as Screen 1. Refer to LCD Display Screens section

of this manual.

NEXT Key

Pressing the NEXT key causes the LCD display to scroll to

the next screen of available information. Pressing and hold-

ing the NEXT key causes the control to scroll to subsequent

screens at the rate of about two screens per second.

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LCD Display Screens

Screen 6 – S1 Phase-to-Neutral, Instant. Voltage

6 Instant S1 Ph-N

Every LCD display screen contains a parameter name,

parameter value, and parameter units. If the control

detects that a parameter value is invalid, the LCD display

shows five dash characters (- - - - -) in the value field of the

screen. Demand metered values are indicated by (D) and

instantaneous values by (I).

Ph1-N

Ph3-N

Ph5-N

____________ V

Screen 1 – Instantaneous Load Current

Screen 1 displays line current values present for the last

overcurrent trip operation. Values are reset to zero when

the fault targets are reset.

Screen 7 – S1 Phase-to-Phase, Instant. Voltage

7 Instant S1 Ph-Ph

Ph1-3

Ph3-5

Ph5-1

____________ V

1 Gnd

Ph1-2

Ph3-4

Ph5-6

____________ A

Screen 8 – S2 Phase-to-Neutral, Instant. Voltage

8 Instant S2 Ph-N

Screen 2 – Fault Targets

Ph2-N

Ph4-N

Ph6-N

____________ V

2 Gnd Fault

Ph1-2 Fault

Ph3-4 Fault

Ph5-6 Fault

____________ A

Screen 9 – S2 Phase-to-Phase, Instant. Voltage

9 Instant S2 Ph-Ph

Ph2-4

Ph4-6

Ph6-2

____________ V

Screen 3 – Frequency Trip

3 Freq Trip____________ Hz

Screen 10 – Instantaneous Voltage

Time

Date

Present Freq ____________ Hz

10 Instant S1-S2

Ph1-2 Dif ____________ V

Ph3-4 Dif ____________ V

Ph5-6 Dif ____________ V

Screen 4 – Voltage Trip

Screen 11 – Real Power

4 Ph1-N VTrip ____________ V

Ph3-N VTrip

Ph5-N VTrip

Time

____________ V

Date

11 Tot

Ph1-2

Ph3-4

Ph5-6

____________ kW

Screen 12 – Instantaneous kVA

Screen 5 – Power kWh

12 Tot

Ph1-2

Ph3-4

Ph5-6

____________ kVA

5 Tot

____________ kWh

Ph1-2

Ph3-4

Ph5-6

____________ kWh

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

Screen 19 – Demand Phase-to-Neutral Voltage

19 Demand S2 Ph-N

Screen 13 – Instantaneous kVAR

13 Tot

Ph1-2

Ph3-4

Ph5-6

____________ kVAr

Ph2-N(d)

Ph4-N(d)

Ph6-N(d)

____________ V

Screen 14 – Instantaneous Power Factor

Screen 20 – Demand Phase-to-Phase Voltage

14 Tot

Ph1-2

Ph3-4

Ph5-6

____________ PF

20 Demand S2 Ph-Ph

Ph2-4(d)

Ph4-6(d)

Ph6-2(d)

____________ V

Screen 15 –Instantaneous Total Harmonic Distortion

Current

Screen 21 – Demand Voltage

15 Gnd

Ph1-2

Ph3-4

Ph5-6

____________ %THDI

21 Demand S1-S2

Ph1-2(d)

Ph3-4(d)

Ph5-6(d)

____________ V

Screen 16 –Instantaneous Total Harmonic Distortion

Voltage

Screen 22 – Demand Current

16 Instant S1 Ph-N

22 Gnd

____________ A

Ph1-N

Ph3-N

Ph5-N

____________ %THDV

Ph1-2 (d)

Ph3-4 (d)

Ph5-6 (d)

Screen 17 – Demand Phase to Neutral Voltage

Screen 23 – Demand kW

17 Demand S1 Ph-N

23 Tot (d)

Ph1-2(d)

Ph3-4 (d)

Ph5-6 (d)

____________ kW

Ph1-N(d) ____________ V

Ph3-N(d) ____________ V

Ph5-N(d) ____________ V

____________ kW

Screen 24 – Demand kVA

Screen 18 – Demand Phase-to-Phase Voltage

24 Tot

____________ kVA

18 Demand S1 Ph-Ph

Ph1-2(d)

Ph3-4(d)

Ph5-6(d)

____________ kVA

Ph1-3 (d) ____________ V

Ph3-5(d) ____________ V

Ph5-1(d) ____________ V

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SAFETY

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S280-79-10

Screen 31 – Battery Monitor

Screen 25 – Total kVAr and kVAr per Phase

The Battery Monitor displays the battery voltage, current,

and voltage during a battery test. The Battery Monitor is

used with the Battery Test pushbutton. Refer to the Bat-

tery Test Procedure section of these instructions for

more information.

25 Tot

____________ kVAr

Ph1-2(d)

Ph3-4(d)

Ph5-6(d)

31 Battery Monitor

Normal

Test

_______ V

_____ mA

_______ V

Screen 26 – Demand Power Factor

26 Tot ____________ PF

Ph1-2(d) ____________ PF

Ph3-4(d) ____________ PF

Ph5-6(d) ____________ PF

Screen 32 – Phase Minimum Trip Settings

Phase minimum trip settings are listed for the four protec-

tion profiles. Line 1 is the normal setting, ALT1 is profile

No. 1, ALT2 is profile No. 2, and ALT3 is profile No. 3.

Phase Minimum Trip Settings allow verification of trip set-

tings before selection of an alternate profile.

Screen 27 – Demand THD Current

32 – Phase MT

ALT1 MT

______ A

27 Gnd

____________ %THDI

Ph1-2(d)

Ph3-4(d)

Ph5-6(d)

ALT2 MT

ALT3 MT

Screen 33 – Ground Minimum Trip Settings

Ground minimum trip settings are listed for the four pro-

tection profiles. Line 1 is the normal setting, ALT1 is pro-

file No. 1, ALT2 is profile No. 2, and ALT3 is profile No. 3.

Ground Minimum Trip Settings allow verification of trip

settings before selection of an alternate profile.

Screen 28 – Demand THD Voltage

28 Demand S1 Ph-N

Ph1-N(d)

Ph3-N(d)

Ph5-N(d)

____________ %THDV

33 Gnd MT

Alt1 MT

______ A

_______A

______A

_______A

Alt2 MT

Alt3 MT

Screen 29 – Number of Trips for Ground and Phase

29 Gnd OC Trip

Ph1-2 OC Trip

Ph3-4 OCTrip

Ph5-6 OC Trip

____________

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

Currents

34 Gnd Max

Time

____________A

Date

Ph1-2 Max

Time

____________A

Date

Screen 30 – Number of SGF Trips and Total Trip

Operations

Screen 35 – Phase 3-4 Max, Phase 5-6 Max Demand

Currents

30 SGF OC Trip ______

35 Ph 3-4 Max

Time

____________A

Date

Operations

______

Ph5-6 Max

Time

____________A

Date

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

Screen 41 – Communication Port 3 Settings

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

Currents

This message displays the protocol settings (2179 or

DNP3.0), baud rate, and address for Serial Port #3.

Baud rate and address are set using the interface soft-

ware, while protocol is set at the factory based on user’s

specifications.

36 Gnd Min

Time

____________A

Date

Ph1-2 Min

Time

____________A

Date

41 – Comm Port 3

Protocol

______

_______

Note: Demand currents are a time integrated value and do not

reflect minimum or maximum instantaneous currents.

The demand integration time constant is set via the inter-

face software demand metering screen. These are the

same values displayed in the histogram screen.

Speed

Address

Operation/Indication Pushbuttons

Nine frequently used features are provided on the control

operator panel (Figure 7).

Screen 37 – Phase 3-4 Min, Phase 5-6 Min Currents

37 Ph3-4 Min

Time

____________A

Date

Note: These features are activated from the keypad, control

interface software or SCADA signal.

Ph5-6 Min

Time

____________A

Date

To initiate an operation from the operator panel, press the

CHANGE/LAMP TEST key to enter the CHANGE mode.

The operator has 10 seconds to select an operation and

modify settings. If no changes are made, the control will

return to its operational state prior to entering the

CHANGE mode. This prevents accidental changing of

settings.

Note: Pressing and holding the RESET TARGETS/RESET

MAX CURRENT key for three seconds will reset the

minimum and maximum Demand values.

Red LEDs located on each switch indicate the status of

the function, regardless of local or remote activation. For

example, if Cold Load Pickup was activated from a

SCADA signal, the red indicator would illuminate even

though it was not activated from the operator panel.

Screen 38 – Fault Location

38 Fault Location

Distance

____________miles

Date

Note: Operation LEDs activated from local or remote sources

do not illuminate when the front panel is in the power-

save mode.

Time

Screen 39 – Control Information

SUPERVISORY

BLOCKED

GND TRIP

BLOCKED

NON

RECLOSING

39 CPU Firmware

X.XX

Firmware FW Database

FAST

TRIPS

DISABLED

COLD LOAD

PICKUP

BLOCKED

BATTERY

TEST

Date

Time

ALTERNATE

PROFILE

NO. 1

ALTERNATE

PROFILE

NO. 2

ALTERNATE

PROFILE

NO. 3

Screen 40 – Communication Port 2 Settings

Figure 7.

This message displays the protocol settings (2179 or

DNP3.0), baud rate, and address for Serial Port #2.

Baud rate and address are set using the interface soft-

ware, while protocol is set at the factory based on user’s

specifications.

Operation/indication pushbuttons.

GND TRIP BLOCKED

Ground Trip Blocked is activated by pressing the

CHANGE/LAMP TEST key, then pressing the GND TRIP

BLOCKED key. The red indicator illuminates.

40 – Comm Port 2

Protocol

______

_______

Speed

Address

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SAFETY

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S280-79-10

NON RECLOSING

HOT LINE TAG Switch

Non-reclosing mode disables any automatic reclosing

operations. Non-reclosing does not alter the active TCC.

The feature is activated by pressing the CHANGE/LAMP

TEST key, then pressing the NON RECLOSING key. The

red indicator illuminates.

WARNING: Hazardous voltage. Do not use Hot

Line Tag as a substitute for a visible disconnect.

Always establish a visible disconnect prior to perform-

ing any work requiring a de-energized line. Failure to

comply may cause death, severe personal injury, or

SUPERVISORY BLOCKED

equipment damage.

T276.0

Supervisory Blocked disables supervisory SCADA and the

interface software; remote SCADA remains active. Opera-

tional data and metering information are available while

the control is in the SUPERVISORY BLOCKED position.

The TRIP and CLOSE pushbuttons are active indepen-

dently of the SUPERVISORY BLOCKED function.

Hot Line Tag is provided for live-line work applications. All

closing operations are disabled when the Hot Line Tag

feature is activated. While active, the control utilizes an

independent, user-selectable time-current curve for trip

operations.

Activation of the feature is restricted to the operator panel

keypad by pressing the CHANGE/LAMP TEST key, then

pressing the SUPERVISORY BLOCKED key.

IMPORTANT: Hot Line Tag activation does not

cause the recloser to trip open. It only prevents the

recloser from closing.

COLD LOAD PICKUP BLOCKED

The Cold Load Pickup feature is blocked while the COLD

LOAD PICKUP BLOCKED is active. When CLPU is not

blocked, the control utilizes the Cold Load Pickup TCC,

reclose interval, operations to lockout and minimum trip set-

tings in lieu of the normal first operation protection settings.

IMPORTANT: Hot Line Tag is intended solely for

live-line work applications, such as maintenance,

repairs or improvements to the distribution system, that

occur while the line remains energized.

Note: The Cold Load Pickup Blocked key is replaced by the SEN-

SITIVE GROUND FAULT key on international controls.

The Hot Line Tag feature (Figure 8) consists of a toggle

switch and an LED indicator which illuminates when the

function is active. When active, Hot Line Tag prevents all

closing attempts and shifts protection to one trip to lockout

on the programmed time-current curve. The Hot Line Tag

function takes precedence over Cold Load Pickup, Non

Reclosing, and Fast Trips Disabled.

BATTERY TEST

Depressing the BATTERY TEST key performs a control

battery test. The red indicator illuminates and turns off

automatically when the control has finished performing the

test. Refer to the Battery Test Procedure section of these

instructions for further details on testing the control battery.

Activation is accomplished by placing the operator panel

toggle switch to the ON position, or via SCADA command.

Hot Line Tag is activated from the operator panel, com-

munication Port 2, communication Port 3, or a Discrete

Interface Module (DIF). All sources must be off to de-acti-

vate Hot Line Tag.

FAST TRIPS DISABLED

Fast Trips Disabled commands the control to use the pro-

grammed Fast Trips Disabled time-current curve for all

tripping operations.

ALTERNATE PROFILE Indicator/Key

The Hot Line Tag feature may only be reset by the source

which initiates the function. For example, if Hot Line Tag

is activated at the operator panel, resetting the function is

only possible at the operator panel, and not via SCADA

command. For SCADA, Hot Line Tag must be disabled

via the same port number where Hot Line Tag was origi-

nally enabled.

The control has four separate protection profiles; a normal

profile, and Alternate Profiles 1, 2, and 3. Each profile

changes all protection parameters for the control. Except for

the normal profile, each has an indication and selection key.

During control operation, if the three alternate profile indica-

tor lights are not illuminated, the normal profile is active.

To select an alternate profile, press the CHANGE/LAMP

TEST key, then press the desired alternate profile. To

return to the normal profile, simply turn off the active alter-

nate profile. These functions can also be operated

remotely via communications interfaces.

Note: Program all protection profiles. Program unused alter-

nate profiles should be programmed with the same set-

ting as one of the applicable profiles. Default settings on

unused alternate profiles can cause unnecessary out-

ages if they are below normal system requirements.

Note: The minimum trip values for each protection profile are

shown on Screens 32 and 33 of the LCD display. Check

these minimum trip values prior to changing an alternate

profile to avoid misoperation of the control under load

conditions.

HOT LINE

TAG

OFF

Figure 8.

Note: On Form 5 UDP controls, Alternate Profile 3 is replaced

Hot Line Tag Switch.

with SWITCH MODE.

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

RS-232 Communication Port

Control Features

The standard Form 5 control is equipped with a operator

panel RS-232 port for interface with a personal computer

running the Form 5 interface software program. This nine-

pin female data communication equipment (DCE) Port 1

permits the uploading of all programming information

stored in the control, including protection profiles, event

recorder, data profiles, alarms, counters, and metering

information. Port 1 provides a simple means to download

operating parameters from a personal computer to the

control.The protocol, baud rate and address for Port 1 are

identified from the LCD display.

The Form 5 recloser control offers numerous standard

features and accessories that allow the user the utmost

flexibility in designing a control suitable for their applica-

tion requirements.

Under/Over Frequency Loadshedding

The Form 5 control includes provisions for frequency

loadshedding that trips the recloser for conditions of under

or over system frequency. Access to this feature is

through frequency threshold, trip time, and allowable volt-

age threshold.

If a fiber-optic or RS-232 accessory board is connected to

Port 2 (located on the back of the operator panel) any

external electrical connection from the operator panel will

disable the accessory board.

With the auto-restoration feature, the Form 5 can be set to

close the recloser after the system frequency and voltage

have recovered. Parameters available for setting include

frequency and voltage thresholds and time delay.

Note: The operator panel RS-232 port is intended only for

temporary connection of a personal computer. Perma-

nent serial communications must be made via the RS-

232 or fiber-optic accessory board.

A frequency alarm is available and can be configured for

notification.

Voltage Protection (120 Vac-based)

Battery Test Procedure

The condition of the control battery is tested by depress-

ing the BATTERY TEST hot key on the operator panel. No

external current/voltage meter is necessary for testing.

Voltage protection functionality is included as standard on

all Form 5 controls. A recloser trip will be issued for under

and over voltage conditions when the monitored voltage

falls outside user-specified limits for a selectable time.

Response mode includes any single-phase, all three

phases, and single-phase with three-phase inhibit.

Response mode facilitates protecting against a single

phase condition common when a high side fuse operates

on a distribution transformer. Parameters are also avail-

able to provide auto restoration after a trip. A voltage

alarm is available and can be configured for notification.

The control performs a self-test every 12 hours or when

initiated by an external command. When a battery test is

initiated, the spurious charge is first drained to allow the

battery voltage to equalize. A 10-ohm, 55-watt resistor is

then placed across the battery terminals and a voltage

drop is calculated. If the drop from the equalized voltage

to the test voltage exceeds 2 volts, then the CHECK BAT-

TERY LED is illuminated.

Protection Profiles

To perform a battery test:

Four separate protection profiles are included to allow the

user to adapt overcurrent settings for varying system con-

ditions such as load, live line work or weather. The active

profile is selected from the operator panel or with the inter-

face software or SCADA (Figure 9). Each profile has 14

TCC specifications plus reclose intervals, sequence coor-

dination and reset times to maintain independent protec-

tion parameters.

1. Using the Next and BACK keys, scroll through the

LCD display to Screen 31, the Battery Monitor screen.

2. Record the NORMAL VOLTS and NORMAL CUR-

RENT readings from the screen.

Note: Voltage should be between 25 to 31 volts with

higher readings at colder temperatures. Under nor-

mal conditions with ac connected and the battery

trickle charging, the current should read less than

20 mA. With ac connected and in bulk charging

mode, current will range from 12 to 600 mA. With ac

disconnected and the battery supplying the load,

current will read -180 mA to -600mA depending on

accessories connected.

3. Momentarily, press the CHANGE/LAMP TEST key,

then BATTERY TEST key.

Note: AC power can be either connected or disconnected

for Step 3.

4. Record the TEST VOLTS reading from the LCD and

the status of the CHECK BATTERY LED. Service the

battery if the CHECK BATTERY LED is illuminated.

Figure 9.

Interface software sample protection profile.

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S280-79-10

Power Metering

Power metering includes single- and three-phase Watts,

VARS, KVARS, KWH measurements, and the per phase

and total system Power Factor (PF).

AC POWER

ABOVE MIN TRIP

CHECK BATTERY

RECLOSER MALFUNCTION

REVERSE POWER FLOW

Power Factor Sign Metering

This feature allows a user to configure the sign that is

applied to the power factor. The user may select between

the standard definition of power factor (cosine of angle

between current and voltage) or the Cooper Power Sys-

tems default of the power factor sign following power flow.

BUSHINGS 1-2 FAULT TARGET

BUSHINGS 3-4 FAULT TARGET

BUSHINGS 5-6 FAULT TARGET

GROUND FAULT TARGET

Voltage Metering

SENSITIVE-GROUND FAULT TARGET

Six voltages (3-source and 3-load) are metered as stan-

dard on the Form 5 control. The user selects either phase-

to-phase or phase-to-ground values from the control

operator panel, interface software, or serial communica-

tions. This reference is changed by selecting the voltage

sensor correction in the “Hardware” setup portion of the

interface software.

BUSHINGS 1-2 VOLTAGE

BUSHINGS 3-4 VOLTAGE

BUSHINGS 5-6 VOLTAGE

Fast Trips Disabled

Fast Trips Disabled provides the user a quick and effi-

cient method for reducing momentary interruptions or

“blinks”. When activated from the front keypad, pro-

grammed trips to lockout will time according to the

selected time-current curve for Fast Trips Disabled. This

curve is programmable for both phase and ground on

each protection profile. A separate trips-to-lockout setting

is also provided. See Figure 9.

RECLOSER CLOSED

RECLOSER OPEN

CONTROL LOCKOUT

Figure 10.

RECLOSER MALFUNCTION, RECLOSER CLOSED,

RECLOSER OPEN and CONTROL LOCKOUT LEDs

will blink for the affected phase as indication of Trip

Failure.

Trip Failure Detection

The Trip Failure Detection feature is an internal diagnos-

tic alarm for verifying the proper operation of circuit trip-

ping and fault clearing of the recloser. Trip Failure

detection indicates the recloser has failed to trip all

phases following a trip signal from the control. Failure to

trip is assumed if a current of at least 10 Amps is detected

approximately 2 seconds after the trip signal is initiated.

IMPORTANT: The recloser must be isolated and de-

energized immediately upon detection of trip failure.

Follow proper procedures and safety practices to iso-

late and de-energize the recloser.

Upon activation of the feature, these four LEDs flash 1

second on, 1 second off (Figure 10):

The Trip Failure Detection alarm may be triggered from

many potential sources including mechanical, electrical,

control, or interrupter failure. Interrupter failure may

include loss of vacuum in a vacuum interrupter.

• RECLOSER MALFUNCTION

• RECLOSER CLOSED

• RECLOSER OPEN

To clear Trip Failure Alarm, depress and hold the RESET

TARGETS/RESET MAX CURRENTS keypad for 3 sec-

onds. This also resets targets and demand currents.

• CONTROL LOCKOUT

Note: There is no remote reset available with the trip failure

detection feature. It cannot be remotely turned off.

DANGER: Explosion. Stay clear of a recloser

that is in a trip failure mode. A recloser in trip fail-

When the trip failure alarm is activated, an event is

recorded and a status alarm activated (if enabled) and

preserved during system resets.

ure mode may explode resulting in death or severe per-

sonal injury.

T271.0

To test the Trip Failure Detection feature, see Testing

With Type MET Tester in the TESTING AND TROU-

BLESHOOTING section of this manual.

WARNING: Hazardous voltage. This device is

not a substitute for a visible disconnect. Follow all

locally approved safety practices. Failure to follow

proper safety practices can result in contact with high

voltage, which will cause death or severe personal

injury.

G112.1

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

Manual Close Delay

Event Recorder

Manual Close Delay provides a delay from the time that

the manual CLOSE button is pushed to the time the man-

ual close operation is performed.

The Event Recorder maintains a log of operating events

for later readout and analysis by the user. Approximately

500 events can be stored in non-volatile memory. For

each event type, time of occurrence, and other relevant

information is stored. When the event recorder has

reached is capacity, the oldest event is deleted as a new

event is added.

The delay is programmable from 0 to 60 seconds in 1 sec-

ond increments. A programmed delay value can be over-

ridden for immediate closing by pressing the CLOSE

button a second time.

Histograms

An active Manual Close Delay can be canceled by press-

ing the TRIP/LOCKOUT button.

Demand metered voltages and currents can be reported

using the histogram tool. It displays the number of occur-

rences of a variable versus its value in between user-

defined minimum and maximum limits. Date and time are

recorded for the maximum and minimum demand values.

The default setting has the feature disabled (0 seconds).

The RECLOSER CLOSED LED indicates the status of the

feature. See Figure 11.

RECLOSER CLOSED

RECLOSER OPEN

Data Profiler

A fully configurable data profiler is available which allows

the user to collect information by sampling demand data

at selectable intervals. These time-stamped values can

then be plotted to determine weekly load profiles, daily

harmonic disturbances or hourly voltage fluctuations. The

data profiler can provide more than 200 days of informa-

tion, depending upon configuration parameters.

CONTROL LOCKOUT

Figure 11.

The blinking of the RECLOSER CLOSED LED indi-

cates Manual Close Delay is active.

Harmonic Analysis

Cold Load Pickup

Extensive harmonic analysis is performed by the Form 5

control for both currents and voltages. Analysis is per-

formed on-line (updates every 30 seconds) or demand

integrated to user-specified time values. The Total Har-

monic Distortion (THD) for current and voltage is available

from the operator panel display (Figure 12) while com-

plete analysis, including graphing capabilities, is provided

from the Form 5 interface software.

Cold Load Pickup (CLPU) must be enabled through the

interface software (Figure 13) before it can be activated

remotely or from the CLOSE pushbutton on the operator

panel. The CLPU feature provides the user with the abil-

ity to alter protection for abnormal system conditions. It is

active for a programmable time interval which begins with

each manual close. Once this time elapses, protection

reverts back to the programmed sequence. Use the Form

5 control interface software to program the activation time

and time-current characteristics applicable to Cold-Load

Pickup.

Pg14 Gnd

Ph1-2

%THDI

Ph3-4

Ph5-6

Note: When CLPU is active, the control utilizes the Cold Load

Pickup TCC, reclose interval, operations to lockout, and

minimum trip settings in lieu of the normal protection

settings.

BACK

RESET

TARGETS

CHANGE

LAMP

TEST

RESET

MAX CURRENT

Figure 12.

Form 5 operator panel harmonic readout.

Reverse Power Flow

Feeder load monitoring is enhanced with the inclusion of

the power flow monitoring feature. When power flow from

the load to the source side of the recloser is detected, the

control illuminates an operator-panel indicator. Response

time to a reverse power condition is one second. An alarm

is also available for remote interrogation.

Note: Voltage sensor polarity must be correct for reverse

Figure 13.

power flow to function properly.

Interface software Cold Load Pickup settings.

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SAFETY

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S280-79-10

Alarms

Status and data alarms are available for many control

parameters such as voltage, currents, thresholds. Data

alarm function compares metered data to user-pro-

grammed alarm high and low limits and issues an alarm of

user-specified priority if limits are exceeded. The status

alarm function monitors status and issues an alarm of

user-defined priority when the user programmed alarm

conditions are met. The alarms are reported via commu-

nication ports and can be configured to trigger a data pro-

file and event record. Alarms do not affect the protection

functions of the control.

Fault Location

Fault Location provides an approximate distance of a fault

from the the Form 5 Control The distance is based on the

current fault magnitude, the type of fault, and system

parameters entered by the user. The LCD display (Screen

38) identifies the estimated distance in miles or kilometers

(km) from the control.

The fault location algorithm performs an impedance cal-

culation based on:

Figure 14.

Fault Location configuration screen.

• Single-phase to ground fault

• Phase-to-phase fault

The following system parameters must be entered via the

Protection Profile menu for each profile:

• Double-line to ground fault

• Three-phase fault

• Nominal system line-to-line voltage

This information is recorded as an event in the control

Event Recorder for retrieval. The fault location algorithm

does not require voltage sensing. If the location cannot be

determined, no event is recorded and dashes are dis-

played on the LCD screen.

Note: If the Fault Location feature is not desired, the nom-

inal system voltage parameter should be set at 1.

• Source-side zero sequence and positive sequence

impedance. This includes impedance up to the loca-

tion of the Form 5 control.

Setting the parameters for Fault Location is done through

the interface software. The user enters line impedance

parameters and system voltage information into the soft-

ware via the Protection Profile menu. See Figure 14.

• Line-side zero sequence and positive sequence

impedance per mile or km.

• The distance units of the line impedance in miles or

km.

IMPORTANT: Fault Location is not a protection func-

tion. Its purpose is to define a fault and provide its

approximate location relative to the Form 5 control

detecting the fault.

Refer to Service Information S280-79-2 Form 5 Micropro-

cessor-Based Recloser Control Programming Guide for

additional information.

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

Torque Angle Width parameter restricts the tripping to an

Directional Sensitive Ground/Earth

(SGF/SEF) Fault

angle of plus or minus the specified width about the

Torque angle setting. For example, if the Maximum

Torque Angle is 45°, and the Torque Angle Width is set for

10°, then the control will trip at angles between 35° and

55°.

The Directional SGF/SEF Fault feature adds directional

capabilities to the SGF/SEF protection features. It pro-

vides a sensitive ground/earth trip if the fault is downline

of the recloser on a radial distribution system. Directional

SGF/SEF is used on ungrounded Delta systems for sup-

pression of ground trips for faults occurring on other circuit

branches.

The Zero Sequence Voltage Threshold is used to set the

threshold voltage below the disabled directional SGF/SEF

tripping voltage.

Note: In most cases, a default value of 4 is adequate.

The user sets the parameters for Direction SGF/SEF

through the interface software via the Protection Profile

menu. See Figure 15. In addition to the normal (non-direc-

tional) SGF/SEF settings, the user enters the following

directional SGF/SEF parameters:

Directional SGF/SEF Fault is recorded as an event in the

control Event Recorder for retrieval. Refer to Service Infor-

mation S280-79-2 Form 5 Microprocessor-Based Recloser

Control Programming Guide for additional information.

• Direction Enable

Note: If Direction Enable is not selected, SGF/SEF tripping

occurs through normal (non-directional) settings.

• Maximum Torque Angle (-180° to 180°, in 1° increments)

• Torque Angle Width (10° to 90°, in 1° increments)

• Zero Sequence Voltage (V ) Threshold (4 to 130 V)

The Maximum Torque Angle parameter determines the

angle of maximum tripping sensitivity between the phase

angle of the zero sequence voltage and current at the time

of fault. The setting of this value depends on knowledge

of the power system. Typically, a resistive fault has a

value of 0°, and a capacitive fault has a value of 90°.

Figure 15.

Directional SGF/SEF configuration screen.

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SAFETY

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S280-79-10

The RS-232 accessory board and the fiber-optic acces-

sory boards are located behind the operator panel. Each

accessory board can be connected to either Port 2 or Port

3; no two boards can use the same port. The operator

panel LEDs indicate the status of communication on the

accessory boards. Temporary connections to the operator

panel RS-232 port disables fiber-optic or RS-232 commu-

nication at Port 2.

Communications

Communication Ports

The Form 5 control has three communication ports from

the CPU module. Two of the three ports are user-acces-

sible. Communication Port 1 is the operator panel LCD

display where data is exchanged between the CPU and

the operator panel. Though not user-configurable, Port 1

allows for flexible modifications to the front panel for cus-

tom applications.

Port 3 provides uninterrupted communication to a

remote terminal unit (RTU). Refer to S280-79-4 Form 5

Serial communications Accessory Operation Instruc-

tions for additional information.

The operator panel RS-232 communication Port 2 pro-

vides temporary local personal computer (PC) access

when connected with a standard 9-pin cable. Port 2 pro-

vides a dual communication interface for the user. The

port includes a software switch for two external connec-

tions; the operator panel RS-232 DB-9 connector, or the

fiber-optic/RS-232 communication accessories. Local

connection to the operator panel RS-232 connection

takes precedence over the communication accessory.

Disconnecting the operator panel RS-232 communication

automatically reconnects the communication accessory

to Port 2.

TX 3

TX 2

RS232

RX 3

RX 2

Figure 17.

Fiber-Optic/RS-232 receive and transmit LEDs and

data port on the operator panel. The TX2 and RX2

LEDs illuminate during communication with the

operator panel RS-232 port.

Accessory Ports 2 and 3 are resident on the back of the

operator panel and can be configured to either 2179 or

DNP3.0 protocols. Port 3 provides uninterrupted commu-

nication to the RS-232 or Fiber-Optic accessory, and is

not affected by any other port or physical connection.

Figure 16 illustrates the communication configuration for

serial ports1, 2, and 3.

Protocols

Three protocols are available for the Form 5 control and

are factory-configurable to communication Ports 2 and 3.

TEMPORARY

ENGINEERING

SCADA SYSYEM

The protocols are:

OPERATIONS

(Local PC)

(Radio, Fiber-Optic, Modem) (Radio, Fiber-Optic, Modem)

• Cooper Power Systems 2179

• DNP3.0, Level 3

OPERATOR PANEL

DISPLAY AND

KEYPAD

OPERATOR

PANEL

RS-232

RS-232 or

FIBER-OPTIC

ACCY

RS-232 or

FIBER-OPTIC

ACCY

• S-Comm Protocol accessory

Protocol DNP3.0 includes “Unsolicited Report by Excep-

tion” functionality and Protocol 2179 includes 2-bit status

functionality.

AUTO TRANSFER

SWITCH

(Operator Panel

Connection Disables

Accessory)

Complete documentation for Cooper Power Systems pro-

tocols are:

COMMUNICATIONS

PORT 2

(Shared)

• Reference Data R280-90-12, Serial Communication

Protocol 2179

COMMUNICATIONS

PORT 1

(Internal Use Only)

COMMUNICATIONS

CPU

PORT 3

(Metering, Histograms

(Dedicated)

Profiles, Alarms, Targets)

• Reference Data R280-90-13, Communication Point

Database for Protocol 2179

Figure 16.

• Reference Date R280-90-14, Communication Point

Database for Protocol DNP3.0

Control communication port configuration.

Control Information

Fiber-Optic/RS-232 Accessory

Control information, including firmware version and

database version, is factory installed and can not be

altered by the user. This information is accessible from

the LCD display, Screen 39.

Two sets of receive and transmit LEDs (Figure 17) are

provided on the operator panel for fiber-optic and RS-232

communications. The TX2 and RX2 LEDs illuminate when

communicating with the operator panel RS-232 port. The

TX3 and RX3 LEDs illuminate when communicating with

either the fiber-optic or RS-232 interface accessory

boards on communication Port 3.

Communication Ports 2 and 3 settings can be referenced

from the LCD display, Screens 40 and 41 respectively.

(Port 1 shares the same settings as Port 2.)

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

To remove the RIF Module for configuration:

AUXILIARY POWER FOR

ACCESSORIES

1. Disconnect the control battery.

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

Connection P9 (Figure 18) on the Power Supply module

provides 24Vdc (12Vdc is available) to power radio com-

munication units, RTUs and other accessories. The auxil-

iary power provides 40W peak load capability. Auxiliary

power is fused and current-limited to prevent user loads

from disabling the control.

Module.

3. Remove the nut and disconnect the grounding strap to

the operator panel. See Figure 4.

4. Disconnect the wiring harness connectors from the

bottom of the RIF Module.

Customer 28V connections for auxiliary power are made

to terminals 3 and 1 and are continually energized. Ter-

minal 2 and 4 are not used at this time.

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

nectors.

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

board to the mounting bracket.

6. Pull the module out of the cabinet.

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

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

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

tion in the control cabinet and secure to the mounting

bracket with screws previously removed.

GDC-1A

9. Replace nut securing the RIF Module grounding strap

SW (-) 4

28V (-) 3

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

SW (+) 2

28V (+) 1

RIF Module.

Example shown for 120Vac operation:

Figure 18.

SENSOR

VOLTAGE

Power Supply Module Connection P9 provides

24Vdc power to radio communication units.

POLE1

POLE2

12Vac

120Vac*

240Vac

OFF

*120Vac is factory-set configuration

RECLOSER INTERFACE (RIF)

MODULE CONFIGURATION

INPUT VOLTAGE

SELECTION

The Recloser Interface (RIF) Module is factory-configured

at 120Vac. For operating voltages other than 120Vac, the

RIF module must be removed from the control cabinet for

configuration.

OFF

POLE 1

BUSHING 2 (XØ)

POLE 2

POLE 1

POLE 2

BUSHING 4 (YØ)

POLE 1

POLE 2

BUSHING 6 (ZØ)

CAUTION: Equipment damage. Always wear a ground-

ing wrist strap to control static electricity before handling

circuit boards. Failure to use this strap may result in cir-

INPUT VOLTAGE

SELECTION

cuit board damage.

T253.1

OFF

POLE 1

BUSHING 1 (AØ)

POLE 2

POLE 1

POLE 2

IMPORTANT: The Form 5 control must be com-

pletely de-energized prior to removing and configuring

the RIF board.

BUSHING 3 (BØ)

BUSHING 5 (CØ)

POLE 1

POLE 2

Figure 19.

Recloser Interface (RIF) Module indicates the fac-

tory-configured metering voltage (120Vac).

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SAFETY

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S280-79-10

FORM 5 UNIVERSAL DEVICE PROTECTION (UDP) CONTROL

The UDP function allows the Form 5 control to become a

switch control to provide indication of overcurrent trip con-

ditions without issuing an overcurrent trip signal. The con-

trol is in the recloser mode when the feature is in the OFF

position, and in the switch mode when the feature is

ACTIVE.

While in the switch mode, all automatic open and close

operations of the recloser (including overcurrent voltage

and frequency) are blocked. Fault targeting, metering,

alarms, and event recording functions are active.

This non-tripping fault indication state is initiated via a

operator panel pushbutton (labeled SWITCH MODE), dig-

ital SCADA, or discrete SCADA. The UDP feature has

local indication at the operator panel (LED), digital indica-

tion, and remote indication via status contacts on the Dis-

crete Interface (DIF) module 1.

Figure 21.

Interface software Switch Mode settings.

SUPERVISORY

BLOCKED

GND TRIP

BLOCKED

NON

RECLOSING

CONTROL OK

AC POWER

FAST

TRIPS

DISABLED

COLD LOAD

PICKUP

BLOCKED

BATTERY

TEST

ABOVE MIN TRIP

CHECK BATTERY

ALTERNATE

PROFILE

NO. 1

ALTERNATE

PROFILE

NO. 2

RECLOSER MALFUNCTION

REVERSE POWER FLOW

SWITCH

MODE

BACK

Figure 20.

BUSHINGS 1-2 FAULT TARGET

BUSHINGS 3-4 FAULT TARGET

BUSHINGS 5-6 FAULT TARGET

GROUND FAULT TARGET

Function/Indication pushbuttons for the Form 5

equipped with the UDP accessory.

RESET

TARGETS

CHANGE

RESET

MAX CURRENT

LAMP

TEST

NON

RECLOSING

GND TRIP

BLOCKED

SENSITIVE-GROUND FAULT TARGET

SUPERVISORY

BLOCKED

COLD LOAD

PICK UP

BLOCKED

FAST

TRIPS

DISABLED

AØ

BATTERY

TEST

SOURCE

VOLTAGE

BØ

CØ

XØ

ALTERNATE

PROFILE

ALTERNATE

PROFILE

SWITCH

MODE

NO.

LOAD

VOLTAGE

YØ

ZØ

TX 2

TX 3

HOT LINE

TAG

RECLOSER CLOSED

RECLOSER OPEN

OFF RX 3

RS232

RX 2

CONTROL LOCKOUT

TRIP

(LOCKOUT)

KYLE

FORM 5/UDP

RECLOSER CONTROL

Figure 22.

Form 5/UDP Operator Panel.

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

FORM 5 DC NOVA CONTROL

The Kyle Form 5 recloser control can be equipped with a

dc-to-dc converter, interface circuit, and a fully shielded

19-pin cable for use with a Type DC NOVA recloser. See

Figure 23.

The dc-to-dc converter board (Figure 24) converts the con-

trol’s 24 Vdc battery supply voltage to 53 Vdc to drive the

trip/close capacitors in the NOVA mechanism. The output

of the board is separately fused for operator indication.

The dc-to-dc converter houses voltage monitoring and

conditioning circuits which protect the battery from failure

and provides trip/close operations without AC power. The

19-pin control cable interfaces the NOVA dc recloser to

the Form 5 control through the interface circuit. The cable

also provides AC power from the control to the recloser

mechanism heater.

dc NOVA

Potential

Transformer

(120/240Vac)

Figure 24.

99007KM

Form 5

Control

Dc-to-dc converter located behind Form 5 operator

panel (removed).

19 Pin

Control Cable

120Vac/240Vac

Power Cable

Figure 23.

Connections of a Form 5 control with dc NOVA

accessory to a dc NOVA recloser.

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S280-79-10

DISCRETE INTERFACE (DIF)

ACCESSORY

CAUTION: Equipment damage; misoperation.

External leads must be shielded and the shield

must be grounded at both ends. Terminate each lead

with a 320 Vac, 160 Joules metal oxide varistor (MOV),

or equivalent, at the remote end. Attach MOVs between

the leads and ground. Failure to properly shield and

protect leads can result in equipment damage and/or

The Discrete Interface (DIF) module accessory (Figure

25) permits connection of contact-type input devices

(switches, relays) and discrete indicating devices (relays,

LEDs, lamps) to the Form 5 control to effect local discrete

input/output (I/O). The DIF module accessory is used for

supplementing normal local controls and status indicators

for discrete SCADA functions. All DIF inputs and outputs

have been factory-set and are shown in Figure 27.

unintentional operation.

G117.3

INPUT COMMON

28V (–)

IMPORTANT: Do not use DIF module for overcurrent

protection. Digital SCADA can be used for this applica-

tion. The control gives priority to TCC timing and issu-

ing a trip signal rather than changing the status of a DIF

output or responding to a DIF input.

28V (+)

WHETTING

VOLTAGE

OUTPUT COMMON

UNLATCHED

OUTPUTS

The DIF module contains 12 factory-set inputs and out-

puts for discrete SCADA functions. Each Form 5 control

can accommodate two DIF modules.

DISCRETE

INTERFACE

MODULE

Whetting voltage for the DIF inputs can be supplied by the

DIF module or by the customer as shown in Figure 26.

ACCESSORY

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

connector P5 for use as whetting voltage for inputs to

P4. As an alternative, the user can supply whetting volt-

age from an auxiliary source, such as a RTU.

LATCHED

OUTPUTS

The input voltage range is 12 to 120 Vac or Vdc. The 12

outputs are Form C relay contacts. Six of the module out-

puts are latching and the other six are non-latching.

Note: Latching is defined as an output that retains its status

when control power is removed.

Non-latching is defined as an output that changes its

status when control power is removed.

Note: A remote function is not controlled by the SUPERVI-

INPUTS

(12 TO 120

VAC OR VDC)

WHETTING

VOLTAGE

SORY BLOCKED switch.

Customer Connection

Information

Figure 25.

Discrete Interface (DIF) Module.

CAUTION: Equipment damage. Do not drill con-

nection holes into the top of the cabinet. Connec-

tion holes in the top of the cabinet will allow moisture to

seep into the control and damage the components or

cause control misoperation. Failure to comply will void

INPUT COMMON

28V (-)

the control’s factory warranty.

T249.0

28V (+)

Customer-Supplied

Wiring for Whetting Voltage

OUTPUT COMMON

Figure 25 shows the customer-supplied wiring of whetting

voltage for DIF module inputs. Connection is made from

terminal P5 on the DIF module to the respective connec-

tions on P4 inputs 1 through 12.

REMOTE

CONTACTS

Note: Wiring to P5-2 and P5-3 can be

reversed if necessary.

To P4

Inputs 1 thru 12

Figure 27 shows customer connections to the DIF outputs

at P2 and P3.

Figure 26.

Customer connections for supplying whetting volt-

age to DIF inputs.

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

FORM 5 CONTROL

*28 Vdc (nominal)

Remote Terminal Unit (RTU)

supplied by

DIF module for

whetting voltage.

INPUT COMMON

*28V (–)

*28V (+)

OUTPUT COMMON

COMMON

CONTROL OK

AC POWER

SUPERVISORY BLOCKED

COLD LOAD PICKUP BLOCKED

INPUT

VOLTAGE

NON-RECLOSING

NORMAL PROFILE

ALTERNATE PROFILE 3

ALTERNATE PROFILE 2

Discrete Interface

Module (DIF)

ALTERNATE PROFILE 1

GROUND TRIP BLOCKED

HOT LINE TAG

RECLOSER OPEN

REMOTE TRIP AND LOCKOUT

Not All Remote

Connections

Shown

REMOTE TRIP AND RECLOSE

SUPERVISORY COLD LOAD PICKUP BLOCKED

SUPERVISORY NON-RECLOSING

SUPERVISORY NORMAL PROFILE

SUPERVISORY ALTERNATE PROFILE 3*

(*SWITCH MODE ON FORM 5 UDP)

SUPERVISORY ALTERNATE PROFILE 2

SUPERVISORY ALTERNATE PROFILE 1

SUPERVISORY GROUND TRIP BLOCKED

REMOTE HOT LINE TAG

SUPV. CLOSE

SUPV. TRIP & L.O.

Figure 27.

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

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SAFETY

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S280-79-10

TABLE 1

DIF Input Ratings

Minimum Detection Level: . . . . . . . . . . . . . . . . . . . . . . . . 8 Vac

Maximum Operating Voltage: . . . . . . . . . . . . . . . . . . . . . 135 Vac

(50 or 60Hz)

10 Vdc

175 Vdc

Input Impedance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 k minimum (inputs are current limited)

Maximum Input Loading: . . . . . . . . . . . . . . . . . . . . . . . . . 2 mA per input

Maximum Leakage Rejection: . . . . . . . . . . . . . . . . . . . . . 1 mA

Maximum Pickup Time: . . . . . . . . . . . . . . . . . . . . . . . . . . 10 msec (does not count control response time)

Minimum Input Pulse Time: . . . . . . . . . . . . . . . . . . . . . . . 100 msec

Minimum Transition Time between Pulse Inputs: . . . . . . 200 msec

Input Protection: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shunting type using MOVs and capacitors.

Opto Isolation from input to system.

IMPORTANT: Each DIF contains a small, isolated

current source for use with external dry contacts. This

supply is intended for use with the DIF inputs only and

must not be used for powering external circuits. This is

considered a dry contact input for customer connection.

TABLE 2

Whetting Voltage Source

(Supplied by Internal Voltage Source of DIF Module)

Voltage Level: . . . . . 28 Vdc (nominal)

Output Current: . . . . 30 mA maximum

TABLE 3

DIF Output Ratings

Maximum Switching Voltage: . . . . . 135 Vac 110 Vdc

Maximum Switching Loading: . . . . . 600 mA

Maximum Pickup-Release Time: . . 3 msec (does not count control response time)

Input Protection: . . . . . . . . . . . . . . . Shunting type using MOVs and capacitors

Standard and UDP Controls

Standard and UDP Form 5 control DIF inputs and outputs

are described in the following pages.

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

Standard and UDP Control DIF Module 1

Inputs

The DIF inputs are factory-configured as momentary (0.25 sec. duration) or maintained functions. Supervisory signals

do not have any effect when supervisory blocked is active. Remote inputs function when supervisory is blocked.

Input

Connector

Function

Description

P4-1

Supervisory Trip and Lockout

Supervisory Trip and Lockout trips the recloser open and locks out

the control. The control remains locked out until closed manually or

by the supervisory close feature. A momentary signal is required.

P4-2

P4-3

Supervisory Close

Supervisory Close initiates a closing signal to the recloser. A

momentary signal is required for proper operation.

Remote Hot Line Tag

Remote Hot Line Tag performs the same functions as the HOT

LINE TAG switch on the operator panel. Remote Hot line Tag is

activated by a maintained SCADA command, a serial command,

or locally via a operator panel switch. This input is active regardless

of the state of the supervisory function.

P4-4

Supervisory Ground Trip Block

Supervisory Ground Trip Block provides supervisory operation of

ground trip block by a remote momentary signal.

This input performs the same function as the GND TRIP BLOCKED

key on the operator panel. This input is inactive if the Supervisory

function is disabled.

P4-5

P4-6

P4-7

Supervisory Alternate Profile 1

Supervisory Alternate Profile 2

Supervisory Alternate Profile 3*

Supervisory Alternate Profiles provides selection of alternate pro-

grammed values for phase and ground. This feature is activated by

a remote momentary signal.

These inputs are active with a momentary whetting voltage and

cause the control to select the respective Supervisory Alternate Pro-

file. The inputs are inactive if the Supervisory function is disabled.

P4-8

Supervisory Normal Profile

Supervisory Normal Profile requires a momentary signal for proper

operation.

This input is active with a whetting voltage and causes the control

to select Normal Protection Profile. This input is inactive if the

Supervisory function is disabled.

Note: Supervisory Alternate Profile 3 replaced by Switch

Mode on UDP controls.

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SAFETY

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S280-79-10

Standard and UDP Control DIF Module 1

Inputs (cont’d)

Input

Connector

Function

Description

P4-9

Supervisory Non-Reclosing

Supervisory Non-Reclosing provides supervisory non-reclosing

input by a remote momentary signal.

This input performs the same function as the NON-RECLOSING

key on the operator panel. This input is inactive if the Supervisory

function is disabled.

P4-10

P4-11

Suprv Cold-Load Pickup Blocked

Remote Trip and Reclose

This input performs the same function as the COLD LOAD

PICKUP BLOCKED key on the operator panel. This input is inac-

tive if the Supervisory function is disabled. A momentary signal is

required for proper operation.

Remote Trip and Reclose initiates a trip operation followed by a

reclose operation. A momentary signal is required for proper

operation.

This input is active with a whetting voltage and causes the control

to perform a trip operation followed by a reclose operation. This

input is active regardless of the state of the Supervisory function.

P4-12

Remote Trip and Lockout

Remote Trip and Lockout trips the recloser open and locks out the

control. It can be used for tripping from external relays and alarms.

A momentary signal is required for proper operation.

This input performs the same function as the TRIP (LOCKOUT)

switch on the operator panel and is active regardless of the state

of the Supervisory function.

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

Standard and UDP Control DIF Module 1

Outputs

The 12 outputs of the DIF Module are Form C relay contacts. Six of the outputs are latching and six are non-latching.

Note: Contacts shown in inactive mode.

Output Connector

Function

Type

Description

P3-1 NC

P3-2 NO

Normal Profile

Non-Latched

Normal Profile is active only when Alternate Profiles are

inactive. Normal reclosing operations will follow.

P3-3 NC

P3-4 NO

Non-Reclosing

Non-Latched

This output is active when the NON-RECLOSING indicator

in the operator panel is illuminated.

P3-5 NC

P3-6 NO

Cold-Load Pickup Blocked Non-Latched

This output is active when the COLD LOAD PICKUP

BLOCKED indicator on the operator panel is illuminated.

P3-7 NC

P3-8 NO

Supervisory Blocked

Non-Latched

Supervisory Blocked prevents operation from supervisory

control. Programming is accessible from the operator panel.

This output is active when the SUPERVISORY BLOCKED

indicator on the operator panel is illuminated.

AC power indicator is active when the control detects the

presence of AC power. This output is active when the AC

power indicator on the operator panel is illuminated.

P3-9 NC

P3-10 NO

AC power

Non-Latched

Latched

P3-11 NC

P3-12 NO

Control OK

Recloser Open

Hot Line Tag

Control OK indicator is active when the control is able to per-

form protection operations. This output is active when the

CONTROL OK indicator on the operator panel is illuminated.

P2-1 NO

P2-2 NC

Recloser Open indicator is active when the recloser signals

the control that the recloser contacts are open. This output is

active when the RECLOSER OPEN indicator is illuminated.

P2-3 NO

P2-4 NC

Latched

With Hot Line Tag active, close circuit is disabled and the

HOT LINE TAG indicator is illuminated. With Hot Line Tag

inactive, the control switched back to the previous time cur-

rent curve for the active profile, close circuit is enabled and

the HOT LINE TAG indicator is off. This output is active

when the operator panel indicator is illuminated.

Ground Trip Blocked causes the control to block ground trip-

ping operations. This output is active when the GND TRIP

BLOCKED INDICATOR on the operator panel is illuminated.

P2-5 NO

P2-6 NC

Ground Trip Blocked

Latched

P2-7 NO

P2-8 NC

Alternate Profile 1

Alternate Profile 2

Alternate Profile 3*

Latched

These outputs are active when the respective ALTERNATE

PROFILE indicators on the operator panel is illuminated.

P2-9 NO

P2-10 NC

P2-11 NO

P2-12 NC

*Note: Supervisory Alternate Profile 3 replaced by Switch

Mode on UDP controls.

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SAFETY

FOR LIFE

S280-79-10

Standard and UDP Control DIF Module 2

Inputs

The DIF inputs are factory-configured as momentary or maintained functions. Whetting voltage for the DIF inputs is

supplied by the DIF module or by the user. The input voltage range is 12 to 120 VAC or VDC.

Input

Connector

Function

Description

P4-1

Supervisory Fast Trips Disabled

This input performs the same function as the FAST TRIPS DIS-

ABLED key on the operator panel and is inactive if the Supervisory

function is disabled. This is a momentary function.

P4-2

Supervisory Reset Targets

This input performs the same function as the RESET

TARGETS/RESET MAX CURRENT key on the operator panel.

This input is inactive if the Supervisory function is disabled. This is

a momentary function.

P4-3

P4-4

P4-5

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

maintained whetting voltage. This input is inactive if the Supervi-

sory function is disabled.

Supervisory Battery Test

This input performs the same function as the BATTERY TEST key

on the operator panel. This input is inactive if the Supervisory func-

tion is disabled. This is a momentary function.

Supervisory SGF Blocked

This input is active with a momentary whetting voltage and causes

the control to block, or unblock sensitive ground fault operations.

The input is inactive if the Supervisory function is disabled.

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

Standard and UDP Control DIF Module 2

Outputs

The 12 outputs of the DIF Module are Form C relay contacts. Six of the outputs are latching and six are non-latching.

Note: Contacts shown in inactive mode.

Output Connector

Function

Type

Description

P3-1 (NC)

P3-2 (NO)

Control Lockout

Non-Latched

This output is active when the CONTROL LOCKOUT

indicator is illuminated.

P3-3 (NC)

P3-4 (NO)

Check Battery

Non-Latched

This output is active when the CHECK BATTERY indi-

cator is illuminated.

P3-5 (NC)

P3-6 (NO)

Reverse Power Flow

Fast Trips Disabled

Operation Counter

This output is active when the REVERSE POWER

FLOW indicator is illuminated.

P3-7 (NC)

P3-8 (NO)

This output is active when the FAST TRIPS DIS-

ABLED indicator is illuminated.

P3-9 (NC)

If the Supervisory function is enabled, this output is

active when the OPERATION COUNTER OFF inputs

from Comm Port 1-DIF2, Comm Port 2 and Comm Port

3 are not active.

P3-10 (NO)

P3-11 (NC) Recloser Malfunction

P3-12 (NO)

Non-Latched

This output is active when the RECLOSER MAL-

FUNCTION indicator is illuminated.

This output is active when the BUSHINGS 1-2 FAULT

TARGET indicator is illuminated.

P2-1 (NO)

P2-2 (NC)

Bushings 1-2 Fault Target

Bushings 3-4 Fault Target

Bushings 5-6 Fault Target

Latched

P2-3 (NO)

P2-4 (NC)

This output is active when the BUSHINGS 3-4 FAULT

TARGET indicator is illuminated.

P2-5 (NO)

P2-6 (NC)

This output is active when the BUSHINGS 5-6 FAULT

TARGET indicator is illuminated.

P2-7 (NO)

P2-8 (NC)

Ground Fault Target

Latched

Output is active when the GROUND FAULT TARGET

indicator is illuminated.

P2-9 (NO)

Sensitive Ground Fault Target

Output is active when the SENSITIVE GROUND

FAULT TARGET indicator is illuminated.

P2-10 (NC)

Output is active when Sensitive Ground Fault is

blocked.

P2-11 (NO) Sensitive Ground Fault Blocked

P2-12 (NC)

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SAFETY

FOR LIFE

S280-79-10

INPUT ACCURACY

Sensed Currents

Sensed Source Voltages

Three-phase voltages used in voltage, power and power-

factor related calculations:

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

does include the phase current summing process.

Phase Current—Individual Phase Currents:

Range: 1 A to 10,000 A for 500:1 CTs

2 A to 20,000 A for 1000:1 CTs

Voltage measurement accuracy:

0.4V from 5V to 80V

0.5% from 80V to 135V

4 A to 40,000 A for 2000:1 CTs

Accuracy: 1 mA from 10 mA to 125 mA

0.8% from 125 mA to 1600 mA

(Control only, does not include sensor

tolerance.)

Ground Current—Vector Sum of Three-Phase Currents:

Range: 1 A to 5,000 A for 500:1 CTs

2 A to 10,000 A for 1000:1 CTs

4 A to 20,000 A for 2000:1 CTs

Accuracy: 3 mA from 10 mA to 125 mA

2.4% from 125 mA to 1600 mA

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

INSTALLATION PROCEDURE

The Form 5 control can be used with the old-style Type A

Initial Programming

Prior to Installation

CTs; however, the event recorder, data profiler and duty

cycle monitor will have limited accuracy for currents

above 5000 Amps.

CAUTION: Equipment Misoperation. Do not

Retrofit kits with the new Type B sensing CTs are avail-

able to upgrade existing families of reclosers for operation

with Form 5 controls. For additional information, contact

your Cooper Power Systems representative.

connect this control to an energized recloser until

all control settings have been properly programmed

and verified. Refer to the programming information for

this control. Failure to comply can result in control and

recloser misoperation, equipment damage, and per-

For identification, Table 4 lists the serial number breaks

between old-style Type A and the new-style Type B sens-

ing CTs. Below this serial number, the recloser is

equipped with the Type A CTs.

sonal injury.

G110.3

The control must be programmed with all necessary oper-

ating settings, all alternate profiles, and parameters prior

to operation with an energized recloser.

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

below, please contact your Cooper Power Systems rep-

resentative with the recloser type and serial number for

verification of Type A or B bushing current transformers.

Note: Program all protection profiles. Unused alternate pro-

files should be programmed with the same settings as

one of the applicable profiles. Default settings on

unused alternate profiles can cause unnecessary out-

ages if they are below normal system requirements.

TABLE 4

Serial Number Break for Reclosers with Type A

Sensing CTs

Initial programming of the control is the responsibility of a

qualified technician or engineer familiar with control func-

tions and programming parameters required for the spe-

cific recloser installation.

Recloser

Below Serial Number

RXE

5831

5894

11199

3695

7199

7208

1204

RVE

The control must be programmed with the Form 5 inter-

face software.

WVE

Control / Recloser Compatibility

VWE

Reclosers manufactured prior to June 1989 are equipped

with Type A bushing current transformers. These

reclosers were designed for use with Form 2, Form 3, and

Form 3A controls. Because the Form 5 control is designed

for use with reclosers equipped with Type B current-sens-

ing Transformers, reclosers retrofitted with Form 5 con-

trols should be retrofitted with Type B current

transformers. All reclosers manufactured since 1989 are

equipped with Type B (1000:1, 1000/500:1, or 2000:1)

sensing CTs.

VWVE27

VWVE38

Control Cable

WARNING: Hazardous voltage. Recloser and

control must be solidly grounded. Follow all locally

approved procedures and safety practices when

grounding this equipment. Improper grounding can

result in contact with high voltage, which will cause

Reclosers equipped with Type B sensing CTs are com-

patible with all Kyle recloser controls (Form 2, Form 3,

Form 3A, Form 4A, Form 4C, FXA, FXB and Form 5, Form

5 LS/UDP controls), and are identified with the following

label prominently displayed on the recloser sleet hood or

the front of the operator cabinet:

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

end and the male receptacle of the control on the other

end.

Note: The control cable must be supported along its length to

prevent repeated movement due to wind or other out-

side forces which can damage the cable.

NOTICE

RECLOSER IS EQUIPPED WITH

TYPE B SENSING CTs.

RECLOSER DOES NOT HAVE A

BATTERY CHARGER.

IMPORTANT: All external inputs to the Form 5 con-

trol must be routed within 8 inches of their correspond-

ing ground. During a surge, a potential of

approximately 1.5 kV per foot can develop in the con-

ductors. Differences between conductor and ground

path lengths can add additional stress to the control

components in the event of a power surge.

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SAFETY

FOR LIFE

S280-79-10

Limits on control cable length are determined by the max-

imum distance between the control and recloser:

Mounting the Control

Mount the Form 5 recloser control in a convenient, acces-

sible location. Mounting dimensions are provided in Fig-

ure 28.

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

(VWE, VWVE27, VWVE38X, WE, WVE27, WVE38X,

and NOVA).

• For pole-mounted installation, a hole and keyway in

the control mounting bracket accommodates a 5/8”

bolt.

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

(VSA12, VSA12B, VSA16, VSA20, VSA20A, VSO12,

VSO16).

• For substation installation, brackets are available as

an accessory for mounting the control to a substation

frame.

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

* These lengths are based on standard control cables.

Consult your Cooper Power Systems representative if

longer cable lengths are required.

Female Receptacle

For Control

Cable

Vent

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

For User 120Vac

Input Connection

(Cap-Plug Installed)

110mm

(4-1/4")

120mm (4-3/4")

40mm

(1-1/2")

45mm (1-3/4") Dia. Hole

For Automation Accessory

(Cap-Plug Installed)

130mm

(5-1/8")

190mm

(7-3/8")

200mm

(7-7/8")

Mtg Hole For

15mm (5/8") Max

Bolt Dia.*

480mm

380mm

(15")

30mm (1-1/8") Hole

In Lifting Lug

(19")

240mm

(9-1/2")

* USER-PROVIDED HARDWARE

40mm (1-1/2")

160mm

(6-3/8")

76mm

(3")

685mm

Die-cast-zinc latchable

(27")

Handle For User-

Provided Utility-Grade

Padlock

Male Receptacle

For Control Cable

110mm

(4-3/8")

350mm

Grounding Terminal

30mm

(13-13/16")

One Internal and

One External

(1-1/8")

165mm

(6-1/2")

Use No. 14 To No. 4

Stranded Wire

52 kg (115 LBS)

CONTROL WEIGHT

Figure 28.

Control cabinet mounting dimensions.

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

Figure 29 illustrates grounding methods for 3-wire

ungrounded and 4-wire multi-grounded systems with local

supply voltage transformer.

Grounding the Control

WARNING: Hazardous Voltage. The recloser

Figure 30 illustrates grounding methods for 3-wire

ungrounded and 4-wire multi-grounded systems with

remote supply voltage transformer.

and control must be solidly grounded. Follow all

locally approved procedures and safety practices when

grounding this equipment. Improper grounding can

result in contact with high voltage, which will cause

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

system.

death, severe personal injury.

G115.1

For effective surge protection all control and power con-

ductors for the Form 5 must be routed parallel to a corre-

sponding ground path. For example, the AC power supply

for the control should be parallel to and equal in length to

the transformer ground path. The control cable should be

parallel to and routed close to the recloser ground path.

The control cabinet must be grounded. A grounding con-

nector on the underside of the cabinet will accommodate

No. 14 solid through No. 4 stranded conductors.

Suggested methods for grounding the control and

recloser are shown in Figures 29, 30, and 31.

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SAFETY

FOR LIFE

S280-79-10

Grounding with a Local Supply Voltage Transformer; 4-Wire Multi-Grounded,

3-Wire Ungrounded, or Impedance-Grounded

Installation of a Form 5 control with a local supply voltage

transformer must include the following:

4-Wire Multi-Grounded Systems

IMPORTANT: In pole-mounted applications, a

ground connection must be made between the

recloser, transformer, recloser control, and SCADA

equipment for proper protection of the equipment. The

pole ground must be sized per local utility practices to

minimize the impedance between the recloser and the

control.

• Protection of the recloser bushings and the supplying

transformer with lightning arresters.

• Grounding of the recloser head and tank.

• Grounding of the transformer tank.

• Grounding of the control cabinet.

• Grounding of the SCADA equipment.

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.

IMPORTANT: All external inputs to the Form 5 con-

trol must be routed within 8 inches of their correspond-

ing ground. During a surge, a potential of approximately

1.5 kV per foot can develop in the conductors. Differ-

ences between conductor and ground path lengths can

add additional stress to the control components in the

event of a power surge.

Surge

Transformer

Arrester

Surge

Supply Voltage

Arrester

Surge

Arrester

Form 5 LS Control

Input Terminal

Block

Transformer

Recloser

NEUTRAL

Head Ground

NEU

GND

External

Ground Lug

Arrester Ground

ELECTRICAL CONNECTIONS

Line to Neutral connected transformer

Supply

Voltage

Recloser

Supply Voltage

Transformer

Form 5 LS Control

Line

Voltage

Control

Cable

Pole

NEUTRAL

Pole

Ground

Form 5 LS

Control

Input Terminal

Block

External

Ground Lug

Input

Terminal

Block

ELECTRICAL CONNECTIONS

Line to Line connected transformer

Customer Ground Connection

At External Lug

Figure 29.

Recommended grounding method for the Form 5 Control installed on 4-wire multi-grounded, 3-wire

ungrounded, or impedance-grounded systems with local supply voltage transformer.

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

Grounding with a Remote Supply Voltage Transformer; 4-Wire Multi-Grounded,

3-Wire Ungrounded, or Impedance-Grounded

Installation of a Form 5 control with a remote supply volt-

age transformer must include the following:

IMPORTANT: In pole-mounted applications, a

ground connection must be made between the

recloser, transformer, recloser control, and SCADA

equipment for proper protection of the equipment. The

pole ground must be sized per local utility practices to

minimize the impedance between the recloser and the

control.

• Protection of the recloser bushings and the supplying

transformer with lightning arresters.

• Grounding of the recloser head and tank.

• Grounding of the transformer tank.

• Grounding of the control cabinet.

IMPORTANT: All external inputs to the Form 5 con-

trol must be routed within 8 inches of their correspond-

ing ground. During a surge, a potential of

approximately 1.5kV per foot can develop in the con-

ductors. Differences between conductor and ground

path lengths can add additional stress to the control

components in the event of a power surge.

• Grounding of the SCADA equipment

Low Voltage Distribution Network

Supply Voltage

Input

115 Vac

Input

Form 5 LS Control

Supply Voltage

Terminal

Block

Terminal

Block

Form 5 LS Control

Transformer

Local Isolation

Transformer

NEUTRAL

Customer

Supplied

NEUTRAL

Low Voltage

Arrester

External

Ground Lug

External

Ground Lug

ELECTRICAL CONNECTIONS - Remote dedicated

supply transformer

ELECTRICAL CONNECTIONS - using isolation transformer

Surge

Arrester

Transformer

Surge

Arrester

Surge

Arrester

Recloser

Head

Ground

HOT

NEU

GND

Arrester

Ground

Arrester

Ground

System

Neutral

Note: Distance between

transformer and

recloser should be

one pole span or

less

Recloser

Control Cable

Pole

Supply

Voltage

Form 5 LS Control

Pole

Ground

Input Terminal Block

Pole

Customer Ground Connection

at External Lug

Figure 30.

Recommended grounding method for the Form 5 Control installed on 4-wire multi-grounded, 3-wire

ungrounded, or impedance-grounded systems with remote supply voltage transformer.

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SAFETY

FOR LIFE

S280-79-10

Grounding on a 3-Wire Uni-Grounded System

Supply Voltage

Transformer

Installation of a Form 5 control on a 3-wire uni-ground sys-

tem must include the following:

Input Terminal Block

Form 5 LS Control

Line

Voltage

• Protection of the recloser bushings and the supplying

transformer with lightning arresters.

Neutral

• Grounding of the recloser head and tank.

• Grounding of the transformer tank.

• Grounding of the control cabinet.

External Ground Lug

ELECTRICAL CONNECTIONS - Dedicated Supply

Transformer

• Grounding of the SCADA equipment.

Surge

Arrester

Surge

Arrester

Surge

WARNING: Hazardous Voltage. Use locally

approved operator safety procedures for proper

Arrester

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

Recloser

Head Ground

HOT

NEU

GND

severe personal injury.

T262.0

Arrester Ground

Recloser

Supply

Voltage

CAUTION: Exported Potential. Do not make

direct electrical connections to remote devices. All

SCADA equipment must be mounted locally or con-

nected using the fiber-optic or radio communication

accessory. Direct connections to remote devices can

produce exported potential causing equipment damage

Control

Cable

Form 5 LS

Control

or personal injury.

T263.0

Input Terminal Block

CAUTION: Hazardous Voltage. Do not use a

Customer Ground

Connection

at External Lug

shared low voltage network to power the recloser

control unless the network is specifically designed to

withstand maximum ground potential rise. Ground

faults on a high voltage network can create a rise in

Pole

Ground

Control Height must be

3 Meters (10 feet)

minimum above earth

ground potential.

T264.0

IMPORTANT: In pole-mounted applications, a

ground connection must be made between the

recloser, transformer, recloser control, and SCADA

equipment for proper protection of the equipment. The

pole ground must be sized per local utility practices to

minimize the impedance between the recloser and the

control.

Figure 31.

Recommended grounding method for the Form 5

Control installed on a 3-wire uni-grounded system.

IMPORTANT: All external inputs to the Form 5 con-

trol must be routed within 8 inches of their correspond-

ing ground. During a surge, a potential of

approximately 1.5kV per foot can develop in the con-

ductors. Differences between conductor and ground

path lengths can add additional stress to the control

components in the event of a power surge.

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

Customer Connections for AC

Power

CAUTION: Equipment damage. Do not drill con-

nection holes into the top of the cabinet. Connec-

tion holes in the top of the cabinet will allow moisture to

seep into the control and damage the components or

cause control misoperation. Failure to comply will void

the control’s factory warranty.

T249.0

Input power to the Form 5 control is connected to terminal

block TB1 (located behind the operator panel, on the left

side of the control). See Figure 33.

Input power is required:

• To power the control

• To provide voltage and power metering

• For voltage detection for loop scheme accessory

• For the low voltage closing accessory

• For the convenience outlet accessory

Figure 33.

Terminal Connector Block TB1.

99003KM

Power Connections

Power Supply Verification

Customer connections to TB1 vary upon application. TB1

connections provide power and metering inputs to the

control. Figures 34 through 39 show the customer con-

nections for 120 Vac and 240 Vac low voltage closing.

Incoming power is routed to the Power Supply module

which is factory configured for either 120 or 240 volt oper-

ation. The power supply module is factory wired to TB-1

and protected by the 3.15 Amp fuse labeled F2 on the

power supply operator panel. A label on the Power Sup-

ply module indicates the proper voltage rating. See Figure

32.

Figures 34 through 37 illustrate customer connections for

single-phase transformers. Figure 34 shows standard

wiring with BØ transformer connected to TB1-2 location.

Other phases should be connected from the single-phase

transformer by wiring the BLACK wire from the Power

Supply module to the terminal of the respective phase as

shown in Figure 38 and 39. For example, Figure 39 shows

connection from the Power Supply module to an AØ

transformer.

GDC-3.15A

CONFIGURED

FOR

120

VAC

The transformer required for power should be a minimum

of 5kVA for low-voltage ac closing reclosers and 1kVA for

dc closing reclosers.

240

VAC

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

either Wye or Delta) can be powered by connecting to

TB1-2 (hot) and TB1-4 (neutral) to an appropriate power

source.

Figure 32.

Label on Power Supply module indicates factory-

configured voltage rating (120Vac).

IMPORTANT: Delta connections are not used on any

Form 5 control accessory that utilizes the low voltage

transfer relay.

Inserting and Releasing Wire

Connections

In Terminal Block TB1, each terminal has a wire locking

clamp that has to be opened to accept and secure the

wire. A 3/32 inch flat-blade screwdriver is inserted into

each terminal hole to open the locking clamp. Figure 34

provides the procedure for opening and securing the wire

connections.

Customer Connections for

Metering

Customer voltage inputs for metering are field config-

urable on the RIF module to accept 12, 120, or 240 Vac.

The incoming power supply must match the indication for

incoming power on the RIF module. The factory-config-

ured settings for the RIF are displayed on the module

panel. See Figure 19.

The wire is inserted into the terminal connection hole

while the screwdriver is placed into the wire release and

locking hole.

Follow the same procedure to release wire connections.

See RIF Module Configuration section of this manual.

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SAFETY

FOR LIFE

S280-79-10

TB1

(Top View)

To insert wire:

1. Insert 3/32 inch flat-

blade screwdriver into

Wire Release and

Locking hole.

TB1

AØ

240Vac CLOSING

OPTION

2. Carefully insert the

screwdriver along side

the locking clamp.

Y' VOLTAGE

120Vac

B' VOLTAGE

120Vac

CLOSING

VOLTAGE

3. Pull toward the center

of terminal block TB1

until the locking clamp

opens.

NEUTRAL

SOURCE 2

BØ

NEUTRAL

SOURCE 1

4. Insert wire into Terminal

Connection hole.

NEUTRAL

5. Release screwdriver.

6. Carefully pull wire to be

sure it is secure.

Note: Only slight pressure is

required to open the

ZØ

CUSTOMER

CONNECTIONS

locking clamp. Excessive

pressure can damage

the terminal block.

CØ

SOURCE 2

POWER

YØ

XØ

Wire Release

and Locking Hole

HOT (LV Closing Output)

NEU (LV Closing Output)

OUTPUT

VOLTAGE

POWER

SOURCE

OUTPUT

Terminal

TB1

NEUTRAL

Connection Hole

NEU

*NEUTRAL

CØ

BØ

AØ

CØ

CUSTOMER

CONNECTIONS

SOURCE 1

POWER

*BØ

AØ

3/32 inch

Flat-Blade

Screwdriver

Connection

Wire

*REQUIRED FOR

CONTROL OPERATION

Figure 34.

Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1

(120Vac or 240Vac Wye Connection).

TB1

AØ

240V CLOSING

OPTION

BØ

ZØ

YØ

XØ

CØ

CUSTOMER

SOURCE 2

POWER

CONNECTIONS

HOT (LV Closing Output)

OUTPUT

VOLTAGE

POWER

SOURCE

OUTPUT

VOLTAGE

CØ

BØ

AØ

*CØ

BØ

CUSTOMER

CONNECTIONS

SOURCE 1

POWER

*AØ

*REQUIRED FOR

CONTROL OPERATION

SEE POWER SUPPLY

MODULE FOR

CORRECT VOLTAGE

Figure 35.

Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1

(120Vac or 240Vac Delta Connection).

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

TB1

AØ

240V CLOSING

OPTION

BØ

CØ

ZØ

YØ

XØ

CUSTOMER

SOURCE 2

POWER

CONNECTIONS

OUTPUT

VOLTAGE

HOT (LV Closing Output)

POWER

SOURCE

OUTPUT

VOLTAGE

CØ

BØ

AØ

*CØ

BØ

CUSTOMER

CONNECTIONS

SOURCE 1

POWER

*AØ

*REQUIRED FOR

CONTROL OPERATION

SEE POWER SUPPLY

MODULE FOR

CORRECT VOLTAGE

Figure 36.

Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1

(120Vac or 240Vac Open-Delta Connection).

TB1

120Vac

HOT (240Vac LV Closing Output)†

240V CLOSING

OPTION

HOT (240Vac LV Closing Output)†

Neutral

120Vac

Y' VOLTAGE

CLOSING

VOLTAGE

120Vac

B' VOLTAGE

120Vac

NEUTRAL

SOURCE 2

NEUTRAL

SOURCE 1

NEUTRAL

ZØ

YØ

CUSTOMER

CONNECTIONS

SOURCE 2

POWER

XØ

OUTPUT

VOLTAGE

HOT (120Vac LV Closing Output)

NEU (120Vac LV Closing Output)

POWER

SOURCE

OUTPUT

VOLTAGE

*NEUTRAL

CØ

CUSTOMER

CONNECTIONS

SOURCE 1

POWER

*BØ

AØ

† For use with accessories:

3-Wire Low-Voltage Closing with receptacle

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

*REQUIRED FOR

CONTROL OPERATION

Figure 37.

Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1

(3-wire, 240Vac Connection).

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SAFETY

FOR LIFE

S280-79-10

TB1

240Vac CLOSING

OPTION

YØ VOLTAGE

120Vac

BØ VOLTAGE

120Vac

CLOSING

VOLTAGE

NEUTRAL

SOURCE 2

BØ

NEUTRAL

SOURCE 1

GDC-3.15A

CONFIGURED

FOR

NEUTRAL

120

VAC

240

ZØ

VAC

CUSTOMER

CONNECTIONS

SOURCE 2

YØ

POWER

BLK

WHT

XØ

HOT (LV Closing Output)

NEU (LV Closing Output)

OUTPUT

VOLTAGE

POWER

SOURCE

OUTPUT

NEUTRAL

NEU

*NEUTRAL

CØ

Jumper**

CUSTOMER

CONNECTIONS

SOURCE 1

*BØ

BØ

POWER

AØ

*REQUIRED FOR

CONTROL OPERATION

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

Figure 38.

Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1 (Single-

Phase Connection, Standard BØ Input).

TB1

240Vac CLOSING

OPTION

Y' VOLTAGE

120Vac

B' VOLTAGE

120Vac

CLOSING

VOLTAGE

NEUTRAL

SOURCE 2

AØ

NEUTRAL

SOURCE 1

GDC-3.15A

CONFIGURED

FOR

NEUTRAL

120

VAC

240

ZØ

VAC

CUSTOMER

CONNECTIONS

SOURCE 2

POWER

YØ

XØ

BLK

WHT

HOT (LV Closing Output)

NEU (LV Closing Output)

OUTPUT

VOLTAGE

POWER

SOURCE

OUTPUT

NEUTRAL

NEU

*NEUTRAL

CØ

Jumper**

CUSTOMER

CONNECTIONS

SOURCE 1

POWER

*BØ

AØ

*REQUIRED FOR

CONTROL OPERATION

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

Figure 39.

Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1 (Single-

Phase Connection, AØ Input).

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

Before Placing the Control and

WARNING: Hazardous voltage. Recloser and

the Recloser into Service

control must be solidly grounded. Follow all

locally approved procedures and safety practices when

grounding this equipment. Improper grounding can

result in contact with high voltage, which will cause

CAUTION: Equipment misoperation. Do not

connect this control to an energized recloser

death or severe personal injury.

G115.1

until all control settings have been properly pro-

grammed and verified. Refer to the programming

information for this control. Failure to comply can

result in control and recloser misoperation, equip-

3. Control and recloser properly grounded in accordance

with guidelines in this manual.

ment damage and personal injury.

G110.3

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

indicator is illuminated.)

5. Control battery connected and tested for proper

Prior to placing the control and recloser into service, the

following installation procedures must be properly com-

pleted and verified:

operation.

6. All control programming entered and verified by

appropriate personnel.

1. Control properly mounted for the installation.

7. Control clock set to the correct time.

2. Recloser installed according to all locally approved

standards and practices.

8. Customer connections for remote and supervisory

operation checked and completed in accordance with

proper shielding and surge protection.

9. Control cable properly connected and supported.

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SAFETY

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S280-79-10

TESTING AND TROUBLESHOOTING

CAUTION: Equipment misoperation. Do not

connect this control to an energized recloser

until all control settings have been properly pro-

grammed and verified. Refer to the programming

information for this control. Failure to comply can

result in control and recloser misoperation, equip-

CPU Module LED Indicator

ment damage and personal injury.

G110.3

IMPORTANT: The Form 5 recloser control can be

taken out of service for testing and placed back into

service without de-energizing its recloser and interrupt-

ing the system. However, during the time the control is

out of service, the recloser is inoperative.

CPU Module

(Central Processing Unit)

Testing an Installed Control

The following tests to determine initial operation of the

Form 5 control can be performed while connected to an

operating recloser. These are the only tests performed on

an installed, operating control. All other tests described in

this Testing and Troubleshooting section require the

Form 5 control to be removed from service, connected to

a bypassed recloser, or tested at a location where the

proper testing equipment is available.

99002KM

Figure 40.

Form 5 control CPU module.

of all operating parameters. Refer to Service Information

S280-76-1 Type MET Electronic Recloser Control Tester

Operator Instructions for proper setup and use of the MET

tester. Refer to Form 5 Control Default Test Procedure

section of this manual for specific tests requiring the

KMET Tester.

1. Wake-up the operator panel display by pressing the

CHANGE/LAMP TEST button on the control operator

panel.

2. Scroll through the LCD display messages as

described in the LCD Display Messages section of

these instructions. Refer to Form 5 Control operator

panel section of this manual.

IMPORTANT: The Form 5 DC NOVA control cannot

be tested with the standard Kyle MET Tester. A junc-

tion box accessory for the MET tester is available for

testing the Form 5 DC NOVA control.

Check the operational values for currents, voltages,

and other metering information.

3. Check that the LED for AC power is illuminated on the

control operator panel. This indicates the presence of

AC power.

IMPORTANT: When the control is open and current

is present, the Trip Fail detection circuit in the Form 5

control will activate when the Kyle Type MET tester

CALIBRATE switch is ON. Depress and hold the

RESET TARGET keypad on the control for 3 seconds

to reset the condition.

4. Test battery operation, using the procedures

described in the Battery Test Procedure section of

these instructions.

Check CPU Status

Check the operating status of the CPU module. Open the

cabinet door and locate the LED indicator (Figure 40).

The LED indicator on the CPU module should flash at a

rate of one flash per second for normal 60 Hz operation

(slightly faster for 50Hz).

Testing With Type MET Tester

The Kyle Type MET Electronic Recloser Control Tester

(Figure 41) is used for testing the Form 5 control.

The MET Tester is completely self-contained, includes all

necessary metering and interconnecting cables, and is

capable of performing all required checks and tests from

a simple verification of operation to a complete verification

010028KM

Figure 41.

Kyle Type MET electronic recloser control tester.

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

Electrical Closing—Motor-Operated

Reclosers

Closing the Recloser During

Testing

WARNING: Hazardous voltage. Solidly ground

WARNING: Hazardous voltage. The switchgear

all equipment. Failure to comply can result in

and high voltage transformer must be in a test

death, severe personal injury, and equipment damage.

cage or similar protective device to prevent accidental

contact with the high voltage parts. Solidly ground all

equipment. Failure to comply can result in death,

T223.2

severe personal injury, and equipment damage.

T221.3

High-voltage is not required for reclosers utilizing a motor-

operated closing mechanism energized from a 230VAC

power source. For information on energizing the recloser,

refer to the appropriate motor-operated recloser installa-

tion manual.

Electrical Closing—Solenoid-Operated

Reclosers

Line voltage is required for automatic recloser operation

during testing of reclosers equipped with a closing

solenoid (except for reclosers equipped with the low volt-

age closing accessory).

Figure 43 shows a test circuit for motor-operated and

solenoid-closing reclosers with low-voltage closing. Since

these reclosers require only a 240 Vac source for closing,

high-voltage transformer T3 and its protective cage is

eliminated. All other equipment is the same as the test

equipment shown in Figure 42.

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

44).

Sensing CTs (3)

For shop testing, the closing solenoid voltage is supplied

by back-feeding a transformer with a low-side rating equal

to the voltage rating of an available power source, and a

high-side rating equal to the voltage rating of the recloser

(Figure 45). A 75kVA transformer of the proper voltage

rating with an impedance drop of approximately 3% is sat-

isfactory. The ac source must have a comparable

impedance drop.

The closing coil requirement is approximately 200kVA

during the two-to-three cycle closing operation. The

solenoid coil operating voltage must be maintained at the

recloser bushings during the cycle interval the closing coil

is energized. This procedure is not used on reclosers

equipped with the low-voltage closing accessory.

Closing

Motor

240 Vac

Power

Supply

WARNING: Hazardous voltage. Interconnect

source leads X and Y and ground solidly to the

recloser tank (Figure 45). Do not connect lead Z to any

other phase or mechanical ground. Dangerous voltages

to ground exist on the phase connected to lead Z. Solidly

ground all equipment. Failure to comply can result in

240 Vac

To Ammeter

and Relay

to operate

cycle counter or

other timing

device

Variable

Autotransformer

240 Vac-20 A

Electronic

Control

severe personal injury and/or equipment damage.

T224.1

120 Vac

Variable

115Vac

Autotransformer

(10 Amp)

600:5

Recloser

Figure 43.

BCT ON 600:5 Tap

Suggested test circuit for motor-operated, solenoid-

closing reclosers with low-voltage closing.

Clamp-On

Ammeter

Note: This test circuit

can apply over

800 Amps to the

recloser.

Electrical Closing—NOVA Reclosers

Note: Use at least 2/0

cable between

bushings.

Type NOVA 3-phase reclosers utilize an interface circuit

located in the mechanism housing. The electronic inter-

face circuit controls the opening and closing signals to the

magnetic actuator.

Figure 42.

Alternate method of producing variable line current

(substitute for T2 and W-X circuit in Figures 43 and

45).

The Dc NOVA Recloser is tested with the dc-to-dc con-

verter and 19-pin cable connected to the dc power supply.

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SAFETY

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S280-79-10

BYPASS SWITCHES

(CLOSED)

LOAD SIDE

SOURCE SIDE

DISCONNECT SWITCHES

(OPEN)

DISCONNECT SWITCHES

(CLOSED)

Figure 44.

Closing source-side switches of a bypassed “on-line” recloser provides closing solenoid power for automatic

operation during testing.

CLOSING

VOLTAGE RATING OF

RECLOSER CLOSING

SOLENOID COIL

SENSING CTs (3)

SOLENOID

CONTACTOR

MAIN

CONTACTS (S)

240 OR

480 VAC

SOURCE

ROTARY

SOLENOID

TRIP

SOLENOID

E F

CLOSING

SOLENOID

COIL

CONTROL

CABLE RECEPTACLE

240 VAC

SOURCE

AMMETER AND RELAY TO

OPERATE CYCLE COUNTER

OR OTHER TIMING DEVICE

ELECTRONIC

CONTROL

VARIABLE

120 VAC

AUTOTRANSFORMER

240 VAC

20 AMPS

Figure 45.

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

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

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

Manual Closing—Solenoid-Operated

Reclosers

while the closing solenoid plunger is moving upward to

reset the main toggle latch.

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

WARNING: Explosion Hazard. Excessive Con-

closed again by operating the manual closing tool.

tact Arcing. Do not use the manual closing tool to

close an oil-insulated, energized recloser. Closing an

energized oil-insulated recloser with a manual closing

tool can cause excessive contact arcing, rapid build-up

of gas within the equipment, and possible explosion

that can cause death, severe personal injury, and

6. Replace the gasket and port cover on the recloser

head after testing has been completed.

equipment damage.

T203.2

If high-voltage for operating the closing solenoid is not

available, manual closing can be substituted for electrical

closing. However, not all control settings can be checked

since manual closing is not synchronized with the closing

coil control circuit in the control.

To manually close the recloser:

1. Remove the closing tool port cover and gasket from

the side of the recloser head casting.

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

into the port, engaging the pin on the closing shaft

(Figure 46).

CAUTION: Equipment damage. Do not turn the man-

ual closing tool more than one-quarter turn clockwise.

Forcing the tool beyond the mechanism stop may shear

82284KMA-F

Figure 46.

the pin on the closing shaft of the recloser.

T222.0

Using a manual closing tool to operate the recloser.

3. Close the recloser by placing the yellow operating

handle (located under the sleethood) into the up or

CLOSED position and turning the closing tool one-

quarter turn clockwise.

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SAFETY

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S280-79-10

FORM 5 CONTROL DEFAULT TEST PROCEDURE

Test Battery Circuitry

CAUTION: Equipment misoperation. Do not con-

nect this control to an energized recloser until all

IMPORTANT: The Battery Test procedure requires

large current drain. Overuse of this procedure will drain

the battery.

control settings have been properly programmed and

verified. Refer to the programming information for this

control. Failure to comply can result in control and

recloser misoperation, equipment damage, and per-

sonal injury.

G110.3

1. Press BACK button on display panel until Battery Test

Screen 31 appears.

2. Record values for all settings.

IMPORTANT: The Form 5 recloser control can be

taken out of service for testing and placed back into

service without de-energizing its recloser and interrupt-

ing the system. However, during the time the control is

out of service, the recloser is inoperative.

3. Press CHANGE button on the display panel.

4. Press BATTERY TEST button on display panel.

5. Record values for all readings.

Test Phase Minimum Trip Values

1. Verify Ground Trip Block LED is on.

IMPORTANT: The Form 5 DC NOVA control can not

be tested with the standard Kyle MET Tester. A junction

box accessory for the MET tester is availble for testing

the Form 5 DC NOVA control.

2. Set KMET Phase Selector S5 to A.

3. Set KMET switch S4 to 300 milliampere range.

4. Set KMET Variac TR1 to zero.

Use this procedure to test the Form 5 control with factory

default control settings. Follow all cautions and warnings

in these service instructions.

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

6. Press the TRIP button on the display panel.

7. Press the CLOSE button on the display panel.

Before installation on an active feeder, the Form 5 con-

trol’s final control settings must be fully tested using an

appropriate test procedure. The Form 5 Control Default

Test Sheet follows these instructions. The Form 5 Control

Default Test Sheet Optimal Values gives the optimal val-

ues for the test results.

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

on display panel. Control should trip out quickly for

load currents above 105 milliamperes. Record value.

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

When performing these tests, change the Form 5 panel

settings by first pressing the CHANGE button and then

pressing the button of the function to be changed.

S5 to B, then C).

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

nate Profile 1.

Initial Settings

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

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

display panel.

tral for standard controls.

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

and 3. The control is programmed to trip out at 200

milliamperes on the Alternate 1, 2, and 3 Profiles.

2. Plug in battery.

3. Verify control is programmed for all default settings.

• Phase Minimum Trip is set to 100 amps.

• Ground Minimum Trip is set to 50 amps.

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

time delayed Time Current Curve with two trips to lock-

out for 30 seconds after closing in the control, per the

default Cold Load Pickup control settings.

4. Disable Sequence Coordination in normal profile

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

dination function enabled while testing the Form 5 con-

trol minimum trip values, it may result in the control

skipping past the fast TCC curves during the test for

minimum trip. The control will then lock out on the

delayed TCC curves.

using personal computer (PC).

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

on Form 5 display panel.

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

5 display panel.

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

file 3, the control will indicate current Above Minimum

Trip, but will not trip out.

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

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

Test Ground Minimum Trip Values

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

the Normal Profile (all three Profile LEDs are off). Dis-

able Ground Trip Block (LED off).

current position. Record timings from the KMET test

set for all trips on the B 5X ___ locations on the test

sheet.

17. Set KMET Phase Selector S5 to phase C.

2. Set KMET switch S4 to 100 milliampere range.

3. Set KMET Variac TR1 to zero.

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

(1000 milliamperes).

4. Set KMET switch S2 to test fault position.

19. Press the TRIP button on the display panel.

20. Press the CLOSE button on the display panel.

5. Verify the Form 5 phase minimum trip values are

higher than the ground trip values.

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

current position. Record timings from the KMET test

set for all trips on the C 10X ___ locations on the test

sheet.

6. Set KMET Phase Selector S5 to A.

7. Press the TRIP button on the display panel.

8. Press the CLOSE button on the display panel.

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

Note that the Phase minimum trip for the Alternate

Profiles is 200 amps. The 200% fault will then be 400

milliamperes or .4 amp, the 500% fault will then be

1000 milliamperes or 1 amp, and the 1000% fault will

then be 2000 milliamperes or 2 amps.

9. Slowly raise TR1 until Above Minimum Trip shows on

Form 5 control. Control should trip out for load cur-

rents above 50 milliamperes. Record values.

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

2, and 3. The control is programmed to trip out at 100

milliamperes on the Alternate 1, 2, and 3 Profiles.

Test Ground Timing

1. Verify control is programmed for all default settings.

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

trip on a time delayed TCC with two trips to lockout for

30 seconds after closing in the control, per the default

Cold Load Pickup control settings.

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

Trip is active.

Test Phase Timing

3. Activate the Normal Profile (Alternate Profile LEDs

off).

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

Profile LEDs off).

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

test set applies a phase to ground fault to the Form 5

control. If the applied fault current exceeds the phase

minimum trip value, the control may time out on the

phase time current curve, which may be shorter than the

proper ground time current curve. For this reason, the

Form 5 phase minimum trip value should be increased

to a higher value while testing Form 5 ground trip time

current curves.

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

Trip is blocked.

3. Set KMET Phase Selector S5 to phase A.

4. Set KMET switch S4 to 300 milliampere range.

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

5 control.

4. Increase the Form 5 phase minimum trip value to

6. Set KMET phase selector S3 to Control Response.

1600 amperes.

7. While holding the KMET Test Fault Current Switch S2

in the Calibrate position, adjust the fault current to 200

percent fault (100 X 2 or 200 milliamperes).

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

position.

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

brate position, adjust the fault current to 200 percent

fault (50 X 2 or 60 milliamperes).

Note: On newer controls, applying fault current while the

control is locked out will set the Recloser Malfunction

LED. This will not affect testing. To clear, press the

Reset Targets button after all tests are complete.

7. Press the TRIP button on the display panel.

8. Press the CLOSE button on the display panel.

8. Press the TRIP button on the display panel.

9. Press the CLOSE button on the display panel.

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

fault current position. Record timings from the KMET

test set for all trips on the G 2X ___ locations on the

test sheet.

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

tion. Record timing readings from the KMET time

clock for all trips on the A 2X___ test sheet location.

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

12. Set KMET Phase Selector S5 to phase B.

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

or 250 milliamperes).

11. Press the TRIP button on the display panel.

12. Press the CLOSE button on the display panel.

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

or 500 milliamperes) using the KMET 1A range.

14. Press the TRIP button on the display panel.

15. Press the CLOSE button on the display panel.

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SAFETY

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S280-79-10

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

fault current position. Record timings from the KMET

test set for all trips on the G 5X ___ locations on the

test sheet.

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

cate open and lockout. Record timing value.

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

7. Repeat steps 2 – 4. Record value.

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

Test Fast Trips Disabled

1. Activate FAST TRIPS DISABLED (LED on).

2. CLOSE the Form 5 control.

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

or 500 milliamperes).

16. Press the TRIP button on the display panel.

17. Press the CLOSE button on the display panel.

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

liamperes.

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

fault current position. Record timings from the KMET

test set for all trips on the G 10X ___ locations on the

test sheet.

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

position.

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

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

Note that the ground minimum trip for the Alternate

Profiles is 100 amps. The 200% fault will then be 200

milliamperes, the 500% fault will then be 500 mil-

liamperes, and the 1000% fault will then be 1000 mil-

liamperes or 1 amps.

TCCs, then indicate OPEN and lockout. Record value.

6. Deactivate Fast Trips Disabled (LED off).

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

slow TCCs. Record values.

Test Hot Line Tag

1. CLOSE the Form 5 control.

20. Return the Normal Profile Phase Minimum Trip Value

to the pretest value, 100 amps.

2. Activate HOT LINE TAG (LED on).

Test Non-Reclose

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

1. Activate NON-RECLOSING (LED on).

2. Activate GROUND TRIP BLOCK (LED on).

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

liamperes.

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

position.

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

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

file LEDs off).

then indicate open and lockout. Record value.

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

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

7. Deactivate HOT LINE TAG (LED off).

liamperes.

6. Press the TRIP button on the display panel.

7. Press the CLOSE button on the display panel.

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

Test Reclose

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

position.

1. Set KMET selector switch S3 to Control Reclose

Reset.

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

out. Record time value.

2. Reset the KMET Time Clock if required.

10. Disable NON-RECLOSE (LED off).

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

liamperes.

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

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

Test Cold Load Pickup Blocked

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

2. CLOSE the Form 5 control.

position.

5. After trip, turn fault switch S2 off.

6. Record reclose time.

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

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

liamperes.

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

Current Switch S2 to fault position.

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

Test Close Circuit Disable Fuse

This test is only applicable to Form 5 LS controls and stan-

dard Form 5 controls below Serial Number 3000.

Verify Instantaneous Demand

Metering

1. Enable GROUND TRIP BLOCK (LED on).

1. Set KMET Fault Switch S2 to OFF.

2. CLOSE the Form 5 control.

2. Set KMET switch S2 to OFF.

3. Set KMET Phase Selector S5 to A.

4. Set KMET Variac to zero.

3. Remove Close Circuit Disable fuse.

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

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

6. CLOSE Form 5 control.

liamperes.

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

7. Set KMET switch S2 to ON.

position. The control will trip once.

8. Set KMET Variac to read 80 milliamperes.

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

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

7. Replace Close Circuit Disable fuse.

10. Verify Instantaneous metering on Phase A and

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

Ground reads 80 milliamperes.

11. Set KMET Phase Selector S5 to B.

12. Verify Instantaneous metering on Phase B and

Ground reads 80 milliamperes.

13. Set KMET Phase Selector S5 to C.

14. Verify Instantaneous metering on Phase C and

Ground reads 80 milliamperes.

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SAFETY

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S280-79-10

Form 5 Control Default Test Optimal Values

Volts

28.0

2.6 Volts

2.6 MA

28.0

550

Battery Circuitry

Volts

27.0

2.6 volts

24.2

Normal Profile

Phase A Amps Phase B Amps

100.5 100.3

Phase A Amps Phase B Amps

200.9 200.2

Phase A Amps Phase B Amps

200.9 200.2

Phase A Amps Phase B Amps

Phase C Amps

100.7

Phase

Profile #1

Profile #2

Profile #3

Phase C Amps

200.5

Minimum Trip

Phase C Amps

200.5

Phase C Amps

200.5

200.9

200.2

50.1

Normal

Ground Amps

Ground

Minimum Trip

Profile #1

Profile #2

Profile #3

100.3

Trip to Lockout Sequence

1st

2nd

3rd

1.416

0.278

0.088

1.443

0.273

4th

Phase Timing

Normal

Phase A 2X

0.161 0.164

0.018 0.017

0.016 0.014

0.153 0.154

0.015 0.014

1.421

0.280

0.086

1.441

0.275

0.087

1.441

0.275

0.087

1.441

0.275

0.087

Phase B 5X

Phase C 10X

Phase A 2X

Phase B 5X

Phase C 10X

Phase A 2X

Phase B 5X

Phase C 10X

Phase A 2X

Phase B 5X

Phase C 10X

Profile #1

Profile #2

Profile #3

0.011

0.009 0.087

0.153 0.154

0.015 0.014

1.443

0.273

0.011

0.009 0.087

0.153 0.154

0.015 0.014

1.443

0.273

0.011

0.009 0.087

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

Form 5 Control Default Test Optimal Values

Trip Sequence

Normal

1st

2nd

3rd

4th

Ground Timing

Ground 2X

Ground 5X

Ground 10X

Ground 2X

Ground 5X

Ground 10X

Ground 2X

Ground 5X

Ground 10X

Ground 2X

Ground 5X

Ground 10X

Phase 2X

0.214

0.212 3.894

3.896

1.099

0.012 0.016 1.097

0.008 0.014

0.652 0.653

0.212 3.894 3.896

Profile #1

Profile #2

Profile #3

0.214

0.012 0.016 0.952* 0.954*

0.008 0.014 0.280* 0.276*

0.214

0.212 3.984

3.896

0.012 0.016 0.952* 0.954*

0.008 0.014 0.280* 0.276*

0.214

0.212 3.894

3.896

0.012 0.016 0.952* 0.954*

0.008 0.014 0.280* 0.276*

0.153 lockout lockout lockout

Enabled

Disabled

Block Off

Block On

Enabled

Non-Reclose

8. Cold Load

PickUp Blocked

9. Fast Trips

Phase 2X

0.152 0.153

1.420 1.433 lockout lockout

0.158 0.154 1.420 1.433

1.419 1.422 lockout lockout

0.155 0.156 1.418 1.424

0.014 lockout lockout lockout

1.420 1.433

Phase 2X

Disabled

No Reclose

Enabled

10.

Hot Line Tag

11.

0.155

0.156 1.148 1.424

2nd 3rd 4th

1.975 1.974 4.968 lockout

Reclose Sequence

Reclose Times

1st

Test Reclose

12.

Fuse Out

Can’t Close?

Yes

XXX

Close Circuit

Disable Fuse

Fuse In

Can Close?

Yes

XXX

13. Instantaneous

Demand Metering

Phase A

Phase B

Phase C

Amps 80

Amps 81

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

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SAFETY

FOR LIFE

S280-79-10

Form 5 Control Default Test Sheet

Date:

Serial No:

Volts

2.6 Volts

2.6 MA

Battery Circuitry

Volts

2.6 volts

Normal Profile

Phase A Amps Phase B Amps

Phase C Amps

Phase

Profile #1

Profile #2

Profile #3

Minimum Trip

Normal

Ground Amps

Ground

Minimum Trip

Profile #1

Profile #2

Profile #3

Trip to Lockout Sequence

1st

2nd

3rd

4th

Phase Timing

Normal

Phase A 2X

Phase B 5X

Phase C 10X

Profile #1

Phase A 2X

Phase B 5X

Phase C 10X

Phase A 2X

Phase B 5X

Phase C 10X

Phase A 2X

Phase B 5X

Phase C 10X

Profile #2

Profile #3

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

Form 5 Control Default Test Sheet

Trip Sequence

Normal

1st

2nd

3rd

4th

Ground Timing

Ground 2X

Ground 5X

Ground 10X

Profile #1

Ground 2X

Ground 5X

Ground 10X

Ground 2X

Ground 5X

Ground 10X

Ground 2X

Ground 5X

Ground 10X

Phase 2X

Profile #2

Profile #3

Enabled

Disabled

Block Off

Block On

Enabled

lockout lockout lockout

lockout lockout

Non-Reclose

8. Cold Load

PickUp Blocked

9. Fast Trips

Phase 2X

lockout lockout

Disabled

No Reclose

Enabled

10.

Hot Line Tag

11.

Reclose Sequence

Reclose Times

1st

Yes

2nd

3rd

4th

Test Reclose

12.

Fuse Out

Can’t Close?

Close Circuit

Disable Fuse

Fuse In

Can Close?

13.Instantaneous

Demand Metering

Phase A

Amps

Phase B

Amps

Phase C

Amps

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SAFETY

FOR LIFE

S280-79-10

REMOVE THE CONTROL

FROM SERVICE

RETURN THE CONTROL TO

SERVICE

IMPORTANT: Disconnect switches for ac sensing

and power connections are necessary to isolate the

Form 5 Recloser Control for testing and servicing.

CAUTION: Equipment misoperation. Do not

connect this control to an energized recloser

until all control settings have been properly pro-

grammed and verified. Refer to the programming

information for this control. Failure to comply can

result in control and recloser misoperation, equip-

1. Enable GND TRIP BLOCKED to allow for ground trip

to be disabled when re-energized.

ment damage, and personal injury.

G110.3

A. Press the CHANGE/LAMP TEST key on the Oper-

ator Panel to enter the CHANGE mode.

Note: The LCD Display Screen will indicate the amount

of time available in CHANGE mode to make a

change.

After the required work is completed, disconnect the con-

trol from the test set and follow this procedure to return the

control to service:

B. Depress the GND TRIP BLOCKED key.

1. Plug in the control battery.

Note: After the GND TRIP BLOCKED key is

depressed, the red LED indicator will illuminate

to indicate GROUND TRIP BLOCKED is active.

2. Apply ac power to the control.

3. Verify that all control settings are correct.

4. Reconnect the control cable to the control.

5. Disable GND TRIP BLOCKED.

WARNING: Hazardous voltage. If the recloser

is energized while the control cable is discon-

nected, the CT secondaries can generate high volt-

ages. Contact with high voltage can cause severe

A. Press the CHANGE/LAMP TEST key on the Oper-

ator Panel to enter the CHANGE mode.

personal injury or death.

T204.2

Note: The LCD Display Screen will indicate the amount

of time available in CHANGE mode to make a

change.

2. Disconnect control cable from the control.

3. De-energize ac power from the control.

4. Unplug the control battery.

B. Depress the GND TRIP BLOCKED key.

Note: After the GND TRIP BLOCKED key is

depressed, the red LED indicator will not be illu-

minated indicating GROUND TRIP BLOCKED is

not active.

6. Reset the control clock after AC power has been re-

applied. Refer to Setting the Control Clock in Service

Information S280-79-2 Form 5 Microprocessor-Based

Recloser Control Programming Guide.

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

ADDITIONAL INFORMATION

Factory Maintenance Classes

CAUTION: This equipment requires routine

inspection and maintenance to ensure proper

The factory service department offers a basic testing and

troubleshooting course for the Form 5 Microprocessor-

Based Electronic Recloser Control and Reclosers. This

course, taught by experienced service technicians, is

held at the factory‘s in-house training facility. For addi-

tional information, contact your Cooper Power Systems

representative.

operation. If it is not maintained, it can fail to operate

properly. Improper operation can cause equipment

damage and possible personal injury.

G105.1

Replacement Kits

Replacement kits for the Kyle Form 5 Control are avail-

able through the factory Service Department. To order

these kits, refer to the Replacement Parts price list for cat-

alog numbers and pricing. Contact your Cooper Power

Systems representative for additional information and

ordering procedures.

Type MET Recloser Control Tester

A 30-minute video cassette program, KSPV7 Kyle Type

MET Electronic Recloser Control Tester Operation and

Testing Procedures is available as a supplemental train-

ing aid for service personnel.

Factory-Authorized Service

Centers

Factory-authorized service centers are located through-

out the continental United States to provide maintenance,

repair and testing services for Kyle controls and reclosers.

For further information, contact your Cooper Power Sys-

tems representative.

SAFETY

FOR LIFE

KA2048-476 Rev: 02

1045 Hickory Street

Pewaukee, WI 53072

www.cooperpower.com

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

KDL

5/05

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