Reclosers

Form 6 Triple-Single/LS Microprocessor-Based Service Information

Pole Mount Recloser Control
Installation and Operation Instructions S280-70-8

030030KM
Figure 1.
Kyle® Form 6 Triple-Single/LS microprocessor-based pole mount recloser control.

Contents
Safety Information ..................................................... 2 Mounting the Control ..............................................20
Product Information .................................................. 3 Grounding the Control ............................................21
Introduction ............................................................ 3 Customer Connections for AC Power ....................24
ANSI Standards ..................................................... 3 Before Placing Control and Recloser into Service ...33
Quality Standards ................................................... 3 Using Removable Inserts .......................................34
Acceptance and Initial Inspection .......................... 3 Accessories ...............................................................35
Handling and Storage ............................................ 3 Loop Sectionalizing Accessories ............................35
Control Power ........................................................ 3 Cable Locking Sleeves ..........................................35
Battery Replacement and Disposal ........................ 4 Cabinet Ordering Accessories ...............................35
Operation Upon Loss of AC Power ........................ 4 120 Vac GFI Duplex Outlet ....................................35
Form 6 Triple-Single/LS Control Description .......... 5 Discrete Interface Board Accessory .......................35
Description ............................................................. 5 Radio Mounting Accessory ....................................36
Theory of Operation ............................................... 6 Communication Board Accessories .......................37
Control Front Panel ................................................ 7 Testing ........................................................................39
Control Features ....................................................14 Testing an Installed Control ....................................39
Communications ....................................................17 Remove the Control from Service ..........................40
Control Information .................................................17 Electrical Testing of NOVA-TS Reclosers ..............40
Control Back Panel ................................................17 Battery Test and Charging Procedures ..................41
Installation Procedure ..............................................18 Return the Control to Service ................................43
Initial Programming Prior to Installation .................18 Additional Information ..............................................44
Control / Recloser Compatibility .............................18 Replacement Kits ...................................................44
Duty Cycle Monitor .................................................18 Factory-Authorized Service Centers ......................44
Control Cable .........................................................19 Factory Maintenance Classes ................................44
Junction Box and Cables .......................................19

December 2004 • New Issue 1

Printed in USA
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

!
SAFETY
!
SAFETY
FOR LIFE
SAFETY FOR LIFE FOR LIFE

Cooper Power Systems products meet or exceed all applicable industry standards relating to product safety. We actively
promote safe practices in the use and maintenance of our products through our service literature, instructional training
programs, and the continuous efforts of all Cooper Power Systems employees involved in product design, manufacture,
marketing, and service.
We strongly urge that you always follow all locally approved safety procedures and safety instructions when working
around high voltage lines and equipment and support our “Safety For Life” mission.

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

• Is trained in the care and use of protective equipment

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

Hazard Statement Definitions

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

WARNING: Indicates a potentially hazardous

! situation which, if not avoided, could result in
WARNING: Power distribution equipment must
death or serious injury.
! be properly selected for the intended application.
It must be installed and serviced by competent person-
CAUTION: Indicates a potentially hazardous
! situation which, if not avoided, may result in
nel who have been trained and understand proper
safety procedures. These instructions are written for
minor or moderate injury. such personnel and are not a substitute for adequate
training and experience in safety procedures. Failure to
CAUTION: Indicates a potentially hazardous situ- properly select, install, or maintain power distribution
ation which, if not avoided, may result in equip- equipment can result in death, severe personal injury,
ment damage only. and equipment damage. G122.2

2
 !
SAFETY
FOR LIFE
S280-70-8

PRODUCT INFORMATION
Introduction Note: To energize the control, apply ac power to the ac sup-
ply input terminal block located in the lower right hand
Service Information S280-70-8 provides installation and corner of the back panel of the control. Refer to the
operation instructions for the Kyle® Form 6 Triple- Customer Connections for AC Power section in this
Single/LS pole mount recloser control. manual.
Refer to Service Information S280-70-9 Form 6-TS Control Battery Storage and Charging
Microprocessor-Based Recloser Control Programming
Guide for additional information. The 24 Vdc control battery in the Form 6 recloser control
is fully charged prior to shipment and is ready for use.
The Form 6 Triple-Single pole mount control with loop
scheme accessory is designed for use with three Kyle® IMPORTANT: To maintain sufficient charge to oper-
NOVA-TS Triple-Single reclosers. Refer to Service ate the control and prevent battery cell damage, the
Information S280-42-2 NOVA-TS Recloser Installation sealed lead-acid batteries should be charged after no
and Operation Instructions. more than three months of storage.
Read This Manual First
Temperature has an effect on battery life. Sealed lead
Read and understand the contents of this manual and fol- acid batteries should be stored, fully charged, at room
low all locally approved procedures and safety practices temperature. Never store lead acid batteries at tempera-
before installing or operating this equipment. tures exceeding 47°C (117°F), as damage can result in
Additional Information approximately one month.

These instructions cannot cover all details or variations in To keep the battery charged, energize the control’s built-
the equipment, procedures, or process described, nor in charger with ac power applied to the user ac supply
provide directions for meeting every possible contingency input connector block TB1. See Customer Connections
during installation, operation, or maintenance. When addi- for AC Power. In addition, if power to the control is not
tional information is desired to satisfy a problem not cov- possible a separate portable charger accessory is avail-
ered sufficiently for the user's purpose, contact your able. Catalog Number KA43ME7001 provides a 120 Volt
Cooper Power Systems sales representative. battery charger to power individual batteries.
Note: When shipped from the factory, the battery source is
ANSI Standards disconnected and its output plugs are taped to the cab-
inet. Connect the battery plugs into the mating connec-
Kyle® reclosers are designed and tested in accordance tors to complete the battery circuit.
with the following ANSI standards: C37.60 and C37.85
and ANSI Guide C37.61.
IMPORTANT: Connect the control battery before ac
power is connected to the control’s ac supply Input
Quality Standards Terminal Block. The battery must be disconnected
ISO 9001:2000-Certified Quality Management System prior to shipping or storing the control.

Acceptance and Initial

Inspection Control Power
Each Form 6 recloser control is completely assembled, CAUTION: Equipment misoperation. Verify that
tested, and inspected at the factory. It is carefully cali- ! the 120/240 Vac selector switch is correctly set
brated, adjusted and in good condition when accepted by for incoming voltage. Failure to comply may cause
the carrier for shipment. misoperation (unintentional operation) of the control
Upon receipt, inspect the carton for signs of damage. and/or equipment damage resulting in personal injury.
Unpack the control and inspect it thoroughly for damage T278.0

incurred during shipment. If damage is discovered, file a

claim with the carrier immediately.
CAUTION: Equipment damage Form 6 LS (Loop
Scheme). Do not connect 240 Vac to B or Y phases on
Handling and Storage terminal blocks TB7 or TB8. 240 Volts will damage
Be careful during handling and storage of the control to min- internal components and cause control misoperation.
imize the possibility of damage. If the control is to be stored T314.0

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

dry storage area. If storage is in a humid atmosphere, make The Form 6-TS/LS control is powered from 120 Vac. The
provisions to keep the control circuitry energized. selector switch on the power supply board must be set to
the 115V position.

3
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

Battery Replacement and Phase B (Ø) is the factory default phase. Unless changed
by the user, the B PHASE VOLTAGE red LED illuminates
Disposal indicating ac is the operating power. If BØ (or the user-
The 24 Vdc control battery has a life expectancy of four indicated phase) loses ac power for more than ten sec-
to six years. It is recommended that the battery be onds, the ALARM red indicator LED will illuminate. The
replaced after four years. ALARM log on the LCD Display will indicate NO AC PRE-
Dispose expired batteries in an environmentally respon- SENT and the CONTROL OK LED will not be illuminated.
sible manner. Consult local regulations for proper battery
disposal. IMPORTANT: If the the control shuts down due to
low battery voltage before ac power is restored, and
the connected energized recloser is CLOSED; it will
Operation Upon Loss of AC only TRIP and LOCKOUT via front panel pushbutton
Power command.
The control is equipped with a 13 Amp-Hour 24 Vdc lead A control that has shut down due to low battery volt-
acid battery for operation upon loss of ac power. The con- age before ac power is restored will have a blank LCD
trol maintains full operation from the battery for a period display (no text message shown).
of time — 25 hour maximum (20°C)
In the event that the ac power has not returned within the
times listed above, the control will disconnect the battery The control clock may require resetting if the operating
from the circuit. power has been disconnected for more than thirty days.
Refer to Service Information S280-70-9 Form 6-TS
Note: The control continuously monitors the battery voltage. Microprocessor-Based Recloser Control Programming
To prevent battery damage, the control shuts down Guide for information on setting the control clock.
automatically upon detection of low battery voltage
(below 22 Vdc) for 60 seconds.
Control programming settings and parameters—includ-
ing event recorder—are stored in non-volatile memory
and retained upon loss of control power. The time/date
clock will continue to operate for approximately 30 days
after loss of control power.

4
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SAFETY
FOR LIFE
S280-70-8

FORM 6 TRIPLE-SINGLE/LS CONTROL DESCRIPTION

Description
The Kyle® Form 6 Triple-Single/LS (Form 6-TS/LS) control
is designed for use with three Kyle® NOVA-TS Triple-
Single reclosers to provide protection, metering, and
automation of distribution feeders in substation and line
applications.
The Form 6-TS/LS control operates three single-phase
NOVA-TS reclosers representing phases A, B, and C.
Note: Phase A, B, and C sequence positions are independent
of each other.
The Form 6-TS/LS control uses three modes of opera-
tion. All modes are configured through the ProViewTM user
interface software. Figure 2. 030002KM

Three-phase trip, Three-phase lockout (ganged) Form 6 Triple-Single/LS recloser control is accessi-
Single-phase trip, Three-phase lockout ble from both the front and back of the cabinet.
Single-phase trip, Single-phase lockout
The control is for application in distribution feeder loop
The Form 6-TS/LS recloser control includes extensive sectionalizing schemes. The control senses the loss of
system protection functionality, including phase, ground, voltage, and after a predetermined time delay, performs
and negative sequence overcurrent protection, the programmed action to restore service to the affected
over/under frequency, and voltage protection, directional- feeder.
ity, sensitive ground fault, and sync check.
The Loop Scheme (LS) functionality will always result in
Analysis tools include fault locating, event recording, three-phase operation independent of the selected mode
TCC EditorTM II, Idea WorkbenchTM, and oscillography of operation. For example, if single-phase trip, single-
functions, including oscillography replay. phase lockout is the selected mode of operation, and
Metering functions include demand and instantaneous Loop-Scheme is enabled, a loss of voltage sensing will
current on a per-phase basis, instantaneous voltage and cause all three phases to open, close, or change profiles
power factor on a per-phase basis, and power (real, reac- (based on the LS settings configuration).
tive, apparent) on a per phase or total basis. Symmetrical The control can be programmed for either the sectional-
components for both voltage and current are displayed izing or tie mode of operation. The sectionalizing mode
along with kilowatt-hours for energy metering. Harmonics senses voltage on the source side of a normally closed
from the 2nd to the 15th harmonic are also included. recloser and is activated upon loss of source-side volt-
The front panel LCD display is used to configure the age. The tie mode of operation senses voltage on both
operating settings for the control. It is also used to display sides of a normally open recloser and is activated upon
metering, counter information, control parameters, loss of voltage on either side. The tie mode is used for
alarms, and provide diagnostic information. both one-way and two-way tie applications.
Control parameters can also be programmed via a per-
sonal computer connected to the control through the front
panel RS-232 port. Control programming, interrogation,
and operations are performed with Form 6 ProViewTM
interface software on a personal computer.
The ProViewTM interface program software includes addi-
tional functions used to create and graphically display
Time Current Curves and provides the Idea WorkbenchTM
for configuring user-selected inputs and outputs, config-
urable event and alarm data, and selectable communica-
tion points for serial communication.
The control operates on 50 and 60 Hz systems.
The control can be configured, by the factory or by the
user, for a wide variety of applications. If user require-
ments change, the control functions can be modified to
meet the new requirements.
The control is accessible from both the front and back of
the cabinet (Figure 2).

5
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

Theory of Operation Phase Operation

A functional block diagram of the Form 6-TS/LS control is In Three-Phase Trip, Three-Phase Lockout (ganged)
shown in Figure 3. Current sensing is provided by three mode, all three phases simultaneously trip and close.
current transformers located in the recloser and inter- In Single-Phase Trip, Three-Phase Lockout and Single-
faced to the control via a junction box and control cable. Phase Trip, Single-Phase Lockout modes, each phase
This cable also supplies Trip, Close, and Recloser status, operates independently with protection parameters the
and connects to the Recloser Interface (RIF) module to same for all three phases.
provide isolation for reliable operation. Voltages for
metering are connected to the analog input module In Single-Phase Trip, Three-Phase Lockout mode, all
through terminal block TB8. three phases trip to lockout when one phase sequences
to lockout.
Line current flowing through the recloser is converted by
the CPU module to a digital signal suitable for metering In Single-Phase Trip, Single-Phase Lockout mode, each
and fault current calculations. Data sampling occurs at a phase independently sequences to lockout.
rate of 64 times per cycle. The CPU contains a data
acquisition section that uses the acquired samples to Ground Operation
compute the fundamental currents and voltage for use in In Three-Phase Trip, Three-Phase Lockout (ganged)
overcurrent, under/overvoltage, and under/overfrequen- mode, all three phases trip and close together.
cy protection, as well as currents and voltages for meter-
In Single-Phase Trip, Three-Phase Lockout and Single-
ing functions. The current for overcurrent protection is
Phase Trip, Single-Phase Lockout modes, ground trip-
calculated on a sub-cycle basis; it includes only the fun-
ping is active when all three phases are closed. Ground
damental and DC component.
trip is disabled during the reclose interval of any one
When the phase or ground current exceeds its pro- phase.
grammed minimum-trip value and associated time-cur-
For faults above the ground minimum trip value, and
rent-curve (TCC) timing, the control initiates the pro-
below the phase minimum trip value, all three phases trip
grammed sequence of recloser tripping and reclosing
on ground and advance to the next sequence position.
operations via the CPU and RIF modules. If the fault is
temporary, the control ceases to command recloser oper- For faults above the phase and ground minimum trip
ations after a successful reclose, and the control resets value, the control trips on the phase(s) above phase min-
to the start of its operating sequence after a preset time imum trip, operating on the phase or ground TCC,
delay. If the fault is permanent, the control performs its whichever is faster. Only tripped phases advance in
complete programmed sequence of reclose commands sequence and are counted as phase operations.
and locks out with the recloser open. Once locked out,
the control must be closed via the operator panel or Phase/Ground Sequencing
SCADA communications. This resets the control to the Phase and ground share the same sequence position. As
start of the operating sequence. the position sequence advances, the phase and ground
TCCs advance together to maintain proper coordination
with upline and downline devices. This is applicable for
temporary and permanent faults including faults on mul-
tiple phases.
FORM 6 TRIPLE-SINGLE/LS CONTROL

NOVA
26 PIN 120/VAC
TRIPLE/SINGLE
CONNECTOR TB7 OUTLET
RECLOSERS
TERMINAL DUPLEX
RS-232
AØ DC/DC POWER BLOCK ACCESSORY
24 VDC IRIG-B
CONVERTER BATTERY
ACTUATOR JUNCTION
BOX COMMUNICATIONS TRANSFER
SWITCHES RELAY
BOARD
CT RIF •RS-485
•FIBER-OPTIC
INTERCON- CPU •ETHERNET
BØ NECTION
OPTICAL TB8
BOARD 3 inputs
ACTUATOR ISOLATION TERMINAL SOURCE I INPUT
USER
CONNECTIONS BLOCK VOLTAGE
SWITCHES 5 outputs SENSING SOURCE II 120 VAC
VOLTAGE
CT INPUTS
MATCHING I/O 8 inputs
TRANSFORMERS USER
CONNECTIONS
CØ AND SIGNAL
8 outputs
CONDITIONING
ACTUATOR
FRONT
SWITCHES ANALOG INPUT PANEL
CT RS-232
(PROVIEW
PROTOCOL
ONLY)

Figure 3.
Form 6 Triple-Single/LS recloser control operational flow diagram.

6
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SAFETY
FOR LIFE
S280-70-8

Control Front Panel Front Panel Text Messaging

The Form 6-TS/LS control front panel is illustrated in The LCD messages are accessed from the front panel by
Figure 4. following the Text Messages menu path. This menu dis-
plays any active user-configured text messages.
The front panel is separated into two clearly identified,
color-coded sections: Up to fourteen user-configurable text messages can be
programmed via the Idea Workbench. Refer to Service
• The top portion of the front panel is used for program- Information S280-70-9 Form 6-TS Control Programming
ming the control and providing LED status indication. Guide for information on programming the text messages.
• The lower portion of the front operating panel is used These text messages appear on the front panel LCD
for operating the control and recloser. and can be programmed to appear for alarm or other
The control includes a Power Save feature that will turn conditions.
off the backlit LCD display and all LEDs (except Hot Line Text messages displayed on the front panel are limited to
Tag) if no front panel keypad is pressed within ten min- four lines of 20 characters each (including spaces). Text
utes. Pressing the LAMP TEST key will re-activate the messages can also be accessed by pressing the LAMP
display and LEDs. TEST one-touch analysis key on the front panel.
Note: The Power Save feature is a ProView interface soft-
ware default setting. This feature can be disabled via The default text message displays the mode of the triple-
the ProView interface software. single configuration and the status of each phase.
The control includes a Reset Menu feature that will cause
the LCD display to revert to the Recloser Status menu
after ten minutes of inactivity.
Note: The ten minute timer and MMI Reset Menu is a
ProView interface software default setting. The menu
selection and timer can be changed via the ProView
interface software.

CONTROL OK A PHASE FAULT ALARM A PHASE VOLTAGE X PHASE VOLTAGE

CONTROL POWER B PHASE FAULT ABOVE MIN TRIP B PHASE VOLTAGE Y PHASE VOLTAGE
LED Indicators CONTROL LOCKOUT C PHASE FAULT TIE C PHASE VOLTAGE Z PHASE VOLTAGE
RECLOSER OPEN GROUND FAULT SECTIONALIZER FREQUENCY TRIP INDICATOR 7
RECLOSER CLOSED SENSITIVE GND LS DISABLED VOLTAGE TRIP INDICATOR 8
LCD Display
LCD Menu Function Keys
METERING SETTINGS

RESET OPER
TARGETS COUNTER

One-Touch F1 F2 F3 F4 One-Touch
Analysis Keys EVENTS ALARMS Analysis Keys

LAMP TEST
MENU + CHANGE

Cursor Movement Arrows

LCD Display
ENTER — LCD Display
Dedicated
RS-232 DATA PORT
Function Keys
Dedicated
Function Keys KYLE F6 Recloser Control ON
GND TRIP NON SUPERVISORY
BLOCKED RECLOSING OFF
RS-232
TRIP CLOSE Configuration
A PHASE B PHASE C PHASE
HOT LINE TAG SELECT SELECT SELECT
Data Port
LS RESET
SOURCE I SOURCE II One-Touch
ENABLED ENABLED
Function Keys
(LOCKOUT)

TRIP (LOCKOUT) Hot Line Tag Toggle Switch and

Pushbutton CLOSE Pushbutton Three-Segment LED Indication

Figure 4.
Form 6 Triple-Single/LS control front panel.

7
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

Programming Panel CHANGE: Allows the user to change the state of the con-
trol functions on the operator panel function keys.
The Programming panel has the following sections:
Note: The CHANGE mode is a ten second period in which one
One-Touch Analysis Keys function setting can be changed. If no change is made
There are eight analysis keys (Figure 5) that allow one- in that time, the control returns to the current setting.
button access to a variety of control and monitoring func- LCD Display
tions that appear in the LCD display.
The LCD Display is a backlit 4-line, 20-character display
Note: The label inserts can be customized, but the analysis that provides extensive distribution system, recloser, and
key functions remain the same. control status information via the navigation keypads
Pressing these buttons causes the following information (Figure 5).
to display or function to occur: Note: The LCD display panel contrast is field-adjustable to allow
METERING: Displays the systems instantaneous meter- for various mounting heights and applications. Press the
ing values for current and voltage on the LCD display. MENU key and then press the (+) or (–) key to increase
or decrease the contrast.
RESET TARGETS: Resets the fault target indicators on
The four LCD navigation buttons are as follows:
the operator panel.
Note: Pressing this button will not reset the LS parameters. MENU: Identifies the LCD Display menu options.

EVENTS: Displays the last 25 events from the Sequence ENTER: Selects a menu option.
of Events log. +: Increases value selection.
LAMP TEST: This button functions two days: –: Decreases value selection.
• Press and immediately release this button to display The four LCD menu function keys activate specific menu
the front panel LED status. commands. When a command appears in the LCD dis-
• Press and hold the LAMP TEST button for two sec- play directly above one of the four LCD menu function
onds to enable the actual LAMP TEST feature. All keys, the user can press the key to accept/select the
operator panel LEDs are illuminated for verification of command.
proper connection and operating status of all indica- The four LCD menu function keys are as follows:
tor lights. All status indicators will then return to their
F1 F2 F3 F4
previous state. While in the LAMP TEST mode, the
control response to operator panel keys is disabled, The four cursor movement arrows allow movement in the
except for the TRIP (LOCKOUT), CLOSE, and HOT following directions:
LINE TAG switches.  Moves the cursor left.
SETTINGS: Displays recloser settings on the LCD display.  Moves the cursor right.
OPER COUNTER: Displays the total number of trip oper-  Moves the cursor up one line.
ations and target counters for each A, B, and C Phase;
Ground, and Sensitive Ground on the LCD display.  Moves the cursor down one line.
ALARMS: Provides status information on the LCD dis-
play for all recloser alarms.

METERING SETTINGS

RESET OPER
TARGETS COUNTER

F1 F2 F3 F4

EVENTS ALARMS

LAMP TEST
MENU + CHANGE

ENTER —
Figure 5.
Analysis keys, LCD display, LCD menu function keys, and cursor movement arrows.

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SAFETY
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S280-70-8

Status Indicator LEDs RECLOSER OPEN: The steady green LED indicates all
The status indicator LEDs in the Programming section of three reclosers are in the open position. The blinking
the Operator Panel give instant information on the control green LED indicates one or two reclosers are in the open
and recloser status: position.

The Form 6-TS/LS status indicator LEDs are illustrated in RECLOSER CLOSED: The steady red LED indicates all
Figure 6. three reclosers are in the closed position. The blinking red
LED indicates one or two reclosers are in the closed position.
All of the default status indicators LEDs (except for CON-
Note: There are several conditions that will cause the alter-
TROL OK, CONTROL POWER, and ALARM) can be nate blinking of the CONTROL LOCKOUT, RECLOSER
reconfigured via the Idea Workbench. Refer to Service OPEN, and RECLOSER CLOSED LEDs: Failure to
Information S280-70-9 Form 6-TS Control Programming Trip, Failure to Close, Interrupter Malfunction, and
Guide for additional information. 52a/b Disagreement.
The label inserts can be user-customized. Refer to Using The LED blinking pattern for these conditions is the
Removable Inserts section of this manual for additional CONTROL LOCKOUT green LED and RECLOSER
information. CLOSED red LED alternating with the RECLOSER
OPEN green LED. The red ALARM LED will also be
CONTROL OK: The green LED indicates the control is illuminated.
operating normally and not in an alarm state.
This LED blinking pattern is different than the continu-
The CONTROL OK LED will not be illuminated during ous blinking of all three LEDs that occurs when all three
these alarms (indicated by the red ALARM LED and dis- reclosers do not have the same status, i.e. OPEN or
played in the alarm status log): CLOSED. To determine the actual status of each
recloser (phase), refer to the Form 6-TS/LS control
• Battery Alarm: This alarm indicates battery voltage is low front panel RECLOSER STATUS LCD menu display.
or the battery failed an operator-initiated manual test.
A PHASE FAULT, B PHASE FAULT, C PHASE FAULT:
• Memory Test: This alarm indicates a failed ROM or The red LEDs indicate A, B, and/or C phase current was
RAM memory test. either the maximum phase current or within 80% of the
• No AC Power: This alarm indicates AC power was maximum when a trip signal was issued.
unavailable for 10 continuous seconds. This alarm GROUND FAULT, SENSITIVE GROUND FAULT: The red
resets when AC power is restored. LEDs indicate that a Ground and/or Sensitive Earth Fault
• Internal Power Failure: This alarm indicates internal tripping function was asserted at the time the trip signal
control operation power was outside of its operating was asserted.
tolerance for more than 20 seconds. This alarm ALARM: The red LED indicates an alarm has been
resets when the internal control operation power issued. Review the alarm status and log on the LCD dis-
returns to operation within its normal tolerances. play for the specific alarm.
• RIF Comms Failure: This alarm indicates a loss of ABOVE MINIMUM TRIP: The red LED indicates the cur-
communication from the RIF (Recloser Interface) cir- rent exceeds the level set for minimum trip.
cuit board to the main CPU circuit board. This alarm
resets if communication is re-established. TIE: The red LED indicates the control is in tie mode and
will respond to voltage conditions on Source I and/or
CONTROL POWER: The green LED indicates there is Source II.
adequate charge (voltage) on the trip circuit capacitor to
trip or close the recloser(s). This LED does not indicate SECTIONALIZER: The red LED indicates the control is
the presence of AC or battery power. in sectionalizing mode and will respond to voltage condi-
tions on Source I.
CONTROL LOCKOUT: The steady green LED indicates
Note: When in Sectionalizing mode, the SOURCE II
the control for all three reclosers is in a locked out state,
ENABLED function key is not responding to voltage
i.e. a reclosing sequence is not in progress on any reclos- even though it is illuminated.
er. The blinking green LED indicates that the control for
one or two reclosers is in a locked-out state, i.e. a reclos-
ing sequence is not in progress on those one or two
reclosers. This LED (blinking or steady) does not indicate
that any recloser is open.

CONTROL OK A PHASE FAULT ALARM A PHASE VOLTAGE X PHASE VOLTAGE

CONTROL POWER B PHASE FAULT ABOVE MIN TRIP B PHASE VOLTAGE Y PHASE VOLTAGE
CONTROL LOCKOUT C PHASE FAULT TIE C PHASE VOLTAGE Z PHASE VOLTAGE
RECLOSER OPEN GROUND FAULT SECTIONALIZER FREQUENCY TRIP INDICATOR 7
RECLOSER CLOSED SENSITIVE GND LS DISABLED VOLTAGE TRIP INDICATOR 8

Figure 6.
Form 6 Triple-Single/LS control status indicator LEDs.

9
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

LS DISABLED: The red LED indicates the LS accessory FREQUENCY TRIP: Indicates the recloser tripped due to
is not active. When LS is disabled, the Form 6-TS/LS a frequency trip.
control will not respond to the LS loss of voltage para-
VOLTAGE TRIP: Indicates the recloser tripped due to a
meters as set in the ProView interface software Loop
voltage trip.
Scheme Settings Dialog screen located in the Idea
Workbench. X PHASE VOLTAGE, Y PHASE VOLTAGE, Z PHASE
Note: In the event of loss of all control power (both AC and
VOLTAGE: These red memory LEDs indicate Source II
battery), the LS control will be disabled when power is (load) voltage is present on X, Y, or Z phase(s). These
restored to the control. LEDs are controlled by the Voltage Controls settings in
the Loop Scheme Settings dialog box.
Note: LS must be enabled via the ProView interface software
Loop Scheme Settings Dialog screen located in the If LS is enabled, at the moment loss of voltage occurs,
Idea Workbench. the LEDs for the phases that have lost voltage turn off
A PHASE VOLTAGE, B PHASE VOLTAGE, C PHASE and the LS option begins timing.
VOLTAGE: These red memory LEDs indicate Source I Note: The TIE mode will not initiate any loss of voltage timing
(source) voltage is present on A, B, or C phase(s). These if both sources are lost. If one source is available, while
LEDs are controlled by the Voltage Controls settings in the TIE mode is timing on loss of voltage, and the avail-
the Loop Scheme Settings dialog box. able source also loses voltage, the TIE will reset the
loss of voltage time to its original value.
If LS is enabled, upon the loss of voltage, the LEDs for
If voltage is restored before the voltage transfer time
the phases that lost voltage turn off and the LS option
delay elapses, the LEDs for the phases with restored
begins timing.
voltage illuminate and the LS timer resets.
Note: The TIE mode will not initiate any loss of voltage timing
if both sources are lost. If one source is available, while If voltage is not restored before the Voltage Transfer time
the TIE mode is timing on loss of voltage, and the avail- delay relay elapses, the LEDs remain off even if voltage
able source also loses voltage, the TIE will reset the returns to a particular phase. This identifies the phase
loss of voltage time to its original value. that caused the LS to operate.
If voltage is restored before the voltage transfer time Activating the LS RESET one-touch function key resets
delay elapses, the LEDs for the phases with restored the LS function and illuminates these LEDs (if voltage is
voltage illuminate and the LS timer resets. present).
If voltage is not restored before the Voltage Transfer time INDICATOR 7, INDICATOR 8: Customizable LEDs that
delay relay elapses, the LEDs remain off even if voltage are used with functions programmed through the Idea
returns to a particular phase. This identifies the phase WorkbenchTM. The LED indicators do not have active
that caused the LS to operate. default values. The LEDs are illuminated when the status
configured via the Idea WorkbenchTM is present.
Activating the LS RESET one-touch function key resets
the LS function and illuminates these LEDs (if voltage is
present).

10
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SAFETY
FOR LIFE
S280-70-8

Operating Panel TRIP (Lockout) Pushbutton

The Operating section includes the following sections: The TRIP pushbutton (Figure 7) provides front-panel
access to trip (lockout) the recloser. When pressed, the
RS-232 Configuration Data Port TRIP pushbutton opens the recloser and locks out the
The RS-232 connector (shown in Figure 4) on the front control.
operating panel allows direct connection to a personal Note: In the event of main microprocessor failure, the trip circuit
computer without any special cables or connectors. This can operate independent of the main microprocessor.
port is used only for configuring the control with ProView
application software. All settings, metering, events, and CLOSE Pushbutton
oscillography data are available from this port. The port is When pressed, the CLOSE pushbutton (Figure 7) returns
Data Communication Equipment (DCE) wired for direct the control to the initial or home sequence position, clos-
connection to a personal computer. ing the recloser. The control is ready for the start of a new
A 9-pin RS-232 cable (Catalog Number KME5-66) to trip/close sequence.
connect from the PC to the RS-232 data port is available Note: Pressing the CLOSE pushbutton from the Lockout posi-
as an accessory. tion initiates Cold Load Pickup (CLPU) protection, if the
feature is enabled.
HOT LINE TAG ON/OFF Toggle Switch and LED
The user does have the ability to block COLD LOAD
Indicator PICKUP through the LCD menu or by configuring one
of the Option one-touch function keys via the Idea
WARNING: Hazardous voltage. Do not use Hot Workbench feature in ProView.
! Line Tag as a substitute for a visible disconnect. If the recloser is closed, pushing and holding the
Always establish a visible disconnect prior to perform- CLOSE pushbutton does not activate the Cold Load
ing any work requiring a de-energized line. Failure to Pickup feature. See Cold Load Pickup in the Control
comply may cause death, severe personal injury, or Features section of this manual.
equipment damage. T276.0

IMPORTANT: If the CLOSE button is pressed after

Hot Line Tag is provided for live-line work applications. All the Close Circuit Disable fuse is removed, do not rein-
closing operations are disabled when the Hot Line Tag stall the fuse until after the ALARM LED illuminates
feature is activated. (within approximately five seconds) to indicate CLOSE
MALFUNCTION. Re-installing the Close Circuit Disable
IMPORTANT: Hot Line Tag activation does not cause fuse prior to the CLOSE MALFUNCTION ALARM indi-
the recloser to trip open. It only prevents the recloser cation will cause the control to close the recloser.
from closing.

IMPORTANT: Hot Line Tag is intended solely for live-

line work applications, such as maintenance, repairs or
improvements to the distribution system, that occur KYLE F6 Recloser Control ON
while the line remains energized.

Hot Line Tag prevents all closing attempts and shifts pro-
TRIP CLOSE
HOT LINE TAG
tection to one trip-to-lockout on the composite curve of the
Hot Line Tag definite time and the TCC1 curve (whichev-
er is faster). Hot Line Tag takes precedence over Cold
Load Pickup, Non-Reclosing, and Fast Trips Disabled.
(LOCKOUT)
Hot Line Tag is activated from either the operator panel tog-
gle switch, serial communications, or a discrete SCADA
function. All sources must be off to de-activate Hot Line Tag. Figure 7.
To activate the function from the operator panel, flip tog- TRIP (Lockout) pushbutton; CLOSE pushbutton; Hot
gle switch up to the ON position. See Figure 7. The LED Line Tag switch, and Hot Line Tag red indicator
indicator illuminates when the function is active. LEDs.
The Hot Line Tag function may only be reset by the source
which initiates it. For example, if Hot Line Tag is activated
at the operator panel, the reset function is only possible at
the operator panel, and not via SCADA command.
IMPORTANT: If the power save feature is enabled
(default), and more than ten minutes elapses since the
last panel operation, all the LEDs, except HOT LINE
TAG (if active), will turn off.

11
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

One-Touch Function Keys SUPERVISORY OFF

Quick access to frequently operated Form 6 control fea- When the SUPERVISORY OFF red indicator is illuminat-
tures is provided with nine function key pushbuttons on ed, supervisory commands are blocked. Supervisory
the control operator panel. functions through the back panel serial communication
The Form 6-TS/LS control operator panel one-touch func- ports and the discrete I/O are blocked. Serial communi-
tion keys are illustrated in Figure 8. cations through the front panel RS-232 port remain active
independent of the status of the SUPERVISORY OFF
switch. Activation of this function key is restricted to the
GND TRIP NON SUPERVISORY operator panel and is accomplished by pressing the
BLOCKED RECLOSING OFF CHANGE key and then pressing the SUPERVISORY
OFF key. Operational data and metering information are
A PHASE B PHASE C PHASE available while the control is in the SUPERVISORY OFF
SELECT SELECT SELECT position. The TRIP and CLOSE pushbuttons and Hot
Line Tag are active independent of the SUPERVISORY
SOURCE I SOURCE II
LS RESET OFF function.
ENABLED ENABLED
A PHASE SELECT, B PHASE SELECT, C PHASE
Figure 8. SELECT
Form 6 Triple-Single/LS control operator panel one- The Form 6 Triple-Single/LS control has phase selection
touch function keys. keys for the user to indicate only which phase of the
NOVA-TS Triple-Single recloser will operate when the
Red LEDs located on each function key indicate the sta- manual TRIP (LOCKOUT) and CLOSE pushbuttons on
tus of the function, regardless of local or remote activa- the Form 6-TS/LS operator panel are pressed. When the
tion. For example, if Ground Trip Blocked is activated TRIP or CLOSE buttons are pressed, only the phases
from a SCADA signal, the red indicator will illuminate that are selected (LED on) will trip or close.
even though it is not activated from the operator panel.
Manual operation of the yellow handles on the NOVA-TS
Operator panel function key activation or de-activation triple-single recloser is used to open and lockout the
requires the operator to first press the CHANGE key to phases, and to disable the electrical and supervisory
enter the CHANGE mode. A function must then be select- closing. The recloser mode of operation determines
ed or de-selected within ten seconds to activate or de-acti- which phases open and close. The Form 6 Triple-
vate the function. Once selected, the control returns to nor- Single/LS control initiates the close signal.
mal operation until prompted for another change request.
This prevents accidental changing of functions of features. WARNING: Hazardous voltage. Do not rely on
Note: Only one function can be changed per each CHANGE
! the open position of the yellow operating handle;
mode activation. it does not ensure that the line has been de-energized.
Always establish a visible disconnect. Failure to follow
GND TRIP BLOCKED proper safety practices can result in contact with high
The Ground Trip Blocked function blocks all ground sens- voltage, which will cause death or severe personal
ing in the control for the active profile. This red indicator injury. G116.0

is illuminated when Ground Trip Block is activated from

the serial port, I/O, the interface software, or locally caus-
ing the control to block all ground sensing. IMPORTANT: Pushing the yellow operating handle
to the CLOSE position will not close the recloser. All
NON RECLOSING close operations are initiated by the Form 6 Triple-
The Non-reclosing mode disables any automatic reclos- Single/LS control.
ing operations. The red indicator is illuminated when the
control is operating in a non-reclosing mode. Non-reclos-
ing does not alter the active TCC. Activation is possible
from the SCADA port, I/O, the interface software, or local-
ly (via the front panel).

12
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SAFETY
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S280-70-8

Three-Phase Trip – Three-Phase Lockout (ganged) LS RESET

or When the LS RESET red indicator is illuminated, the LS
Single-Phase Trip – Three-Phase Lockout function has been reset and the control is ready to
respond to the next loss of voltage occurrence. Activation
If the control is in Three-Phase Trip – Three-Phase is possible from the SCADA port, I/O or locally (via the
Lockout (ganged) mode or Single-Phase Trip – Three- front panel). This LED cannot be de-selected. It will only
Phase Lockout mode, all three phases are permanently turn off when an LS action occurs.
selected and the A PHASE SELECT, B PHASE SELECT,
and C PHASE SELECT LEDs are illuminated. SOURCE I ENABLED

When one phase is opened with the yellow operating When the SOURCE I ENABLED red indicator is illumi-
handle, all three phases open and lockout. The nated, the control is in LS mode and responding to volt-
RECLOSER OPEN and CONTROL LOCKOUT indicator age conditions on Source I (Source side Phases A, B,
LEDs illuminate on the control panel. and C). Activation/de-activation is possible from the
SCADA port, I/O, the interface software, or locally (via the
With the yellow operating handle of the appropriate front panel).
phase in the CLOSE position, press the CLOSE push-
button on the control operator panel. All three phases SOURCE II ENABLED
close and the RECLOSER CLOSED LED illuminates. When the SOURCE II ENABLED red indicator is illumi-
Single-Phase Trip – Single-Phase Lockout nated, the control is in Tie mode and responding to volt-
age conditions on Source II (Load side Phases X, Y, and
When in Single-Phase Trip – Single-Phase Lockout Z). Activation/de-activation is possible from the SCADA
mode any combination of phases can be selected and port, I/O, the interface software, or locally (via the front
the respective PHASE SELECT LED illuminates. Each panel).
selected phase must be closed individually. Note: When the control is in Sectionalizing mode, the
When the selected phase is opened with the yellow oper- SOURCE II ENABLED function key may or may not be
ating handle, only that phase opens and locks out. The illuminated (depending on the LS Enable SII setting in
RECLOSER OPEN, RECLOSER CLOSED, and CON- the Loop Scheme Settings Dialog box). It is not
TROL LOCKOUT indicator LEDs blink on the control responding to Source II voltage.
panel.
The default text message on the LCD displays the mode
of the triple-single configuration and the status of each
phase.
With the yellow operating handle of the selected phase in
the CLOSE position, press the CLOSE pushbutton on the
control panel. The phase closes and the RECLOSER
CLOSED LED illuminates.

IMPORTANT: If the power save feature is enabled

(default), and more than ten minutes elapses since the
last panel operation, all the LEDs, except HOT LINE
TAG (if active), will turn off.
Verify the phase or phases you want activated are
selected prior to pressing the TRIP or CLOSE button.

13
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

Control Features Sequence Coordination

The Form 6-TS/LS recloser control offers numerous stan- Sequence Coordination eliminates nuisance tripping
dard features and accessories that allow the user the through trip coordination. It allows the control to step
utmost flexibility applying the recloser control. through selected operations in the operating sequence
without tripping. The number of Sequence Coordination
Control Security advances is programmable from one to three operations
The Form 6-TS/LS recloser control has multiple cus- to provide trip coordination with a downline recloser. This
tomer-programmable security codes to limit control pro- feature is independently selectable for each protection
gramming and viewing function access to authorized per- profile.
sonnel. The front panel Human-Machine Interface (HMI) Cold Load Pickup
includes a user-selected security code to access the set-
tings. Plus, the ProViewTM interface software has it’s own The control includes a Cold Load Pickup feature to pre-
security levels for multiple-user access. vent the control from tripping while energizing non-fault
system loads. This feature has independently program-
Refer to Service Information S280-70-9 Form 6-TS mable minimum trip value time-current curve, reclose
Microprocessor-Based Recloser Control Programming interval, and number of independent operations to lock-
Guide for additional information. out for each protection profile. Cold Load Pickup also
Protection Profiles includes TCC Multipliers, TCC Adders, Minimum
Response Time, Time Dial Reset, and High Current
Four protection profiles capable of fully specifying control Lockout. Also, direct values, not multiples of minimum
operation are standard in the control. Each protection trip, are provided for high current lockout.
profile includes the following as a minimum:
• Overcurrent Protection
Fast Trips Disabled
The control includes a Fast Trips Disabled feature to
• Over/Undervoltage Protection
modify protection, so that all trip operations use the pro-
• Over/Underfrequency Protection grammed TCC2. This feature is independently selectable
• Directional Protection for each protection profile. All trip operations will time on
TCC2. Typically, TCC1 is fast and TCC2 is delayed. So,
• Hot Line Tag Functionality as an example, the control will change it’s sequence from
• Sync Check 2 fast and 2 delayed operations to 2 operations on TCC2
when Fast Trips Disabled is active.
• Sensitive Earth Fault Protection
• Sequence Coordination High Current Lockout
• Operation Settings The High Current Lockout feature will automatically lock-
out the control on the selected operation when current
Time Current Curves exceeds a programmable level. The active trip numbers
for the lockout is selectable for phase, ground, and neg-
Time-current curves are available for numerous functions, ative sequence. This feature is independently selectable
including fast and delayed operations for phase, ground, for each protection profile.
and negative sequence protection. Each time-current is
selected from a defined fifty curves which can be further Sensitive Ground/Earth Fault
customized by the user. The time-current curves are also Operation
selected from a graphical TCC EditorTM II to visualize any
modifications prior to configuring the control. The control has a Sensitive Ground/Earth Fault Trip fea-
ture that provides tripping of the recloser after a pro-
The time-current curves include the following modifications grammable, definite time for ground currents below nor-
for phase, ground, and negative sequence protection: mal ground minimum trip levels. The feature has pro-
• Time Multiplier with a range of 0.1 to 25 in .1 increments. grammable operations to lockout and reclose intervals
independent of the ground settings. This feature is inde-
• Time Adder with a range of 0 to 30 seconds in .01 pendently selectable for each protection profile.
second increments.
• Minimum Response Time with a range of 0.01 to 1 Thermostatically Controlled Heater
seconds in .001 second increments. The control has a standard 15 Watt thermostatically con-
• High Current Trip multiplier with a range of 1 to 32 trolled heater (ON at 70°F on falling temperature, OFF at
multipliers in increments of 0.1. 85°F on rising temperature) for humidity control and volt-
age input independent. The heater is powered from the
• High Current Trip Time Delay with a range of 0.01 to power supply board.
.150 second in .001 second increments.
• Time Dial Reset co-efficient with a range of .1 to 30
seconds in 1 second increments.

14
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SAFETY
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S280-70-8

Metering The control also provides a minimum of three config-

urable input control contacts. Each control contact is con-
The control provides instantaneous and/or demand figurable using a graphical interface software. Contacts
metering with programmable integration intervals for the accept a whetting voltage range of 12–250 Vdc, 120/240
following functions: Vac. Each digital input is configured for either a momen-
• Real and reactive power for each phase and total, tary, maintained, or maintained with precedence contact.
including directional, on an individual phase basis. Default input control contacts are: Supervisory Trip and
Lockout, Supervisory Close, and Remote Trip and
• Demand currents on a per phase basis.
Lockout.
• Instantaneous currents, including ground current.
A Discrete Interface Board is also available as an acces-
• Instantaneous voltage on a per phase basis. sory to provide an additional eight output status contacts
• Instantaneous frequency. and eight input control contacts. The expansion I/O board
is completely user-configurable.
• Positive, negative, and zero sequence voltages.
• Instantaneous power factor on a per phase basis.
TCC EditorTM II
Coordination and actual time current modifications are
• Metering settings to include demand interval, and
available with a graphic interactive TCC EditorTM or simi-
alarm thresholds for current, single-phase kW, three-
lar graphical software.
phase kW, single-phase kVAr, and three-phase kVAr.
The TCC EditorTM II includes a complete database of
Event Recorder standard recloser industry time current curves (TCC),
The Form 6-TS/LS control contains capabilities to per- both ANSI and IEC types, along with the ability to cus-
form Sequence of Events time-stamping for up to 69 tomize the TCCs with multipliers, constant time adders,
event types. Sixteen additional inputs can be user- or minimum response time adders. Also, the user is able
defined through the Idea WorkbenchTM. to derive their own specific TCC through data point entry.
Each modified time current curve can be identified with a
Factory-defined event types include: user-customized name and is selectable for configuring
• Overcurrent Protection Trip the control. The grid and format for presenting the TCCs
• External Trip has a user-adjustable scale, including the option of pre-
• Non-Reclose Trip senting multiple TCCs in various user-configured colors.
• External Close Oscillography
• Lockout Oscillography is provided to present current and voltage
• Reset waveforms, along with protection element and recloser
The Event Recorder maintains a minimum of 90 event response status changes. Filtered and unfiltered data are
records. The last 25 events are viewable on the front panel provided for viewing
LCD display. Refer to S280-70-9 Form 6 Triple-Single The recorded values are super-imposed on the protec-
Control Programming Guide for additional information. tion scheme, and the state or value at any point in the
scheme is displayed. The user has the capability to move
Recloser Duty Monitor through the event and watch the response of every func-
The Form 6-TS/LS recloser control software is equipped tion. All analog signals, digital inputs, and contact outputs
with a Recloser Interrupting Duty Monitor. The Duty are monitored. Analog oscillography is displayed at 16
Monitor accumulates the summation of I1.5 for all inter- samples per cycle.
rupted currents on each interrupter. This feature permits Oscillographic data is recorded to analyze multiple
programmable entries to preset the duty of an existing events during a permanent fault or other event type. The
recloser. The recloser duty monitor displays interrupting oscillographic data shows two cycles before the trigger
duty in percent of duty used. If the duty cycle monitor point and eight cycles after the trigger point (default).
exceeds 100%, the recloser should be examined for
maintenance. Note: The configuration settings are programmable.
Oscillography automatically initiates trigger points for the
Discrete SCADA Communications following functions:
The control provides five configurable output status con- • Above Minimum Trip for Phase, Ground, and
tacts and three configurable input control contacts as Sensitive Ground Fault
standard. Each status contact is configurable using
graphical interface software to combine status functional- • Single- and Three-Phase Overvoltage
ity along with Boolean algebra. Default output status con- • Single- and Three-Phase Undervoltage
tacts are: AØ Lockout, AØ Recloser Open, AØ Recloser
Closed, Ground Trip Block, and Hot Line Tag. One output • Over- and Underfrequency
status contact is a solid state output (SS1) with a pickup • Trip Signal Issued
time no longer than two milliseconds.
• Close Signal Issued

15
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

Removable Inserts depends upon configuration parameters. Refer to

Service Information S280-70-9 Form 6-TS
Removable inserts are included with the control design Microprocessor-Based Recloser Control Programming
for customization of specific protection requirements. Guide for additional information.
Inserts are available for the status indicator LEDs, the
operator panel function keys, and the analysis keys. The Fault Location
removable inserts are designed for use without adhe-
sives, labelmakers, or temporary labels. Refer to Using The control includes an impedance-based fault locator
Removable Inserts in this manual for more information. based upon the Takagi algorithm1. Load-compensated
impedance calculation is used for calculating the dis-
An electronic label template is included on the ProView tance. Positive and zero sequence is configured in ohms,
application software CD and can be accessed through and the fault locator line length is configured in kilome-
the following default address: ters/miles.
C:\Program Files\Cooper\Proview40\Form6\Form 6 1
T. Takagi, Y. Yamakoshi, J. Baba, K. Uemura, T. Sakaguchi, "A New
Inserts.doc Algorithm of an Accurate Fault Location for EHV/UHV Transmission
Lines: Part I - Fourier Transformation Method", IEEE Trans. on PAS,
Idea WorkbenchTM Vol. PAS-100, No. 3, March 1981, pp 1316-1323.

The Idea WorkbenchTM provides access to various inputs, Sync Check

intermediate variables, and internal Form 6 alarms, sta-
Sync Check is a permissive system used to qualify any
tus, and targets to allow user-customization of the Form
close signal to the mechanism when enabled via the sync
6 recloser control to meet specific and unique applica-
check settings. Sync check allows for closing for any
tions. The Idea WorkbenchTM also gives the user the abil-
combination of dead/live bus/line, and to perform antici-
ity to perform logical functions with these variables by
patory closing for a live bus/live line condition by calcu-
using a simple graphical user interface. Refer to Service
lating slip and anticipating the mechanism closing delay.
Information S280-70-9 Form 6-TS Microprocessor-
In addition to the anticipatory close calculation, the sync
Based Recloser Control Programming Guide for addi-
check system performs verification of line and bus volt-
tional Idea WorkbenchTM information.
age magnitudes and frequencies to determine that they
Over/Underfrequency Protection are within pre-determined ranges, and that the angular
difference between the two systems is also within the
The control includes two-stage operation for both under- pre-determined range. For a live/live close, where there
frequency and overfrequency protection. A fixed time is no slip between the systems, the sync check system
delay ranging from 0 to 100 seconds in .001 second allows permissive closing after the two systems are with-
increments is available for both over and underfrequen- in frequency and voltage limits, and the angular differ-
cy. A frequency restoration function, enabled or disabled ence between the systems has been within the allowable
by the user, is provided to allow the recloser to automat- limits for a pre-determined time.
ically close should frequency return to within configured
settings for a user-settable time. Over/Underfrequency Sync Check functionality includes the following applica-
Protection is included as part of each protection profile. tions: Hot Line/Hot Bus Closing; Dead Line/Hot Bus
Closing; Hot Line/Dead Bus Closing; and Dead
Over/Undervoltage Protection Line/Dead Bus Closing.
The control includes single-phase and three-phase under Sync Check Parameters include the following config-
voltage tripping. The control also includes three-phase urable settings: Voltage Angle; Mechanism Operating
overvoltage tripping. Both over and undervoltage func- Delay; Static Angle Delay; Dead Threshold; Live
tions include a single-phase and three-phase pick-up set- Threshold; Positive Sequence Dead Threshold; Upper
ting; a single-phase and three-phase time delay setting Voltage Limit; Lower Voltage Limit; Lower Frequency
ranging from 0 to 100 seconds. Limit; Upper Frequency Limit; and Fail to Close Timer.

Directional Manual Close Delay

Directional functionality is included to maintain system Manual Close Delay provides a delay from the time that
coordination from multiple sources, as well as circuit the manual CLOSE button is pushed to the time the man-
reconfiguration for each profile. Directional applies to ual close operation is performed.
phase, ground, and negative sequence protection, The delay is programmable from 0 to 60 seconds in 1
selected independently. A maximum torque angle has a second increments. A programmed delay value can be
range of 0–90 degrees. overridden for immediate closing by pressing the CLOSE
button a second time.
Data Profiler
An active Manual Close Delay can be canceled by press-
A fully-configurable data profiler is available which allows
ing the TRIP/LOCKOUT button.
the user to collect information by sampling data at selec-
table intervals. These time-stamped values can then be The default setting has the feature disabled (0 seconds).
viewed to determine weekly load profiles, daily harmonic A countdown on the front panel LCD screen indicates
disturbances or hourly voltage fluctuations. The number Manual Close Delay is active.
of days of information the data profiler can provide

16
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SAFETY
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S280-70-8

Communications Ethernet configuration is accomplished via ProView inter-

face software. Refer to S280-70-9 Form 6 Triple-Single
Communication Ports Control Programming Guide, Section 4: Schemes,
Communicating with the Form 6 Control, for Ethernet
The Form 6-TS/LS control has two back panel communi-
Configuration information.
cation ports and a front panel configuration data port.
When a communication protocol is selected for the
The front panel configuration data port is described in the
optional communication boards (serial fiber or the RS-485
Operating Panel section of this manual.
serial port), the RS-232 serial port is defaulted to
There is one standard 9-pin RS-232 and one optional ProViewTM interface software protocol.
communication port (RS-485, serial fiber, Ethernet wire
DNP3 is factory-defaulted to the RS-232 port.
or fiber or both) on the back operator panel, as well as a
standard IRIG-B port for user time-syncing. See Figure 9. When a communication protocol is selected for the RS-
232 serial port, the optional RS-485 or serial fiber optic
Communication Protocols board is not active.
Three communication protocols are available for the The RS-485 or fiber optic serial ports do not support
Form 6 Triple-Single/LS recloser control: ProViewTM interface software protocol.
• Modbus The user can simultaneously communicate to the Form
• DNP3 6-TS/LS control using both the front panel data port and
the appropriate back panel serial communication port
• 2179 (provided the back panel RS-232 port or the Ethernet
One communication protocol can be selected for either the optional communications board is not configured to be
back panel RS-232 or the optional communication port. ProView protocol).
All three protocols are selected and configured by the
user with the ProViewTM Communications WorkbenchTM
Control Information
application software. Control information includes firmware identification by
catalog number and name, date code, and ProView
Ethernet Communications release number. Control information is available through
• ProView over TCP/IP the Settings menu on the front panel (Figure 4).
• DNP3 over TCP/IP Control Back Panel
Ethernet connection allows for network application of the The control back panel is easily accessible through the
Form 6 Triple-Single/LS control for both DNP3 and back door of the control cabinet (Figure 2) with readily
ProView protocols. In addition, the front panel data port identifiable serial ports and connections (Figure 9).
can simultaneously communicate ProView to the PC.

RS-232 Serial Communication Port

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

RS-485 Serial Communication Port (optional)

2 4 6
CI1 CI2
8 10 12 14 16 18
CI3 SS1 CO1 CO2 CO3 CO4
RS-232 DTE
IRIG-B
Fiber Optic port, "ST" Type Connector (optional),
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11 CO12

TB3
1 3 5 7 9 11 13 15 17 19 21 1 3 5 7 9 11 13
TB4
Ethernet Port, "MT-RJ" Fiber RJ45 Connector (optional)
2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11CO12

TB9
IRIG-B Time Sync Connector
+ –
28 VDC
WHETTING VOLTAGE

Power Supply Board

P1 P4

AC Power Fuse 1
2
3
4

VOLTAGE SENSING
1

2
3
4
1
2
3
4
P2
1 2 3

53VDC
4 5
P3
24 23 22
12 11 10
21
9

CONTROL CABLE
20 19
8 7
18 17
6 5
16
4
15 14
3 2
13
1
1

1
2

2
3

28 VAC
4

4
5

120/240 Vac
Selector Switch

Battery Connector (2-position)

Voltage Sensing 1 2 3 4 7 8 9 10 11 12

Customer Connection
Terminal Block TB8
1 2 3 4 5 6
Power Supply LED
Power Connections

Grounding Terminal, One

AC Customer Connection
External & One Internal
Terminal Block TB7
(#14 to #4 Stranded)

Figure 9.
Form 6 recloser control back panel terminal block and communication port identification.

17
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

INSTALLATION PROCEDURE Control / Recloser Compatibility

The Form 6-TS/LS pole mount recloser control is only
compatible with the NOVA-TS recloser. Refer to Service
Initial Programming Information S280-42-2 NOVA-TS Recloser Installation
Prior to Installation and Operation Instructions for additional information.

CAUTION: Equipment misoperation. Do not Duty Cycle Monitor

! connect this control to an energized recloser until The Duty Cycle Monitor provides the following duty cycle
all control settings have been properly programmed information:
and verified. Refer to the programming information for
this control. Failure to comply can result in control and • Measures and records duty for each individual phase
recloser misoperation, equipment damage, and per- in non-volatile memory.
sonal injury. G110.3 • The recloser duty is measured and stored on the
basis of Current1.5 x Number of Operations for Each
Phase (ANSI C37.61).
CAUTION: Equipment misoperation. Check mini- • Readout is based on a percentage of total duty cycle
mum trip values prior to changing an alternate profile. used for each phase.
Failure to do so may cause misoperation of the control
under load conditions. T280.0
• Duty record can be adjusted or reset if recloser is
changed-out, serviced, etc.
Using Table 1, select the appropriate NOVA-TS recloser
IMPORTANT: Program all protection profiles. interrupting duty cycle factor and enter that value via the
Unused alternate profiles should be programmed with ProViewTM interface software.
the same settings as one of the applicable profiles.
Default settings on unused alternate profiles can TABLE 1
cause unnecessary outages if they are below normal Duty Cycle Factor
system requirements.
Interrupting 100% Duty
The control must be programmed with all necessary Recloser Rating Cycle
operating settings, all alternate profiles, and parameters Type (rms sym Amps) Factor*
prior to operation with an energized recloser. NOVA-TS 8,000 568
Note: Initial programming of the control is the responsibility of NOVA-TS 12,500 1111
a qualified technician or engineer familiar with control
functions and programming parameters required for the *Duty Cycle Factor is Value x 105.
specific recloser installation.
The control must be programmed with the Form 6
ProView interface software. Refer to Service Information
S280-70-9 Form 6-TS Microprocessor-Based Recloser
Control Programming Guide for additional information.
Note: The Pole Mounted Control checkbox in the ProView
System Configuration screen must be selected for all
Form 6 pole mount controls. This includes both pole
and substation applications.

IMPORTANT: Form 6-TS/LS control users must acti-

vate the loop scheme default settings in the ProView
application software Idea Workbench:
1. Click on LOAD IDEA WB STRUCTURE.
2. Select WBI-Form6-F6Default-LS.sch and click on
Open.
3. Click on READ IDEA WB SETTINGS FROM DISK.
4. Select WBI_Form6_Settings_F6 Default-LS.txt
and click on Open.
5. Enable the LS functionality by selecting the LS
Enable checkbox in the Loop Scheme Settings
Dialog box located in the Idea Workbench Optional
Loop Scheme Workbench.

18
 !
SAFETY
FOR LIFE
S280-70-8

Control Cable Junction Box and Cables

The Type NOVA-TS Triple-Single recloser is connected
WARNING: Hazardous voltage. Recloser and to the Form 6-TS/LS recloser control at a junction box.
! control must be solidly grounded. Follow all See Figure 10.
approved procedures and safety practices when
grounding this equipment. Improper grounding can The maximum junction box cable length between the
result in contact with high voltage, which will cause triple-single junction box and the NOVA-TS recloser is 30
death or severe personal injury. G115.1 feet. Three junction box cables are required - one for
each recloser.
The maximum control cable length between the Form 6- • In a pole-mounting application, the junction box is
TS/LS control and the triple-single junction box is 95 feet. mounted on the mounting frame.
Note: The control cable must be supported along its length to • For substation applications, the junction box is
prevent repeated movement due to wind or other out- mounted on the frame between the Type NOVA-TS
side forces which can damage the cable. Triple-Single recloser and the Form 6-TS/LS control.

IMPORTANT: All external inputs to the Form 6 IMPORTANT: The triple-single recloser junction box
recloser control must be routed within 8 inches of their is mounted with all cable connections made at the bot-
corresponding ground. During a surge, a potential of tom of the box. Do not invert.
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.
NOVA-TS
Pole-mounting Junction Box
or Substation
mounting frame
AØ BØ CØ

Form 6-TS/LS
(3) Triple-Single Control Cable
Recloser Cables

Figure 10.
NOVA-TS Triple-Single reclosers are connected to
the Form 6-TS/LS control through a junction box.

19
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

Mounting the Control Mount the Form 6 recloser control in a convenient,

accessible location. Mounting dimensions are provided in
Figure 11.
WARNING: This equipment is not intended to
!protect human life. Follow all locally approved Note: Unless otherwise specified, dimensions shown in mm
(inches).
procedures and safety practices when installing or
operating this equipment. Failure to comply may result A hole and keyway in the control mounting bracket
in death, severe personal injury and equipment dam- accommodates a 15.9 mm (5/8”) bolt.
age. G102.1

29
(1.25)
310
(12.25) 16 (.63) Dia.
Mounting Holes (2)

CONTROL OK
CONTROL POWER
CONTROL LOCKOUT
RECLOSER OPEN
RECLOSER CLOSED
A PHASE FAULT
B PHASE FAULT
C PHASE FAULT
GROUND FAULT
SENSITIVE GND
ALARM
ABOVE MIN TRIP
INDICATOR 1
INDICATOR 2
INDICATOR 3
A PHASE VOLTAGE
B PHASE VOLTAGE
C PHASE VOLTAGE
FREQUENCY TRIP
VOLTAGE TRIP
INDICATOR 4
INDICATOR 5
INDICATOR 6
INDICATOR 7
INDICATOR 8
RS-232
METERING

RESET
TARGETS
SETTINGS

OPER
COUNTER
Connection
Port
F1 F2 F3 F4

EVENTS ALARMS

LAMP TEST
MENU + CHANGE

ENTER —
RS-232 DATA PORT

KYLE F6 Recloser Control ON

GND TRIP NON SUPERVISORY
BLOCKED RECLOSING OFF

TRIP

(LOCKOUT)
CLOSE
HOT LINE TAG
A PHASE
SELECT

OPTION #1
B PHASE
SELECT

OPTION #2
C PHASE
SELECT

OPTION #3
710 665
(28.0) (26.25)

Front View 170

(6.75)
355 (14.0) Grounding
400 (15.75) Terminal
Vent Vent
#14 To #4
Right Side View Stranded
Mounting Angle
1.44 Dia. Hole for
Voltage Input Connection
1.44 Dia. Hole for (Caplug Installed)
Connection 1.44 Dia. Hole
(Caplug Installed) (Caplug Installed)

Control Cable
38 Receptacle 1.81 Dia.
(1.5) (26-pin)
67 67 79
(2.75) (2.75) (3.25)
Bottom View

CONTROL WEIGHT 34 kg (75 lbs)

Figure 11.
Form 6-TS/LS pole mount recloser control weight and dimensions.

20
 !
SAFETY
FOR LIFE
S280-70-8

Grounding the Control Figure 12 illustrates grounding methods for 4-wire multi-
grounded systems with local supply voltage transformer.
WARNING: Hazardous voltage. Recloser and Figure 13 illustrates grounding methods for 4-wire multi-
! control must be solidly grounded. Follow all local- grounded systems with remote supply voltage transformer.
ly approved procedures and safety practices when For effective surge protection, all control and power con-
grounding this equipment. Improper grounding can ductors for the Form 6 control must be routed parallel to
result in contact with high voltage, which will cause a corresponding ground path. For example, the ac power
death or severe personal injury. G115.1
supply for the control should be parallel to and equal in
length to the transformer ground path. The control cable
The control cabinet must be grounded. A grounding con- should be parallel to and routed close to the recloser
nector on the underside of the cabinet will accommodate ground path.
No. 14 solid through No. 4 stranded conductors.
Suggested methods for grounding the control and reclos-
er are shown in Figures 12 and 13.

21
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

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

Installation of a Form 6-TS/LS pole mount recloser 4-Wire Multi-Grounded Systems

control with a local supply voltage transformer must
include the following: IMPORTANT: In pole-mounted applications, a
• Protection of the recloser bushings and the supplying ground connection must be made between the reclos-
transformer with lightning arresters. er, transformer, recloser control, and SCADA equip-
ment for proper protection of the equipment. The pole
• Grounding of the recloser head and tank. ground must be sized per local utility practices to min-
• Grounding of the transformer tank. imize the impedance between the recloser and the
control.
• Grounding of the control cabinet.
• Grounding of the SCADA equipment

IMPORTANT: All external inputs to the Form 6-

TS/LS control must be routed within 8 inches of their
corresponding ground. During a surge, a potential of
approximately 1.5 kV per foot can develop in the con-
ductors. Differences between conductor and ground
path lengths can add additional stress to the control
components in the event of a power surge.

Transformer
Surge Typical transformer mounting is
Arrester 180° to the recloser.

AC
NEU Pole
GND Surge
Arrester Surge
Recloser Arrester
Head
Ground

Supply Voltage
Surge
Form 6-TS/LS Control Input Terminal
Arrester Block
Transformer
AC
NEUTRAL
CLOSED
CLOSED Arrester
Ground

External
Supply Ground Lug
Recloser
Voltage Head ELECTRICAL CONNECTIONS
Ground
Line to Neutral connected transformer

NOVA-TS
Triple-Single
Recloser

Pole Mounting
Accessory

Junction Box

Control
Cable

Pole Ground
Form 6-TS/LS
Control

Input Terminal
Block
NEU
AC

Customer Ground Connection

At External Lug

Figure 12.
Recommended grounding method for the Form 6-TS/LS control installed on 4-wire multi-grounded, with local
supply voltage transformer.

22
 !
SAFETY
FOR LIFE
S280-70-8

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

Installation of a Form 6-TS/LS control with a remote sup-

IMPORTANT: In pole-mounted applications, a
ply voltage transformer must include the following:
ground connection must be made between the reclos-
• Protection of the recloser bushings and the supplying er, transformer, recloser control, and SCADA equip-
transformer with lightning arresters. ment for proper protection of the equipment. The pole
• Grounding of the recloser heads and tanks. ground must be sized per local utility practices to min-
imize the impedance between the recloser and the
• Grounding of the transformer tank. control.
• Grounding of the control cabinet.
• Grounding of the SCADA equipment. IMPORTANT: All external inputs to the Form 6-
TS/LS control must be routed within 8 inches of their
corresponding ground. During a surge, a potential of
approximately 1.5 kV per foot can develop in the con-
ductors. Differences between conductor and ground
Supply Voltage
Form 6-TS/LS Control
Input
Terminal
path lengths can add additional stress to the control
Transformer Block components in the event of a power surge.
AC
NEUTRAL

External
Ground Lug

ELECTRICAL CONNECTIONS - Remote dedicated

supply transformer

Surge Pole
Arrester Surge
Transformer Arrester
Surge
Arrester

Surge
Arrester

Arrester
Ground

AC
CLOSED CLOSED

NEU
GND
Recloser
Head
Ground

NOVA-TS
Triple-Single
Recloser
Pole Mounting
Accessory
Junction Box System
Neutral
Note: Distance between
transformer and Supply
Voltage
recloser should be
one pole span or less
Control
Cable

Pole Ground
Form 6-TS/LS Control

Input Terminal
Pole Ground Block
NEU

Pole
AC

Customer Ground Connection

At External Lug

Figure 13.
Recommended grounding method for the Form 6-TS/LS Control installed on 4-wire multi-grounded, with
remote supply voltage transformer.

23
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

Customer Connections for AC CAUTION: Equipment misoperation. Verify that

Power to Form 6-TS/LS Control ! the 120/240 Vac selector switch is correctly set
for incoming voltage. Failure to comply may cause
CAUTION: Equipment damage. Do not drill connec- misoperation (unintentional operation) of the control
tion holes into the top of the cabinet. Connection holes and/or equipment damage resulting in personal injury.
in the top of the cabinet will allow moisture to seep into T278.0

the control and damage the components or cause con-

trol misoperation. Failure to comply will void the con-
trol’s factory warranty. T249.0
AC
Power
Fuse
Input power (120 Vac) to the Form 6-TS/LS control is
connected to Terminal TB8. B phase (H) is connected to
TB8-3. B phase (N) is connected to TB8-4. Y phase (H)
is connected to TB8-9. Y phase (N) is connected to TB8-
10. Refer to Figure 15. Selector Switch Power Supply Board
Input power is required: 030003KM
Figure 14.
• To power the control Power Supply / Battery Charger Board.
• To provide voltage and power metering
• To power the thermostatically controlled heater Terminal Blocks
• For the convenience outlet accessory Two terminal blocks are used for connection to the Form
6-TS/LS control. Both terminal blocks are fit for a #6
IMPORTANT: Delta connections are not used on the screw which can allow a maximum ring size for a #10
Form 6-TS/LS control. AWG for metering.
Terminal Block TB7 provides power to the Form 6-TS/LS
Power Supply / Battery Charger Board control and is directly connected to the power supply cir-
cuit board. Terminal Block TB8 is used to connect sensing
CAUTION: Equipment damage Form 6-LS (Loop transformer voltage. The wiring of the transformers should
Scheme). Do not connect 240 Vac to B or Y phases on follow the application illustrations per Figure 16 or 17.
terminal blocks TB7 or TB8. 240 Volts will damage
internal components and cause control misoperation. Loop Scheme
T314.0
The Form 6-TS/LS control is equipped with a transfer
relay to provide power to the control and power to the
Incoming ac power is routed to the Power Supply / recloser if either voltage is present on the source or load
Battery Charger Board. While this board is designed to side of the recloser. The relay transfers the control power
accept either 120 Vac or 240 Vac through a selector source from Source I of the control to Source II (load
switch located directly on the board (Figure 14), the Form side) upon loss of source side voltage. This circuitry is
6-TS/LS control must be set for 120 Vac incoming power. rated for 120 Vac operation only, and is connected to B
and Y phases on TB8 as Source I and Source II respec-
The battery charger includes a temperature-compensat- tively. Transfer relay output contacts connect to TB7.
ed design to optimally charge the control battery. The Refer to Figure 15.
power supply / battery charger board also includes an
auxiliary power supply for connection to communication Power Connections
equipment (radios, modems, etc.). The auxiliary power
supply is rated 28 Vdc, 65 Watts peak. A separate 28 Vdc The transformer required for power is 1kVA minimum.
to 13.8 Vdc power supply accessory is available for com- Transfer relay connections are shown in Figure 15.
munication equipment rated for 13.8 Vdc. Refer to Radio
Mounting Accessory in the Accessories section of this
manual for additional information regarding the radio
power supply. Some additional features are as follows:
• Positive LED indicator for power supply presence
• Self-protective fuse (5 amp, 250 Vac)
• 28 Vdc whetting voltage for I/O contact inputs

IMPORTANT: Prior to energizing the control, the

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

24
 SAFETY
!
FOR LIFE

Power to Control

Figure 15.
Heater &
Convenience Outlet

incoming supply.
TRANSFER
RELAY
COIL

Transfer Relay
(shown de-energized) 15 Amp
fuse

BØ YØ
Factory Wiring for
Wye Connection
TB8
15
Amp
fuse

1 2 3 4 5 6 7 8 9 10 11 12
Voltage Sensing Connections
Source Load
1 2 3 4 5 6
V (1-2) V(3-4) V(5-6) V1 V2 V3
TB7 120 120/240 NEU
(L2)120 (L1) NEU
Power Connections

Note: Terminal Block positions TB7-3 and

TB7-4 are factory-jumpered together.

Default factory wiring (transfer relay connections) connected to B-Phase voltage metering with B-Phase
Terminal Block positions TB7-5 and
TB7-6 are factory-jumpered together.

25
S280-70-8
26
Form 6-TS/LS Control

Figure 16.
AØ A A
1

D
2

BØ B B
3

CØ C C
5

N 6

tion only (TB8 Terminal Block Connection).

XØ X E
7
H
8

YØ Y F
9

10

ZØ Z G
11

N 12

TB8
KA145LS-5X*
KA235LS1 Junction Box Sensing/Low Voltage
Cable for the Control

NOVA-TS NOVA-TS NOVA-TS KME6-805-3

Recloser (AØ) Recloser (BØ) Recloser (CØ) 120 Vac Input
Receptacle
(8-pin)
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

Junction Box Control Cable

* = cable length

Typical tie application with junction box accessory. Six single-phase Transformer Connection, Wye configura-
 !
SAFETY
FOR LIFE
S280-70-8

CØ
AØ

BØ

NEU

BØ
CØ

AØ
12

User-Supplied
V3

Disconnect
Switches
11
10
Load
Voltage Sensing Connections

V2

9
8
V1

7
6
V (1-2) V(3-4) V(5-6)

5
Source

4
3
2
1
TB8

Figure 17.
Typical sectionalizer application, no junction box. Three-Phase Transformer Connection, Wye configuration
only (TB8 Terminal Block Connection).

27
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

Standard Default Supervisory Input TABLE 2

Control and Output Status Contacts Operating Current Requirements for Standard and
Optional Supervisory Inputs
Standard customer connections TB1 and accessory cus-
tomer connections are TB3 and TB4. Refer to Figures 18 Nominal Minimum
and 19 and Tables 2, 3, and 4. Input Voltage Current Operating Time
The Idea WorkbenchTM allows customization of all the 12 Vdc – 250 Vdc,
control and status points. Refer to Service Information
120/240 Vac 5 mA 5 milliseconds
S280-70-9 Form 6-TS Microprocessor-Based Recloser
Control Programming Guide for additional information.
TABLE 3
IMPORTANT Ratings Table for Output Status Contacts CO1
through CO12
Shielding and Surge Protection of (Resistive Load – Pickup Time 8 ms, Dropout 15 ms)
Supervisory Cables Contact
All supervisory operation and control monitor leads must Input Voltage Rating
be protected within shielded cables. Refer to Figure 20. 120 Vac 8A
CAUTION: Equipment damage; misoperation. 12 Vdc 8A
External leads must be shielded and the shield must be
grounded at both ends. Terminate each lead with a 320 24 Vdc 8A
Vac, 160 Joules metal oxide resistor (MOV), or equiva-
48 Vdc 1A
lent, at the remote end. Attach MOVs between the leads
and ground. Failure to properly shield and protect leads 125 Vdc 0.4 A
can result in equipment damage and/or unintentional
operation. G117.3
TABLE 4
Ratings Table for Output Status Contact SS1
(Resistive Load – Pickup Time 2 ms, Dropout 15 ms)
Contact
Input Voltage Rating

120 Vac 8A

12 Vdc 8A

24 Vdc 8A

48 Vdc 8A

125 Vdc 8A

28
 !
SAFETY
FOR LIFE
S280-70-8

IMPORTANT
Shielding and Surge Protection of
Supervisory Cables
All supervisory operation and control monitor leads must
be protected within shielded cables. Refer to Figure 20.

CAUTION: Equipment damage; misoperation.

External leads must be shielded and the shield must be
grounded at both ends. Terminate each lead with a 320
Vac, 160 Joules metal oxide resistor (MOV), or equiva-
lent, at the remote end. Attach MOVs between the leads
and ground. Failure to properly shield and protect leads
can result in equipment damage and/or unintentional
operation. G117.3

Customer-Supplied Voltage Inputs**

Three-Phase Supervisory Trip and Lockout
Three-Phase Remote Trip and Lockout

Three-Phase Supervisory Close

Remote/Supervisory Common

**Whetting voltage is also available from

the Form 6 Recloser Control on
Terminal Block TB9. Refer to Figure 20.

Note: Contact output relays revert to

de-energized positions as shown
upon downloading new schemes
or Workbench files.

CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4

1 3 5 7 9 11 13 15 17 19

TB1

2 4 6 8 10 12 14 16 18

CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4

Customer Wiring A B
AØ Control Control Hotline Ground Trip
Lockout AØ Recloser OK Tag Blocked
Status Status Status Status Status
(Not (Recloser (Control (Hotline (GRD TRIP
Lockout)* Open)* Not OK)* Tag Off)* Normal)*

*Relay Contacts shown

for Indicated Status

Figure 18.
Form 6-TS/LS recloser control standard default supervisory input control and output status contacts.
Contacts are shown in de-energized position.

29
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

IMPORTANT

TB4

*Relay Contacts shown

Shielding and Surge Protection of

for Indicated Status

Supervisory Cables

Normal)*
CO12

(Voltage
Voltage
13

Alarm
All supervisory operation and control monitor leads must

CO12
be protected within shielded cables. Refer to Figure 20.

12

Status (Frequency
11
***The default contact type for CO9,

Alternate Alternate Alternate Frequency

(Not in Normal)*
CAUTION: Equipment damage; misoperation.

CO11***

CO11

Alarm
CO10, and CO11 is Form-a.

10
External leads must be shielded and the shield must be
grounded at both ends. Terminate each lead with a 320

Profile 1 Profile 2 Profile 3

Vac, 160 Joules metal oxide resistor (MOV), or equiva-

Profile)* Profile)* Profile)*

CO10

Alt 3
lent, at the remote end. Attach MOVs between the leads

CO9*** CO10***

8
and ground. Failure to properly shield and protect leads

7
can result in equipment damage and/or unintentional

(Not in
Status

Alt 2
CO9
6
operation. G117.3

(Not in
Status

Alt 1
CO8
4
CO8

3
de-energized positions as shown
upon downloading new schemes
Note: Contact output relays revert to

Profile)*
Normal

Normal
(Not in
Profile
Status
CO7
2
CO7

1
or Workbench files.

(No Alarms)*
21

Alarms
Status
CO6

CO6
Form 6 Recloser Control on Terminal Block

20
19

Non-Reclosing
**Whetting voltage is available from the

Reclose)*
(Normal
CO5

Status
CO5
18
17
TB9. Refer to Figure 20.

CI11
Remote/Supervisory Common
CI11

16
15

Remote Normal Profile

CI10

CI10
14
13

Remote Alternate Profile 3

CI9
CI9

12
11

Remote Alternate Profile 2

Customer Wiring
CI8
CI8
Customer-Supplied

10
Voltage Inputs**

Remote Alternate Profile 1

CI7
CI7

8
7

Unassigned
CI6

CI6
6
5

Supervisory Reset Targets

CI5

CI5
4
3

Supervisory Non-Reclose
CI4

CI4
2
1

Supervisory Ground Trip Block

TB3

Figure 19.
Form 6-TS/LS recloser control Discrete Interface Board Accessory default supervisory input control and out-
put status contacts. Contacts are shown in de-energized position.

30
 !
SAFETY
FOR LIFE
S280-70-8

FORM 6-TS/LS RECLOSER CONTROL

TB9
SHIELD

Factory-Supplied Customer Wiring 28 Vdc Whetting Voltage Terminals

28 Vdc Whetting
Voltage
+
— Customer Wiring

REMOTE
BOX

Three-Phase
Supervisory 8 CI3
Trip and CI3 7
Lockout

Three-Phase
Supervisory 6 CI2
CI2 5
Close

Three-Phase
Remote 4 CI1
CI1 3
Trip and
Lockout

13

A Phase B*
Recloser
Status 12 CO1
A*
*Contacts shown
with recloser in 11
OPEN position. CO1
Not All Remote
Connections
TB1 Shown

NOTES: Arresters to be metal oxide varistors (MOVs) 320 Vac,

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

Figure 20.
Shielding and Surge Protection for Supervisory and Remote Cables.

31
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

Rear Panel RS-232 Communication

Port Pin Assignments
RS-232 Serial IRIG-B Time
Tables 5 indicates the pin assignments for the rear panel Communication Port Sync Connector
RS-232 communication port (Figure 21). Refer to Figure
22 for pin identification. Refer to Protocols for additional
information.
Refer to the Accessories section of this manual for addi- CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4
1 3 5 7 9 11 13 15 17 19
tional communication options. TB1
J1-RS-232

IRIG-B
RS-232 DTE
2 4 6 8 10 12 14 16 18
TABLE 5 CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4
CO7 CO8 CO9 CO10 CO11 CO12
Rear Panel RS-232 Communication Port Pin TB3
CI4 CI5 CI6
1 3 5
CI7 CI8 CI9 CI10 CI11 CO5
7 9 11 13 15 17 19 21
CO6
1 3 5 7 9 11 13
TB4
Assignments
2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11CO12
Pin Number Signal Name
TB9
1 DCD . . . . . . . . . . . . . . . . . . . Carrier Detect

2 RXD . . . . . . . . . . . . . . . . . . . Receive Data + –

28 VDC
WHETTING VOLTAGE

3 TXD . . . . . . . . . . . . . . . . . . . . Transmit Data

P1 P4
4 DTR . . . . . . . . . . . . . . . . . . . . Data Terminal Ready 1 3 1 3 1 3
P2 P3
24 23 22 20 19
1 2 3 4 5

(Not Connected)
21 18 17 16 15 14 13
1 3 1 2 3 4 5
2 4 2 4 2 4 2 4 5 12 11 10 9 8 7 6 4
5 3 2 1

VOLTAGE SENSING 53VDC CONTROL CABLE 28 VAC

5 GND . . . . . . . . . . . . . . . . . . . Signal Ground

6 DSR . . . . . . . . . . . . . . . . . . . Data Set Ready

(Not Connected)
Figure 21.
7 RTS . . . . . . . . . . . . . . . . . . . . Request to Send Form 6-TS/LS control rear panel RS-232 communi-
cation ports (standard configuration).
8 CTS . . . . . . . . . . . . . . . . . . . . Clear to Send

9 NC . . . . . . . . . . . . . . . . . . . . . Not Used

10 (Shroud) . . . . . . . . . . . . . . . .Chassis Ground

J1-RS-232

1 2 3 4 5
6 7 8 9

RS-232 DTE
Figure 22.
Rear panel RS-232 communication port pin
identification.

32
 !
SAFETY
FOR LIFE
S280-70-8

Before Placing the Control and D. Press the F4 button to test the battery.
the Recloser into Service Note: This message will appear on the programming
panel LCD display: ----TESTING----
CAUTION: Equipment misoperation. Do not The battery test results will display in the battery
! connect this control to an energized recloser until metering menu.
all control settings have been properly programmed
Note: With AC disconnected and the battery supplying
and verified. Refer to the programming information for the load, current will read -400 to -600 mA
this control. Failure to comply can result in control and depending on accessories connected.
recloser misoperation, equipment damage, and per-
sonal injury. G110.3
9. AC power connected to the control. (CONTROL OK
LED indicator is illuminated.)
Prior to placing the control and recloser into service, the Note: The control Power Save feature will turn off the
following installation procedures must be properly com- backlit LCD display and all LEDs if no front panel
keypad is pressed within ten minutes.
pleted and verified:
1. Front panel label inserts changed (if applicable). 10. All control programming entered and verified by
appropriate personnel.
Note: Refer to Using Removable Inserts in this manual.
Note: The Pole Mounted Control checkbox in the
2. Control properly mounted for the installation. ProView System Configuration screen must be
selected for all Form 6 pole mount controls. This
3. NOVA-TS reclosers (3) installed according to all includes both pole and substation applications.
locally approved standards and practices.
Refer to Service Information S280-70-9 Form 6-TS
4. AC disconnect switches installed. Microprocessor-Based Recloser Control
5. Control and reclosers properly grounded in accor- Programming Guide for additional information.
dance with guidelines in this manual and the NOVA-
TS recloser manual. Refer to Service Information IMPORTANT: Form 6-TS/LS control users must acti-
S280-42-2 NOVA-TS Recloser Installation and vate the loop scheme default settings in the ProView
Operation Instructions. application software Idea Workbench:
6. Control cables properly connected and supported. 1. Click on LOAD IDEA WB STRUCTURE.
2. Select WBI-Form6-F6Default-LS.sch and click on
CAUTION: Equipment misoperation. Verify that Open.
! the 120/240 Vac selector switch is correctly set
3. Click on READ IDEA WB SETTINGS FROM DISK.
for incoming voltage. Failure to comply may cause
misoperation (unintentional operation) of the control 4. Select WBI_Form6_Settings_F6 Default-LS.txt
and/or equipment damage resulting in personal injury. and click on Open.
T278.0
5. Enable the LS functionality by selecting the LS
Enable checkbox in the Loop Scheme Settings
CAUTION: Equipment damage Form 6 LS (Loop Dialog box located in the Idea Workbench Optional
Scheme). Do not connect 240 Vac to B or Y phases on Loop Scheme Workbench.
terminal blocks TB7 or TB8. 240 Volts will damage
internal components and cause control misoperation. 11. Control clock set to the correct time.
T314.0
Refer to Service Information S280-70-9 Form 6-TS
7. Verify the selector switch on the Power Microprocessor-Based Recloser Control
Supply/Battery Charger Board is set to the 115V posi- Programming Guide for additional information.
tion for 120 Vac incoming power.
CAUTION: Equipment damage; misoperation.
8. Control battery connected and tested for proper External leads must be shielded and the shield must be
operation. grounded at both ends. Terminate each lead with a 320
Note: The battery test is blocked for 30 seconds upon Vac, 160 Joules metal oxide resistor (MOV), or equiva-
power-up of the control. lent, at the remote end. Attach MOVs between the
Test the battery as follows: leads and ground. Failure to properly shield and protect
leads can result in equipment damage and/or uninten-
A. Press the MENU button on the front panel. tional operation. G117.3

B. Using the down arrow key, navigate to the BAT-

TERY menu and press ENTER. 12. Customer connections for remote and supervisory
C. Using the down arrow key, navigate to the TEST operation checked and completed in accordance with
BATTERY menu and press ENTER. proper shielding and surge protection (Figure 20).

33
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

Using Removable Inserts 4. Use tweezers to gently pull out the removable insert.
Note: The insert will slide out of the right side of the oper-
ating panel (Figure 24).
CAUTION: Control damage. De-energize both ac
and dc power prior to removing or installing any inter- Note: The insert will slide out of the top of the program-
nal connections or circuit boards in the control. Failure ming panel indicator section (Figure 23).
to comply can result in damage to the control. T241.1 5. Change the existing label or slide in a new label with
the name of the programmed option.
An electronic label template is included on the
CAUTION: Equipment damage. Always wear a
ProViewTM application software CD and can be
grounding wrist strap to control static electricity before
accessed through the following default address:
handling circuit boards. Failure to use this strap may
result in circuit board damage. T253.1 C: \ Program Files \ Cooper \ Proview40 \ Form 6 \
Form 6 Inserts.doc
The front panel inserts can be changed, if desired. IMPORTANT: Laminate the removable inserts prior
1. De-energize both ac and dc power. to installing. This will seal the ink/toner and avoid dam-
age to the front panel.
2. Use a flathead screwdriver to unscrew the six front
panel screws.
6. Gently push the removable insert from right to left into
3. Pull the right side of the front panel out towards the the right side of the operating panel (Figure 24) or
left (Figure 23). down into the programming panel LED indicator sec-
Note: Various connecting wires will keep the panel tion (Figure 23).
attached to the control.
Note: It is not necessary to disconnect any wires.

Removable LED
Status Indicator Panel

000008KM
Figure 24.
Labels are easily removed from and inserted into
the operating panel.

7. Place the front cover panel back onto the control.

Using a flathead screwdriver screw the screws into
the control and tighten all hardware completely.

030029KM
Figure 23.
Open front panel. Labels are easily removed from
and inserted into the top of the programming panel
LED status indicator section.

34
 !
SAFETY
FOR LIFE
S280-70-8

ACCESSORIES
These accessories are available. Contact your Cooper 120 Vac GFI Duplex Outlet
Power Systems representative for additional information.
The GFI Duplex Outlet (Catalog Number KME6-1776-2)
is available for controls powered by 120 Vac three-wire
Loop Sectionalizing Accessories supply power. This convenience outlet is rated for 15
Various wiring options for control-powered NOVA Amperes and is accessible through the front door in the
reclosers, 120 vac single or three-phase sensing are control cabinet. The 120 Vac GFI Duplex Outlet is used
available. Refer to Table 6 for ordering options. for many applications such as power for the MET Tester,
auxiliary measurement equipment, and supplemental
TABLE 6 lighting.
Loop Sectionalizing Accessories
Description Catalog Number
Wiring Options for NOVA-TS recloser, 120 Vac Single- or Three-Phase Sensing
Junction box equipped with Source 1 and Source 2 sensing cables. (4-conductor, 5 ft. length) includes
hardwiring the sensing/low voltage cable for the control (KA145LS-X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .KA235LS1*
Input-sensing/low voltage cable, 8 conductor, 120 Vac (basic cable, no length) . . . . . . . . . . . . . . . . . . . . . . .KA145LS
Replace “X” with desired length. Select from 5 to 80 feet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .KA145LS-X
120 Vac/240 Vac Input receptacle, 8-pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .KME6-805-3
*KA145LS-5X cable and the KME6-805-1 receptacle are to be ordered separately.

Cable Locking Sleeves Discrete Interface Board (DIF)

To prevent detachment of the control cable from the con- Option Accessory
trol cabinet by unauthorized personnel, a cable-locking A Discrete Interface Board Option accessory provides
sleeve is available to enclose the cable plug. The plug is eight configurable input control contacts and eight con-
passed through the sleeve and the sleeve is then fas- figurable output status contacts (Figure 25). The ordering
tened from inside the control cabinet. There is no access options include: Standard (3 inputs / 5 outputs) or
to the cable receptacle without opening the locked cabi- Additional (8 inputs / 8 outputs).
net door and detaching the sleeve.
Catalog Number KME6-1772-1: Quantity 1
Catalog Number KME6-1772-2: Quantity 2
Catalog Number KME6-1772-3: Quantity 3 DIF Board Accessory
Catalog Number KME6-1772-4: Quantity 4
RS-485 C + –
CO2 CO3 CO4

Cabinet Ordering Accessories

CI1 CI2 CI3 SS1 CO1
1 3 5 7 9 11 13 15 17 19 J1-RS-232
TB1

IRIG-B

• AISI 304 stainless steel cabinet construction 2 4 6

CI1 CI2
8 10 12 14 16 18
CI3 SS1 CO1 CO2 CO3 CO4
RS-232 DTE

CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11 CO12
1 3 7 9 11 13
• Three-point door latch TB3
1 3 5 7 9 11 13 15 17 19 21 5
TB4

2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11CO12

TB9

+ –
28 VDC
WHETTING VOLTAGE

P1 P4
P2 P3 1 2 3 4 5
1 3 1 3 1 3 24 23 22 21 20 19 18 17 16 15 14 13
1 3 1 2 3 4 5
2 4 2 4 2 4 2 4 5 12 11 10 9 8 7 6 4
5 3 2 1

VOLTAGE SENSING 53VDC CONTROL CABLE 28 VAC

Figure 25.
Form 6-TS/LS control discrete interface board
accessory.

35
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

Radio Mounting Accessory TABLE 7

Radio Mounting Accessories
The radio mounting accessory (Figure 26) is powered
from a voltage regulated power supply factory-calibrated Description Catalog Number
with an output of 13.8 Vdc.
Full Automation accessory
The radio power supply input is fused by a 1 Amp in-line 12 Vdc radio provision . . . . . . . . . . . . . . . KME6-1774-5
fuse for a nominal voltage of 28 Vdc. The output is 13.8
(Radio and fiber-optic/RS232 interface not included)
Vdc between P2-1 (+) and P2-2 (-) on the radio power
supply circuit board with a maximum continuous watt rat- Automation accessory (bracket only)
ing of 17.25W @ 13.8 Vdc. 12 Vdc provision . . . . . . . . . . . . . . . . . . . . KME6-1774-4
Note: This output cannot be field-calibrated.
The radio will continue to operate during the loss of ac
power as long as power is supplied from the battery. The
power supply is designed to provide up to 40 Watts
(peak) and is fused to isolate any potential radio prob-
lems without disturbing the protection system in the
recloser control. Refer to Table 7.
Contact your Cooper Power Systems representative for
any additional voltage requirements.

RS-485 C + –

J1-RS-232

IRIG-B
RS-232 DTE

TB9

+ –
28 VDC
WHETTING VOLTAGE

P1 P4
P2 P3

Customer-Supplied
1 2 3 4 5
1 3 1 3 1 3 24 23 22 21 20 19 18 17 16 15 14 13
1 3 1 2 3 4 5
2 4 2 4 2 4 2 4 5 12 11 10 9 8 7 6 4
5 3 2 1

VOLTAGE SENSING 53VDC CONTROL CABLE 28 VAC

Radio

Power Cable
In-Line 1 Amp Fuse
Radio-Mounting
Bracket +–
12

P2

24 Vdc to 13.8 Vdc

Converter
Customer-Supplied
Power Leads
Radio Antenna
Cable (only
available with full
automation accessory)
Antenna Surge
Suppresser and
Connector (only
available with full
automation accessory)

Figure 26.
Form 6-TS/LS control radio mounting accessory.

36
 !
SAFETY
FOR LIFE
S280-70-8

Communication Board A pair of industry standard ST type fiber-optic connectors

are mounted on the back of the board enabling customer
Accessories connection to a digital communication system using fiber-
The Form 6-TS/LS control is equipped with a optic cables (customer-supplied).
Communication Board Accessory (expansion bay) offer-
The fiber-optic link has separate receive (RX) and trans-
ing versatile support for modern communication media.
mit (TX) ports operating at 820nm. Typical transmission
Six distinct communication options (Figure 27) are avail-
distance is 2000m with 62.5/125µm multi-mode fiber.
able, providing two-way, real time digital communications
Consult your Cooper Power Systems representative for
with a remote terminal unit (RTU), wireless, telephone
availability of long haul and single mode fiber solutions.
modem, Ethernet network, or other communication
Link communication speed is controlled through software
devices. The following options are available:
and can be set at: 1200, 2400, 4800, 9600, 19.2k, 38.4k,
• No auxiliary communication card installed (standard) 57.6k, and 115kBPS.
• RS485 (isolated) Serial communication card The fiber-optic accessory must be programmed through
• Fiber-optic-based Serial Communication Card (ST) the Communications Workbench for the appropriate pro-
tocol. Refer to S280-70-9 Form 6 Triple-Single Control
• 10/100 Base-T dual Ethernet communication card Programming Guide for additional information.
(2*RJ-45)
The fiber-optic based serial accessory includes TX and
• 100 Base-FX dual Ethernet communication card RX indicating LEDs for verifying communications along
(2*MT-RJ) with an echo / non echo switch for supporting ring / star
• 10/100 Base-T, 100 Base-FX Ethernet communica- fiber topologies.
tion card (RJ-45 + MT-RJ) When operated in a ring configuration, the toggle switch
The expansion bay based Communication Board must be set in the ECHO position. In this mode, the fiber-
Accessory concept offers high versatility with respect to optic card will repeat (pass through) all messages
communication medium and protocol support. Additional received on the RX fiber, and will respond to the Master
accessories are being continuously developed. Contact station by first echoing the incoming command and then
your Cooper Power Systems representative for the latest sending the response. This arrangement is best suited
information regarding particular media and communica- for creation of low cost multi device fiber loops. For reli-
tion protocol support. able communications, the fiber loop system requires that
all devices in the loop remain powered at all times, thus
RS485 Serial Communication Card enabling unobstructed flow of information throughout the
loop.
The RS485 serial communication card accessory pro-
vides means for establishing asynchronous link-based A more resilient system can be designed by using the
digital communications with the Form 6-TS/LS control. fiber-optic ports in a point-to-point or multiple point-to-
The Galvanic isolated (1000V DC) RS485 port uses a point (star) configuration. For this mode, the toggle
single shielded twisted pair connection and can support switch must be set in the NON-ECHO mode. The Form
16 devices in multi-drop configuration. Communication 6-TS/LS control will respond to the Master station by
speed is controlled through software and can be set at: sending a response only (total separation of Receive
1200, 2400, 4800, 9600, 19.2k, 38.4k, 57.6k, and and Transmit fibers). Additional hardware (fiber-optic
115kBPS. star coupler) is required to support the multiple point-to-
point device configurations.
Digital communications must be programmed through
the Communications Workbench to ensure proper opera- Ethernet Communication Cards
tion of the RS485 communication card accessory. Refer
to S280-70-9 Form 6 Triple-Single Control Programming The Ethernet communication card accessory brings the
Guide for additional protocol support information. Ethernet network connectivity to the Form 6-TS/LS
recloser control platform. It is highly flexible, offering
Fiber-Optic Based Serial simultaneous support for multiple sessions, device man-
Communication Card agement (ProView over TCP/IP) and SCADA communi-
cations (DNP3 over TCP/IP).
The Fiber-Optic based Serial Communication Card offers
means of establishing asynchronous (RS-232 like) digital By natively supporting a set of widely accepted industry
communications through multi-mode fiber media. The standards (TCP/IP, UDP/IP, OSI) the Ethernet communi-
use of the fiber-optic based serial communication card cation accessory ensures seamless interoperability with
accessory can enhance communication reliability, and other network devices.
provides excellent electrical isolation thus protecting
transmitted data from extraneous electrical interference.
An optional fiber-optic-to-RS-232D converter with DB-25
connector (Catalog Number KME4-163) is available for
interfacing between an optical signal and a hard-wired
RS-232 signal, when required.

37
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

Standard
(No Communication Option) RS-485 Communication Serial Fiber
RS-485 C + -
TX NON-ECHO RX
TX RX

IRIG-B IRIG-B IRIG-B

#2 #1 #2 #1 #2 #1 Default Primary
ETHERNET ETHERNET ETHERNET Ethernet Interface

IRIG-B IRIG-B IRIG-B

Ethernet 10/100 Base-T Ethernet 100 Base-FX Ethernet 10/100 Base-T,

Type 1 Type 2 100 Base-FX
Type 3
Figure 27.
Back panel Ethernet and Communication options.

The Ethernet communication card accessory is offered in The Ethernet communication accessory card (Figure 27)
3 physical layer configurations (twisted pair and optical- is equipped with two physical ports configured to act as
fiber options) as shown in Table 8. primary and standby LAN connections. Availability of the
backup communication port enables creation of highly
TABLE 8 redundant Ethernet networks thus increasing the overall
Ethernet Communication Card Configurations system reliability.
Card Output Communication Note: Under normal network conditions, all communications
Type Configurations Connectors Speed will be channeled through the primary port (#1, Figure
27), with the standby port either logically disabled, or
1 10/100 Base-T 2 * RJ-45 10 / 100MBps configured for fast automatic throw-over in case of the
(auto switching)
primary Ethernet link failure. Refer to S280-70-9 Form
2 100 Base-FX 2 * MT-RJ 100MBps 6 Triple-Single Control Programming Guide for addi-
(fiber) (full duplex) tional Ethernet accessory configuration information.

3 10/100 Base-T, RJ-45 + MT-RJ 10/100MBps

100 Base-FX and 100MBps

Maximum link length is determined by the use of the par-

ticular physical layer implementation, and can be further
constrained by the actual network configuration. In case
of the 100Base-FX MT-RJ connector based implementa-
tion, maximum link length in excess of 2000m can be
achieved with 62.5/125µm multi mode fiber. The fiber-
optic link uses 1300nm wavelength, and can easily be
interfaced to other 100Base-FX solutions (ST connector
patch cord solution).

38
 !
SAFETY
FOR LIFE
S280-70-8

TESTING
3. Test battery operation as follows:
CAUTION: Equipment misoperation. Do not
! connect this control to an energized recloser until Note: The battery test is blocked for 30 seconds upon
power up of the control.
all control settings have been properly programmed
and verified. Refer to the programming information for Note: AC power can be either connected or disconnected
this control. Failure to comply can result in control and for battery test.
recloser misoperation, equipment damage, and per- A. Press the MENU button on the front panel.
sonal injury. G110.3
B. Using the down arrow key, navigate to the BAT-
TERY menu, and press ENTER.
IMPORTANT: The Form 6 control can be taken out C. Using the down arrow key, navigate to the TEST
of service for testing and placed back into service BATTERY menu and press ENTER.
without de-energizing its recloser and interrupting the
D. Press the F4 button to test the battery.
system. However, during the time the control is out of
service, the recloser is inoperative. Note: This message will appear on the programming
panel LCD display: ----TESTING----
The battery test results will display in the battery
Testing an Installed Control metering menu.
The following tests to determine initial operation of the Note: Voltage should be between 25–31 Vdc – with
Form 6 recloser control can be performed while connect- the higher voltage at colder temperatures.
ed to an operating recloser.
Under normal conditions, with AC connected
Note: These are the only tests performed on an installed, and a fully charged battery, the charging current
operating control. should be less than 20 mA.
1. Verify operating status of all indicator lights by press- With AC connected and a discharged battery,
ing and holding the LAMP TEST key for two seconds the current range should be 20–450 mA.
on the programming panel (Figure 28). With AC disconnected and the battery supplying
2. Check the operational values for currents, voltages, the load, current will read -400 to -600 mA
and other metering information. depending on accessories connected.

Note: Scroll through the LCD display messages by press- 4. Verify the Control OK LED is illuminated on the con-
ing the  and  cursor movement arrows under- trol operator panel (Figure 29). This indicates the
neath the LCD display on the programming panel presence of ac power.
(Figure 28). Note: The control includes a Power Save feature that will
turn off the backlit LCD display and all LEDs if no
front panel keypad is pressed within ten minutes.
Pressing the LAMP TEST key will reactivate the
LCD Display display and active LEDs.
METERING SETTINGS

RESET OPER
All other tests described in this TESTING section require
LAMP TEST Key
TARGETS COUNTER
the Form 6 recloser control to be removed from service,
EVENTS
F1 F2 F3 F4

ALARMS
connected to a bypassed recloser, or tested at a location
LAMP TEST
MENU + CHANGE
where the proper testing equipment is available.
Cursor Movement
Arrows ENTER —
RS-232 DATA PORT

CONTROL OK A PHASE FAULT

Figure 28. CONTROL POWER B PHASE FAULT
Lamp Test button, LCD display, and cursor move- CONTROL LOCKOUT C PHASE FAULT
RECLOSER OPEN GROUND FAULT
ment arrows.
RECLOSER CLOSED SENSITIVE GND

Control OK LED

Figure 29.
Control OK LED.

39
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

Remove the Control from Electrical Testing of NOVA-TS

Service Triple-Single Reclosers
IMPORTANT: Disconnect switches for ac sensing WARNING: Hazardous voltage. Solidly ground
and power connections are necessary to isolate the
Form 6 control for testing and servicing.
! all equipment. Failure to comply can result in
death, severe personal injury, and equipment damage.
T223.2

IMPORTANT: The control must be removed from ser-

vice in the exact order specified in this section. Each unit in the Type NOVA-TS Triple-Single recloser uti-
lizes an interface circuit located in its mechanism hous-
1. Enable GND TRIP BLOCKED to allow for ground trip ing. The electronic interface circuit controls the opening
to be disabled when re-energized. and closing signals to the magnetic actuator.
A. Press the CHANGE button on the Operator Panel Figure 30 shows a test circuit for NOVA-TS reclosers with
to enter the CHANGE mode. the Form 6-TS/LS control.
B. Depress the GND TRIP BLOCKED button within Use this circuit to simulate load current and for testing
ten seconds after entering the CHANGE mode. minimum trip operation and sequencing the mechanism
Note: If the GND TRIP BLOCK button is not with the Form 6-TS/LS control for each phase.
depressed within ten seconds, the function is
not activated. IMPORTANT: To ensure proper operation, always
verify that the three cables between the junction box
2. Disconnect the battery.
and the reclosers are connected when the control is in
3. Remove control ac sensing and power connections single-phase trip, three-phase lockout mode or three-
from the control using a separate disconnect switch. phase trip, three-phase lockout (ganged) mode.

WARNING: Hazardous voltage. If the recloser

!is energized while the control cable is discon-
115Vac Variable
Autotransformer
(10 Amp)
600:5
nected, the CT secondaries can generate high volt- Use 2/0 cable or larger
Recloser
BCT ON 600:5 Tap

ages. Contact with high voltage can cause severe per-

6 4
sonal injury or death. T204.2
2
Load
2 Clamp-On
Ammeter

Source
5 3
CAUTION: Equipment misoperation. Disconnect all 1

control power sources prior to disconnecting the con-

trol cable from the control. Failure to comply can result
in recloser misoperation at the time of disconnection or
reconnection of the control cable to the control. T311.0

4. Disconnect control cable from control.

Note: Do not disconnect any of the three recloser cables
from the reclosers or junction box unless all of the
above steps have been completed. Refer to Triple-Single Form 6-TS/LS
Service Information S280-42-2 NOVA-TS Recloser Junction Box Control
Installation and Operation Instructions.

CAUTION: Hazardous Voltage. Cable conduc- Figure 30.

! tors attached to NOVA reclosers will remain at Suggested test circuit for NOVA-TS Triple-Single
reclosers with Form 6-TS/LS control.
53Vdc potential after disconnection of source power to
the recloser. Contact with any pins at the end of cables
directly or indirectly connected to a NOVA recloser can
RS-485 C + –
result in personal injury or equipment damage. T312.0 1
CI1
3
CI2
5
CI3 SS1
7 9
CO1 CO2 CO3 CO4
11 13 15 17 19 J1-RS-232
TB1

5. Remove any control input and status output wiring 2 4 6 8 10 12 14 16 18

RS-232 DTE
IRIG-B

CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4

from TB1, TB3, and TB4 (Figure 31). CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11 CO12
1 3 7 9 11 13
1 3 5 7 9 11 13 15 17 19 21 5
TB3 TB4
6. Disconnect any serial communications ports and IRIG-
B timing connections (Figure 31). 2 4 6
CI4 CI5 CI6
8 10 12 14 16 18 20
CI7 CI8 CI9 CI10 CI11 CO5 CO6
2 4 6 8 10 12
CO7 CO8 CO9 CO10 CO11CO12

7. Disconnect the ground from the control.

Figure 31.
8. Carefully transport the control to a suitable service Back view of top half of Form 6-TS/LS recloser
facility. control.

40
 !
SAFETY
FOR LIFE
S280-70-8

Battery Test and Charging Test Procedure for Uninstalled

Procedures Battery
Test Procedure for Installed Battery CAUTION: Recloser misoperation. The control
Follow the procedure below to perform a battery test in
! must be removed from service before discon-
necting the control battery. Disconnecting the control
the Form 6 control. The values in the test procedures are
battery from an in-service control may cause recloser
based on testing at 25˚C (77˚F).
misoperation (unintentional operation) Failure to com-
The condition of the Form 6 control battery can be deter- ply can result in equipment damage and personal
mined by using the Battery Test function in the BATTERY injury. T213.4

MENU. No external current/voltage meter is necessary

for testing. The entire process should be conducted in a clean envi-
Alarm Conditions: ronment, such as a repair shop.
• During a manual battery test a 5Ω, 55 watt resistor is Refer to Table 9 and follow this procedure to perform a
placed across the battery terminals for approximate- bench test on a control battery in a service shop:
ly 5 seconds. The Form 6 control measures the bat- 1. Remove the control from service. Refer to Remove
tery voltage, if the voltage drops below 22.8 Vdc for the Control from Service procedure within the
one full second, the ALARM LED (battery alarm) is Testing section of this manual.
illuminated.
2. Remove the battery from the control and carefully
• When the Form 6 control is disconnected from AC transport it to a suitable service facility.
power and the control battery drops below 23.5 Vdc
for 60 seconds, the ALARM LED will illuminate. If the 3. Measure battery voltage.
battery voltage continues to decay and drops below 4. Apply test load and measure battery voltage after 5
22 Vdc, the Form 6 control will shut down. seconds of load to determine voltage drop. Refer to
Note: The battery test is blocked for 30 seconds upon power Table 9 for Bench Test Load Condition.
up of the control.
5. Remove test load.
Note: AC power can be either connected or disconnected for
battery test. If the battery fails the test or is at least four years old, it
should be replaced. Refer to Table 9 for battery catalog
1. Press the MENU button on the front panel. part numbers.
2. Using the down arrow key, navigate to the BATTERY
menu and press ENTER.
3. Using the down arrow key, navigate to the TEST BAT-
TERY menu and press ENTER.
4. Press the F4 button to test the battery. The battery
test results will display in the battery metering menu.
Note: Voltage should be between 25–31 Vdc with the
higher voltage at colder temperatures.
Under normal conditions, with AC connected and a
fully charged battery, the charging current should
be less than 20 mA.
With AC connected and a discharged battery the
current range should be between 20 and less than
450 mA. Current of 450 mA or greater indicates a
problem with the charging circuit on the pole mount
power supply.
With AC disconnected and the battery supplying
the load, current will read -400 to -600 mA depend-
ing on connected accessories.
TABLE 9
Control Battery Bench Testing and Replacement Information
Bench Acceptable
Battery Test Load Voltage Drop
Catalog Amp/ Condition at End of
Control Type Battery Part # Voltage Type Hour for 5 sec. Test Load
Form 6-TS/LS (high capacity) Hawker KME5-134-1 24v Lead 13 5Ω 2v
Genesis (two Acid 55 watt or less
12v
batteries)

41
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

Battery Charging Charge the battery with a KA43ME7001 (120 Vac)

portable charger. Connect the battery directly to the
If it is not possible to charge the battery with the control’s KA43ME7001 charger. The charger continuously moni-
built-in charger, a KA43ME7001 (120 Vac) portable tors the battery voltage.
bench type battery charger is available. Refer to S280-
79-14 KA43ME7001 Portable Lead Acid Battery Charger Note: A red LED indicator on the body of the charger illumi-
Instructions for additional information. nates when charging.

IMPORTANT: Do not attempt to charge a lead acid IMPORTANT: Never connect a single 12 volt battery to
battery below 19 Vdc with the KA43ME7001 charger. the KA43ME7001 charger. Use adapter KME5-325-1
Attempting to do so will damage the charger. with the battery assembly when connecting the charg-
er to the two 12 volt batteries.
If the lead acid battery is below 19 Vdc, replace the
battery. The expired battery should be disposed of in
an environmentally responsible manner. Consult local The charger senses when the battery voltage reaches
regulations for proper battery disposal. 2.27 volts per cell, then the charge rate reduces to main-
tain a trickle charge.
The red LED flickers to indicate the battery has reached
a full charge. This process can take up to 24 hours.

42
 !
SAFETY
FOR LIFE
S280-70-8

Return the Control to Service CAUTION: Equipment misoperation. Verify that

! the 120/240 Vac selector switch is correctly set
CAUTION: Equipment misoperation. Do not for incoming voltage. Failure to comply may cause
! connect this control to an energized recloser until misoperation (unintentional operation) of the control
all control settings have been properly programmed and/or equipment damage resulting in personal injury.
and verified. Refer to the programming information for T278.0

this control. Failure to comply can result in control and

recloser misoperation, equipment damage, and per- 5. Verify the selector switch on the Power
sonal injury. G110.3 Supply/Battery Charger Board is set to the 115V posi-
tion for 120 Vac incoming power.
6. Apply ac power to the control.
After the required work is completed, disconnect the con-
trol from the test set and follow this procedure to return 7. Disable GND TRIP BLOCKED.
the control to service: A. Press the CHANGE button on the Operator Panel
1. While still in service shop, appropriate personnel to enter the CHANGE mode.
must verify that all control settings are correct. B. Depress the GND TRIP BLOCKED button within
2. Reconnect the ground cable to the control. ten seconds after entering the CHANGE mode.
Note: Once selected (or after ten seconds), the control
CAUTION: Equipment misoperation. Disconnect all returns to normal operation.
control power sources prior to disconnecting the con- 8. Verify the control clock is set to the current time after
trol cable from the control. Failure to comply can result ac power has been reapplied.
in recloser misoperation at the time of disconnection or
reconnection of the control cable to the control. T311.0 Note: The control clock may require resetting if the oper-
ating power has been disconnected for more than
thirty days. Refer to Service Information S280-70-9
IMPORTANT: Prior to reconnecting the control cable, Form 6-TS Recloser Control Programming Guide
verify the control was removed from service in the for information on setting the control clock.
exact order specified in the Remove the Control from
Service section of this manual.

3. Control cable properly connected and supported.

4. Plug in the control battery.
Note: The Form 6-TS/LS recloser control will not power
up until ac power is applied.

43
Form 6 Triple-Single/LS Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

ADDITIONAL INFORMATION
Factory-Authorized Service
CAUTION: This equipment requires routine Centers
!inspection and maintenance to ensure proper
operation. If it is not maintained, it can fail to operate Factory-authorized service centers are located through-
properly. Improper operation can cause equipment out the continental United States to provide mainte-
damage and possible personal injury. G105.1
nance, repair and testing services for Kyle controls and
reclosers. For further information, contact your Cooper
Power Systems representative.
Replacement Kits
Replacement kits for the Kyle® Form 6/Triple-Single-LS Factory Maintenance Classes
pole mount control are available through the factory The factory service department offers a basic testing and
Service Department. To order these kits, refer to the troubleshooting course for the Form 6 recloser control.
Replacement Parts price list for catalog numbers and This course, taught by experienced service technicians,
pricing. Contact your Cooper Power Systems represen- is held at the factory’s in-house training facility. For addi-
tative for additional information and order procedures. tional information, contact your Cooper Power Systems
representative.

!
SAFETY
FOR LIFE

KA2048-622 Rev: 00

©2004 Cooper Power Systems or its affiliates.

Kyle® is a registered trademark of Cooper Power Systems or its affiliates. 1045 Hickory Street
ProViewTM, Idea WorkbenchTM, Communications WorkbenchTM, and Pewaukee, WI 53072
TCC EditorTM are trademarks of Cooper Power Systems or its affiliates. www.cooperpower.com

44 KDL
12/04