Cooper Lighting Power Supply S280 79 10 User Manual

Reclosers  
®
Service Information  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA  
Microprocessor-Based Recloser Controls  
Installation and Operation Instructions  
S280-79-10  
Applicable to serial numbers above 3000 or beginning with CP57.  
99001KM  
Figure 1.  
®
Kyle Form 5/UDP microprocessor-based recloser control.  
Contents  
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 2  
Product Information . . . . . . . . . . . . . . . . . . . . . . . . 3  
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
ANSI Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
Quality Standards . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
Acceptance and Initial Inspection . . . . . . . . . . . . . . 3  
Handling and Storage . . . . . . . . . . . . . . . . . . . . . . . 3  
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . 3  
Control Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
Initializing the Control . . . . . . . . . . . . . . . . . . . . . . . 4  
Form 5 Control Description . . . . . . . . . . . . . . . . . . 5  
Recloser Interface (RIF) Module . . . . . . . . . . . . . . 6  
Central Processing Unit (CPU) Module . . . . . . . . . 6  
Discrete Interface (DIF) Module . . . . . . . . . . . . . . . 6  
Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . 6  
Form 5 Control Operator Panel . . . . . . . . . . . . . . . 7  
Battery Test Procedure . . . . . . . . . . . . . . . . . . . . . . 14  
Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . 19  
Auxiliary Power for Accessories . . . . . . . . . . . . . . 20  
Recloser Interface (RIF) Module Configuration . . 20  
Discrete Interface (DIF) Accessory . . . . . . . . . . . . 23  
Customer Connection Information . . . . . . . . . . . . . 23  
Standard and UDP DIF Module 1 Inputs . . . . . . . . 26  
Standard and UDP DIF Module 1 Outputs . . . . . . . 28  
Standard and UDP Module 2 Inputs . . . . . . . . . . . . 29  
Standard and UDP Module 2 Outputs . . . . . . . . . . 30  
Input Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31  
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . 32  
Initial Programming Prior to Installation . . . . . . . . . 32  
Control / Recloser Compatibility . . . . . . . . . . . . . . . 32  
Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32  
Mounting the Control . . . . . . . . . . . . . . . . . . . . . . . 33  
Grounding the Control . . . . . . . . . . . . . . . . . . . . . . 34  
Customer Connections for AC Power . . . . . . . . . . . 38  
Customer Connections for Metering . . . . . . . . . . . . 38  
Before Placing Control and Recloser into Service . 42  
Testing and Troubleshooting . . . . . . . . . . . . . . . . 43  
Testing an Installed Control . . . . . . . . . . . . . . . . . . 43  
Testing with Type MET Tester . . . . . . . . . . . . . . . . 43  
Closing the Recloser During Testing . . . . . . . . . . . 44  
Form 5 Control Default Test Procedure . . . . . . . . 47  
Remove the Control from Service . . . . . . . . . . . . . 55  
Return the Control to Service . . . . . . . . . . . . . . . . 55  
Additional Information . . . . . . . . . . . . . . . . . . . . . . 56  
Form 5 Universal Device Protection (UDP)  
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21  
Form 5 DC NOVA Control . . . . . . . . . . . . . . . . . . . 22  
November 2001 • Supersedes 1/01  
1
Download from Www.Somanuals.com. All Manuals Search And Download.  
Printed in USA  
!
SAFETY  
FOR LIFE  
S280-79-10  
PRODUCT INFORMATION  
Control Battery Storage and Charging  
Introduction  
Service Information S280-79-10 provides installation and  
operation instructions for the Kyle Form 5 and Form 5  
UDP microprocessor-based electronic recloser controls.  
The 24 Vdc control battery in the Form 5 control is fully  
charged prior to shipment and is ready for use. In order to  
maintain sufficient charge to operate the control, the  
sealed lead acid battery should be charged after no more  
than three months of storage.  
Read This Manual First  
Note: Two 12 Vdc, 13 amp-hour batteries are available for  
use with the Form 5 Distribution Automation upgrade  
accessory.  
Read and understand the contents of this manual and fol-  
low all locally approved procedures and safety practices  
before installing or operating this equipment.  
Temperature has an effect on battery life. Sealed lead  
acid batteries should be stored, fully charged, at room  
temperature. Never store lead acid batteries at tempera-  
ture exceeding 47°C (117°F), as damage can result in  
approximately one month.  
Additional Information  
These instructions cannot cover all details or variations in  
the equipment, procedures, or process described, nor  
provide directions for meeting every possible contingency  
during installation, operation, or maintenance. When  
additional information is desired to satisfy a problem not  
covered sufficiently for the user's purpose, please contact  
your Cooper Power Systems sales representative.  
IMPORTANT: To maintain sufficient charge to oper-  
ate the control and prevent battery cell damage, the  
sealed lead-acid batteries should be charged after no  
more than three months of storage.  
ANSI Standards  
Kyle reclosers are designed and tested in accordance  
with the following ANSI standards: C37.60 and C37.85  
and ANSI Guide C37.61.  
To keep the battery charged, energize the control’s built-  
in charger with AC power applied to the user AC supply  
input connector block TB1, located left of the RIF module  
within the control cabinet.  
Note: When shipped from the factory, the battery source is  
disconnected and its output plugs are taped to the cab-  
inet. Connect the battery plugs into the mating connec-  
tors to complete the battery circuit.  
Quality Standards  
ISO 9001:2000-Certified Quality Management System  
Acceptance and  
Initial Inspection  
Each Form 5 control is completely assembled, tested, and  
inspected at the factory. It is carefully calibrated, adjusted  
and in good condition when accepted by the carrier for  
shipment.  
IMPORTANT: Connect the control battery when AC  
power is connected to the control’s AC supply Input Ter-  
minal Block. The battery must be disconnected prior to  
shipping or storing the control.  
Upon receipt, inspect the carton for signs of damage.  
Unpack the control and inspect it thoroughly for damage  
incurred during shipment. If damage is discovered, file a  
claim with the carrier immediately.  
Battery Replacement  
The 24 Vdc control battery has a life expectancy of 4 to 6  
years. It is recommended that the battery be replaced  
after 4 years.  
Handling and Storage  
Control Power  
Be careful during handling and storage of the control to min-  
imize the possibility of damage. If the control is to be stored  
for any length of time prior to installation, provide a clean,  
dry storage area. If storage is in a humid atmosphere, make  
provisions to keep the control circuitry energized.  
The primary source of power is factory configured for 120 Vac  
or 240 Vac. The 240 Vac version is available as an option  
at time of order entry. Primary power is rectified to charge  
the power capacitor and to power the dc/dc converter that  
provides power to the control. A minimum of 500 mA of ac  
current is required for heater operation, battery charging  
current, and to keep all modules energized.  
Note: To energize the control, apply AC power to the AC sup-  
ply input connector block TB1 located left of the  
Recloser Interface (RIF) module within the control.  
Refer to the Customer Connection for AC power sec-  
tion in this manual.  
3
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
The AC power LED indicator on the operator panel of the  
AC Reclosers  
control will turn off after 15 seconds upon loss of AC  
power. The indicator will illuminate immediately upon  
return of ac power.  
Power to operate the tripping and closing solenoids in the  
recloser is provided by the power capacitor located  
behind the operator panel of the control. A sealed, 24-volt,  
lead acid battery is located in the lower portion of the con-  
trol cabinet and is utilized to provide operating and trip-  
ping energy when AC power is temporarily lost. The  
control is equipped with an ac-powered, temperature-  
compensated battery charger.  
Initializing the Control  
Two methods are available to initialize the Form 5 control.  
Method 1: Connect AC power to the input connector ter-  
minal TB-1. Refer to the Customer Connec-  
tions for AC Power section of this manual.  
Operation Upon Loss Of AC Power  
Method 2: Connect the battery terminal on the control  
and press the MANUAL BATTERY RECON-  
NECT button located on the Form 5 power  
supply. See Figure 4.  
If the control is equipped with the standard 24 Vdc lead-  
acid battery, the control maintains full operation from the  
battery power supply for a minimum of 32 hours at 20°C  
(24 hours at -40°C). To prevent battery damage, the con-  
trol shuts down automatically upon detection of low bat-  
tery voltage below 22.7 Vdc.  
Note: Method 2 powers the control off the battery  
and is not intended for long term operation.  
In both methods, after initialization, set the control clock  
via the interface software.  
Control programming settings and parameters—including  
event recorder, duty monitor, and data profile metering  
parameters—are stored in non-volatile memory and  
retained upon loss of control power. The time/date clock  
resets to 0:00:00, 1970 upon loss of control power.  
LCD Display  
CONTROL OK  
AC POWER  
ABOVE MIN TRIP  
CHECK BATTERY  
RECLOSER MALFUNCTION  
REVERSE POWER FLOW  
BACK  
NEXT  
BUSHINGS 1-2 FAULT TARGET  
LED Indicators  
RESET  
TARGETS  
BUSHINGS 3-4 FAULT TARGET  
CHANGE  
RESET  
MAX CURRENT  
LAMP  
TEST  
BUSHINGS 5-6 FAULT TARGET  
GROUND FAULT TARGET  
LCD Display Dedicated  
Function Keys  
NON  
RECLOSING  
GND TRIP  
BLOCKED  
SUPERVISORY  
BLOCKED  
SENSITIVE-GROUND FAULT TARGET  
COLD LOAD  
PICK UP  
FAST  
TRIPS  
DISABLED  
BUSHINGS 1-2 VOLTAGE  
BUSHINGS 3-4 VOLTAGE  
BUSHINGS 5-6 VOLTAGE  
BATTERY  
TEST  
BLOCKED  
ALTERNATE  
PROFILE  
ALTERNATE  
PROFILE  
ALTERNATE  
PROFILE  
NO.  
1
NO.  
2
NO.  
3
Operation "Hot Keys"  
TX 2  
TX 3  
HOT LINE  
TAG  
RECLOSER CLOSED  
RECLOSER OPEN  
ON  
OFF RX 3  
CLOSE Pushbutton  
RS232  
RX 2  
CONTROL LOCKOUT  
RS232 Data Port  
Hot Line Tag  
TRIP (LOCKOUT)  
Pushbutton  
TRIP  
(LOCKOUT)  
®
CLOSE  
KYLE  
FORM 5  
RECLOSER CONTROL  
Figure 2.  
Form 5 recloser control operator panel.  
99005KM  
4
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
FORM 5 CONTROL DESCRIPTION  
Current sensing is provided by three current transformers  
located in the recloser and interfaced to the Form 5 control  
via the control cable. This cable also supplies Trip, Close,  
and Recloser status, and connects to the Recloser Inter-  
face (RIF) module to provide isolation for reliable opera-  
tion. Voltages for metering are also connected to the RIF  
module via the connector terminal block, TB-1 (Figure 3).  
The following chain of events occurs for an operating  
sequence of two trips to lockout:  
1. The overcurrent signal is integrated with time on the  
selected curve for the first trip operation (TCC1) to  
produce the signal which energizes the trip circuit.  
2. Energizing the trip circuit connects the battery and  
capacitor to the trip solenoid to open the recloser.  
A functional block diagram of the Form 5 control is shown  
in Figure 3. Line current flowing through the recloser is  
converted by the CPU module to a digital signal suitable  
for metering and fault current calculations. Data sampling  
occurs at a rate 32 times per cycle. The CPU contains a  
data acquisition section that uses the acquired samples to  
compute the fundamental currents and voltage for use in  
overcurrent, under/over voltage and under/over frequency  
protection, as well as currents and voltages for metering  
functions. The current for overcurrent protection is calcu-  
lated on a sub-cycle basis; it includes only the fundamen-  
tal and DC component. For metering, the fundamental and  
harmonic current and voltages are determined.  
3. Upon opening, the control starts timing on the first  
reclosing interval-delay time.  
4. Upon expiration of this reclosing interval-delay, a clos-  
ing signal is issued from the control, closing the  
recloser and selecting the time-current characteristics  
for the second trip operation (TCC2).  
5. If current remains above the minimum-trip level, the  
tripping and reclosing sequence is repeated.  
6. The control begins the reset-delay timer if the over-  
current is cleared before the operating sequence  
reaches lockout indicated by a closed recloser and  
current below minimum trip.  
When the phase or ground current exceeds its pro-  
grammed minimum-trip value and associated time-cur-  
rent curve (TCC) timing, the control initiates the  
programmed sequence of recloser tripping and reclosing  
operations via the CPU and RIF modules. If the fault is  
temporary, the control ceases to command recloser oper-  
ations after a successful reclose, and the control resets to  
the start of its operating sequence after a preset time  
delay. If the fault is permanent, the control performs its  
complete programmed sequence of reclose commands  
and locks out with the recloser open. Once locked out, the  
control must be closed via the operator panel or SCADA  
communications. This resets the control to the start of the  
operating sequence.  
7. When the reset-delay times out, the control is reset to  
the home state and is ready for another programmed  
operating sequence. If current rises above minimum  
trip prior to the reset-delay timing out, the timer is  
halted and the control resumes the operating  
sequence while the accumulated reset-delay timing is  
restarted.  
TB1 TERMINAL BLOCK  
POWER SUPPLY  
BATTERY  
CUSTOMER P.T. INPUTS  
RECLOSER  
RIF  
OPTICAL  
ISOLATION  
OPERATOR'S  
PANEL  
DIF#2  
(OPTIONAL)  
TRIP SOLENOID  
DIF#1  
(OPTIONAL)  
CPU  
OPTICAL  
ISOLATION  
CLOSE SOLENOID  
KEYBOARD  
LED's  
OPEN / CLOSE  
SWITCHES  
OPTICAL  
ISOLATION  
LCD  
RS232 PORT  
A Ø CT  
B Ø CT  
C Ø CT  
MATCHING  
TRANSFORMERS  
AND SIGNAL  
CONDITIONING  
12  
12  
RS232  
Or  
12  
12  
FIBER-OPTIC  
PORT  
USER  
USER  
CT COMMON  
CONNECTIONS  
6 unlatched outputs  
6 latched outputs  
12 inputs  
CONNECTIONS  
6 unlatched outputs  
6 latched outputs  
12 inputs  
OPTIONS  
RS232  
Or  
FIBER-OPTIC  
PCB  
Figure 3.  
Form 5 control operational flow diagram.  
5
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
The Form 5 control is constructed in a modular fashion to  
Central Processing Unit (CPU)  
simplify service and the addition of accessories (Figure  
4). The standard configuration incorporates a Central  
Processing Unit (CPU) module, power supply module,  
Recloser Interface (RIF) module, and an operator panel.  
Module  
The CPU module is the center of the Form 5 control. The  
CPU contains a 32-bit micro-controller, a Digital Signal  
Processor, RAM and EEPROM memory, and a 16-bit  
analog-to-digital converter. The CPU module accepts 16  
analog inputs which it routes through the digital signal  
processor, which samples 32 times per cycle, to compute  
harmonic analysis to the 15th harmonic.  
Discrete Interface (DIF) module(s), the fiber-optic board  
and the RS-232 communication interface cards may be  
ordered as accessories. Mounting provisions can be  
provided to add customer-supplied radio and modem  
modules.  
Discrete Interface (DIF) Module  
Recloser Interface (RIF) Module  
The Discrete Interface (DIF) module allows users with  
existing RTUs the ability to interface with the Form 5 con-  
trol. The DIF module contains 12 inputs and 12 outputs  
can be customized for a remote or supervisory function.  
One Form 5 control can accommodate two DIF modules.  
See DISCRETE INTERFACE (DIF) ACCESSORY sec-  
tion of this manual.  
The Recloser Interface (RIF) Module provides the inter-  
face between the recloser and the CPU module, as well  
as the interface between the voltage sensors and the  
CPU module. The RIF is designed to interface with the fol-  
lowing reclosers: WE/WVE group, NOVA group,  
VSA/VSO group, and KFME/KFVME (50Hz) group.  
The recloser connector includes three current-trans-  
former inputs, Open and Closed status sensing, and Trip  
and Close controls. The voltage sensor connector  
accepts six voltage inputs; three for source-side, and  
three for load-side voltage. Two sets of dip switches,  
located on the RIF front panel, utilize different switch posi-  
tions to configure the desired voltage. See Figure 17.  
Power Supply Module  
The Power Supply module is designed to accept 100 to  
134 Vac or 200 to 268 Vac user-supplied input power at  
either 50 or 60 Hz.  
The Power supply module (connection P9) provides aux-  
iliary power to radio communications units, RTUs and  
other accessories. The auxiliary output provides 24 Vdc  
(12 Vdc is available) for user loads. The auxiliary power  
supply has the capability to provide a load of up to 40 W  
peak (1 second) and 3 W average. The auxiliary power is  
fused and current-limited to prevent user loads from dis-  
abling the control.  
The RIF board accepts either 12, 120, or 240 Vac voltage  
inputs for metering. The factory configuration is outlined  
on the module label and can be customized to user spec-  
ification. See RECLOSER INTERFACE (RIF) MODULE  
CONFIGURATION section of this manual.  
Recloser Interface  
(RIF) Module  
Manual Battery  
Reconnect Button  
Auxiliary Power  
Connection (P9)  
Grounding Strap  
Power Capacitor  
Central Processing  
Unit (CPU) Module  
Power  
Supply  
Module  
(Located behind operator  
panel)  
TB1 Connector  
Block  
Control Cable Receptacle  
and Control Grounding Lug  
(located beneath cabinet)  
Control Battery  
99001KM  
Figure 4.  
Form 5 UDP control operating panel with interface modules and radio mounting provisions.  
6
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
AC POWER  
Form 5 Control Operator Panel  
This green LED is illuminated when the presence of ac  
input power to the control is sensed. The LED will turn off  
if ac power is lost for more than 10 seconds.  
The Form 5 control operator panel (Figure 8) allows local  
operation and status interrogation through built-in operator  
controls and status displays. The operator panel contains  
LED indicators, operational pushbuttons, membrane-type  
functional/indication switches, backlit LCD display, and  
Hot Line Tag switch with indication. An RS-232 port is also  
provided to permit the temporary connection of a PC for  
programming the parameters in the control.  
ABOVE MIN TRIP  
This red LED is illuminated when the control detects that  
current is above the programmed minimum trip value for  
Bushings 1-2, Bushings 3-4, Bushings 5-6, Ground, or  
Sensitive Ground.  
All indicators with the exception of Hot Line Tag and  
recloser status are automatically turned off after 5 minutes  
of operator panel inactivity.  
CHECK BATTERY  
This red indicator illuminates for two conditions:  
Reactivating is accomplished by pressing any operation  
switch. The LCD messages will remain while in this  
power-saving mode, although the illuminating backlight  
will shut off.  
1. Battery voltage is below 20 Vdc or drops 2Vdc or more  
during battery test.  
2. The control fails a manual battery test. The LED will  
remain on until a successful battery test is completed.  
Refer to the Battery Test Procedure in this manual for  
more information.  
CONTROL OK  
AC POWER  
ABOVE MIN TRIP  
RECLOSER MALFUNCTION  
This red indicator is illuminated when the control detects  
a failure in a trip or close operation. It turns off automati-  
cally if the recloser returns to the proper state.  
CHECK BATTERY  
RECLOSER MALFUNCTION  
REVERSE POWER FLOW  
BACK  
NEXT  
BUSHINGS 1-2 FAULT TARGET  
REVERSE POWER FLOW  
RESET  
TARGETS  
BUSHINGS 3-4 FAULT TARGET  
BUSHINGS 5-6 FAULT TARGET  
GROUND FAULT TARGET  
CHANGE  
RESET  
MAX CURRENT  
LAMP  
TEST  
This red indicator illuminates when the control detects  
power flow from the load side to the source side of the  
recloser.  
NON  
GND TRIP  
BLOCKED  
SENSITIVE-GROUND FAULT TARGET  
SUPERVISORY  
BLOCKED  
RECLOSING  
Note: Voltage sensor polarity and phase must be correct for  
COLD LOAD  
PICK UP  
FAST  
TRIPS  
DISABLED  
BUSHINGS 1-2 VOLTAGE  
BUSHINGS 3-4 VOLTAGE  
BUSHINGS 5-6 VOLTAGE  
BATTERY  
TEST  
BLOCKED  
reverse power flow to function properly.  
ALTERNATE  
PROFILE  
ALTERNATE  
PROFILE  
ALTERNATE  
PROFILE  
NO.  
1
NO.  
2
NO.  
3
BUSHINGS 1-2 FAULT TARGET  
BUSHINGS 3-4 FAULT TARGET  
BUSHINGS 5-6 FAULT TARGET  
GROUND FAULT TARGET  
TX 2  
TX 3  
HOT LINE  
TAG  
RECLOSER CLOSED  
RECLOSER OPEN  
ON  
OFF RX 3 RX 2  
RS232  
CONTROL LOCKOUT  
SENSITIVE GROUND FAULT TARGET  
These red target LEDs illuminate when the control issues  
an overcurrent trip signal while the respective phase cur-  
rent or ground current exceeds the minimum pickup  
value. Reset is accomplished automatically when Auto  
Reset is activated and a successful close operation is per-  
formed or manual reset is accomplished by pressing the  
RESET TARGETS button on the control operator panel.  
TRIP  
(LOCKOUT)  
®
CLOSE  
KYLE  
FORM 5  
RECLOSER CONTROL  
Figure 5.  
BUSHINGS 1-2 VOLTAGE  
BUSHINGS 3-4 VOLTAGE  
BUSHINGS 5-6 VOLTAGE  
Form 5 control operator panel.  
LED Indicators  
These red voltage LEDs illuminate when the control  
detects the presence of voltage on the respective bush-  
ings as connected to TB1. Refer to the Customer Con-  
nections for AC Power section in these instructions to  
determine the appropriate power connections.  
The operator panel LED indicators (Figure 5) give instant  
information on the control and recloser status.  
LED indicators include:  
CONTROL OK  
RECLOSER CLOSED  
This green LED is illuminated when the continuous self-  
diagnostics of the control have detected no CPU or mem-  
ory malfunctions and indicate that the control is capable of  
normal operation.  
This red indicator is illuminated when the control senses  
that the recloser mechanism is in the closed position.  
7
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
RECLOSER OPEN  
This green indicator is illuminated when the control senses  
that the recloser mechanism is in the open position.  
CONTROL LOCKOUT  
This green indicator is illuminated when the recloser is  
open and a reclosing sequence is not in progress or when  
the lockout handle on the recloser mechanism is in the  
BACK  
NEXT  
down position; i.e., trip and close circuits are open.  
RESET  
TARGETS  
Note: The RECLOSER MALFUNCTION, RECLOSER OPEN,  
RECLOSER CLOSED, and RECLOSER LOCKOUT  
LEDs will flash upon detection of a trip failure. See the  
Control Features section of this manual.  
CHANGE  
RESET  
MAX CURRENT  
LAMP  
TEST  
Figure 6.  
TRIP (Lockout) Pushbutton  
LCD display and dedicated function keys.  
The TRIP pushbutton (Figure 2) provides front-panel  
access to trip (lockout) the recloser. When pressed, the  
TRIP push-button opens the recloser and locks out the  
control.  
BACK Key  
Pressing the BACK key causes the LCD display to scroll  
to the previous screen of available information. Pressing  
and holding the BACK key causes the control to scroll to  
previous screen.  
CLOSE Pushbutton  
When pressed, the CLOSE pushbutton (Figure 2) returns  
the control to the initial or home position, closing the  
recloser. The control is ready for the start of a new  
trip/close sequence.  
RESET TARGETS/RESET MAX  
CURRENT Key  
Pressing the RESET TARGETS/RESET MAX CURRENT  
key resets the fault target indicators on the control opera-  
tor panel. The fault current values shown on Screen 2 of  
the LCD display will reset to values of zero.  
Note: Pressing the CLOSE pushbutton from the Lockout posi-  
tion, will initiate Cold Load Pickup (CLPU) protection, if  
the feature is first enabled from the interface software  
Protection Profile screen, and the COLD LOAD PICKUP  
BLOCKED LED on the operator panel is not lit.  
Pressing and holding the RESET TARGETS/RESET  
MAX CURRENT key for three seconds will reset the min-  
imum and maximum current and histogram values in LCD  
Display screens 34 through 37. This key will also reset the  
Trip Failure Detection feature. See the Control Features  
section of this manual.  
If the recloser is closed, pushing the CLOSE pushbutton  
has no effect on the control. Depressing and holding the  
CLOSE pushbutton does not activate the Cold Load  
Pickup feature. See Cold Load Pickup in the Control  
Features section of this manual.  
The Form 5 control has a Manual Close Delay feature that  
provides an interval of time from when the CLOSE push-  
button is depressed to the time when manual close oper-  
ation is performed. See Manual Close Delay in the  
Control Features section of this manual.  
CHANGE/LAMP TEST Key  
Pressing this key for less than three seconds places the  
control into a CHANGE mode for 10 seconds as indicated  
by the LCD display. CHANGE mode permits the user to  
change the state of the nine function/indicator switches on  
the operator panel. Security is enhanced by permitting a  
only one selection for each CHANGE mode period.  
LCD Display  
The control operator panel has a large, backlit LCD dis-  
play (Figure 6) used for viewing control parameters and  
monitoring system conditions. Data is organized into  
screens of information, with each display containing four  
lines of information, with up to 20 characters per line.  
Access to the screens is obtained through navigational  
keys which permit the user to scroll through the menu in a  
timely and efficient manner.  
Pressing and holding the CHANGE/LAMP TEST key for  
three seconds will cause the control to perform a front-  
panel lamp test. In the Lamp Test Mode, the status indi-  
cators flash three times (one second on, one second off).  
All status indicators then return to their previous state.  
While in the Lamp Test Mode, the control response to  
operator panel keys is disabled, except for the TRIP  
(LOCKOUT), CLOSE, and HOT LINE TAG switches.  
When an overcurrent trip occurs, the control automatically  
displays the fault current values as shown on the LCD dis-  
play as Screen 1. Refer to LCD Display Screens section  
of this manual.  
NEXT Key  
Pressing the NEXT key causes the LCD display to scroll to  
the next screen of available information. Pressing and hold-  
ing the NEXT key causes the control to scroll to subsequent  
screens at the rate of about two screens per second.  
8
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
LCD Display Screens  
Screen 6 S1 Phase-to-Neutral, Instant. Voltage  
6 Instant S1 Ph-N  
Every LCD display screen contains a parameter name,  
parameter value, and parameter units. If the control  
detects that a parameter value is invalid, the LCD display  
shows five dash characters (- - - - -) in the value field of the  
screen. Demand metered values are indicated by (D) and  
instantaneous values by (I).  
Ph1-N  
Ph3-N  
Ph5-N  
____________ V  
____________ V  
____________ V  
Screen 1 Instantaneous Load Current  
Screen 1 displays line current values present for the last  
overcurrent trip operation. Values are reset to zero when  
the fault targets are reset.  
Screen 7 S1 Phase-to-Phase, Instant. Voltage  
7 Instant S1 Ph-Ph  
Ph1-3  
Ph3-5  
Ph5-1  
____________ V  
____________ V  
____________ V  
1 Gnd  
Ph1-2  
Ph3-4  
Ph5-6  
____________ A  
____________ A  
____________ A  
____________ A  
Screen 8 S2 Phase-to-Neutral, Instant. Voltage  
8 Instant S2 Ph-N  
Screen 2 Fault Targets  
Ph2-N  
Ph4-N  
Ph6-N  
____________ V  
____________ V  
____________ V  
2 Gnd Fault  
Ph1-2 Fault  
Ph3-4 Fault  
Ph5-6 Fault  
____________ A  
____________ A  
____________ A  
____________ A  
Screen 9 S2 Phase-to-Phase, Instant. Voltage  
9 Instant S2 Ph-Ph  
Ph2-4  
Ph4-6  
Ph6-2  
____________ V  
____________ V  
____________ V  
Screen 3 Frequency Trip  
3 Freq Trip____________ Hz  
Screen 10 Instantaneous Voltage  
Time  
Date  
Present Freq ____________ Hz  
10 Instant S1-S2  
Ph1-2 Dif ____________ V  
Ph3-4 Dif ____________ V  
Ph5-6 Dif ____________ V  
Screen 4 Voltage Trip  
Screen 11 Real Power  
4 Ph1-N VTrip ____________ V  
Ph3-N VTrip  
Ph5-N VTrip  
Time  
____________ V  
____________ V  
Date  
11 Tot  
Ph1-2  
Ph3-4  
Ph5-6  
____________ kW  
____________ kW  
____________ kW  
____________ kW  
Screen 12 Instantaneous kVA  
Screen 5 Power kWh  
12 Tot  
Ph1-2  
Ph3-4  
Ph5-6  
____________ kVA  
____________ kVA  
____________ kVA  
____________ kVA  
5 Tot  
____________ kWh  
Ph1-2  
Ph3-4  
Ph5-6  
____________ kWh  
____________ kWh  
____________ kWh  
9
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
Screen 19 Demand Phase-to-Neutral Voltage  
19 Demand S2 Ph-N  
Screen 13 Instantaneous kVAR  
13 Tot  
Ph1-2  
Ph3-4  
Ph5-6  
____________ kVAr  
____________ kVAr  
____________ kVAr  
____________ kVAr  
Ph2-N(d)  
Ph4-N(d)  
Ph6-N(d)  
____________ V  
____________ V  
____________ V  
Screen 14 Instantaneous Power Factor  
Screen 20 Demand Phase-to-Phase Voltage  
14 Tot  
Ph1-2  
Ph3-4  
Ph5-6  
____________ PF  
____________ PF  
____________ PF  
____________ PF  
20 Demand S2 Ph-Ph  
Ph2-4(d)  
Ph4-6(d)  
Ph6-2(d)  
____________ V  
____________ V  
____________ V  
Screen 15 Instantaneous Total Harmonic Distortion  
Current  
Screen 21 Demand Voltage  
15 Gnd  
Ph1-2  
Ph3-4  
Ph5-6  
____________ %THDI  
____________ %THDI  
____________ %THDI  
____________ %THDI  
21 Demand S1-S2  
Ph1-2(d)  
Ph3-4(d)  
Ph5-6(d)  
____________ V  
____________ V  
____________ V  
Screen 16 Instantaneous Total Harmonic Distortion  
Voltage  
Screen 22 Demand Current  
16 Instant S1 Ph-N  
22 Gnd  
____________ A  
____________ A  
____________ A  
____________ A  
Ph1-N  
Ph3-N  
Ph5-N  
____________ %THDV  
____________ %THDV  
____________ %THDV  
Ph1-2 (d)  
Ph3-4 (d)  
Ph5-6 (d)  
Screen 17 Demand Phase to Neutral Voltage  
Screen 23 Demand kW  
17 Demand S1 Ph-N  
23 Tot (d)  
Ph1-2(d)  
Ph3-4 (d)  
Ph5-6 (d)  
____________ kW  
Ph1-N(d) ____________ V  
Ph3-N(d) ____________ V  
Ph5-N(d) ____________ V  
____________ kW  
____________ kW  
____________ kW  
Screen 24 Demand kVA  
Screen 18 Demand Phase-to-Phase Voltage  
24 Tot  
____________ kVA  
18 Demand S1 Ph-Ph  
Ph1-2(d)  
Ph3-4(d)  
Ph5-6(d)  
____________ kVA  
____________ kVA  
____________ kVA  
Ph1-3 (d) ____________ V  
Ph3-5(d) ____________ V  
Ph5-1(d) ____________ V  
10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
Screen 31 Battery Monitor  
Screen 25 Total kVAr and kVAr per Phase  
The Battery Monitor displays the battery voltage, current,  
and voltage during a battery test. The Battery Monitor is  
used with the Battery Test pushbutton. Refer to the Bat-  
tery Test Procedure section of these instructions for  
more information.  
25 Tot  
____________ kVAr  
____________ kVAr  
____________ kVAr  
____________ kVAr  
Ph1-2(d)  
Ph3-4(d)  
Ph5-6(d)  
31 Battery Monitor  
Normal  
Normal  
Test  
_______ V  
_____ mA  
_______ V  
Screen 26 Demand Power Factor  
26 Tot ____________ PF  
Ph1-2(d) ____________ PF  
Ph3-4(d) ____________ PF  
Ph5-6(d) ____________ PF  
Screen 32 Phase Minimum Trip Settings  
Phase minimum trip settings are listed for the four protec-  
tion profiles. Line 1 is the normal setting, ALT1 is profile  
No. 1, ALT2 is profile No. 2, and ALT3 is profile No. 3.  
Phase Minimum Trip Settings allow verification of trip set-  
tings before selection of an alternate profile.  
Screen 27 Demand THD Current  
32 Phase MT  
ALT1 MT  
______ A  
______ A  
______ A  
______ A  
27 Gnd  
____________ %THDI  
____________ %THDI  
____________ %THDI  
____________ %THDI  
Ph1-2(d)  
Ph3-4(d)  
Ph5-6(d)  
ALT2 MT  
ALT3 MT  
Screen 33 Ground Minimum Trip Settings  
Ground minimum trip settings are listed for the four pro-  
tection profiles. Line 1 is the normal setting, ALT1 is pro-  
file No. 1, ALT2 is profile No. 2, and ALT3 is profile No. 3.  
Ground Minimum Trip Settings allow verification of trip  
settings before selection of an alternate profile.  
Screen 28 Demand THD Voltage  
28 Demand S1 Ph-N  
Ph1-N(d)  
Ph3-N(d)  
Ph5-N(d)  
____________ %THDV  
____________ %THDV  
____________ %THDV  
33 Gnd MT  
Alt1 MT  
______ A  
_______A  
______A  
_______A  
Alt2 MT  
Alt3 MT  
Screen 29 Number of Trips for Ground and Phase  
29 Gnd OC Trip  
Ph1-2 OC Trip  
Ph3-4 OCTrip  
Ph5-6 OC Trip  
____________  
____________  
____________  
____________  
Screen 34 Ground Max, Phase 1-2 Max Demand  
Currents  
34 Gnd Max  
Time  
____________A  
Date  
Ph1-2 Max  
Time  
____________A  
Date  
Screen 30 Number of SGF Trips and Total Trip  
Operations  
Screen 35 Phase 3-4 Max, Phase 5-6 Max Demand  
Currents  
30 SGF OC Trip ______  
35 Ph 3-4 Max  
Time  
____________A  
Date  
Operations  
______  
Ph5-6 Max  
Time  
____________A  
Date  
11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
Screen 41 Communication Port 3 Settings  
Screen 36 Ground Min, Phase 1-2 Min Demand  
Currents  
This message displays the protocol settings (2179 or  
DNP3.0), baud rate, and address for Serial Port #3.  
Baud rate and address are set using the interface soft-  
ware, while protocol is set at the factory based on users  
specifications.  
36 Gnd Min  
Time  
____________A  
Date  
Ph1-2 Min  
Time  
____________A  
Date  
41 Comm Port 3  
Protocol  
______  
_______  
_______  
_______  
Note: Demand currents are a time integrated value and do not  
reflect minimum or maximum instantaneous currents.  
The demand integration time constant is set via the inter-  
face software demand metering screen. These are the  
same values displayed in the histogram screen.  
Speed  
Address  
Operation/Indication Pushbuttons  
Nine frequently used features are provided on the control  
operator panel (Figure 7).  
Screen 37 Phase 3-4 Min, Phase 5-6 Min Currents  
37 Ph3-4 Min  
Time  
____________A  
Date  
Note: These features are activated from the keypad, control  
interface software or SCADA signal.  
Ph5-6 Min  
Time  
____________A  
Date  
To initiate an operation from the operator panel, press the  
CHANGE/LAMP TEST key to enter the CHANGE mode.  
The operator has 10 seconds to select an operation and  
modify settings. If no changes are made, the control will  
return to its operational state prior to entering the  
CHANGE mode. This prevents accidental changing of  
settings.  
Note: Pressing and holding the RESET TARGETS/RESET  
MAX CURRENT key for three seconds will reset the  
minimum and maximum Demand values.  
Red LEDs located on each switch indicate the status of  
the function, regardless of local or remote activation. For  
example, if Cold Load Pickup was activated from a  
SCADA signal, the red indicator would illuminate even  
though it was not activated from the operator panel.  
Screen 38 Fault Location  
38 Fault Location  
Distance  
____________miles  
<Control Identification>  
Date  
Note: Operation LEDs activated from local or remote sources  
do not illuminate when the front panel is in the power-  
save mode.  
Time  
Screen 39 Control Information  
SUPERVISORY  
BLOCKED  
GND TRIP  
BLOCKED  
NON  
RECLOSING  
39 CPU Firmware  
X.XX  
Firmware FW Database  
X
FAST  
TRIPS  
DISABLED  
COLD LOAD  
PICKUP  
BLOCKED  
BATTERY  
TEST  
<Control Identification>  
Date  
Time  
ALTERNATE  
PROFILE  
NO. 1  
ALTERNATE  
PROFILE  
NO. 2  
ALTERNATE  
PROFILE  
NO. 3  
Screen 40 Communication Port 2 Settings  
Figure 7.  
This message displays the protocol settings (2179 or  
DNP3.0), baud rate, and address for Serial Port #2.  
Baud rate and address are set using the interface soft-  
ware, while protocol is set at the factory based on users  
specifications.  
Operation/indication pushbuttons.  
GND TRIP BLOCKED  
Ground Trip Blocked is activated by pressing the  
CHANGE/LAMP TEST key, then pressing the GND TRIP  
BLOCKED key. The red indicator illuminates.  
40 Comm Port 2  
Protocol  
______  
_______  
_______  
_______  
Speed  
Address  
12  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
NON RECLOSING  
HOT LINE TAG Switch  
Non-reclosing mode disables any automatic reclosing  
operations. Non-reclosing does not alter the active TCC.  
The feature is activated by pressing the CHANGE/LAMP  
TEST key, then pressing the NON RECLOSING key. The  
red indicator illuminates.  
WARNING: Hazardous voltage. Do not use Hot  
!
Line Tag as a substitute for a visible disconnect.  
Always establish a visible disconnect prior to perform-  
ing any work requiring a de-energized line. Failure to  
comply may cause death, severe personal injury, or  
SUPERVISORY BLOCKED  
equipment damage.  
T276.0  
Supervisory Blocked disables supervisory SCADA and the  
interface software; remote SCADA remains active. Opera-  
tional data and metering information are available while  
the control is in the SUPERVISORY BLOCKED position.  
The TRIP and CLOSE pushbuttons are active indepen-  
dently of the SUPERVISORY BLOCKED function.  
Hot Line Tag is provided for live-line work applications. All  
closing operations are disabled when the Hot Line Tag  
feature is activated. While active, the control utilizes an  
independent, user-selectable time-current curve for trip  
operations.  
Activation of the feature is restricted to the operator panel  
keypad by pressing the CHANGE/LAMP TEST key, then  
pressing the SUPERVISORY BLOCKED key.  
IMPORTANT: Hot Line Tag activation does not  
cause the recloser to trip open. It only prevents the  
recloser from closing.  
COLD LOAD PICKUP BLOCKED  
The Cold Load Pickup feature is blocked while the COLD  
LOAD PICKUP BLOCKED is active. When CLPU is not  
blocked, the control utilizes the Cold Load Pickup TCC,  
reclose interval, operations to lockout and minimum trip set-  
tings in lieu of the normal first operation protection settings.  
IMPORTANT: Hot Line Tag is intended solely for  
live-line work applications, such as maintenance,  
repairs or improvements to the distribution system, that  
occur while the line remains energized.  
Note: The Cold Load Pickup Blocked key is replaced by the SEN-  
SITIVE GROUND FAULT key on international controls.  
The Hot Line Tag feature (Figure 8) consists of a toggle  
switch and an LED indicator which illuminates when the  
function is active. When active, Hot Line Tag prevents all  
closing attempts and shifts protection to one trip to lockout  
on the programmed time-current curve. The Hot Line Tag  
function takes precedence over Cold Load Pickup, Non  
Reclosing, and Fast Trips Disabled.  
BATTERY TEST  
Depressing the BATTERY TEST key performs a control  
battery test. The red indicator illuminates and turns off  
automatically when the control has finished performing the  
test. Refer to the Battery Test Procedure section of these  
instructions for further details on testing the control battery.  
Activation is accomplished by placing the operator panel  
toggle switch to the ON position, or via SCADA command.  
Hot Line Tag is activated from the operator panel, com-  
munication Port 2, communication Port 3, or a Discrete  
Interface Module (DIF). All sources must be off to de-acti-  
vate Hot Line Tag.  
FAST TRIPS DISABLED  
Fast Trips Disabled commands the control to use the pro-  
grammed Fast Trips Disabled time-current curve for all  
tripping operations.  
ALTERNATE PROFILE Indicator/Key  
The Hot Line Tag feature may only be reset by the source  
which initiates the function. For example, if Hot Line Tag  
is activated at the operator panel, resetting the function is  
only possible at the operator panel, and not via SCADA  
command. For SCADA, Hot Line Tag must be disabled  
via the same port number where Hot Line Tag was origi-  
nally enabled.  
The control has four separate protection profiles; a normal  
profile, and Alternate Profiles 1, 2, and 3. Each profile  
changes all protection parameters for the control. Except for  
the normal profile, each has an indication and selection key.  
During control operation, if the three alternate profile indica-  
tor lights are not illuminated, the normal profile is active.  
To select an alternate profile, press the CHANGE/LAMP  
TEST key, then press the desired alternate profile. To  
return to the normal profile, simply turn off the active alter-  
nate profile. These functions can also be operated  
remotely via communications interfaces.  
Note: Program all protection profiles. Program unused alter-  
nate profiles should be programmed with the same set-  
ting as one of the applicable profiles. Default settings on  
unused alternate profiles can cause unnecessary out-  
ages if they are below normal system requirements.  
Note: The minimum trip values for each protection profile are  
shown on Screens 32 and 33 of the LCD display. Check  
these minimum trip values prior to changing an alternate  
profile to avoid misoperation of the control under load  
conditions.  
HOT LINE  
TAG  
ON  
OFF  
Figure 8.  
Note: On Form 5 UDP controls, Alternate Profile 3 is replaced  
Hot Line Tag Switch.  
with SWITCH MODE.  
13  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
RS-232 Communication Port  
Control Features  
The standard Form 5 control is equipped with a operator  
panel RS-232 port for interface with a personal computer  
running the Form 5 interface software program. This nine-  
pin female data communication equipment (DCE) Port 1  
permits the uploading of all programming information  
stored in the control, including protection profiles, event  
recorder, data profiles, alarms, counters, and metering  
information. Port 1 provides a simple means to download  
operating parameters from a personal computer to the  
control.The protocol, baud rate and address for Port 1 are  
identified from the LCD display.  
The Form 5 recloser control offers numerous standard  
features and accessories that allow the user the utmost  
flexibility in designing a control suitable for their applica-  
tion requirements.  
Under/Over Frequency Loadshedding  
The Form 5 control includes provisions for frequency  
loadshedding that trips the recloser for conditions of under  
or over system frequency. Access to this feature is  
through frequency threshold, trip time, and allowable volt-  
age threshold.  
If a fiber-optic or RS-232 accessory board is connected to  
Port 2 (located on the back of the operator panel) any  
external electrical connection from the operator panel will  
disable the accessory board.  
With the auto-restoration feature, the Form 5 can be set to  
close the recloser after the system frequency and voltage  
have recovered. Parameters available for setting include  
frequency and voltage thresholds and time delay.  
Note: The operator panel RS-232 port is intended only for  
temporary connection of a personal computer. Perma-  
nent serial communications must be made via the RS-  
232 or fiber-optic accessory board.  
A frequency alarm is available and can be configured for  
notification.  
Voltage Protection (120 Vac-based)  
Battery Test Procedure  
The condition of the control battery is tested by depress-  
ing the BATTERY TEST hot key on the operator panel. No  
external current/voltage meter is necessary for testing.  
Voltage protection functionality is included as standard on  
all Form 5 controls. A recloser trip will be issued for under  
and over voltage conditions when the monitored voltage  
falls outside user-specified limits for a selectable time.  
Response mode includes any single-phase, all three  
phases, and single-phase with three-phase inhibit.  
Response mode facilitates protecting against a single  
phase condition common when a high side fuse operates  
on a distribution transformer. Parameters are also avail-  
able to provide auto restoration after a trip. A voltage  
alarm is available and can be configured for notification.  
The control performs a self-test every 12 hours or when  
initiated by an external command. When a battery test is  
initiated, the spurious charge is first drained to allow the  
battery voltage to equalize. A 10-ohm, 55-watt resistor is  
then placed across the battery terminals and a voltage  
drop is calculated. If the drop from the equalized voltage  
to the test voltage exceeds 2 volts, then the CHECK BAT-  
TERY LED is illuminated.  
Protection Profiles  
To perform a battery test:  
Four separate protection profiles are included to allow the  
user to adapt overcurrent settings for varying system con-  
ditions such as load, live line work or weather. The active  
profile is selected from the operator panel or with the inter-  
face software or SCADA (Figure 9). Each profile has 14  
TCC specifications plus reclose intervals, sequence coor-  
dination and reset times to maintain independent protec-  
tion parameters.  
1. Using the Next and BACK keys, scroll through the  
LCD display to Screen 31, the Battery Monitor screen.  
2. Record the NORMAL VOLTS and NORMAL CUR-  
RENT readings from the screen.  
Note: Voltage should be between 25 to 31 volts with  
higher readings at colder temperatures. Under nor-  
mal conditions with ac connected and the battery  
trickle charging, the current should read less than  
20 mA. With ac connected and in bulk charging  
mode, current will range from 12 to 600 mA. With ac  
disconnected and the battery supplying the load,  
current will read -180 mA to -600mA depending on  
accessories connected.  
3. Momentarily, press the CHANGE/LAMP TEST key,  
then BATTERY TEST key.  
Note: AC power can be either connected or disconnected  
for Step 3.  
4. Record the TEST VOLTS reading from the LCD and  
the status of the CHECK BATTERY LED. Service the  
battery if the CHECK BATTERY LED is illuminated.  
Figure 9.  
Interface software sample protection profile.  
14  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
Power Metering  
Power metering includes single- and three-phase Watts,  
VARS, KVARS, KWH measurements, and the per phase  
and total system Power Factor (PF).  
AC POWER  
ABOVE MIN TRIP  
CHECK BATTERY  
RECLOSER MALFUNCTION  
REVERSE POWER FLOW  
Power Factor Sign Metering  
This feature allows a user to configure the sign that is  
applied to the power factor. The user may select between  
the standard definition of power factor (cosine of angle  
between current and voltage) or the Cooper Power Sys-  
tems default of the power factor sign following power flow.  
BUSHINGS 1-2 FAULT TARGET  
BUSHINGS 3-4 FAULT TARGET  
BUSHINGS 5-6 FAULT TARGET  
GROUND FAULT TARGET  
Voltage Metering  
SENSITIVE-GROUND FAULT TARGET  
Six voltages (3-source and 3-load) are metered as stan-  
dard on the Form 5 control. The user selects either phase-  
to-phase or phase-to-ground values from the control  
operator panel, interface software, or serial communica-  
tions. This reference is changed by selecting the voltage  
sensor correction in the Hardwaresetup portion of the  
interface software.  
BUSHINGS 1-2 VOLTAGE  
BUSHINGS 3-4 VOLTAGE  
BUSHINGS 5-6 VOLTAGE  
Fast Trips Disabled  
Fast Trips Disabled provides the user a quick and effi-  
cient method for reducing momentary interruptions or  
blinks. When activated from the front keypad, pro-  
grammed trips to lockout will time according to the  
selected time-current curve for Fast Trips Disabled. This  
curve is programmable for both phase and ground on  
each protection profile. A separate trips-to-lockout setting  
is also provided. See Figure 9.  
RECLOSER CLOSED  
RECLOSER OPEN  
CONTROL LOCKOUT  
Figure 10.  
RECLOSER MALFUNCTION, RECLOSER CLOSED,  
RECLOSER OPEN and CONTROL LOCKOUT LEDs  
will blink for the affected phase as indication of Trip  
Failure.  
Trip Failure Detection  
The Trip Failure Detection feature is an internal diagnos-  
tic alarm for verifying the proper operation of circuit trip-  
ping and fault clearing of the recloser. Trip Failure  
detection indicates the recloser has failed to trip all  
phases following a trip signal from the control. Failure to  
trip is assumed if a current of at least 10 Amps is detected  
approximately 2 seconds after the trip signal is initiated.  
IMPORTANT: The recloser must be isolated and de-  
energized immediately upon detection of trip failure.  
Follow proper procedures and safety practices to iso-  
late and de-energize the recloser.  
Upon activation of the feature, these four LEDs flash 1  
second on, 1 second off (Figure 10):  
The Trip Failure Detection alarm may be triggered from  
many potential sources including mechanical, electrical,  
control, or interrupter failure. Interrupter failure may  
include loss of vacuum in a vacuum interrupter.  
RECLOSER MALFUNCTION  
RECLOSER CLOSED  
RECLOSER OPEN  
To clear Trip Failure Alarm, depress and hold the RESET  
TARGETS/RESET MAX CURRENTS keypad for 3 sec-  
onds. This also resets targets and demand currents.  
CONTROL LOCKOUT  
Note: There is no remote reset available with the trip failure  
detection feature. It cannot be remotely turned off.  
DANGER: Explosion. Stay clear of a recloser  
!
that is in a trip failure mode. A recloser in trip fail-  
When the trip failure alarm is activated, an event is  
recorded and a status alarm activated (if enabled) and  
preserved during system resets.  
ure mode may explode resulting in death or severe per-  
sonal injury.  
T271.0  
To test the Trip Failure Detection feature, see Testing  
With Type MET Tester in the TESTING AND TROU-  
BLESHOOTING section of this manual.  
WARNING: Hazardous voltage. This device is  
!
not a substitute for a visible disconnect. Follow all  
locally approved safety practices. Failure to follow  
proper safety practices can result in contact with high  
voltage, which will cause death or severe personal  
injury.  
G112.1  
15  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
Manual Close Delay  
Event Recorder  
Manual Close Delay provides a delay from the time that  
the manual CLOSE button is pushed to the time the man-  
ual close operation is performed.  
The Event Recorder maintains a log of operating events  
for later readout and analysis by the user. Approximately  
500 events can be stored in non-volatile memory. For  
each event type, time of occurrence, and other relevant  
information is stored. When the event recorder has  
reached is capacity, the oldest event is deleted as a new  
event is added.  
The delay is programmable from 0 to 60 seconds in 1 sec-  
ond increments. A programmed delay value can be over-  
ridden for immediate closing by pressing the CLOSE  
button a second time.  
Histograms  
An active Manual Close Delay can be canceled by press-  
ing the TRIP/LOCKOUT button.  
Demand metered voltages and currents can be reported  
using the histogram tool. It displays the number of occur-  
rences of a variable versus its value in between user-  
defined minimum and maximum limits. Date and time are  
recorded for the maximum and minimum demand values.  
The default setting has the feature disabled (0 seconds).  
The RECLOSER CLOSED LED indicates the status of the  
feature. See Figure 11.  
RECLOSER CLOSED  
RECLOSER OPEN  
Data Profiler  
A fully configurable data profiler is available which allows  
the user to collect information by sampling demand data  
at selectable intervals. These time-stamped values can  
then be plotted to determine weekly load profiles, daily  
harmonic disturbances or hourly voltage fluctuations. The  
data profiler can provide more than 200 days of informa-  
tion, depending upon configuration parameters.  
CONTROL LOCKOUT  
Figure 11.  
The blinking of the RECLOSER CLOSED LED indi-  
cates Manual Close Delay is active.  
Harmonic Analysis  
Cold Load Pickup  
Extensive harmonic analysis is performed by the Form 5  
control for both currents and voltages. Analysis is per-  
formed on-line (updates every 30 seconds) or demand  
integrated to user-specified time values. The Total Har-  
monic Distortion (THD) for current and voltage is available  
from the operator panel display (Figure 12) while com-  
plete analysis, including graphing capabilities, is provided  
from the Form 5 interface software.  
Cold Load Pickup (CLPU) must be enabled through the  
interface software (Figure 13) before it can be activated  
remotely or from the CLOSE pushbutton on the operator  
panel. The CLPU feature provides the user with the abil-  
ity to alter protection for abnormal system conditions. It is  
active for a programmable time interval which begins with  
each manual close. Once this time elapses, protection  
reverts back to the programmed sequence. Use the Form  
5 control interface software to program the activation time  
and time-current characteristics applicable to Cold-Load  
Pickup.  
Pg14 Gnd  
Ph1-2  
%THDI  
%THDI  
%THDI  
%THDI  
Ph3-4  
Ph5-6  
Note: When CLPU is active, the control utilizes the Cold Load  
Pickup TCC, reclose interval, operations to lockout, and  
minimum trip settings in lieu of the normal protection  
settings.  
BACK  
NEXT  
RESET  
TARGETS  
CHANGE  
LAMP  
TEST  
RESET  
MAX CURRENT  
Figure 12.  
Form 5 operator panel harmonic readout.  
Reverse Power Flow  
Feeder load monitoring is enhanced with the inclusion of  
the power flow monitoring feature. When power flow from  
the load to the source side of the recloser is detected, the  
control illuminates an operator-panel indicator. Response  
time to a reverse power condition is one second. An alarm  
is also available for remote interrogation.  
Note: Voltage sensor polarity must be correct for reverse  
Figure 13.  
power flow to function properly.  
Interface software Cold Load Pickup settings.  
16  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
Alarms  
Status and data alarms are available for many control  
parameters such as voltage, currents, thresholds. Data  
alarm function compares metered data to user-pro-  
grammed alarm high and low limits and issues an alarm of  
user-specified priority if limits are exceeded. The status  
alarm function monitors status and issues an alarm of  
user-defined priority when the user programmed alarm  
conditions are met. The alarms are reported via commu-  
nication ports and can be configured to trigger a data pro-  
file and event record. Alarms do not affect the protection  
functions of the control.  
Fault Location  
Fault Location provides an approximate distance of a fault  
from the the Form 5 Control The distance is based on the  
current fault magnitude, the type of fault, and system  
parameters entered by the user. The LCD display (Screen  
38) identifies the estimated distance in miles or kilometers  
(km) from the control.  
The fault location algorithm performs an impedance cal-  
culation based on:  
Figure 14.  
Fault Location configuration screen.  
Single-phase to ground fault  
Phase-to-phase fault  
The following system parameters must be entered via the  
Protection Profile menu for each profile:  
Double-line to ground fault  
Three-phase fault  
Nominal system line-to-line voltage  
This information is recorded as an event in the control  
Event Recorder for retrieval. The fault location algorithm  
does not require voltage sensing. If the location cannot be  
determined, no event is recorded and dashes are dis-  
played on the LCD screen.  
Note: If the Fault Location feature is not desired, the nom-  
inal system voltage parameter should be set at 1.  
Source-side zero sequence and positive sequence  
impedance. This includes impedance up to the loca-  
tion of the Form 5 control.  
Setting the parameters for Fault Location is done through  
the interface software. The user enters line impedance  
parameters and system voltage information into the soft-  
ware via the Protection Profile menu. See Figure 14.  
Line-side zero sequence and positive sequence  
impedance per mile or km.  
The distance units of the line impedance in miles or  
km.  
IMPORTANT: Fault Location is not a protection func-  
tion. Its purpose is to define a fault and provide its  
approximate location relative to the Form 5 control  
detecting the fault.  
Refer to Service Information S280-79-2 Form 5 Micropro-  
cessor-Based Recloser Control Programming Guide for  
additional information.  
17  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
Torque Angle Width parameter restricts the tripping to an  
Directional Sensitive Ground/Earth  
(SGF/SEF) Fault  
angle of plus or minus the specified width about the  
Torque angle setting. For example, if the Maximum  
Torque Angle is 45°, and the Torque Angle Width is set for  
10°, then the control will trip at angles between 35° and  
55°.  
The Directional SGF/SEF Fault feature adds directional  
capabilities to the SGF/SEF protection features. It pro-  
vides a sensitive ground/earth trip if the fault is downline  
of the recloser on a radial distribution system. Directional  
SGF/SEF is used on ungrounded Delta systems for sup-  
pression of ground trips for faults occurring on other circuit  
branches.  
The Zero Sequence Voltage Threshold is used to set the  
threshold voltage below the disabled directional SGF/SEF  
tripping voltage.  
Note: In most cases, a default value of 4 is adequate.  
The user sets the parameters for Direction SGF/SEF  
through the interface software via the Protection Profile  
menu. See Figure 15. In addition to the normal (non-direc-  
tional) SGF/SEF settings, the user enters the following  
directional SGF/SEF parameters:  
Directional SGF/SEF Fault is recorded as an event in the  
control Event Recorder for retrieval. Refer to Service Infor-  
mation S280-79-2 Form 5 Microprocessor-Based Recloser  
Control Programming Guide for additional information.  
Direction Enable  
Note: If Direction Enable is not selected, SGF/SEF tripping  
occurs through normal (non-directional) settings.  
Maximum Torque Angle (-180° to 180°, in 1° increments)  
Torque Angle Width (10° to 90°, in 1° increments)  
Zero Sequence Voltage (V ) Threshold (4 to 130 V)  
0
The Maximum Torque Angle parameter determines the  
angle of maximum tripping sensitivity between the phase  
angle of the zero sequence voltage and current at the time  
of fault. The setting of this value depends on knowledge  
of the power system. Typically, a resistive fault has a  
value of 0°, and a capacitive fault has a value of 90°.  
Figure 15.  
Directional SGF/SEF configuration screen.  
18  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
The RS-232 accessory board and the fiber-optic acces-  
sory boards are located behind the operator panel. Each  
accessory board can be connected to either Port 2 or Port  
3; no two boards can use the same port. The operator  
panel LEDs indicate the status of communication on the  
accessory boards. Temporary connections to the operator  
panel RS-232 port disables fiber-optic or RS-232 commu-  
nication at Port 2.  
Communications  
Communication Ports  
The Form 5 control has three communication ports from  
the CPU module. Two of the three ports are user-acces-  
sible. Communication Port 1 is the operator panel LCD  
display where data is exchanged between the CPU and  
the operator panel. Though not user-configurable, Port 1  
allows for flexible modifications to the front panel for cus-  
tom applications.  
Port 3 provides uninterrupted communication to a  
remote terminal unit (RTU). Refer to S280-79-4 Form 5  
Serial communications Accessory Operation Instruc-  
tions for additional information.  
The operator panel RS-232 communication Port 2 pro-  
vides temporary local personal computer (PC) access  
when connected with a standard 9-pin cable. Port 2 pro-  
vides a dual communication interface for the user. The  
port includes a software switch for two external connec-  
tions; the operator panel RS-232 DB-9 connector, or the  
fiber-optic/RS-232 communication accessories. Local  
connection to the operator panel RS-232 connection  
takes precedence over the communication accessory.  
Disconnecting the operator panel RS-232 communication  
automatically reconnects the communication accessory  
to Port 2.  
TX 3  
TX 2  
RS232  
RX 3  
RX 2  
Figure 17.  
Fiber-Optic/RS-232 receive and transmit LEDs and  
data port on the operator panel. The TX2 and RX2  
LEDs illuminate during communication with the  
operator panel RS-232 port.  
Accessory Ports 2 and 3 are resident on the back of the  
operator panel and can be configured to either 2179 or  
DNP3.0 protocols. Port 3 provides uninterrupted commu-  
nication to the RS-232 or Fiber-Optic accessory, and is  
not affected by any other port or physical connection.  
Figure 16 illustrates the communication configuration for  
serial ports1, 2, and 3.  
Protocols  
Three protocols are available for the Form 5 control and  
are factory-configurable to communication Ports 2 and 3.  
TEMPORARY  
ENGINEERING  
ENGINEERING  
SCADA SYSYEM  
The protocols are:  
OPERATIONS  
(Local PC)  
(Radio, Fiber-Optic, Modem) (Radio, Fiber-Optic, Modem)  
Cooper Power Systems 2179  
DNP3.0, Level 3  
OPERATOR PANEL  
DISPLAY AND  
KEYPAD  
OPERATOR  
PANEL  
RS-232  
RS-232 or  
FIBER-OPTIC  
ACCY  
RS-232 or  
FIBER-OPTIC  
ACCY  
S-Comm Protocol accessory  
Protocol DNP3.0 includes Unsolicited Report by Excep-  
tionfunctionality and Protocol 2179 includes 2-bit status  
functionality.  
AUTO TRANSFER  
SWITCH  
(Operator Panel  
Connection Disables  
Accessory)  
Complete documentation for Cooper Power Systems pro-  
tocols are:  
COMMUNICATIONS  
PORT 2  
(Shared)  
Reference Data R280-90-12, Serial Communication  
Protocol 2179  
COMMUNICATIONS  
PORT 1  
(Internal Use Only)  
COMMUNICATIONS  
CPU  
PORT 3  
(Metering, Histograms  
(Dedicated)  
Profiles, Alarms, Targets)  
Reference Data R280-90-13, Communication Point  
Database for Protocol 2179  
Figure 16.  
Reference Date R280-90-14, Communication Point  
Database for Protocol DNP3.0  
Control communication port configuration.  
Control Information  
Fiber-Optic/RS-232 Accessory  
Control information, including firmware version and  
database version, is factory installed and can not be  
altered by the user. This information is accessible from  
the LCD display, Screen 39.  
Two sets of receive and transmit LEDs (Figure 17) are  
provided on the operator panel for fiber-optic and RS-232  
communications. The TX2 and RX2 LEDs illuminate when  
communicating with the operator panel RS-232 port. The  
TX3 and RX3 LEDs illuminate when communicating with  
either the fiber-optic or RS-232 interface accessory  
boards on communication Port 3.  
Communication Ports 2 and 3 settings can be referenced  
from the LCD display, Screens 40 and 41 respectively.  
(Port 1 shares the same settings as Port 2.)  
19  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
To remove the RIF Module for configuration:  
AUXILIARY POWER FOR  
ACCESSORIES  
1. Disconnect the control battery.  
2. Remove the four connectors from the front of the RIF  
Connection P9 (Figure 18) on the Power Supply module  
provides 24Vdc (12Vdc is available) to power radio com-  
munication units, RTUs and other accessories. The auxil-  
iary power provides 40W peak load capability. Auxiliary  
power is fused and current-limited to prevent user loads  
from disabling the control.  
Module.  
3. Remove the nut and disconnect the grounding strap to  
the operator panel. See Figure 4.  
4. Disconnect the wiring harness connectors from the  
bottom of the RIF Module.  
Customer 28V connections for auxiliary power are made  
to terminals 3 and 1 and are continually energized. Ter-  
minal 2 and 4 are not used at this time.  
Note: Press the locking tabs to release the harness con-  
nectors.  
5. Remove the four 11mm (.437 in) screws securing the  
board to the mounting bracket.  
6. Pull the module out of the cabinet.  
P
8
The dip switches are located on the side of the module.  
7. Configure the RIF board as shown in Figure 19.  
P
C
P
O
U
W
E
R
F1  
8. After configuration, place the module back into posi-  
tion in the control cabinet and secure to the mounting  
bracket with screws previously removed.  
GDC-1A  
S
9. Replace nut securing the RIF Module grounding strap  
U
P
9
SW (-) 4  
28V (-) 3  
P
P
L
10. Replace all connectors on the front and bottom of the  
A
U
X
SW (+) 2  
28V (+) 1  
RIF Module.  
Y
Example shown for 120Vac operation:  
Figure 18.  
SENSOR  
VOLTAGE  
Power Supply Module Connection P9 provides  
24Vdc power to radio communication units.  
POLE1  
POLE2  
12Vac  
120Vac*  
240Vac  
OFF  
OFF  
ON  
OFF  
ON  
ON  
*120Vac is factory-set configuration  
RECLOSER INTERFACE (RIF)  
MODULE CONFIGURATION  
INPUT VOLTAGE  
SELECTION  
The Recloser Interface (RIF) Module is factory-configured  
at 120Vac. For operating voltages other than 120Vac, the  
RIF module must be removed from the control cabinet for  
configuration.  
OFF  
ON  
POLE 1  
BUSHING 2 (XØ)  
POLE 2  
POLE 1  
POLE 2  
BUSHING 4 (YØ)  
POLE 1  
POLE 2  
S
BUSHING 6 (ZØ)  
CAUTION: Equipment damage. Always wear a ground-  
ing wrist strap to control static electricity before handling  
circuit boards. Failure to use this strap may result in cir-  
S7  
INPUT VOLTAGE  
SELECTION  
cuit board damage.  
T253.1  
OFF  
ON  
POLE 1  
BUSHING 1 (AØ)  
POLE 2  
POLE 1  
POLE 2  
IMPORTANT: The Form 5 control must be com-  
pletely de-energized prior to removing and configuring  
the RIF board.  
BUSHING 3 (BØ)  
BUSHING 5 (CØ)  
POLE 1  
POLE 2  
S8  
Figure 19.  
Recloser Interface (RIF) Module indicates the fac-  
tory-configured metering voltage (120Vac).  
20  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
FORM 5 UNIVERSAL DEVICE PROTECTION (UDP) CONTROL  
The UDP function allows the Form 5 control to become a  
switch control to provide indication of overcurrent trip con-  
ditions without issuing an overcurrent trip signal. The con-  
trol is in the recloser mode when the feature is in the OFF  
position, and in the switch mode when the feature is  
ACTIVE.  
While in the switch mode, all automatic open and close  
operations of the recloser (including overcurrent voltage  
and frequency) are blocked. Fault targeting, metering,  
alarms, and event recording functions are active.  
This non-tripping fault indication state is initiated via a  
operator panel pushbutton (labeled SWITCH MODE), dig-  
ital SCADA, or discrete SCADA. The UDP feature has  
local indication at the operator panel (LED), digital indica-  
tion, and remote indication via status contacts on the Dis-  
crete Interface (DIF) module 1.  
Figure 21.  
Interface software Switch Mode settings.  
SUPERVISORY  
BLOCKED  
GND TRIP  
BLOCKED  
NON  
RECLOSING  
CONTROL OK  
AC POWER  
FAST  
TRIPS  
DISABLED  
COLD LOAD  
PICKUP  
BLOCKED  
BATTERY  
TEST  
ABOVE MIN TRIP  
CHECK BATTERY  
ALTERNATE  
PROFILE  
NO. 1  
ALTERNATE  
PROFILE  
NO. 2  
RECLOSER MALFUNCTION  
REVERSE POWER FLOW  
SWITCH  
MODE  
BACK  
NEXT  
Figure 20.  
BUSHINGS 1-2 FAULT TARGET  
BUSHINGS 3-4 FAULT TARGET  
BUSHINGS 5-6 FAULT TARGET  
GROUND FAULT TARGET  
Function/Indication pushbuttons for the Form 5  
equipped with the UDP accessory.  
RESET  
TARGETS  
CHANGE  
RESET  
MAX CURRENT  
LAMP  
TEST  
NON  
RECLOSING  
GND TRIP  
BLOCKED  
SENSITIVE-GROUND FAULT TARGET  
SUPERVISORY  
BLOCKED  
COLD LOAD  
PICK UP  
BLOCKED  
FAST  
TRIPS  
DISABLED  
AØ  
BATTERY  
TEST  
SOURCE  
VOLTAGE  
BØ  
CØ  
XØ  
ALTERNATE  
PROFILE  
ALTERNATE  
PROFILE  
SWITCH  
MODE  
NO.  
1
NO.  
2
LOAD  
VOLTAGE  
YØ  
ZØ  
TX 2  
TX 3  
HOT LINE  
TAG  
RECLOSER CLOSED  
RECLOSER OPEN  
ON  
OFF RX 3  
RS232  
RX 2  
CONTROL LOCKOUT  
TRIP  
(LOCKOUT)  
®
CLOSE  
KYLE  
FORM 5/UDP  
RECLOSER CONTROL  
Figure 22.  
Form 5/UDP Operator Panel.  
21  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
FORM 5 DC NOVA CONTROL  
The Kyle Form 5 recloser control can be equipped with a  
dc-to-dc converter, interface circuit, and a fully shielded  
19-pin cable for use with a Type DC NOVA recloser. See  
Figure 23.  
The dc-to-dc converter board (Figure 24) converts the con-  
trols 24 Vdc battery supply voltage to 53 Vdc to drive the  
trip/close capacitors in the NOVA mechanism. The output  
of the board is separately fused for operator indication.  
The dc-to-dc converter houses voltage monitoring and  
conditioning circuits which protect the battery from failure  
and provides trip/close operations without AC power. The  
19-pin control cable interfaces the NOVA dc recloser to  
the Form 5 control through the interface circuit. The cable  
also provides AC power from the control to the recloser  
mechanism heater.  
dc NOVA  
Potential  
Transformer  
O
P
E
N
(120/240Vac)  
Figure 24.  
99007KM  
Form 5  
Control  
Dc-to-dc converter located behind Form 5 operator  
panel (removed).  
19 Pin  
Control Cable  
120Vac/240Vac  
Power Cable  
Figure 23.  
Connections of a Form 5 control with dc NOVA  
accessory to a dc NOVA recloser.  
22  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
DISCRETE INTERFACE (DIF)  
ACCESSORY  
CAUTION: Equipment damage; misoperation.  
!
External leads must be shielded and the shield  
must be grounded at both ends. Terminate each lead  
with a 320 Vac, 160 Joules metal oxide varistor (MOV),  
or equivalent, at the remote end. Attach MOVs between  
the leads and ground. Failure to properly shield and  
protect leads can result in equipment damage and/or  
The Discrete Interface (DIF) module accessory (Figure  
25) permits connection of contact-type input devices  
(switches, relays) and discrete indicating devices (relays,  
LEDs, lamps) to the Form 5 control to effect local discrete  
input/output (I/O). The DIF module accessory is used for  
supplementing normal local controls and status indicators  
for discrete SCADA functions. All DIF inputs and outputs  
have been factory-set and are shown in Figure 27.  
unintentional operation.  
G117.3  
INPUT COMMON  
28V ()  
4
3
2
1
IMPORTANT: Do not use DIF module for overcurrent  
protection. Digital SCADA can be used for this applica-  
tion. The control gives priority to TCC timing and issu-  
ing a trip signal rather than changing the status of a DIF  
output or responding to a DIF input.  
P5  
28V (+)  
WHETTING  
VOLTAGE  
OUTPUT COMMON  
12  
11  
10  
9
8
7
6
5
4
3
6
5
4
3
2
1
P3  
UNLATCHED  
OUTPUTS  
The DIF module contains 12 factory-set inputs and out-  
puts for discrete SCADA functions. Each Form 5 control  
can accommodate two DIF modules.  
DISCRETE  
INTERFACE  
MODULE  
2
1
Whetting voltage for the DIF inputs can be supplied by the  
DIF module or by the customer as shown in Figure 26.  
ACCESSORY  
12  
11  
10  
9
8
7
6
5
4
3
12  
11  
10  
9
Note: 28 Vdc (nominal) is provided from the DIF module via  
connector P5 for use as whetting voltage for inputs to  
P4. As an alternative, the user can supply whetting volt-  
age from an auxiliary source, such as a RTU.  
P2  
LATCHED  
OUTPUTS  
The input voltage range is 12 to 120 Vac or Vdc. The 12  
outputs are Form C relay contacts. Six of the module out-  
puts are latching and the other six are non-latching.  
8
2
1
7
Note: Latching is defined as an output that retains its status  
12  
11  
10  
9
8
7
6
5
4
when control power is removed.  
12  
11  
10  
9
Non-latching is defined as an output that changes its  
status when control power is removed.  
8
7
6
5
4
3
2
1
Note: A remote function is not controlled by the SUPERVI-  
P4  
INPUTS  
(12 TO 120  
VAC OR VDC)  
WHETTING  
VOLTAGE  
SORY BLOCKED switch.  
3
2
1
Customer Connection  
Information  
Figure 25.  
Discrete Interface (DIF) Module.  
CAUTION: Equipment damage. Do not drill con-  
nection holes into the top of the cabinet. Connec-  
!
tion holes in the top of the cabinet will allow moisture to  
seep into the control and damage the components or  
cause control misoperation. Failure to comply will void  
P5  
INPUT COMMON  
4
28V (-)  
3
the controls factory warranty.  
T249.0  
28V (+)  
2
Customer-Supplied  
Wiring for Whetting Voltage  
OUTPUT COMMON  
1
Figure 25 shows the customer-supplied wiring of whetting  
voltage for DIF module inputs. Connection is made from  
terminal P5 on the DIF module to the respective connec-  
tions on P4 inputs 1 through 12.  
REMOTE  
CONTACTS  
Note: Wiring to P5-2 and P5-3 can be  
reversed if necessary.  
To P4  
Inputs 1 thru 12  
Figure 27 shows customer connections to the DIF outputs  
at P2 and P3.  
Figure 26.  
Customer connections for supplying whetting volt-  
age to DIF inputs.  
23  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
FORM 5 CONTROL  
*28 Vdc (nominal)  
P5  
Remote Terminal Unit (RTU)  
supplied by  
DIF module for  
whetting voltage.  
INPUT COMMON  
*28V ()  
*28V (+)  
OUTPUT COMMON  
COMMON  
P3  
CONTROL OK  
AC POWER  
R
SUPERVISORY BLOCKED  
COLD LOAD PICKUP BLOCKED  
INPUT  
VOLTAGE  
NON-RECLOSING  
NORMAL PROFILE  
G
R
P2  
ALTERNATE PROFILE 3  
ALTERNATE PROFILE 2  
Discrete Interface  
Module (DIF)  
ALTERNATE PROFILE 1  
GROUND TRIP BLOCKED  
HOT LINE TAG  
RECLOSER OPEN  
P4  
REMOTE TRIP AND LOCKOUT  
Not All Remote  
Connections  
Shown  
REMOTE TRIP AND RECLOSE  
SUPERVISORY COLD LOAD PICKUP BLOCKED  
SUPERVISORY NON-RECLOSING  
SUPERVISORY NORMAL PROFILE  
SUPERVISORY ALTERNATE PROFILE 3*  
(*SWITCH MODE ON FORM 5 UDP)  
SUPERVISORY ALTERNATE PROFILE 2  
SUPERVISORY ALTERNATE PROFILE 1  
SUPERVISORY GROUND TRIP BLOCKED  
REMOTE HOT LINE TAG  
SUPV. CLOSE  
SUPV. TRIP & L.O.  
Figure 27.  
Customer connections to DIF module outputs with shielding and surge protection.  
24  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
TABLE 1  
DIF Input Ratings  
Minimum Detection Level: . . . . . . . . . . . . . . . . . . . . . . . . 8 Vac  
Maximum Operating Voltage: . . . . . . . . . . . . . . . . . . . . . 135 Vac  
(50 or 60Hz)  
(50 or 60Hz)  
10 Vdc  
175 Vdc  
Input Impedance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 k minimum (inputs are current limited)  
Maximum Input Loading: . . . . . . . . . . . . . . . . . . . . . . . . . 2 mA per input  
Maximum Leakage Rejection: . . . . . . . . . . . . . . . . . . . . . 1 mA  
Maximum Pickup Time: . . . . . . . . . . . . . . . . . . . . . . . . . . 10 msec (does not count control response time)  
Minimum Input Pulse Time: . . . . . . . . . . . . . . . . . . . . . . . 100 msec  
Minimum Transition Time between Pulse Inputs: . . . . . . 200 msec  
Input Protection: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shunting type using MOVs and capacitors.  
Opto Isolation from input to system.  
IMPORTANT: Each DIF contains a small, isolated  
current source for use with external dry contacts. This  
supply is intended for use with the DIF inputs only and  
must not be used for powering external circuits. This is  
considered a dry contact input for customer connection.  
TABLE 2  
Whetting Voltage Source  
(Supplied by Internal Voltage Source of DIF Module)  
Voltage Level: . . . . . 28 Vdc (nominal)  
Output Current: . . . . 30 mA maximum  
TABLE 3  
DIF Output Ratings  
Maximum Switching Voltage: . . . . . 135 Vac 110 Vdc  
Maximum Switching Loading: . . . . . 600 mA  
Maximum Pickup-Release Time: . . 3 msec (does not count control response time)  
Input Protection: . . . . . . . . . . . . . . . Shunting type using MOVs and capacitors  
Standard and UDP Controls  
Standard and UDP Form 5 control DIF inputs and outputs  
are described in the following pages.  
25  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
Standard and UDP Control DIF Module 1  
Inputs  
The DIF inputs are factory-configured as momentary (0.25 sec. duration) or maintained functions. Supervisory signals  
do not have any effect when supervisory blocked is active. Remote inputs function when supervisory is blocked.  
Input  
Connector  
Function  
Description  
1
P4-1  
Supervisory Trip and Lockout  
Supervisory Trip and Lockout trips the recloser open and locks out  
the control. The control remains locked out until closed manually or  
by the supervisory close feature. A momentary signal is required.  
2
3
P4-2  
P4-3  
Supervisory Close  
Supervisory Close initiates a closing signal to the recloser. A  
momentary signal is required for proper operation.  
Remote Hot Line Tag  
Remote Hot Line Tag performs the same functions as the HOT  
LINE TAG switch on the operator panel. Remote Hot line Tag is  
activated by a maintained SCADA command, a serial command,  
or locally via a operator panel switch. This input is active regardless  
of the state of the supervisory function.  
4
P4-4  
Supervisory Ground Trip Block  
Supervisory Ground Trip Block provides supervisory operation of  
ground trip block by a remote momentary signal.  
This input performs the same function as the GND TRIP BLOCKED  
key on the operator panel. This input is inactive if the Supervisory  
function is disabled.  
5
6
7
P4-5  
P4-6  
P4-7  
Supervisory Alternate Profile 1  
Supervisory Alternate Profile 2  
Supervisory Alternate Profile 3*  
Supervisory Alternate Profiles provides selection of alternate pro-  
grammed values for phase and ground. This feature is activated by  
a remote momentary signal.  
These inputs are active with a momentary whetting voltage and  
cause the control to select the respective Supervisory Alternate Pro-  
file. The inputs are inactive if the Supervisory function is disabled.  
8
P4-8  
Supervisory Normal Profile  
Supervisory Normal Profile requires a momentary signal for proper  
operation.  
This input is active with a whetting voltage and causes the control  
to select Normal Protection Profile. This input is inactive if the  
Supervisory function is disabled.  
Note: Supervisory Alternate Profile 3 replaced by Switch  
Mode on UDP controls.  
26  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
Standard and UDP Control DIF Module 1  
Inputs (cont’d)  
Input  
Connector  
Function  
Description  
9
P4-9  
Supervisory Non-Reclosing  
Supervisory Non-Reclosing provides supervisory non-reclosing  
input by a remote momentary signal.  
This input performs the same function as the NON-RECLOSING  
key on the operator panel. This input is inactive if the Supervisory  
function is disabled.  
10  
11  
P4-10  
P4-11  
Suprv Cold-Load Pickup Blocked  
Remote Trip and Reclose  
This input performs the same function as the COLD LOAD  
PICKUP BLOCKED key on the operator panel. This input is inac-  
tive if the Supervisory function is disabled. A momentary signal is  
required for proper operation.  
Remote Trip and Reclose initiates a trip operation followed by a  
reclose operation. A momentary signal is required for proper  
operation.  
This input is active with a whetting voltage and causes the control  
to perform a trip operation followed by a reclose operation. This  
input is active regardless of the state of the Supervisory function.  
12  
P4-12  
Remote Trip and Lockout  
Remote Trip and Lockout trips the recloser open and locks out the  
control. It can be used for tripping from external relays and alarms.  
A momentary signal is required for proper operation.  
This input performs the same function as the TRIP (LOCKOUT)  
switch on the operator panel and is active regardless of the state  
of the Supervisory function.  
27  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
Standard and UDP Control DIF Module 1  
Outputs  
The 12 outputs of the DIF Module are Form C relay contacts. Six of the outputs are latching and six are non-latching.  
Note: Contacts shown in inactive mode.  
Output Connector  
Function  
Type  
Description  
1
2
3
P3-1 NC  
P3-2 NO  
Normal Profile  
Non-Latched  
Normal Profile is active only when Alternate Profiles are  
inactive. Normal reclosing operations will follow.  
P3-3 NC  
P3-4 NO  
Non-Reclosing  
Non-Latched  
This output is active when the NON-RECLOSING indicator  
in the operator panel is illuminated.  
P3-5 NC  
P3-6 NO  
Cold-Load Pickup Blocked Non-Latched  
This output is active when the COLD LOAD PICKUP  
BLOCKED indicator on the operator panel is illuminated.  
4
P3-7 NC  
P3-8 NO  
Supervisory Blocked  
Non-Latched  
Supervisory Blocked prevents operation from supervisory  
control. Programming is accessible from the operator panel.  
This output is active when the SUPERVISORY BLOCKED  
indicator on the operator panel is illuminated.  
AC power indicator is active when the control detects the  
presence of AC power. This output is active when the AC  
power indicator on the operator panel is illuminated.  
5
6
7
8
P3-9 NC  
P3-10 NO  
AC power  
Non-Latched  
Non-Latched  
Latched  
P3-11 NC  
P3-12 NO  
Control OK  
Recloser Open  
Hot Line Tag  
Control OK indicator is active when the control is able to per-  
form protection operations. This output is active when the  
CONTROL OK indicator on the operator panel is illuminated.  
P2-1 NO  
P2-2 NC  
Recloser Open indicator is active when the recloser signals  
the control that the recloser contacts are open. This output is  
active when the RECLOSER OPEN indicator is illuminated.  
P2-3 NO  
P2-4 NC  
Latched  
With Hot Line Tag active, close circuit is disabled and the  
HOT LINE TAG indicator is illuminated. With Hot Line Tag  
inactive, the control switched back to the previous time cur-  
rent curve for the active profile, close circuit is enabled and  
the HOT LINE TAG indicator is off. This output is active  
when the operator panel indicator is illuminated.  
Ground Trip Blocked causes the control to block ground trip-  
ping operations. This output is active when the GND TRIP  
BLOCKED INDICATOR on the operator panel is illuminated.  
9
P2-5 NO  
P2-6 NC  
Ground Trip Blocked  
Latched  
10  
11  
12  
P2-7 NO  
P2-8 NC  
Alternate Profile 1  
Alternate Profile 2  
Alternate Profile 3*  
Latched  
Latched  
Latched  
These outputs are active when the respective ALTERNATE  
PROFILE indicators on the operator panel is illuminated.  
P2-9 NO  
P2-10 NC  
P2-11 NO  
P2-12 NC  
*Note: Supervisory Alternate Profile 3 replaced by Switch  
Mode on UDP controls.  
28  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
Standard and UDP Control DIF Module 2  
Inputs  
The DIF inputs are factory-configured as momentary or maintained functions. Whetting voltage for the DIF inputs is  
supplied by the DIF module or by the user. The input voltage range is 12 to 120 VAC or VDC.  
Input  
Connector  
Function  
Description  
1
P4-1  
Supervisory Fast Trips Disabled  
This input performs the same function as the FAST TRIPS DIS-  
ABLED key on the operator panel and is inactive if the Supervisory  
function is disabled. This is a momentary function.  
2
P4-2  
Supervisory Reset Targets  
This input performs the same function as the RESET  
TARGETS/RESET MAX CURRENT key on the operator panel.  
This input is inactive if the Supervisory function is disabled. This is  
a momentary function.  
3
4
5
P4-3  
P4-4  
P4-5  
Supervisory Operation Counter OFF The operation counter is disabled when this input is active with a  
maintained whetting voltage. This input is inactive if the Supervi-  
sory function is disabled.  
Supervisory Battery Test  
This input performs the same function as the BATTERY TEST key  
on the operator panel. This input is inactive if the Supervisory func-  
tion is disabled. This is a momentary function.  
Supervisory SGF Blocked  
This input is active with a momentary whetting voltage and causes  
the control to block, or unblock sensitive ground fault operations.  
The input is inactive if the Supervisory function is disabled.  
29  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
Standard and UDP Control DIF Module 2  
Outputs  
The 12 outputs of the DIF Module are Form C relay contacts. Six of the outputs are latching and six are non-latching.  
Note: Contacts shown in inactive mode.  
Output Connector  
Function  
Type  
Description  
1
2
3
4
5
P3-1 (NC)  
P3-2 (NO)  
Control Lockout  
Non-Latched  
This output is active when the CONTROL LOCKOUT  
indicator is illuminated.  
P3-3 (NC)  
P3-4 (NO)  
Check Battery  
Non-Latched  
Non-Latched  
Non-Latched  
Non-Latched  
This output is active when the CHECK BATTERY indi-  
cator is illuminated.  
P3-5 (NC)  
P3-6 (NO)  
Reverse Power Flow  
Fast Trips Disabled  
Operation Counter  
This output is active when the REVERSE POWER  
FLOW indicator is illuminated.  
P3-7 (NC)  
P3-8 (NO)  
This output is active when the FAST TRIPS DIS-  
ABLED indicator is illuminated.  
P3-9 (NC)  
If the Supervisory function is enabled, this output is  
active when the OPERATION COUNTER OFF inputs  
from Comm Port 1-DIF2, Comm Port 2 and Comm Port  
3 are not active.  
P3-10 (NO)  
6
P3-11 (NC) Recloser Malfunction  
P3-12 (NO)  
Non-Latched  
This output is active when the RECLOSER MAL-  
FUNCTION indicator is illuminated.  
This output is active when the BUSHINGS 1-2 FAULT  
TARGET indicator is illuminated.  
7
8
9
P2-1 (NO)  
P2-2 (NC)  
Bushings 1-2 Fault Target  
Bushings 3-4 Fault Target  
Bushings 5-6 Fault Target  
Latched  
Latched  
Latched  
P2-3 (NO)  
P2-4 (NC)  
This output is active when the BUSHINGS 3-4 FAULT  
TARGET indicator is illuminated.  
P2-5 (NO)  
P2-6 (NC)  
This output is active when the BUSHINGS 5-6 FAULT  
TARGET indicator is illuminated.  
10  
11  
12  
P2-7 (NO)  
P2-8 (NC)  
Ground Fault Target  
Latched  
Latched  
Latched  
Output is active when the GROUND FAULT TARGET  
indicator is illuminated.  
P2-9 (NO)  
Sensitive Ground Fault Target  
Output is active when the SENSITIVE GROUND  
FAULT TARGET indicator is illuminated.  
P2-10 (NC)  
Output is active when Sensitive Ground Fault is  
blocked.  
P2-11 (NO) Sensitive Ground Fault Blocked  
P2-12 (NC)  
30  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
INPUT ACCURACY  
Sensed Currents  
Sensed Source Voltages  
Three-phase voltages used in voltage, power and power-  
factor related calculations:  
Note: Control only, does not include sensor tolerance, but  
does include the phase current summing process.  
Phase CurrentIndividual Phase Currents:  
Range: 1 A to 10,000 A for 500:1 CTs  
2 A to 20,000 A for 1000:1 CTs  
Voltage measurement accuracy:  
0.4V from 5V to 80V  
0.5% from 80V to 135V  
4 A to 40,000 A for 2000:1 CTs  
Accuracy: 1 mA from 10 mA to 125 mA  
0.8% from 125 mA to 1600 mA  
(Control only, does not include sensor  
tolerance.)  
Ground CurrentVector Sum of Three-Phase Currents:  
Range: 1 A to 5,000 A for 500:1 CTs  
2 A to 10,000 A for 1000:1 CTs  
4 A to 20,000 A for 2000:1 CTs  
Accuracy: 3 mA from 10 mA to 125 mA  
2.4% from 125 mA to 1600 mA  
31  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
INSTALLATION PROCEDURE  
The Form 5 control can be used with the old-style Type A  
Initial Programming  
Prior to Installation  
CTs; however, the event recorder, data profiler and duty  
cycle monitor will have limited accuracy for currents  
above 5000 Amps.  
CAUTION: Equipment Misoperation. Do not  
Retrofit kits with the new Type B sensing CTs are avail-  
able to upgrade existing families of reclosers for operation  
with Form 5 controls. For additional information, contact  
your Cooper Power Systems representative.  
!
connect this control to an energized recloser until  
all control settings have been properly programmed  
and verified. Refer to the programming information for  
this control. Failure to comply can result in control and  
recloser misoperation, equipment damage, and per-  
For identification, Table 4 lists the serial number breaks  
between old-style Type A and the new-style Type B sens-  
ing CTs. Below this serial number, the recloser is  
equipped with the Type A CTs.  
sonal injury.  
G110.3  
The control must be programmed with all necessary oper-  
ating settings, all alternate profiles, and parameters prior  
to operation with an energized recloser.  
Note: For reclosers shipped prior to June 1989 and not listed  
below, please contact your Cooper Power Systems rep-  
resentative with the recloser type and serial number for  
verification of Type A or B bushing current transformers.  
Note: Program all protection profiles. Unused alternate pro-  
files should be programmed with the same settings as  
one of the applicable profiles. Default settings on  
unused alternate profiles can cause unnecessary out-  
ages if they are below normal system requirements.  
TABLE 4  
Serial Number Break for Reclosers with Type A  
Sensing CTs  
Initial programming of the control is the responsibility of a  
qualified technician or engineer familiar with control func-  
tions and programming parameters required for the spe-  
cific recloser installation.  
Recloser  
Below Serial Number  
RXE  
5831  
5894  
11199  
3695  
7199  
7208  
1204  
RVE  
The control must be programmed with the Form 5 inter-  
face software.  
WE  
WVE  
Control / Recloser Compatibility  
VWE  
Reclosers manufactured prior to June 1989 are equipped  
with Type A bushing current transformers. These  
reclosers were designed for use with Form 2, Form 3, and  
Form 3A controls. Because the Form 5 control is designed  
for use with reclosers equipped with Type B current-sens-  
ing Transformers, reclosers retrofitted with Form 5 con-  
trols should be retrofitted with Type B current  
transformers. All reclosers manufactured since 1989 are  
equipped with Type B (1000:1, 1000/500:1, or 2000:1)  
sensing CTs.  
VWVE27  
VWVE38  
Control Cable  
WARNING: Hazardous voltage. Recloser and  
!
control must be solidly grounded. Follow all locally  
approved procedures and safety practices when  
grounding this equipment. Improper grounding can  
result in contact with high voltage, which will cause  
Reclosers equipped with Type B sensing CTs are com-  
patible with all Kyle recloser controls (Form 2, Form 3,  
Form 3A, Form 4A, Form 4C, FXA, FXB and Form 5, Form  
5 LS/UDP controls), and are identified with the following  
label prominently displayed on the recloser sleet hood or  
the front of the operator cabinet:  
death or severe personal injury.  
G115.1  
The control cable is fabricated with connectors which  
mate with the female receptacle of the recloser on one  
end and the male receptacle of the control on the other  
end.  
Note: The control cable must be supported along its length to  
prevent repeated movement due to wind or other out-  
side forces which can damage the cable.  
NOTICE  
RECLOSER IS EQUIPPED WITH  
TYPE B SENSING CTs.  
RECLOSER DOES NOT HAVE A  
BATTERY CHARGER.  
IMPORTANT: All external inputs to the Form 5 con-  
trol must be routed within 8 inches of their correspond-  
ing ground. During a surge, a potential of  
approximately 1.5 kV per foot can develop in the con-  
ductors. Differences between conductor and ground  
path lengths can add additional stress to the control  
components in the event of a power surge.  
32  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
Limits on control cable length are determined by the max-  
imum distance between the control and recloser:  
Mounting the Control  
Mount the Form 5 recloser control in a convenient, acces-  
sible location. Mounting dimensions are provided in Fig-  
ure 28.  
Up to 410 m (125* ft) for solenoid-operated reclosers  
(VWE, VWVE27, VWVE38X, WE, WVE27, WVE38X,  
and NOVA).  
For pole-mounted installation, a hole and keyway in  
the control mounting bracket accommodates a 5/8”  
bolt.  
Up to 10,7 m (35* ft) for motor-operated reclosers  
(VSA12, VSA12B, VSA16, VSA20, VSA20A, VSO12,  
VSO16).  
For substation installation, brackets are available as  
an accessory for mounting the control to a substation  
frame.  
Up to 41 m (135* ft) for NOVA DC.  
* These lengths are based on standard control cables.  
Consult your Cooper Power Systems representative if  
longer cable lengths are required.  
Female Receptacle  
C
L
For Control  
Cable  
Vent  
35mm (1-7/16") Dia. Hole  
For User 120Vac  
Input Connection  
(Cap-Plug Installed)  
110mm  
(4-1/4")  
120mm (4-3/4")  
40mm  
(1-1/2")  
45mm (1-3/4") Dia. Hole  
For Automation Accessory  
(Cap-Plug Installed)  
130mm  
(5-1/8")  
190mm  
(7-3/8")  
C
L
200mm  
(7-7/8")  
Mtg Hole For  
15mm (5/8") Max  
Bolt Dia.*  
480mm  
380mm  
(15")  
30mm (1-1/8") Hole  
In Lifting Lug  
(19")  
240mm  
(9-1/2")  
* USER-PROVIDED HARDWARE  
40mm (1-1/2")  
160mm  
(6-3/8")  
76mm  
(3")  
685mm  
Die-cast-zinc latchable  
(27")  
Handle For User-  
Provided Utility-Grade  
Padlock  
Male Receptacle  
For Control Cable  
110mm  
(4-3/8")  
350mm  
Grounding Terminal  
30mm  
(13-13/16")  
One Internal and  
One External  
(1-1/8")  
165mm  
(6-1/2")  
Use No. 14 To No. 4  
Stranded Wire  
52 kg (115 LBS)  
CONTROL WEIGHT  
Figure 28.  
Control cabinet mounting dimensions.  
33  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
Figure 29 illustrates grounding methods for 3-wire  
ungrounded and 4-wire multi-grounded systems with local  
supply voltage transformer.  
Grounding the Control  
WARNING: Hazardous Voltage. The recloser  
Figure 30 illustrates grounding methods for 3-wire  
ungrounded and 4-wire multi-grounded systems with  
remote supply voltage transformer.  
!
and control must be solidly grounded. Follow all  
locally approved procedures and safety practices when  
grounding this equipment. Improper grounding can  
result in contact with high voltage, which will cause  
Figure 31 illustrates grounding on a 3-wire uni-grounded  
system.  
death, severe personal injury.  
G115.1  
For effective surge protection all control and power con-  
ductors for the Form 5 must be routed parallel to a corre-  
sponding ground path. For example, the AC power supply  
for the control should be parallel to and equal in length to  
the transformer ground path. The control cable should be  
parallel to and routed close to the recloser ground path.  
The control cabinet must be grounded. A grounding con-  
nector on the underside of the cabinet will accommodate  
No. 14 solid through No. 4 stranded conductors.  
Suggested methods for grounding the control and  
recloser are shown in Figures 29, 30, and 31.  
34  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
Grounding with a Local Supply Voltage Transformer; 4-Wire Multi-Grounded,  
3-Wire Ungrounded, or Impedance-Grounded  
Installation of a Form 5 control with a local supply voltage  
transformer must include the following:  
4-Wire Multi-Grounded Systems  
IMPORTANT: In pole-mounted applications, a  
ground connection must be made between the  
recloser, transformer, recloser control, and SCADA  
equipment for proper protection of the equipment. The  
pole ground must be sized per local utility practices to  
minimize the impedance between the recloser and the  
control.  
Protection of the recloser bushings and the supplying  
transformer with lightning arresters.  
Grounding of the recloser head and tank.  
Grounding of the transformer tank.  
Grounding of the control cabinet.  
Grounding of the SCADA equipment.  
3-Wire Ungrounded and Impedance Grounded Systems  
The use of a grounding mat may be required depending  
upon the local safety regulations defining the permissible  
step and touch potential levels. Consult local regulations  
for proper grounding procedures.  
IMPORTANT: All external inputs to the Form 5 con-  
trol must be routed within 8 inches of their correspond-  
ing ground. During a surge, a potential of approximately  
1.5 kV per foot can develop in the conductors. Differ-  
ences between conductor and ground path lengths can  
add additional stress to the control components in the  
event of a power surge.  
Surge  
Transformer  
Arrester  
Surge  
Supply Voltage  
Arrester  
Surge  
Arrester  
Form 5 LS Control  
Input Terminal  
Block  
Transformer  
AC  
Recloser  
NEUTRAL  
Head Ground  
AC  
NEU  
GND  
External  
Ground Lug  
Arrester Ground  
ELECTRICAL CONNECTIONS  
Line to Neutral connected transformer  
Supply  
Voltage  
Recloser  
Supply Voltage  
Transformer  
Form 5 LS Control  
Line  
to  
Line  
Voltage  
Control  
Cable  
AC  
Pole  
NEUTRAL  
Pole  
Ground  
Form 5 LS  
Control  
Input Terminal  
Block  
External  
Ground Lug  
Input  
Terminal  
Block  
ELECTRICAL CONNECTIONS  
Line to Line connected transformer  
Customer Ground Connection  
At External Lug  
Figure 29.  
Recommended grounding method for the Form 5 Control installed on 4-wire multi-grounded, 3-wire  
ungrounded, or impedance-grounded systems with local supply voltage transformer.  
35  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
Grounding with a Remote Supply Voltage Transformer; 4-Wire Multi-Grounded,  
3-Wire Ungrounded, or Impedance-Grounded  
Installation of a Form 5 control with a remote supply volt-  
age transformer must include the following:  
IMPORTANT: In pole-mounted applications, a  
ground connection must be made between the  
recloser, transformer, recloser control, and SCADA  
equipment for proper protection of the equipment. The  
pole ground must be sized per local utility practices to  
minimize the impedance between the recloser and the  
control.  
Protection of the recloser bushings and the supplying  
transformer with lightning arresters.  
Grounding of the recloser head and tank.  
Grounding of the transformer tank.  
Grounding of the control cabinet.  
IMPORTANT: All external inputs to the Form 5 con-  
trol must be routed within 8 inches of their correspond-  
ing ground. During a surge, a potential of  
approximately 1.5kV per foot can develop in the con-  
ductors. Differences between conductor and ground  
path lengths can add additional stress to the control  
components in the event of a power surge.  
Grounding of the SCADA equipment  
Low Voltage Distribution Network  
Supply Voltage  
Input  
115 Vac  
Input  
Form 5 LS Control  
Supply Voltage  
Terminal  
Block  
Terminal  
Block  
Form 5 LS Control  
Transformer  
Local Isolation  
Transformer  
AC  
AC  
NEUTRAL  
Customer  
Supplied  
NEUTRAL  
Low Voltage  
Low Voltage  
Arrester  
External  
Ground Lug  
External  
Ground Lug  
ELECTRICAL CONNECTIONS - Remote dedicated  
supply transformer  
ELECTRICAL CONNECTIONS - using isolation transformer  
Surge  
Arrester  
Transformer  
Surge  
Arrester  
Surge  
Arrester  
Recloser  
Head  
Ground  
HOT  
NEU  
GND  
Arrester  
Ground  
Arrester  
Ground  
System  
Neutral  
Note: Distance between  
transformer and  
recloser should be  
one pole span or  
less  
Recloser  
Control Cable  
Pole  
Supply  
Voltage  
Form 5 LS Control  
Pole  
Ground  
Input Terminal Block  
Pole  
Customer Ground Connection  
at External Lug  
Figure 30.  
Recommended grounding method for the Form 5 Control installed on 4-wire multi-grounded, 3-wire  
ungrounded, or impedance-grounded systems with remote supply voltage transformer.  
36  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
Grounding on a 3-Wire Uni-Grounded System  
Supply Voltage  
Transformer  
Installation of a Form 5 control on a 3-wire uni-ground sys-  
tem must include the following:  
Input Terminal Block  
Form 5 LS Control  
Line  
to  
Line  
Voltage  
AC  
Protection of the recloser bushings and the supplying  
transformer with lightning arresters.  
Neutral  
Grounding of the recloser head and tank.  
Grounding of the transformer tank.  
Grounding of the control cabinet.  
External Ground Lug  
ELECTRICAL CONNECTIONS - Dedicated Supply  
Transformer  
Grounding of the SCADA equipment.  
Surge  
Arrester  
Surge  
Arrester  
Surge  
WARNING: Hazardous Voltage. Use locally  
approved operator safety procedures for proper  
Arrester  
!
insulation when maintaining this equipment. High Volt-  
age step and touch potential is characteristic in uni-  
ground systems. Failure to comply can cause death or  
Recloser  
Head Ground  
HOT  
NEU  
GND  
severe personal injury.  
T262.0  
Arrester Ground  
Recloser  
Supply  
Voltage  
CAUTION: Exported Potential. Do not make  
!
direct electrical connections to remote devices. All  
SCADA equipment must be mounted locally or con-  
nected using the fiber-optic or radio communication  
accessory. Direct connections to remote devices can  
produce exported potential causing equipment damage  
Control  
Cable  
Form 5 LS  
Control  
or personal injury.  
T263.0  
Input Terminal Block  
CAUTION: Hazardous Voltage. Do not use a  
Customer Ground  
Connection  
at External Lug  
!
shared low voltage network to power the recloser  
control unless the network is specifically designed to  
withstand maximum ground potential rise. Ground  
faults on a high voltage network can create a rise in  
Pole  
Ground  
Control Height must be  
3 Meters (10 feet)  
minimum above earth  
ground potential.  
T264.0  
IMPORTANT: In pole-mounted applications, a  
ground connection must be made between the  
recloser, transformer, recloser control, and SCADA  
equipment for proper protection of the equipment. The  
pole ground must be sized per local utility practices to  
minimize the impedance between the recloser and the  
control.  
Figure 31.  
Recommended grounding method for the Form 5  
Control installed on a 3-wire uni-grounded system.  
IMPORTANT: All external inputs to the Form 5 con-  
trol must be routed within 8 inches of their correspond-  
ing ground. During a surge, a potential of  
approximately 1.5kV per foot can develop in the con-  
ductors. Differences between conductor and ground  
path lengths can add additional stress to the control  
components in the event of a power surge.  
37  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
Customer Connections for AC  
Power  
CAUTION: Equipment damage. Do not drill con-  
!
nection holes into the top of the cabinet. Connec-  
tion holes in the top of the cabinet will allow moisture to  
seep into the control and damage the components or  
cause control misoperation. Failure to comply will void  
the controls factory warranty.  
T249.0  
Input power to the Form 5 control is connected to terminal  
block TB1 (located behind the operator panel, on the left  
side of the control). See Figure 33.  
Input power is required:  
To power the control  
To provide voltage and power metering  
For voltage detection for loop scheme accessory  
For the low voltage closing accessory  
For the convenience outlet accessory  
Figure 33.  
Terminal Connector Block TB1.  
99003KM  
Power Connections  
Power Supply Verification  
Customer connections to TB1 vary upon application. TB1  
connections provide power and metering inputs to the  
control. Figures 34 through 39 show the customer con-  
nections for 120 Vac and 240 Vac low voltage closing.  
Incoming power is routed to the Power Supply module  
which is factory configured for either 120 or 240 volt oper-  
ation. The power supply module is factory wired to TB-1  
and protected by the 3.15 Amp fuse labeled F2 on the  
power supply operator panel. A label on the Power Sup-  
ply module indicates the proper voltage rating. See Figure  
32.  
Figures 34 through 37 illustrate customer connections for  
single-phase transformers. Figure 34 shows standard  
wiring with BØ transformer connected to TB1-2 location.  
Other phases should be connected from the single-phase  
transformer by wiring the BLACK wire from the Power  
Supply module to the terminal of the respective phase as  
shown in Figure 38 and 39. For example, Figure 39 shows  
connection from the Power Supply module to an AØ  
transformer.  
M
F2  
O
GDC-3.15A  
D
CONFIGURED  
U
FOR  
L
120  
VAC  
E
The transformer required for power should be a minimum  
of 5kVA for low-voltage ac closing reclosers and 1kVA for  
dc closing reclosers.  
240  
VAC  
Note: An out-of-service Form 5 or Form 5 UDP control (for  
either Wye or Delta) can be powered by connecting to  
TB1-2 (hot) and TB1-4 (neutral) to an appropriate power  
source.  
Figure 32.  
Label on Power Supply module indicates factory-  
configured voltage rating (120Vac).  
IMPORTANT: Delta connections are not used on any  
Form 5 control accessory that utilizes the low voltage  
transfer relay.  
Inserting and Releasing Wire  
Connections  
In Terminal Block TB1, each terminal has a wire locking  
clamp that has to be opened to accept and secure the  
wire. A 3/32 inch flat-blade screwdriver is inserted into  
each terminal hole to open the locking clamp. Figure 34  
provides the procedure for opening and securing the wire  
connections.  
Customer Connections for  
Metering  
Customer voltage inputs for metering are field config-  
urable on the RIF module to accept 12, 120, or 240 Vac.  
The incoming power supply must match the indication for  
incoming power on the RIF module. The factory-config-  
ured settings for the RIF are displayed on the module  
panel. See Figure 19.  
The wire is inserted into the terminal connection hole  
while the screwdriver is placed into the wire release and  
locking hole.  
Follow the same procedure to release wire connections.  
See RIF Module Configuration section of this manual.  
38  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
TB1  
(Top View)  
To insert wire:  
1. Insert 3/32 inch flat-  
blade screwdriver into  
Wire Release and  
Locking hole.  
TB1  
16  
AØ  
240Vac CLOSING  
OPTION  
2. Carefully insert the  
screwdriver along side  
the locking clamp.  
15  
14  
Y' VOLTAGE  
120Vac  
B' VOLTAGE  
120Vac  
CLOSING  
VOLTAGE  
3. Pull toward the center  
of terminal block TB1  
until the locking clamp  
opens.  
13  
12  
NEUTRAL  
SOURCE 2  
BØ  
NEUTRAL  
SOURCE 1  
11  
10  
9
4. Insert wire into Terminal  
Connection hole.  
NEUTRAL  
5. Release screwdriver.  
6. Carefully pull wire to be  
sure it is secure.  
Note: Only slight pressure is  
required to open the  
AC  
ZØ  
CUSTOMER  
CONNECTIONS  
locking clamp. Excessive  
pressure can damage  
the terminal block.  
CØ  
SOURCE 2  
POWER  
YØ  
XØ  
8
Wire Release  
and Locking Hole  
7
6
HOT (LV Closing Output)  
NEU (LV Closing Output)  
OUTPUT  
VOLTAGE  
POWER  
SOURCE  
OUTPUT  
Terminal  
TB1  
NEUTRAL  
5
Connection Hole  
16  
NEU  
*NEUTRAL  
4
3
15  
14  
13  
AC  
CØ  
BØ  
AØ  
CØ  
CUSTOMER  
CONNECTIONS  
SOURCE 1  
POWER  
*BØ  
AØ  
2
1
12  
11  
10  
9
3/32 inch  
Flat-Blade  
Screwdriver  
Connection  
Wire  
*REQUIRED FOR  
CONTROL OPERATION  
8
Figure 34.  
Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1  
(120Vac or 240Vac Wye Connection).  
TB1  
AØ  
16  
240V CLOSING  
OPTION  
15  
14  
13  
12  
BØ  
11  
10  
9
ZØ  
YØ  
XØ  
CØ  
AC  
CUSTOMER  
SOURCE 2  
POWER  
8
CONNECTIONS  
7
6
HOT (LV Closing Output)  
HOT (LV Closing Output)  
OUTPUT  
VOLTAGE  
POWER  
SOURCE  
OUTPUT  
OUTPUT  
VOLTAGE  
5
CØ  
BØ  
AØ  
4
3
*CØ  
BØ  
AC  
CUSTOMER  
CONNECTIONS  
SOURCE 1  
POWER  
*AØ  
2
1
*REQUIRED FOR  
CONTROL OPERATION  
SEE POWER SUPPLY  
MODULE FOR  
CORRECT VOLTAGE  
Figure 35.  
Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1  
(120Vac or 240Vac Delta Connection).  
39  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
TB1  
AØ  
16  
240V CLOSING  
OPTION  
15  
14  
13  
12  
BØ  
CØ  
11  
10  
9
ZØ  
YØ  
XØ  
AC  
CUSTOMER  
SOURCE 2  
POWER  
8
CONNECTIONS  
7
6
OUTPUT  
VOLTAGE  
HOT (LV Closing Output)  
HOT (LV Closing Output)  
POWER  
SOURCE  
OUTPUT  
OUTPUT  
VOLTAGE  
5
CØ  
BØ  
AØ  
4
3
*CØ  
BØ  
AC  
CUSTOMER  
CONNECTIONS  
SOURCE 1  
POWER  
*AØ  
2
1
*REQUIRED FOR  
CONTROL OPERATION  
SEE POWER SUPPLY  
MODULE FOR  
CORRECT VOLTAGE  
Figure 36.  
Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1  
(120Vac or 240Vac Open-Delta Connection).  
TB1  
120Vac  
HOT (240Vac LV Closing Output)†  
16  
240V CLOSING  
OPTION  
HOT (240Vac LV Closing Output)†  
Neutral  
120Vac  
15  
Y' VOLTAGE  
14  
13  
12  
CLOSING  
VOLTAGE  
120Vac  
B' VOLTAGE  
120Vac  
NEUTRAL  
SOURCE 2  
NEUTRAL  
SOURCE 1  
11  
10  
9
NEUTRAL  
AC  
ZØ  
YØ  
CUSTOMER  
CONNECTIONS  
8
SOURCE 2  
POWER  
XØ  
7
6
OUTPUT  
VOLTAGE  
HOT (120Vac LV Closing Output)  
NEU (120Vac LV Closing Output)  
POWER  
SOURCE  
OUTPUT  
OUTPUT  
VOLTAGE  
5
4
3
*NEUTRAL  
AC  
CØ  
CUSTOMER  
CONNECTIONS  
SOURCE 1  
POWER  
2
1
*BØ  
AØ  
For use with accessories:  
3-Wire Low-Voltage Closing with receptacle  
or  
3-Wire Low-Voltage Closing with inlet hole for hardwiring  
*REQUIRED FOR  
CONTROL OPERATION  
Figure 37.  
Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1  
(3-wire, 240Vac Connection).  
40  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
P
O
W
E
TB1  
16  
240Vac CLOSING  
OPTION  
R
15  
14  
S
U
P
P
L
YØ VOLTAGE  
P
9
120Vac  
BØ VOLTAGE  
120Vac  
CLOSING  
VOLTAGE  
13  
12  
A
U
X
Y
NEUTRAL  
SOURCE 2  
BØ  
M
O
D
U
L
F2  
NEUTRAL  
SOURCE 1  
GDC-3.15A  
11  
10  
9
CONFIGURED  
FOR  
NEUTRAL  
120  
VAC  
E
AC  
240  
ZØ  
VAC  
CUSTOMER  
CONNECTIONS  
SOURCE 2  
YØ  
8
POWER  
BLK  
WHT  
XØ  
7
6
HOT (LV Closing Output)  
NEU (LV Closing Output)  
OUTPUT  
VOLTAGE  
POWER  
SOURCE  
OUTPUT  
NEUTRAL  
5
NEU  
*NEUTRAL  
4
3
AC  
CØ  
Jumper**  
CUSTOMER  
CONNECTIONS  
SOURCE 1  
*BØ  
BØ  
2
1
POWER  
AØ  
*REQUIRED FOR  
CONTROL OPERATION  
**Jumper necessary for use with Low-Voltage Closing Accessory  
Figure 38.  
Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1 (Single-  
Phase Connection, Standard BØ Input).  
P
O
TB1  
16  
W
E
R
240Vac CLOSING  
OPTION  
15  
14  
S
U
P
P
L
Y' VOLTAGE  
P
9
120Vac  
B' VOLTAGE  
120Vac  
CLOSING  
VOLTAGE  
13  
12  
A
U
X
Y
NEUTRAL  
SOURCE 2  
AØ  
M
O
D
U
L
F2  
NEUTRAL  
SOURCE 1  
GDC-3.15A  
11  
10  
9
CONFIGURED  
FOR  
NEUTRAL  
120  
VAC  
E
AC  
240  
ZØ  
VAC  
CUSTOMER  
CONNECTIONS  
SOURCE 2  
POWER  
YØ  
XØ  
8
BLK  
WHT  
7
6
HOT (LV Closing Output)  
NEU (LV Closing Output)  
OUTPUT  
VOLTAGE  
POWER  
SOURCE  
OUTPUT  
NEUTRAL  
5
NEU  
*NEUTRAL  
4
3
AC  
CØ  
Jumper**  
CUSTOMER  
CONNECTIONS  
SOURCE 1  
POWER  
*BØ  
AØ  
2
1
AØ  
*REQUIRED FOR  
CONTROL OPERATION  
**Jumper necessary for use with Low-Voltage Closing Accessory  
Figure 39.  
Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1 (Single-  
Phase Connection, AØ Input).  
41  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
Before Placing the Control and  
WARNING: Hazardous voltage. Recloser and  
the Recloser into Service  
!
control must be solidly grounded. Follow all  
locally approved procedures and safety practices when  
grounding this equipment. Improper grounding can  
result in contact with high voltage, which will cause  
CAUTION: Equipment misoperation. Do not  
!
connect this control to an energized recloser  
death or severe personal injury.  
G115.1  
until all control settings have been properly pro-  
grammed and verified. Refer to the programming  
information for this control. Failure to comply can  
result in control and recloser misoperation, equip-  
3. Control and recloser properly grounded in accordance  
with guidelines in this manual.  
ment damage and personal injury.  
G110.3  
4. AC power connected to the control. (AC power LED  
indicator is illuminated.)  
5. Control battery connected and tested for proper  
Prior to placing the control and recloser into service, the  
following installation procedures must be properly com-  
pleted and verified:  
operation.  
6. All control programming entered and verified by  
appropriate personnel.  
1. Control properly mounted for the installation.  
7. Control clock set to the correct time.  
2. Recloser installed according to all locally approved  
standards and practices.  
8. Customer connections for remote and supervisory  
operation checked and completed in accordance with  
proper shielding and surge protection.  
9. Control cable properly connected and supported.  
42  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
TESTING AND TROUBLESHOOTING  
CAUTION: Equipment misoperation. Do not  
!
connect this control to an energized recloser  
until all control settings have been properly pro-  
grammed and verified. Refer to the programming  
information for this control. Failure to comply can  
result in control and recloser misoperation, equip-  
CPU Module LED Indicator  
ment damage and personal injury.  
G110.3  
IMPORTANT: The Form 5 recloser control can be  
taken out of service for testing and placed back into  
service without de-energizing its recloser and interrupt-  
ing the system. However, during the time the control is  
out of service, the recloser is inoperative.  
CPU Module  
(Central Processing Unit)  
Testing an Installed Control  
The following tests to determine initial operation of the  
Form 5 control can be performed while connected to an  
operating recloser. These are the only tests performed on  
an installed, operating control. All other tests described in  
this Testing and Troubleshooting section require the  
Form 5 control to be removed from service, connected to  
a bypassed recloser, or tested at a location where the  
proper testing equipment is available.  
99002KM  
Figure 40.  
Form 5 control CPU module.  
of all operating parameters. Refer to Service Information  
S280-76-1 Type MET Electronic Recloser Control Tester  
Operator Instructions for proper setup and use of the MET  
tester. Refer to Form 5 Control Default Test Procedure  
section of this manual for specific tests requiring the  
KMET Tester.  
1. Wake-up the operator panel display by pressing the  
CHANGE/LAMP TEST button on the control operator  
panel.  
2. Scroll through the LCD display messages as  
described in the LCD Display Messages section of  
these instructions. Refer to Form 5 Control operator  
panel section of this manual.  
IMPORTANT: The Form 5 DC NOVA control cannot  
be tested with the standard Kyle MET Tester. A junc-  
tion box accessory for the MET tester is available for  
testing the Form 5 DC NOVA control.  
Check the operational values for currents, voltages,  
and other metering information.  
3. Check that the LED for AC power is illuminated on the  
control operator panel. This indicates the presence of  
AC power.  
IMPORTANT: When the control is open and current  
is present, the Trip Fail detection circuit in the Form 5  
control will activate when the Kyle Type MET tester  
CALIBRATE switch is ON. Depress and hold the  
RESET TARGET keypad on the control for 3 seconds  
to reset the condition.  
4. Test battery operation, using the procedures  
described in the Battery Test Procedure section of  
these instructions.  
Check CPU Status  
Check the operating status of the CPU module. Open the  
cabinet door and locate the LED indicator (Figure 40).  
The LED indicator on the CPU module should flash at a  
rate of one flash per second for normal 60 Hz operation  
(slightly faster for 50Hz).  
Testing With Type MET Tester  
The Kyle Type MET Electronic Recloser Control Tester  
(Figure 41) is used for testing the Form 5 control.  
The MET Tester is completely self-contained, includes all  
necessary metering and interconnecting cables, and is  
capable of performing all required checks and tests from  
a simple verification of operation to a complete verification  
010028KM  
Figure 41.  
Kyle Type MET electronic recloser control tester.  
43  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
Electrical Closing—Motor-Operated  
Reclosers  
Closing the Recloser During  
Testing  
WARNING: Hazardous voltage. Solidly ground  
WARNING: Hazardous voltage. The switchgear  
!
!
all equipment. Failure to comply can result in  
and high voltage transformer must be in a test  
death, severe personal injury, and equipment damage.  
cage or similar protective device to prevent accidental  
contact with the high voltage parts. Solidly ground all  
equipment. Failure to comply can result in death,  
T223.2  
severe personal injury, and equipment damage.  
T221.3  
High-voltage is not required for reclosers utilizing a motor-  
operated closing mechanism energized from a 230VAC  
power source. For information on energizing the recloser,  
refer to the appropriate motor-operated recloser installa-  
tion manual.  
Electrical Closing—Solenoid-Operated  
Reclosers  
Line voltage is required for automatic recloser operation  
during testing of reclosers equipped with a closing  
solenoid (except for reclosers equipped with the low volt-  
age closing accessory).  
Figure 43 shows a test circuit for motor-operated and  
solenoid-closing reclosers with low-voltage closing. Since  
these reclosers require only a 240 Vac source for closing,  
high-voltage transformer T3 and its protective cage is  
eliminated. All other equipment is the same as the test  
equipment shown in Figure 42.  
For on-line testing, bypass the recloser, open the load-  
side disconnects and keep the source-side disconnects  
closed. This will remove the recloser from service, but will  
keep line voltage supplied to the closing solenoid (Figure  
44).  
Sensing CTs (3)  
For shop testing, the closing solenoid voltage is supplied  
by back-feeding a transformer with a low-side rating equal  
to the voltage rating of an available power source, and a  
high-side rating equal to the voltage rating of the recloser  
(Figure 45). A 75kVA transformer of the proper voltage  
rating with an impedance drop of approximately 3% is sat-  
isfactory. The ac source must have a comparable  
impedance drop.  
5
6
J
3
1
4
2
H
G
The closing coil requirement is approximately 200kVA  
during the two-to-three cycle closing operation. The  
solenoid coil operating voltage must be maintained at the  
recloser bushings during the cycle interval the closing coil  
is energized. This procedure is not used on reclosers  
equipped with the low-voltage closing accessory.  
X
W
K
Closing  
Motor  
240 Vac  
Power  
Supply  
WARNING: Hazardous voltage. Interconnect  
source leads X and Y and ground solidly to the  
!
recloser tank (Figure 45). Do not connect lead Z to any  
other phase or mechanical ground. Dangerous voltages  
to ground exist on the phase connected to lead Z. Solidly  
ground all equipment. Failure to comply can result in  
240 Vac  
To Ammeter  
and Relay  
to operate  
cycle counter or  
other timing  
device  
T1  
Variable  
Autotransformer  
240 Vac-20 A  
T2  
Electronic  
Control  
severe personal injury and/or equipment damage.  
T224.1  
120 Vac  
Variable  
115Vac  
Autotransformer  
(10 Amp)  
600:5  
Recloser  
Figure 43.  
BCT ON 600:5 Tap  
Suggested test circuit for motor-operated, solenoid-  
closing reclosers with low-voltage closing.  
2
Clamp-On  
Ammeter  
1
Note: This test circuit  
can apply over  
800 Amps to the  
recloser.  
Electrical Closing—NOVA Reclosers  
Note: Use at least 2/0  
cable between  
bushings.  
Type NOVA 3-phase reclosers utilize an interface circuit  
located in the mechanism housing. The electronic inter-  
face circuit controls the opening and closing signals to the  
magnetic actuator.  
Figure 42.  
Alternate method of producing variable line current  
(substitute for T2 and W-X circuit in Figures 43 and  
45).  
The Dc NOVA Recloser is tested with the dc-to-dc con-  
verter and 19-pin cable connected to the dc power supply.  
44  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
BYPASS SWITCHES  
(CLOSED)  
C
B
A
5
3
1
6
4
2
LOAD SIDE  
SOURCE SIDE  
DISCONNECT SWITCHES  
(OPEN)  
DISCONNECT SWITCHES  
(CLOSED)  
Figure 44.  
Closing source-side switches of a bypassed on-linerecloser provides closing solenoid power for automatic  
operation during testing.  
CLOSING  
VOLTAGE RATING OF  
RECLOSER CLOSING  
SOLENOID COIL  
SENSING CTs (3)  
SOLENOID  
CONTACTOR  
Z
5
6
J
TO  
MAIN  
CONTACTS (S)  
240 OR  
480 VAC  
SOURCE  
ROTARY  
SOLENOID  
T3  
Y
3
4
TRIP  
SOLENOID  
E F  
H
CLOSING  
SOLENOID  
COIL  
A
B
X
W
2
1
CONTROL  
CABLE RECEPTACLE  
G
K
TO  
240 VAC  
SOURCE  
TO  
AMMETER AND RELAY TO  
OPERATE CYCLE COUNTER  
OR OTHER TIMING DEVICE  
ELECTRONIC  
CONTROL  
T2  
VARIABLE  
120 VAC  
AUTOTRANSFORMER  
240 VAC  
20 AMPS  
Figure 45.  
Suggested test circuit for shop-testingsolenoid-closing reclosers.  
45  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
4. After each trip operation, about 1/2 second elapses  
Manual Closing—Solenoid-Operated  
Reclosers  
while the closing solenoid plunger is moving upward to  
reset the main toggle latch.  
5. After the main toggle latch resets, the recloser can be  
WARNING: Explosion Hazard. Excessive Con-  
!
closed again by operating the manual closing tool.  
tact Arcing. Do not use the manual closing tool to  
close an oil-insulated, energized recloser. Closing an  
energized oil-insulated recloser with a manual closing  
tool can cause excessive contact arcing, rapid build-up  
of gas within the equipment, and possible explosion  
that can cause death, severe personal injury, and  
6. Replace the gasket and port cover on the recloser  
head after testing has been completed.  
equipment damage.  
T203.2  
If high-voltage for operating the closing solenoid is not  
available, manual closing can be substituted for electrical  
closing. However, not all control settings can be checked  
since manual closing is not synchronized with the closing  
coil control circuit in the control.  
To manually close the recloser:  
1. Remove the closing tool port cover and gasket from  
the side of the recloser head casting.  
2. Insert the tee-handled tool (available as an accessory)  
into the port, engaging the pin on the closing shaft  
(Figure 46).  
CAUTION: Equipment damage. Do not turn the man-  
ual closing tool more than one-quarter turn clockwise.  
Forcing the tool beyond the mechanism stop may shear  
82284KMA-F  
Figure 46.  
the pin on the closing shaft of the recloser.  
T222.0  
Using a manual closing tool to operate the recloser.  
3. Close the recloser by placing the yellow operating  
handle (located under the sleethood) into the up or  
CLOSED position and turning the closing tool one-  
quarter turn clockwise.  
46  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
FORM 5 CONTROL DEFAULT TEST PROCEDURE  
Test Battery Circuitry  
CAUTION: Equipment misoperation. Do not con-  
!
nect this control to an energized recloser until all  
IMPORTANT: The Battery Test procedure requires  
large current drain. Overuse of this procedure will drain  
the battery.  
control settings have been properly programmed and  
verified. Refer to the programming information for this  
control. Failure to comply can result in control and  
recloser misoperation, equipment damage, and per-  
sonal injury.  
G110.3  
1. Press BACK button on display panel until Battery Test  
Screen 31 appears.  
2. Record values for all settings.  
IMPORTANT: The Form 5 recloser control can be  
taken out of service for testing and placed back into  
service without de-energizing its recloser and interrupt-  
ing the system. However, during the time the control is  
out of service, the recloser is inoperative.  
3. Press CHANGE button on the display panel.  
4. Press BATTERY TEST button on display panel.  
5. Record values for all readings.  
Test Phase Minimum Trip Values  
1. Verify Ground Trip Block LED is on.  
IMPORTANT: The Form 5 DC NOVA control can not  
be tested with the standard Kyle MET Tester. A junction  
box accessory for the MET tester is availble for testing  
the Form 5 DC NOVA control.  
2. Set KMET Phase Selector S5 to A.  
3. Set KMET switch S4 to 300 milliampere range.  
4. Set KMET Variac TR1 to zero.  
Use this procedure to test the Form 5 control with factory  
default control settings. Follow all cautions and warnings  
in these service instructions.  
5. Set KMET switch S2 to test fault current position.  
6. Press the TRIP button on the display panel.  
7. Press the CLOSE button on the display panel.  
Before installation on an active feeder, the Form 5 con-  
trols final control settings must be fully tested using an  
appropriate test procedure. The Form 5 Control Default  
Test Sheet follows these instructions. The Form 5 Control  
Default Test Sheet Optimal Values gives the optimal val-  
ues for the test results.  
8. Slowly raise TR1 until Above Minimum Trip LED is on,  
on display panel. Control should trip out quickly for  
load currents above 105 milliamperes. Record value.  
9. Repeat steps 4 8 for phases B and C (move KMET  
When performing these tests, change the Form 5 panel  
settings by first pressing the CHANGE button and then  
pressing the button of the function to be changed.  
S5 to B, then C).  
10. Change Form 5 control from Normal Profile to Alter-  
nate Profile 1.  
Initial Settings  
11. Verify Cold Load Pickup Blocked (LED is on) on the  
1. Apply 120 (240) Vac to the control phase B and neu-  
display panel.  
tral for standard controls.  
12. Repeat steps 2 9 for Form 5 Alternate Profiles 1, 2,  
and 3. The control is programmed to trip out at 200  
milliamperes on the Alternate 1, 2, and 3 Profiles.  
2. Plug in battery.  
3. Verify control is programmed for all default settings.  
Phase Minimum Trip is set to 100 amps.  
Ground Minimum Trip is set to 50 amps.  
Note: If Cold Load Pickup LED is off, the control will trip on a  
time delayed Time Current Curve with two trips to lock-  
out for 30 seconds after closing in the control, per the  
default Cold Load Pickup control settings.  
4. Disable Sequence Coordination in normal profile  
Note: If Alternate Profiles 1, 2, and 3 have the sequence coor-  
dination function enabled while testing the Form 5 con-  
trol minimum trip values, it may result in the control  
skipping past the fast TCC curves during the test for  
minimum trip. The control will then lock out on the  
delayed TCC curves.  
using personal computer (PC).  
5. Activate COLD LOAD PICKUP BLOCKED (LED is on)  
on Form 5 display panel.  
6. Activate GROUND TRIP BLOCK (LED is on) on Form  
5 display panel.  
Note: If the Form 5 control has Switch Mode rather than Pro-  
file 3, the control will indicate current Above Minimum  
Trip, but will not trip out.  
47  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
16. Set KMET test set Fault Current Switch S2 to test fault  
Test Ground Minimum Trip Values  
1. Change the Form 5 control from an Alternate Profile to  
the Normal Profile (all three Profile LEDs are off). Dis-  
able Ground Trip Block (LED off).  
current position. Record timings from the KMET test  
set for all trips on the B 5X ___ locations on the test  
sheet.  
17. Set KMET Phase Selector S5 to phase C.  
2. Set KMET switch S4 to 100 milliampere range.  
3. Set KMET Variac TR1 to zero.  
18. Calibrate KMET Phase Selector S5 to 1000% of fault  
(1000 milliamperes).  
4. Set KMET switch S2 to test fault position.  
19. Press the TRIP button on the display panel.  
20. Press the CLOSE button on the display panel.  
5. Verify the Form 5 phase minimum trip values are  
higher than the ground trip values.  
21. Set KMET test set Fault Current Switch S2 to test fault  
current position. Record timings from the KMET test  
set for all trips on the C 10X ___ locations on the test  
sheet.  
6. Set KMET Phase Selector S5 to A.  
7. Press the TRIP button on the display panel.  
8. Press the CLOSE button on the display panel.  
22. Repeat steps 2 21 for Alternate Profiles 1, 2, and 3.  
Note that the Phase minimum trip for the Alternate  
Profiles is 200 amps. The 200% fault will then be 400  
milliamperes or .4 amp, the 500% fault will then be  
1000 milliamperes or 1 amp, and the 1000% fault will  
then be 2000 milliamperes or 2 amps.  
9. Slowly raise TR1 until Above Minimum Trip shows on  
Form 5 control. Control should trip out for load cur-  
rents above 50 milliamperes. Record values.  
10. Repeat steps 4 9 for the Form 5 Alternate Profiles 1,  
2, and 3. The control is programmed to trip out at 100  
milliamperes on the Alternate 1, 2, and 3 Profiles.  
Test Ground Timing  
1. Verify control is programmed for all default settings.  
Note: If Cold Load Pickup is activated (LED off), the control will  
trip on a time delayed TCC with two trips to lockout for  
30 seconds after closing in the control, per the default  
Cold Load Pickup control settings.  
2. Disable GROUND TRIP BLOCK (LED off). Ground  
Trip is active.  
Test Phase Timing  
3. Activate the Normal Profile (Alternate Profile LEDs  
off).  
1. Set the Form 5 control to Normal profile (all Alternate  
Profile LEDs off).  
Note: When testing the ground trip timing circuit, the KMET  
test set applies a phase to ground fault to the Form 5  
control. If the applied fault current exceeds the phase  
minimum trip value, the control may time out on the  
phase time current curve, which may be shorter than the  
proper ground time current curve. For this reason, the  
Form 5 phase minimum trip value should be increased  
to a higher value while testing Form 5 ground trip time  
current curves.  
2. Activate GROUND TRIP BLOCK (LED on). Ground  
Trip is blocked.  
3. Set KMET Phase Selector S5 to phase A.  
4. Set KMET switch S4 to 300 milliampere range.  
5. Press the Form 5 trip switch once to lock out the Form  
5 control.  
4. Increase the Form 5 phase minimum trip value to  
6. Set KMET phase selector S3 to Control Response.  
1600 amperes.  
7. While holding the KMET Test Fault Current Switch S2  
in the Calibrate position, adjust the fault current to 200  
percent fault (100 X 2 or 200 milliamperes).  
5. Set KMET Test Set switch S4 to the 300 milliampere  
position.  
6. While holding the Fault Current Switch S2 in the Cali-  
brate position, adjust the fault current to 200 percent  
fault (50 X 2 or 60 milliamperes).  
Note: On newer controls, applying fault current while the  
control is locked out will set the Recloser Malfunction  
LED. This will not affect testing. To clear, press the  
Reset Targets button after all tests are complete.  
7. Press the TRIP button on the display panel.  
8. Press the CLOSE button on the display panel.  
8. Press the TRIP button on the display panel.  
9. Press the CLOSE button on the display panel.  
9. Set KMET test set Fault Current switch S2 in the test  
fault current position. Record timings from the KMET  
test set for all trips on the G 2X ___ locations on the  
test sheet.  
10. Set KMET Fault Switch S2 to test fault current posi-  
tion. Record timing readings from the KMET time  
clock for all trips on the A 2X___ test sheet location.  
11. Set KMET Test Set switch S4 to the 1A position.  
12. Set KMET Phase Selector S5 to phase B.  
10. Calibrate KMET fault current to 500 percent, (50 X 5  
or 250 milliamperes).  
11. Press the TRIP button on the display panel.  
12. Press the CLOSE button on the display panel.  
13. Calibrate KMET fault current to 500 percent (100 X 5  
or 500 milliamperes) using the KMET 1A range.  
14. Press the TRIP button on the display panel.  
15. Press the CLOSE button on the display panel.  
48  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
13. Set KMET test set Fault Current switch S2 in the test  
fault current position. Record timings from the KMET  
test set for all trips on the G 5X ___ locations on the  
test sheet.  
5. Control should trip twice on slow TCC curve, then indi-  
cate open and lockout. Record timing value.  
6. Activate COLD LOAD PICKUP BLOCKED (LED on).  
7. Repeat steps 2 4. Record value.  
14. Set KMET Test Set switch S4 to the 1A position.  
Test Fast Trips Disabled  
1. Activate FAST TRIPS DISABLED (LED on).  
2. CLOSE the Form 5 control.  
15. Calibrate KMET fault current to 1000 percent, (50 X 10  
or 500 milliamperes).  
16. Press the TRIP button on the display panel.  
17. Press the CLOSE button on the display panel.  
3. Adjust fault current to 200 percent or 200 mil-  
liamperes.  
18. Set KMET test set Fault Current switch S2 in the test  
fault current position. Record timings from the KMET  
test set for all trips on the G 10X ___ locations on the  
test sheet.  
4. Set KMET test set Fault Current Switch S2 to fault  
position.  
5. Control should trip two times to lockout, on all slow  
19. Repeat steps 4 18 for Alternate Profiles 1, 2, and 3.  
Note that the ground minimum trip for the Alternate  
Profiles is 100 amps. The 200% fault will then be 200  
milliamperes, the 500% fault will then be 500 mil-  
liamperes, and the 1000% fault will then be 1000 mil-  
liamperes or 1 amps.  
TCCs, then indicate OPEN and lockout. Record value.  
6. Deactivate Fast Trips Disabled (LED off).  
7. Repeat steps 2 -4. Control should trip on two fast, two  
slow TCCs. Record values.  
Test Hot Line Tag  
1. CLOSE the Form 5 control.  
20. Return the Normal Profile Phase Minimum Trip Value  
to the pretest value, 100 amps.  
2. Activate HOT LINE TAG (LED on).  
Test Non-Reclose  
3. Adjust fault current to 200 percent or 200 mil-  
1. Activate NON-RECLOSING (LED on).  
2. Activate GROUND TRIP BLOCK (LED on).  
3. Set KMET Phase Selector switch S5 to phase A.  
liamperes.  
4. Set KMET test set Fault Current Switch S2 to fault  
position.  
4. Set Form 5 control to Normal Profile (all Alternate Pro-  
5. Control should trip out once on the 101 TCC curve,  
file LEDs off).  
then indicate open and lockout. Record value.  
5. Adjust fault current to 200 percent or 200 mil-  
6. Verify that it is not possible to close the Form 5 control.  
7. Deactivate HOT LINE TAG (LED off).  
liamperes.  
6. Press the TRIP button on the display panel.  
7. Press the CLOSE button on the display panel.  
8. Verify that you can CLOSE the Form 5 control.  
Test Reclose  
8. Set KMET test set Fault Current Switch S2 to fault  
position.  
1. Set KMET selector switch S3 to Control Reclose  
Reset.  
9. Control should trip once, then indicate open and lock-  
out. Record time value.  
2. Reset the KMET Time Clock if required.  
10. Disable NON-RECLOSE (LED off).  
3. Adjust fault current to 200 percent or 200 mil-  
liamperes.  
11. Repeat steps 5 8, to lockout. Record time value.  
4. Set KMET test set Fault Current Switch S2 to fault  
Test Cold Load Pickup Blocked  
1. Disable COLD LOAD PICKUP BLOCKED (LED off).  
2. CLOSE the Form 5 control.  
position.  
5. After trip, turn fault switch S2 off.  
6. Record reclose time.  
3. Adjust fault current to 200 percent or 200 mil-  
7. Repeat steps 2 6 until control locks out.  
liamperes.  
4. Within 30 seconds of Step 3, set KMET test set Fault  
Current Switch S2 to fault position.  
49  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
Test Close Circuit Disable Fuse  
This test is only applicable to Form 5 LS controls and stan-  
dard Form 5 controls below Serial Number 3000.  
Verify Instantaneous Demand  
Metering  
1. Enable GROUND TRIP BLOCK (LED on).  
1. Set KMET Fault Switch S2 to OFF.  
2. CLOSE the Form 5 control.  
2. Set KMET switch S2 to OFF.  
3. Set KMET Phase Selector S5 to A.  
4. Set KMET Variac to zero.  
3. Remove Close Circuit Disable fuse.  
4. Adjust fault current to 200 percent or 200 mil-  
5. Set KMET switch S4 to the 100 milliampere range.  
6. CLOSE Form 5 control.  
liamperes.  
5. Set KMET test set Fault Current Switch S2 to fault  
7. Set KMET switch S2 to ON.  
position. The control will trip once.  
8. Set KMET Variac to read 80 milliamperes.  
9. Scroll the Form 5 LCD screen to screen 1.  
6. Verify that it is not possible to close the Form 5 control.  
7. Replace Close Circuit Disable fuse.  
10. Verify Instantaneous metering on Phase A and  
8. Verify it is now possible to CLOSE the Form 5 control.  
Ground reads 80 milliamperes.  
11. Set KMET Phase Selector S5 to B.  
12. Verify Instantaneous metering on Phase B and  
Ground reads 80 milliamperes.  
13. Set KMET Phase Selector S5 to C.  
14. Verify Instantaneous metering on Phase C and  
Ground reads 80 milliamperes.  
50  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
Form 5 Control Default Test Optimal Values  
2.  
Volts  
MA  
28.0  
35  
2.6 Volts  
2.6 MA  
28.0  
550  
Battery Circuitry  
Volts  
27.0  
2.6 volts  
24.2  
3.  
Normal Profile  
Phase A Amps Phase B Amps  
100.5 100.3  
Phase A Amps Phase B Amps  
200.9 200.2  
Phase A Amps Phase B Amps  
200.9 200.2  
Phase A Amps Phase B Amps  
Phase C Amps  
100.7  
Phase  
Profile #1  
Profile #2  
Profile #3  
Phase C Amps  
200.5  
Minimum Trip  
Phase C Amps  
200.5  
Phase C Amps  
200.5  
200.9  
200.2  
50.1  
4.  
Normal  
Ground Amps  
Ground Amps  
Ground Amps  
Ground Amps  
Ground  
Minimum Trip  
Profile #1  
Profile #2  
Profile #3  
100.3  
100.3  
100.3  
5.  
Trip to Lockout Sequence  
1st  
2nd  
3rd  
1.416  
0.278  
0.088  
1.443  
0.273  
4th  
Phase Timing  
Normal  
Phase A 2X  
0.161 0.164  
0.018 0.017  
0.016 0.014  
0.153 0.154  
0.015 0.014  
1.421  
0.280  
0.086  
1.441  
0.275  
0.087  
1.441  
0.275  
0.087  
1.441  
0.275  
0.087  
Phase B 5X  
Phase C 10X  
Phase A 2X  
Phase B 5X  
Phase C 10X  
Phase A 2X  
Phase B 5X  
Phase C 10X  
Phase A 2X  
Phase B 5X  
Phase C 10X  
Profile #1  
Profile #2  
Profile #3  
0.011  
0.009 0.087  
0.153 0.154  
0.015 0.014  
1.443  
0.273  
0.011  
0.009 0.087  
0.153 0.154  
0.015 0.014  
1.443  
0.273  
0.011  
0.009 0.087  
51  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
Form 5 Control Default Test Optimal Values  
6.  
Trip Sequence  
Normal  
1st  
2nd  
3rd  
4th  
Ground Timing  
Ground 2X  
Ground 5X  
Ground 10X  
Ground 2X  
Ground 5X  
Ground 10X  
Ground 2X  
Ground 5X  
Ground 10X  
Ground 2X  
Ground 5X  
Ground 10X  
Phase 2X  
0.214  
0.212 3.894  
3.896  
1.099  
0.012 0.016 1.097  
0.008 0.014  
0.652 0.653  
0.212 3.894 3.896  
Profile #1  
Profile #2  
Profile #3  
0.214  
0.012 0.016 0.952* 0.954*  
0.008 0.014 0.280* 0.276*  
0.214  
0.212 3.984  
3.896  
0.012 0.016 0.952* 0.954*  
0.008 0.014 0.280* 0.276*  
0.214  
0.212 3.894  
3.896  
0.012 0.016 0.952* 0.954*  
0.008 0.014 0.280* 0.276*  
0.153 lockout lockout lockout  
7.  
Enabled  
Disabled  
Block Off  
Block On  
Enabled  
Non-Reclose  
8. Cold Load  
PickUp Blocked  
9. Fast Trips  
Phase 2X  
0.152 0.153  
1.420 1.433 lockout lockout  
0.158 0.154 1.420 1.433  
1.419 1.422 lockout lockout  
0.155 0.156 1.418 1.424  
0.014 lockout lockout lockout  
1.420 1.433  
Phase 2X  
Phase 2X  
Phase 2X  
Phase 2X  
Phase 2X  
Disabled  
No Reclose  
Enabled  
10.  
Hot Line Tag  
11.  
0.155  
0.156 1.148 1.424  
2nd 3rd 4th  
1.975 1.974 4.968 lockout  
Reclose Sequence  
Reclose Times  
1st  
Test Reclose  
12.  
Fuse Out  
Cant Close?  
Yes  
No  
XXX  
No  
Close Circuit  
Disable Fuse  
Fuse In  
Can Close?  
Yes  
XXX  
13. Instantaneous  
Demand Metering  
Phase A  
Phase B  
Phase C  
Amps 80  
Amps 80  
Amps 81  
*Refer to the Test Ground Timing section of this manual.  
52  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
Form 5 Control Default Test Sheet  
Date:  
Serial No:  
2.  
Volts  
MA  
2.6 Volts  
2.6 MA  
Battery Circuitry  
Volts  
2.6 volts  
3.  
Normal Profile  
Phase A Amps Phase B Amps  
Phase A Amps Phase B Amps  
Phase A Amps Phase B Amps  
Phase A Amps Phase B Amps  
Phase C Amps  
Phase C Amps  
Phase C Amps  
Phase C Amps  
Phase  
Profile #1  
Profile #2  
Profile #3  
Minimum Trip  
4.  
Normal  
Ground Amps  
Ground Amps  
Ground Amps  
Ground Amps  
Ground  
Minimum Trip  
Profile #1  
Profile #2  
Profile #3  
5.  
Trip to Lockout Sequence  
1st  
2nd  
3rd  
4th  
Phase Timing  
Normal  
Phase A 2X  
Phase B 5X  
Phase C 10X  
Profile #1  
Phase A 2X  
Phase B 5X  
Phase C 10X  
Phase A 2X  
Phase B 5X  
Phase C 10X  
Phase A 2X  
Phase B 5X  
Phase C 10X  
Profile #2  
Profile #3  
53  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
Form 5 Control Default Test Sheet  
6.  
Trip Sequence  
Normal  
1st  
2nd  
3rd  
4th  
Ground Timing  
Ground 2X  
Ground 5X  
Ground 10X  
Profile #1  
Ground 2X  
Ground 5X  
Ground 10X  
Ground 2X  
Ground 5X  
Ground 10X  
Ground 2X  
Ground 5X  
Ground 10X  
Phase 2X  
Profile #2  
Profile #3  
7.  
Enabled  
Disabled  
Block Off  
Block On  
Enabled  
lockout lockout lockout  
lockout lockout  
Non-Reclose  
8. Cold Load  
PickUp Blocked  
9. Fast Trips  
Phase 2X  
Phase 2X  
Phase 2X  
Phase 2X  
Phase 2X  
Phase 2X  
lockout lockout  
Disabled  
No Reclose  
Enabled  
10.  
Hot Line Tag  
11.  
Reclose Sequence  
Reclose Times  
1st  
Yes  
Yes  
2nd  
No  
3rd  
4th  
Test Reclose  
12.  
Fuse Out  
Cant Close?  
Close Circuit  
Disable Fuse  
Fuse In  
Can Close?  
No  
13.Instantaneous  
Demand Metering  
Phase A  
Amps  
Phase B  
Amps  
Phase C  
Amps  
54  
Download from Www.Somanuals.com. All Manuals Search And Download.  
!
SAFETY  
FOR LIFE  
S280-79-10  
REMOVE THE CONTROL  
FROM SERVICE  
RETURN THE CONTROL TO  
SERVICE  
IMPORTANT: Disconnect switches for ac sensing  
and power connections are necessary to isolate the  
Form 5 Recloser Control for testing and servicing.  
CAUTION: Equipment misoperation. Do not  
!
connect this control to an energized recloser  
until all control settings have been properly pro-  
grammed and verified. Refer to the programming  
information for this control. Failure to comply can  
result in control and recloser misoperation, equip-  
1. Enable GND TRIP BLOCKED to allow for ground trip  
to be disabled when re-energized.  
ment damage, and personal injury.  
G110.3  
A. Press the CHANGE/LAMP TEST key on the Oper-  
ator Panel to enter the CHANGE mode.  
Note: The LCD Display Screen will indicate the amount  
of time available in CHANGE mode to make a  
change.  
After the required work is completed, disconnect the con-  
trol from the test set and follow this procedure to return the  
control to service:  
B. Depress the GND TRIP BLOCKED key.  
1. Plug in the control battery.  
Note: After the GND TRIP BLOCKED key is  
depressed, the red LED indicator will illuminate  
to indicate GROUND TRIP BLOCKED is active.  
2. Apply ac power to the control.  
3. Verify that all control settings are correct.  
4. Reconnect the control cable to the control.  
5. Disable GND TRIP BLOCKED.  
WARNING: Hazardous voltage. If the recloser  
is energized while the control cable is discon-  
nected, the CT secondaries can generate high volt-  
ages. Contact with high voltage can cause severe  
!
A. Press the CHANGE/LAMP TEST key on the Oper-  
ator Panel to enter the CHANGE mode.  
personal injury or death.  
T204.2  
Note: The LCD Display Screen will indicate the amount  
of time available in CHANGE mode to make a  
change.  
2. Disconnect control cable from the control.  
3. De-energize ac power from the control.  
4. Unplug the control battery.  
B. Depress the GND TRIP BLOCKED key.  
Note: After the GND TRIP BLOCKED key is  
depressed, the red LED indicator will not be illu-  
minated indicating GROUND TRIP BLOCKED is  
not active.  
6. Reset the control clock after AC power has been re-  
applied. Refer to Setting the Control Clock in Service  
Information S280-79-2 Form 5 Microprocessor-Based  
Recloser Control Programming Guide.  
55  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions  
ADDITIONAL INFORMATION  
Factory Maintenance Classes  
CAUTION: This equipment requires routine  
!
inspection and maintenance to ensure proper  
The factory service department offers a basic testing and  
troubleshooting course for the Form 5 Microprocessor-  
Based Electronic Recloser Control and Reclosers. This  
course, taught by experienced service technicians, is  
held at the factorys in-house training facility. For addi-  
tional information, contact your Cooper Power Systems  
representative.  
operation. If it is not maintained, it can fail to operate  
properly. Improper operation can cause equipment  
damage and possible personal injury.  
G105.1  
Replacement Kits  
Replacement kits for the Kyle Form 5 Control are avail-  
able through the factory Service Department. To order  
these kits, refer to the Replacement Parts price list for cat-  
alog numbers and pricing. Contact your Cooper Power  
Systems representative for additional information and  
ordering procedures.  
Type MET Recloser Control Tester  
A 30-minute video cassette program, KSPV7 Kyle Type  
MET Electronic Recloser Control Tester Operation and  
Testing Procedures is available as a supplemental train-  
ing aid for service personnel.  
®
Factory-Authorized Service  
Centers  
Factory-authorized service centers are located through-  
out the continental United States to provide maintenance,  
repair and testing services for Kyle controls and reclosers.  
For further information, contact your Cooper Power Sys-  
tems representative.  
!
SAFETY  
FOR LIFE  
KA2048-476 Rev: 02  
1045 Hickory Street  
Pewaukee, WI 53072  
©2005 Cooper Power Systems or its affiliates.  
Kyle® is a registered trademark of Cooper Power Systems or its affiliates.  
KDL  
5/05  
56  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Concord Camera Digital Camera 4360Z User Manual
ConnectPRO Home Theater Server VGAEDIDKITU1 User Manual
Craftsman Chainsaw 31521213 User Manual
Cuisinart Waffle Iron GR WAFP User Manual
D Link Network Router DWR 730 User Manual
Dukane Projector 8925H RJ User Manual
Durst Printer Rho 800 User Manual
Everpure Water System DEV9108 17 User Manual
Festool Sander PI570789 User Manual
Garland Oven CPO ED 12H User Manual