S280 79 10 UUD S2807910

S280-79-10 to the manual 578efdee-fdbc-4371-b33c-fc455d2ef3ac

User Manual: S280-79-10

Open the PDF directly: View PDF .
Page Count: 56

Printed in USA

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

Form 5 Universal Device Protection (UDP)

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

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

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

Service Information

Reclosers

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

Microprocessor-Based Recloser Controls

Installation and Operation Instructions S280-79-10

November 2001 • Supersedes 1/01

Figure 1.

Kyle®Form 5/UDP microprocessor-based recloser control.

99001KM

Contents

Applicable to serial numbers above 3000 or beginning with CP57.

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

The instructions in this manual are not intended as a sub-

stitute for proper training or adequate experience in the

safe operation of the equipment described. Only compe-

tent technicians who are familiar with this equipment

should install, operate, and service it.

A competent technician has these qualifications:

• Is thoroughly familiar with these instructions.

• Is trained in industry-accepted high- and low-voltage

safe operating practices and procedures.

• Is trained and authorized to energize, de-energize,

clear, and ground power distribution equipment.

• Is trained in the care and use of protective equipment

such as flash clothing, safety glasses, face shield,

hard hat, rubber gloves, hotstick, etc.

Following is important safety information. For safe instal-

lation and operation of this equipment, be sure to read

and understand all cautions and warnings.

Safety Instructions

Following are general caution and warning statements

that apply to this equipment. Additional statements,

related to specific tasks and procedures, are located

throughout the manual.

SAFETY INFORMATION

SAFETY FOR LIFE

Cooper Power Systems products meet or exceed all applicable industry standards relating to product safety. We actively

promote safe practices in the use and maintenance of our products through our service literature, instructional training

programs, and the continuous efforts of all Cooper Power Systems employees involved in product design, manufacture,

marketing, and service.

We strongly urge that you always follow all locally approved safety procedures and safety instructions when working

around high voltage lines and equipment and support our “Safety For Life” mission.

SAFETY

FOR LIFE

SAFETY

FOR LIFE

WARNING: This equipment is not intended to

protect human life. Follow all locally approved pro-

cedures and safety practices when installing or operat-

ing this equipment. Failure to comply can result in death,

severe personal injury and equipment damage.

G102.1

DANGER: Hazardous voltage. Contact with haz-

ardous voltage will cause death or severe per-

sonal injury. Follow all locally approved safety

procedures when working around high and low voltage

lines and equipment. G103.3

WARNING: Before installing, operating, main-

taining, or testing this equipment, carefully read

and understand the contents of this manual. Improper

operation, handling or maintenance can result in death,

severe personal injury, and equipment damage. G101.0

This manual may contain four types of hazard

statements:

DANGER: Indicates an imminently haz-

ardous situation which, if not avoided, will

result in death or serious injury.

WARNING: Indicates a potentially hazardous

situation which, if not avoided, could result in

death or serious injury.

CAUTION: Indicates a potentially hazardous

situation which, if not avoided, may result in

minor or moderate injury.

CAUTION: Indicates a potentially hazardous situ-

ation which, if not avoided, may result in equip-

ment damage only.

Hazard Statement Definitions

WARNING: Power distribution equipment must

be properly selected for the intended application. It

must be installed and serviced by competent personnel

who have been trained and understand proper safety

procedures. These instructions are written for such per-

sonnel and are not a substitute for adequate training

and experience in safety procedures. Failure to properly

select, install, or maintain power distribution equipment

can result in death, severe personal injury, and equip-

ment damage. G122.2

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.

Read This Manual First

Read and understand the contents of this manual and fol-

low all locally approved procedures and safety practices

before installing or operating this equipment.

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.

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.

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.

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.

Handling and Storage

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.

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.

Control Battery Storage and Charging

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.

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

use with the Form 5 Distribution Automation upgrade

accessory.

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.

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.

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.

Control Power

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.

S280-79-10

SAFETY

FOR LIFE

PRODUCT INFORMATION

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.

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.

AC Reclosers

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.

Operation Upon Loss Of AC Power

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.

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.

The AC power LED indicator on the operator panel of the

control will turn off after 15 seconds upon loss of AC

power. The indicator will illuminate immediately upon

return of ac power.

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.

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.

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.

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

CONTROL OK

AC POWER

ABOVE MIN TRIP

REVERSE POWER FLOW

RECLOSER MALFUNCTION

CHECK BATTERY

BUSHINGS 1-2 FAULT TARGET

BUSHINGS 3-4 FAULT TARGET

BUSHINGS 5-6 FAULT TARGET

GROUND FAULT TARGET

SENSITIVE-GROUND FAULT TARGET

BUSHINGS 1-2 VOLTAGE

BUSHINGS 3-4 VOLTAGE

BUSHINGS 5-6 VOLTAGE

RECLOSER CLOSED

RECLOSER OPEN

CONTROL LOCKOUT

BACK NEXT

LAMP

TEST

CHANGE

RESET

TARGETS

RESET

MAX CURRENT

GND TRIP

BLOCKED

NON

RECLOSING

SUPERVISORY

BLOCKED

COLD LOAD

PICK UP

BLOCKED

BATTERY

TEST

FAST

TRIPS

DISABLED

ALTERNATE

PROFILE

NO. 1

ALTERNATE

PROFILE

NO. 2

ALTERNATE

PROFILE

NO. 3

HOT LINE

TAG ON

OFF

TX 3

RX 3

TRIP

(LOCKOUT) KYLE®

FORM 5

RECLOSER CONTROL

RS232

TX 2

RX 2

LED Indicators

LCD Display

TRIP (LOCKOUT)

Pushbutton

CLOSE Pushbutton

LCD Display Dedicated

Function Keys

Operation "Hot Keys"

RS232 Data Port

Hot Line Tag

Figure 2. 99005KM

Form 5 recloser control operator panel.

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).

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.

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.

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.

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.

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.

S280-79-10

SAFETY

FOR LIFE

Figure 3.

Form 5 control operational flow diagram.

FORM 5 CONTROL DESCRIPTION

BATTERY

TRIP SOLENOID

CLOSE SOLENOID

A Ø CT

B Ø CT

C Ø CT

OPEN / CLOSE

SWITCHES

CT COMMON

RECLOSER RIF

OPTICAL

ISOLATION

OPTICAL

ISOLATION

OPTICAL

ISOLATION

OPTICAL

ISOLATION

MATCHING

TRANSFORMERS

AND SIGNAL

CONDITIONING

TB1 TERMINAL BLOCK

CUSTOMER P.T. INPUTS POWER SUPPLY

CPU

RS232

FIBER-OPTIC

PORT

RS232

FIBER-OPTIC

PCB

OPTIONS

OPERATOR'S

PANEL

KEYBOARD

LED's

LCD

RS232 PORT

DIF#1

(OPTIONAL)

DIF#2

(OPTIONAL)

USER

CONNECTIONS

6 unlatched outputs

6 latched outputs

12 inputs

USER

CONNECTIONS

6 unlatched outputs

6 latched outputs

12 inputs

The Form 5 control is constructed in a modular fashion to

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.

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.

Recloser Interface (RIF) Module

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.

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.

Central Processing Unit (CPU)

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

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.

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.

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

Figure 4.

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

99001KM

Control Cable Receptacle

and Control Grounding Lug

(located beneath cabinet) Control Battery

Central Processing

Unit (CPU) Module

Recloser Interface

(RIF) Module

TB1 Connector

Block

Power

Supply

Module

Power Capacitor

(Located behind operator

panel)

Grounding Strap

Manual Battery

Reconnect Button

Auxiliary Power

Connection (P9)

Form 5 Control Operator Panel

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.

All indicators with the exception of Hot Line Tag and

recloser status are automatically turned off after 5 minutes

of operator panel inactivity.

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.

LED Indicators

The operator panel LED indicators (Figure 5) give instant

information on the control and recloser status.

LED indicators include:

CONTROL OK

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.

AC POWER

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.

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.

CHECK BATTERY

This red indicator illuminates for two conditions:

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.

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.

REVERSE POWER FLOW

This red indicator illuminates when the control detects

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

recloser.

Note: Voltage sensor polarity and phase must be correct for

reverse power flow to function properly.

BUSHINGS 1-2 FAULT TARGET

BUSHINGS 3-4 FAULT TARGET

BUSHINGS 5-6 FAULT TARGET

GROUND FAULT TARGET

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.

BUSHINGS 1-2 VOLTAGE

BUSHINGS 3-4 VOLTAGE

BUSHINGS 5-6 VOLTAGE

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.

RECLOSER CLOSED

This red indicator is illuminated when the control senses

that the recloser mechanism is in the closed position.

S280-79-10

SAFETY

FOR LIFE

Figure 5.

Form 5 control operator panel.

CONTROL OK

AC POWER

ABOVE MIN TRIP

REVERSE POWER FLOW

RECLOSER MALFUNCTION

CHECK BATTERY

BUSHINGS 1-2 FAULT TARGET

BUSHINGS 3-4 FAULT TARGET

BUSHINGS 5-6 FAULT TARGET

GROUND FAULT TARGET

SENSITIVE-GROUND FAULT TARGET

BUSHINGS 1-2 VOLTAGE

BUSHINGS 3-4 VOLTAGE

BUSHINGS 5-6 VOLTAGE

RECLOSER CLOSED

RECLOSER OPEN

CONTROL LOCKOUT

BACK NEXT

LAMP

TEST

CHANGE

RESET

TARGETS

RESET

MAX CURRENT

GND TRIP

BLOCKED

NON

RECLOSING

SUPERVISORY

BLOCKED

COLD LOAD

PICK UP

BLOCKED

BATTERY

TEST

FAST

TRIPS

DISABLED

ALTERNATE

PROFILE

NO. 1

ALTERNATE

PROFILE

NO. 2

ALTERNATE

PROFILE

NO. 3

HOT LINE

TAG ON

OFF

TX 3

RX 3

TRIP

(LOCKOUT) KYLE®

FORM 5

RECLOSER CONTROL

RS232

TX 2

RX 2

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

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

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.

TRIP (Lockout) Pushbutton

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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

Figure 6.

LCD display and dedicated function keys.

NEXT BACK

RESET

TARGETS CHANGE

LAMP

TEST

RESET

MAX CURRENT

LCD Display Screens

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).

S280-79-10

SAFETY

FOR LIFE

1 Gn d ____________ A

Ph1-2 ____________ A

Ph3-4 ____________ A

Ph5-6 ____________ A

2 Gnd Fault ____________ A

Ph1-2 Fault ____________ A

Ph3-4 Fault ____________ A

Ph5-6 Fault ____________ A

3 Freq Trip____________ Hz

Time Date

Present Freq ____________ Hz

4 Ph1-N VTrip ____________ V

Ph3-N VTrip ____________ V

Ph5-N VTrip ____________ V

Time Date

5 To t ____________ kWh

Ph1-2 ____________ kWh

Ph3-4 ____________ kWh

Ph5-6 ____________ kWh

6 Instant S1 Ph-N

Ph1-N ____________ V

Ph3-N ____________ V

Ph5-N ____________ V

7 Instant S1 Ph-Ph

Ph1-3 ____________ V

Ph3-5 ____________ V

Ph5-1 ____________ V

8 Instant S2 Ph-N

Ph2-N ____________ V

Ph4-N ____________ V

Ph6-N ____________ V

9 Instant S2 Ph-Ph

Ph2-4 ____________ V

Ph4-6 ____________ V

Ph6-2 ____________ 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 2 – Fault Targets

Screen 3 – Frequency Trip

Screen 4 – Voltage Trip

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

Screen 5 – Power kWh

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

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

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

11 T ot ____________ kW

Ph1-2 ____________ kW

Ph3-4 ____________ kW

Ph5-6 ____________ kW

Screen 11 – Real Power

10 Instant S1-S2

Ph1-2 Dif ____________ V

Ph3-4 Dif ____________ V

Ph5-6 Dif ____________ V

Screen 10 – Instantaneous Voltage

12 T ot ____________ kVA

Ph1-2 ____________ kVA

Ph3-4 ____________ kVA

Ph5-6 ____________ kVA

Screen 12 – Instantaneous kVA

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

14 T ot ____________ PF

Ph1-2 ____________ PF

Ph3-4 ____________ PF

Ph5-6 ____________ PF

15 G nd ____________ %THDI

Ph1-2 ____________ %THDI

Ph3-4 ____________ %THDI

Ph5-6 ____________ %THDI

16 Instant S1 Ph-N

Ph1-N ____________ %THDV

Ph3-N ____________ %THDV

Ph5-N ____________ %THDV

17 Demand S1 Ph-N

Ph1-N(d) ____________ V

Ph3-N(d) ____________ V

Ph5-N(d) ____________ V

19 Demand S2 Ph-N

Ph2-N(d) ____________ V

Ph4-N(d) ____________ V

Ph6-N(d) ____________ V

20 Demand S2 Ph-Ph

Ph2-4(d) ____________ V

Ph4-6(d) ____________ V

Ph6-2(d) ____________ V

13 T ot ____________ kVAr

Ph1-2 ____________ kVAr

Ph3-4 ____________ kVAr

Ph5-6 ____________ kVAr

Screen 17 – Demand Phase to Neutral Voltage

Screen 18 – Demand Phase-to-Phase Voltage

Screen 19 – Demand Phase-to-Neutral Voltage

Screen 13 – Instantaneous kVAR

Screen 20 – Demand Phase-to-Phase Voltage

Screen 14 – Instantaneous Power Factor

Screen 15 –Instantaneous Total Harmonic Distortion

Current

Screen 16 –Instantaneous Total Harmonic Distortion

Voltage

21 Demand S1-S2

Ph1-2(d) ____________ V

Ph3-4(d) ____________ V

Ph5-6(d) ____________ V

Screen 21 – Demand Voltage

18 Demand S1 Ph-Ph

Ph1-3 (d) ____________ V

Ph3-5(d) ____________ V

Ph5-1(d) ____________ V

22 G nd ____________ A

Ph1-2 (d) ____________ A

Ph3-4 (d) ____________ A

Ph5-6 (d) ____________ A

23 Tot (d) ____________ kW

Ph1-2(d) ____________ kW

Ph3-4 (d) ____________ kW

Ph5-6 (d) ____________ kW

24 T ot ____________ kVA

Ph1-2(d) ____________ kVA

Ph3-4(d) ____________ kVA

Ph5-6(d) ____________ kVA

Screen 22 – Demand Current

Screen 23 – Demand kW

Screen 24 – Demand kVA

S280-79-10

SAFETY

FOR LIFE

25 T ot ____________ kVAr

Ph1-2(d) ____________ kVAr

Ph3-4(d) ____________ kVAr

Ph5-6(d) ____________ kVAr

26 T ot ____________ PF

Ph1-2(d) ____________ PF

Ph3-4(d) ____________ PF

Ph5-6(d) ____________ PF

27 G nd ____________ %THDI

Ph1-2(d) ____________ %THDI

Ph3-4(d) ____________ %THDI

Ph5-6(d) ____________ %THDI

28 Demand S1 Ph-N

Ph1-N(d) ____________ %THDV

Ph3-N(d) ____________ %THDV

Ph5-N(d) ____________ %THDV

29 Gnd OC Trip ____________

Ph1-2 OC Trip ____________

Ph3-4 OCTrip ____________

Ph5-6 OC Trip ____________

30 SGF OC Trip ______

Operations ______

31 Battery Monitor

Normal _______ V

Normal _____ mA

Test _______ V

32 – Phase MT ______ A

ALT1 MT ______ A

ALT2 MT ______ A

ALT3 MT ______ A

Screen 25 – Total kVAr and kVAr per Phase

Screen 26 – Demand Power Factor

Screen 27 – Demand THD Current

Screen 28 – Demand THD Voltage

Screen 29 – Number of Trips for Ground and Phase

Screen 30 –Number of SGF Trips and Total Trip

Operations

Screen 31 – Battery Monitor

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.

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.

33 Gnd MT ______ A

Alt1 MT _______ A

Alt2 MT ______ A

Alt3 MT _______ A

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.

34 Gnd Max ____________A

Time Date

Ph1-2 Max ____________A

Time Date

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

Currents

35 Ph 3-4 Max ____________A

Time Date

Ph5-6 Max ____________A

Time Date

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

Currents

Operation/Indication Pushbuttons

Nine frequently used features are provided on the control

operator panel (Figure 7).

Note: These features are activated from the keypad, control

interface software or SCADA signal.

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.

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.

Note: Operation LEDs activated from local or remote sources

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

save mode.

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.

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

GND TRIP

BLOCKED NON

RECLOSING

SUPERVISORY

BLOCKED

COLD LOAD

PICKUP

BLOCKED

BATTERY

TEST

FAST

TRIPS

DISABLED

ALTERNATE

PROFILE

NO. 1

ALTERNATE

PROFILE

NO. 2

ALTERNATE

PROFILE

NO. 3

Figure 7.

Operation/indication pushbuttons.

37 Ph3-4 Min ____________A

Time Date

Ph5-6 Min ____________A

Time Date

40 – Comm Port 2 ______

Protocol _______

Speed _______

Address _______

41 – Comm Port 3 ______

Protocol _______

Speed _______

Address _______

38 Fault Location

Distance ____________miles

Time Date

39 CPU Firmware X.XX

Firmware FW Database X

Time Date

Screen 38 – Fault Location

Screen 39 – Control Information

Screen 40 – Communication Port 2 Settings

This message displays the protocol settings (2179 or

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

Baud rate and address are set using the interface soft-

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

specifications.

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

Screen 41 – Communication Port 3 Settings

This message displays the protocol settings (2179 or

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

Baud rate and address are set using the interface soft-

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

specifications.

Note: Pressing and holding the RESET TARGETS/RESET

MAX CURRENT key for three seconds will reset the

minimum and maximum Demand values.

36 Gnd Min ____________A

Time Date

Ph1-2 Min ____________A

Time Date

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

Currents

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.

NON RECLOSING

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.

SUPERVISORY BLOCKED

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.

Activation of the feature is restricted to the operator panel

keypad by pressing the CHANGE/LAMP TEST key, then

pressing the SUPERVISORY BLOCKED key.

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.

Note:

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

SITIVE GROUND FAULT key on international controls.

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.

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 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.

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

with SWITCH MODE.

HOT LINE TAG Switch

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.

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.

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.

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.

S280-79-10

SAFETY

FOR LIFE

HOT LINE

TAG ON

OFF

Figure 8.

Hot Line Tag Switch.

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

equipment damage. T276.0

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.

IMPORTANT: Hot Line Tag activation does not

cause the recloser to trip open. It only prevents the

recloser from closing.

RS-232 Communication Port

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.

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.

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.

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.

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.

To perform a battery test:

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.

Control Features

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.

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.

A frequency alarm is available and can be configured for

notification.

Voltage Protection (120 Vac-based)

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.

Protection Profiles

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.

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

Figure 9.

Interface software sample protection profile.

Power Metering

Power metering includes single- and three-phase Watts,

VARS, KVARS, KWH measurements, and the per phase

and total system Power Factor (PF).

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.

Voltage Metering

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

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

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

operator panel, interface software, or serial communica-

tions. This reference is changed by selecting the voltage

sensor correction in the “Hardware” setup portion of the

interface software.

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.

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.

Upon activation of the feature, these four LEDs flash 1

second on, 1 second off (Figure 10):

•RECLOSER MALFUNCTION

•RECLOSER CLOSED

•RECLOSER OPEN

•CONTROL LOCKOUT

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.

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.

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

detection feature. It cannot be remotely turned off.

When the trip failure alarm is activated, an event is

recorded and a status alarm activated (if enabled) and

preserved during system resets.

To test the Trip Failure Detection feature, see Testing

With Type MET Tester in the TESTING AND TROU-

BLESHOOTING section of this manual.

S280-79-10

SAFETY

FOR LIFE

AC POWER

ABOVE MIN TRIP

REVERSE POWER FLOW

RECLOSER MALFUNCTION

CHECK BATTERY

BUSHINGS 1-2 FAULT TARGET

BUSHINGS 3-4 FAULT TARGET

BUSHINGS 5-6 FAULT TARGET

GROUND FAULT TARGET

SENSITIVE-GROUND FAULT TARGET

BUSHINGS 1-2 VOLTAGE

BUSHINGS 3-4 VOLTAGE

BUSHINGS 5-6 VOLTAGE

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.

DANGER: Explosion. Stay clear of a recloser

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

ure mode may explode resulting in death or severe per-

sonal injury. T271.0

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.

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

Manual Close Delay

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 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.

An active Manual Close Delay can be canceled by press-

ing the TRIP/LOCKOUT button.

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

The RECLOSER CLOSED LED indicates the status of the

feature. See Figure 11.

Harmonic Analysis

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.

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

power flow to function properly.

Event Recorder

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.

Histograms

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.

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.

Cold Load Pickup

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.

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.

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

Figure 13.

Interface software Cold Load Pickup settings.

Figure 12.

Form 5 operator panel harmonic readout.

NEXT BACK

RESET

TARGETS CHANGE

Pg14 Gnd %THDI

Ph1-2 %THDI

Ph3-4 %THDI

Ph5-6 %THDI

RESET

MAX CURRENT

LAMP

TEST

RECLOSER CLOSED

RECLOSER OPEN

CONTROL LOCKOUT

Figure 11.

The blinking of the RECLOSER CLOSED LED indi-

cates Manual Close Delay is active.

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:

•Single-phase to ground fault

•Phase-to-phase fault

•Double-line to ground fault

•Three-phase fault

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.

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.

The following system parameters must be entered via the

Protection Profile menu for each profile:

•Nominal system line-to-line voltage

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.

•Line-side zero sequence and positive sequence

impedance per mile or km.

•The distance units of the line impedance in miles or

km.

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

cessor-Based Recloser Control Programming Guide for

additional information.

S280-79-10

SAFETY

FOR LIFE

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.

Figure 14.

Fault Location configuration screen.

Directional Sensitive Ground/Earth

(SGF/SEF) Fault

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 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:

•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 (V0)Threshold (4 to 130 V)

The Maximum Torque Angle parameter determines the

angle of maximum tripping sensitivity between the phase

angle of the zero sequence voltage and current at the time

of fault. The setting of this value depends on knowledge

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

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

Torque Angle Width parameter restricts the tripping to an

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 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.

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.

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

Figure 15.

Directional SGF/SEF configuration screen.

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.

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.

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.

Fiber-Optic/RS-232 Accessory

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.

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.

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.

Protocols

Three protocols are available for the Form 5 control and

are factory-configurable to communication Ports 2 and 3.

The protocols are:

•Cooper Power Systems 2179

•DNP3.0, Level 3

•S-Comm Protocol accessory

Protocol DNP3.0 includes “Unsolicited Report by Excep-

tion” functionality and Protocol 2179 includes 2-bit status

functionality.

Complete documentation for Cooper Power Systems pro-

tocols are:

•Reference Data R280-90-12, Serial Communication

Protocol 2179

•Reference Data R280-90-13, Communication Point

Database for Protocol 2179

•Reference Date R280-90-14, Communication Point

Database for Protocol DNP3.0

Control Information

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.

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.)

S280-79-10

SAFETY

FOR LIFE

COMMUNICATIONS

PORT 1

(Internal Use Only)

COMMUNICATIONS

PORT 2

(Shared)

(Metering, Histograms

Profiles, Alarms, Targets)

CPU

TEMPORARY

ENGINEERING

(Local PC)

OPERATOR PANEL

DISPLAY AND

KEYPAD

OPERATIONS

OPERATOR

PANEL

RS-232

ENGINEERING

(Radio, Fiber-Optic, Modem)

RS-232 or

FIBER-OPTIC

ACCY

RS-232 or

FIBER-OPTIC

ACCY

SCADA SYSYEM

(Radio, Fiber-Optic, Modem)

COMMUNICATIONS

PORT 3

(Dedicated)

AUTO TRANSFER

SWITCH

(Operator Panel

Connection Disables

Accessory)

Figure 16.

Control communication port configuration.

TX 2

RX 2

TX 3

RX 3 RS232

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.

AUXILIARY POWER FOR

ACCESSORIES

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.

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.

RECLOSER INTERFACE (RIF)

MODULE CONFIGURATION

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.

To remove the RIF Module for configuration:

1. Disconnect the control battery.

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

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.

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

nectors.

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

board to the mounting bracket.

6. Pull the module out of the cabinet.

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

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

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

tion in the control cabinet and secure to the mounting

bracket with screws previously removed.

9. Replace nut securing the RIF Module grounding strap

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

RIF Module.

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

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-

cuit board damage. T253.1

INPUT VOLTAGE

SELECTION

INPUT VOLTAGE

SELECTION

POLE 2

POLE 1

POLE 2

POLE 1

POLE 2

POLE 1

POLE 2

POLE 1

POLE 2

BUSHING 2 (XØ)

BUSHING 4 (YØ)

BUSHING 6 (ZØ)

BUSHING 1 (AØ)

BUSHING 3 (BØ)

BUSHING 5 (CØ)

OFF ON

SENSOR

VOLTAGE POLE1 POLE2

12Vac OFF OFF

120Vac* OFF ON

240Vac ON ON

Example shown for 120Vac operation:

*120Vac is factory-set configuration

Figure 19.

Recloser Interface (RIF) Module indicates the fac-

tory-configured metering voltage (120Vac).

GDC-1A

SW (-) 4

28V (-) 3

SW (+) 2

28V (+) 1

Figure 18.

Power Supply Module Connection P9 provides

24Vdc power to radio communication units.

IMPORTANT: The Form 5 control must be com-

pletely de-energized prior to removing and configuring

the RIF board.

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.

S280-79-10

SAFETY

FOR LIFE

Figure 21.

Interface software Switch Mode settings.

GND TRIP

BLOCKED NON

RECLOSING

SUPERVISORY

BLOCKED

COLD LOAD

PICKUP

BLOCKED

BATTERY

TEST

FAST

TRIPS

DISABLED

ALTERNATE

PROFILE

NO. 1

ALTERNATE

PROFILE

NO. 2

SWITCH

MODE

Figure 20.

Function/Indication pushbuttons for the Form 5

equipped with the UDP accessory.

FORM 5 UNIVERSAL DEVICE PROTECTION (UDP) CONTROL

CONTROL OK

AC POWER

ABOVE MIN TRIP

REVERSE POWER FLOW

RECLOSER MALFUNCTION

CHECK BATTERY

BUSHINGS 1-2 FAULT TARGET

BUSHINGS 3-4 FAULT TARGET

BUSHINGS 5-6 FAULT TARGET

GROUND FAULT TARGET

SENSITIVE-GROUND FAULT TARGET

AØ

BØ

CØ

RECLOSER CLOSED

RECLOSER OPEN

CONTROL LOCKOUT

BACK NEXT

LAMP

TEST

CHANGE

RESET

TARGETS

RESET

MAX CURRENT

GND TRIP

BLOCKED

NON

RECLOSING

SUPERVISORY

BLOCKED

COLD LOAD

PICK UP

BLOCKED

BATTERY

TEST

FAST

TRIPS

DISABLED

ALTERNATE

PROFILE

NO. 1

ALTERNATE

PROFILE

NO. 2

SWITCH

MODE

HOT LINE

TAG ON

OFF

TX 3

RX 3

TRIP

(LOCKOUT) KYLE®

FORM 5/UDP

RECLOSER CONTROL

RS232

TX 2

RX 2

SOURCE

VOLTAGE

XØ

YØ

ZØ

LOAD

VOLTAGE

Figure 22.

Form 5/UDP Operator Panel.

The Kyle Form 5 recloser control can be equipped with a

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

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

Figure 23.

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

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

trip/close capacitors in the NOVA mechanism. The output

of the board is separately fused for operator indication.

The dc-to-dc converter houses voltage monitoring and

conditioning circuits which protect the battery from failure

and provides trip/close operations without AC power. The

19-pin control cable interfaces the NOVA dc recloser to

the Form 5 control through the interface circuit. The cable

also provides AC power from the control to the recloser

mechanism heater.

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

FORM 5 DC NOVA CONTROL

Form 5

Control

Potential

Transformer

(120/240Vac)

120Vac/240Vac

Power Cable

19 Pin

Control Cable

dc NOVA

Figure 23.

Connections of a Form 5 control with dc NOVA

accessory to a dc NOVA recloser.

Figure 24. 99007KM

Dc-to-dc converter located behind Form 5 operator

panel (removed).

S280-79-10

SAFETY

FOR LIFE

DISCRETE INTERFACE (DIF)

ACCESSORY

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.

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

puts for discrete SCADA functions. Each Form 5 control

can accommodate two DIF modules.

Whetting voltage for the DIF inputs can be supplied by the

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

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.

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

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

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

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

when control power is removed.

Non-latching is defined as an output that changes its

status when control power is removed.

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

SORY BLOCKED switch.

Customer Connection

Information

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.

Figure 27 shows customer connections to the DIF outputs

at P2 and P3.

INPUT COMMON

28V (–)

28V (+)

OUTPUT COMMON

DISCRETE

INTERFACE

MODULE

ACCESSORY

WHETTING

VOLTAGE

UNLATCHED

OUTPUTS

LATCHED

OUTPUTS

INPUTS

(12 TO 120

VAC OR VDC)

WHETTING

VOLTAGE

Figure 25.

Discrete Interface (DIF) Module.

INPUT COMMON

28V (-)

28V (+)

OUTPUT COMMON

To P4

Inputs 1 thru 12

Customer-Supplied

Wiring for Whetting Voltage

REMOTE

CONTACTS

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

reversed if necessary.

Figure 26.

Customer connections for supplying whetting volt-

age to DIF inputs.

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

unintentional operation. G117.3

CAUTION: Equipment damage. Do not drill con-

nection holes into the top of the cabinet. Connec-

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

seep into the control and damage the components or

cause control misoperation. Failure to comply will void

the control’s factory warranty. T249.0

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.

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

FORM 5 CONTROL

Remote Terminal Unit (RTU)

NORMAL PROFILE

NON-RECLOSING

COLD LOAD PICKUP BLOCKED

INPUT COMMON

SUPV. CLOSE

SUPV. TRIP & L.O.

Not All Remote

Connections

Shown

INPUT

VOLTAGE

COMMON

67 8512 43910

11 12

Discrete Interface

Module (DIF)

REMOTE HOT LINE TAG

SUPERVISORY GROUND TRIP BLOCKED

SUPERVISORY ALTERNATE PROFILE 1

SUPERVISORY ALTERNATE PROFILE 2

SUPERVISORY ALTERNATE PROFILE 3*

(*SWITCH MODE ON FORM 5 UDP)

SUPERVISORY NORMAL PROFILE

SUPERVISORY NON-RECLOSING

SUPERVISORY COLD LOAD PICKUP BLOCKED

REMOTE TRIP AND RECLOSE

REMOTE TRIP AND LOCKOUT

SUPERVISORY BLOCKED

AC POWER

CONTROL OK

RECLOSER OPEN

HOT LINE TAG

GROUND TRIP BLOCKED

ALTERNATE PROFILE 1

ALTERNATE PROFILE 2

ALTERNATE PROFILE 3

*28V (–)

*28V (+)

OUTPUT COMMON

67 8512 43910

11 12

67 8512 43910

11 12

*28 Vdc (nominal)

supplied by

DIF module for

whetting voltage.

Figure 27.

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

S280-79-10

SAFETY

FOR LIFE

Standard and UDP Controls

Standard and UDP Form 5 control DIF inputs and outputs

are described in the following pages.

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

Minimum Detection Level: . . . . . . . . . . . . . . . . . . . . . . . . 8 Vac (50 or 60Hz) 10 Vdc

Maximum Operating Voltage: . . . . . . . . . . . . . . . . . . . . . 135 Vac (50 or 60Hz) 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.

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

Output Current: . . . . 30 mA maximum

TABLE 1

DIF Input Ratings

TABLE 2

Whetting Voltage Source

(Supplied by Internal Voltage Source of DIF Module)

TABLE 3

DIF Output Ratings

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.

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

Note: Supervisory Alternate Profile 3 replaced by Switch

Mode on UDP controls.

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 P4-2 Supervisory Close Supervisory Close initiates a closing signal to the recloser. A

momentary signal is required for proper operation.

3 P4-3 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 P4-5 Supervisory Alternate Profile 1

6 P4-6 Supervisory Alternate Profile 2

7 P4-7 Supervisory Alternate Profile 3*

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.

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.

S280-79-10

SAFETY

FOR LIFE

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 P4-10 Suprv Cold-Load Pickup Blocked 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.

11 P4-11 Remote Trip and Reclose 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.

*Note: Supervisory Alternate Profile 3 replaced by Switch

Mode on UDP controls.

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 P3-1 NC Normal Profile Non-Latched

P3-2 NO

2 P3-3 NC Non-Reclosing Non-Latched

P3-4 NO

3 P3-5 NC Cold-Load Pickup Blocked Non-Latched

P3-6 NO

4 P3-7 NC Supervisory Blocked Non-Latched

P3-8 NO

5 P3-9 NC AC power Non-Latched

P3-10 NO

6 P3-11 NC Control OK Non-Latched

P3-12 NO

7 P2-1 NO Recloser Open Latched

P2-2 NC

8 P2-3 NO Hot Line Tag Latched

P2-4 NC

9 P2-5 NO Ground Trip Blocked Latched

P2-6 NC

10 P2-7 NO Alternate Profile 1 Latched

P2-8 NC

11 P2-9 NO Alternate Profile 2 Latched

P2-10 NC

12 P2-11 NO Alternate Profile 3* Latched

P2-12 NC

Normal Profile is active only when Alternate Profiles are

inactive. Normal reclosing operations will follow.

This output is active when the NON-RECLOSING indicator

in the operator panel is illuminated.

This output is active when the COLD LOAD PICKUP

BLOCKED indicator on the operator panel is illuminated.

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.

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.

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.

These outputs are active when the respective ALTERNATE

PROFILE indicators on the operator panel is illuminated.

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.

S280-79-10

SAFETY

FOR LIFE

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 P4-3 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.

4 P4-4 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.

5 P4-5 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.

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 P3-1 (NC) Control Lockout Non-Latched

P3-2 (NO)

2 P3-3 (NC) Check Battery Non-Latched

P3-4 (NO)

3 P3-5 (NC) Reverse Power Flow Non-Latched

P3-6 (NO)

4 P3-7 (NC) Fast Trips Disabled Non-Latched

P3-8 (NO)

5 P3-9 (NC) Operation Counter Non-Latched

P3-10 (NO)

6 P3-11 (NC) Recloser Malfunction Non-Latched

P3-12 (NO)

7 P2-1 (NO) Bushings 1-2 Fault Target Latched

P2-2 (NC)

8 P2-3 (NO) Bushings 3-4 Fault Target Latched

P2-4 (NC)

9 P2-5 (NO) Bushings 5-6 Fault Target Latched

P2-6 (NC)

10 P2-7 (NO) Ground Fault Target Latched

P2-8 (NC)

11 P2-9 (NO) Sensitive Ground Fault Target Latched

P2-10 (NC)

12 P2-11 (NO) Sensitive Ground Fault Blocked Latched

P2-12 (NC)

This output is active when the CONTROL LOCKOUT

indicator is illuminated.

This output is active when the CHECK BATTERY indi-

cator is illuminated.

This output is active when the REVERSE POWER

FLOW indicator is illuminated.

This output is active when the FAST TRIPS DIS-

ABLED indicator is illuminated.

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.

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.

This output is active when the BUSHINGS 3-4 FAULT

TARGET indicator is illuminated.

This output is active when the BUSHINGS 5-6 FAULT

TARGET indicator is illuminated.

Output is active when the GROUND FAULT TARGET

indicator is illuminated.

Output is active when the SENSITIVE GROUND

FAULT TARGET indicator is illuminated.

Output is active when Sensitive Ground Fault is

blocked.

Sensed Currents

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

does include the phase current summing process.

Phase Current—Individual Phase Currents:

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

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

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

Accuracy:± 1 mA from 10 mA to 125 mA

0.8% from 125 mA to 1600 mA

(Control only, does not include sensor

tolerance.)

Ground Current—Vector Sum of Three-Phase Currents:

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

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

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

Accuracy: ± 3 mA from 10 mA to 125 mA

2.4% from 125 mA to 1600 mA

Sensed Source Voltages

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

factor related calculations:

Voltage measurement accuracy:

± 0.4V from 5V to 80V

0.5% from 80V to 135V

S280-79-10

SAFETY

FOR LIFE

INPUT ACCURACY

Initial Programming

Prior to Installation

The control must be programmed with all necessary oper-

ating settings, all alternate profiles, and parameters prior

to operation with an energized recloser.

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.

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.

The control must be programmed with the Form 5 inter-

face software.

Control / Recloser Compatibility

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.

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:

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

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

cycle monitor will have limited accuracy for currents

above 5000 Amps.

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.

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.

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.

Control Cable

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.

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

TABLE 4

Serial Number Break for Reclosers with Type A

Sensing CTs

Recloser Below Serial Number

RXE 5831

RVE 5894

WE 11199

WVE 3695

VWE 7199

VWVE27 7208

VWVE38 1204

NOTICE

RECLOSER IS EQUIPPED WITH

TYPE B SENSING CTs.

RECLOSER DOES NOT HAVE A

BATTERY CHARGER.

INSTALLATION PROCEDURE

CAUTION: Equipment Misoperation. Do not

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-

sonal injury. G110.3

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

death or severe personal injury. G115.1

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.

Mounting the Control

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

sible location. Mounting dimensions are provided in Fig-

ure 28.

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

the control mounting bracket accommodates a 5/8”

bolt.

•For substation installation, brackets are available as

an accessory for mounting the control to a substation

frame.

Limits on control cable length are determined by the max-

imum distance between the control and recloser:

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

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

and NOVA).

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

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

VSO16).

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.

S280-79-10

SAFETY

FOR LIFE

CONTROL WEIGHT 52 kg (115 LBS)

350mm

(13-13/16")

30mm

(1-1/8")

Male Receptacle

For Control Cable

685mm

(27")

Grounding Terminal

One Internal and

One External

Use No. 14 To No. 4

Stranded Wire

110mm

(4-3/8")

165mm

(6-1/2")

580mm (23")

640mm (25-1/4")

40mm (1-1/2")

380mm

(15")

30mm (1-1/8") Hole

In Lifting Lug 240mm

(9-1/2")

76mm

(3")

480mm

(19")

Mtg Hole For

15mm (5/8") Max

Bolt Dia.*

Die-cast-zinc latchable

Handle For User-

Provided Utility-Grade

Padlock

130mm

(5-1/8")

190mm

(7-3/8")

120mm (4-3/4")

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

For Automation Accessory

(Cap-Plug Installed)

Vent

Female Receptacle

For Control

Cable

* USER-PROVIDED HARDWARE

110mm

(4-1/4")

40mm

(1-1/2")

200mm

(7-7/8")

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

For User 120Vac

Input Connection

(Cap-Plug Installed)

160mm

(6-3/8")

Figure 28.

Control cabinet mounting dimensions.

Grounding the Control

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.

Figure 29 illustrates grounding methods for 3-wire

ungrounded and 4-wire multi-grounded systems with local

supply voltage transformer.

Figure 30 illustrates grounding methods for 3-wire

ungrounded and 4-wire multi-grounded systems with

remote supply voltage transformer.

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

system.

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.

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

WARNING: Hazardous Voltage. The 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

death, severe personal injury. G115.1

Installation of a Form 5 control with a local supply voltage

transformer must include the following:

•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.

4-Wire Multi-Grounded Systems

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.

S280-79-10

SAFETY

FOR LIFE

Surge

Arrester

Recloser

Head Ground

Surge

Arrester

Transformer

Surge

Arrester

Arrester Ground

Recloser

Pole

Supply

Voltage

Pole

Ground Form 5 LS

Control

Customer Ground Connection

At External Lug

NEU

GND

NEU

Input

Terminal

Block

Control

Cable

NEUTRAL

Form 5 LS Control

Supply Voltage

Transformer

ELECTRICAL CONNECTIONS

Line to Neutral connected transformer

Form 5 LS Control

NEUTRAL

Input Terminal

Block

Supply Voltage

Transformer

ELECTRICAL CONNECTIONS

Line to Line connected transformer

Line

Voltage

External

Ground Lug

Input Terminal

Block External

Ground 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.

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.

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.

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 remote supply volt-

age transformer must include the following:

•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

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

Surge

Arrester

Recloser

Head

Ground

Supply

Voltage

Pole

Ground

Pole

Recloser

Pole

Surge

Arrester

Transformer

Arrester

Ground

Form 5 LS Control

HOT

NEU

GND

NEU

Input Terminal Block

Control Cable

Surge

Arrester

Ground

Customer Ground Connection

at External Lug

NEUTRAL

Form 5 LS Control

Supply Voltage

Transformer

ELECTRICAL CONNECTIONS - Remote dedicated

supply transformer

Form 5 LS Control

NEUTRAL

Input

Terminal

Block

115 Vac

Supply Voltage

Local Isolation

Transformer

ELECTRICAL CONNECTIONS - using isolation transformer

Customer

Supplied

Low Voltage

External

Ground Lug

Low Voltage

Arrester

Note: Distance between

transformer and

recloser should be

one pole span or

less

System

Neutral

External

Ground Lug

Input

Terminal

Block

Low Voltage Distribution Network

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.

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.

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.

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

3-Wire Ungrounded, or Impedance-Grounded

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

tem must include the following:

•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.

S280-79-10

SAFETY

FOR LIFE

Surge

Arrester

Recloser

Head Ground

Surge

Arrester

Surge

Arrester

Arrester Ground

Recloser

Supply

Voltage

Pole

Ground

Form 5 LS

Control

Customer Ground

Connection

at External Lug

GND

NEU

HOT

Input Terminal Block

Control

Cable

Neutral

Form 5 LS Control Input Terminal Block

Supply Voltage

Transformer

ELECTRICAL CONNECTIONS - Dedicated Supply

Transformer

Line

Voltage

External Ground Lug

NEU

Control Height must be

3 Meters (10 feet)

minimum above earth

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.

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.

WARNING: Hazardous Voltage. Use locally

approved operator safety procedures for proper

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

severe personal injury. T262.0

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

or personal injury. T263.0

CAUTION: Hazardous Voltage. Do not use a

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

ground potential. T264.0

Grounding on a 3-Wire Uni-Grounded System

Customer Connections for AC

Power

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

Power Supply Verification

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.

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.

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.

Power Connections

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.

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.

The transformer required for power should be a minimum

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

dc closing reclosers.

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.

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.

See RIF Module Configuration section of this manual.

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

CAUTION: Equipment damage. Do not drill con-

nection holes into the top of the cabinet. Connec-

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

seep into the control and damage the components or

cause control misoperation. Failure to comply will void

the control’s factory warranty. T249.0

Figure 33. 99003KM

Terminal Connector Block TB1.

IMPORTANT: Delta connections are not used on any

Form 5 control accessory that utilizes the low voltage

transfer relay.

CONFIGURED

FOR

120

VAC

240

VAC

GDC-3.15A

Figure 32.

Label on Power Supply module indicates factory-

configured voltage rating (120Vac).

S280-79-10

SAFETY

FOR LIFE

TB1

Y' VOLTAGE

120Vac

B' VOLTAGE

120Vac

CLOSING

VOLTAGE

NEUTRAL

SOURCE 2

NEUTRAL

SOURCE 1

CUSTOMER

CONNECTIONS

NEUTRAL

ZØ

YØ

SOURCE 2

POWER

XØ

OUTPUT

VOLTAGE

NEUTRAL

*NEUTRAL

POWER

SOURCE

OUTPUT

CØ

*BØ

AØ

CUSTOMER

CONNECTIONS

SOURCE 1

POWER

*REQUIRED FOR

CONTROL OPERATION

240Vac CLOSING

OPTION

NEU

CØ

BØ

AØ

16 AØ

BØ

CØ

NEU (LV Closing Output)

HOT (LV Closing Output)

Figure 34.

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

(120Vac or 240Vac Wye Connection).

CUSTOMER

CONNECTIONS

ZØ

YØ

XØ

SOURCE 2

POWER

OUTPUT

VOLTAGE

OUTPUT

VOLTAGE

*CØ

POWER

SOURCE

OUTPUT

BØ

*AØ

CUSTOMER

CONNECTIONS

SOURCE 1

POWER

*REQUIRED FOR

CONTROL OPERATION

SEE POWER SUPPLY

MODULE FOR

CORRECT VOLTAGE

TB1

CØ

BØ

AØ

240V CLOSING

OPTION 15

AØ

BØ

CØ

HOT (LV Closing Output)

Figure 35.

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

(120Vac or 240Vac Delta Connection).

TB1

1. Insert 3/32 inch flat-

blade screwdriver into

Wire Release and

Locking hole.

2. Carefully insert the

screwdriver along side

the locking clamp.

3. Pull toward the center

of terminal block TB1

until the locking clamp

opens.

4. Insert wire into Terminal

Connection hole.

5. Release screwdriver.

6. Carefully pull wire to be

sure it is secure.

To insert wire:

Terminal

Connection Hole

3/32 inch

Flat-Blade

Screwdriver

TB1

(Top View)

Connection

Wire

Wire Release

and Locking Hole

Note: Only slight pressure is

required to open the

locking clamp. Excessive

pressure can damage

the terminal block.

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

CUSTOMER

CONNECTIONS

ZØ

YØ

XØ

SOURCE 2

POWER

OUTPUT

VOLTAGE

OUTPUT

VOLTAGE

*CØ

POWER

SOURCE

OUTPUT

BØ

*AØ

CUSTOMER

CONNECTIONS

SOURCE 1

POWER

*REQUIRED FOR

CONTROL OPERATION

SEE POWER SUPPLY

MODULE FOR

CORRECT VOLTAGE

TB1

CØ

BØ

AØ

240V CLOSING

OPTION 15

AØ

BØ

CØ

HOT (LV Closing Output)

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).

CUSTOMER

CONNECTIONS

ZØ

YØ

XØ

SOURCE 2

POWER

OUTPUT

VOLTAGE

OUTPUT

VOLTAGE

CØ

POWER

SOURCE

OUTPUT

*BØ

AØ

CUSTOMER

CONNECTIONS

SOURCE 1

POWER

*REQUIRED FOR

CONTROL OPERATION

TB1

240V CLOSING

OPTION 15

120Vac

Neutral

120Vac

NEU (120Vac LV Closing Output)

HOT (120Vac LV Closing Output)

HOT (240Vac LV Closing Output)†

Y' VOLTAGE

120Vac

B' VOLTAGE

120Vac

NEUTRAL

SOURCE 2

NEUTRAL

SOURCE 1

NEUTRAL

*NEUTRAL

CLOSING

VOLTAGE

† For use with accessories:

3-Wire Low-Voltage Closing with receptacle

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

Figure 37.

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

(3-wire, 240Vac Connection).

S280-79-10

SAFETY

FOR LIFE

TB1

YØ VOLTAGE

120Vac

BØ VOLTAGE

120Vac

CLOSING

VOLTAGE

NEUTRAL

SOURCE 2

NEUTRAL

SOURCE 1

CUSTOMER

CONNECTIONS

NEUTRAL

ZØ

YØ

SOURCE 2

POWER

XØ

OUTPUT

VOLTAGE

NEUTRAL

*NEUTRAL

POWER

SOURCE

OUTPUT

CØ

*BØ

AØ

CUSTOMER

CONNECTIONS

SOURCE 1

POWER

*REQUIRED FOR

CONTROL OPERATION

240Vac CLOSING

OPTION

NEU

BØ

NEU (LV Closing Output)

HOT (LV Closing Output)

CONFIGURED

FOR

120

VAC

240

VAC

GDC-3.15A

BLK

WHT

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

Jumper**

Figure 38.

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

Phase Connection, Standard BØ Input).

TB1

Y' VOLTAGE

120Vac

B' VOLTAGE

120Vac

CLOSING

VOLTAGE

NEUTRAL

SOURCE 2

NEUTRAL

SOURCE 1

CUSTOMER

CONNECTIONS

NEUTRAL

ZØ

YØ

SOURCE 2

POWER

XØ

OUTPUT

VOLTAGE

NEUTRAL

*NEUTRAL

POWER

SOURCE

OUTPUT

CØ

*BØ

AØ

CUSTOMER

CONNECTIONS

SOURCE 1

POWER

*REQUIRED FOR

CONTROL OPERATION

240Vac CLOSING

OPTION

NEU

AØ

NEU (LV Closing Output)

HOT (LV Closing Output)

CONFIGURED

FOR

120

VAC

240

VAC

GDC-3.15A

BLK

WHT

AØ

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

Jumper**

Figure 39.

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

Phase Connection, AØ Input).

Before Placing the Control and

the Recloser into Service

Prior to placing the control and recloser into service, the

following installation procedures must be properly com-

pleted and verified:

1. Control properly mounted for the installation.

2. Recloser installed according to all locally approved

standards and practices.

3. Control and recloser properly grounded in accordance

with guidelines in this manual.

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

indicator is illuminated.)

5. Control battery connected and tested for proper

operation.

6. All control programming entered and verified by

appropriate personnel.

7. Control clock set to the correct time.

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.

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

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-

ment damage and personal injury. G110.3

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

death or severe personal injury. G115.1

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.

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.

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.

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

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.

S280-79-10

SAFETY

FOR LIFE

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.

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-

ment damage and personal injury. G110.3

Figure 40.

Form 5 control CPU module.

99002KM

CPU Module

(Central Processing Unit)

CPU Module LED Indicator

Figure 41.

Kyle Type MET electronic recloser control tester.

010028KM

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.

TESTING AND TROUBLESHOOTING

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.

Closing the Recloser During

Testing

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).

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).

For shop testing, the closing solenoid voltage is supplied

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

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

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

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

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

isfactory. The ac source must have a comparable

impedance drop.

The closing coil requirement is approximately 200kVA

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

solenoid coil operating voltage must be maintained at the

recloser bushings during the cycle interval the closing coil

is energized. This procedure is not used on reclosers

equipped with the low-voltage closing accessory.

Electrical Closing—Motor-Operated

Reclosers

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.

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.

Electrical Closing—NOVA Reclosers

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.

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

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

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

WARNING: Hazardous voltage. Solidly ground

all equipment. Failure to comply can result in

death, severe personal injury, and equipment damage.

T223.2

Figure 43.

Suggested test circuit for motor-operated, solenoid-

closing reclosers with low-voltage closing.

Electronic

Control

240 Vac

Power

Supply

Closing

Motor

T1 T2

240 Vac

Variable

Autotransformer

240 Vac-20 A

120 Vac

To Ammeter

and Relay

to operate

cycle counter or

other timing

device

Sensing CTs (3)

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

severe personal injury and/or equipment damage. T224.1

Figure 42.

Alternate method of producing variable line current

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

45).

600:5

Recloser

BCT ON 600:5 Tap

Note: This test circuit

can apply over

800 Amps to the

recloser.

Note: Use at least 2/0

cable between

bushings.

115Vac Variable

Autotransformer

(10 Amp)

Clamp-On

Ammeter

WARNING: Hazardous voltage. The switchgear

and high voltage transformer must be in a test

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,

severe personal injury, and equipment damage. T221.3

S280-79-10

SAFETY

FOR LIFE

T3 Y

VOLTAGE RATING OF

RECLOSER CLOSING

SOLENOID COIL

SENSING CTs (3) CLOSING

SOLENOID

CONTACTOR

ROTARY

SOLENOID

MAIN

CONTACTS (S)

240 OR

480 VAC

SOURCE

240 VAC

SOURCE

CLOSING

SOLENOID

COIL

TRIP

SOLENOID

CONTROL

CABLE RECEPTACLE

ELECTRONIC

CONTROL

AMMETER AND RELAY TO

OPERATE CYCLE COUNTER

OR OTHER TIMING DEVICE

120 VAC

VARIABLE

AUTOTRANSFORMER

240 VAC

20 AMPS

Figure 45.

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

5 6

1 2

BYPASS SWITCHES

(CLOSED)

SOURCE SIDE

DISCONNECT SWITCHES

(CLOSED)

LOAD SIDE

DISCONNECT SWITCHES

(OPEN)

CLOSING

COIL

LOAD

SOURCE

LOAD

Figure 44.

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

operation during testing.

Manual Closing—Solenoid-Operated

Reclosers

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).

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.

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

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

closed again by operating the manual closing tool.

6. Replace the gasket and port cover on the recloser

head after testing has been completed.

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

WARNING: Explosion Hazard. Excessive Con-

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

equipment damage. T203.2

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

the pin on the closing shaft of the recloser. T222.0 Figure 46.

Using a manual closing tool to operate the recloser.

82284KMA-F

Use this procedure to test the Form 5 control with factory

default control settings. Follow all cautions and warnings

in these service instructions.

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

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

appropriate test procedure. The Form 5 Control Default

Test Sheet follows these instructions. The Form 5 Control

Default Test Sheet Optimal Values gives the optimal val-

ues for the test results.

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.

Initial Settings

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

tral for standard controls.

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.

4. Disable Sequence Coordination in normal profile

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.

Test Battery Circuitry

1. Press BACK button on display panel until Battery Test

Screen 31 appears.

2. Record values for all settings.

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.

2. Set KMET Phase Selector S5 to A.

3. Set KMET switch S4 to 300 milliampere range.

4. Set KMET Variac TR1 to zero.

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.

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

S5 to B, then C).

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

nate Profile 1.

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

display panel.

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.

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.

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.

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.

S280-79-10

SAFETY

FOR LIFE

CAUTION: Equipment misoperation. Do not con-

nect 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-

sonal 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.

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.

FORM 5 CONTROL DEFAULT TEST PROCEDURE

IMPORTANT: The Battery Test procedure requires

large current drain. Overuse of this procedure will drain

the battery.

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).

2. Set KMET switch S4 to 100 milliampere range.

3. Set KMET Variac TR1 to zero.

4. Set KMET switch S2 to test fault position.

5. Verify the Form 5 phase minimum trip values are

higher than the ground trip values.

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.

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.

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.

Test Phase Timing

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

Profile LEDs off).

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.

6. Set KMET phase selector S3 to Control Response.

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).

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.

8. Press the TRIP button on the display panel.

9. Press the CLOSE button on the display panel.

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.

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.

16. 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 B 5X ___ locations on the test

sheet.

17. Set KMET Phase Selector S5 to phase C.

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

(1000 milliamperes).

19. Press the TRIP button on the display panel.

20. Press the CLOSE button on the display panel.

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.

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.

Test Ground Timing

1. Verify control is programmed for all default settings.

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

Trip is active.

3. Activate the Normal Profile (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.

4. Increase the Form 5 phase minimum trip value to

1600 amperes.

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).

7. Press the TRIP button on the display panel.

8. 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. 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.

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

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.

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

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.

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.

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.

20. Return the Normal Profile Phase Minimum Trip Value

to the pretest value, 100 amps.

Test Non-Reclose

1. Activate NON-RECLOSING (LED on).

2. Activate GROUND TRIP BLOCK (LED on).

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

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

file LEDs off).

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

liamperes.

6. Press the TRIP button on the display panel.

7. Press the CLOSE button on the display panel.

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

position.

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

out. Record time value.

10. Disable NON-RECLOSE (LED off).

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

Test Cold Load Pickup Blocked

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

2. CLOSE the Form 5 control.

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

liamperes.

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

Current Switch S2 to fault position.

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.

Test Fast Trips Disabled

1. Activate FAST TRIPS DISABLED (LED on).

2. CLOSE the Form 5 control.

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

liamperes.

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

position.

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

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.

2. Activate HOT LINE TAG (LED on).

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

liamperes.

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

position.

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

then indicate open and lockout. Record value.

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

7. Deactivate HOT LINE TAG (LED off).

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

Test Reclose

1. Set KMET selector switch S3 to Control Reclose

Reset.

2. Reset the KMET Time Clock if required.

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

liamperes.

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

position.

5. After trip, turn fault switch S2 off.

6. Record reclose time.

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

S280-79-10

SAFETY

FOR LIFE

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.

1. Set KMET Fault Switch S2 to OFF.

2. CLOSE the Form 5 control.

3. Remove Close Circuit Disable fuse.

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

liamperes.

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

position. The control will trip once.

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

7. Replace Close Circuit Disable fuse.

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

Verify Instantaneous Demand

Metering

1. Enable GROUND TRIP BLOCK (LED on).

2. Set KMET switch S2 to OFF.

3. Set KMET Phase Selector S5 to A.

4. Set KMET Variac to zero.

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

6. CLOSE Form 5 control.

7. Set KMET switch S2 to ON.

8. Set KMET Variac to read 80 milliamperes.

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

10. Verify Instantaneous metering on Phase A and

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.

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

S280-79-10

SAFETY

FOR LIFE

Form 5 Control Default Test Optimal Values

2. Volts 28.0 2.6 Volts 28.0

Battery Circuitry MA 35 2.6 MA 550

Volts 27.0 2.6 volts 24.2

3. Normal Profile Phase A Amps Phase B Amps Phase C Amps

100.5 100.3 100.7

Phase Profile #1 Phase A Amps Phase B Amps Phase C Amps

Minimum Trip 200.9 200.2 200.5

Profile #2 Phase A Amps Phase B Amps Phase C Amps

200.9 200.2 200.5

Profile #3 Phase A Amps Phase B Amps Phase C Amps

200.9 200.2 200.5

4. Normal Ground Amps 50.1

Ground Profile #1 Ground Amps 100.3

Minimum Trip Profile #2 Ground Amps 100.3

Profile #3 Ground Amps 100.3

5. Trip to Lockout Sequence 1st 2nd 3rd 4th

Phase Timing Normal Phase A 2X 0.161 0.164 1.416 1.421

Phase B 5X 0.018 0.017 0.278 0.280

Phase C 10X 0.016 0.014 0.088 0.086

Profile #1 Phase A 2X 0.153 0.154 1.443 1.441

Phase B 5X 0.015 0.014 0.273 0.275

Phase C 10X 0.011 0.009 0.087 0.087

Profile #2 Phase A 2X 0.153 0.154 1.443 1.441

Phase B 5X 0.015 0.014 0.273 0.275

Phase C 10X 0.011 0.009 0.087 0.087

Profile #3 Phase A 2X 0.153 0.154 1.443 1.441

Phase B 5X 0.015 0.014 0.273 0.275

Phase C 10X 0.011 0.009 0.087 0.087

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 1st 2nd 3rd 4th

Ground Timing Normal Ground 2X 0.214 0.212 3.894 3.896

Ground 5X 0.012 0.016 1.097 1.099

Ground 10X 0.008 0.014 0.652 0.653

Profile #1 Ground 2X 0.214 0.212 3.894 3.896

Ground 5X 0.012 0.016 0.952* 0.954*

Ground 10X 0.008 0.014 0.280* 0.276*

Profile #2 Ground 2X 0.214 0.212 3.984 3.896

Ground 5X 0.012 0.016 0.952* 0.954*

Ground 10X 0.008 0.014 0.280* 0.276*

Profile #3 Ground 2X 0.214 0.212 3.894 3.896

Ground 5X 0.012 0.016 0.952* 0.954*

Ground 10X 0.008 0.014 0.280* 0.276*

7. Enabled Phase 2X 0.153 lockout lockout lockout

Non-Reclose Disabled Phase 2X 0.152 0.153 1.420 1.433

8. Cold Load Block Off Phase 2X 1.420 1.433 lockout lockout

PickUp Blocked Block On 0.158 0.154 1.420 1.433

9. Fast Trips Enabled Phase 2X 1.419 1.422 lockout lockout

Disabled Phase 2X 0.155 0.156 1.418 1.424

10. No Reclose Phase 2X 0.014 lockout lockout lockout

Hot Line Tag Enabled Phase 2X 0.155 0.156 1.148 1.424

11. Reclose Sequence 1st 2nd 3rd 4th

Test Reclose Reclose Times 1.975 1.974 4.968 lockout

12. Fuse Out Can’t Close? Yes No

Close Circuit XXX

Disable Fuse Fuse In Can Close? Yes No

XXX

13. Instantaneous Phase A Phase B Phase C

Demand Metering Amps 80 Amps 81 Amps 80

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

S280-79-10

SAFETY

FOR LIFE

Form 5 Control Default Test Sheet

Date: Serial No:

2. Volts 2.6 Volts

Battery Circuitry MA 2.6 MA

Volts 2.6 volts

3. Normal Profile Phase A Amps Phase B Amps Phase C Amps

Phase Profile #1 Phase A Amps Phase B Amps Phase C Amps

Minimum Trip

Profile #2 Phase A Amps Phase B Amps Phase C Amps

Profile #3 Phase A Amps Phase B Amps Phase C Amps

4. Normal Ground Amps

Ground Profile #1 Ground Amps

Minimum Trip Profile #2 Ground Amps

Profile #3 Ground Amps

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

Profile #2 Phase A 2X

Phase B 5X

Phase C 10X

Profile #3 Phase A 2X

Phase B 5X

Phase C 10X

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 1st 2nd 3rd 4th

Ground Timing Normal Ground 2X

Ground 5X

Ground 10X

Profile #1 Ground 2X

Ground 5X

Ground 10X

Profile #2 Ground 2X

Ground 5X

Ground 10X

Profile #3 Ground 2X

Ground 5X

Ground 10X

7. Enabled Phase 2X lockout lockout lockout

Non-Reclose Disabled Phase 2X

8. Cold Load Block Off Phase 2X lockout lockout

PickUp Blocked Block On

9. Fast Trips Enabled Phase 2X lockout lockout

Disabled Phase 2X

10. No Reclose Phase 2X

Hot Line Tag Enabled Phase 2X

11. Reclose Sequence 1st 2nd 3rd 4th

Test Reclose Reclose Times

12. Fuse Out Can’t Close? Yes No

Close Circuit

Disable Fuse Fuse In Can Close? Yes No

13.Instantaneous Phase A Phase B Phase C

Demand Metering Amps Amps Amps

REMOVE THE CONTROL

FROM SERVICE

1. Enable GND TRIP BLOCKED to allow for ground trip

to be disabled when re-energized.

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.

B. Depress the GND TRIP BLOCKED key.

Note: After the GND TRIP BLOCKED key is

depressed, the red LED indicator will illuminate

to indicate GROUND TRIP BLOCKED is active.

2. Disconnect control cable from the control.

3. De-energize ac power from the control.

4. Unplug the control battery.

RETURN THE CONTROL TO

SERVICE

After the required work is completed, disconnect the con-

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

control to service:

1. Plug in the control battery.

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.

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.

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.

S280-79-10

SAFETY

FOR LIFE

IMPORTANT: Disconnect switches for ac sensing

and power connections are necessary to isolate the

Form 5 Recloser Control for testing and servicing.

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

personal injury or death. T204.2

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-

ment damage, and personal injury. G110.3

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.

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.

Factory Maintenance Classes

The factory service department offers a basic testing and

troubleshooting course for the Form 5 Microprocessor-

Based Electronic Recloser Control and Reclosers. This

course, taught by experienced service technicians, is

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

tional information, contact your Cooper Power Systems

representative.

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.

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

56 KDL

5/05

1045 Hickory Street

Pewaukee, WI 53072

www.cooperpower.com

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

KA2048-476 Rev: 02

SAFETY

FOR LIFE

ADDITIONAL INFORMATION

CAUTION: This equipment requires routine

inspection and maintenance to ensure proper

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

properly. Improper operation can cause equipment

damage and possible personal injury. G105.1

S280 79 10 UUD S2807910

S280-79-10 to the manual 578efdee-fdbc-4371-b33c-fc455d2ef3ac

Navigation menu

Versions of this User Manual:

Views

Navigation