Reclosers

Form 6 Triple-Single Service Information

Microprocessor-Based Pole Mount Recloser
Control Installation and Operation Instructions S280-70-7

030030KM
Figure 1.
Kyle® Form 6 Triple-Single Microprocessor-Based Pole Mount Recloser Control.

Contents
Safety Information ..................................................... 2 Mounting the Control ..............................................18
Product Information .................................................. 3 Grounding the Control ............................................19
Introduction ............................................................ 3 Customer Connections for AC Power ....................23
ANSI Standards ..................................................... 3 Before Placing Control and Recloser into Service ...32
Quality Standards ................................................... 3 Using Removable Inserts .......................................33
Acceptance and Initial Inspection .......................... 3 Accessories ...............................................................34
Handling and Storage ............................................ 3 Incoming Power Receptacles ................................34
Control Power ........................................................ 3 Discrete Interface Board Accessory .......................34
Battery Replacement and Disposal ........................ 3 Cable Locking Sleeves ..........................................34
Operation Upon Loss of AC Power ........................ 4 RS-232 Cable .........................................................34
Form 6 Triple-Single Control Description ............... 4 Stainless Steel Cabinet ..........................................34
Description ............................................................. 4 120 Vac GFI Duplex Outlet ....................................34
Theory of Operation ............................................... 5 Radio Mounting Accessory ....................................35
Control Front Panel ................................................ 6 Communication Board Accessory ..........................36
Control Features ....................................................12 Testing ........................................................................38
Communications ....................................................15 Testing an Installed Control ....................................38
Control Information .................................................15 Remove the Control from Service ..........................39
Control Back Panel ................................................15 Electrical Testing of NOVA-TS Reclosers ..............39
Installation Procedure ..............................................16 Battery Test and Charging Procedures ..................40
Initial Programming Prior to Installation .................16 Return the Control to Service ................................42
Control / Recloser Compatibility .............................16 Additional Information ..............................................43
Duty Cycle Monitor .................................................16 Replacement Kits ...................................................43
Control Cable .........................................................17 Factory-Authorized Service Centers ......................43
Junction Box and Cables .......................................17 Factory Maintenance Classes ................................43

October 2003 • New Issue 1

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

!
SAFETY
!
SAFETY
FOR LIFE
SAFETY FOR LIFE FOR LIFE

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

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

• Is trained in the care and use of protective equipment

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

Hazard Statement Definitions

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

WARNING: Indicates a potentially hazardous

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

2
 !
SAFETY
FOR LIFE
S280-70-7

PRODUCT INFORMATION
Introduction Note: To energize the control, apply ac power to the ac sup-
ply input terminal block located in the lower right hand
Service Information S280-70-7 provides installation and corner of the back panel of the control. Refer to the
operation instructions for the Kyle® Form 6 Triple-Single Customer Connections for AC Power section in this
pole mount recloser control. manual.
Refer to Service Information S280-70-9 Form 6-TS Control Battery Storage and Charging
Microprocessor-Based Recloser Control Programming
Guide for additional information. The 24 Vdc control battery in the Form 6-TS recloser con-
trol is fully charged prior to shipment and is ready for use.
The Form 6 Triple-Single control is designed for use with
three Kyle® NOVA-TS Triple-Single reclosers. Refer to
IMPORTANT: To maintain sufficient charge to oper-
Service Information S280-42-2 NOVA-TS Recloser
ate the control and prevent battery cell damage, the
Installation and Operation Instructions.
sealed lead-acid batteries should be charged after no
Read This Manual First more than three months of storage.
Read and understand the contents of this manual and fol- Temperature has an effect on battery life. Sealed lead
low all locally approved procedures and safety practices acid batteries should be stored, fully charged, at room
before installing or operating this equipment. temperature. Never store lead acid batteries at tempera-
Additional Information tures exceeding 47°C (117°F), as damage can result in
approximately one month.
These instructions cannot cover all details or variations in
the equipment, procedures, or process described, nor To keep the battery charged, energize the control’s built-
provide directions for meeting every possible contingency in charger with ac power applied to the user ac supply
during installation, operation, or maintenance. When addi- input connector block TB1. See Customer Connections
tional information is desired to satisfy a problem not cov- for AC Power. In addition, if power to the control is not
ered sufficiently for the user's purpose, contact your possible a separate portable charger accessory is avail-
Cooper Power Systems sales representative. able. Catalog Number KA43ME7001 provides a 120 Volt
battery charger to power individual batteries.
ANSI Standards
IMPORTANT: Connect the control battery when ac
Kyle® reclosers are designed and tested in accordance power is connected to the control’s ac supply Input
with the following ANSI standards: C37.60 and C37.85 Terminal Block. The battery must be disconnected
and ANSI Guide C37.61. prior to shipping or storing the control.

Quality Standards Note: When shipped from the factory, the battery source is
The Quality System at the Cooper Power Systems Kyle disconnected and its output plugs are taped to the cab-
Distribution Switchgear plant is certified to the ISO 9001 inet. Connect the battery plugs into the mating connec-
standard. tors to complete the battery circuit.

Acceptance and Initial Control Power

Inspection The control is powered from 120 or 240 Vac. The selec-
tor switch on the power supply board allows the user to
Each Form 6-TS recloser control is completely assem-
select between 120 Vac or 240 Vac.
bled, tested, and inspected at the factory. It is carefully
calibrated, adjusted and in good condition when accept- Note: The selector switch is factory-set for each control
ed by the carrier for shipment. based upon the customer order requirement.

Upon receipt, inspect the carton for signs of damage.

Unpack the control and inspect it thoroughly for damage
Battery Replacement and
incurred during shipment. If damage is discovered, file a Disposal
claim with the carrier immediately. The 24 Vdc control battery has a life expectancy of four
to six years. It is recommended that the battery be
Handling and Storage replaced after four years.
Be careful during handling and storage of the control to min- Dispose expired batteries in an environmentally respon-
imize the possibility of damage. If the control is to be stored sible manner. Consult local regulations for proper battery
for any length of time prior to installation, provide a clean, disposal.
dry storage area. If storage is in a humid atmosphere, make
provisions to keep the control circuitry energized.

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

Operation Upon Loss of AC FORM 6 TRIPLE-SINGLE

Power CONTROL DESCRIPTION
The control is equipped with a 13 Amp-Hour 24 Vdc lead
acid battery for operation upon loss of ac power. The con-
trol maintains full operation from the battery for a period Description
of time — 25 hour maximum (20°C)
The Kyle® Form 6 Triple-Single control is designed for use
In the event that the ac power has not returned within the with three Kyle® NOVA-TS Triple-Single reclosers to pro-
times listed above, the control will disconnect the battery vide protection, metering, and automation of distribution
from the circuit. feeders in substation and line applications.
Note: The control continuously monitors the battery voltage. The Form 6-TS control operates three single-phase
To prevent battery damage, the control shuts down NOVA-TS reclosers representing phases A, B, and C.
automatically upon detection of low battery voltage
(below 22 Vdc) for 60 seconds. Note: Phase A, B, and C sequence positions are independent
of each other.
Control programming settings and parameters—includ-
ing event recorder—are stored in non-volatile memory The Form 6-TS control uses three modes of operation. All
and retained upon loss of control power. The time/date modes are configured through the ProViewTM user inter-
clock will continue to operate for approximately 30 days face software.
after loss of control power. Three-phase trip, Three-phase lockout (ganged)
Phase B (Ø) is the factory default phase. Unless changed Single-phase trip, Three-phase lockout
by the user, the B PHASE VOLTAGE red LED illuminates Single-phase trip, Single-phase lockout
indicating ac is the operating power. If BØ (or the user-
indicated phase) loses ac power for more than ten sec- The Form 6-TS recloser control includes extensive sys-
onds, the ALARM red indicator LED will illuminate. The tem protection functionality, including phase, ground, and
ALARM log on the LCD Display will indicate NO AC PRE- negative sequence overcurrent protection, over/under
SENT and the CONTROL OK LED will not be illuminated. frequency, and voltage protection, directionality, sensitive
ground fault, and sync check.
IMPORTANT: If the the control shuts down due to Analysis tools include fault locating, event recording,
low battery voltage before ac power is restored, and TCC EditorTM II, Idea WorkbenchTM, and oscillography
the connected energized recloser is CLOSED; it will functions, including oscillography replay.
only TRIP and LOCKOUT via front panel pushbutton Metering functions include demand and instantaneous
command. current on a per-phase basis, instantaneous voltage and
A control that has shut down due to low battery volt- power factor on a per-phase basis, and power (real, reac-
age before ac power is restored will have a blank LCD tive, apparent) on a per phase or total basis. Symmetrical
display (no text message shown). components for both voltage and current are displayed
along with kilowatt-hours for energy metering. Harmonics
from the 2nd to the 15th harmonic are also included.
The control clock may require resetting if the operating
The front panel LCD display is used to configure the
power has been disconnected for more than thirty days.
operating settings for the control. It is also used to display
Refer to Service Information S280-70-9 Form 6-TS
metering, counter information, control parameters,
Microprocessor-Based Recloser Control Programming
alarms, and provide diagnostic information.
Guide for information on setting the control clock.
Control parameters can also be programmed via a per-
sonal computer connected to the control through the front
panel RS-232 port. Control programming, interrogation,
and operations are performed with Form 6 ProViewTM
interface software on a personal computer.
The ProViewTM interface program software includes addi-
tional functions used to create and graphically display
Time Current Curves and provides the Idea WorkbenchTM
for configuring user-selected inputs and outputs, config-
urable event and alarm data, and selectable communica-
tion points for serial communication.
The control operates on 50 and 60 Hz systems.
The control can be configured, by the factory or by the
user, for a wide variety of applications. If user require-
030002KM ments change, the control functions can be modified to
Figure 2.
meet the new requirements.
Form 6 triple-single recloser control is accessible
from both the front and back of the cabinet. The control is accessible from both the front and back of
the cabinet (Figure 2).
4
 !
SAFETY
FOR LIFE
S280-70-7

Theory of Operation Phase Operation

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

FORM 6 TRIPLE-SINGLE CONTROL

NOVA
26 PIN 120/VAC
TRIPLE/SINGLE
CONNECTOR TB7 OUTLET
RECLOSERS
TERMINAL DUPLEX
AØ DC/DC POWER RS-232 BLOCK ACCESSORY
24 VDC
CONVERTER IRIG-B
BATTERY
ACTUATOR JUNCTION
BOX COMMUNICATIONS
SWITCHES
BOARD ACCY
CT RIF •RS-485
•FIBER-OPTIC
TB8
INTERCON- CPU •ETHERNET
TERMINAL
BØ NECTION
OPTICAL BLOCK
BOARD 3 inputs
ACTUATOR ISOLATION USER
SENSING
CONNECTIONS VOLTAGE
SWITCHES 5 outputs POWER INPUTS
CONNECTIONS
CT 120/240
MATCHING I/O 8 inputs
TRANSFORMERS USER
CONNECTIONS
CØ AND SIGNAL
8 outputs
CONDITIONING
ACTUATOR
FRONT
SWITCHES ANALOG INPUT PANEL
CT RS-232
(PROVIEW
PROTOCOL
ONLY)

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

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

Control Front Panel Front Panel Text Messaging

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

CONTROL OK A PHASE FAULT ALARM A PHASE VOLTAGE INDICATOR 4

CONTROL POWER B PHASE FAULT ABOVE MIN TRIP B PHASE VOLTAGE INDICATOR 5
LED Indicators CONTROL LOCKOUT C PHASE FAULT INDICATOR 1 C PHASE VOLTAGE INDICATOR 6
RECLOSER OPEN GROUND FAULT INDICATOR 2 FREQUENCY TRIP INDICATOR 7
RECLOSER CLOSED SENSITIVE GND INDICATOR 3 VOLTAGE TRIP INDICATOR 8
LCD Display
LCD Menu Function Keys
METERING SETTINGS

RESET OPER
TARGETS COUNTER

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

LAMP TEST
MENU + CHANGE

Cursor Movement Arrows

LCD Display
ENTER — LCD Display
Dedicated
RS-232 DATA PORT
Function Keys
Dedicated
Function Keys KYLE F6 Recloser Control ON
GND TRIP NON SUPERVISORY
BLOCKED RECLOSING OFF
RS-232
TRIP CLOSE Configuration
A PHASE B PHASE C PHASE
HOT LINE TAG SELECT SELECT SELECT
Data Port
OPTION #1 OPTION #2 OPTION #3 One-Touch
Function Keys
(LOCKOUT)

Hot Line Tag Toggle Switch and

TRIP (LOCKOUT)
CLOSE Pushbutton Three-Segment LED Indication
Pushbutton
(Hardwire Connected)

Figure 4.
Form 6 Triple-Single control front panel.
6
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SAFETY
FOR LIFE
S280-70-7

Programming Panel CHANGE: Allows the user to change the state of the con-
trol functions on the operator panel function keys.
The Programming panel has the following sections:
Note: The CHANGE mode is a ten second period in which one
One-Touch Analysis Keys function setting can be changed. If no change is made
There are eight analysis keys (Figure 5) that allow one- in that time, the control returns to the current setting.
button access to a variety of control and monitoring func- LCD Display
tions that appear in the LCD display.
The LCD Display is a backlit 4-line, 20-character display
Note: The label inserts can be customized, but the analysis that provides extensive distribution system, recloser, and
key functions remain the same. control status information via the navigation keypads
Pressing these buttons causes the following information (Figure 5).
to display or function to occur: Note: The LCD display panel contrast is field-adjustable to allow
METERING: Displays the systems instantaneous meter- for various mounting heights and applications. Press the
ing values for current and voltage on the LCD display. MENU key and then press the (+) or (–) key to increase
or decrease the contrast.
RESET TARGETS: Resets the fault target indicators on
The four LCD navigation buttons are as follows:
the operator panel.
MENU: Identifies the LCD Display menu options.
EVENTS: Displays the last 25 events from the Sequence
of Events log. ENTER: Selects a menu option.
LAMP TEST: This button functions two ways: +: Scrolls up menu or increases value selection.
• Press and immediately release this button to display –: Scrolls down menu or decreases value selection.
the front panel LED status. The four LCD menu function keys activate specific menu
• Press and hold the LAMP TEST button for two sec- commands. When a command appears in the LCD dis-
onds to enable the actual LAMP TEST feature. All play directly above one of the four LCD menu function
operator panel LEDs are illuminated for verification of keys, the user can press the key to accept/select the
proper connection and operating status of all indica- command.
tor lights. All status indicators will then return to their The four LCD menu function keys are as follows:
previous state. While in the LAMP TEST mode, the
control response to operator panel keys is disabled, F1 F2 F3 F4
except for the TRIP (LOCKOUT), CLOSE, and HOT The four cursor movement arrows allow movement in the
LINE TAG switches. following directions:
SETTINGS: Displays recloser settings on the LCD display.  Moves the cursor left.
OPER COUNTER: Displays the total number of trip oper-  Moves the cursor right.
ations and target counters for each A, B, and C Phase;
Ground, and Sensitive Ground on the LCD display.  Moves the cursor up one line.
ALARMS: Provides status information on the LCD dis-  Moves the cursor down one line.
play for all recloser alarms. Alarms are issued if user-
specified settings are exceeded.

METERING SETTINGS

RESET OPER
TARGETS COUNTER

F1 F2 F3 F4

EVENTS ALARMS

LAMP TEST
MENU + CHANGE

ENTER —
Figure 5.
Form 6 recloser control shortcut keys, LCD display, LCD menu function keys, and cursor movement arrows.

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

Status Indicator LEDs CONTROL LOCKOUT: The green LED indicates the
The status indicator LEDs in the Programming section of recloser is open and a reclosing sequence is not in
the Operator Panel give instant information on the control progress. Manual tripping of the recloser is an example of
and recloser status: control lockout.

• The Form 6-TS status indicator LEDs are illustrated RECLOSER OPEN: The steady green LED indicates all
in Figure 6. three reclosers are in the open position. The blinking
green LED indicates one or two reclosers are in the open
All of the default status indicators LEDs (except for CON- position.
TROL OK, CONTROL POWER, and ALARM) can be
reconfigured via the Idea Workbench. Refer to Service RECLOSER CLOSED: The steady red LED indicates all
Information S280-70-9 Form 6-TS Control Programming three reclosers are in the closed position. The blinking
Guide for additional information. red LED indicates one or two reclosers are in the closed
position.
The label inserts can be user-customized. Refer to Using
Removable Inserts section of this manual for additional A PHASE FAULT, B PHASE FAULT, C PHASE FAULT,
information. GROUND FAULT, SENSITIVE GROUND FAULT: The red
LEDs indicate the control issued an overcurrent trip sig-
CONTROL OK: The green LED indicates the control is nal while A, B, or C phase or ground current exceeded
operating normally and not in an alarm state. the minimum pickup value. The red LEDs will also indi-
The CONTROL OK LED will not be illuminated during cate if A, B, or C phase or ground current was within 80%
these alarms (indicated by the red ALARM LED and dis- of minimum pickup when another phase exceeded mini-
played in the alarm status log): mum trip value.
• Battery Alarm: This alarm indicates battery voltage is low ALARM: The red LED indicates an alarm has been
or the battery failed an operator-initiated manual test. issued. Review the alarm status and log on the LCD dis-
play for the specific alarm.
• Memory Test: This alarm indicates a failed ROM or
RAM memory test. ABOVE MINIMUM TRIP: The red LED indicates the cur-
rent exceeds the level set for minimum trip.
• No AC Power: This alarm indicates AC power was
unavailable for 10 continuous seconds. This alarm FREQUENCY TRIP: The red LED indicates the recloser
resets when AC power is restored. control has issued a trip signal based upon frequency
settings.
• Internal Power Failure: This alarm indicates internal
control operation power was outside of its operating VOLTAGE TRIP: The red indicator LED indicates the volt-
tolerance for more than 20 seconds. This alarm age exceeds or fails to achieve a certain threshold.
resets when the internal control operation power A PHASE VOLTAGE, B PHASE VOLTAGE, C PHASE
returns to operation within its normal tolerances. VOLTAGE: The red LED indicates voltage is present on
• RIF Comms Failure: This alarm indicates a loss of the A, B, or C phase bushings.
communication from the RIF (Recloser Interface) cir- INDICATOR 1, INDICATOR 2, INDICATOR 3, INDICA-
cuit board to the main CPU circuit board. This alarm TOR 4, INDICATOR 5, INDICATOR 6, INDICATOR 7,
resets if communication is re-established. INDICATOR 8: Customizable LEDs that are used with
CONTROL POWER: The green LED indicates there is functions programmed through the Idea WorkbenchTM.
adequate charge (voltage) on the trip circuit capacitor to The LED indicators do not have active default values.
trip or close the recloser. This LED does not indicate the The LEDs are illuminated when the status configured via
presence of AC or battery power. the Idea WorkbenchTM is present.

CONTROL OK A PHASE FAULT ALARM A PHASE VOLTAGE INDICATOR 4

CONTROL POWER B PHASE FAULT ABOVE MIN TRIP B PHASE VOLTAGE INDICATOR 5
CONTROL LOCKOUT C PHASE FAULT INDICATOR 1 C PHASE VOLTAGE INDICATOR 6
RECLOSER OPEN GROUND FAULT INDICATOR 2 FREQUENCY TRIP INDICATOR 7
RECLOSER CLOSED SENSITIVE GND INDICATOR 3 VOLTAGE TRIP INDICATOR 8

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

8
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SAFETY
FOR LIFE
S280-70-7

Operating Panel TRIP (Lockout) Pushbutton

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

IMPORTANT: Hot Line Tag activation does not cause

the recloser to trip open. It only prevents the recloser
KYLE F6 Recloser Control ON
from closing.

TRIP CLOSE
IMPORTANT: Hot Line Tag is intended solely for live- HOT LINE TAG
line work applications, such as maintenance, repairs or
improvements to the distribution system, that occur
while the line remains energized.
(LOCKOUT)
Hot Line Tag prevents all closing attempts from the con-
trol and shifts protection to one trip-to-lockout on the com-
posite curve of the Hot Line Tag definite time and the Figure 7.
TCC1 curve (whichever is faster). Hot Line Tag takes TRIP (Lockout) pushbutton; CLOSE pushbutton; Hot
precedence over Cold Load Pickup, Non-Reclosing, and Line Tag switch and Hot Line Tag red indicator LED.
Fast Trips Disabled.
Hot Line Tag is activated from either the operator panel
toggle switch, serial communications, or a discrete
SCADA function. All sources must be off to de-activate
Hot Line Tag.
To activate the function from the operator panel, flip tog-
gle switch up to the ON position. See Figure 7. The LED
indicator illuminates when the function is active.
The Hot Line Tag function may only be reset by the source
which initiates it. For example, if Hot Line Tag is activated
at the operator panel, the reset function is only possible at
the operator panel, and not via SCADA command.
IMPORTANT: If the power save feature is enabled
(default), and more than ten minutes elapses since the
last panel operation, all the LEDs, except HOT LINE
TAG (if active), will turn off.

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

One-Touch Function Keys NON RECLOSING

Quick access to frequently operated Form 6-TS control The control is operating in a non-reclosing mode when
features is provided with nine function key pushbuttons the NON RECLOSING red indicator is illuminated. Non-
on the control operator panel. reclosing mode disables any automatic reclosing opera-
The Form 6-TS control operator panel one-touch function tions. Non-reclosing does not alter the active TCC.
keys are illustrated in Figure 8. Activation is possible from the serial port, I/O, the inter-
face software, or locally.
SUPERVISORY OFF
GND TRIP NON SUPERVISORY
BLOCKED RECLOSING OFF When the SUPERVISORY OFF red indicator is illuminat-
ed, supervisory commands are blocked. Supervisory
A PHASE B PHASE C PHASE functions through the back panel serial communication
SELECT SELECT SELECT ports and the discrete I/O are blocked. Serial communi-
cations through the front panel RS-232 port remain active
OPTION #1 OPTION #2 OPTION #3 independent of the status of the SUPERVISORY OFF
switch. Activation of this function key is restricted to the
operator panel and is accomplished by pressing the
Figure 8. CHANGE key and then pressing the SUPERVISORY
Form 6 Triple-Single control operator panel one- OFF key. Operational data and metering information are
touch function keys. available while the control is in the SUPERVISORY OFF
position. The TRIP and CLOSE pushbuttons and Hot
These nine features can be activated locally from the Line Tag are active independent of the SUPERVISORY
pushbuttons or remotely via the ProView interface OFF function.
software.
A PHASE SELECT, B PHASE SELECT, C PHASE
Red LEDs located on each function key indicate the sta- SELECT
tus of the function, regardless of local or remote activa-
The Form 6 Triple-Single control has phase selection
tion. For example, if Ground Trip Blocked is activated
keys for the user to indicate only which phase of the
from a SCADA signal, the red indicator will illuminate
NOVA-TS Triple-Single recloser will operate when the
even though it is not activated from the operator panel.
manual TRIP (LOCKOUT) and CLOSE pushbuttons on
Operator panel function key activation or de-activation the Form 6-TS operator panel are pressed. When the
requires the operator to first press the CHANGE key to TRIP or CLOSE buttons are pressed, only the phases
enter the CHANGE mode. A function must then be select- that are selected (LED on) will trip or close.
ed or de-selected within ten seconds to activate or de-acti-
Manual operation of the yellow handles on the NOVA-TS
vate the function. Once selected, the control returns to nor-
triple-single recloser is used to open and lockout the
mal operation until prompted for another change request.
phases, and to disable the electrical and supervisory
This prevents accidental changing of settings.
closing. The recloser mode of operation determines
Note: Only one function can be changed per each CHANGE which phases open and close. The Form 6 Triple-Single
mode activation. control initiates the close signal.
GND TRIP BLOCKED
WARNING: Hazardous Voltage. Do not rely on
The Ground Trip Blocked function blocks all ground sens-
ing in the control for the active profile. This red indicator
! the open position of the yellow operating handle;
it does not ensure that the line has been de-energized.
is illuminated when Ground Trip Block is activated from
Always establish a visible disconnect. Failure to follow
the serial port, I/O, the interface software, or locally caus-
proper safety practices can result in contact with high
ing the control to block all ground sensing.
voltage, which will cause death or severe personal
injury. G116.0

IMPORTANT: Pushing the yellow operating handle

to the CLOSE position will not close the recloser. All
close operations are initiated by the Form 6 Triple-
Single control.

10
 !
SAFETY
FOR LIFE
S280-70-7

Three-Phase Trip – Three-Phase Lockout (ganged) OPTION #1, OPTION #2, AND OPTION #3
or The OPTION #1, OPTION #2, and OPTION #3 function
Single-Phase Trip – Three-Phase Lockout keys must be programmed via the ProViewTM Idea
WorkbenchTM software. These options do not have active
If the control is in Three-Phase Trip – Three-Phase default values.
Lockout (ganged) mode or Single-Phase Trip – Three-
The OPTION LEDs are illuminated when the options con-
Phase Lockout mode, all three phases are permanently
figured via the Idea Workbench are selected. Refer to
selected and the A PHASE SELECT, B PHASE SELECT,
Service Information S280-70-9 Form 6-TS Control
and C PHASE SELECT LEDs are illuminated.
Programming Guide for additional information.
When one phase is opened with the yellow operating
These OPTION keys provide a momentary signal. For
handle, all three phases open and lockout. The
instance, these keys can be programmed to toggle con-
RECLOSER OPEN and CONTROL LOCKOUT indicator
trol status, protective functions, or a momentary input
LEDs illuminate on the control panel.
pulse.
With the yellow operating handle of the appropriate
phase in the CLOSE position, press the CLOSE push-
button on the control operator panel. All three phases
close and the RECLOSER CLOSED LED illuminates.
Single-Phase Trip – Single-Phase Lockout
When in Single-Phase Trip – Single-Phase Lockout
mode any combination of phases can be selected and
the respective PHASE SELECT LED illuminates. Each
selected phase must be closed individually.
When the selected phase is opened with the yellow oper-
ating handle, only that phase opens and locks out. The
RECLOSER OPEN, RECLOSER CLOSED, and CON-
TROL LOCKOUT indicator LEDs blink on the control
panel.
The default text message on the LCD displays the mode
of the triple-single configuration and the status of each
phase.
With the yellow operating handle of the selected phase in
the CLOSE position, press the CLOSE pushbutton on the
control panel. The phase closes and the RECLOSER
CLOSED LED illuminates.

IMPORTANT: If the power save feature is enabled

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

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

Control Features Sequence Coordination

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

12
 !
SAFETY
FOR LIFE
S280-70-7

Metering The control also provides a minimum of three config-

urable input control contacts. Each control contact is con-
The control provides instantaneous and/or demand figurable using a graphical interface software. Contacts
metering with programmable integration intervals for the accept a whetting voltage range of 12–250 Vdc, 120/240
following functions: Vac. Each digital input is configured for either a momen-
• Real and reactive power for each phase and total, tary, maintained, or maintained with precedence contact.
including directional, on an individual phase basis. Default input control contacts are: Supervisory Trip and
Lockout, Supervisory Close, and Hot Line Tag.
• Demand currents on a per phase basis.
A Discrete Interface Board is also available as an acces-
• Instantaneous currents, including ground current.
sory to provide an additional eight output status contacts
• Instantaneous voltage on a per phase basis. and eight input control contacts. The expansion I/O board
• Instantaneous frequency. is completely user-configurable.

• Positive, negative, and zero sequence voltages. TCC EditorTM II

• Instantaneous power factor on a per phase basis. Coordination and actual time current modifications are
available with a graphic interactive TCC EditorTM or simi-
• Metering settings to include demand interval, and
lar graphical software.
alarm thresholds for current, single-phase kW, three-
phase kW, single-phase kVAr, and three-phase kVAr. The TCC EditorTM II includes a complete database of
standard recloser industry time current curves (TCC),
Event Recorder both ANSI and IEC types, along with the ability to cus-
The Form 6-TS control contains capabilities to perform tomize the TCCs with multipliers, constant time adders,
Sequence of Events time-stamping for up to 69 event or minimum response time adders. Also, the user is able
types. Sixteen additional inputs can be user-defined to derive their own specific TCC through data point entry.
through the Idea WorkbenchTM. Each modified time current curve can be identified with a
user-customized name and is selectable for configuring
Factory-defined event types include: the control. The grid and format for presenting the TCCs
• Overcurrent Protection Trip has a user-adjustable scale, including the option of pre-
senting multiple TCCs in various user-configured colors.
• External Trip
• Non-Reclose Trip Oscillography
• External Close Oscillography is provided to present current and voltage
waveforms, along with protection element and recloser
• Lockout response status changes.
• Reset The recorded values are super-imposed on the protec-
The Event Recorder maintains a minimum of 90 event tion scheme, and the state or value at any point in the
records. scheme is displayed. The user has the capability to move
through the event and watch the response of every func-
Recloser Duty Monitor tion. All analog signals, digital inputs, and contact outputs
are monitored. The oscillography sampling rate is a min-
The Form 6-TS recloser control software is equipped with
imum of 64 samples per cycle.
a Recloser Interrupting Duty Monitor. The Duty Monitor
accumulates the summation of I1.5 for all interrupted cur- Oscillographic data is recorded to analyze multiple
rents on each interrupter. This feature permits program- events during a permanent fault or other event type. The
mable entries to preset the duty of an existing recloser. oscillographic data shows two cycles before the trigger
The recloser duty monitor displays interrupting duty in point and eight cycles after the trigger point (default).
percent of duty used. If the duty cycle monitor exceeds Note: The configuration settings are programmable.
100%, the recloser should be examined for maintenance.
Oscillography automatically initiates trigger points for the
Discrete SCADA Communications following functions:
The control provides five configurable output status con- • Above Minimum Trip for Phase, Ground, and
tacts and three configurable input control contacts as Sensitive Ground Fault
standard. Each status contact is configurable using • Single- and Three-Phase Overvoltage
graphical interface software to combine status functional-
ity along with Boolean algebra. Default output status con- • Single- and Three-Phase Undervoltage
tacts are: AØ Lockout, AØ Recloser Open, AØ Recloser • Over- and Underfrequency
Closed, Ground Trip Block, and Hot Line Tag. One output
status contact is a solid state output (SS1) with a pickup • Trip Signal Issued
time no longer than two milliseconds. • Close Signal Issued

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

Removable Inserts Fault Location

Removable inserts are included with the control design The control includes an impedance-based fault locator
for customization of specific protection requirements. based upon the Takagi algorithm. Load-compensated
Inserts are available for the status indicator LEDs, the impedance calculation is used for calculating the dis-
operator panel function keys, and the analysis keys. The tance. Positive and zero sequence is configured in
removable inserts are designed for use without adhe- ohms, and the fault locator line length is configured in
sives, labelmakers, or temporary labels. kilometers/miles.
An electronic label template is included on the ProViewTM Sync Check
application software CD and can be accessed through
the following default address: Sync Check functionality includes the following applications:
C: / Program Files / Cooper / Proview40 / Form 6 / • Hot Line/Hot Bus Closing
Form 6 Inserts.doc • Dead Line/Hot Bus Closing
Refer to Using Removable Inserts for more information. • Hot Line/Dead Bus Closing
Idea Workbench TM
• Dead Line/Dead Bus Closing
The Idea Workbench provides access to various inputs,
TM
Sync Check Parameters include the following config-
intermediate variables, and internal Form 6 alarms, sta- urable settings:
tus, and targets to allow user-customization of the Form • Voltage Angle
6-TS recloser control to meet specific and unique appli-
cations. The Idea WorkbenchTM also gives the user the • Mechanism Operating Delay
ability to perform logical functions with these variables by • Static Angle Delay
using a simple graphical user interface. Use of the Idea
WorkbenchTM is not a requirement for operation. • Dead Threshold
Refer to Service Information S280-70-9 Form 6-TS • Live Threshold
Microprocessor-Based Recloser Control Programming • Positive Sequence Dead Threshold
Guide for additional Idea WorkbenchTM information.
• Upper Voltage Limit
Over/Underfrequency Protection • Lower Voltage Limit
The control includes two-stage operation for both under- • Lower Frequency Limit
frequency and overfrequency protection. A fixed time
delay ranging from 0 to 100 seconds in .001 second • Upper Frequency Limit
increments is available for both over and underfrequen- • Fail to Close Timer
cy. A frequency restoration function, enabled or disabled
by the user, is provided to allow the recloser to automat- Data Profiler
ically close should frequency return to within configured A fully-configurable data profiler is available which allows
settings for a user-settable time. Over/Underfrequency the user to collect information by sampling data at selec-
Protection is included as part of each protection profile. table intervals. These time-stamped values can then be
Over/Undervoltage Protection plotted to determine weekly load profiles, daily harmonic
disturbances or hourly voltage fluctuations. The number
The control includes single-phase and three-phase under of days of information the data profiler can provide
voltage tripping. The control also includes three-phase depends upon configuration parameters.
overvoltage tripping. Both over and undervoltage func-
tions include a single-phase and three-phase pick-up set- Refer to Service Information S280-70-9 Form 6-TS
ting; a single-phase and three-phase time delay setting Microprocessor-Based Recloser Control Programming
ranging from 0 to 100 seconds. Guide for additional information.

Directional Manual Close Delay

Directional functionality is included to maintain system Manual Close Delay provides a delay from the time that
coordination from multiple sources, as well as circuit the manual CLOSE button is pushed to the time the man-
reconfiguration for each profile. Directional applies to ual close operation is performed.
phase, ground, and negative sequence protection, The delay is programmable from 0 to 60 seconds in 1
selected independently. A maximum torque angle has a second increments. A programmed delay value can be
range of 45–90 degrees within an accuracy of ±1 degree. overridden 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).
A countdown on the front panel LCD screen indicates
Manual Close Delay is active.
14
 !
SAFETY
FOR LIFE
S280-70-7

Communications Ethernet configuration is accomplished via ProView inter-

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

RS-232 Serial Communication Port

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

RS-485 Serial Communication Port (optional)

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

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

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

Power Supply Board

P1 P4

AC Power Fuse 1
2
3
4

VOLTAGE SENSING
1

2
3
4
1
2
3
4
P2
1 2 3

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

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

1
2

2
3

28 VAC
4

4
5

120/240 Vac
Selector Switch

Battery Connector (2-position)

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

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

Grounding Terminal, One

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

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

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

INSTALLATION PROCEDURE
Initial Programming Control / Recloser Compatibility
Prior to Installation The Form 6-TS pole mount recloser control is only com-
patible with the NOVA-TS recloser. Refer to Service
Information S280-42-2 NOVA-TS Recloser Installation
CAUTION: Equipment misoperation. Do not and Operation Instructions for additional information.
! connect this control to an energized recloser until
all control settings have been properly programmed Duty Cycle Monitor
and verified. Refer to the programming information for
this control. Failure to comply can result in control and The Duty Cycle Monitor provides the following duty cycle
recloser misoperation, equipment damage, and per- information:
sonal injury. G110.3
• Measures and records duty for each individual phase
in non-volatile memory.
CAUTION: Equipment Misoperation. Check mini- • The recloser duty is measured and stored on the
mum trip values prior to changing an alternate profile. basis of Current1.5 x Number of Operations for Each
Failure to do so may cause misoperation of the control Phase (ANSI C37.61).
under load conditions. T280.0
• Readout is based on a percentage of total duty cycle
used for each phase.
IMPORTANT: Program all protection profiles.
• Duty record can be adjusted or reset if recloser is
Unused alternate profiles should be programmed with
changed-out, serviced, etc.
the same settings as one of the applicable profiles.
Default settings on unused alternate profiles can Using Table 1, select the appropriate NOVA-TS recloser
cause unnecessary outages if they are below normal interrupting duty cycle factor and enter that value via the
system requirements. ProViewTM interface software.
TABLE 1
The control must be programmed with all necessary Duty Cycle Factor
operating settings, all alternate profiles, and parameters
prior to operation with an energized recloser. Interrupting 100% Duty
Note: Initial programming of the control is the responsibility of Recloser Rating Cycle
Type (rms sym Amps) Factor*
a qualified technician or engineer familiar with control
functions and programming parameters required for the NOVA-TS-8 8,000 568
specific recloser installation. NOVA-TS-12 12,500 1111
The control must be programmed with the Form 6
ProView interface software. Refer to Service Information *Duty Cycle Factor is Value x 105.
S280-70-9 Form 6-TS Microprocessor-Based Recloser
Control Programming Guide for additional information.
Note: The Pole Mounted Control checkbox in the ProView
System Configuration screen must be selected for all
Form 6 pole mount controls. This includes both pole
and substation applications.

16
 !
SAFETY
FOR LIFE
S280-70-7

Control Cable Junction Box and Cables

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

IMPORTANT: All external inputs to the Form 6 IMPORTANT: The triple-single recloser junction box
recloser control must be routed within 8 inches of their is mounted with all cable connections made at the bot-
corresponding ground. During a surge, a potential of tom of the box. Do not invert.
approximately 1.5 kV per foot can develop in the con-
ductors. Differences between conductor and ground
path lengths can add additional stress to the control
components in the event of a power surge.

NOVA-TS
Pole-mounting Junction Box
or Substation
mounting frame
AØ BØ CØ

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

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

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

Mounting the Control Mount the Form 6-TS recloser control in a convenient,
accessible location. Mounting dimensions are provided in
WARNING: This equipment is not intended to Figure 11.
!protect human life. Follow all locally approved Note: Unless otherwise specified, dimensions shown in mm
procedures and safety practices when installing or (inches).
operating this equipment. Failure to comply may result
A hole and keyway in the control mounting bracket
in death, severe personal injury and equipment dam-
accommodates a 15.9 mm (5/8”) bolt.
age. G102.1

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

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

RESET
TARGETS
SETTINGS

OPER
COUNTER
Connection
Port
F1 F2 F3 F4

EVENTS ALARMS

LAMP TEST
MENU + CHANGE

ENTER —
RS-232 DATA PORT

KYLE F6 Recloser Control ON

GND TRIP NON SUPERVISORY
BLOCKED RECLOSING OFF

TRIP

(LOCKOUT)
CLOSE
HOT LINE TAG
A PHASE
SELECT

OPTION #1
B PHASE
SELECT

OPTION #2
C PHASE
SELECT

OPTION #3
710 665
(28.0) (26.25)

Front View 170

(6.75)
355 (14.0) Grounding
400 (15.75) Terminal
#14 To #4
Right Side View Stranded
Vent Vent

Mounting Angle
1.44 Dia. Hole for
Voltage Input Connection
1.44 Dia. Hole for (Caplug Installed)
Connection 1.44 Dia. Hole
(Caplug Installed) (Caplug Installed)

Control Cable
38 Receptacle 1.81 Dia.
(1.5) (26-pin)
67 67 79
(2.75) (2.75) (3.25)
Bottom View
CONTROL WEIGHT 34 kg (75 lbs)

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

18
 !
SAFETY
FOR LIFE
S280-70-7

Grounding the Control Figure 12 illustrates grounding methods for 3-wire

ungrounded and 4-wire multi-grounded systems with
local supply voltage transformer.
WARNING: Hazardous voltage. Recloser and
! control must be solidly grounded. Follow all local- Figure 13 illustrates grounding methods for 3-wire
ly approved procedures and safety practices when ungrounded and 4-wire multi-grounded systems with
grounding this equipment. Improper grounding can remote supply voltage transformer.
result in contact with high voltage, which will cause Figure 14 illustrates grounding on a 3-wire uni-grounded
death or severe personal injury. G115.1
system.
The control cabinet must be grounded. A grounding con- For effective surge protection all control and power con-
nector on the underside of the cabinet will accommodate ductors for the Form 6-TS control must be routed parallel
No. 14 solid through No. 4 stranded conductors. to a corresponding ground path. For example, the AC
power supply for the control should be parallel to and
Suggested methods for grounding the control and reclos- equal in length to the transformer ground path. The con-
er are shown in Figures 12, 13, and 14. trol cable should be parallel to and routed close to the
recloser ground path.

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

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

3-Wire Ungrounded, or Impedance-Grounded
Installation of the Form 6-TS control must include the 4-Wire Multi-Grounded Systems
following:
• Protection of the recloser bushings and the supplying IMPORTANT: In pole-mounted applications, a
transformer with lightning arresters. ground connection must be made between the reclos-
er, transformer, recloser control, and SCADA equip-
• Grounding of all three recloser heads and tanks. ment for proper protection of the equipment. The pole
• Grounding of the transformer tank. ground must be sized per local utility practices to min-
imize the impedance between the recloser and the
• Grounding of the control cabinet. control.
• Grounding of the SCADA equipment
3-Wire Ungrounded and Impedance Grounded
IMPORTANT: All external inputs to the Form 6-TS Systems
control must be routed within 8 inches of their corre- The use of a grounding mat may be required depending
sponding ground. During a surge, a potential of upon the local safety regulations defining the permissible
approximately 1.5 kV per foot can develop in the con- step and touch potential levels. Consult local regulations
ductors. Differences between conductor and ground for proper grounding procedures.
path lengths can add additional stress to the control
components in the event of a power surge.

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

AC
NEU Pole
GND Surge
Arrester Surge
Recloser Arrester
Head
Ground

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

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

NOVA-TS
Triple-Single
Recloser Supply Voltage
Pole Mounting Form 6-TS Control
Accessory
Transformer Line
AC to
Junction Box
NEUTRAL Line
Voltage

Input Terminal
Control Block External
Cable Ground Lug

Pole Ground
ELECTRICAL CONNECTIONS
Form 6-TS Line to Line connected transformer
Control

Input Terminal
Block
NEU
AC

Customer Ground Connection

At External Lug

Figure 12.
Recommended grounding method for the Form 6-TS control installed on 4-wire multi-grounded, 3-wire
ungrounded, or impedance-grounded systems with local supply voltage.

20
 !
SAFETY
FOR LIFE
S280-70-7

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

3-Wire Ungrounded, or Impedance-Grounded
Installation of a Form 6-TS control with a remote supply
IMPORTANT: In pole-mounted applications, a
voltage transformer must include the following:
ground connection must be made between the reclos-
• Protection of the recloser bushings and the supplying er, transformer, recloser control, and SCADA equip-
transformer with lightning arresters. ment for proper protection of the equipment. The pole
• Grounding of all three recloser heads and tanks. ground must be sized per local utility practices to min-
imize the impedance between the recloser and the
• Grounding of the transformer tank. control.
• Grounding of the control cabinet.
• Grounding of the SCADA equipment. IMPORTANT: All external inputs to the Form 6-TS
control must be routed within 8 inches of their corre-
sponding 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.

Low Voltage Distribution Network

Supply Voltage Input 115 Vac

Input Supply Voltage
Form 6-TS Control Terminal
Terminal
Block Form 6-TS Control Local Isolation
Transformer Block
AC Transformer
AC Customer
NEUTRAL
NEUTRAL Supplied
Low Voltage

Low Voltage
External
External Arrester
Ground Lug
Ground Lug
ELECTRICAL CONNECTIONS - Remote dedicated
ELECTRICAL CONNECTIONS - using isolation transformer
supply transformer

Surge Pole
Arrester Surge
Transformer Arrester
Surge
Arrester

Surge
Arrester

AC
CLOSED CLOSED

NEU
GND

Surge
Recloser Arrester
Head
Ground

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

Pole Ground
Form 6-TS Control

Input Terminal
Pole Ground Block
NEU

Pole
AC

Customer Ground Connection

At External Lug

Figure 13.
Recommended grounding method for the Form 6-TS Control installed on 4-wire multi-grounded, 3-wire
ungrounded, or impedance-grounded systems with remote supply voltage transformer.

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

Grounding on a 3-Wire Uni-grounded System

Installation of a Form 6-TS control on a 3-wire uni-ground Supply Voltage

system must include the following: Form 6-TS Control Input Terminal
Block
Transformer
• Protection of the recloser bushings and the supplying AC
NEUTRAL
transformer with lightning arresters.
• Grounding of all three recloser heads and tanks.
External
• Grounding of the transformer tank. Ground Lug
ELECTRICAL CONNECTIONS
Line to Neutral connected transformer
• Grounding of the control cabinet.
• Grounding of the SCADA equipment. Transformer

Typical transformer mounting is

Surge 180° to the recloser.
Arrester

WARNING: Hazardous Voltage. Use locally

! approved operator safety procedures for proper
AC
Pole
Surge
Arrester
insulation when maintaining this equipment. High NEU
GND Surge
Arrester
Voltage step and touch potential is characteristic in uni-
ground systems. Failure to comply can cause death or
severe personal injury. T262.0

Recloser
Head
CLOSED CLOSED Ground

Surge
CAUTION: Exported Potential. Do not make
! direct electrical connections to remote devices. Supply
Voltage
Arrester

All SCADA equipment must be mounted locally or con-

nected using the fiber-optic or radio communication NOVA-TS
Triple-Single Pole
Recloser Mounting
accessory. Direct connections to remote devices can Accessory

produce exported potential causing equipment dam- Junction Box

age or personal injury. T263.0

Pole
Form 6-TS Control Ground

CAUTION: Hazardous Voltage. Do not use a

! shared low voltage network to power the reclos-
Input Terminal
Block
NEU
AC

er control unless the network is specifically designed

Customer Ground
to withstand maximum ground potential rise. Ground Connection
At External Lug
faults on a high voltage network can create a rise in
ground potential. T264.0
Control
Cable

Control Height must be

IMPORTANT: In pole-mounted applications, a 3 meters (10 feet)

minimum above earth

ground connection must be made between the reclos-

er, transformer, recloser control, and SCADA equip-
ment for proper protection of the equipment. The pole
ground must be sized per local utility practices to min-
imize the impedance between the recloser and the
control.

IMPORTANT: All external inputs to the Form 6-TS

control must be routed within 8 inches of their corre- Figure 14.
sponding ground. During a surge, a potential of approx- Recommended grounding method for the Form 6-TS
imately 1.5 kV per foot can develop in the conductors. Control installed on a 3-wire uni-grounded system.
Differences between conductor and ground path
lengths can add additional stress to the control compo-
nents in the event of a power surge.

22
 !
SAFETY
FOR LIFE
S280-70-7

Customer Connections for AC CAUTION: Equipment misoperation. Verify that

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

moisture to seep into the control and damage the com-

ponents or cause control misoperation. Failure to
comply will void the control’s factory warranty. T249.0 AC
Power
Input power to the Form 6-TS recloser control is con- Fuse
nected to terminal block TB7 for single-phase power or
TB8 for three-phase power. See Figures 17, 19, and 21.
For single-phase incoming voltage supply for 120 Vac or
240 Vac, connect to TB7 as shown in Figure 17. For
three-phase incoming voltage supply, the user should
supply and connect to TB8 as show in Figure 19. For 240 Selector Switch Power Supply Board
Volt, 3-wire transformer connection refer to Figure 21.
030003KM
Input power is required: Figure 15.
Power Supply / Battery Charger Board.
• To power the control
• To provide voltage and power metering
Terminal Blocks
• To power the thermostatically controlled heater
Two terminal blocks are used for connection to the Form
• For the convenience outlet accessory 6-TS recloser control. Both terminal blocks are fit for a #6
screw which can allow a maximum ring size for a #10
Power Supply / Battery Charger Board AWG for metering.
Incoming ac power is routed to the Power Supply / Terminal Block TB7 provides power to the Form 6-TS
Battery Charger Board designed to accept either 120 Vac control and is directly connected to the power supply cir-
or 240 Vac through a selector switch located directly on cuit board. Terminal Block TB8 is used to connect sens-
the board (Figure 15). The battery charger includes a ing transformer voltage. The wiring of the transformers
temperature-compensated design to optimally charge the should follow the application illustrations per Figures 18,
control battery. The power supply / battery charger board 19, 20, and 21.
also includes an auxiliary power supply for connection to
communication equipment (radios, modems, etc.). The Default factory wiring includes connection of two wires
auxiliary power supply is rated 28 Vdc, 65 Watts peak. A from Power Supply Terminal Block TB7 to the Metering
separate 28 Vdc to 13.8 Vdc power supply accessory is Terminal Block TB8. See Figure 16.
available for communication equipment rated for 13.8 Figure 20 shows customer connections for TB8, 120 Vac
Vdc. Some additional features are as follows: Delta Connection.
• Positive LED indicator for power supply presence The wiring from TB7-3 to TB8-3 and from TB7-5 to TB8-
• Selectable 120/240 Vac switch for adapting to multi- 4 connects the metering B phase to the control power
ple transformer connections. The selector switch is inputs (Figure 17). If the incoming power supply voltage
factory-set based upon each customer order. is different, the B phase power supply input must be
moved to the appropriate location. See Figure 18.
• Self-protective fuse (5 amp, 250 Vac)
For A phase incoming power, connect to TB8-1.
• 28 Vdc whetting voltage for I/O contact inputs (refer
to Figure 24) For C phase incoming power, connect to TB8-5.
Note: Terminal Block positions TB7-3 and TB7-4 are factory-
IMPORTANT: Prior to energizing the control, the jumpered together.
selector switch must be set as follows: Note: Terminal Block positions TB7-5 and TB7-6 are factory-
• For 120 Vac incoming power, the selector switch jumpered together.
must be set to the 115V position.
Power Connections
• For 240 Vac incoming power, the selector switch
The transformer required for power should be a minimum
must be set to the 230V position.
of 1kVA.

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

Voltage Sensing Connections *Loadside voltages V2 and V3 only used if the

optional voltage input accessory is included.
Source Load
V (1-2) V(3-4) V(5-6) V1 V2* V3*

BØ
TB8

1 2 3 4 5 6 7 8 9 10 11 12

Factory Wiring for Wye Connection

Note: Terminal Block positions TB7-3 and

TB7-4 are factory-jumpered together.
1 2 3 4 5 6
Terminal Block positions TB7-5 and
TB7-6 are factory-jumpered together. TB7 120 120/240 NEU
Remove the factory jumpers between
(L2)120 (L1) NEU
TB8 and TB7 for separate control Power Connections
power and sensing voltage inputs.

Figure 16.
Default factory wiring connected to B-Phase voltage metering with B-Phase incoming supply.

Power Connections
120 120/240 NEU
TB7 (L2) 120 (L1) NEU

1 2 3 4 5 6 BØ

NEU

BØ

Note: Terminal Block positions TB7-3 and TB7-4 User-Supplied

are factory-jumpered together. Disconnect
Switch
Terminal Block positions TB7-5 and TB7-6
are factory-jumpered together.

Figure 17.
Single-Phase Transformer Connection, B phase input for Power and Sensing.

24
 !
SAFETY
FOR LIFE
S280-70-7

Voltage Sensing Connections *Loadside voltages V2 and V3 only used if the

Load optional voltage input accessory is included.
Source
V (1-2) V(3-4) V(5-6) V1 V2* V3*

AØ

1 2 3 4 5 6 7 8 9 10 11 12
TB8

User-Supplied
Disconnect
Switch
AØ
1 2 3 4 5 6

TB7
Note: Terminal Block positions TB7-3 and TB7-4 120 120/240 NEU
are factory-jumpered together. (L2) 120 (L1) NEU
Power Connections
Terminal Block positions TB7-5 and TB7-6
are factory-jumpered together.

Figure 18.
Modified wiring connected to A-Phase voltage metering with A-Phase incoming supply.

AØ

*Loadside voltages V2 and V3 only used if the

optional voltage input accessory is included.
TB8
Voltage Sensing Connections
BØ
Source Load
V (1-2) V(3-4) V(5-6) V1 V2* V3*

CØ

1 2 3 4 5 6 7 8 9 10 11 12

NEU

CØ

BØ

AØ

User-Supplied
Disconnect
Switches

Figure 19.
Three-Phase Transformer Connection, Wye configuration only (TB8 Terminal Block Connection).

25
Form 6 Triple-Single Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

Voltage Sensing Connections *Loadside voltages V2 and V3 only used if the

optional voltage input accessory is included.
Source Load
V (1-2) V(3-4) V(5-6) V1 V2* V3*
CØ

BØ
1 2 3 4 5 6 7 8 9 10 11 12

TB8

AØ

User-Supplied
Disconnect
Switches
Note: Terminal Block positions TB8-1 and
TB8-6 are factory-jumpered together.
Terminal Block positions TB8-2 and
TB8-3 are factory-jumpered together.
Terminal Block positions TB8-4 and
TB8-5 are factory-jumpered together.

Figure 20.
Customer connections to TB8, 120 Vac Delta Connection.

User-Supplied
Disconnect
Switch
Voltage Sensing Connections *Loadside voltages V2 and V3 Load Side
Source Load only used if the optional voltage
V (1-2) V(3-4) V(5-6) V1 V2* V3* input accessory is included. 120
TB8

1 2 3 4 5 6 7 8 9 10 11 12

NEU

YØ

BØ
Source Side
Power Connections 120

240
120 120/240 NEU 120

TB7 (L2) 120 (L1) NEU

Note: Terminal Block positions User-Supplied
TB7-3 and TB7-4 are fac- Disconnect
Switches
tory-jumpered together.
Terminal Block positions 1 2 3 4 5 6
TB7-5 and TB7-6 are fac-
tory-jumpered together.

Figure 21.
240 Volt, 3-wire transformer connection. B phase input for Power and Sensing. *YØ for Sync Check Voltage.

26
 !
SAFETY
FOR LIFE
S280-70-7

Standard Default Supervisory Input TABLE 2

Control and Output Status Contacts Operating Current Requirements for Standard and
Optional Supervisory Inputs
Standard customer connections TB1 and accessory cus-
tomer connections are TB3 and TB4. Refer to Figures 22 Nominal Minimum
and 23 and Tables 2, 3, and 4. The Idea WorkbenchTM Input Voltage Current Operating Time
allows customization of all the control and status points.
Refer to Service Information S280-70-9 Form 6-TS 12 Vdc – 250 Vdc,
Microprocessor-Based Recloser Control Programming 120/240 Vac 5 mA 5 milliseconds
Guide for additional information.

IMPORTANT TABLE 3
Ratings Table for Output Status Contacts CO1
Shielding and Surge Protection of through CO12
Supervisory Cables (Resistive Load – Pickup Time 8 ms, Dropout 15 ms)
All supervisory operation and control monitor leads must Contact
be protected within shielded cables. Refer to Figure 24. Input Voltage Rating

120 Vac 8A
CAUTION: Equipment damage; misoperation.
! External leads must be shielded and the shield 12 Vdc 8A
must be grounded at both ends. Terminate each lead
with a 320 Vac, 160 Joules metal oxide resistor (MOV), 24 Vdc 8A
or equivalent, at the remote end. Attach MOVs between 48 Vdc 1A
the leads and ground. Failure to properly shield and pro-
tect leads can result in equipment damage and/or unin- 125 Vdc 0.4 A
tentional operation. G117.3

TABLE 4
Ratings Table for Output Status Contact SS1
(Resistive Load – Pickup Time 2 ms, Dropout 15 ms)
Contact
Input Voltage Rating

120 Vac 8A

12 Vdc 8A

24 Vdc 8A

48 Vdc 8A

125 Vdc 8A

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

IMPORTANT
Shielding and Surge Protection of
Supervisory Cables
All supervisory operation and control monitor leads must
be protected within shielded cables. Refer to Figure 24.

CAUTION: Equipment damage; misoperation.

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

Customer-Supplied Voltage Inputs**

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

Three-Phase Supervisory Close

Remote/Supervisory Common

**Whetting voltage is also available from

the Form 6 Recloser Control on
Terminal Block TB9. Refer to Figure 24.

Note: Contact output relays revert to

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

CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4

1 3 5 7 9 11 13 15 17 19

TB1

2 4 6 8 10 12 14 16 18

CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4

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

*Relay Contacts shown

for Indicated Status

Figure 22.
Form 6-TS recloser control standard default supervisory input control and output status contacts. Contacts
are shown in de-energized position.

28
 !

!
SAFETY
FOR LIFE

Figure 23.
tentional operation.
Supervisory Cables

**Whetting voltage is available from the

Customer-Supplied Form 6 Recloser Control on Terminal Block
Voltage Inputs** TB9. Refer to Figure 24.
IMPORTANT

Unassigned
Shielding and Surge Protection of

be protected within shielded cables. Refer to Figure 24.

G117.3
tect leads can result in equipment damage and/or unin-
External leads must be shielded and the shield

the leads and ground. Failure to properly shield and pro-

or equivalent, at the remote end. Attach MOVs between
with a 320 Vac, 160 Joules metal oxide resistor (MOV),
must be grounded at both ends. Terminate each lead
CAUTION: Equipment damage; misoperation.
All supervisory operation and control monitor leads must

Supervisory Non-Reclose
Supervisory Reset Targets
Supervisory Normal Profile

Supervisory Alternate Profile 1

Supervisory Alternate Profile 2
Supervisory Alternate Profile 3
Remote/Supervisory Common
Note: Contact output relays revert to

Supervisory Ground Trip Block

de-energized positions as shown
upon downloading new schemes ***The default contact type for CO9,

status contacts. Contacts are shown in de-energized position.

or Workbench files. CO10, and CO11 is Form-a.

CI4 CI9 CO7 CO8 CO9*** CO10*** CO11*** CO12

TB4
CI5 CI6 CI7 CI8 CI10 CI11 CO5 CO6
TB3
1 3 5 7 9 11 13 15 17 19 21 1 3 5 7 9 11 13

2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12

CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11 CO12

Customer Wiring Non-Reclosing

Status Normal Alternate Alternate Alternate Frequency
(Normal Profile Profile 1 Profile 2 Profile 3 Alarm
Voltage
Reclose)* Alarms Status Status Status Status (Frequency
Alarm
Status (Not in (Not in (Not in (Not in Normal)*
(Voltage
(No Alarms)* Normal Alt 1 Alt 2 Alt 3
Normal)*
Profile)* Profile)* Profile)* Profile)*
*Relay Contacts shown
for Indicated Status

Form 6-TS recloser control Discrete Interface Board Accessory default supervisory input control and output

29
S280-70-7
Form 6 Triple-Single Microprocessor-Based Pole Mount Recloser Control Installation and Operation Instructions

FORM 6-TS RECLOSER CONTROL

TB9
SHIELD

Factory-Supplied Customer Wiring 28 Vdc Whetting Voltage Terminals

28 Vdc Whetting
Voltage
+
— Customer Wiring

REMOTE
BOX

Three-Phase
Supervisory 8 CI3
Trip and CI3 7
Lockout

Three-Phase
Supervisory 6 CI2
CI2 5
Close

Three-Phase
Remote 4 CI1
CI1 3
Trip and
Lockout

13

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

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

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

Figure 24.
Shielding and Surge Protection for Supervisory and Remote Cables.

30
 !
SAFETY
FOR LIFE
S280-70-7

Rear Panel RS-232 Communication

Port Pin Assignments RS-232 Serial IRIG-B Time
Communication Port Sync Connector
Tables 5 indicates the pin assignments for the rear panel
RS-232 communication port (Figure 25). Refer to Figure
26 for pin identification. Refer to Protocols for additional
information.
CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4
1 3 5 7 9 11 13 15 17 19 J1-RS-232
Refer to the Accessories section of this manual for addi- TB1

tional communication options. 2 4 6 8 10 12 14 16 18

RS-232 DTE
IRIG-B

CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4

TABLE 5 TB3
CI4 CI5 CI6
1 3 5
CI7 CI8 CI9 CI10 CI11 CO5
7 9 11 13 15 17 19 21
CO6 CO7 CO8 CO9 CO10 CO11 CO12
1 3 5 7 9 11 13
TB4
Rear Panel RS-232 Communication Port Pin
Assignments 2 4 6
CI4 CI5 CI6
8 10 12 14 16 18 20
CI7 CI8 CI9 CI10 CI11 CO5 CO6
2 4 6 8 10 12
CO7 CO8 CO9 CO10 CO11CO12

Pin Number Signal Name TB9

1 DCD . . . . . . . . . . . . . . . . . . . Carrier Detect

+ –
28 VDC
2 RXD . . . . . . . . . . . . . . . . . . . Receive Data WHETTING VOLTAGE

3 TXD . . . . . . . . . . . . . . . . . . . . Transmit Data P1 P4

P2 P3 1 2 3 4 5
1 3 1 3 1 3 24 23 22 21 20 19 18 17 16 15 14 13

4 DTR . . . . . . . . . . . . . . . . . . . . Data Terminal Ready 1 3 1 2 3 4 5

2 4 2 4 2 4 2 4 5 12 11 10 9 8 7 6 4
5 3 2 1

VOLTAGE SENSING 53VDC CONTROL CABLE 28 VAC

(Not Connected)

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

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

(Not Connected)
Figure 25.
7 RTS . . . . . . . . . . . . . . . . . . . . Request to Send Form 6-TS recloser control rear panel RS-232 com-
munication ports (standard configuration).
8 CTS . . . . . . . . . . . . . . . . . . . . Clear to Send

9 GND . . . . . . . . . . . . . . . . . . . Not Used

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

J1-RS-232

1 2 3 4 5
6 7 8 9

RS-232 DTE
Figure 26.
Rear Panel RS-232 Communication Port Pin
Identification.

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

Before Placing the Control and 8. Control battery connected and tested for proper
operation.
the Recloser into Service
Note: The battery test is blocked for 60 seconds upon
CAUTION: Equipment misoperation. Do not power-up of the control.
! connect this control to an energized recloser until Test the battery as follows:
all control settings have been properly programmed
and verified. Refer to the programming information for A. Press the MENU button on the front panel.
this control. Failure to comply can result in control and B. Using the down arrow key, navigate to the BAT-
recloser misoperation, equipment damage, and per- TERY menu and press ENTER.
sonal injury. G110.3
C. Using the down arrow key, navigate to the TEST
BATTERY menu and press ENTER.
Prior to placing the control and recloser into service, the
following installation procedures must be properly com- D. Press the F4 button to test the battery.
pleted and verified: Note: This message will appear on the programming
panel LCD display: ----TESTING----
1. Front panel label inserts changed (if applicable).
The battery test results will display in the battery
Note: Refer to Using Removable Inserts in this manual.
metering menu.
2. Control properly mounted for the installation. Note: With AC disconnected and the battery supplying
3. NOVA-TS reclosers (3) installed according to all the load, current will read -400 to -600 mA
locally approved standards and practices. depending on accessories connected.

4. AC disconnect switches installed. 9. AC power connected to the control. (Control OK LED

indicator is illuminated.)
5. Control and reclosers properly grounded in accor-
dance with guidelines in this manual and the NOVA- Note: The control Power Save feature will turn off the
backlit LCD display and all LEDs if no front panel
TS recloser manual. Refer to Service Information
keypad is pressed within ten minutes.
S280-42-2 NOVA-TS Recloser Installation and
Operation Instructions. 10. All control programming entered and verified by
appropriate personnel.
6. Control cables properly connected and supported.
Note: Refer to Service Information S280-70-9 Form 6-TS
Microprocessor-Based Recloser Control
CAUTION: Equipment misoperation. Verify that
! the 120/240 Vac selector switch is correctly set
Programming Guide for additional information.
for incoming voltage. Failure to comply may cause 11. Control clock set to the correct time.
misoperation (unintentional operation) of the control Note: Refer to Service Information S280-70-9 Form 6-TS
and/or equipment damage resulting in personal injury. Microprocessor-Based Recloser Control
T278.0 Programming Guide for additional information.

7. Verify the selector switch on the Power

Supply/Battery Charger Board is set to the correct CAUTION: Equipment damage; misoperation.
position based upon the incoming power supply: ! External leads must be shielded and the shield
must be grounded at both ends. Terminate each lead
• For 120 Vac incoming power, the selector switch with a 320 Vac, 160 Joules metal oxide resistor (MOV),
must be set to the 115V position. or equivalent, at the remote end. Attach MOVs between
• For 240 Vac incoming power, the selector switch the leads and ground. Failure to properly shield and
must be set to the 230V position. protect leads can result in equipment damage and/or
unintentional operation. G117.3

12. Customer connections for remote and supervisory

operation checked and completed in accordance with
proper shielding and surge protection (Figure 24).

32
 !
SAFETY
FOR LIFE
S280-70-7

Using Removable Inserts 4. Use tweezers to gently pull out the removable insert.
Note: The insert will slide out of the right side of the oper-
ating panel (Figure 28).
CAUTION: Control damage. De-energize both ac
and dc power prior to removing or installing any inter- Note: The insert will slide out of the top of the program-
nal connections or circuit boards in the control. Failure ming panel indicator section (Figure 27).
to comply can result in damage to the control. T241.1 5. Change the existing label or slide in a new label with
the name of the programmed option.
An electronic label template is included on the
CAUTION: Equipment damage. Always wear a ProViewTM application software CD and can be
grounding wrist strap to control static electricity before accessed through the following default address:
handling circuit boards. Failure to use this strap may
result in circuit board damage. T253.1 C: / Program Files / Cooper / Proview40 / Form 6 /
Form 6 Inserts.doc
The front panel inserts can be changed, if desired. IMPORTANT: Laminate the removable inserts prior
1. De-energize both ac and dc power. to installing. This will seal the ink/toner and avoid dam-
age to the front panel.
2. Use a flathead screwdriver to unscrew the six front
panel screws.
6. Gently push the removable insert from right to left into
3. Pull the right side of the front panel out towards the the right side of the operating panel (Figure 28) or
left (Figure 27). down into the programming panel LED indicator sec-
Note: Various connecting wires will keep the panel tion (Figure 27).
attached to the control.
Note: It is not necessary to disconnect any wires.

Removable LED
Status Indicator Panel

000008KM
Figure 28.
Labels are easily removed from and inserted into
the operating panel.

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

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

030029KM
Figure 27.
Open front panel. Labels are easily removed from
and inserted into the top of the programming panel
LED status indicator section.

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

ACCESSORIES
These accessories are available. Contact your Cooper Cable Locking Sleeves
Power Systems representative for additional information.
To prevent detachment of the control cable from the con-
trol cabinet by unauthorized personnel, a cable-locking
Incoming Power Receptacles sleeve is available to enclose the cable plug. The plug is
The Incoming Power Receptacle allows the user to con- passed through the sleeve and the sleeve is then fas-
veniently plug the power cable into the control, eliminat- tened from inside the control cabinet. There is no access
ing the need for hardwiring to the control. Various options to the cable receptacle without opening the locked cabi-
are available based upon the input power voltage, and net door and detaching the sleeve.
phase sensing requirements. Table 6 includes the avail-
able input receptacles for the Form 6-TS recloser control. RS-232 Cable
TABLE 6 A nine-pin RS-232 Cable is available to connect from the
Low Voltage Input Receptacles personal computer to the data port on the front panel of
the Form 6-TS pole mount recloser control. The front
Description Catalog Number panel RS-232 port is wired as a DCE port for direct con-
120 Vac or 240 Vac input receptacle, 2-pin . KME6-1775-H nection to the personal computer.
120 Vac input receptacle, 3-pin . . . . . . . . . . KME6-1775-J
Stainless Steel Cabinet
240 Vac input receptacle, 3-pin . . . . . . . . . . KME6-1775-K
A cabinet constructed from AISI 304 stainless steel is
available as an accessory.
Discrete Interface Board (DIF)
Accessory 120 Vac GFI Duplex Outlet
A Discrete Interface Board accessory provides eight con- The GFI Duplex Outlet is available for controls powered
figurable input control contacts and eight configurable by 120 Vac or 240 Vac three-wire supply power. This con-
output status contacts (Figure 29). The ordering options venience outlet is rated for 15 Amperes and is accessible
include: Standard (3 inputs / 5 outputs) or Additional (8 through the front door in the control cabinet. The 120 Vac
inputs / 8 outputs). GFI Duplex Outlet is used for many applications such as
power for the MET Tester, auxiliary measurement equip-
ment, and supplemental lighting.
DIF Board Accessory

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

IRIG-B
RS-232 DTE
2 4 6 8 10 12 14 16 18
CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4

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

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

TB9

+ –
28 VDC
WHETTING VOLTAGE

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

VOLTAGE SENSING 53VDC CONTROL CABLE 28 VAC

Figure 29.
Form 6-TS recloser control discrete interface board
accessory.

34
 !
SAFETY
FOR LIFE
S280-70-7

Radio Mounting Accessory

The radio mounting accessory (Figure 30) is powered
from a voltage regulated power supply factory-calibrated CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4
RS-485 C + –

with an output of 13.8 Vdc.

1 3 5 7 9 11 13 15 17 19 J1-RS-232
TB1

IRIG-B
RS-232 DTE
2 4 6 8 10 12 14 16 18
CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4

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

Note: This output cannot be field-calibrated. 2 4 6

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

TB9

The radio will continue to operate during the loss of ac + –

28 VDC

power as long as power is supplied from the battery. The

WHETTING VOLTAGE

P1 P4
P2 P3

Customer-Supplied
power supply is designed to provide up to 40 Watts
1 2 3 4 5
1 3 1 3 1 3 24 23 22 21 20 19 18 17 16 15 14 13
1 3 1 2 3 4 5
2 4 2 4 2 4 2 4 5 12 11 10 9 8 7 6 4
5 3 2 1

VOLTAGE SENSING 53VDC CONTROL CABLE 28 VAC

Radio
(peak) and is fused to isolate any potential radio prob-
Power Cable
lems without disturbing the protection system in the
recloser control. Refer to Table 7. Radio-Mounting
Bracket
Contact your Cooper Power Systems representative for
any additional voltage requirements. 24 Vdc to 13.8 Vdc
Converter
Customer-Supplied
There is one standard 9-pin RS-232 and one optional Power Leads
Radio Antenna
communication port (RS-485, serial fiber, Ethernet wire Cable (only
or fiber or both) on the back operator panel, as well as a available with full
automation accessory)
standard IRIG-B port for user time-syncing. See Figure 9. Antenna Surge
Suppresser and
Connector (only
available with full
automation accessory)

TABLE 7 Figure 30.

Radio Mounting Accessories Form 6-TS recloser control radio mounting
Description Catalog Number accessory.

Full Automation accessory

12 Vdc radio provision . . . . . . . . . . . . . . . KME6-1774-3
(Radio and fiber-optic/RS232 interface not included)
Automation accessory (bracket only)
12 Vdc provision . . . . . . . . . . . . . . . . . . . . KME6-1774-2

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

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

are mounted on the back of the board enabling customer
Accessory connection to a digital communication system using fiber-
The Form 6 Triple-Single control is equipped with a optic cables (customer-supplied).
Communication Board Accessory (expansion bay) offer-
The fiber-optic link has separate receive (RX) and trans-
ing versatile support for modern communication media.
mit (TX) ports operating at 820nm. Typical transmission
Six distinct communication options (Figure 31) are avail-
distance is 2000m with 62.5/125µm multi-mode fiber.
able, providing two-way, real time digital communications
Consult your Cooper Power Systems representative for
with a remote terminal unit (RTU), wireless, telephone
availability of long haul and single mode fiber solutions.
modem, Ethernet network, or other communication
Link communication speed is controlled through software
devices. The following options are available:
and can be set at: 1200, 2400, 4800, 9600, 19.2k, 38.4k,
• No auxiliary communication card installed (standard) 57.6k, and 115kBPS.
• RS485 Serial communication card The fiber-optic accessory must be programmed through
• Fiber-optic-based Serial Communication Card (ST) the Communications Workbench for the appropriate pro-
tocol. Refer to S280-70-9 Form 6 Triple-Single Control
• 10/100 Base-T dual Ethernet communication card (2 Programming Guide for additional information.
* RJ-45)
The fiber-optic based serial accessory includes TX and
• 100 Base-FX dual Ethernet communication card (2 * RX indicating LEDs for verifying communications along
MT-RJ) with an echo / no echo switch for supporting ring / star
• 10/100 Base-T, 100 Base-FX Ethernet communica- fiber topologies.
tion card (RJ-45 + MT-RJ) When operated in a ring configuration, the toggle switch
The expansion bay based Communication Board must be set in the ECHO position. In this mode, the fiber-
Accessory concept offers high versatility with respect to optic card will repeat (pass through) all messages
communication medium and protocol support. Additional received on the RX fiber, and will respond to the Master
accessories are being continuously developed. Contact station by first echoing the incoming command and then
your Cooper Power Systems representative for the latest sending the response. This arrangement is best suited
information regarding particular media and communica- for creation of low cost multi device fiber loops. For reli-
tion protocol support. able communications, the fiber loop system requires that
all devices in the loop remain powered at all times, thus
RS485 Serial Communication Card enabling unobstructed flow of information throughout the
loop.
The RS485 serial communication card accessory pro-
vides means for establishing asynchronous link-based A more resilient system can be designed by using the
digital communications with the Form 6-TS control. The fiber-optic ports in a point-to-point or multiple point-to-
Galvanic isolated (1000V DC) RS485 port uses a single point (star) configuration. For this mode, the toggle
shielded twisted pair connection and can support 16 switch must be set in the NO-ECHO mode. The Form 6-
devices in multi-drop configuration. Communication TS control will respond to the Master station by sending
speed is controlled through software and can be set at: a response only (total separation of Receive and
1200, 2400, 4800, 9600, 19.2k, 38.4k, 57.6k, and Transmit fibers). Additional hardware (fiber-optic star
115kBPS. coupler) is required to support the multiple point-to-point
device configurations.
Digital communications must be programmed through
the Communications Workbench to ensure proper opera- Ethernet Communication Cards
tion of the RS485 communication card accessory. Refer
to S280-70-9 Form 6 Triple-Single Control Programming The Ethernet communication card accessory brings the
Guide for additional protocol support information. Ethernet network connectivity to the Form 6-TS recloser
control platform. It is highly flexible, offering simultaneous
Fiber-Optic Based Serial support for multiple sessions, device management
Communication Card (ProView over TCP/IP) and SCADA communications
(DNP3 over TCP/IP).
The Fiber-Optic based Serial Communication Card offers
means of establishing asynchronous (RS-232 like) digital By natively supporting a set of widely accepted industry
communications through multi-mode fiber media. The standards (TCP/IP, UDP/IP, OSI) the Ethernet communi-
use of the fiber-optic based serial communication card cation accessory ensures seamless interoperability with
accessory can enhance communication reliability, and other network devices.
provides excellent electrical isolation thus protecting
transmitted data from extraneous electrical interference.
An optional fiber-optic-to-RS-232D converter is available
for interfacing between an optical signal and a hard-wired
RS-232 signal, when required.

36
 !
SAFETY
FOR LIFE
S280-70-7

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

IRIG-B IRIG-B IRIG-B

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

IRIG-B IRIG-B IRIG-B

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

Type 1 Type 2 100 Base-FX
Type 3
Figure 31.
Back panel Ethernet and Communication options.

The Ethernet communication card accessory is offered in The Ethernet communication accessory card (Figure 31)
3 physical layer configurations (twisted pair and optical- is equipped with two physical ports configured to act as
fiber options) as shown in Table 8. primary and standby LAN connections. Availability of the
backup communication port enables creation of highly
TABLE 8 redundant Ethernet networks thus increasing the overall
Ethernet Communication Card Configurations system reliability.
Card Output Communication Note: Under normal network conditions, all communications
Type Configurations Connectors Speed will be channeled through the primary port (#1, Figure
31), with the standby port either logically disabled, or
1 10/100 Base-T 2 * RJ-45 10 / 100MBps configured for fast automatic throw-over in case of the
(auto switching)
primary Ethernet link failure. Refer to S280-70-9 Form
2 100 Base-FX 2 * MT-RJ 100MBps 6 Triple-Single Control Programming Guide for addi-
(fiber) (full duplex) tional Ethernet accessory configuration information.

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

100 Base-FX and 100MBps

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

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

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

TESTING
3. Test battery operation as follows:
CAUTION: Equipment misoperation. Do not
! connect this control to an energized recloser until
Note: The battery test is blocked for 60 seconds upon
power up of the control.
all control settings have been properly programmed
and verified. Refer to the programming information for Note: AC power can be either connected or disconnected
this control. Failure to comply can result in control and for battery test.
recloser misoperation, equipment damage, and per- A. Press the MENU button on the front panel.
sonal injury. G110.3
B. Using the down arrow key, navigate to the BAT-
TERY menu, and press ENTER.
IMPORTANT: The Form 6 control can be taken out C. Using the down arrow key, navigate to the TEST
of service for testing and placed back into service BATTERY menu and press ENTER.
without de-energizing its recloser and interrupting the D. Press the F4 button to test the battery.
system. However, during the time the control is out of
service, the recloser is inoperative. Note: This message will appear on the programming
panel LCD display: ----TESTING----
Testing an Installed Control The battery test results will display in the battery
metering menu.
The following tests to determine initial operation of the
Form 6-TS recloser control can be performed while con- Note: Voltage should be between 25–31 Vdc – with
nected to an operating recloser. the higher voltage at colder temperatures.

Note: These are the only tests performed on an installed, Under normal conditions, with AC connected
operating control. and a fully charged battery, the charging current
should be less than 20 mA.
1. Verify operating status of all indicator lights by press-
With AC connected and a discharged battery,
ing and holding the LAMP TEST key for two seconds the current range should be 20–450 mA.
on the programming panel (Figure 32).
With AC disconnected and the battery supplying
2. Check the operational values for currents, voltages, the load, current will read -400 to -600 mA
and other metering information. depending on accessories connected.
Note: Scroll through the LCD display messages by press- 4. Verify the Control OK LED is illuminated on the con-
ing the  and  cursor movement arrows under- trol operator panel (Figure 33). This indicates the
neath the LCD display on the programming panel
presence of ac power.
(Figure 32).
Note: The control includes a Power Save feature that will
turn off the backlit LCD display and all LEDs if no
front panel keypad is pressed within ten minutes.
LCD Display
Pressing the LAMP TEST key will reactivate the
METERING SETTINGS display and active LEDs.
RESET OPER

LAMP TEST Key

TARGETS COUNTER
All other tests described in this TESTING section require
EVENTS
F1 F2 F3 F4

ALARMS
the Form 6-TS recloser control to be removed from ser-
LAMP TEST
MENU + CHANGE
vice, connected to a bypassed recloser, or tested at a
location where the proper testing equipment is available.
Cursor Movement
Arrows ENTER —
RS-232 DATA PORT

Figure 32. CONTROL OK A PHASE FAULT

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

Control OK LED

Figure 33.
Control OK LED.

38
 !
SAFETY
FOR LIFE
S280-70-7

Remove the Control from Electrical Testing of NOVA-TS

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

IMPORTANT: The control must be removed from ser- Each unit in the Type NOVA-TS Triple-Single recloser uti-
vice in the exact order specified in this section. lizes an interface circuit located in its mechanism hous-
ing. The electronic interface circuit controls the opening
1. Enable GND TRIP BLOCKED to allow for ground trip and closing signals to the magnetic actuator.
to be disabled when re-energized. Figure 35 shows a test circuit for NOVA-TS reclosers with
A. Press the CHANGE button on the Operator Panel the Form 6-TS control.
to enter the CHANGE mode. Use this circuit to simulate load current and for testing
B. Depress the GND TRIP BLOCKED button within minimum trip operation and sequencing the mechanism
ten seconds after entering the CHANGE mode. with the Form 6-TS control for each phase.
Note: If the GND TRIP BLOCK button is not
depressed within ten seconds, the function is
not activated.
115Vac Variable
Autotransformer
2. Disconnect the battery. (10 Amp)
600:5
Recloser
3. Remove control ac sensing and power connections Use 2/0 cable or larger BCT ON 600:5 Tap

from the control using a separate disconnect switch.

6 4 2
Load
2 Clamp-On
Ammeter
WARNING: Hazardous voltage. If the recloser
! is energized while the control cable is discon- 5 3 1
Source

nected, the CT secondaries can generate high volt-

ages. Contact with high voltage can cause severe per-
sonal injury or death. T204.2

CAUTION: Equipment misoperation. Disconnect all

control power sources prior to disconnecting the con-
trol cable from the control. Failure to comply can result
in recloser misoperation at the time of disconnection or
reconnection of the control cable to the control. T311.0
Triple-Single Form 6-TS
Junction Box Control
4. Disconnect control cable from control.

CAUTION: Hazardous Voltage. Cable conduc- Figure 35.

! tors attached to NOVA reclosers will remain at Suggested test circuit for NOVA-TS Triple-Single
53Vdc potential after disconnection of source power to reclosers with Form 6-TS control.
the recloser. Contact with any pins at the end of cables
directly or indirectly connected to a NOVA recloser can
result in personal injury or equipment damage. T312.0
RS-485 C + –
CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4
1 3 5 7 9 11 13 15 17 19 J1-RS-232
TB1
5. Remove any control input and status output wiring
IRIG-B
from TB1, TB3, and TB4 (Figure 34). 2 4 6
CI1 CI2
8 10 12 14 16 18
CI3 SS1 CO1 CO2 CO3 CO4
RS-232 DTE

6. Disconnect any serial communications ports and IRIG- TB3

CI4 CI5 CI6
1 3 5
CI7 CI8 CI9 CI10 CI11 CO5
7 9 11 13 15 17 19 21
CO6 CO7 CO8 CO9 CO10 CO11 CO12
1 3 5 7 9 11 13
TB4
B timing connections (Figure 34).
2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12
7. Disconnect the ground from the control. CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11CO12

Figure 34.
Back view of top half of Form 6-TS recloser control.

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

Battery Test and Charging Test Procedure for Uninstalled

Procedures Battery
Test Procedure for Installed Battery CAUTION: Recloser misoperation. The control
Follow the procedure below to perform a battery test in ! must be removed from service before discon-
the Form 6-TS control. The values in the test procedures necting the control battery. Disconnecting the control
are based on testing at 25˚C (77˚F). battery from an in-service control may cause recloser
misoperation (unintentional operation) Failure to com-
The condition of the Form 6-TS control battery can be ply can result in equipment damage and personal
determined by using the Battery Test function in the BAT- injury. T213.4
TERY MENU. No external current/voltage meter is nec-
essary for testing. The entire process should be conducted in a clean envi-
Alarm Conditions: ronment, such as a repair shop.
• During a manual battery test a 5Ω, 55 watt resistor is Refer to Table 9 and follow this procedure to perform a
placed across the battery terminals for approximate- bench test on a control battery in a service shop:
ly 5 seconds. The Form 6-TS control measures the 1. Remove the control from service. Refer to Remove
battery voltage, if the voltage drops below 22.8 Vdc the Control from Service procedure within the
for one full second, the ALARM LED (battery alarm) Testing section of this manual.
is illuminated.
2. Remove the battery from the control and carefully
• When the Form 6-TS control is disconnected from AC transport it to a suitable service facility.
power and the control battery drops below 23.5 Vdc
for 60 seconds, the ALARM LED will illuminate. If the 3. Measure battery voltage.
battery voltage continues to decay and drops below 4. Apply test load and measure battery voltage after 5
22 Vdc, the Form 6-TS control will shut down. seconds of load to determine voltage drop. Refer to
Note: The battery test is blocked for 60 seconds upon power Table 9 for Bench Test Load Condition.
up of the control.
5. Remove test load.
Note: AC power can be either connected or disconnected for
battery test. If the battery fails the test or is at least four years old, it
should be replaced. Refer to Table 9 for battery catalog
1. Press the MENU button on the front panel. part number.
2. Using the down arrow key, navigate to the BATTERY
menu and press ENTER.
3. Using the down arrow key, navigate to the TEST BAT-
TERY menu and press ENTER.
4. Press the F4 button to test the battery. The battery
test results will display in the battery metering menu.
Note: Voltage should be between 25–31 Vdc with the
higher voltage at colder temperatures.
Under normal conditions, with AC connected and a
fully charged battery, the charging current should
be less than 20 mA.
With AC connected and a discharged battery the
current range should be 20–450 mA.
With AC disconnected and the battery supplying
the load, current will read -400 to -600 mA depend-
ing on connected accessories.

TABLE 9
Control Battery Bench Testing and Replacement Information
Bench Acceptable
Battery Test Load Voltage Drop
Catalog Amp/ Condition at End of
Control Type Battery Part # Voltage Type Hour for 5 sec. Test Load
Form 6-TS (high capacity) Hawker KME5-134-1 24v Lead 13 5Ω 2v
Genesis (two Acid 55 watt or less
12v
batteries)

40
 !
SAFETY
FOR LIFE
S280-70-7

Battery Charging
If it is not possible to charge the battery with the control’s
built-in charger, a KA43ME7001 (120 Vac) portable
bench type battery charger is available. Refer to S280-
79-14 KA43ME7001 Portable Lead Acid Battery Charger
Instructions for additional information.

IMPORTANT: Do not attempt to charge a lead acid

battery below 19 Vdc with the KA43ME7001 charger.
Attempting to do so will damage the charger.
If the lead acid battery is below 19 Vdc, replace the
battery. The expired battery should be disposed of in
an environmentally responsible manner. Consult local
regulations for proper battery disposal.

Charge the battery with a KA43ME7001 (120 Vac)

portable charger. Connect the battery directly to the
KA43ME7001 charger. The charger continuously moni-
tors the battery voltage.
Note: A red LED indicator on the body of the charger illumi-
nates when charging.

IMPORTANT: Never connect a single 12 volt battery to

the KA43ME7001 charger. Use adapter KME5-325-1
with the battery assembly when connecting the charg-
er to the two 12 volt batteries.

The charger senses when the battery voltage reaches

2.27 volts per cell, then the charge rate reduces to main-
tain a trickle charge.
The red LED flickers to indicate the battery has reached
a full charge. This process can take up to 24 hours.

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

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

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

this control. Failure to comply can result in control and

recloser misoperation, equipment damage, and per- 5. Verify the selector switch on the Power
sonal injury. G110.3 Supply/Battery Charger Board is set to the correct
position based upon the incoming power supply:
• For 120 Vac incoming power, the selector switch
After the required work is completed, disconnect the con-
must be set to the 115V position.
trol from the test set and follow this procedure to return
the control to service: • For 240 Vac incoming power, the selector switch
must be set to the 230V position.
1. While still in service shop, appropriate personnel
must verify that all control settings are correct. 6. Apply ac power to the control.
2. Reconnect the ground cable to the control. 7. Disable GND TRIP BLOCKED.
A. Press the CHANGE button on the Operator Panel
CAUTION: Equipment misoperation. Disconnect all to enter the CHANGE mode.
control power sources prior to disconnecting the con-
trol cable from the control. Failure to comply can result B. Depress the GND TRIP BLOCKED button within
in recloser misoperation at the time of disconnection or ten seconds after entering the CHANGE mode.
reconnection of the control cable to the control. T311.0 Note: Once selected (or after ten seconds), the control
returns to normal operation.
IMPORTANT: Prior to reconnecting the control cable, 8. Verify the control clock is set to the current time after
verify the control was removed from service in the ac power has been reapplied.
exact order specified in the Remove the Control from Note: The control clock may require resetting if the oper-
Service section of this manual. ating power has been disconnected for more than
thirty days. Refer to Service Information S280-70-9
3. Control cable properly connected and supported. Form 6-TS Recloser Control Programming Guide
4. Plug in the control battery. for information on setting the control clock.

Note: The Form 6-TS recloser control will not power up

until ac power is applied.

42
 !
SAFETY
FOR LIFE
S280-70-7

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

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

!
SAFETY
FOR LIFE

©2003 Cooper Industries, Inc.

Kyle® is a registered trademark of Cooper Industries, Inc. P.O. Box 1640
ProViewTM, Idea WorkbenchTM, Communications WorkbenchTM, Waukesha, WI 53187
and TCC EditorTM are trademarks of Cooper Industries, Inc. www.cooperpower.com

KA2048-621 Rev: 00 KMW

10/03