Cooper Power Systems Form 6 Series User manual

1
Form 6 Microprocessor-Based
Pole-Mount Recloser Control
Installation and Operation Instructions
Reclosers
Service Information
Safety Information ..................................................... 2
Product Information .................................................. 3
Introduction ............................................................ 3
ANSI Standards ...................................................... 3
Quality Standards ................................................... 3
Acceptance and Initial Inspection ........................... 3
Handling and Storage ............................................ 3
Control Power ........................................................ 3
Battery Replacement and Disposal ........................ 3
Operation Upon Loss of AC Power ........................ 4
Form 6 Recloser Control Description ...................... 5
Description ............................................................. 5
Theory of Operation ............................................... 5
Control Front Panel ................................................ 6
Control Features ..................................................... 11
Communications .................................................... 14
Control Information ................................................. 14
Control Back Panel ................................................ 14
Installation Procedure ............................................... 15
Initial Programming Prior to Installation ................... 15
Control / Recloser Compatibility ............................. 15
Duty Cycle Monitor ................................................. 16
Mounting the Control .............................................. 16
Locking the Control ................................................ 16
Control Cable ......................................................... 18
Grounding the Control ............................................ 18
Customer Connections for AC Power .................... 21
Before Placing Control and Recloser into Service .... 30
Using Removable Inserts ........................................ 31
Accessories ............................................................... 32
Low Voltage Closing ............................................... 32
Internal Voltage Sensing .......................................... 32
Incoming Power Receptacles ................................. 32
Cable Locking Sleeves ........................................... 32
120 VAC GFI Duplex Outlet .................................... 32
BCT Terminal Blocks Accessory.............................. 41
Auxiliary Terminal Block Accessory .......................... 41
Cabinet Ordering Accessories ................................ 41
Discrete Interface Board Option Accessory ............ 42
Radio Mounting Accessory ..................................... 42
Communication Board Accessories ........................ 42
Testing ........................................................................ 45
Testing an Installed Control .................................... 45
Remove the Control from Service ........................... 46
Preliminary Testing with No AC Available ................ 46
Testing with Type MET Tester ................................. 46
Closing the Recloser During Testing ....................... 47
Battery Test and Charging Procedures ................... 50
Return the Control to Service ................................. 52
Recloser VTC Interface ............................................. 52
Control VTC Interface ............................................... 53
Additional Information ............................................... 54
Replacement Kits ................................................... 54
Factory-Authorized Service Centers ....................... 54
Factory Maintenance Classes ................................. 54
Contents
S280-70-3
October 2012 • Supersedes 7/05
Figure 1.
Form 6 microprocessor-based pole-mount recloser control.
For Type F6-P2A Control,
and Type F6-P2B Control,
above Serial Number 10,000
or beginning with CP57.
•F6-P2AappliestoForm6controlfor
use with W, VS, and auxiliary-
powered NOVA reclosers.
 •F6-P2Bappliestocontrol-powered
NOVA Form 6 control for use with
control-powered reclosers.
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Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
2
The instructions in this manual are not intended as a
substitute for proper training or adequate experience in the
safe operation of the equipment described. Only competent
technicians who are familiar with this equipment should
install, operate, and service it.
A competent technician has these qualifications:
• Is thoroughly familiar with these instructions.
• Is trained in industry-accepted high- and low-voltage
safe operating practices and procedures.
• Is trained and authorized to energize, de-energize,
clear, and ground power distribution equipment.
• Is trained in the care and use of protective equipment
such as flash clothing, safety glasses, face shield, hard
hat, rubber gloves, hotstick, etc.
Following is important safety information. For safe installation
and operation of this equipment, be sure to read and
understand all cautions and warnings.
Safety Instructions
Following are general caution and warning statements that
apply to this equipment. Additional statements, related to
specific tasks and procedures, are located throughout the
manual.
SAFETY INFORMATION
SAFETY FOR LIFE
Cooper Power Systems products meet or exceed all applicable industry standards relating to product safety. We actively
promote safe practices in the use and maintenance of our products through our service literature, instructional training
programs, and the continuous efforts of all Cooper Power Systems employees involved in product design, manufacture,
marketing, and service.
We strongly urge that you always follow all locally approved safety procedures and safety instructions when working around
high voltage lines and equipment and support our “Safety For Life” mission.
This manual may contain four types of hazard
statements:
DANGER: Indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
WARNING: Indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
CAUTION: Indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
CAUTION: Indicates a potentially hazardous
situation which, if not avoided, may result in
equipment damage only.
Hazard Statement Definitions WARNING:
This equipment is not intended to protect human life.
Follow all locally approved procedures and safety
practices when installing or operating this equipment.
Failure to comply may result in death, severe personal
injury, and equipment damage. G102.1
DANGER:
Hazardous voltage. Contact with hazardous voltage will
cause death or severe personal injury. Follow all locally
approved safety procedures when working around high-
and low-voltage lines and equipment. G103.3
WARNING:
Before installing, operating, maintaining, or testing this
equipment, carefully read and understand the contents
of this manual. Improper operation, handling, or
maintenance can result in death, severe personal injury,
and equipment damage. G101.0
WARNING:
Power distribution and transmission equipment must be
properly selected for the intended application. It must
be installed and serviced by competent personnel who
have been trained and understand proper safety proce-
dures. These instructions are written for such personnel
and are not a substitute for adequate training and expe-
rience in safety procedures. Failure to properly select,
install, or maintain power distribution and transmission
equipment can result in death, severe personal injury,
and equipment damage. G122.3
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Introduction
Service Information S280-70-3 provides installation and
operation instructions for the Form 6 pole-mount recloser
control above serial number 10,000 or beginning with
CP57.
Refer to the following information as appropriate for your
version of ProView software:
• Service Information S280-70-4 Form 6 Recloser Control
Programming Guide: ProView 4.X.X software
• Service Information S280-70-21 Form 6 Recloser
Control Programming Guide: ProView 5.X.X software
Read This Manual First
Read and understand the contents of this manual and
follow all locally approved procedures and safety practices
before installing or operating this equipment.
Additional Information
These instructions cannot cover all details or variations in
the equipment, procedures, or process described, nor
provide directions for meeting every possible contingency
during installation, operation, or maintenance. When
additional information is desired to satisfy a problem not
covered sufficiently for the user's purpose, contact your
Cooper Power Systems sales representative.
ANSI Standards
Kyle reclosers are designed and tested in accordance with
the following ANSI standards: C37.60 and C37.85 and
ANSI Guide C37.61.
Quality Standards
ISO 9001-Certified Quality Management System
Acceptance and Initial Inspection
Each Form 6 recloser control is completely assembled,
tested, and inspected at the factory. It is carefully calibrated,
adjusted and in good condition when accepted by the
carrier for shipment.
Upon receipt, inspect the carton for signs of damage.
Unpack the control and inspect it thoroughly for damage
incurred during shipment. If damage is discovered, file a
claim with the carrier immediately.
Handling and Storage
Be careful during handling and storage of the control to
minimize the possibility of damage. If the control is to be
stored for any length of time prior to installation, provide a
clean, dry storage area. If storage is in a humid atmosphere,
make provisions to keep the control circuitry energized.
Note: To energize the control, apply AC power to the AC supply
input terminal block located in the lower right hand
corner of the back panel of the control. Refer to the
Customer Connections for AC Power section in this
manual.
Control Battery Storage and Charging
The 24 VDC control battery in the Form 6 recloser control is
fully charged prior to shipment and is ready for use.
Temperature has an effect on battery life. Sealed lead acid
batteries should be stored, fully charged, at room
temperature. Never store lead acid batteries at temperatures
exceeding 47°C (117°F), as damage can result in
approximately one month.
The batteries must be tested and charged for 24 hours
following every three months of storage from the last test
date. A separate portable charger accessory is available.
Catalog Number KA43ME7001 provides a 120 Volt battery
charger to power individual batteries.
Note: When shipped from the factory, the battery source is
disconnected and its output plugs are taped to the
cabinet. Connect the battery plugs into the mating
connectors to complete the battery circuit.
Control Power
The control is powered from 120 or 240 VAC. The selector
switch on the power supply board allows the user to select
between 120 VAC or 240 VAC.
Note: The selector switch is factory-set for each control based
upon the customer order requirement.
Battery Replacement and Disposal
The 24 VDC control battery has a life expectancy of four
years. It is recommended that the battery be replaced after
four years or if the battery fails a battery test - whichever
occurs first.
Note: Battery life is decreased at higher temperatures.
Dispose expired batteries in an environmentally responsible
manner. Consult local regulations for proper battery
disposal.
S280-70-3
3
PRODUCT INFORMATION
IMPORTANT: To maintain sufficient charge to operate
the control and prevent battery cell damage, the sealed
lead-acid batteries should be charged after no more
than three months of storage.
IMPORTANT: Connect the control battery before ac
power is connected to the control’s AC supply Input
Terminal Block. The battery must be disconnected prior
to shipping or storing the control.
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Operation Upon Loss of AC Power
The control is equipped with either an 8 Amp-Hour or 13
Amp-Hour 24 VDC lead acid battery for operation upon
loss of AC power. The control maintains full operation from
the battery for a period of time dependent upon the battery
size:
• 8 Amp-Hour — 12 hour maximum (20°C)
• 13 Amp-Hour — 24 hour maximum (20°C)
In the event that the AC power has not returned within the
times listed above, the control will disconnect the battery
from the circuit.
Note: The control continuously monitors the battery voltage. To
prevent battery damage, the control shuts down
automatically upon detection of low battery voltage
(below 22 VDC) for 60 seconds.
Control programming settings and parameters—including
event recorder—are stored in non-volatile memory and
retained upon loss of control power. The time/date clock
will continue to operate for approximately 30 days after
loss of control power.
Phase B (Ø) is the factory default phase. Unless changed
by the user, the B PHASE VOLTAGE red LED illuminates
indicating AC is the operating power. If BØ (or the user-
indicated phase) loses AC power, the ALARM red indicator
LED will illuminate. The ALARM log on the LCD Display will
indicate NO AC PRESENT and the CONTROL OK LED will
not be illuminated.
The control clock may require resetting if the operating
power has been disconnected for more than thirty days.
Refer to Service Information S280-70-4 (ProView 4.X.X) or
S280-70-21 (ProView 5.X.X) Form 6 Microprocessor-
Based Recloser Control Programming Guide for informa-
tion on setting the control clock.
Note: When AC power is present, the control will operate
regardless of back-up battery presence.
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
4
IMPORTANT: If the the control shuts down due to low
battery voltage before AC power is restored, and the
connected energized recloser is CLOSED; it will only
TRIP and LOCKOUT via front panel pushbutton
command.
A control that has shut down due to low battery voltage
before AC power is restored will have a blank LCD
display (no text message shown) and none of the LEDs
will be illuminated.
Figure 2.
Form 6 pole-mount recloser control is accessible from
both the front and back of the cabinet.
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Description
The Form 6 pole-mount microprocessor-based recloser
control includes extensive system protection functionality,
including phase, ground, and negative sequence overcurrent
protection, over/underfrequency, and voltage protection,
directionality, sensitive ground fault, and sync check.
Analysis tools include fault locating, event recording, TCC
Editor II, Idea Workbench, Data Profiler, and oscillography
functions, including oscillography replay.
Metering functions include demand and instantaneous
current on a per-phase basis, instantaneous voltage and
power factor on a per-phase basis, and power (real,
reactive, apparent) on a per phase or total basis.
Symmetrical 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 front panel LCD display is used to configure the
operating settings for the control. It is also used to display
metering, counter information, control parameters, reset
alarms, and provide diagnostic information.
Control parameters can also be programmed via a personal
computer connected to the control through the front panel
RS-232 port. Control programming, interrogation, and
operations are performed with Form 6 ProView interface
software on a personal computer.
ProView interface program software includes additional
functions used to create and graphically display Time
Current Curves and provides the Idea Workbench for
configuring user-selected inputs and outputs, configurable
event and alarm data, and selectable communication
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 requirements
change, the control functions can be modified to meet the
new requirements.
The control is accessible from both the front and back of
the cabinet (Figure 2).
Theory of Operation
A functional block diagram of the Form 6 recloser control
is shown in Figure 3. Current sensing is provided by three
current transformers located in the recloser and interfaced
to the Form 6 recloser control via the control cable. This
cable also supplies Trip, Close, and Recloser status, and
connects to the Recloser Interface (RIF) module to provide
isolation for reliable operation. Voltages for metering are
connected to the analog input module through terminal
block TB8.
Line current flowing through the recloser is converted by
the CPU module to a digital signal suitable for metering and
fault current calculations. Data sampling occurs at a rate of
64 times per cycle. The CPU contains a data acquisition
section that uses the acquired samples to compute the
fundamental currents and voltage for use in overcurrent,
under/overvoltage, and under/overfrequency protection,
as well as currents and voltages for metering functions.
The current for overcurrent protection is calculated on a
sub-cycle basis; it includes only the fundamental and DC
component.
When the phase or ground current exceeds its programmed
minimum-trip value and associated time-current-curve
(TCC) timing, the control initiates the programmed sequence
of recloser tripping and reclosing operations via the CPU
and RIF modules. If the fault is temporary, the control
ceases to command recloser operations after a successful
reclose, and the control resets to the start of its operating
S280-70-3
5
TRIP SOLENOID
CLOSE SOLENOID
A Ø CT
B Ø CT
C Ø CT
OPEN / CLOSE
SWITCHES
CT COMMON
RECLOSER
POWER BATTERY
INTERCON-
NECTION
BOARD
CPU
I/O
FRONT
PANEL
RS-232
(PROVIEW
PROTOCOL
ONLY)
TB7
TERMINAL
BLOCK
120/VAC
OUTLET
DUPLEX
ACCESSORY
TB8
TERMINAL
BLOCK
SENSING
VOLTAGE
INPUTS
3 inputs
USER
CONNECTIONS
5 outputs
8 inputs
USER
CONNECTIONS
8 outputs
POWER
CONNECTIONS
120/240
MATCHING
TRANSFORMERS
AND SIGNAL
CONDITIONING
ANALOG INPUT
RIF
OPTICAL
ISOLATION
OPTICAL
ISOLATION
OPTICAL
ISOLATION
OPTICAL
ISOLATION
RS-232
IRIG-B
COMMUNICATIONS
BOARD ACCY
•RS-485
•FIBER-OPTIC
•ETHERNET
Figure 3.
Form 6 pole-mount recloser control operational flow diagram.
FORM 6 RECLOSER CONTROL DESCRIPTION
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sequence after a preset time delay. If the fault is permanent,
the control performs its complete programmed sequence
of reclose commands and locks out with the recloser open.
Once locked out, the control must be closed via the
operator panel or SCADA communications. This resets the
control to the start of the operating sequence.
The following chain of events occurs for an operating
sequence of two trips to lockout (one trip on TCC1, one
trip on TCC2):
1. The overcurrent signal is integrated with time on the
selected curve for the first trip operation (TCC1) to pro-
duce the signal which energizes the trip circuit.
2. Energizing the trip circuit connects the supply to the
trip solenoid to open the recloser.
3. Upon opening, the control starts timing on the first
reclosing interval-delay time.
4. Upon expiration of this reclosing interval-delay, a clos-
ing signal is issued from the control, closing the reclos-
er, and selecting the time-current characteristics for the
second trip operation (TCC2).
5. If current remains above the minimum-trip level, the
recloser will trip on TCC2 and lockout the recloser.
Control Front Panel
The Form 6 control front panel is illustrated in Figure 4.
The front panel is separated into two clearly identified,
color-coded sections:
• The top portion of the front panel is used for programming
the control and providing LED status indication.
• The lower portion of the front operating panel is used
for operating the control and recloser.
The control includes a Power Save feature that will turn off
the backlit LCD display and all LEDs (except Hot Line Tag)
if no front panel keypad is pressed within ten minutes.
Pressing the LAMP TEST key will re-activate the display
and LEDs.
Note: The Power Save feature is a ProView interface software
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 root menu after ten minutes
of inactivity.
Note: The ten minute timer and MMI Reset Menu is a ProView
interface software default setting. The menu selection
and timer can be changed via the ProView interface
software.
Front Panel Text Messaging
The LCD messages are accessed from the front panel by
following the Text Messages menu path. This menu
displays any active user-configured text messages.
Up to fourteen user-configurable text messages can be
programmed via the Idea Workbench. Refer to Service
Information S280-70-4 (ProView 4.X.X) or S280-70-21
(ProView 5.X.X) Form 6 Control Programming Guide for
information on programming the text messages.
These text messages appear on the front panel LCD and
can be programmed to appear for alarm or other
conditions.
Text messages displayed on the front panel are limited to
four lines of 20 characters each (including spaces). Text
messages can also be accessed by pressing the LAMP
TEST one-touch analysis key on the front panel.
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
6
CONTROL POWER
CONTROL OK
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
METERING
RESET
TARGETS
EVENTS
LAMP TEST
MENU
ENTER
+
—
SETTINGS
OPER
COUNTER
ALARMS
CHANGE
F1 F2 F3 F4
TRIP CLOSE
HOT LINE TAG
ON
GND TRIP
BLOCKED
NON
RECLOSING
SUPERVISORY
OFF
ALTERNATE
PROFILE #1
ALTERNATE
PROFILE #2
ALTERNATE
PROFILE #3
F6 Recloser Control
RS-232 DATA PORT
OPTION #1 OPTION #2 OPTION #3
(LOCKOUT)
LCD Display
LCD Display
Dedicated
Function Keys
One-Touch
Analysis Keys
Hot Line Tag Toggle Switch and
Three-Segment LED Indication
RS-232
Configuration
Data Port
CLOSE Pushbutton
TRIP (LOCKOUT)
Pushbutton
(Hardwire Connected)
LED Indicators
LCD Display
Dedicated
Function Keys
One-Touch
Function Keys
Cursor Movement Arrows
LCD Menu Function Keys
One-Touch
Analysis Keys
INDICATOR 4
INDICATOR 5
INDICATOR 6
INDICATOR 7
INDICATOR 8
CLOSE CIRCUIT
DISABLE
Close Circuit
Disable Fuse
and Fuseholder
Figure 4.
Form 6 pole-mount control front panel.
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Programming Panel
The Programming panel has the following sections:
One-Touch Analysis Keys
There are eight analysis keys (Figure 5) that allow one-
button access to a variety of control and monitoring func-
tions that appear in the LCD display. Pressing these but-
tons causes the following information to display or function
to occur:
Note: When pressing a membrane pushbutton, always press
and hold for 0.5 seconds to ensure the button press is
recognized by the device.
METERING: Displays the systems instantaneous metering
values for current and voltage on the LCD display.
RESET TARGETS: Resets the fault target indicators on the
operator panel.
EVENTS: Displays the last 25 events from the Sequence of
Events log.
LAMP TEST: All operator panel LEDs are illuminated for
verification of proper connection and operating status of all
indicator lights. All status indicators will then return to their
previous state. While in the LAMP TEST mode, the control
response to operator panel keys is disabled, except for the
TRIP (LOCKOUT), CLOSE, and HOT LINE TAG switches.
SETTINGS: Displays recloser settings on the LCD display.
OPER COUNTER: Displays the total number of trip opera-
tions and target counters for each A, B, and C Phase;
Ground, and Sensitive Ground on the LCD display.
ALARMS: Provides status information on the LCD display
for all recloser alarms.
CHANGE: Allows the user to change the state of the con-
trol functions on the operator panel function keys.
Note: The CHANGE mode is a ten second period in which one
function setting can be changed. If no change is made in
that time, the control returns to the current setting.
LCD Display
The LCD Display is a backlit 4-line, 20-character display
that provides extensive distribution system, recloser, and
control status information using a minimum of eight
navigation keypads (Figure 5).
Note: The LCD display panel contrast is field-adjustable to allow
for various mounting heights and applications. Press the
MENU key and then press the (+) or (–) key to increase or
decrease the contrast.
The four LCD navigation buttons are as follows:
MENU: Identifies the LCD Display menu options.
ENTER: Selects a menu option.
+: Increases value selection.
–: Decreases value selection.
The four LCD menu function keys activate specific menu
commands. When a command appears in the LCD display
directly above one of the four LCD menu function keys, the
user can press the key to accept/select the command.
The four LCD menu function keys are as follows:
F1 F2 F3 F4
The four cursor movement arrows allow movement in the
following directions:
Moves the cursor left.
Moves the cursor right.
Moves the cursor up one line.
Moves the cursor down one line.
S280-70-3
7
METERING
RESET
TARGETS
EVENTS
LAMP TEST
MENU
ENTER
+
—
SETTINGS
OPER
COUNTER
ALARMS
F1 F2 F3 F4
CHANGE
Figure 5.
Analysis keys, LCD display, LCD menu function keys, and cursor movement arrows.
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Status Indicator LEDs
The status indicator LEDs (Figure 6) in the Programming
section of the Operator Panel give instant information on
the control and recloser status:
All of the default status indicators LEDs (except for
CONTROL OK, CONTROL POWER, and ALARM) can be
reconfigured via the Idea Workbench. Refer to Service
Information S280-70-4 (ProView 4.X.X) or S280-70-21
(ProView 5.X.X) Form 6 Control Programming Guide for
additional information.
The label inserts can be user-customized. Refer to Using
Removable Inserts section of this manual for additional
information.
CONTROL OK: The green LED indicates the control is
operating normally and not in an alarm state.
The CONTROL OK LED will not be illuminated during these
alarms (indicated by the red ALARM LED and displayed in
the alarm status log):
• Battery Alarm: This alarm indicates battery voltage is
low or the battery failed an operator-initiated manual
test.
• RAM Failure: This alarm indicates a failed RAM memo-
ry test.
• ROM Failure: This alarm indicates a failed ROM mem-
ory test.
• No AC Present: This alarm indicates AC power was
unavailable for 10 continuous seconds. This alarm
resets when AC power is restored.
• Power Supply Malf[unction]: This alarm indicates inter-
nal control operation power was outside of its operat-
ing tolerance for more than 20 seconds. This alarm
resets when the internal control operation power
returns to operation within its normal tolerances.
• RIF Comm Failure: This alarm indicates a loss of
communication from the RIF (Recloser Interface) circuit
board to the main CPU circuit board. This alarm resets
if communication is re-established.
CONTROL POWER: The green LED indicates there is
adequate VTC voltage to trip the recloser. This LED does
not indicate the presence of AC or battery power.
CONTROL LOCKOUT: The green LED indicates the control
is in a locked out state, i.e. a reclosing sequence is not in
progress. This LED does not indicate that the recloser is
open.
RECLOSER OPEN: The green LED indicates the recloser
is in the open position.
RECLOSER CLOSED: The red LED indicates the recloser
is in the closed position.
Note: There are several conditions that will cause the alternate
blinking of the CONTROL LOCKOUT, RECLOSER OPEN,
and RECLOSER CLOSED LEDs: Failure to Trip, Failure to
Close, Interrupter Malfunction, and 52a/b Disagreement.
The LED blinking pattern for these conditions is the
CONTROL LOCKOUT green LED and RECLOSER
CLOSED red LED alternating with the RECLOSER OPEN
green LED.
In addition to the above LED blinking pattern, the red
ALARM LED will also be illuminated for these alarms:
Failure to Trip, Failure to Close, and Interrupter
Malfunction.
A PHASE FAULT, B PHASE FAULT, C PHASE FAULT: The
red LEDs indicate A, B, and/or C phase current was either
the maximum phase current or within 20% of the maximum
when a trip signal was issued.
GROUND FAULT, SENSITIVE GROUND FAULT: The red
LEDs indicate that a Ground and/or Sensitive Earth Fault
tripping function was asserted at the time the trip signal
was asserted.
ALARM: The red LED indicates an alarm has been issued.
Review the alarm status and log on the LCD display for the
specific alarm.
ABOVE MINIMUM TRIP: The red LED indicates the current
exceeds the level set for minimum trip.
FREQUENCY TRIP: Indicates the recloser tripped due to
an under or over frequency condition.
VOLTAGE TRIP: Indicates the recloser tripped due to an
under or over voltage condition.
A PHASE VOLTAGE, B PHASE VOLTAGE, C PHASE
VOLTAGE: The red LED indicates a presence of voltage on
the respective phases. The Single-Phase Undervoltage
Pickup setting controls the voltage indication for the front
panel LEDs as defined in the Voltage setting dialog box for
the active setting profile. Refer to Settings - Voltage in the
Schemes section of S280-70-4 (ProView 4.X.X) or S280-
70-21 (ProView 5.X.X) Form 6 Control Programming
Guide.
INDICATOR 1, INDICATOR 2, INDICATOR 3, INDICATOR
4, INDICATOR 5, INDICATOR 6, INDICATOR 7, INDICATOR
8: Customizable LEDs that are used with functions
programmed through the Idea Workbench. The LED
indicators do not have active default values. The LEDs are
illuminated when the status configured via the Idea
Workbench is present.
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
8
CONTROL POWER
CONTROL OK
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
Figure 6.
Form 6 pole-mount control status indicator LEDs.
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Operating Panel
RS-232 Configuration Data Port
The RS-232 connector (shown in Figure 4) on the front
operating panel allows direct connection to a personal
computer without any special cables or connectors. This
port is used only for configuring the control with ProView
application software. All settings, metering, events, and
oscillography data are available from this port. The port is
Data Communication Equipment (DCE) wired for direct
connection to a personal computer.
A 9-pin RS-232 cable (Catalog Number KME5-66) to
connect from the PC to the RS-232 data port is available
as an accessory.
HOT LINE TAG ON/OFF Toggle Switch and LED
Indicator
Hot Line Tag is provided for live-line work applications. All
closing operations are disabled when the Hot Line Tag
feature is activated.
Hot Line Tag prevents all closing attempts from the control
and shifts protection to one trip-to-lockout on the composite
curve of the Hot Line Tag definite time and the TCC1 curve
(whichever is faster). Hot Line Tag takes precedence over
Cold Load Pickup, Non-Reclosing, and 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 toggle
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.
CLOSE CIRCUIT DISABLE
Close Circuit Disable (Figure 7) is a removable fuse that,
when removed from the front operating panel, disables the
close circuit from the control to the recloser. Removing the
fuse from the control disables all electrical closing of the
recloser and provides a physical disconnect to the recloser
closing circuit. As a result, the control cannot perform a
close operation. This disconnect overrides all close
functions and makes a remote or manual close operation
impossible.
Note: When the Close Circuit Disable fuse is removed, the trip
circuit remains active and will trip per the programmed
time current curve for a faulted condition.
TRIP (Lockout) Pushbutton
The TRIP pushbutton (Figure 7) provides front-panel access
to trip (lockout) the recloser. When pressed, the TRIP
pushbutton opens the recloser and locks out the control.
Note: In the event of main microprocessor failure, the trip circuit
can operate independent of the main microprocessor.
CLOSE Pushbutton
When pressed, the CLOSE pushbutton (Figure 7) returns
the control to the initial or home sequence position, closing
the recloser. The control is ready for the start of a new trip/
close sequence.
Note: The Close Malfunction alarm must be reset before
Closing will be allowed.
Note: Pressing the CLOSE pushbutton from the Lockout
position initiates Cold Load Pickup (CLPU) protection, if
the feature is enabled.
The user does have the ability to block COLD LOAD
PICKUP through the LCD menu or by configuring one of
the Option one-touch function keys via the Idea
Workbench feature in ProView.
If the recloser is closed, pushing and holding the CLOSE
pushbutton does not activate the Cold Load Pickup
feature. See Cold Load Pickup in the Control Features
section of this manual.
S280-70-3
9
TRIP CLOSE
HOT LINE TAG
ON
CLOSE
CIRCUIT
DISABLE
F6 RECLOSER CONTROL
(LOCKOUT)
Figure 7.
TRIP (Lockout) pushbutton; CLOSE pushbutton; Hot
Line Tag switch and Hot Line Tag red indicator LEDs.
WARNING: Hazardous voltage. Do not use Hot
Line Tag as a substitute for a visible disconnect.
Always establish a visible disconnect prior to performing
any work requiring a de-energized line. Failure to comply
may cause death, severe personal injury, or equipment
damage. T276.0
IMPORTANT: Hot Line Tag is intended solely for live-line
work applications, such as maintenance, repairs or
improvements to the distribution system, that occur
while the line remains energized.
IMPORTANT: Hot Line Tag activation does not cause
the recloser to trip open. It only prevents the recloser
from closing.
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.
IMPORTANT: If the CLOSE button is pressed after the
Close Circuit Disable fuse is removed, do not reinstall the
fuse until after the ALARM LED illuminates (within approx-
imately five seconds) to indicate CLOSE MALFUNCTION.
Re-installing the Close Circuit Disable fuse prior to the
CLOSE MALFUNCTION ALARM indication will cause the
control to close the recloser.
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One-Touch Function Keys
Quick access to frequently operated Form 6 control fea-
tures is provided with nine function key pushbuttons on the
control operator panel.
The Form 6 control operator panel one-touch function keys
are illustrated in Figure 8.
Red LEDs located on each function key indicate the status
of the function, regardless of local or remote activation. For
example, if Ground Trip Blocked is activated from a SCADA
signal, the red indicator will illuminate even though it was
not activated from the operator panel.
Operator panel function key activation or de-activation
requires the operator to first press the CHANGE key to
enter the CHANGE mode. A function must then be
selected or de-selected within ten seconds to activate or
de-activate the function. Once selected, the control returns
to normal operation until prompted for another change
request. This prevents accidental changing of functions or
features.
Note: Only one function can be changed per each CHANGE
mode activation.
GND TRIP BLOCKED
The Ground Trip Blocked function blocks all ground
sensing in the control for the active profile. This red
indicator is illuminated when Ground Trip Block is activated
from the serial port, I/O, the interface software, or locally
(via the front panel) causing the control to block all ground
sensing.
NON RECLOSING
The control is operating in a non-reclosing mode when the
NON RECLOSING red indicator is illuminated. Non-
reclosing mode disables any automatic reclosing operations.
Non-reclosing does not alter the active TCC. Activation is
possible from the SCADA port, I/O, the interface software,
or locally (via the front panel).
SUPERVISORY OFF
When the SUPERVISORY OFF red indicator is illuminated,
supervisory commands are blocked. Supervisory functions
through the back panel serial communication ports and the
discrete I/O are blocked. Serial communications through
the front panel RS-232 port remain active independent of
the status of the SUPERVISORY OFF switch. Activation of
this function key is restricted to the operator panel and is
accomplished by pressing the CHANGE key and then
pressing the SUPERVISORY OFF key. Operational data
and metering information are available while the control is
in the SUPERVISORY OFF position. The TRIP and CLOSE
pushbuttons and Hot Line Tag are active independent of
the SUPERVISORY OFF function.
ALTERNATE PROFILE #1, #2, and #3
The Form 6 control has four separate protection profiles; a
normal profile, and Alternate Profiles 1, 2, and 3. Each
profile changes all protection parameters for the control.
Except for the normal profile, each has an indication and
selection key. When the operator panel display lights are
active and none of the three indicators are on, the normal
profile is active. Only one profile can be active.
To select an alternate profile, press the CHANGE key and
then press the desired alternate profile.
To return to the normal profile, press the CHANGE key and
then press the active alternate profile to deselect it. These
functions can also be completed remotely via
communications interfaces.
OPTION #1, OPTION #2, AND OPTION #3
The OPTION #1, OPTION #2, and OPTION #3 function
keys must be programmed via the ProView Idea Workbench
software.
The OPTION LEDs are illuminated when the options
configured via the Idea Workbench are selected. Refer to
Service Information S280-70-4 (Proview 4.X.X) or S280-
70-21 (ProView 5.X.X) Form 6 Control Programming Guide
for additional information.
These OPTION keys provide a momentary signal. For
instance, these keys can be programmed to toggle control
status, protective functions, or a momentary input pulse.
The OPTION #1, OPTION #2, and OPTION #3 function
keys are intentionally not defaulted to any function. The
functions are assigned to each OPTION key via the Idea
Workbench application.
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
10
GND TRIP
BLOCKED
NON
RECLOSING
SUPERVISORY
OFF
ALTERNATE
PROFILE #1
ALTERNATE
PROFILE #2
ALTERNATE
PROFILE #3
OPTION #1 OPTION #2 OPTION #3
Figure 8.
Form 6 pole-mount control operator panel one-touch
function keys.
IMPORTANT: Unused alternate profiles should be
programmed with the same settings as one of the
applicable profiles. Default settings on unused alternate
profiles can cause unnecessary outages if they are
below normal system requirements.
IMPORTANT: Check minimum trip values prior to
changing an alternate profile to avoid misoperation of
the control under load conditions.
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Control Features
The Form 6 pole-mount recloser control offers numerous
standard features and accessories that allow the user the
utmost flexibility applying the recloser control.
Control Security
The Form 6 pole-mount recloser control has multiple
customer-programmable security codes to limit control
programming and viewing function access to authorized
personnel. The front panel Man-Machine Interface (MMI)
includes a user-selected security code to access the
settings. Plus, the ProView interface software has it’s own
security levels for multiple-user access.
Refer to Service Information S280-70-4 (ProView 4.X.X) or
S280-70-21 (ProView 5.X.X) Form 6 Microprocessor-
Based Recloser Control Programming Guide for additional
information.
Protection Profiles
Four protection profiles capable of fully specifying control
operation are standard in the control. Each protection pro-
file includes the following as a minimum:
• Overcurrent Protection
• Over/Undervoltage Protection
• Over/Underfrequency Protection
• Directional Protection
• Hot Line Tag Functionality
• Sync Check
• Sensitive Earth Fault Protection
• Sequence Coordination
• Operation Settings
Time Current Curves
Time-current curves are available for numerous functions,
including fast and delayed operations for phase, ground,
and negative sequence protection. Each time-current is
selected from a defined fifty curves which can be further
customized by the user. The time-current curves are also
selected from a graphical TCC Editor II to visualize any
modifications prior to configuring the control.
The time-current curves include the following modifications
for phase, ground, and negative sequence protection:
• Time Multiplier with a range of 0.1 to 25 in .1
increments.
• Time Adder with a range of 0 to 30 seconds in .01
second increments.
• Minimum Response Time with a range of 0.01 to 1
seconds in .001 second increments.
• High Current Trip multiplier with a range of 1 to 32
multipliers in increments of 0.1.
• 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.
Sequence Coordination
Sequence Coordination eliminates nuisance tripping
through trip coordination. It allows the control to step
through selected operations in the operating sequence
without tripping. The number of Sequence Coordination
advances is programmable from one to three operations to
provide trip coordination with a downline recloser. This
feature is independently selectable for each protection
profile.
Cold Load Pickup
The control includes a Cold Load Pickup feature to prevent
the control from tripping while energizing non-fault system
loads. This feature has independently programmable
minimum trip value time-current curve, reclose interval, and
number of independent operations to lockout for each
protection profile. Cold Load Pickup also includes TCC
Multipliers, TCC Adders, Minimum Response Time, Time
Dial Reset, and High Current Lockout. Also, direct values,
not multiples of minimum trip, are provided for high current
lockout.
Fast Trips Disabled
The control includes a Fast Trips Disabled feature to modify
protection, so that all trip operations use the programmed
TCC2. This feature is independently selectable for each
protection profile. All trip operations will time on TCC2.
Typically, TCC1 is fast and TCC2 is delayed. So, as an
example, the control will change it’s sequence from 2 fast
and 2 delayed operations to 2 operations on TCC2 when
Fast Trips Disabled is active.
High Current Lockout
The High Current Lockout feature will automatically lockout
the control on the selected operation when current exceeds
a programmable level. The active trip numbers for the
lockout is selectable for phase, ground, and negative
sequence. This feature is independently selectable for each
protection profile.
Sensitive Ground/Earth Fault Operation
The control has a Sensitive Ground/Earth Fault Trip feature
that provides tripping of the recloser after a programmable,
definite time for ground currents below normal ground
minimum trip levels. The feature has programmable
operations to lockout and reclose intervals independent of
the ground settings. This feature is independently selectable
for each protection profile.
Thermostatically Controlled Heater
The control has a standard 15 Watt thermostatically
controlled heater (ON 70°F, OFF 85°F) for humidity control
and voltage input independent. The heater is powered
from the power supply board.
S280-70-3
11
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Metering
The control provides instantaneous and/or demand
metering with programmable integration intervals for the
following functions:
• Real and reactive power for each phase and total,
including directional, on an individual phase basis.
• Demand currents on a per phase basis.
• Instantaneous currents, including ground current.
• Instantaneous voltage on a per phase basis.
• Instantaneous frequency.
• Positive, negative, and zero sequence voltages.
• Instantaneous power factor on a per phase basis.
• Metering settings to include demand interval, and
alarm thresholds for current, single-phase kW, three-
phase kW, single-phase kvar, and three-phase kvar.
Event Recorder
The Form 6 control contains capabilities to perform
Sequence of Events time-stamping for up to 33 event
types. Sixteen additional inputs can be user-defined
through the Idea Workbench.
Factory-defined event types include:
• Overcurrent Protection Trip
• External Trip
• Non-Reclose Trip
• External Close
• Lockout
• Reset
The Event Recorder maintains a minimum of 90 event
records. The last 25 events are viewable on the front panel
LCD display. Refer to S280-70-4 (ProView 4.X.X) or S280-
70-21 (ProView 5.X.X) Form 6 Control Programming Guide
for additional information.
Recloser Duty Monitor
The Form 6 recloser control software is equipped with a
Recloser Interrupting Duty Monitor. The Duty Monitor
accumulates the summation of I1.5 for all interrupted
currents on each interrupter. This feature permits
programmable entries to preset the duty of an existing
recloser. The recloser duty monitor displays interrupting
duty in percent of duty used. If the duty cycle monitor
exceeds 100%, the recloser should be examined for
maintenance.
Discrete SCADA Communications
The control provides five configurable output status con-
tacts and three configurable input control contacts as
standard. Each status contact is configurable using graph-
ical interface software to combine status functionality along
with Boolean algebra. Default output status contacts are:
Lockout, Recloser Open, Recloser Closed, Ground Trip
Block, and Hot Line Tag. One output status contact is a
solid state output (SS1) with a pickup time no longer than
two milliseconds.
The control also provides a minimum of three configurable
input control contacts. Each control contact is configurable
using a graphical interface software. Contacts accept a
whetting voltage range of 12–250 VDC, 120/240 VAC.
Each digital input is configured for either a momentary,
maintained, or maintained with precedence contact. Default
input control contacts are: Supervisory Trip and Lockout,
Supervisory Close, and Remote Trip and Lockout.
A Discrete Interface Board is also available as an accessory
to provide an additional eight output status contacts and
eight input control contacts. The expansion I/O board is
completely user-configurable.
TCC Editor II
Coordination and actual time current modifications are
available with a graphic interactive TCC Editor or similar
graphical software.
The TCC Editor II includes a complete database of
standard recloser industry time current curves (TCC), both
ANSI and IEC types, along with the ability to customize the
TCCs with multipliers, constant time adders, or minimum
response time adders. Also, the user is able to derive their
own specific TCC through data point entry. Each modified
time current curve can be identified with a user-customized
name and is selectable for configuring the control. The grid
and format for presenting the TCCs has a user-adjustable
scale, including the option of presenting multiple TCCs in
various user-configured colors.
Oscillography
Oscillography is provided to present current and voltage
waveforms, along with protection element and recloser
response status changes. Filtered and unfiltered data are
provided for viewing.
The recorded values are super-imposed on the protection
scheme, and the state or value at any point in the scheme
is displayed. The user has the capability to move through
the event and watch the response of every function. All
analog signals, digital inputs, and contact outputs are
monitored. Analog oscillography is displayed at 16 samples
per cycle.
Oscillographic data is recorded to analyze multiple events
during a permanent fault or other event type. The
oscillographic data shows two cycles before the trigger
point and eight cycles after the trigger point (default).
Note: The configuration settings are programmable.
Oscillography automatically initiates trigger points for the
following functions:
• Above Minimum Trip for Phase, Ground, and Sensitive
Ground Fault
• Single- and Three-Phase Overvoltage
• Single- and Three-Phase Undervoltage
• Over- and Underfrequency
• Trip Signal Issued
• Close Signal Issued
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
12
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Removable Inserts
Removable inserts are included with the control design for
customization of specific protection requirements. Inserts
are available for the status indicator LEDs, the operator
panel function keys, and the analysis keys. The removable
inserts are designed for use without adhesives, labelmakers,
or temporary labels. Refer to Using Removable Inserts
for more information.
An electronic label template is included on the ProView
application software CD and can be accessed through the
following default address: C: \ Program Files \ Cooper \
ProviewXX\ Form 6 \ Form 6 Inserts.doc
Idea Workbench
The Idea Workbench provides access to various inputs,
intermediate variables, and internal Form 6 alarms, status,
and targets to allow user-customization of the Form 6
recloser control to meet specific and unique applications.
The Idea Workbench also gives the user the ability to
perform logical functions with these variables by using a
simple graphical user interface. Use of the Idea Workbench
is not a requirement for operation.
Refer to Service Information S280-70-4 (ProView 4.X.X) or
S280-70-21 (ProView 5.X.X) Form 6 Microprocessor-
Based Recloser Control Programming Guide for additional
Idea Workbench information.
Over/Underfrequency Protection
The control includes two-stage operation for both under-
frequency and overfrequency protection. A fixed time delay
ranging from 0 to 100 seconds in .001 second increments
is available for both over and underfrequency. A frequency
restoration function, enabled or disabled by the user, is
provided to allow the recloser to automatically close should
frequency return to within configured settings for a user-
settable time. Over/Underfrequency Protection is included
as part of each protection profile.
Over/Undervoltage Protection
The control includes single-phase and three-phase under
voltage tripping. The control also includes three-phase
overvoltage tripping. Both over and undervoltage functions
include a single-phase and three-phase pick-up setting; a
single-phase and three-phase time delay setting ranging
from 0 to 100 seconds.
Directional
Directional functionality is included to maintain system
coordination from multiple sources, as well as circuit
reconfiguration for each profile. Directional applies to
phase, ground, and negative sequence protection, selected
independently. A maximum torque angle has a range of 0
- 90 degrees.
Fault Location
The control includes an impedance-based fault locator
based upon the Takagi algorithm1. Load-compensated
impedance calculation is used for calculating the distance.
Positive and zero sequence is configured in ohms, and the
fault locator line length is configured in kilometers/miles.
1 T. Takagi, Y. Yamakoshi, J. Baba, K. Uemura, T. Sakaguchi, "A New
Algorithm of an Accurate Fault Location for EHV/UHV Transmission Lines:
Part I - Fourier Transformation Method", IEEE Trans. on PAS, Vol.
PAS-100, No. 3, March 1981, pp 1316-1323.
Sync Check
Sync Check is a permissive system used to qualify any
close signal to the mechanism when enabled via the sync
check settings. Sync check allows for closing for any
combination of dead/live bus/line, and to perform
anticipatory closing for a live bus/live line condition by
calculating slip and anticipating the mechanism closing
delay. In addition to the anticipatory close calculation, the
sync check system performs verification of line and bus
voltage magnitudes and frequencies to determine that they
are within pre-determined ranges, and that the angular
difference between the two systems is also within the pre-
determined range. For a live/live close, where there is no
slip between the systems, the sync check system allows
permissive closing after the two systems are within
frequency and voltage limits, and the angular difference
between the systems has been within the allowable limits
for a pre-determined time.
Sync Check functionality includes the following applications:
Hot Line/Hot Bus Closing; Dead Line/Hot Bus Closing; Hot
Line/Dead Bus Closing; and Dead Line/Dead Bus
Closing.
Sync Check Parameters include the following configurable
settings: Voltage Angle; Mechanism Operating Delay;
Static Angle Delay; Dead Threshold; Live Threshold;
Positive Sequence Dead Threshold; Upper Voltage Limit;
Lower Voltage Limit; Lower Frequency Limit; Upper
Frequency Limit; and Fail to Close Timer.
Data Profiler
A fully-configurable data profiler is available which allows
the user to collect information by sampling data at
selectable intervals. These time-stamped values can then
be viewed to determine weekly load profiles, daily harmonic
disturbances or hourly voltage fluctuations. The number of
days of information the data profiler can provide depends
upon configuration parameters.
Refer to Service Information S280-70-4 (ProView 4.X.X) or
S280-70-21 (ProView 5.X.X) Form 6 Microprocessor-
Based Recloser Control Programming Guide for additional
Idea Workbench information.
Manual Close Delay
Manual Close Delay provides a delay from the time that the
manual CLOSE button is pushed to the time the manual
close operation is performed.
The delay is programmable from 0 to 60 seconds in 1
second increments. A programmed delay value can be
overridden for immediate closing by pressing the CLOSE
button a second time.
An active Manual Close Delay can be canceled by pressing
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.
S280-70-3
13
StockCheck.com

Communications
Communication Ports
The Form 6 control has two back panel communication
ports and a front panel configuration data port.
The front panel configuration data port is described in the
Operating Panel section of this manual.
There is one standard 9-pin RS-232 and one optional
communication port (RS-485, serial fiber, Ethernet wire or
fiber or both) on the back operator panel, as well as a
standard IRIG-B port for user time-syncing. See Figure 9.
Communication Protocols
Four communication protocols are available for the Form 6
recloser control:
• Modbus
• DNP3
• 2179
• IEC870-5-101
One communication protocol can be selected for either the
back panel RS-232 or the optional communication port.
All four protocols are selected and configured by the user
with the ProView Communications Workbench application
software.
Ethernet Communications
• ProView over TCP/IP
• DNP3 over TCP/IP
Ethernet connection allows for network application of the
Form 6 pole-mount control for both DNP3 and ProView
protocols. In addition, the front panel data port can
simultaneously communicate ProView to the PC.
Ethernet configuration is accomplished via ProView
interface software. Refer to Service Information S280-70-4
(ProView 4.X.X) or S280-70-21 (ProView 5.X.X) Form 6
ProgrammingGuide,Section4:Schemes,Communicating
with the Form 6 Control, for Ethernet Configuration
information.
When a communication protocol is selected for the optional
communication boards (serial fiber or the RS-485 serial
port), the RS-232 serial port is defaulted to ProView
interface software protocol.
DNP3 is factory-defaulted to the RS-232 port.
When a communication protocol is selected for the RS-232
serial port, the optional RS-485 or serial fiber optic board
is not active.
The RS-485 or fiber optic serial ports do not support
ProView interface software protocol.
The user can simultaneously communicate to the Form 6
control using both the front panel data port and the
appropriate back panel serial communication port (provided
the back panel RS-232 port or the Ethernet optional
communications board is not configured to be ProView
protocol).
Control Information
Control information includes firmware identification by
catalog number and name, date code, and ProView
release number. Control information is available through
the Settings menu on the front panel (Figure 4).
Control Back Panel
The control back panel is easily accessible through the
back door of the control cabinet (Figure 2) with readily
identifiable serial ports and connections (Figure 9).
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
14
TB1
1
2
35 7911 13 15 17 19
46 81012141618
CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4
CI4
CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4
TB3
13579111315171921
CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6
TB4
246 8101214161820
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6
13 57911 13
CO7 CO8 CO9 CO10 CO11 CO12
246 81012
CO7 CO8 CO9 CO10 CO11 CO12
J1-RS-232
IRIG-B
RS-485
RS-232 DTE
Discrete Interface
Board (Accessory)
AC Power Fuse
RS-232 Serial Communication Port
Fiber Optic port, "ST" Type Connector (optional),
Ethernet Port, "MT-RJ" Fiber RJ45 Connector (optional)
Power Supply Board
AC Customer Connection
Terminal Block TB7
Grounding Terminal, One
External & One Internal
(#14 to #4 Stranded)
165
43
2
Power Supply LED
Power Connections
143
271211
109
8
Voltage Sensing
Customer Connection
Terminal Block TB8
120/240 VAC
Selector Switch
Battery Connector (2-position)
RS-485 Serial Communication Port (optional)
TB9
+–
28 VDC
WHETTING VOLTAGE
P1
P2 P3
P4
VOLTAGESENSING 53VDC CONTROL CABLE 28 VAC
12345
12345
23 22 21 20 19
11 10 987
18 17 16 15 14
65432
13
1
24
12
12345
31313
42424
1
2
C + –
IRIG-B Time Sync Connector
Figure 9.
Form 6 pole-mount recloser control back panel terminal block and communication port identification.
StockCheck.com

Initial Programming
Prior to Installation
The control must be programmed with all necessary
operating settings, all alternate profiles, and parameters
prior to operation with an energized recloser.
Note: Initial programming of the control is the responsibility of a
qualified technician or engineer familiar with control
functions and programming parameters required for the
specific recloser installation.
The control must be programmed with the Form 6 ProView
interface software. Refer to Service Information S280-70-4
(ProView 4.X.X) or S280-70-21 (ProView 5.X.X) Form 6
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.
Control / Recloser Compatibility
The Form 6 pole-mount recloser control is adaptable to the
following Kyle reclosers:
WE*, WVE27, WVE38X, VWE, VWVE27, VWVE38X, RVE,
VSA12, VSA16, VSA20, VSA12B, VSA20A, VS012, VS016,
NOVA15**, NOVA27** and NOVA38**.
* This control is not compatible with Form 1 Type WE reclosers
below s/n 300 and RE reclosers below s/n 400.
** Control-powered NOVA reclosers that are manufactured after
September 2004 require a Voltage Trip/Close (VTC) interface
for tripping and closing. This VTC requirement applies to three-
phase control-powered NOVA reclosers with a Type A or a Type
D mechanism and Form 5, Form 5 LS/UDP, Form 6, and Form
6 LS controls with the control-powered interface. These
reclosers and controls are equipped with 19-pin control cable
receptacles. Refer to RECLOSER VTC INTERFACE and
CONTROL VTC INTERFACE sections of this manual for
additional information.
Reclosers manufactured prior to June 1989 are equipped
with Type A bushing current transformers. These reclosers
were designed for use with Form 2, Form 3, and Form 3A
controls. Because the Form 6 recloser control is designed
for use with reclosers equipped with Type B current-
sensing Transformers, reclosers retrofitted with Form 6
recloser controls should be retrofitted with Type B current
transformers. All reclosers manufactured since 1989 are
equipped with Type B (1000:1, 1000/500:1, or 2000:1)
sensing CTs.
Reclosers equipped with Type B sensing CTs are compatible
with all Kyle recloser controls (Form 2, Form 3, Form 3A,
Form 4A, Form 4C, FXA, FXB Form 5, Form 5 LS/UDP, and
Form 6 recloser controls), and are identified with the
following label prominently displayed on the recloser sleet
hood or the front of the operator cabinet:
S280-70-3
15
CAUTION: Equipment misoperation. Do not
connect this control to an energized recloser until
all control settings have been properly programmed and
verified. Refer to the programming information for this
control. Failure to comply can result in control and
recloser misoperation, equipment damage, and per-
sonal injury. G110.3
IMPORTANT: Program all protection profiles. Unused
alternate profiles should be programmed with the same
settings as one of the applicable profiles. Default settings
on unused alternate profiles can cause unnecessary out-
ages if they are below normal system requirements.
CAUTION: Equipment misoperation. Check minimum
trip values prior to changing an alternate profile. Failure
to do so may cause misoperation of the recloser under
load conditions. T280.1
INSTALLATION PROCEDURE
NOTICE
RECLOSER IS EQUIPPED WITH TYPE
B SENSING CTs.
RECLOSER DOES NOT HAVE A
BATTERY CHARGER.
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The Form 6 recloser control can be used with the old-style
Type A CTs; however, the event recorder and duty cycle
monitor will have limited accuracy for currents above 5000
Amps.
Retrofit kits with the new Type B sensing CTs are
available to upgrade existing families of reclosers for
operation with Form 6 recloser controls. For additional
information, contact your Cooper Power Systems
representative.
For identification, Table 1 lists the serial number breaks
between old-style Type A and the new-style Type B sensing
CTs. Below this serial number, the recloser is equipped
with the Type A CTs.
Note: For reclosers shipped prior to June 1989 and not listed
below, please contact your Cooper Power Systems
representative with the recloser type and serial number
for verification of type A or B bushing current
transformers.
Duty Cycle Monitor
The Duty Cycle Monitor provides the following duty cycle
information:
• Measures and records duty for each individual phase in
non-volatile memory.
• The recloser duty is measured and stored on the basis
of Current1.5 x Number of Operations for Each Phase
(ANSI C37.61).
• Readout is based on a percentage of total duty cycle
for each phase.
• Duty record can be adjusted or reset if recloser is
changed-out, serviced, etc.
Using Table 2, select the appropriate recloser interrupting
duty cycle factor and enter that value via the ProView
interface software.
Mounting the Control
Mount the Form 6 pole-mount recloser control in a
convenient, accessible location. Mounting dimensions are
provided in Figure 10.
Note: Unless otherwise specified, dimensions shown in mm
(inches).
A hole and keyway in the control mounting bracket accom-
modates a 15.9 mm (5/8”) bolt.
Locking the Control
The handles on the Form 6 control cabinet are able to
accept a padlock to prevent unauthorized access. For
cabinets with the quarter-turn latch, the top handle has two
locking holes provided depending on the diameter of the
lock shackle being used. Refer to Figure 10.
• Use the smaller hole for shackle diameters of .177-
295”.
• Use the larger hole for shackle diameters of .295-.394”.
Note: DO NOT use a smaller shackle (.177-.295) in the
larger diameter hole as it will NOT LOCK the cabinet.
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
16
TABLE 2
Duty Cycle Factor
Interrupting 100% Duty
Recloser Rating Cycle
Type (rms sym Amps) Factor*
RXE, RVE 6,000 97
WE 12,000 @ 4.8 kV 257
WE 10,000 @ 14.4 kV 196
VWE
VWVE27 12,000 1045
VWVE38X
WVE27 8,000 140
WVE38X 8,000 140
VSA12 12,000 1045
VSA16 16,000 1608
VSA20
VSA20A 20,000 2248
VSA20B
VSO12 12,000 1045
VSO16 16,000 1608
Auxiliary-Powered
NOVA 12,500 1111
Control-Powered
NOVA 12,500 1111
*Duty Cycle Factor is Value x 105.
TABLE 1
Serial Number Break for Reclosers with Type A
Sensing CTs
Recloser Below Serial Number
RXE 5831
RVE 5894
WE 11199
WVE 3695
VWE 7199
VWVE27 7208
VWVE38 1204
All VSA reclosers are equipped with Type A Sensing CTs.
All VSML reclosers are equipped with Type A Sensing CTs.
All VSA12, VSA12B, VSA16, VSA20, VSA20A, and VSA20B
reclosers are equipped with Type B Sensing CTs.
All VWVE38X and VWE38X reclosers are equipped with Type B
Sensing CTs.
WARNING: This equipment is not intended to
protect human life. Follow all locally approved pro-
cedures and safety practices when installing or operating
this equipment. Failure to comply may result in death,
severe personal injury and equipment damage. G102.1
CAUTION: Follow all locally approved safety practices
when lifting and mounting the equipment. Use the lifting
lugs provided. Lift the unit smoothly and do not allow the
unit to shift. Improper lifting can result in equipment
damage. G106.2
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S280-70-3
17
Figure 10.
Form 6 pole-mount recloser control weight, dimensions, and pad-lock shackle diameters.
Front View
710
(28.0)
310
(12.25)
Vent
Bottom View
Vent
1.44 Dia. Hole for
Voltage Input Connection
(Caplug Installed)
Mounting Angle
Control Cable
Receptacle
(14-pin or 19-pin)
1.44 Dia. Hole
(Caplug Installed)
1.44 Dia. Hole for
Low Voltage Closing
Connection
(Caplug Installed)
67
(2.75)
38
(1.5) 67
(2.75)
79
(3.25)
RS-232
Connection
Port
29
(1.25)
CONTROLPOWER
CONTROLOK
CONTROLLOCKOUT
RECLOSEROPEN
RECLOSERCLOSED
APHASE FAULT
BPHASE FAULT
CPHASE FAULT
GROUNDFAULT
SENSITIVEGND
ALARM
ABOVEMIN TRIP
INDICATOR1
INDICATOR2
INDICATOR3
APHASE VOLTAGE
BPHASE VOLTAGE
CPHASE VOLTAGE
FREQUENCYTRIP
VOLTAGETRIP
METERING
RESET
TARGETS
EVENTS
LAMPTEST
MENU
ENTER
+
—
SETTINGS
OPER
COUNTER
ALARMS
CHANGE
F1 F2 F3 F4
TRIP CLOSE
HOT LINE TAG
ON
GND TRIP
BLOCKED
NON
RECLOSING
SUPERVISORY
OFF
ALTERNATIVE
PROFILE #1
ALTERNATIVE
PROFILE #2
ALTERNATIVE
PROFILE #3
RS-232DATA PORT
OPTION #1 OPTION #2 OPTION#3
(LOCKOUT)
INDICATOR4
INDICATOR5
INDICATOR6
INDICATOR7
INDICATOR8
CLOSE CIRCUIT
DISABLE
CONTROL WEIGHT 34 kg (75 lbs)
170
(6.75)
355 (14.0)
400 (15.75)
16 (.63) Dia.
Mounting Holes (2)
Grounding
Terminal
#14 To #4
Stranded
665
(26.25)
Right Side View
Lifting
Lugs
SHACKLE DIAMETER
.177-295"
SHACKLE DIAMETER
.295-.394"
Note: DO NOT use a smaller shackle (.177-
.295) in the larger diameter hole as it
will NOT LOCK the cabinet.
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Control Cable
The control cable is fabricated with connectors which mate
with the female receptacle of the recloser on one end, and
the male receptacle of the control or junction box on the
other end.
Note: The control cable must be supported along its length to
prevent repeated movement due to wind or other outside
forces which can damage the cable.
Limits on control cable lengths are determined by the
recloser type and the distance between the control and
recloser: See Table 3 for available Form 6 recloser control
cable lengths for Kyle reclosers.
Grounding the Control
The control cabinet must be grounded. A grounding
connector on the underside of the cabinet will accommodate
No. 14 solid through No. 4 stranded conductors.
Suggested methods for grounding the control and recloser
are shown in Figures 11 and 12.
Figure 11 illustrates grounding methods for 4-wire multi-
grounded systems with local supply voltage transformer.
Figure 12 illustrates grounding methods for 4-wire multi-
grounded systems with remote supply voltage transformer.
For effective surge protection, all control and power
conductors for the Form 6 control must be routed parallel
to a corresponding ground path. For example, the AC
power supply for the control should be parallel to and equal
in length to the transformer ground path. The control cable
should be parallel to and routed close to the recloser
ground path.
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
18
WARNING: Hazardous voltage. Recloser and
control must be solidly grounded. Follow all
locally approved procedures and safety practices when
grounding this equipment. Improper grounding can
result in contact with high voltage, which will cause
death or severe personal injury. G115.1
TABLE 3
Available Form 6 Control Cable Lengths for Kyle Reclosers
Recloser Type Gauge Length (Meters) Length (Feet)
WE, WVE27, WVE38X, VWE, VWVE27, VWVE38X;
Auxiliary-Powered NOVA15, NOVA27, and NOVA38 18 24.1 (maximum) 79 (maximum)
16 24.4 to 38 80 to 125
14 38.4 to 61 126 to 200
VSA12, VSA12B, VSA16, VSA20,
VSA20A, VSO12, VSO16 18 3.4 to 6 11 to 20
16 6.4 to 10.7 21 to 35
14 11 to 15.25 36 to 50
Control-Powered NOVA15,NOVA27, and NOVA38 16 3.4 to 38 11 to 125
WARNING: Hazardous voltage. Recloser and
control must be solidly grounded. Follow all
approved procedures and safety practices when
grounding this equipment. Improper grounding can
result in contact with high voltage, which will cause
death or severe personal injury. G115.1
IMPORTANT: All external inputs to the Form 6 recloser
control must be routed within 8 inches of their
corresponding ground. During a surge, a potential of
approximately 1.5 kV per foot can develop in the
conductors. Differences between conductor and ground
path lengths can add additional stress to the control
components in the event of a power surge.
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Installation of a Form 6 pole-mount recloser control with
a local supply voltage transformer must include the
following:
• Protection of the recloser bushings and the supplying
transformer with lightning arresters.
• Grounding of the recloser head and tank.
• Grounding of the transformer tank.
• Grounding of the control cabinet.
• Grounding of the SCADA equipment.
4-Wire Multi-Grounded Systems
S280-70-3
19
Surge
Arrester
Recloser
Head Ground
Surge
Arrester
Transformer
Surge
Arrester
Arrester Ground
Recloser
Pole
Supply
Voltage
Pole
Ground
Form 6
Control
Customer Ground Connection
At External Lug
NEU AC
GND
NEU
AC
Input
Terminal
Block
Control
Cable
AC
NEUTRAL
Form 6 Control
Supply Voltage
Transformer
ELECTRICAL CONNECTIONS
Line to Neutral connected transformer
Input Terminal
Block
External
Ground Lug
Figure 11.
Recommended grounding method for the Form 6 pole-mount recloser control installed on 4-wire multi-grounded,
with local supply voltage transformer.
IMPORTANT: All external inputs to the Form 6 recloser
control must be routed within 8 inches of their
corresponding ground. During a surge, a potential of
approximately 1.5 kV per foot can develop in the
conductors. Differences between conductor and ground
path lengths can add additional stress to the control
components in the event of a power surge.
IMPORTANT: In pole-mounted applications, a ground
connection must be made between the recloser,
transformer, recloser control, and SCADA equipment for
proper protection of the equipment. The pole ground
must be sized per local utility practices to minimize the
impedance between the recloser and the control.
Grounding with a Local Supply Voltage Transformer; 4-Wire Multi-Grounded
StockCheck.com

Installation of a Form 6 pole-mount recloser control with a
remote supply voltage transformer must include the
following:
• Protection of the recloser bushings and the supplying
transformer with lightning arresters.
• Grounding of the recloser head and tank.
• Grounding of the transformer tank.
• Grounding of the control cabinet.
• Grounding of the SCADA equipment.
Form 6 Microprocessor-Based Pole-mount Recloser Control Installation and Operation Instructions
20
Surge
Arrester
Recloser
Head
Ground
Supply
Voltage
Pole
Ground
Pole
Recloser
Pole
Surge
Arrester
Transformer
Arrester
Ground
Form 6 Control
HOT
NEU
GND
NEU
AC
Input Terminal Block
Control Cable
Surge
Arrester
Arrester
Ground
Customer Ground Connection
at External Lug
AC
NEUTRAL
Form 6 Control
Supply Voltage
Transformer
ELECTRICAL CONNECTIONS - Remote dedicated supply
transformer
Input
Terminal
Block
External
Ground Lug
Note: Distance between
transformer and
recloser should be
one pole span or
less
System
Neutral
Figure 12.
Recommended grounding method for the Form 6 recloser control installed on 4-wire multi-grounded with remote
supply voltage transformer.
Grounding with a Remote Supply Voltage Transformer; 4-Wire Multi-Grounded
IMPORTANT: All external inputs to the Form 6 recloser
control must be routed within 8 inches of their
corresponding ground. During a surge, a potential of
approximately 1.5 kV per foot can develop in the
conductors. Differences between conductor and ground
path lengths can add additional stress to the control
components in the event of a power surge.
IMPORTANT: In pole-mounted applications, a ground
connection must be made between the recloser,
transformer, recloser control, and SCADA equipment for
proper protection of the equipment. The pole ground
must be sized per local utility practices to minimize the
impedance between the recloser and the control.
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