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Eaton Cooper Power Series Installation And Operation Instruction Manual

Form 4d microprocessor-based pole-mount recloser control
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Reclosers
MN280049EN
Form 4D Microprocessor-based pole-mount recloser control
installation and operation instructions
Figure 1. Form 4D microprocessor-based pole-mount recloser control
Applicable to the following serial numbers:
Type KME4DPA control: serial number CP571231477
●
●
and above, applies to Form 4D control for use with W,
VS, and auxiliary-powered NOVA reclosers.
COOPER POWER
Effective September 2017
Supersedes January 2012 (S280-104-1)
Type KME4DPB control: serial number CP571231527
●
●
and above, applies to control-powered NOVA Form 4D
control for use with control-powered reclosers.
SERIES

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  • Page 1 COOPER POWER Reclosers SERIES Effective September 2017 MN280049EN Supersedes January 2012 (S280-104-1) Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Figure 1. Form 4D microprocessor-based pole-mount recloser control Applicable to the following serial numbers: Type KME4DPB control: serial number CP571231527 ●...
  • Page 2 CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES. In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or other-wise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to...

  • Page 3: Table Of Contents

    Contents DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY ........I SAFETY INFORMATION .
  • Page 4 Contents (continued) TESTINg ................36 Testing an installed control .

  • Page 5: Safety Information

    FOR LIFE FOR LIFE Eaton’s Cooper Power series 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 Eaton employees involved in product design, manufacture, marketing, and service.

  • Page 6: Product Information

    Transformer high-voltage primary windings Eaton’s Cooper Power series reclosers are designed and will become live when 120/240v AC is applied to the tested in accordance with applicable sections of the following ANSI standards: C37 .60 and C37 .85 and ANSI Guide C37 .61.

  • Page 7: Control Power

    Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions IMPORTANT IMPORTANT To avoid damage to the wiring or batteries, do not If the control shuts down due to low battery voltage transport the control with the batteries installed. before AC power is restored, and the connected energized recloser is CLOSED, no operations are possible until AC power is restored or the battery is replaced Control power...

  • Page 8: Theory Of Operation

    Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Theory of operation The front panel LCD display is used to configure the operating settings for the control. It is also used to display A functional block diagram of the Form 4D recloser control metering, counter information, control parameters, alarms, is shown in Figure 2.

  • Page 9: Control Front Panel

    Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions 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. 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 sequence after a preset time...
  • Page 10 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions The  (right) key is used to move right when editing ● ● parameters. FAULT ALARM The ESC (escape) key is used for the following tasks: ● ● Go up one Menu level. CONTROL OK ●...
  • Page 11 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions IMPORTANT PHASE FAULT The CLOSED LED will blink and a countdown-to-close ALARM timer will appear on the LCD display when a delayed CLOSE is active. A CLOSE will occur when the manual CONTROL OK close delay timer expires.
  • Page 12 VE MIN TRIP EDIT Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions DATA PORTS IMPORTANT The DATA PORTS section (Figure 7) on the front operating To enable or disable specific alarms, use the Proview panel allows for direct connection to a personal computer. KOUT NXG software to configure the alarms.
  • Page 13 LOCKOUT Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions OPEN DATA PORTS CLOSED IMPORTANT The Form 4D control operator panel one-touch function keys are illustrated in Figure 9. Hot Line Tag activation does not cause the recloser to trip open.

  • Page 14: Control Features

    Password recovery each protection profile. Cold Load Pickup also includes TCC If your password is lost, contact your Eaton representative. Multipliers, TCC Adders, Minimum Response Time, Reset Co-efficient, and High Current Lockout. Also, direct values,...
  • Page 15 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions its sequence from 2 fast and 2 delayed operations to 2 Ext. Close Request. ● ● operations on FTD TCC when Fast Trips Disabled is enabled. Phase Fault. ● ● Overcurrent Reset.
  • Page 16 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Over/underfrequency protection sampling data at user-programmable intervals. These time- stamped values can then be viewed to determine weekly The control includes six elements for underfrequency and load profiles, daily harmonic disturbances or hourly voltage overfrequency protection.

  • Page 17: Communications

    Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Communications release number. Control information is available through the NAMEPLATE DATA menu on the front panel (Figure 4). Communication ports Control side panel The Form 4D control has a front panel configuration data port and provisions for two optional side-panel The control side panel is easily accessible when the swing- communication ports (Figure 10).

  • Page 18: Control/Recloser Compatibility

    Form 4D recloser controls should be retrofitted with (ANSI C37 .61). Type B current transformers. All Eaton Cooper Power series Readout is based on a percentage of total duty cycle for reclosers manufactured since June 1989 are equipped with ●...

  • Page 19: Mounting The Control

    Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Mounting the control Using Table 2, select the appropriate recloser interrupting duty cycle factor and enter that value via the ProView NXG interface software. WARNINg Table 2. Duty cycle factor. This equipment is not intended to protect human life.

  • Page 20: Control Cable

    The control cable should be type. See Table 3 for available Form 4D recloser control parallel to and routed close to the recloser ground path. cable lengths for Eaton’s Cooper Power series reclosers. Grounding with a local supply voltage IMPORTANT transformer;...
  • Page 21 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Surge Transformer Arrester Surge Supply Voltage Arrester Surge Form 4D Control Input Terminal Arrester Block TB1 Transformer Recloser NEUTRAL Head Ground External Ground Lug Supply Arrester Ground Voltage ELECTRICAL CONNECTIONS Line to Neutral connected transformer WARNINg Recloser...

  • Page 22: Customer Connections For Ac Power

    Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Supply Voltage Input Form 4D Control Terminal Block TB1 Transformer NEUTRAL External Ground Lug ELECTRICAL CONNECTIONS - Remote dedicated supply transformer Surge Transformer Surge Arrester Surge Arrester Arrester Recloser Head Ground Arrester Ground...
  • Page 23 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Input power to the Form 4D pole-mount recloser control The charger includes a temperature-compensated design to is connected to terminal block TB1 or AC input receptacle optimally charge the control battery. if provided.
  • Page 24 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions otee: The Form 4D control only displays Line-to-Neutral Refer to Service Information S280-104-2 Form 4D Microprocessor-Based Recloser Control Programming Guide voltages regardless of the system connection. for additional information. Figure 14. 120 or 240 vAC 2-wire control power input (shown with default factory wiring connected to B-phase voltage metering with B-phase incoming supply) operation inStrUCtionS MN280049EN September 2017...
  • Page 25 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Figure 15. 120 or 240 vAC 2-wire with ground control power input (shown with default factory wiring connected to B-phase voltage metering with B-phase incoming supply) operation inStrUCtionS MN280049EN September 2017...
  • Page 26 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Figure 16. 120/240 vAC 3-wire center-tapped PT control power input (shown with default factory wiring connected to B-phase voltage metering with B-phase incoming supply) operation inStrUCtionS MN280049EN September 2017...
  • Page 27 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Remove the factory jumper wires from L1 to V2+ and N to V2- for separate control otee: power and voltage sensing inputs. Figure 17. Three-phase Wye voltage sensing (shown with default factory wiring connected to B-phase voltage metering with B-phase incoming supply) operation inStrUCtionS MN280049EN September 2017...
  • Page 28 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Figure 18. Three-phase Delta voltage sensing (shown with default factory wiring connected to B-phase voltage metering with B-phase incoming supply). The Form 4D control only displays Line-to-Neutral voltages regardless of the system connection operation inStrUCtionS MN280049EN September 2017...

  • Page 29: Customer Connections For Contact I/O Module

    Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Customer connections for contact i/o NOTICE module option External leads must be shielded and the shield must be grounded at both ends. Terminate each lead with a 320 vAC, 150 Joules metal oxide resistor (MOv), or CAuTION equivalent, at the remote end.
  • Page 30 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions NOTICE External leads must be shielded and the shield must be grounded at both ends. Terminate each lead with a 320 vAC, 150 Joules metal oxide resistor (MOv), or equivalent, at the remote end. Attach MOvs between the leads and ground.

  • Page 31: Before Placing Control And Recloser Into Service

    Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Table 4. Contact I/O option module input ratings Minimum Detection Level: 10 V (AC rms or DC) (50 or 60Hz) (Using control-supplied whetting Voltage is recommended) Maximum Applied Voltage: 250 VAC, rms, or 125 VDC Nominal Input Loading: 2 mA per input (internally current limited) Typical Control Response Time:...
  • Page 32 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Prior to placing the control and recloser into service, “ATTENTION – 3” indicates Battery Test the following installation procedures must be properly Currently Running completed and verified: “ATTENTION – 4” indicates Battery Test Front panel label inserts changed (if applicable).

  • Page 33: Accessories

    KME4D-1775-F, and KME4D-1775-G low voltage closing receptacles. Replace X with desired length. Select from 10 to 80 feet. *Low-voltage closing receptacles are only applicable to Eaton’s Cooper Power series auxiliary and line-powered reclosers with 14-pin connection (WE,WVE27 , WVE38X, VWE, VWVE27 , VWVE38X, VSA12, VSA12B, VSA16, VSA20, VSA20A, VSO12, VSO16, NOVA15, NOVA27 , NOVA38).
  • Page 34 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions DANgER WARNINg Hazardous voltage. Do not connect potential Hazardous voltage. Before applying power to the transformer low-voltage secondaries to the control control, confirm that male pins of the input power through cables or other wiring until the unit is installed receptacle are electrically insulated to prevent in the field.
  • Page 35 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions DANgER WARNINg Hazardous voltage. Do not connect potential Hazardous voltage. Before applying power to the control, transformer low-voltage secondaries to the control confirm that male pins of the input power receptacle are through cables or other wiring until the unit is installed electrically insulated to prevent unintentional contact in the field.
  • Page 36 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions WARNINg DANgER Hazardous voltage. Before applying power to the control, Hazardous voltage. Do not connect potential confirm that male pins of the input power receptacle are transformer low-voltage secondaries to the control electrically insulated to prevent unintentional contact through cables or other wiring until the unit is installed with 120/240v AC voltage.

  • Page 37: Cable Locking Sleeves

    Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Cable locking sleeves 120 VAC GFI Duplex outlet To prevent detachment of the control cable from the control The GFI Duplex Outlet (Catalog Number KME4D-1776) cabinet by unauthorized personnel, a cable-locking sleeve is available for controls powered by 120 VAC or 240 VAC (Catalog Number KME4D-1772-X [replace X with quantity: three-wire supply power.

  • Page 38: Communication Board Accessories

    ● connector options supporting both single- and multi-mode. Ethernet fiber, MTRJ Serial, RS-232 Additional accessories are being continuously developed. Contact your Eaton representative for the latest information regarding particular media and communication protocol support. Ethernet fiber, LC Serial, RS-485 Ethernet fiber, SC Serial fiber, ST Figure 26.
  • Page 39 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Table 11. Communication support equipment Description Catalog number USB cable, Type A male-to-Type B male KME4D-66 connectors, 2 meters (6.5 ft.) length RS-232 serial communication card The RS-232 Serial communication card accessory provides means for establishing asynchronous link-based digital communications with the Form 4D pole-mount control.
  • Page 40 (TX) ports operating at 820nm. Typical transmission distance is 2000m with 62.5/125µm multi-mode fiber. Consult your Eaton representative for availability of long haul solutions. Link communication speed is controlled through software and can be set at: 1200, 2400, 4800, 9600, 19.2k, and 38.4k.

  • Page 41: Testing

    Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Testing Table 14. Ethernet communication card configurations Type Card Output Communication configurations connectors speed CAuTION 10/100 Base-T (wired) RJ-45 10/100MBps (auto-switching) Equipment misoperation. Do not connect this control to an energized recloser until all control settings have 100 Base-FX (multi-mode fiber) MT-RJ 100MBps...

  • Page 42: Remove The Control From Service

    Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Press the down arrow button to scroll to the Test backlight on and restore all LEDs to their current on/ Battery command. Press the ENTER button. off states. The following message will appear: 082 Test All other tests described in this TESTINg section require the Battery (CONFIRM).

  • Page 43: Preliminary Testing With No Ac Available

    Recloser Control Tester Operating Instructions for proper recessed inside the control side panel (Figure 36). setup and use of the MET Tester. Figure 37. Eaton’s Cooper Power series Type MET Figure 36. Location of push-button switch on the Form electronic recloser control tester...

  • Page 44: Closing The Recloser During Testing

    Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Malfunction diagnostic, go to Function Code 80 Solidly ground all equipment. Failure to comply can result in death, severe personal injury, and Reset Targets and press the ENTER button two times equipment damage.
  • Page 45 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Variable 115Vac Autotransformer (10 Amp) 600:5 Recloser BCT ON 600:5 Tap Clamp-On Ammeter Note: This test circuit can apply over 800 Amps to the recloser. Note: Use at least 2/0 cable between bushings.
  • Page 46 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Electrical closing – motor-operated low voltage Manual closing – solenoid-operated reclosers closing solenoid/nova reclosers WARNINg WARNINg Explosion Hazard. Excessive Contact Arcing. Do not use the manual closing tool to close an oil-insulated energized Hazardous voltage.

  • Page 47: Battery Test And Charging Procedures

    Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Battery test and charging procedures Alarm conditione: During a battery test a 5Ω, 55 watt resistor is placed ● ● across the battery terminals for approximately 5 seconds. Test procedure for installed battery The Form 4D control measures the battery voltage, if View battery information and test battery operation as the voltage drops below 22.8 VDC the BATTERY LED...
  • Page 48 Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Battery charging This procedure applies to a control with one or two batteries. If it is not possible to charge the battery with the control’s built-in charger, a KME5-60-1 (120 VAC) portable bench Follow all locally approved safety procedures.

  • Page 49: Return The Control To Service

    Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Return the control to service If there are two batteries, remove the top battery and dual battery wire assembly. Otherwise, proceed to the After the required work is completed, proceed as next step.

  • Page 50: Remove Existing Module

    Form 4D Microprocessor-based pole-mount recloser control installation and operation instructions Tilt back, but do not remove, the module from the Slide the new insert(s) into the module and align so the swing panel (Figure 47). text and LED slots are oriented in the window opening on the front panel.

  • Page 51: Install Module

    United States to provide maintenance, to an energized recloser until all control settings have repair and testing services for Eaton’s Cooper Power series been properly programmed and verified. Refer to the controls and reclosers. For further information, contact your programming information for this control.
  • Page 52 Waukesha, WI 53188 United States Eaton.com/cooperpowerseries © 2017 Eaton All Rights Reserved Printed in USA Eaton is a registered trademark. For Eaton’s Cooper Power series product Publication No. MN280049EN information September 2017 call 1-877-277-4636 or visit: All trademarks are property www.eaton.com/cooperpowerseries.

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