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Cooper S280-79-10 Install And Operation Instructions

Microprocessor-based recloser controls
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Reclosers
Kyle
®
Form 5, Form 5 UDP, Form 5 DC NOVA
Microprocessor-Based Recloser Controls
Installation and Operation Instructions
Applicable to serial numbers above 3000 or beginning with CP57.
Figure 1.
Kyle
®
Form 5/UDP microprocessor-based recloser control.
Contents
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 2
Product Information . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ANSI Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Quality Standards . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Acceptance and Initial Inspection . . . . . . . . . . . . . . 3
Handling and Storage . . . . . . . . . . . . . . . . . . . . . . . 3
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . 3
Control Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Initializing the Control . . . . . . . . . . . . . . . . . . . . . . . 4
Form 5 Control Description . . . . . . . . . . . . . . . . . . 5
Discrete Interface (DIF) Module . . . . . . . . . . . . . . . 6
Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . 6
Form 5 Control Operator Panel . . . . . . . . . . . . . . . 7
Battery Test Procedure . . . . . . . . . . . . . . . . . . . . . . 14
Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Auxiliary Power for Accessories . . . . . . . . . . . . . . 20
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
November 2001 • Supersedes 1/01
Printed in USA
. . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . 22
S280-79-10
Discrete Interface (DIF) Accessory . . . . . . . . . . . . 23
Customer Connection Information . . . . . . . . . . . . . 23
Standard and UDP Module 2 Inputs . . . . . . . . . . . . 29
Standard and UDP Module 2 Outputs . . . . . . . . . . 30
Input Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . 32
Control / Recloser Compatibility . . . . . . . . . . . . . . . 32
Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Mounting the Control . . . . . . . . . . . . . . . . . . . . . . . 33
Grounding the Control . . . . . . . . . . . . . . . . . . . . . . 34
Customer Connections for AC Power . . . . . . . . . . . 38
Customer Connections for Metering . . . . . . . . . . . . 38
Testing and Troubleshooting . . . . . . . . . . . . . . . . 43
Testing an Installed Control . . . . . . . . . . . . . . . . . . 43
Testing with Type MET Tester . . . . . . . . . . . . . . . . 43
Closing the Recloser During Testing . . . . . . . . . . . 44
Remove the Control from Service . . . . . . . . . . . . . 55
Return the Control to Service . . . . . . . . . . . . . . . . 55
Additional Information . . . . . . . . . . . . . . . . . . . . . . 56
Service Information
99001KM
1

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Summary of Contents for Cooper S280-79-10

  • Page 1: Table Of Contents

    Discrete Interface (DIF) Module ....6 Power Supply Module ..... . . 6 Form 5 Control Operator Panel .

  • Page 2: Safety Information

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

  • Page 3: Product Information

    SAFETY FOR LIFE PRODUCT INFORMATION Introduction Service Information S280-79-10 provides installation and operation instructions for the Kyle Form 5 and Form 5 UDP microprocessor-based electronic recloser controls. Read This Manual First Read and understand the contents of this manual and fol- low all locally approved procedures and safety practices before installing or operating this equipment.

  • Page 4: Initializing The Control

    If the control is equipped with the standard 24 Vdc lead- acid battery, the control maintains full operation from the battery power supply for a minimum of 32 hours at 20°C (24 hours at -40°C). To prevent battery damage, the con- trol shuts down automatically upon detection of low bat- tery voltage below 22.7 Vdc.

  • Page 5: Form 5 Control Description

    POWER SUPPLY P.T. INPUTS OPTICAL OPERATOR'S ISOLATION OPTICAL OPTICAL ISOLATION ISOLATION OPTICAL ISOLATION MATCHING TRANSFORMERS AND SIGNAL CONDITIONING OPTIONS S280-79-10 BATTERY DIF#2 DIF#1 PANEL (OPTIONAL) (OPTIONAL) KEYBOARD LED's RS232 PORT RS232 FIBER-OPTIC USER USER PORT CONNECTIONS CONNECTIONS 6 unlatched outputs...

  • Page 6: Recloser Interface (Rif) Module

    See DISCRETE INTERFACE (DIF) ACCESSORY sec- tion of this manual. Power Supply Module The Power Supply module is designed to accept 100 to 134 Vac or 200 to 268 Vac user-supplied input power at either 50 or 60 Hz. The Power supply module (connection P9) provides aux- iliary power to radio communications units, RTUs and other accessories.

  • Page 7: Form 5 Control Operator Panel

    TB1. Refer to the Customer Con- nections for AC Power section in these instructions to determine the appropriate power connections. RECLOSER CLOSED This red indicator is illuminated when the control senses that the recloser mechanism is in the closed position. S280-79-10...
  • Page 8 Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions RECLOSER OPEN This green indicator is illuminated when the control senses that the recloser mechanism is in the open position. CONTROL LOCKOUT This green indicator is illuminated when the recloser is open and a reclosing sequence is not in progress or when the lockout handle on the recloser mechanism is in the down position;...
  • Page 9 Ph5-6 Dif ____________ V Screen 11 – Real Power 11 Tot ____________ kW Ph1-2 ____________ kW Ph3-4 ____________ kW Ph5-6 ____________ kW Screen 12 – Instantaneous kVA 12 Tot ____________ kVA Ph1-2 ____________ kVA Ph3-4 ____________ kVA Ph5-6 ____________ kVA S280-79-10...
  • Page 10 Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions Screen 13 – Instantaneous kVAR 13 Tot ____________ kVAr Ph1-2 ____________ kVAr Ph3-4 ____________ kVAr Ph5-6 ____________ kVAr Screen 14 – Instantaneous Power Factor 14 Tot ____________ PF Ph1-2...
  • Page 11 Screen 34 – Ground Max, Phase 1-2 Max Demand Currents 34 Gnd Max ____________A Time Date Ph1-2 Max ____________A Time Date Screen 35 – Phase 3-4 Max, Phase 5-6 Max Demand Currents 35 Ph 3-4 Max ____________A Time Date Ph5-6 Max ____________A Time Date S280-79-10...
  • Page 12 Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions Screen 36 – Ground Min, Phase 1-2 Min Demand Currents 36 Gnd Min ____________A Time Date Ph1-2 Min ____________A Time Date Note: Demand currents are a time integrated value and do not reflect minimum or maximum instantaneous currents.
  • Page 13 SCADA command. For SCADA, Hot Line Tag must be disabled via the same port number where Hot Line Tag was origi- nally enabled. HOT LINE Figure 8. Hot Line Tag Switch. S280-79-10 T276.0...

  • Page 14: Battery Test Procedure

    Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions RS-232 Communication Port The standard Form 5 control is equipped with a operator panel RS-232 port for interface with a personal computer running the Form 5 interface software program. This nine- pin female data communication equipment (DCE) Port 1 permits the uploading of all programming information stored in the control, including protection profiles, event...
  • Page 15 When the trip failure alarm is activated, an event is recorded and a status alarm activated (if enabled) and T271.0 preserved during system resets. To test the Trip Failure Detection feature, see Testing With Type MET Tester in the TESTING AND TROU- BLESHOOTING section of this manual. G112.1 S280-79-10...
  • Page 16 Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions Manual Close Delay Manual Close Delay provides a delay from the time that the manual CLOSE button is pushed to the time the man- ual close operation is performed.
  • Page 17 IMPORTANT: Fault Location is not a protection func- tion. Its purpose is to define a fault and provide its approximate location relative to the Form 5 control detecting the fault. Refer to Service Information S280-79-2 Form 5 Micropro- cessor-Based Recloser Control Programming Guide for additional information. S280-79-10...
  • Page 18 Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions Directional Sensitive Ground/Earth (SGF/SEF) Fault The Directional SGF/SEF Fault feature adds directional capabilities to the SGF/SEF protection features. It pro- vides a sensitive ground/earth trip if the fault is downline of the recloser on a radial distribution system.

  • Page 19: Communications

    LCD display, Screen 39. Communication Ports 2 and 3 settings can be referenced from the LCD display, Screens 40 and 41 respectively. (Port 1 shares the same settings as Port 2.) S280-79-10 TX 3 TX 2 RS232 RX 3...

  • Page 20: Auxiliary Power For Accessories

    Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions AUXILIARY POWER FOR ACCESSORIES Connection P9 (Figure 18) on the Power Supply module provides 24Vdc (12Vdc is available) to power radio com- munication units, RTUs and other accessories. The auxil- iary power provides 40W peak load capability.

  • Page 21: Form 5 Universal Device Protection (Udp)

    UDP accessory. Figure 21. Interface software Switch Mode settings. FAST TRIPS MODE Figure 22. Form 5/UDP Operator Panel. S280-79-10 CONTROL OK AC POWER ABOVE MIN TRIP CHECK BATTERY RECLOSER MALFUNCTION REVERSE POWER FLOW BUSHINGS 1-2 FAULT TARGET...

  • Page 22: Form 5 Dc Nova Control

    Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions FORM 5 DC NOVA CONTROL The Kyle Form 5 recloser control can be equipped with a dc-to-dc converter, interface circuit, and a fully shielded 19-pin cable for use with a Type DC NOVA recloser.

  • Page 23: Discrete Interface (Dif) Accessory

    28V (+) OUTPUT COMMON Note: Wiring to P5-2 and P5-3 can be reversed if necessary. Inputs 1 thru 12 Figure 26. Customer connections for supplying whetting volt- age to DIF inputs. S280-79-10 G117.3 28V (–) 28V (+) WHETTING VOLTAGE UNLATCHED OUTPUTS...
  • Page 24 Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions FORM 5 CONTROL *28 Vdc (nominal) supplied by DIF module for whetting voltage. SUPERVISORY BLOCKED COLD LOAD PICKUP BLOCKED NON-RECLOSING NORMAL PROFILE ALTERNATE PROFILE 3 ALTERNATE PROFILE 2 Discrete Interface Module (DIF)
  • Page 25 Input Protection: ....Shunting type using MOVs and capacitors Standard and UDP Controls Standard and UDP Form 5 control DIF inputs and outputs are described in the following pages. (50 or 60Hz) 10 Vdc (50 or 60Hz) 175 Vdc Opto Isolation from input to system. S280-79-10...

  • Page 26: Standard And Udp Dif Module 1 Inputs

    Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions Standard and UDP Control DIF Module 1 The DIF inputs are factory-configured as momentary (0.25 sec. duration) or maintained functions. Supervisory signals do not have any effect when supervisory blocked is active. Remote inputs function when supervisory is blocked. Input Connector P4-1...
  • Page 27 It can be used for tripping from external relays and alarms. A momentary signal is required for proper operation. This input performs the same function as the TRIP (LOCKOUT) switch on the operator panel and is active regardless of the state of the Supervisory function. S280-79-10 Description...

  • Page 28: Standard And Udp Dif Module 1 Outputs

    Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions Standard and UDP Control DIF Module 1 The 12 outputs of the DIF Module are Form C relay contacts. Six of the outputs are latching and six are non-latching. Note: Contacts shown in inactive mode.

  • Page 29: Standard And Udp Module 2 Inputs

    This is a momentary function. This input is active with a momentary whetting voltage and causes the control to block, or unblock sensitive ground fault operations. The input is inactive if the Supervisory function is disabled. S280-79-10...

  • Page 30: Standard And Udp Module 2 Outputs

    Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions Standard and UDP Control DIF Module 2 The 12 outputs of the DIF Module are Form C relay contacts. Six of the outputs are latching and six are non-latching. Note: Contacts shown in inactive mode.

  • Page 31: Input Accuracy

    Accuracy: ± 3 mA from 10 mA to 125 mA 2.4% from 125 mA to 1600 mA INPUT ACCURACY Sensed Source Voltages Three-phase voltages used in voltage, power and power- factor related calculations: Voltage measurement accuracy: ± 0.4V from 5V to 80V 0.5% from 80V to 135V S280-79-10...

  • Page 32: Installation Procedure

    Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions INSTALLATION PROCEDURE Initial Programming Prior to Installation CAUTION: Equipment Misoperation. Do not connect this control to an energized recloser until all control settings have been properly programmed and verified.

  • Page 33: Mounting The Control

    Handle For User- Provided Utility-Grade Padlock 110mm 350mm (4-3/8") (13-13/16") 165mm (6-1/2") 52 kg (115 LBS) S280-79-10 120mm (4-3/4") 45mm (1-3/4") Dia. Hole For Automation Accessory (Cap-Plug Installed) Mtg Hole For 15mm (5/8") Max Bolt Dia.* 480mm (19") * USER-PROVIDED HARDWARE 40mm (1-1/2")

  • Page 34: Grounding The Control

    For effective surge protection all control and power con- ductors for the Form 5 must be routed parallel to a corre- sponding ground path. For example, the AC power supply for the control should be parallel to and equal in length to the transformer ground path.
  • Page 35 Form 5 LS Control NEUTRAL Form 5 LS Input Terminal Control Block Input Terminal Block Customer Ground Connection At External Lug S280-79-10 Form 5 LS Control Input Terminal Block NEUTRAL External Ground Lug ELECTRICAL CONNECTIONS Supply Voltage Transformer Line Line...
  • Page 36 Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions Grounding with a Remote Supply Voltage Transformer; 4-Wire Multi-Grounded, 3-Wire Ungrounded, or Impedance-Grounded Installation of a Form 5 control with a remote supply volt- age transformer must include the following: •...
  • Page 37 Control Height must be 3 Meters (10 feet) minimum above earth T264.0 Figure 31. Recommended grounding method for the Form 5 Control installed on a 3-wire uni-grounded system. S280-79-10 Input Terminal Block Form 5 LS Control Neutral External Ground Lug Transformer Surge...

  • Page 38: Customer Connections For Ac Power

    Incoming power is routed to the Power Supply module which is factory configured for either 120 or 240 volt oper- ation. The power supply module is factory wired to TB-1 and protected by the 3.15 Amp fuse labeled F2 on the power supply operator panel.
  • Page 39 NEU (LV Closing Output) NEUTRAL OUTPUT *NEUTRAL CØ CØ CUSTOMER BØ SOURCE 1 *BØ CONNECTIONS POWER AØ AØ *REQUIRED FOR CONTROL OPERATION AØ BØ CØ HOT (LV Closing Output) HOT (LV Closing Output) CØ BØ AØ S280-79-10 AØ BØ CØ...
  • Page 40 SOURCE 1 *AØ CONNECTIONS POWER *REQUIRED FOR CONTROL OPERATION SEE POWER SUPPLY MODULE FOR CORRECT VOLTAGE Figure 36. Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1 (120Vac or 240Vac Open-Delta Connection).
  • Page 41 **Jumper necessary for use with Low-Voltage Closing Accessory Figure 39. Form 5 and Form 5 UDP Power and Low Voltage Closing customer connections to terminal block TB1 (Single- Phase Connection, AØ Input). GDC-3.15A CONFIGURED Jumper** BØ GDC-3.15A CONFIGURED Jumper** AØ S280-79-10 BØ AØ...

  • Page 42: Before Placing Control And Recloser Into Service

    Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions Before Placing the Control and the Recloser into Service CAUTION: Equipment misoperation. Do not connect this control to an energized recloser until all control settings have been properly pro- grammed and verified.

  • Page 43: Testing And Troubleshooting

    Kyle Type MET tester CALIBRATE switch is ON. Depress and hold the RESET TARGET keypad on the control for 3 seconds to reset the condition. Figure 41. Kyle Type MET electronic recloser control tester. S280-79-10 99002KM 010028KM...

  • Page 44: Closing The Recloser During Testing

    The electronic inter- face circuit controls the opening and closing signals to the magnetic actuator. The Dc NOVA Recloser is tested with the dc-to-dc con- verter and 19-pin cable connected to the dc power supply. Sensing CTs (3) Closing Motor...
  • Page 45 LOAD SIDE DISCONNECT SWITCHES (OPEN) CLOSING SENSING CTs (3) SOLENOID CONTACTOR ROTARY SOLENOID CLOSING SOLENOID COIL S280-79-10 MAIN CONTACTS (S) TRIP SOLENOID CONTROL CABLE RECEPTACLE AMMETER AND RELAY TO ELECTRONIC OPERATE CYCLE COUNTER CONTROL OR OTHER TIMING DEVICE 120 VAC...
  • Page 46 Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions Manual Closing—Solenoid-Operated Reclosers WARNING: Explosion Hazard. Excessive Con- tact Arcing. Do not use the manual closing tool to close an oil-insulated, energized recloser. Closing an energized oil-insulated recloser with a manual closing tool can cause excessive contact arcing, rapid build-up of gas within the equipment, and possible explosion...

  • Page 47: Form 5 Control Default Test Procedure

    The control will then lock out on the delayed TCC curves. Note: If the Form 5 control has Switch Mode rather than Pro- file 3, the control will indicate current Above Minimum Trip, but will not trip out. S280-79-10...
  • Page 48 Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions Test Ground Minimum Trip Values 1. Change the Form 5 control from an Alternate Profile to the Normal Profile (all three Profile LEDs are off). Dis- able Ground Trip Block (LED off).
  • Page 49 3. Adjust fault current to 200 percent or 200 mil- liamperes. 4. Set KMET test set Fault Current Switch S2 to fault position. 5. After trip, turn fault switch S2 off. 6. Record reclose time. 7. Repeat steps 2 – 6 until control locks out. S280-79-10...
  • Page 50 Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions Test Close Circuit Disable Fuse This test is only applicable to Form 5 LS controls and stan- dard Form 5 controls below Serial Number 3000. 1.
  • Page 51 Phase B 5X Phase C 10X Phase A 2X Phase B 5X Phase C 10X Phase A 2X Phase B 5X Phase C 10X S280-79-10 2.6 Volts 28.0 2.6 MA 2.6 volts 24.2 Phase B Amps Phase C Amps 100.3 100.7...
  • Page 52 Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions Form 5 Control Default Test Optimal Values Trip Sequence Ground Timing Normal Profile #1 Profile #2 Profile #3 Enabled Non-Reclose Disabled 8. Cold Load Block Off PickUp Blocked Block On...
  • Page 53 Phase C 10X Phase A 2X Phase B 5X Phase C 10X Phase A 2X Phase B 5X Phase C 10X S280-79-10 2.6 Volts 2.6 MA 2.6 volts Phase B Amps Phase C Amps Phase B Amps Phase C Amps...
  • Page 54 Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions Form 5 Control Default Test Sheet Trip Sequence Ground Timing Normal Ground 10X Profile #1 Profile #2 Profile #3 Enabled Non-Reclose Disabled 8. Cold Load Block Off PickUp Blocked Block On...

  • Page 55: Remove The Control From Service

    LED indicator will not be illu- minated indicating GROUND TRIP BLOCKED is not active. 6. Reset the control clock after AC power has been re- applied. Refer to Setting the Control Clock in Service Information S280-79-2 Form 5 Microprocessor-Based Recloser Control Programming Guide. S280-79-10 G110.3...

  • Page 56: Additional Information

    Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions ADDITIONAL INFORMATION CAUTION: This equipment requires routine inspection and maintenance to ensure proper operation. If it is not maintained, it can fail to operate properly.

This manual is also suitable for:

Kyle form 5Form 5 udpForm 5 dc nova

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