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Cooper Lighting S280-79-10 - page 1
Printed in USA Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 2 Product Information . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ANSI Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Quality Standards . . . . . . . . . . . . . . ...
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Cooper Lighting S280-79-10 - page 2
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions 2 The instructions in this manual are not intended as a sub- stitute for proper training or adequate experience in the safe operation of the equipment described. Only compe- tent technicians who are familiar with this equipment should install, operate, ...
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Cooper Lighting S280-79-10 - page 3
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 thi ...
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Cooper Lighting S280-79-10 - page 4
AC Reclosers Power to operate the tripping and closing solenoids in the recloser is provided by the power capacitor located behind the operator panel of the control. A sealed, 24-volt, lead acid battery is located in the lower portion of the con- trol cabinet and is utilized to provide operating and trip- ping energy when AC power is temporarily lo ...
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Cooper Lighting S280-79-10 - page 5
Current sensing is provided by three current transformers located in the recloser and interfaced to the Form 5 control via the control cable. This cable also supplies Trip, Close, and Recloser status, and connects to the Recloser Inter- face (RIF) module to provide isolation for reliable opera- tion. Voltages for metering are also connected to the ...
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Cooper Lighting S280-79-10 - page 6
The Form 5 control is constructed in a modular fashion to simplify service and the addition of accessories (Figure 4). The standard configuration incorporates a Central Processing Unit (CPU) module, power supply module, Recloser Interface (RIF) module, and an operator panel. Discrete Interface (DIF) module(s), the fiber-optic board and the RS-232 c ...
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Cooper Lighting S280-79-10 - page 7
For m 5 Contr ol Operator Panel The Form 5 control operator panel (Figure 8) allows local operation and status interrogation through built-in operator controls and status displays. The operator panel contains LED indicators, operational pushbuttons, membrane-type functional/indication switches, backlit LCD display, and Hot Line Tag switch with indi ...
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Cooper Lighting S280-79-10 - page 8
RECLOSER OPEN This green indicator is illuminated when the control senses that the recloser mechanism is in the open position. CONTROL LOCKOUT This green indicator is illuminated when the recloser is open and a reclosing sequence is not in progress or when the lockout handle on the recloser mechanism is in the down position; i.e., trip and close ci ...
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Cooper Lighting S280-79-10 - page 9
LCD Display Screens Every LCD display screen contains a parameter name, parameter value, and parameter units. If the control detects that a parameter value is invalid, the LCD display shows five dash characters (- - - - -) in the value field of the screen. Demand metered values are indicated by (D) and instantaneous values by (I). S280-79-10 9 ! SA ...
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Cooper Lighting S280-79-10 - page 10
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions 10 1 4 T o t ____________ P F Ph1-2 ____________ P F Ph3-4 ____________ P F Ph5-6 ____________ P F 1 5 G n d ____________ %THDI Ph1-2 ____________ %THDI Ph3-4 ____________ %THDI Ph5-6 ____________ %THDI 16 Instant S1 Ph-N Ph1-N ____________ %THDV Ph3-N ...
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Cooper Lighting S280-79-10 - page 11
S280-79-10 11 ! SAFETY FOR LIFE 2 5 T o t ____________ kVAr Ph1-2(d) ____________ kVAr Ph3-4(d) ____________ kVAr Ph5-6(d) ____________ kVAr 2 6 T o t ____________ P F Ph1-2(d) ____________ P F Ph3-4(d) ____________ P F Ph5-6(d) ____________ P F 2 7 G n d ____________ %THDI Ph1-2(d) ____________ %THDI Ph3-4(d) ____________ %THDI Ph5-6(d) __________ ...
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Cooper Lighting S280-79-10 - page 12
Operation/Indication Pushbuttons Nine frequently used features are provided on the control operator panel (Figure 7). Note: These features are activated from the keypad, control interface software or SCADA signal. To initiate an operation from the operator panel, press the CHANGE/LAMP TEST key to enter the CHANGE mode. The operator has 10 seconds t ...
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Cooper Lighting S280-79-10 - page 13
NON RECLOSING Non-reclosing mode disables any automatic reclosing operations. Non-reclosing does not alter the active TCC. The feature is activated by pressing the CHANGE/LAMP TEST key, then pressing the NON RECLOSING key. The red indicator illuminates. SUPERVISORY BLOCKED Supervisory Blocked disables supervisory SCADA and the interface software; r ...
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Cooper Lighting S280-79-10 - page 14
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 pro ...
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Cooper Lighting S280-79-10 - page 15
Power Metering Power metering includes single- and three-phase Watts, VARS, KVARS, KWH measurements, and the per phase and total system Power Factor (PF). Power Factor Sign Metering This feature allows a user to configure the sign that is applied to the power factor. The user may select between the standard definition of power factor (cosine of ang ...
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Cooper Lighting S280-79-10 - page 16
Manual Close Delay Manual Close Delay provides a delay from the time that the manual CLOSE button is pushed to the time the man- ual close operation is performed. The delay is programmable from 0 to 60 seconds in 1 sec- ond increments. A programmed delay value can be over- ridden for immediate closing by pressing the CLOSE button a second time. An ...
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Cooper Lighting S280-79-10 - page 17
Alarms Status and data alarms are available for many control parameters such as voltage, currents, thresholds. Data alarm function compares metered data to user-pro- grammed alarm high and low limits and issues an alarm of user-specified priority if limits are exceeded. The status alarm function monitors status and issues an alarm of user-defined p ...
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Cooper Lighting S280-79-10 - page 18
Directional Sensitive Gr ound/Ear th (SGF/SEF) Fault The Directional SGF/SEF Fault feature adds directional capabilities to the SGF/SEF protection features. It pro- vides a sensitive ground/earth trip if the fault is downline of the recloser on a radial distribution system. Directional SGF/SEF is used on ungrounded Delta systems for sup- pression o ...
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Cooper Lighting S280-79-10 - page 19
Communications Communication Ports The Form 5 control has three communication ports from the CPU module. Two of the three ports are user-acces- sible. Communication Port 1 is the operator panel LCD display where data is exchanged between the CPU and the operator panel. Though not user-configurable, Port 1 allows for flexible modifications to the fr ...
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Cooper Lighting S280-79-10 - page 20
AUXILIAR Y POWER FOR ACCESSORIES Connection P9 (Figure 18) on the Power Supply module provides 24Vdc (12Vdc is available) to power radio com- munication units, RTUs and other accessories. The auxil- iary power provides 40W peak load capability. Auxiliary power is fused and current-limited to prevent user loads from disabling the control. Customer 2 ...
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Cooper Lighting S280-79-10 - page 21
The UDP function allows the Form 5 control to become a switch control to provide indication of overcurrent trip con- ditions without issuing an overcurrent trip signal . The con- trol is in the recloser mode when the feature is in the OFF position, and in the switch mode when the feature is ACTIVE. While in the switch mode, all automatic open and c ...
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Cooper Lighting S280-79-10 - page 22
The Kyle Form 5 recloser control can be equipped with a dc-to-dc converter, interface circuit, and a fully shielded 19-pin cable for use with a Type DC NOVA recloser. See Figure 23. The dc-to-dc converter board (Figure 24) converts the con- trol ’ s 24 Vdc battery supply voltage to 53 Vdc to drive the trip/close capacitors in the NOVA mechanism. ...
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Cooper Lighting S280-79-10 - page 23
S280-79-10 23 ! SAFETY FOR LIFE DISCRETE INTERF ACE (DIF) ACCESSOR Y The Discrete Interface (DIF) module accessory (Figure 25) permits connection of contact-type input devices (switches, relays) and discrete indicating devices (relays, LEDs, lamps) to the Form 5 control to effect local discrete input/output (I/O). The DIF module accessory is used f ...
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Cooper Lighting S280-79-10 - page 24
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions 24 R R FORM 5 CONTROL Remote Terminal Unit (RTU) NORMAL PROFILE NON-RECLOSING COLD LOAD PICKUP BLOCKED INPUT COMMON SUPV. CLOSE SUPV. TRIP & L.O. Not All Remote Connections Shown INPUT VOLTAGE COMMON 67 8 5 12 4 3 91 0 11 12 Discrete Interface Modul ...
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Cooper Lighting S280-79-10 - page 25
S280-79-10 25 ! SAFETY FOR LIFE Standard and UDP Contr ols Standard and UDP Form 5 control DIF inputs and outputs are described in the following pages. Maximum Switching Voltage: . . . . . 135 Vac 110 Vdc Maximum Switching Loading: . . . . . 600 mA Maximum Pickup-Release Time: . . 3 msec (does not count control response time) Input Protection: . . ...
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Cooper Lighting S280-79-10 - page 26
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions 26 Note: Supervisory Alternate Profile 3 replaced by Switch Mode on UDP controls. Standard and UDP Contr ol DIF Module 1 Inputs The DIF inputs are factory-configured as momentary (0.25 sec. duration) or maintained functions. Supervisory signals do not h ...
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Cooper Lighting S280-79-10 - page 27
S280-79-10 27 ! SAFETY FOR LIFE Standard and UDP Contr ol DIF Module 1 Inputs (cont’d) Input Connector Function Description 9 P4-9 Supervisory Non-Reclosing Supervisory Non-Reclosing provides supervisory non-reclosing input by a remote momentary signal. This input performs the same function as the NON-RECLOSING key on the operator panel. This inp ...
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Cooper Lighting S280-79-10 - page 28
* Note: Supervisory Alternate Profile 3 replaced by Switch Mode on UDP controls. Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions 28 Standard and UDP Contr ol DIF Module 1 Outputs The 12 outputs of the DIF Module are Form C relay contacts. Six of the outputs are latching and six are non-latching. Note ...
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Cooper Lighting S280-79-10 - page 29
S280-79-10 29 ! SAFETY FOR LIFE Standard and UDP Contr ol DIF Module 2 Inputs The DIF inputs are factory-configured as momentary or maintained functions. Whetting voltage for the DIF inputs is supplied by the DIF module or by the user. The input voltage range is 12 to 120 VAC or VDC. Input Connector Function Description 1 P4-1 Supervisory Fast Trip ...
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Cooper Lighting S280-79-10 - page 30
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions 30 Standard and UDP Contr ol DIF Module 2 Outputs The 12 outputs of the DIF Module are Form C relay contacts. Six of the outputs are latching and six are non-latching. Note: Contacts shown in inactive mode. Output Connector Function Type Description 1 P ...
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Cooper Lighting S280-79-10 - page 31
Sensed Curr ents Note: Control only, does not include sensor tolerance, but does include the phase current summing process. Phase Current — Individual Phase Currents: Range: 1 A to 10,000 A for 500:1 CTs 2 A to 20,000 A for 1000:1 CTs 4 A to 40,000 A for 2000:1 CTs Accuracy: ± 1 mA from 10 mA to 125 mA 0.8% from 125 mA to 1600 mA (Control only, ...
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Cooper Lighting S280-79-10 - page 32
Initial Programming Prior to Installation The control must be programmed with all necessary oper- ating settings, all alternate profiles, and parameters prior to operation with an energized recloser. Note: Program all protection profiles. Unused alternate pro- files should be programmed with the same settings as one of the applicable profiles. Defa ...
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Cooper Lighting S280-79-10 - page 33
Mounting the Control Mount the Form 5 recloser control in a convenient, acces- sible location. Mounting dimensions are provided in Fig- ure 28. • For pole-mounted installation, a hole and keyway in the control mounting bracket accommodates a 5/8 ” bolt. • For substation installation, brackets are available as an accessory for mounting the con ...
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Cooper Lighting S280-79-10 - page 34
Grounding the Contr ol The control cabinet must be grounded. A grounding con- nector on the underside of the cabinet will accommodate No. 14 solid through No. 4 stranded conductors. Suggested methods for grounding the control and recloser are shown in Figures 29, 30, and 31. Figure 29 illustrates grounding methods for 3-wire ungrounded and 4-wire m ...
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Cooper Lighting S280-79-10 - page 35
Installation of a Form 5 control with a local supply voltage transformer must include the following: • Protection of the recloser bushings and the supplying transformer with lightning arresters. • Grounding of the recloser head and tank. • Grounding of the transformer tank. • Grounding of the control cabinet. • Grounding of the SCADA equi ...
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Cooper Lighting S280-79-10 - page 36
Installation of a Form 5 control with a remote supply volt- age transformer must include the following: • Protection of the recloser bushings and the supplying transformer with lightning arresters. • Grounding of the recloser head and tank. • Grounding of the transformer tank. • Grounding of the control cabinet. • Grounding of the SCADA e ...
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Cooper Lighting S280-79-10 - page 37
Installation of a Form 5 control on a 3-wire uni-ground sys- tem must include the following: • Protection of the recloser bushings and the supplying transformer with lightning arresters. • Grounding of the recloser head and tank. • Grounding of the transformer tank. • Grounding of the control cabinet. • Grounding of the SCADA equipment. S ...
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Cooper Lighting S280-79-10 - page 38
Customer Connections for AC Power Input power to the Form 5 control is connected to terminal block TB1 (located behind the operator panel, on the left side of the control). See Figure 33. Input power is required: • To power the control • To provide voltage and power metering • For voltage detection for loop scheme accessory • For the low vo ...
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Cooper Lighting S280-79-10 - page 39
S280-79-10 39 ! SAFETY FOR LIFE TB1 Y' VOL T AGE 120V ac B' VOL T AGE 120V ac CLOSING VOLT A GE NEUTRAL SOURCE 2 NEUTRAL SOURCE 1 AC CUSTOMER CONNECTIONS NEUTRAL Z Ø Y Ø SOURCE 2 POWER X Ø OUTPUT VOLT A GE NEUTRAL *NEUTRAL POWER SOURCE OUTPUT C Ø *B Ø A Ø AC CUSTOMER CONNECTIONS SOURCE 1 POWER *REQUIRED FOR CONTROL OPERA TION 1 2 3 ...
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Cooper Lighting S280-79-10 - page 40
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions 40 AC CUSTOMER CONNECTIONS Z Ø Y Ø X Ø SOURCE 2 POWER OUTPUT VOLT AG E OUTPUT VOLT AG E *C Ø POWER SOURCE OUTPUT B Ø *A Ø AC CUSTOMER CONNECTIONS SOURCE 1 POWER *REQUIRED FOR CONTROL OPERA TION SEE POWER SUPPL Y MODULE FOR CORRECT VOL T AGE TB1 1 ...
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Cooper Lighting S280-79-10 - page 41
S280-79-10 41 ! SAFETY FOR LIFE TB1 Y Ø VOLT AG E 120V ac B Ø VOLT AG E 120V ac CLOSING VOLT AG E NEUTRAL SOURCE 2 NEUTRAL SOURCE 1 AC CUSTOMER CONNECTIONS NEUTRAL Z Ø Y Ø SOURCE 2 POWER X Ø OUTPUT VOLT AG E NEUTRAL *NEUTRAL POWER SOURCE OUTPUT C Ø *B Ø A Ø AC CUSTOMER CONNECTIONS SOURCE 1 POWER *REQUIRED FOR CONTROL OPERA TION 1 2 3 4 5 6 ...
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Cooper Lighting S280-79-10 - page 42
Before Placing the Contr ol and the Recloser into Ser vice Prior to placing the control and recloser into service, the following installation procedures must be properly com- pleted and verified: 1. Control properly mounted for the installation. 2. Recloser installed according to all locally approved standards and practices. 3. Control and recloser ...
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Cooper Lighting S280-79-10 - page 43
T esting an Installed Control The following tests to determine initial operation of the Form 5 control can be performed while connected to an operating recloser. These are the only tests performed on an installed, operating control. All other tests described in this Testing and Troubleshooting section require the Form 5 control to be removed from s ...
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Cooper Lighting S280-79-10 - page 44
Closing the Recloser During T esting Electrical Closing—Solenoid-Operated Reclosers Line voltage is required for automatic recloser operation during testing of reclosers equipped with a closing solenoid (except for reclosers equipped with the low volt- age closing accessory). For on-line testing , bypass the recloser, open the load- side disconne ...
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Cooper Lighting S280-79-10 - page 45
S280-79-10 45 ! SAFETY FOR LIFE 3 6 4 T3 Y H X Z VOLTAGE RATING OF RECLOSER CLOSING SOLENOID COIL SENSING CTs (3) CLOSING SOLENOID CONTACTOR ROTARY SOLENOID MAIN CONTACTS (S) GK AB EF TO 240 OR 480 VAC SOURCE TO 240 VAC SOURCE CLOSING SOLENOID COIL TRIP SOLENOID CONTROL CABLE RECEPTACLE W ELECTRONIC CONTROL TO AMMETER AND RELAY TO OPERATE CYCLE COU ...
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Cooper Lighting S280-79-10 - page 46
Manual Closing—Solenoid-Operated Reclosers If high-voltage for operating the closing solenoid is not available, manual closing can be substituted for electrical closing. However, not all control settings can be checked since manual closing is not synchronized with the closing coil control circuit in the control. To manually close the recloser: 1. ...
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Cooper Lighting S280-79-10 - page 47
Use this procedure to test the Form 5 control with factory default control settings. Follow all cautions and warnings in these service instructions. Before installation on an active feeder, the Form 5 con- trol ’ s final control settings must be fully tested using an appropriate test procedure. The Form 5 Control Default Test Sheet follows these ...
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Cooper Lighting S280-79-10 - page 48
T est Gr ound Minimum T rip V alues 1 . Change the Form 5 control from an Alternate Profile to the Normal Profile (all three Profile LEDs are off). Dis- able Ground Trip Block (LED off). 2 . Set KMET switch S4 to 100 milliampere range. 3. Set KMET Variac TR1 to zero. 4. Set KMET switch S2 to test fault position. 5. Verify the Form 5 phase minimum t ...
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Cooper Lighting S280-79-10 - page 49
13. Set KMET test set Fault Current switch S2 in the test fault current position. Record timings from the KMET test set for all trips on the G 5X ___ locations on the test sheet. 14. Set KMET Test Set switch S4 to the 1A position. 15. Calibrate KMET fault current to 1000 percent, (50 X 10 or 500 milliamperes). 16. Press the TRIP button on the displ ...
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Cooper Lighting S280-79-10 - page 50
T est Close Cir cuit Disable Fuse This test is only applicable to Form 5 LS controls and stan- dard Form 5 controls below Serial Number 3000. 1. Set KMET Fault Switch S2 to OFF. 2. CLOSE the Form 5 control. 3. Remove Close Circuit Disable fuse. 4. Adjust fault current to 200 percent or 200 mil- liamperes. 5. Set KMET test set Fault Current Switch S ...
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Cooper Lighting S280-79-10 - page 51
S280-79-10 51 ! SAFETY FOR LIFE For m 5 Contr ol Default T est Optimal V alues 2. V olts 28.0 2.6 V olts 28.0 Battery Circuitry MA 35 2.6 MA 550 V olts 27.0 2.6 volts 24.2 3. Normal Profile Phase A Amps Phase B Amps Phase C Amps 100.5 100.3 100.7 Phase Profile #1 Phase A Amps Phase B Amps Phase C Amps Minimum T rip 200.9 200.2 200.5 Profile #2 Phas ...
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Cooper Lighting S280-79-10 - page 52
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions 52 For m 5 Contr ol Default T est Optimal V alues 6. T rip Sequence 1st 2nd 3rd 4th Ground T iming Normal Ground 2X 0.214 0.212 3.894 3.896 Ground 5X 0.012 0.016 1.097 1.099 Ground 10X 0.008 0.014 0.652 0.653 Profile #1 Ground 2X 0.214 0.212 3.894 3.896 ...
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Cooper Lighting S280-79-10 - page 53
S280-79-10 53 ! SAFETY FOR LIFE For m 5 Contr ol Default T est Sheet Date: Serial No: 2. V olts 2.6 V olts Battery Circuitry MA 2.6 MA V olts 2.6 volts 3. Normal Profile Phase A Amps Phase B Amps Phase C Amps Phase Profile #1 Phase A Amps Phase B Amps Phase C Amps Minimum T rip Profile #2 Phase A Amps Phase B Amps Phase C Amps Profile #3 Phase A Am ...
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Cooper Lighting S280-79-10 - page 54
Kyle Form 5, Form 5 UDP, Form 5 DC NOVA Recloser Control Installation and Operation Instructions 54 For m 5 Contr ol Default T est Sheet 6. T rip Sequence 1st 2nd 3rd 4th Ground T iming Normal Ground 2X Ground 5X Ground 10X Profile #1 Ground 2X Ground 5X Ground 10X Profile #2 Ground 2X Ground 5X Ground 10X Profile #3 Ground 2X Ground 5X Ground 10X ...
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Cooper Lighting S280-79-10 - page 55
REMOVE THE CONTROL FROM SER VICE 1. Enable GND TRIP BLOCKED to allow for ground trip to be disabled when re-energized. A. Press the CHANGE/LAMP TEST key on the Oper- ator Panel to enter the CHANGE mode. Note: The LCD Display Screen will indicate the amount of time available in CHANGE mode to make a change. B. Depress the GND TRIP BLOCKED key. Note: ...
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Cooper Lighting S280-79-10 - page 56
Replacement Kits Replacement kits for the Kyle Form 5 Control are avail- able through the factory Service Department. To order these kits, refer to the Replacement Parts price list for cat- alog numbers and pricing. Contact your Cooper Power Systems representative for additional information and ordering procedures. Factor y-Authorized Service Cente ...
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