Service Information Form 6 Recloser Control Disassembly ... · Form 6 Recloser Control Disassembly, Reassembly, and Testing Instructions ... Cooper Power Systems products ... Form

1

Form 6 Recloser Control Disassembly,Reassembly, and Testing Instructions

ReclosersService Information

Safety Information ..................................................... 2

Hazard Statement Definitions ................................ 2

Safety Instructions .................................................. 2

Product Information .................................................. 3

Introduction ............................................................ 3

ANSI Standards ..................................................... 3

Quality Standards ................................................... 3

Acceptance and Initial Inspection .......................... 3

Handling and Storage ............................................ 3

Description ............................................................. 3

Disassembly .............................................................. 4

Disassembly Instructions ....................................... 4

Open the Module ................................................... 5

Remove/Replace CPU Board ................................ 5

Remove/Replace Comms. Accsy. Board Only ....... 6

Remove/Replace I/O Board ................................... 7

Remove/Replace Power Supply or RIF Board ...... 7

Remove/Replace Analog Board ............................. 8

Reassembly ............................................................... 8

Reassembly Instructions ........................................ 8

Place Module in Control ......................................... 8

Before Placing the Control Into Service ................. 9

Installation ................................................................. 9

Initial Programming Prior to Installation ................. 9

Testing ........................................................................10

Testing Instructions ................................................10

Communication Ports .............................................10

Contact Inputs/Outputs ..........................................10

Testing with Type MET Tester ................................11

Additional Information ..............................................12

Replacement Kits ...................................................12

Factory-Authorized Service Centers ......................12

Factory Testing and Troubleshooting Classes .......12

Contents

S280-70-11

Printed in USA1August 2005 • Supersedes 6/04

Figure 1.Kyle® Form 6 Pole Mount, Yard Mount, and Rack Mount recloser controls.

Form 6 Recloser Control Disassembly, Reassembly, and Testing Instructions

2

The instructions in this manual are not intended as a sub-stitute for proper training or adequate experience in thesafe operation of the equipment described. Only compe-tent technicians who are familiar with this equipmentshould 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-voltagesafe 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 equipmentsuch as flash clothing, safety glasses, face shield,hard hat, rubber gloves, hotstick, etc.

Following is important safety information. For safe instal-lation and operation of this equipment, be sure to readand understand all cautions and warnings.

Safety InstructionsFollowing are general caution and warning statementsthat apply to this equipment. Additional statements, relat-ed to specific tasks and procedures, are located through-out the manual.

SAFETY INFORMATION

SAFETY FOR LIFECooper Power Systems products meet or exceed all applicable industry standards relating to product safety. We activelypromote safe practices in the use and maintenance of our products through our service literature, instructional trainingprograms, 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 workingaround high voltage lines and equipment and support our “Safety For Life” mission.

!SAFETYFOR LIFE

!SAFETYFOR LIFE

This manual may contain four types of hazardstatements:

DANGER: Indicates an imminently haz-ardous situation which, if not avoided, will

result in death or serious injury.

WARNING: Indicates a potentially haz-ardous situation which, if not avoided, could

result in death or serious injury.

CAUTION: Indicates a potentially hazardoussituation which, if not avoided, may result in

minor or moderate injury.

CAUTION: Indicates a potentially hazardous situ-ation which, if not avoided, may result in equip-ment damage only.

!

!

Hazard Statement Definitions

!

WARNING: This equipment is not intended toprotect human life. Follow all locally approved

procedures and safety practices when installing oroperating this equipment. Failure to comply can resultin death, severe personal injury and equipment dam-age. G102.1

!

DANGER: Hazardous voltage. Contact withhazardous voltage will cause death or severe

personal injury. Follow all locally approved safety pro-cedures when working around high- and low-voltagelines and equipment. G103.3

!

WARNING: Before installing, operating, main-taining, or testing this equipment, carefully read

and understand the contents of this manual. Improperoperation, handling or maintenance can result indeath, severe personal injury, and equipment damage.

G101.0

!

WARNING: Power distribution equipment mustbe properly selected for the intended application.

It must be installed and serviced by competent person-nel who have been trained and understand proper safe-ty procedures. These instructions are written for suchpersonnel and are not a substitute for adequate trainingand experience in safety procedures. Failure to proper-ly select, install, or maintain power distribution equip-ment can result in death, severe personal injury, andequipment damage. G122.2

!

IntroductionService Information S280-70-11 provides disassembly,reassembly, and testing instructions for the Kyle® Form 6recloser control.

Read This Manual FirstRead and understand the contents of this manual and fol-low all locally approved procedures and safety practicesbefore installing or operating this equipment.

Additional InformationThese instructions cannot cover all details or variations inthe equipment, procedures, or process described, norprovide directions for meeting every possible contin-gency during installation, operation, or maintenance. Foradditional information, contact your Cooper PowerSystems sales representative.

ANSI StandardsKyle reclosers are designed and tested in accordancewith the following ANSI standards: C37.60 and C37.85and ANSI Guide C37.61.

Quality StandardsISO 9001:2000-certified quality management system

Acceptance andInitial InspectionEach unit is in good condition at the factory and whenaccepted by the carrier for shipment.

Upon receipt, inspect the carton for signs of damage.Unpack the unit(s) and inspect it thoroughly for damageincurred during shipment. If damage is discovered, file aclaim with the carrier immediately.

Handling and StorageBe careful during handling and storage of the unit to min-imize the possibility of damage. If the unit is to be storedfor any length of time prior to installation, provide a clean,dry storage area.

DescriptionService Information S280-70-11 provides disassembly,reassembly, and testing instructions for the Form 6 RackMount, Yard Mount, Pole Mount, and Triple-Single PoleMount recloser controls.

For additional information on installing the control,removing the control from service, and control testingprocedures, refer to the appropriate instructions:

• Service Information S280-70-1 Form 6 Rack MountRecloser Control Installation and OperationInstructions

• Service Information S280-70-2 Form 6 Yard MountRecloser Control Installation and OperationInstructions

• Service Information S280-70-3 Form 6 Pole MountRecloser Control installation and OperationInstructions

• Service Information S280-70-7 Form 6 Triple-SinglePole Mount Recloser Control Installation andOperation Instructions

S280-70-11

3

!SAFETYFOR LIFE

PRODUCT INFORMATION

Form 6 Recloser ControlDisassembly InstructionsThese instructions describe the disassembly of the Form6 recloser control.

1. Remove the Form 6 Control from Service. Refer toappropriate Service Information Instructions:

• Service Information S280-70-1 Form 6 Rack MountControl Installation and Operation InstructionsRemove the Control from Service section

• Service Information S280-70-2 Form 6 Yard MountControl Installation and Operation InstructionsRemove the Control from Service section

• Service Information S280-70-3 Form 6 Pole MountControl Installation and Operation InstructionsRemove the Control from Service section

• Service Information S280-70-7 Form 6 TripleSingle Pole Mount Control Installation andOperation Instructions Remove the Control fromService section

2. Carefully transport the recloser control to a suitableservice facility.

Note: The entire disassembly, reassembly, and testingprocess should be conducted in a clean environ-ment, such as a repair shop.

This step applies to Form 6 Pole and Yard mount controls.

3. Remove module from cabinet as applicable.

A. For complete scheme structure and verificationrefer to appropriate instructions:

• Service Information S280-70-4 Form 6 ControlSchemes section

• Service Information S280-70-9 Form 6-TSControl Schemes section

B. Disconnect SCADA communications to the Form 6control.

C. Remove all applicable connecting wires frommodule.

D. Remove the 7/16 inch grounding nut and lock-washers located on the bottom of the control mod-ule (Figure 2).

E. Remove the four mounting nuts that secure thefront of the module to the cabinet (Figure 3).


4

DISASSEMBLY

CAUTION: Recloser misoperation. The control mustbe removed from service prior to performing any main-tenance, testing, or programming changes. Failure tocomply can result in misoperation (unintentional oper-ation) of the recloser. T216.2

IMPORTANT: Isolate all power connections to theForm 6 recloser control, i.e., AC voltage sensing andSCADA, before removing control from service.

IMPORTANT: Make sure the power is turned off andthe battery is disconnected.

CAUTION: Equipment damage. Always wear agrounding wrist strap to control static electricity beforehandling circuit boards. Failure to use this strap mayresult in circuit board damage. T253.1

TB11

2

3 5 7 9 11 13 15 17 19

4 6 8 10 12 14 16 18

CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4

CI4


TB31 3 5 7 9 11 13 15 17 19 21

CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6

TB4

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

1 3 5 7 9 11 13CO7 CO8 CO9 CO10 CO11 CO12

2 4 6 8 10 12CO7 CO8 CO9 CO10 CO11CO12

J1 RS232 J2 IRIG-B

TTL IRIG-B

J3 RS485

2-Wire RS485

TB5

RECLOSER INTERFACE CONNECTIONSA1

D3

F5 7

2B

4C

6E

TB6

RS232 DTE

TB2 •1 2

•3 4

•5 6

•7 8

•9 10

•11 12

•13 14

•15 16

•17 18

•19 20

I(1-2) I(3-4) I(5-6) V(1-2) V(3-4) V(5-6) V1I(SEF)

6 5 4 3 2 178910

Grounding Nutand Lockwashers

Figure 2.Location of grounding nut and lockwashers on therear panel of the Form 6 pole mount control (belowSN 10000).

CAUTION: Recloser misoperation. Beforedownloading configuration files or settings to the

equipment, verify that the files and settings are correctfor the location and application. Downloading configu-ration files or settings designed for a different locationor application can result in severe personal injury andequipment damage. G133.0

!

Figure 3.Location of the four mounting nuts on the front ofthe Form 6 pole mount control.

Hex Nuts

Open the Module1. Discharge internal capacitors using a 10 ohm (5 watt)

load across TB6-1 and TB6-7 for five seconds.

2. Use a flat-head screwdriver to unscrew the six frontpanel screws.

3. Pull the right side of the panel outward toward the left.

Note: Various wire connections will keep the front panelattached to the control module. This will allow thedisplay panel to be placed next to the control mod-ule while work on internal circuit boards takes place(Figure 4).

4. Disconnect the ribbon wire assembly from the prima-ry connector board by lifting the locking tabs on eitherside and pulling out the connector.

5. Use a flat-head screwdriver to loosen the five captivescrews on the primary connector board.

6. Holding the middle two screws on the primary con-nector board, firmly pull the primary connector boardoutward working left to right so as not to bend pins.

Removal/Replacement of CPU Board

1. Remove CPU board. Refer to Form 6 RecloserControl Disassembly Instructions section.

2. Remove the TB1 terminal block strip from the back ofthe module (Figure 2).

3. Carefully pull CPU board outward so as not to dam-age the capacitor or any of the electrical componentson the Bezel tabs (Figure 6).

4. Proceed as appropriate for kit contents:

• If mounting plate is included with the kit proceed tostep 5.

• If mounting plate is not included with the kit contin-ue with this step.

A. Unscrew the five captive screws on top of theCPU board to release it from the mountingplate.

B. Flip the mounting plate over and remove the twomounting screws from the bottom of the mount-ing plate.

C. Lift the CPU from the mounting plate.

D. Install new CPU onto mounting plate andreplace the five captive screws.

E. Flip mounting plate over and replace the mount-ing screws on the bottom of the mounting plate.

5. If a new back plate is included with the kit, unscrewthe six back plate screws using a Phillips-headscrewdriver and replace the back plate (Figure 5).

6. Slide mounting plate into card guide and carefully lineup terminal strip to opening on the back plate.

7. Replace all of the terminal block strips.

8. Attach the new back plate over the communicationsport on the back panel using two screws and washersprovided with kit.

9. Configure communications board with applicableswitches and program as necessary.

S280-70-11

5

!SAFETYFOR LIFE

Figure 4.Form 6 control internal ribbon wire.

Internal ribbon wire

Primary Connector Board

CAUTION: Equipment damage. Always wear agrounding wrist strap to control static electricity beforehandling circuit boards. Failure to use this strap mayresult in circuit board damage. T253.1

TB11

2

3 5 7 9 11 13 15 17 19

4 6 8 10 12 14 16 18


CI4


TB31 3 5 7 9 11 13 15 17 19 21


TB4


1 3 5 7 9 11 13CO7 CO8 CO9 CO10 CO11 CO12

2 4 6 8 10 12CO7 CO8 CO9 CO10 CO11CO12

J1-RS-232

IRIG-BRS-232 DTE

TB5


D3

F5 7

2B

4C

6E

TB6

TB2 •1 2

•3 4

•5 6

•7 8

•9 10

•11 12

•13 14

•15 16

•17 18

•19 20

I(1-2) I(3-4) I(5-6) V(1-2) V(3-4) V(5-6) V1I(SEF)

6 5 4 3 2 178910

CommunicationsBack Panel

Figure 5.Form 6 control back plate.

CAUTION: Equipment misoperation. Do notconnect this control to an energized recloser until

all control settings have been properly programmedand verified. Refer to the programming information forthis control. Failure to comply can result in control andrecloser misoperation, equipment damage, and per-sonal injury. G110.3

!

Removal/Replacement ofCommunications Accessory Board OnlyThe Form 6 control is equipped with a CommunicationBoard Accessory (expansion bay) offering versatile sup-port for modern communication media. Seven distinctcommunication options are available, providing two-way,real time digital communications with a remote terminalunit (RTU), wireless, telephone modem, Ethernet net-work, or other communication devices. The followingoptions are available:

• No auxiliary communication card installed (standard)

• RS485 (isolated) Serial Communication Card (KME6-3839-1S)

• Fiber-optic-based Serial Communication Card (ST)(KME6-3839-2S)

• 10/100 Base-T dual Ethernet Communication Card(2*RJ-45) (KME6-3839-5S)

• 100 Base-FX dual Ethernet Communication Card(2*MT-RJ) (KME6-3839-3S)

• 10/100 Base-T, 100 Base-FX EthernetCommunication Card (RJ-45 + MT-RJ) Multi-mode(KME6-3839-4S)

• 100 Base FX dual Ethernet Communication Card (2SC) Single-Mode (KME6-3839-6S)

Additional accessories are being continuously devel-oped. Contact your Cooper Power Systems representa-tive for the latest information regarding particular mediaand communication protocol support.

Note: Form 6 Rack Mount Controls with serial numbers below20,000 and Form 6 Pole and Yard Mount Controls withserial numbers below 10,000 will need an additionalCPU replacement kit to upgrade a communicationsboard. Refer to KME6-3837-3S (pole mount) or KME6-3837-4S (rack/yard mount).

This procedure will be used when changing communica-tions accessory board:

1. Remove the CPU circuit board. Refer to Form 6Removal/Replacement of CPU Board section.

2. Remove the TB1 terminal block strip from the back ofthe module (Figure 2).

3. Carefully pull the CPU board outward so as not todamage the capacitor or any of the electrical compo-nents on the Bezel tabs (Figure 6).

4. Install two standoffs with copper washers into theholes on the left side of the CPU board (Figure 7).

5. Carefully install the communication board onto theCPU board so as to not bend any connections.

6. Install two screws with lock washers onto the com-munications board.

Note: Use 10 in-lbs. of torque. Do not overtightenstandoffs.


6

Figure 6.Internal view of the Form 6 pole mount recloser control module.

CPU and Communications Board

Input/Output Board

Power Supply and RIF Board

Analog Board

Capacitor

Bezel TabsShield Tabs

7. Slide mounting plate into card guide and carefullypush the assembly into the module.

8. Replace the TB1 terminal block strip.

9. Attach fiber/wire cover plate over the communicationsport on the back panel using two screws and washers.

10. Configure communications board with applicableswitches, and program as necessary.

Removal/Replacement of I/O Board1. Remove the I/O circuit board. Refer to Form 6

Recloser Control Disassembly Instructions section.

2. Remove the TB3 and TB4 terminal block strips orcover plate from the back of the control module(Figure 2).

3. Carefully pull I/O board outward so as not to damageany of the electrical components.

4. Unscrew the five screws on top of the I/O board usinga Phillips-head screwdriver to release it from themounting plate.

5. Lift I/O board from shield.

6. Install new I/O board onto mounting plate and replacethe five screws.

7. Slide mounting plate into card guide and carefully lineup terminal strip to opening on the back plate.

8. Replace the TB3 and TB4 terminal block strips.

Removal/Replacement of Power Supplyor Recloser Interface Board (RIF)Note: The Form 6 pole mount control will not contain an inter-

nal power supply board.

1. Remove the power supply or RIF circuit board. Referto Form 6 Recloser Control DisassemblyInstructions section.

2. Remove the TB5 and TB6 terminal block strips fromback of the control module (Figure 2).

3. Carefully pull power supply and RIF board mountingplate outward (Figure 4). Disconnect wire assemblyfrom the display assembly.

4. Unscrew the four screws on top of the power supplyor RIF board using a Phillips-head screwdriver.

5. Lift power supply board off of mounting plate andcarefully separate the board to board connectorbetween the RIF and the power supply board.

6. Install new power supply board onto mounting plateand replace the four screws.

7. Slide mounting plate into card guide and carefully lineup terminal block strip to opening on the back plate.

8. Replace the TB5 and TB6 terminal block strips.

S280-70-11

7

!SAFETYFOR LIFE



!

Figure 7.Location of standoffs on CPU board.

IMPORTANT: Do not damage the capacitor or anyother electrical components on the Bezel tabs(Figure 6).

Standoff

Standoff

Removal/Replacement of Analog Board1. Remove the analog circuit board. Refer to Form 6

Recloser Control Disassembly Instructions section.

2. Remove the bottom two screws on the outside of theright panel, left panel, and back plate of the module.

3. Remove the two screws on the bottom panel locatedunder the TB2 terminal block strip (Figure 6).

4. If applicable disconnect each wire connector from theTB2 terminal block strip.

5. Remove bottom panel carefully so as not to removegrounding strip.

6. Unscrew the five screws on top of the analog boardusing a Phillips-head screwdriver.

7. Install new analog board onto mounting plate andreplace the five screws.

8. Reconnect each of the wire connectors to the TB2terminal block strip (Table 1).

9. Slide mounting plate into card guide and replaceeach of the two screws on the right panel, left panel,back panel, and bottom of the control housing.

REASSEMBLY

Form 6 Recloser ControlReassembly InstructionsThese instructions describe the reassembly of the Form6 recloser control.

1. Ensure that the board that was serviced or replacedis seated firmly and has been aligned properly.

Note: All connections must be made carefully to ensureproper alignment.

2. Carefully seat the primary connector board at each ofthe five captive screws sites using gentle pressure soas not to bend any connection pins.

3. Using a flat-head screwdriver tighten the five captivescrews.

4. Carefully attach ribbon cable to the ribbon wire con-nector and secure locking tabs.

5. Replace the front panel.

6. Carefully thread each of the six front panel screwsinto place.

Note: Use 5-7 in-lbs. of torque. Do not cross thread orovertighten.

7. Tighten each screw in an alternating manner.

8. Check all fasteners for tightness and assure that allconnections are properly made before applyingpower.

Place Module in ControlFor Yard and Pole mount modules, rewire TB2 terminalblock strip per Table 1.

1. Place the module into the control,

2. Secure the module with the four mounting screws.

3. Replace the 7/16 inch nut (with appropriate lock-washers) located below the TB2 terminal block strip.

4. Connect all wires.

5. Place the control in service. Refer to the BeforePlacing the Recloser Control into Service section.

6. Apply local procedures to enable an electronic reclos-er control.

7. Reconnect SCADA communications to the Form 6.


8

CAUTION: Equipment damage. Use care to properlyalign and seat connection pins to the terminal blockstrips. Failure to comply can result in equipment dam-age and protective device misoperation. T317.0

TB2 Wire Color1 White/BlacK

2* Black*

3 Red/Black

4* Black*

5 Green/Black

6* Black*

7* Black*

8 Orange/Black

9 White/Red RW

10 White/Brown RW

11 Black RW

12 White RW

13 Gray RW

14 Violet RW

15 Blue RW

16 Green RW

17 Yellow RW

18 Orange RW

19 Red RW

20 Brown RW

TABLE 1Form 6 Yard and Pole Mount (below S/N 10000)Control TB2 Wiring Connections

* = Wire connected togetherRW = Ribbon wire

Before Placing the Recloser Controlinto Service

Prior to placing the Form 6 recloser control into service,installation procedures must be properly completed andverified.

For information on placing the control into service refer tothe appropriate instructions:

• Service Information S280-70-1 Form 6 Rack MountControl Installation and Operation Instructions

• Service Information S280-70-2 Form 6 Yard MountControl Installation and Operation Instructions

• Service Information S280-70-3 Form 6 Pole MountControl installation and Operation Instructions

• Service Information S280-70-7 Form 6 Triple-SinglePole Mount Control Installation and OperationInstructions

INSTALLATION

Initial Programming Prior toInstallationThe control must be programmed with all necessaryoperating settings, all alternate profiles, and parametersprior to operation with an energized recloser.

Note: Initial programming of the control is the responsibility ofa qualified technician or engineer familiar with controlfunctions and programming parameters required for thespecific recloser installation.

The control must be programmed with the Form 6ProView interface software. Refer to the appropriate con-trol programming guide for information:

• S280-70-4 Form 6 Control Programming Guide

• S280-70-9 Form 6 Triple-Single Pole Mount ControlProgramming Guide

S280-70-11

9

!SAFETYFOR LIFE



! CAUTION: Equipment misoperation. Do notconnect this control to an energized recloser until


!

IMPORTANT: Program all protection profiles.Unused alternate profiles should be programmed withthe same settings as one of the applicable profiles.Default settings on unused alternate profiles can causeunnecessary outages if they are below normal systemrequirements.

CAUTION: Equipment misoperation. Check mini-mum trip values prior to changing an alternate profile.Failure to do so may cause misoperation of the controlunder load conditions. T280.0

Form 6 Recloser Control TestingInstructionsThese instructions describe the testing of the Form 6recloser control.

Communication PortsVerify that the communication settings have been appropri-ately configured for your selected communication protocol.

For information on configuring communications refer tothe appropriate instructions:

• S280-70-4 Form 6 Control Programming Guide

• S280-70-9 Form 6 Triple-Single ControlProgramming Guide

Contact Input/OutputsStandard Default Supervisory InputControl and Output Status ContactsTest inputs/outputs by asserting appropriate alarms perthe ProView™ software to verify that all contact outputsoperate (open and close). Figures 8 and 9 show the loca-tion of the controls module manufacturing numbers.Refer to Tables 2 and 3 for Operating VoltageRequirements for Standard and Optional SupervisoryInputs.

For information on testing refer to the appropriateinstructions:

• Service Information S280-70-1 Form 6 Rack MountControl Installation and Operation Instructions

• Service Information S280-70-2 Form 6 Yard MountControl Installation and Operation Instructions

• Service Information S280-70-3 Form 6 Pole MountControl Installation and Operation Instructions

• Service Information S280-70-7 Form 6 Triple-SinglePole Mount Control Installation and OperationInstructions


10

TESTING

CAUTION: Equipment damage; misoperation.External leads must be shielded and the shield must begrounded at both ends. Terminate each lead with a 320Vac, 160 Joules metal oxide resistor (MOV), or equiva-lent, at the remote end. Attach MOVs between theleads and ground. Failure to properly shield and protectleads can result in equipment damage and/or uninten-tional operation. G117.3

Figure 8.Module Mfg. No. location on back of Form 6 polemount control.

TB11

2

3 5 7 9 11 13 15 17 19

4 6 8 10 12 14 16 18


CI4


TB31 3 5 7 9 11 13 15 17 19 21


TB4


1 3 5 7 9 11 13CO7 CO8 CO9 CO10 CO11 CO12

2 4 6 8 10 12CO7 CO8 CO9 CO10 CO11CO12

J1 RS232 J2 IRIG-B

TTL IRIG-B

J3 RS485

2-Wire RS485


D3

F5 7

2B

4C

6E

TB6

RS232 DTE

TB2 •1 2

•3 4

•5 6

•7 8

•9 10

•11 12

•13 14

•15 16

•17 18

•19 20

I(1-2) I(3-4) I(5-6) V(1-2) V(3-4) V(5-6) V1I(SEF)

1 65432

TB5

6 5 4 3 2 178910

Power Connections

1 432 7 12111098

Mfg. No. 6A0016010XX

*Location ofModule Mfg. No.Refer to Table 2

MinimumModule Nominal OperatingMfg. No.* Input Voltage Current Time

6A00160101 12 Vdc – 48 Vdc 5 mA 5 milliseconds

through

6A00160104

6A00160105 48 Vdc – 125 Vdc, 5 mA 5 milliseconds

through 120 Vac

6A00160108

6A00160161 12 Vdc – 250 Vdc, 5 mA 5 milliseconds

6A00160160 120 Vac-240 Vac(Triple-Single)

TABLE 2Operating Voltage Requirements for Standard and OptionalSupervisory Inputs for Form 6 Pole Mount Recloser Control

Refer to Figure 6 for location of Module Mfg. No.

Testing with Type MET TesterUse the Kyle® Type MET electronic recloser control tester(Figure 10) to test the following functions of the Form 6recloser control:

• Overcurrent Timing

• Reclose Time

• Operating Sequence

• Reset Time

The MET Tester is completely self-contained, capable ofperforming all required checks and tests to verify over-current protection parameters.

Refer to Service Information S280-76-1 Type METElectronic Recloser Control Tester Operating Instructionsfor proper setup and use of the MET Tester.

Additional Testing RequiredApply and verify source side voltage levels per your localstandard utility procedures.

S280-70-11

11

!SAFETYFOR LIFE

TB11

2

3 5 7 9 11 13 15 17 19

4 6 8 10 12 14 16 18


CI4


TB31 3 5 7 9 11 13 15 17 19 21


TB4


1 3 5 7 9 11 13CO7 CO8 CO9 CO10 CO11 CO12

2 4 6 8 10 12CO7 CO8 CO9 CO10 CO11CO12

J1 RS232 J2 IRIG-B

TTL IRIG-B

J3 RS485

2-Wire RS485

FUSE

(10 AMP)

FUSE

(10 AMP)

TB5+1

-5

2-

4+

INPUT POWER AUXILIARY POWER

28 VDC


D3

F5 7

2B

4C

6E

TB6

RS232 DTE

TB2 •1 2

•3 4

•5 6

•7 8

•9 10

•11 12

•13 14

•15 16

•17 18

•19 20

I(1-2) I(3-4) I(5-6) V(1-2) V(3-4) V(5-6) V1I(SEF)

Mfg. No. 6A0016010XX

*Location ofModule Mfg. No.Refer to Table 3

Figure 9.Module Mfg. No. location on back of Form 6 rackand yard mount control.

Module Input Nominal MinimumMfg. No.* Voltage Current Operating Time6A00160121 12 Vdc – 48 Vdc 5 mA 5 millisecondsthrough6A001601286A00160129 48 Vdc – 125 Vdc, 5 mA 5 millisecondsthrough 120 Vac6A001601366A00160170 12 Vdc – 250 Vdc 5 mA 5 milliseconds

120 Vac – 240 Vac

TABLE 3Operating Voltage Requirements for Standard andOptional Supervisory Inputs for Form 6 Rack andYard Mount Recloser Controls

*Refer to Figure 7 for location of Module Mfg. No.

Figure 10.Kyle® Type MET electronic recloser control tester.

010028KM

Replacement KitsReplacement kits for the Kyle Form 6 recloser controlsare available through the factory Service Department. Toorder these kits, refer to the Replacement Parts price listS260-01 through S280-01 for catalog numbers and pric-ing. Contact your Cooper Power Systems representativefor additional information and order procedures.

Factory-Authorized ServiceCentersFactory-authorized service centers are located through-out the continental United States to provide mainte-nance, repair and testing services for Kyle controls andreclosers. For further information, contact your CooperPower Systems representative.

Factory Testing andTroubleshooting ClassesThe factory service department offers a basic testing andtroubleshooting course for the Form 6 microprocessor-based recloser control. This course, taught by experi-enced service technicians, is held at the factory’s in-house training facility. For additional information, contactyour Cooper Power Systems representative.

Type MET Recloser Control TesterA 30-minute video cassette program KSPV7 Kyle® TypeMET Electronic Recloser Control Tester Operation andTesting Procedures is available as a supplemental train-ing aid for service personnel.


12

ADDITIONAL INFORMATION

CAUTION: This equipment requires routineinspection and maintenance to ensure proper

operation. If it is not maintained, it can fail to operateproperly. Improper operation can cause equipmentdamage and possible personal injury. G105.1

!

©2005 Cooper Power Systems or its affiliates.Kyle® is a registered trademark of Cooper Power Systems or its affiliates.ProViewTM is a trademark of Cooper Power Systems or its affiliates.

KA2048-637 Rev: 01

!SAFETYFOR LIFE

KDL8/05

1045 Hickory StreetPewaukee, WI 53072www.cooperpower.com

Service Information Form 6 Recloser Control Disassembly ... · Form 6 Recloser Control Disassembly, Reassembly, and Testing Instructions ... Cooper Power Systems products ... Form

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