Cooper Form 5 DC NOVA Install And Operation Instructions Download 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 profiles, event
recorder, data profiles, alarms, counters, and metering
information. Port 1 provides a simple means to download
operating parameters from a personal computer to the
control.The protocol, baud rate and address for Port 1 are
identified from the LCD display.

If a fiber-optic or RS-232 accessory board is connected to
Port 2 (located on the back of the operator panel) any
external electrical connection from the operator panel will
disable the accessory board.

Note:

The operator panel RS-232 port is intended only for
temporary connection of a personal computer. Perma-
nent serial communications must be made via the RS-
232 or fiber-optic accessory board.

Battery Test Procedure

The condition of the control battery is tested by depress-
ing the BATTERY TEST hot key on the operator panel. No
external current/voltage meter is necessary for testing.

The control performs a self-test every 12 hours or when
initiated by an external command. When a battery test is
initiated, the spurious charge is first drained to allow the
battery voltage to equalize. A 10-ohm, 55-watt resistor is
then placed across the battery terminals and a voltage
drop is calculated. If the drop from the equalized voltage
to the test voltage exceeds 2 volts, then the CHECK BAT-
TERY LED is illuminated.

To perform a battery test:

1.

Using the Next and BACK keys, scroll through the
LCD display to Screen 31, the Battery Monitor screen.

2.

Record the NORMAL VOLTS and NORMAL CUR-
RENT readings from the screen.

Note:

Voltage should be between 25 to 31 volts with
higher readings at colder temperatures. Under nor-
mal conditions with ac connected and the battery
trickle charging, the current should read less than
20 mA. With ac connected and in bulk charging
mode, current will range from 12 to 600 mA. With ac
disconnected and the battery supplying the load,
current will read -180 mA to -600mA depending on
accessories connected.

3.

Momentarily, press the CHANGE/LAMP TEST key,
then BATTERY TEST key.

Note:

AC power can be either connected or disconnected
for Step 3.

4.

Record the TEST VOLTS reading from the LCD and
the status of the CHECK BATTERY LED. Service the
battery if the CHECK BATTERY LED is illuminated.

Control Features

The Form 5 recloser control offers numerous standard
features and accessories that allow the user the utmost
flexibility in designing a control suitable for their applica-
tion requirements.

Under/Over Frequency Loadshedding

The Form 5 control includes provisions for frequency
loadshedding that trips the recloser for conditions of under
or over system frequency. Access to this feature is
through frequency threshold, trip time, and allowable volt-
age threshold.

With the auto-restoration feature, the Form 5 can be set to
close the recloser after the system frequency and voltage
have recovered. Parameters available for setting include
frequency and voltage thresholds and time delay.

A frequency alarm is available and can be configured for
notification.

Voltage Protection (120 Vac-based)

Voltage protection functionality is included as standard on
all Form 5 controls. A recloser trip will be issued for under
and over voltage conditions when the monitored voltage
falls outside user-specified limits for a selectable time.
Response mode includes 

any single-phase, all three

phases, and single-phase with three-phase inhibit

.

Response mode facilitates protecting against a single
phase condition common when a high side fuse operates
on a distribution transformer. Parameters are also avail-
able to provide auto restoration after a trip. A voltage
alarm is available and can be configured for notification.

Protection Profiles

Four separate protection profiles are included to allow the
user to adapt overcurrent settings for varying system con-
ditions such as load, live line work or weather. The active
profile is selected from the operator panel or with the inter-
face software or SCADA (Figure 9). Each profile has 14
TCC specifications plus reclose intervals, sequence coor-
dination and reset times to maintain independent protec-
tion parameters.

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

14

Figure 9.
Interface software sample protection profile.

Summary of Contents for Form 5 DC NOVA

Page 1: ...Standard and UDP Module 2 Inputs 29 Standard and UDP Module 2 Outputs 30 Input Accuracy 31 Installation Procedure 32 Initial Programming Prior to Installation 32 Control Recloser Compatibility 32 Con...

Page 2: ...g around high voltage lines and equipment and support our Safety For Life mission SAFETY FOR LIFE SAFETY FOR LIFE WARNING This equipment is not intended to protect human life Follow all locally approv...

Page 3: ...omer Connection for AC power sec tion in this manual Control Battery Storage and Charging The 24 Vdc control battery in the Form 5 control is fully charged prior to shipment and is ready for use In or...

Page 4: ...ble to initialize the Form 5 control Method 1 Connect AC power to the input connector ter minal TB 1 Refer to the Customer Connec tions for AC Power section of this manual Method 2 Connect the battery...

Page 5: ...DA communications This resets the control to the start of the operating sequence The following chain of events occurs for an operating sequence of two trips to lockout 1 The overcurrent signal is inte...

Page 6: ...ains a 32 bit micro controller a Digital Signal Processor RAM and EEPROM memory and a 16 bit analog to digital converter The CPU module accepts 16 analog inputs which it routes through the digital sig...

Page 7: ...ed when the control detects a failure in a trip or close operation It turns off automati cally if the recloser returns to the proper state REVERSE POWER FLOW This red indicator illuminates when the co...

Page 8: ...navigational keys which permit the user to scroll through the menu in a timely and efficient manner When an overcurrent trip occurs the control automatically displays the fault current values as shown...

Page 9: ..._______ V 7 Instant S1 Ph Ph Ph1 3 ____________ V Ph3 5 ____________ V Ph5 1 ____________ V 8 Instant S2 Ph N Ph2 N ____________ V Ph4 N ____________ V Ph6 N ____________ V 9 Instant S2 Ph Ph Ph2 4 __...

Page 10: ...____________ kVAr Screen 17 Demand Phase to Neutral Voltage Screen 18 Demand Phase to Phase Voltage Screen 19 Demand Phase to Neutral Voltage Screen 13 Instantaneous kVAR Screen 20 Demand Phase to Ph...

Page 11: ...ttery Monitor displays the battery voltage current and voltage during a battery test The Battery Monitor is used with the Battery Test pushbutton Refer to the Bat tery Test Procedure section of these...

Page 12: ...Figure 7 Operation indication pushbuttons 37 Ph3 4 Min ____________A Time Date Ph5 6 Min ____________A Time Date 40 Comm Port 2 ______ Protocol _______ Speed _______ Address _______ 41 Comm Port 3 ___...

Page 13: ...s Program unused alter nate profiles should be programmed with the same set ting as one of the applicable profiles Default settings on unused alternate profiles can cause unnecessary out ages if they...

Page 14: ...oad current will read 180 mA to 600mA depending on accessories connected 3 Momentarily press the CHANGE LAMP TEST key then BATTERY TEST key Note AC power can be either connected or disconnected for St...

Page 15: ...off Figure 10 RECLOSER MALFUNCTION RECLOSER CLOSED RECLOSER OPEN CONTROL LOCKOUT The Trip Failure Detection alarm may be triggered from many potential sources including mechanical electrical control...

Page 16: ...he oldest event is deleted as a new event is added Histograms Demand metered voltages and currents can be reported using the histogram tool It displays the number of occur rences of a variable versus...

Page 17: ...ent in the control Event Recorder for retrieval The fault location algorithm does not require voltage sensing If the location cannot be determined no event is recorded and dashes are dis played on the...

Page 18: ...gle parameter determines the angle of maximum tripping sensitivity between the phase angle of the zero sequence voltage and current at the time of fault The setting of this value depends on knowledge...

Page 19: ...use the same port The operator panel LEDs indicate the status of communication on the accessory boards Temporary connections to the operator panel RS 232 port disables fiber optic or RS 232 commu nic...

Page 20: ...itches are located on the side of the module 7 Configure the RIF board as shown in Figure 19 8 After configuration place the module back into posi tion in the control cabinet and secure to the mountin...

Page 21: ...Y FOR LIFE Figure 21 Interface software Switch Mode settings GND TRIP BLOCKED NON RECLOSING SUPERVISORY BLOCKED COLD LOAD PICKUP BLOCKED BATTERY TEST FAST TRIPS DISABLED ALTERNATE PROFILE NO 1 ALTERNA...

Page 22: ...hich protect the battery from failure and provides trip close operations without AC power The 19 pin control cable interfaces the NOVA dc recloser to the Form 5 control through the interface circuit T...

Page 23: ...ade from terminal P5 on the DIF module to the respective connec tions on P4 inputs 1 through 12 Figure 27 shows customer connections to the DIF outputs at P2 and P3 4 3 2 1 4 3 2 1 8 7 6 5 12 11 10 9...

Page 24: ...OFILE 1 SUPERVISORY ALTERNATE PROFILE 2 SUPERVISORY ALTERNATE PROFILE 3 SWITCH MODE ON FORM 5 UDP SUPERVISORY NORMAL PROFILE SUPERVISORY NON RECLOSING SUPERVISORY COLD LOAD PICKUP BLOCKED REMOTE TRIP...

Page 25: ...nput Maximum Leakage Rejection 1 mA Maximum Pickup Time 10 msec does not count control response time Minimum Input Pulse Time 100 msec Minimum Transition Time between Pulse Inputs 200 msec Input Prote...

Page 26: ...by a maintained SCADA command a serial command or locally via a operator panel switch This input is active regardless of the state of the supervisory function 4 P4 4 Supervisory Ground Trip Block Supe...

Page 27: ...d A momentary signal is required for proper operation 11 P4 11 Remote Trip and Reclose Remote Trip and Reclose initiates a trip operation followed by a reclose operation A momentary signal is required...

Page 28: ...OCKED indicator on the operator panel is illuminated Supervisory Blocked prevents operation from supervisory control Programming is accessible from the operator panel This output is active when the SU...

Page 29: ...ction as the RESET TARGETS RESET MAX CURRENT key on the operator panel This input is inactive if the Supervisory function is disabled This is a momentary function 3 P4 3 Supervisory Operation Counter...

Page 30: ...get Latched P2 10 NC 12 P2 11 NO Sensitive Ground Fault Blocked Latched P2 12 NC This output is active when the CONTROL LOCKOUT indicator is illuminated This output is active when the CHECK BATTERY in...

Page 31: ...rom 125 mA to 1600 mA Control only does not include sensor tolerance Ground Current Vector Sum of Three Phase Currents Range 1 A to 5 000 A for 500 1 CTs 2 A to 10 000 A for 1000 1 CTs 4 A to 20 000 A...

Page 32: ...our Cooper Power Systems representative For identification Table 4 lists the serial number breaks between old style Type A and the new style Type B sens ing CTs Below this serial number the recloser i...

Page 33: ...based on standard control cables Consult your Cooper Power Systems representative if longer cable lengths are required S280 79 10 33 SAFETY FOR LIFE CONTROL WEIGHT 52 kg 115 LBS 350mm 13 13 16 30mm 1...

Page 34: ...rounding on a 3 wire uni grounded system 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 powe...

Page 35: ...ral connected transformer Form 5 LS Control AC NEUTRAL Input Terminal Block Supply Voltage Transformer ELECTRICAL CONNECTIONS Line to Line connected transformer Line to Line Voltage External Ground Lu...

Page 36: ...mer Supplied Low Voltage External Ground Lug Low Voltage Arrester Note Distance between transformer and recloser should be one pole span or less System Neutral External Ground Lug Input Terminal Block...

Page 37: ...ces between conductor and ground path lengths can add additional stress to the control components in the event of a power surge IMPORTANT In pole mounted applications a ground connection must be made...

Page 38: ...ase transformers Figure 34 shows standard wiring with B transformer connected to TB1 2 location Other phases should be connected from the single phase transformer by wiring the BLACK wire from the Pow...

Page 39: ...OPERATION SEE POWER SUPPLY MODULE FOR CORRECT VOLTAGE TB1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 C B A 240V CLOSING OPTION 15 16 A B C HOT LV Closing Output HOT LV Closing Output Figure 35 Form 5 and Form...

Page 40: ...Open Delta Connection AC CUSTOMER CONNECTIONS Z Y X SOURCE 2 POWER OUTPUT VOLTAGE OUTPUT VOLTAGE C POWER SOURCE OUTPUT B A AC CUSTOMER CONNECTIONS SOURCE 1 POWER REQUIRED FOR CONTROL OPERATION TB1 1...

Page 41: ...5 UDP Power and Low Voltage Closing customer connections to terminal block TB1 Single Phase Connection Standard B Input TB1 Y VOLTAGE 120Vac B VOLTAGE 120Vac CLOSING VOLTAGE NEUTRAL SOURCE 2 NEUTRAL S...

Page 42: ...ctions for remote and supervisory operation checked and completed in accordance with proper shielding and surge protection 9 Control cable properly connected and supported Kyle Form 5 Form 5 UDP Form...

Page 43: ...metering and interconnecting cables and is capable of performing all required checks and tests from a simple verification of operation to a complete verification of all operating parameters Refer to S...

Page 44: ...d All other equipment is the same as the test equipment shown in Figure 42 Electrical Closing NOVA Reclosers Type NOVA 3 phase reclosers utilize an interface circuit located in the mechanism housing T...

Page 45: ...ROL TO AMMETER AND RELAY TO OPERATE CYCLE COUNTER OR OTHER TIMING DEVICE 120 VAC VARIABLE AUTOTRANSFORMER 240 VAC 20 AMPS T2 1 2 5 J Figure 45 Suggested test circuit for shop testing solenoid closing...

Page 46: ...plunger is moving upward to reset the main toggle latch 5 After the main toggle latch resets the recloser can be closed again by operating the manual closing tool 6 Replace the gasket and port cover...

Page 47: ...milliamperes Record value 9 Repeat steps 4 8 for phases B and C move KMET S5 to B then C 10 Change Form 5 control from Normal Profile to Alter nate Profile 1 11 Verify Cold Load Pickup Blocked LED is...

Page 48: ...e 14 Press the TRIP button on the display panel 15 Press the CLOSE button on the display panel 16 Set KMET test set Fault Current Switch S2 to test fault current position Record timings from the KMET...

Page 49: ...lockout Record time value Test Cold Load Pickup Blocked 1 Disable COLD LOAD PICKUP BLOCKED LED off 2 CLOSE the Form 5 control 3 Adjust fault current to 200 percent or 200 mil liamperes 4 Within 30 sec...

Page 50: ...ify Instantaneous Demand Metering 1 Enable GROUND TRIP BLOCK LED on 2 Set KMET switch S2 to OFF 3 Set KMET Phase Selector S5 to A 4 Set KMET Variac to zero 5 Set KMET switch S4 to the 100 milliampere...

Page 51: ...00 5 4 Normal Ground Amps 50 1 Ground Profile 1 Ground Amps 100 3 Minimum Trip Profile 2 Ground Amps 100 3 Profile 3 Ground Amps 100 3 5 Trip to Lockout Sequence 1st 2nd 3rd 4th Phase Timing Normal Ph...

Page 52: ...016 0 952 0 954 Ground 10X 0 008 0 014 0 280 0 276 7 Enabled Phase 2X 0 153 lockout lockout lockout Non Reclose Disabled Phase 2X 0 152 0 153 1 420 1 433 8 Cold Load Block Off Phase 2X 1 420 1 433 lo...

Page 53: ...ps Minimum Trip Profile 2 Phase A Amps Phase B Amps Phase C Amps Profile 3 Phase A Amps Phase B Amps Phase C Amps 4 Normal Ground Amps Ground Profile 1 Ground Amps Minimum Trip Profile 2 Ground Amps P...

Page 54: ...round 2X Ground 5X Ground 10X 7 Enabled Phase 2X lockout lockout lockout Non Reclose Disabled Phase 2X 8 Cold Load Block Off Phase 2X lockout lockout PickUp Blocked Block On 9 Fast Trips Enabled Phase...

Page 55: ...HANGE 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 After the GND TRIP BLOCKED key is depressed th...

Page 56: ...This course taught by experienced service technicians is held at the factory s in house training facility For addi tional information contact your Cooper Power Systems representative Type MET Reclose...

Reviews: