Cooper - Recloser - Type NOVA Service Brochure S280-42-1.pdf

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Types NOVA15 and NOVA27;Three-Phase Microprocessor-Controlled;Installation and Operation Instructions

ReclosersService Informatio

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

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

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

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

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

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

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

Description of Operation ........................................ 3

Ratings and Specifications ...................................... 5

Check Recloser Ratings Prior to Installation ......... 5

Dimensions and Mass (Weight) ...............................6

Installation Procedure .............................................. 7

Moving the Recloser .............................................. 7

Lifting the Recloser ................................................ 7

Operation ................................................................... 10

Electrical Operation ................................................10

OPEN/CLOSE Contact Position Indicator ..............1

Hotstick Operation (Manual Open, Electrical Close)...1

Accessories ............................................................... 1

Auxiliary Switch.......................................................1

Terminals ................................................................1

Pole-Mounting Hanger ...........................................1

Arrester-Mounting Brackets ...................................1

Substation-Mounting Frame ...................................1

Service Information ................................................... 1

Service Requirements ............................................1

Frequency of Inspection .........................................1

Testing Operation ...................................................1

High-Potential Withstand Testing ...........................1

Troubleshooting ........................................................ 1

Unit Will Not Close .................................................1

Unit Will Not Open Electrically ...............................1

Contents

S280-42-1

February 2001 • Supersedes 3/00

Figure 1.Kyle ® Type NOVA three-phase, microprocessor-controlled recloser.(Shown with two-hole flat pad accessory.)

000029KM

NOVA 15 for Serial Number 3000 and above

NOVA 27 for Serial Number 2036 and above



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 equipment

should 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-voltage safe 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 equipment such 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 Instructions

Following are general caution and warning statementhat apply to this equipment. Additional statements, rela

ed to specific tasks and procedures, are located througout the manual.

SAFETY INFORMATION

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

cedures and safety practices when installing or operating this equipment. Failure to comply can result indeath, severe personal injury and equipment damage

G102.1

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

personal injury. Follow all locally approved safety procedures when working around high and low voltagelines and equipment. G103.

WARNING: Before installing, operating, maintaining, or testing this equipment, carefully read

and understand the contents of this manual. Impropeoperation, handling or maintenance can result in deathsevere personal injury, and equipment damage. G101.0

WARNING: Power distribution equipment musbe selected for the intended application. It mus

be installed and serviced by competent personnel whohave been trained and understand proper safety procedures. These instructions are written for such personneand are not a substitute for adequate training and experience in safety procedures. Failure to properly selectinstall, or maintain this equipment can result in deathsevere personal injury, and equipment damage. G122.

SAFETY FOR LIFECooper Power Systems products meet or exceed all applicable industry standards relating to product safety. We activepromote safe practices in the use and maintenance of our products through our service literature, instructional trainin

programs, and the continuous efforts of all Cooper Power Systems employees involved in product design, manufacturmarketing, and service.

We strongly urge that you always follow all locally approved safety procedures and safety instructions when workinaround high voltage lines and equipment and support our “Safety For Life” mission.

This manual may contain four types of hazards t a t e m e n t s :

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

result in death or serious injury.

WARNING: Indicates a potentially hazardous

situation which, if not avoided, could result indeath 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

Type NO VA Three-Phase, M icroprocessor-C ontrolled Recloser Installation and O peration Instructions



Introduction

Service Information S280-42-1 provides installation,operation, and maintenance instructions for the Kyle TypeNOVA three-phase, microprocessor-controlled recloser.Before installing and operating this recloser, carefullyread and understand the contents of this manual.

Read This Manual First

Read and understand the contents of this manual and fol-low all locally approved procedures and safety practicesbefore installing or operating this equipment. This reclos-er is used in conjunction with a Kyle microprocessor-based recloser control. If used with a Form 4C control,refer to Service Information S280-77-1. If used with anFXB control, refer to Service Information S280-78-1. Ifused with a Form 5 control, refer to Service Information S280-79-10 .

Additional Information

These 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, please contact your CooperPower Systems’ representative.

Acceptance and InitialInspection

Each recloser is completely assembled, tested, andinspected at the factory. It is in good condition whenaccepted by the carrier for shipment. Upon receipt,inspect the shipping container for signs of damage.

Unpack the recloser and inspect it thoroughly for damageincurred during shipment. If damage is discovered, file aclaim with the carrier immediately.

Handling and Storage

Be careful during handling and storage of the recloser tominimize the possibility of damage. Refer to the Movingthe Recloser and Lifting the Recloser sections. If therecloser is to be stored for any length of time prior toinstallation, provide a clean, dry storage area.

Standards

The Kyle Type NOVA reclosers are designed and testein accordance with:

ANSI/IEEE C37.60 - 1981

ANSI C37.61 - 1973/IEEE 321 - 1973

ANSI C37.85 - 1989

Quality Standards

The Quality System at the Cooper Power Systems, KylDistribution Switchgear plant is certified to the followinstandards:

ISO 9001, 1994

CAN/CSA ISO 9001, 1994

BS EN ISO 9001, 1994

ANSI/ASQC Q9001, 1994

Description of OperationThe Kyle Type NOVA recloser is a three-phase, microprocessor-controlled, vacuum recloser. The NOVrecloser can be operated and interrogated through SCADA system for fault detection and recloser isolationThe Type NOVA recloser is available with two contrinput configurations: ac interface and dc interface. Refeto Ac Interface and Dc Interface sections. The solid polymer insulation system does not rely on a gaseous or liquid dielectric. The NOVA recloser is highly resistant tozone, oxygen, moisture, contamination, and ultraviolelight. The NOVA recloser has three, solid-polymer interupter modules, an encapsulated current transformeand a standard aluminum mechanism housing. It is sui

able for operation through a temperature range of -40°to +55°C.

S280-42-

PRODUCT INFORMATION




Figure 2.Kyle Type NOVA recloser (dc version) mechanism (view from bottom of recloser with bottom cover removed).

98019KM

Heater Manual OPEN HandleCT Protection BoardTrip and Close CapacitorsMagnetic Actuator

OPEN/CLOSE

Contact PositionIndicator

Actuator Board Control Cable

Receptacle

Mechanical

Operations Counter

Ground Connector

#10 - #2 Stranded

Aluminum

Mechanism Housing(Standard)



Check Recloser Ratings Prior ToInstallation

The recloser must be applied within its specified ratings.Check data plate ratings and compare with the systemcharacteristics at the point of application prior to installa-

tion. Tables 1, 2, 3, and 4 list the ratings and specifica-tions for the Type NOVA recloser.

- -

RATINGS AND SPECIFICATIONS

Description NOVA 15 NOVA 27

Maximum Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5 kV 27.0 kV

Rated Basic Impulse Voltage. . . . . . . . . . . . . . . . . . . . . . . 110.0 kV 125.0 kV

Radio Noise Limit (microvolts) . . . . . . . . . . . . . . . . . . . . . . 100 @ 9.4 kV 100 @ 16.4 kV

Power Frequency Withstand (Dry). . . . . . . . . . . . . . . . . . . 50.0 kV 60.0 kV

Power Frequency Withstand (Wet). . . . . . . . . . . . . . . . . . . 45.0 kV 50.0 kV

TABLE 1Voltage Ratings (kV)


Rated Continuous Current. . . . . . . . . . . . . . . . . . . . . . . . . 630 A* 630 A*

Short Circuit Current, Symmetrical. . . . . . . . . . . . . . . . . . . 12.5 kA 12.5 kA

Making Current, Asymmetrical Peak . . . . . . . . . . . . . . . . . 31.0 kA 31.0 kA

Making Current, Asymmetrical RMS. . . . . . . . . . . . . . . . . . 20.0 kA 20.0 kA

TABLE 2Current Ratings (Amperes)


Mechanical Operations:

Close/Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500 2500

TABLE 3Mechanical Ratings

Percentage of Number of Minimum

Type Interrupting Rating Unit Operations Circuit X/R Value

NOVA 15-20 88 4

45-55 112 890-100 32 15

Total 232

TABLE 4Duty Cycle

*800 amp accessory is also available.




Figure 3.Type NOVA recloser dimensions.

DIMENSIONS AND MASS (WEIGHT)

*On the same phase.

Description NOVA15 NOVA27

Terminal to terminal* 1052 1052

(41.5) (41.5)Lower terminal to ground 673 772

(26.5) (30.5)

Creepage Distances

TABLE 5Type NOVA Recloser Mass (Weight)

Description NOVA15 NOVA27

NOVA recloser - kilograms (pounds) 86 (190) 91 (200)

B C

NOVA 15 791 508(31.25) (20.0)

NOVA 27 847 564(33.25) (22.25)

Terminal Options A

Eyebolt, 1/0 - 500 mcm 80 (3.25)Cable Range (630 amps maximum)


Flat Pad, 2-hole (630 amps) 117 (4.5)or 4-hole (800 amps maximum)

Stud Type, 1.125-12 threads, 82 (3.25)(800 amps maximum)



When installing the recloser, refer to the applicablerecloser mounting frame instructions. Installation instruc-tions are included with the mounting frame.

1. Check the data plate ratings. Make sure the ratingsand settings on the recloser data plate (see Figure11) are correct for the planned installation.

2. Perform high-potential withstand tests. Prior toinstalling the NOVA recloser, perform high-potentialwithstand tests. Refer to SERVICE INFORMATIONsection for high-potential withstand test procedures.

3. Install the recloser. Install the recloser in the appro-priate Cooper Power Systems pole- or substation-mounting frame. See Figure 4 for moving and liftinginstructions.

4. Ground the recloser. Make the ground connection tothe ground connector. The ground connector is locat-ed on the back of the mechanism housing. SeeFigure 2 for ground connector location. The groundclamp accepts #10 to #2 stranded cables. SeeFigures 5 and 6 for recommended grounding for theType NOVA recloser.

5. Install the control. Refer to the control installationmanual and install the control. Make sure the controlcable is connected between the control and therecloser, the control is properly programmed for theplanned installation, and the control is grounded.

- -

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

cedures and safety practices when installing or operat-ing this equipment. Failure to comply can result in death,severe personal injury, and equipment damage. G102.1

WARNING: Hazardous voltage. Always use ahotstick when working with this equipment.

Failure to do so can result in contact with high voltage,which will cause death or severe personal injury. G108.1

WARNING: Hazardous voltage. Solidly ground allequipment. Failure to comply can result in death,

severe personal injury, and equipment damage. T223.2

CAUTION: Follow all locally approved safetypractices when lifting and mounting the equip

ment. Use the lifting lugs provided. Lift the unit smoothly and do not allow the unit to shift. Improper lifting canresult in equipment damage. G106.2

C A U T I O N : Personal injury. Bushings havesharp edges. Wear protective gloves when han

dling the unit. Failure to do so can result in cuts andabrasions. T258.0

Figure 4.Moving and lifting instructions for the Type NOVArecloser.

Moving the Recloser

Type NOVA reclosers are shipped palletized (boltedonto a pallet). When moving with a fork truck/lift, therecloser must remain bolted to the pallet to avoid dam-age to the OPEN/CLOSE contact position indicator.

Lifting the Recloser

Follow all approved safety practices when makinghitches and lifting the equipment. Lift the unit smoothlyand do not allow the unit to shift.

Type NOVA reclosers have four lifting lugs - all foulugs must be used when lifting.

INSTALLATION PROCEDURE



Installation must include the following:

• Protection of the recloser bushings and the supplyingtransformer with lightning arresters.

• Grounding of the recloser.

• Grounding of the transformer tank.

• Grounding of the control cabinet.


Figure 5.Recommended grounding method for NOVA recloser with microprocessor-based control and local supplyvoltage transformer.



Installation must include the following:

• Protection of the recloser bushings and the supplyingtransformer with lightning arresters.

• Grounding of the recloser.

• Grounding of the transformer tank.

• Grounding of the control cabinet.

- -

Figure 6.Recommended grounding method for NOVA reclosers with Kyle microprocessor-based control and remotesupply voltage transformer.



6. Make high-voltage line connections (see Figure 7).

Note: Disconnect switches and bypass switches are not

required, but are highly recommended as they facil-

itate switching and isolation.

A. Connect high-voltage lines to recloser bushingterminals.

B. Provide surge arrester protection. Surge arresterprotection should be provided on both sides.

Refer to Figure 8 for terminal identification of the TypeNOVA recloser.

Electrical Operation

The Type NOVA recloser utilizes an interface circuitlocated in the mechanism housing. The electronic inter-face circuit controls the opening and closing signals tothe magnetic actuator. Both ac and dc interface optionsare available. See Figures 16 and 17 for wiring diagrams.

ype NO VA T hree-Phase, M icroprocessor-C ontrolled Recloser Installation and O peration Instructions

Figure 7.Connection diagram shows complete surge protec-tion and illustrates bypass and disconnect switches.


cedures and safety practices when installing or operat-ing this equipment. Failure to comply can result indeath, severe personal injury, and equipment damage.

G102.1

IMPORTANT: If the yellow manual OPEN handleremains in the down position, the recloser cannot beclosed electrically.

WARNING: Hazardous voltage. Do not rely onthe open position of the yellow manual OPEN

handle or the contact position indicator; it does notensure that the line has been de-energized. Alwaysestablish a visible disconnect. Failure to follow propersafety practices can result in contact with high voltage,which will cause death or severe personal injury.

G114.1

OPERATION

CAUTION: Equipment Damage. Do not adjustor rotate bushing terminals. The bushing termi-

nals are factory-calibrated to meet the continuous cur-rent requirement of the switchgear. Adjusting or rotat-ing the bushing terminals can damage the encapsulat-ed interrupter resulting in equipment damage or per-sonal injury. T270.0

Figure 8.Terminal Identification of Type NOVA recloser.



Ac Interface

The Type NOVA recloser with ac interface is fully opera-tional with standard Kyle Form 4C, Form 5, Form 6, andFXB microprocessor-based controls and standard controlcables. Ac power must be connected through a two-pinconnector and cable to the switchgear (see Figure 9).

Dc Interface

The Type NOVA recloser with dc interface is fully opera-tional with Kyle Form 4C, Form 5, and Form 6 micro-processor-based controls equipped with the requireddc-to-dc converter, interface circuit, and a fully shielded19-pin cable (see Figure 10). The dc-to-dc converterboard converts the control’s 24 Vdc battery supply to53 Vdc to drive the trip/close capacitors in the NOVA

mechanism. The output of the board is separately fusedfor operator indication. The dc-to-dc converter board alsohouses voltage monitoring and conditioning circuits thatprotect the battery from failure and provide trip/closeoperations without ac power. The 19-pin control cableinterfaces the NOVA dc recloser to the control throughthe interface circuit board. In addition, the cable providesac power to the mechanism heater.

The OPEN/CLOSE contact position indicator consists oa red CLOSED and a green OPEN indicator located othe bottom of the mechanism housing (see Figure 11).

The recloser may be opened manually by using a hotsticto pull down the yellow manual OPEN handle, located othe front of the recloser (see Figure 11). To close threcloser, first, push the yellow manual open handle upThen, using the microprocessor control, close the reclose

- -

Figure 10.Type NOVA recloser configuration with dc interface.

Figure 9.Type NOVA recloser configuration with ac interface.

WARNING: Hazardous voltage. Always use ahotstick when working with this equipment

Failure to do so can result in contact with high voltagewhich will cause death or severe personal injury. G108.1

Hotstick Operation (ManualOpen, Electrical Close)

WARNING: Hazardous voltage. Do not rely onthe open position of the contact position indicator

it does not ensure that the line has been de-energizedAlways establish a visible disconnect. Failure to follow

proper safety practices can result in contact with highvoltage, which can result in death or severe personainjury. G123.0

OPEN/CLOSE Contact PositionIndicator

Figure 11.Type NOVA recloser OPEN/CLOSE contact positionindicator, data plate, and manual OPEN handle.

ManualOPEN Handl

Data Plate

OPEN/CLOSE ContactPosition Indicator



Auxiliary Switch

A three-stage auxiliary switch can be provided as anaccessory. Each stage has two independent contactsthat permit any desired combination of “a” (follow state ofrecloser contacts) and “b” (opposite recloser contacts)positions.

The switch contacts are insulated for 600 volts and havea continuous current rating of 10 amps. Their interruptingratings are shown in Table 6.

Terminals

The standard terminal is an eyebolt, 1/0 - 500 mcm(630 amps). Eyebolt 4/0 - 1000 mcm (800 amps). 2-holeand 4-hole flat pad terminals, and stud type terminals areavailable as an accessory (see Figure 14). Pole-Mounting Hanger

A pole-mounting hanger (see Figure 12), which boltsdirectly to the recloser frame, is available for pole-mounting installation.

ype NO VA Three-Phase, M icroprocessor-C ontrolled R ecloser Installation and O peration Instructions

ACCESSORIES

Figure 12.Dimensions of Type NOVA recloser with pole-mounting hanger accessory.

TABLE 6Auxiliary Switch Interrupting Ratings

Non- Non-Inductive Inductive Inductive Inductive

ac ac dc dcVolts (amps) (amps) (amps) (amps)

24 – – 15.0 20.0

48 – – 7.5 10.0120 60 80 – –

125 – – 1.5 2.0240 30 60 – – 250 – – 0.45 0.5

Terminal Options B





Dimension A

NOVA 15 791(31.25)

NOVA 27 847(33.25)



Arrester-Mounting Brackets

The arrester-mounting bracket accessory (see Figure 13)can be bolted to the recloser frame and pole-mountinghanger for the addition of inboard and outboard arresters.The arresters are not included with the brackets.

- -

Figure 13.Dimensions of Type NOVA recloser with pole-mounting hanger and arrester-mounting bracket accessories.




Substation-Mounting Frame

A substation-mounting frame accessory (see Figure 14)is available for substation-mounting applications.

Figure 14.Dimensions of Type NOVA recloser with substation-mounting frame accessory.

Terminal Options B





A C

NOVA 15 506 508(20.0) (20.0)

NOVA 27 562 564(22.25) (22.25)



- -

Service Requirements

The Kyle Type NOVA recloser has been designed with aminimum mechanical life of 2500 operations. The NOVArecloser requires routine inspection to check for physicaldamage and verify proper operation.

Frequency of Inspection

Because these reclosers are applied under widely vary-ing operating and climatic conditions, service intervalsare best determined by the user based on actual operat-ing experience.

Testing Operation

This recloser is used with Kyle microprocessor-basedrecloser controls. Refer to the control operation manual.

1. Check the data plate ratings. Make sure the ratingsand settings on the recloser data plate (see Figure11) are correct for the planned testing.

2. Test electrical open and close operation. Closeand open the recloser contacts using the micro-processor control. Confirm that the contacts haveclosed and opened by:

A. The OPEN/CLOSE contact position indicator, or

B. By a continuity check between the recloserterminals.

3. Test manual open. Pull the yellow manual open han-dle (see Figure 11) down to open the recloser con-tacts. Confirm that the contacts have opened by:

A. The OPEN/CLOSE contact position indicator, or

B. By a continuity check between the recloserterminals.

4. To close the recloser contacts:

A. First, push the yellow manual open handle up.

B. Close the recloser using the microprocessor-

based control.

High Potential WithstandTesting

Use the following procedures to perform high-potentiwithstand tests at 75% of the rated low-frequency with

stand voltage for 60 seconds. See Table 7 for test volages and Figure 15 for test connection diagrams.

Test 1

1. Close the recloser contacts.

2. Ground the recloser.

3. Connect terminals 2, 4, and 6 (see Figure 8) togethe

4. Apply proper test voltage (see Table 7) to terminals 24, and 6.

5. The recloser should withstand the test voltage for 6seconds.

Test 2

1. Close the recloser contacts.2. Ground the recloser.

3. Ground Phase A (terminal 2) and Phase C (terminal 6

4. Apply proper test voltage to Phase B (terminal 3).


SERVICE INFORMATION

TABLE 7Type NOVA Recloser Withstand Test VoltageRatings Information

75% of Rated Low-FrequencyWithstand Voltage

(1 minute dry) (kV rms)

Description ac dc

NOVA15 37.5 53.0

NOVA27 45.0 63.5

WARNING: Hazardous voltage. The switchgeaand high voltage transformer must be in a tes

cage or similar protective device to prevent accidentacontact with high voltage parts. Solidly ground alequipment. Failure to comply can result in deathsevere personal injury, and equipment damage. T221.3

CAUTION: Radiation. At voltages up to thespecified test voltages, the radiation emitted by

the vacuum interrupter is negligible. However, abovethese voltages, radiation injurious to personnel can beemitted. G109.2


cedures and safety practices when installing or operat-ing this equipment. Failure to comply can result in death,severe personal injury and equipment damage. G102.1



Test 3

1. Open the recloser contacts.

2. Ground the recloser.

3. Connect and ground terminals 1, 3, and 5 (see Figure 8).

4. Connect terminals 2, 4, and 6.

5. Apply proper test voltage to terminals 2, 4, and 6.


7. Reverse the connections: ground terminals 2, 4, and6.

8. Apply test voltage to terminals 1, 3, and 5 for 60 sec-onds.


Withstand Test Results

The high-potential withstand tests provide information onthe dielectric condition of the recloser and the vacuumintegrity of the interrupters.

If the recloser passes the closed-contacts tests (Tests 1and 2), but fails the open-contacts test (Test 3), the causeis likely to be in the interrupter assembly. Retest each

phase individually to determine the failed phase or phases.If the recloser does not pass Tests 1, 2, or 3, contact anauthorized service center or your Cooper Power Systemsrepresentative.

TROUBLESHOOTINGIf the Type NOVA recloser does not perform as describedin the OPERATION section of this manual, the followinginformation may assist in troubleshooting:

Unit Will Not Close

• Make sure the yellow manual open handle is com-pletely up.

• Check all cables for proper connection.

• Verify that the control has power.

• Upon loss of ac power, check battery level.

• Check ac power supply (potential transformer).

• For NOVA reclosers with dc interface, check the fus-ing on the dc-to-dc converter board located in thecontrol cabinet.

Unit Will Not Open Electrically

• Check all cables for proper connection.

• Verify that the control has power.

ype NO VA Three-Phase, M icroprocessor-C ontrolled Recloser Installation and O peration Instructions

Figure 15.Connection diagrams for high potential withstandtesting.



- -

Figure 16.Wiring diagram for NOVA recloser with ac interface.




Figure 17.Wiring diagram for NOVA recloser with dc interface.



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P.O . B ox 1640Waukesha WI 53187

© 2001 C ooper Industries, Inc.K yle® is a registered trademark of Cooper Industries I nc


Cooper - Recloser - Type NOVA Service Brochure S280-42-1.pdf

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