Reclosers COOPER POWER

SERIES
Effective May 2017
MN280083EN Supersedes August 2005 (S280-70-11)

Form 6 recloser control disassembly, reassembly, and

testing instructions

F6 Recloser Control
COOPER POWER
SERIES

COOPER POWER
SERIES
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY
The information, recommendations, descriptions and safety notations in this document are based on Eaton Corporation’s
(“Eaton”) experience and judgment and may not cover all contingencies. If further information is required, an Eaton sales
office should be consulted. Sale of the product shown in this literature is subject to the terms and conditions outlined in
appropriate Eaton selling policies or other contractual agreement between Eaton and the purchaser.
THERE ARE NO UNDERSTANDINGS, AGREEMENTS, WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES
OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY
EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON. THE
CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES.
In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or
other-wise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to
damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of
existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information,
recommendations and descriptions contained herein. The information contained in this manual is subject to change
without notice.

testing instructions MN280083EN May 2017 i

Contents

DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Safety for life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Product information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ANSI Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Quality standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Acceptance and initial inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Handling and storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Open the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal/replacement of CPU board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal/replacement of communications
accessory board only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal/replacement of i/o board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal/replacement of power supply or recloser interface board (RIF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal/replacement of analog board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Place module in control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Before placing the recloser control into service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Initial programming prior to installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Form 6 recloser control testing instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Communication ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Contact input/outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Testing with type MET tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Additional information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Replacement Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Factory-authorized service centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Factory testing and troubleshooting classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

ii testing instructions MN280083EN May 2017

 !
SAFETY
!
Safety for life
SAFETY
FOR LIFE FOR LIFE

Eaton meets or exceeds all applicable industry standards relating to product safety in its Cooper Power™ series products.
We actively promote safe practices in the use and maintenance of our products through our service literature, instructional
training programs, and the continuous efforts of all Eaton 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 working around
high voltage lines and equipment, and support our “Safety For Life” mission.

Safety information
The instructions in this manual are not intended as a Safety instructions
substitute for proper training or adequate experience in the
Following are general caution and warning statements that
safe operation of the equipment described. Only competent
apply to this equipment. Additional statements, related to
technicians who are familiar with this equipment should
specific tasks and procedures, are located throughout
install, operate, and service it.
the manual.
A competent technician has these qualifications:
• Is thoroughly familiar with these instructions.
DANGER
• Is trained in industry-accepted high and low-voltage safe
operating practices and procedures. Hazardous voltage. Contact with hazardous voltage will
cause death or severe personal injury. Follow all locally
• Is trained and authorized to energize, de-energize, clear, approved safety procedures when working around
and ground power distribution equipment. high- and low-voltage lines and equipment. G103.3

• Is trained in the care and use of protective equipment

such as arc flash clothing, safety glasses, face shield, hard
hat, rubber gloves, clampstick, hotstick, etc. WARNING
Following is important safety information. For safe Before installing, operating, maintaining, or testing this
installation and operation of this equipment, be sure to read equipment, carefully read and understand the contents
and understand all cautions and warnings. of this manual. Improper operation, handling or
maintenance can result in death, severe personal injury,
and equipment damage. G101.0
Hazard Statement Definitions
This manual may contain four types of hazard statements:
WARNING
DANGER This equipment is not intended to protect human
life. Follow all locally approved procedures and safety
Indicates an imminently hazardous situation which, if practices when installing or operating this equipment.
not avoided, will result in death or serious injury. Failure to comply can result in death, severe personal
injury and equipment damage. G102.1
WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
WARNING
Power distribution and transmission equipment must
CAUTION be properly selected for the intended application. It
must be installed and serviced by competent personnel
Indicates a potentially hazardous situation which, if not who have been trained and understand proper safety
avoided, may result in minor or moderate injury. procedures. These instructions are written for such
personnel and are not a substitute for adequate training
CAUTION and experience in safety procedures. Failure to properly
select, install or maintain power distribution and
Indicates a potentially hazardous situation which, if not transmission equipment can result in death, severe
avoided, may result in equipment damage only. personal injury, and equipment damage. G122.3

testing instructions MN280083EN May 2017 iii

Form 6 recloser control disassembly, reassembly, and testing instructions

Product information ●● Service Information MN280076EN Form 6 Yard Mount

Recloser Control Installation and Operation Instructions

Introduction ●● Service Information MN280077EN Form 6 Pole Mount

Recloser Control installation and Operation Instructions
Service Information MN280083EN provides disassembly,
reassembly, and testing instructions for the Eaton Cooper ●● Service Information MN280080EN Form 6 Triple-Single
Power series Form 6 recloser control. Pole Mount Recloser Control Installation and Operation
Instructions
Read this manual first
Read and understand the contents of this manual and follow Disassembly
all locally approved procedures and safety practices before
installing or operating this equipment.

Form 6 recloser control disassembly instructions

Additional information These instructions describe the disassembly of the Form
These instructions cannot cover all details or vari­ations 6 recloser control.
in the equipment, procedures, or process described, nor
provide directions for meeting every possible contin­gency CAUTION
during installation, operation, or maintenance. For additional
information, contact your Eaton representative. Recloser misoperation. The control must be removed
from service prior to performing any main-tenance,
testing, or programming changes. Failure to comply
ANSI Standards can result in misoperation (unintentional operation) of
Eaton Cooper Power series reclosers are designed and the recloser. T216.2
tested in accordance with the following ANSI standards:
C37.60 and C37.85 and ANSI Guide C37.61. 1. Remove the Form 6 Control from Service. Refer to
appropriate Service Information Instructions:
Quality standards ●● Service Information MN280075EN Form 6 Rack Mount
ISO 9001-certified quality management system Control Installation and Operation Instructions Remove
the Control from Service section
Acceptance and initial inspection ●● Service Information MN280076EN Form 6 Yard Mount
Control Installation and Operation Instructions Remove
Each unit is in good condition at the factory and when the Control from Service section
accepted by the carrier for shipment.
Upon receipt, inspect the carton for signs of damage. ●● Service Information MN280077EN Form 6 Pole Mount
Unpack the unit(s) and inspect it thoroughly for damage Control Installation and Operation Instructions Remove
incurred during shipment. If damage is discovered, file a the Control from Service section
claim with the carrier immediately.
●● Service Information MN280080EN Form 6 Triple Single
Pole Mount Control Installation and Operation Instructions
Handling and storage Remove the Control from Service section
Be careful during handling and storage of the unit to
min-imize the possibility of damage. If the unit is to be Important:
stored for any length of time prior to installation, provide a
clean, dry storage area. Make sure the power is turned off and the battery is
disconnected.
Description
Service Information MN280083EN provides disassembly, IMPORTANT
reassembly, and testing instructions for the Form 6 Rack Isolate all power connections to the Form 6 recloser
Mount, Yard Mount, Pole Mount, and Triple-Single Pole control, i.e., AC voltage sensing and SCADA, before
Mount recloser controls. removing control from service.
For additional information on installing the control, removing 2. Carefully transport the recloser control to a suitable
the control from service, and control testing procedures, service facility.
refer to the appropriate instructions:
NNote: The entire disassembly, reassembly, and testing
●● Service Information MN280075EN Form 6 Rack Mount process should be conducted in a clean environ-
Recloser Control Installation and Operation Instructions
ment, such as a repair shop.

1 testing instructions MN280083EN May 2017

Form 6 recloser control disassembly, reassembly, and testing instructions

 CAUTION
Equipment damage. Always wear a grounding wrist
strap to control static electricity before handling circuit
boards. Failure to use this strap may result in circuit
board damage. T253.1
Hex Nuts

  WARNING
Equipment misoperation. Use of the ProView operating
system may result in the creation of many combinations
of settings and scheme files. Many of these
combinations can be downloaded into any device using
the ProView operating system. Before downloading
settings and scheme files to the equipment, verify they
are tested and correct for the location and application.
Downloading settings or scheme files designed for a
different location or application can result in death,
severe personal injury, and equipment damage. G169.0

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

3. Remove module from cabinet as applicable.
A. For complete scheme structure and verification Figure 2.  Location of the four mounting nuts on the
refer to appropriate instructions: front of the Form 6 pole mount control.
●● Service Information S280-70-4 Form 6 Control Open the module
Schemes section
1. Discharge internal capacitors using a 10 ohm (5 watt)
●● Service Information S280-70-9 Form 6-TS Control load across TB6-1 and TB6-7 for five seconds.
Schemes section
2. Use a flat-head screwdriver to unscrew the six front
B. Disconnect SCADA communications to the panel screws.
Form 6 control. 3. Pull the right side of the panel outward toward the left.
C. Remove all applicable connecting wires NNote: Various wire connections will keep the front panel
from module. attached to the control module. This will allow the
D. Remove the 7/16 inch grounding nut and display panel to be placed next to the control
lock-washers located on the bottom of the control module while work on internal circuit boards takes
module (Figure 2). place (Figure 4).
E. Remove the four mounting nuts that secure the
front of the module to the cabinet (Figure 3).

CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4

1 3 5 7 9 11 13 15 17 19
TB1 J1 RS232 J2 IRIG-B J3 RS485

2 4 6 8 10 12 14 16 18 RS232 DTE TTL IRIG-B 2-Wire RS485

CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4

CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11 CO12
1 3 5 7 9 11 13 15 17 19 21 1 3 5 7 9 11 13
TB3 TB4

2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11CO12

RECLOSER INTERFACE CONNECTIONS

A D F
TB5 1 3 5 7 TB6

10 9 8 7 6 5 4 3 2 1
2 4 6
B C E

• • • • • • • • • •
TB2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Internal ribbon wire

Primary Connector Board
I(1-2) I(3-4) I(5-6) I(SEF) V(1-2) V(3-4) V(5-6) V1

Grounding Nut
and Lockwashers

Figure 1.  Location of grounding nut and lockwashers Figure 3.  Form 6 control internal ribbon wire.
on the rear panel of the Form 6 pole mount control
(below SN 10000).

testing instructions MN280083EN May 2017 2

Form 6 recloser control disassembly, reassembly, and testing instructions

4. Disconnect the ribbon wire assembly from the primary 5. If a new back plate is included with the kit, unscrew
connector board by lifting the locking tabs on either the six back plate screws using a Phillips-head
side and pulling out the connector. screwdriver and replace the back plate (Figure 5).
5. Use a flat-head screwdriver to loosen the five captive 6. Slide mounting plate into card guide and carefully line
screws on the primary connector board. up terminal strip to opening on the back plate.
6. Holding the middle two screws on the primary 7. Replace all of the terminal block strips.
connector board, firmly pull the primary connector
board outward working left to right so as not to 8. Attach the new back plate over the communications
bend pins. port on the back panel using two screws and washers
provided with kit.
Removal/replacement of CPU board 9. Configure communications board with applicable
switches and program as necessary.
CAUTION
 CAUTION
Equipment damage. Always wear a grounding wrist
strap to control static electricity before handling circuit Equipment misoperation. Do not connect this control
boards. Failure to use this strap may result in circuit to an energized recloser until all control settings have
board damage. T253.1 been properly programmed and verified. Refer to the
programming information for this control. Failure to
1. Remove CPU board. Refer to Form 6 Recloser Control comply can result in control and recloser misoperation,
Disassembly Instructions section. equipment damage, and personal injury. G110.3

2. Remove the TB1 terminal block strip from the back of Communications
the module (Figure 2). Back Panel
3. Carefully pull CPU board outward so as not to damage
the capacitor or any of the electrical components on CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4
the Bezel tabs (Figure 6). TB1
1 3 5 7 9 11 13 15 17 19 J1-RS-232

4. Proceed as appropriate for kit contents: 2 4 6 8 10 12 14 16 18

RS-232 DTE
IRIG-B

CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4

●● If mounting plate is included with the kit proceed to CI4 CI5 CI6
1 3 5
CI7 CI8 CI9 CI10 CI11 CO5
7 9 11 13 15 17 19
CO6
21
CO7 CO8 CO9 CO10 CO11 CO12
1 3 5 7 9 11 13

step 5. TB3 TB4

●● If mounting plate is not included with the kit continue 2 4 6

CI4 CI5 CI6
8 10 12 14 16 18 20
CI7 CI8 CI9 CI10 CI11 CO5 CO6
2 4 6 8 10 12
CO7 CO8 CO9 CO10 CO11CO12

with this step.

RECLOSER INTERFACE CONNECTIONS
A D F
TB5 1 3 5 7 TB6
A. Unscrew the five captive screws on top of the
CPU board to release it from the mounting plate. 10 9 8 7 6 5 4 3 2 1
2 4 6
B C E
B. Flip the mounting plate over and remove the two
mounting screws from the bottom of the TB2 1
•
2
•
3 4
•
5 6
•
7 8
•
9 10
•
11 12
•
13 14
•
15 16
•
17 18
•
19 20

mounting plate.
I(1-2) I(3-4) I(5-6) I(SEF) V(1-2) V(3-4) V(5-6) V1
C. Lift the CPU from the mounting plate.
D. Install new CPU onto mounting plate and replace
the five captive screws. Figure 4.  Form 6 control back plate.
E. Flip mounting plate over and replace the mounting
screws on the bottom of the mounting plate.

3 testing instructions MN280083EN May 2017

Form 6 recloser control disassembly, reassembly, and testing instructions

Shield Tabs
Bezel Tabs

Capacitor

CPU and Communications Board

Input/Output Board

Power Supply and RIF Board

Analog Board

Figure 5.  Internal view of the Form 6 pole mount recloser control module.

Removal/replacement of communications NNote: Form 6 Rack Mount Controls with serial numbers
accessory board only below 20,000 and Form 6 Pole and Yard Mount
Controls with serial numbers below 10,000 will need
The Form 6 control is equipped with a Communication an additional CPU replacement kit to upgrade a
Board Accessory (expansion bay) offering versatile
communications board. Refer to KME6-3837-3S
support for modern communication media. Seven distinct
(pole mount) or KME6-3837-4S (rack/yard mount).
communication options are available, providing two-way,
real time digital communications with a remote terminal This procedure will be used when changing communications
unit (RTU), wireless, telephone modem, Ethernet net-work, accessory board:
or other communication devices. The following options
are available: 1. Remove the CPU circuit board. Refer to Form 6
Removal/Replacement of CPU Board section.
●● No auxiliary communication card installed (standard)
2. Remove the TB1 terminal block strip from the back of
●● RS485 (isolated) Serial Communication Card the module (Figure 2).
(KME6-3839-1S)
3. Carefully pull the CPU board outward so as not
●● Fiber-optic-based Serial Communication Card (ST) to damage the capacitor or any of the electrical
(KME6-3839-2S) components on the Bezel tabs (Figure 6).
●● 10/100 Base-T dual Ethernet Communication Card 4. Install two standoffs with copper washers into the
(2*RJ-45) (KME6-3839-5S) holes on the left side of the CPU board (Figure 7).
●● 100 Base-FX dual Ethernet Communication Card 5. Carefully install the communication board onto the CPU
(2*MT-RJ) (KME6-3839-3S) board so as to not bend any connections.
●● 10/100 Base-T, 100 Base-FX Ethernet Communication 6. Install two screws with lock washers onto the
Card (RJ-45 + MT-RJ) Multi-mode (KME6-3839-4S) communications board.
●● 100 Base FX dual Ethernet Communication Card (2 SC) NNote: Use 10 in-lbs. of torque. Do not overtighten standoffs.
Single-Mode (KME6-3839-6S)
7. Slide mounting plate into card guide and carefully push
Additional accessories are being continuously developed. the assembly into the module.
Contact your Eaton representative for the latest
information regarding particular media and communication
protocol support.

testing instructions MN280083EN May 2017 4

Form 6 recloser control disassembly, reassembly, and testing instructions

IMPORTANT 5. Lift I/O board from shield.

Do not damage the capacitor or any other electrical 6. Install new I/O board onto mounting plate and replace
components on the Bezel tabs (Figure 6). the five screws.
7. Slide mounting plate into card guide and carefully line
8. Replace the TB1 terminal block strip. up terminal strip to opening on the back plate.
9. Attach fiber/wire cover plate over the communications 8. Replace the TB3 and TB4 terminal block strips.
port on the back panel using two screws and washers.
10. Configure communications board with applicable Removal/replacement of power supply or recloser
switches, and program as necessary. interface board (RIF)
NNote: The Form 6 pole mount control will not contain an
 CAUTION internal power supply board.
Equipment misoperation. Do not connect this control 1. Remove the power supply or RIF circuit board. Refer to
to an energized recloser until all control settings have Form 6 Recloser Control Disassembly Instructions
been properly programmed and verified. Refer to the section.
programming information for this control. Failure to
comply can result in control and recloser misoperation, 2. Remove the TB5 and TB6 terminal block strips from
equipment damage, and personal injury. G110.3
back of the control module (Figure 2).
3. Carefully pull power supply and RIF board mounting
Standoff plate outward (Figure 4). Disconnect wire assembly
from the display assembly.
4. Unscrew the four screws on top of the power supply or
RIF board using a Phillips-head screwdriver.
5. Lift power supply board off of mounting plate and
carefully separate the board to board connector
between the RIF and the power supply board.
6. Install new power supply board onto mounting plate
and replace the four screws.
7. Slide mounting plate into card guide and carefully line
up terminal block strip to opening on the back plate.
8. Replace the TB5 and TB6 terminal block strips.

Removal/replacement of analog board

1. Remove the analog circuit board. Refer to Form 6
Recloser Control Disassembly Instructions section.
2. Remove the bottom two screws on the outside of the
right panel, left panel, and back plate of the module.
3. Remove the two screws on the bottom panel located
under the TB2 terminal block strip (Figure 6).
Standoff 4. If applicable disconnect each wire connector from the
TB2 terminal block strip.
Figure 6.  Location of standoffs on CPU board. 5. Remove bottom panel carefully so as not to remove
Removal/replacement of i/o board grounding strip.
1. Remove the I/O circuit board. Refer to Form 6 Recloser 6. Unscrew the five screws on top of the analog board
Control Disassembly Instructions section. using a Phillips-head screwdriver.
2. Remove the TB3 and TB4 terminal block strips or cover 7. Install new analog board onto mounting plate and
plate from the back of the control module (Figure 2). replace the five screws.
3. Carefully pull I/O board outward so as not to damage 8. Reconnect each of the wire connectors to the TB2
any of the electrical components. terminal block strip (Table 1).
4. Unscrew the five screws on top of the I/O board 9. Slide mounting plate into card guide and replace each
using a Phillips-head screwdriver to release it from the of the two screws on the right panel, left panel, back
mounting plate. panel, and bottom of the control housing.

5 testing instructions MN280083EN May 2017

Form 6 recloser control disassembly, reassembly, and testing instructions

Table 1.  Form 6 yard and pole mount (below S/N 10000) 4. Carefully attach ribbon cable to the ribbon wire
control TB2 wiring connections connector and secure locking tabs.
TB2 Wire color 5. Replace the front panel.
1 White/BlacK 6. Carefully thread each of the six front panel screws
2* Black* into place.
3 Red/Black NNote: Use 5-7 in-lbs. of torque. Do not cross thread
4* Black* or overtighten.
5 Green/Black 7. Tighten each screw in an alternating manner.
6* Black* 8. Check all fasteners for tightness and assure that all
7* Black* connections are properly made before applying power.

8 Orange/Black
Place module in control
9 White/Red RW
For Yard and Pole mount modules, rewire TB2 terminal block
10 White/Brown RW strip per Table 1.
11 Black RW 1. Place the module into the control,
12 White RW
2. Secure the module with the four mounting screws.
13 Gray RW
3. Replace the 7/16 inch nut (with appropriate lock-
14 Violet RW washers) located below the TB2 terminal block strip.
15 Blue RW
4. Connect all wires.
16 Green RW
5. Place the control in service. Refer to the Before
17 Yellow RW Placing the Recloser Control into Service section.
18 Orange RW 6. Apply local procedures to enable an electronic
19 Red RW recloser control.
20 Brown RW 7. Reconnect SCADA communications to the Form 6.
* = Wire connected together
RW = Ribbon wire Before placing the recloser control into service

Reassembly  CAUTION
Equipment misoperation. Do not connect this control
to an energized recloser until all control settings have
Form 6 recloser control reassembly instructions been properly programmed and verified. Refer to the
programming information for this control. Failure to
These instructions describe the reassembly of the Form 6
comply can result in control and recloser misoperation,
recloser control.
equipment damage, and personal injury. G110.3

1. Ensure that the board that was serviced or replaced is

seated firmly and has been aligned properly. Prior to placing the Form 6 recloser control into service,
NNote: All connections must be made carefully to ensure installation procedures must be properly completed and
proper alignment. verified.
For information on placing the control into service refer to
CAUTION the appropriate instructions:
Equipment damage. Use care to properly align and seat ●● Service Information MN280075EN Form 6 Rack Mount
connection pins to the terminal block strips. Failure to Control Installation and Operation Instructions
comply can result in equipment damage and protective
device misoperation. T317.0
●● Service Information MN280076EN Form 6 Yard Mount
Control Installation and Operation Instructions

2. Carefully seat the primary connector board at each of ●● Service Information MN280077EN Form 6 Pole Mount
the five captive screws sites using gentle pressure so Control installation and Operation Instructions
as not to bend any connection pins. ●● Service Information MN280080EN Form 6 Triple-Single
3. Using a flat-head screwdriver tighten the five Pole Mount Control Installation and Operation Instructions
captive screws.

testing instructions MN280083EN May 2017 6

Form 6 recloser control disassembly, reassembly, and testing instructions

Installation Contact input/outputs

 CAUTION Standard default supervisory input

control and output status contacts
Equipment misoperation. Do not connect this control Test inputs/outputs by asserting appropriate alarms per the
to an energized recloser until all control settings have ProView™ software to verify that all contact outputs operate
been properly programmed and verified. Refer to the (open and close). Figures 8 and 9 show the location of the
programming information for this control. Failure to controls module manufacturing numbers. Refer to Tables 2
comply can result in control and recloser misoperation, and 3 for Operating Voltage Requirements for Standard and
equipment damage, and personal injury. G110.3
Optional Supervisory Inputs.

CAUTION
NOTICE
Equipment misoperation. Check minimum trip
values prior to changing an alternate profile. Failure External leads must be shielded and the shield must
to do so may cause misoperation of the recloser be grounded at both ends. Terminate each lead with
under load conditions. T280.1
a 320VAC, 150 Joules metal oxide varistor (MOV), or
equivalent, at the remote end. Attach MOV’s between
the leads and ground. Failure to properly shield and
IMPORTANT protect leads can result in equipment damage and/or
unintentional operation.
Program all protection profiles. Unused alternate profiles
should be programmed with the same settings as one For information on testing refer to the appropriate instructions:
of the applicable profiles. Default settings on unused
alternate profiles can cause unnecessary outages if they ●● Service Information MN280075EN Form 6 Rack Mount
are below normal system requirements. Control Installation and Operation Instructions
●● Service Information MN280076EN Form 6 Yard Mount
Initial programming prior to installation Control Installation and Operation Instructions
The control must be programmed with all necessary ●● Service Information MN280077EN Form 6 Pole Mount
operating settings, all alternate profiles, and parameters Control Installation and Operation Instructions
prior to operation with an energized recloser.
●● Service Information MN280080EN Form 6 Triple-Single
NNote: Initial programming of the control is the responsibility of Pole Mount Control Installation and Operation Instructions
a qualified technician or engineer familiar with control
functions and programming parameters required for the
specific recloser installation. *Location of TB1
1
CI1
3
CI2
5
CI3 SS1
7 9
CO1 CO2 CO3 CO4
11 13 15 17 19
J1 RS232 J2 IRIG-B J3 RS485

Module Mfg. No. 2 4 6 8 10 12 14 16 18 RS232 DTE TTL IRIG-B 2-Wire RS485

The control must be programmed with the Form 6 ProView

CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4
CI4 CI5 CI6 CI7 CI8 CI9 CI10 CI11 CO5 CO6 CO7 CO8 CO9 CO10 CO11 CO12

Refer to Table 2
1 3 5 7 9 11 13 15 17 19 21 1 3 5 7 9 11 13
TB3 TB4

interface software. Refer to the appropriate control 2 4 6

CI4 CI5 CI6
8 10 12 14 16 18 20
CI7 CI8 CI9 CI10 CI11 CO5 CO6
2 4 6 8 10 12
CO7 CO8 CO9 CO10 CO11CO12

programming guide for information: Mfg. No. 6A0016010XX

TB5
RECLOSER INTERFACE CONNECTIONS
A
1
D
3
F
5 7 TB6

10 9 8 7 6 5 4 3 2 1

●● S280-70-4 Form 6 Control Programming Guide • • • • • • •

2
B

•
4
C
6
E

• •
TB2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

●● S280-70-9 Form 6 Triple-Single Pole Mount Control I(1-2) I(3-4) I(5-6) I(SEF) V(1-2) V(3-4) V(5-6) V1

Programming Guide

Testing

Form 6 recloser control testing instructions

These instructions describe the testing of the Form 6
1 2 3 4 7 8 9 10 11 12

recloser control.

Communication ports
1 2 3 4 5 6

Power Connections

Verify that the communication settings have been appropri-

ately configured for your selected communication protocol.
For information on configuring communications refer to the
Figure 7.  Module Mfg. No. location on back of Form 6
appropriate instructions:
pole mount control.
●● S280-70-4 Form 6 Control Programming Guide
●● S280-70-9 Form 6 Triple-Single Control Programming Guide

7 testing instructions MN280083EN May 2017

Form 6 recloser control disassembly, reassembly, and testing instructions

Table 2.  Operating voltage requirements for standard ●● Overcurrent Timing

and optional supervisory inputs for form 6 pole mount
recloser control
●● Reclose Time

Module Input voltage Nominal Minimum

●● Operating Sequence
Mfg. No.* current operating time ●● Reset Time
6A00160101 12 Vdc – 48 Vdc 5 mA 5 milliseconds
The MET Tester is completely self-contained, capable
through
6A00160104
of performing all required checks and tests to verify
over-current protection parameters.
6A00160105 48 Vdc – 125 Vdc, 5 mA 5 milliseconds
through 120 Vac Refer to Service Information MN280067EN Type MET
6A00160108 Electronic Recloser Control Tester Operating Instructions
for proper setup and use of the MET Tester.
6A00160161 12 Vdc – 250 Vdc, 5 mA 5 milliseconds
120 Vac-240 Vac
6A00160160
(Triple-Single)
Refer to Figure 6 for location of Module Mfg. No.

Table 3.  Operating Voltage Requirements for Standard

and Optional Supervisory Inputs for Form 6 Rack and
Yard Mount Recloser Controls
Minimum
Module Nominal operating
Mfg. No.* Input voltage current time
6A00160121 12 Vdc – 48 Vdc 5 mA 5 milliseconds
through
6A00160128
6A00160129 48 Vdc – 125 Vdc, 5 mA 5 milliseconds
through 120 Vac
6A00160136
6A00160170 12 Vdc – 250 Vdc 5 mA 5 milliseconds
120 Vac – 240 Vac
*Refer to Figure 7 for location of Module Mfg. No.
C + –

CI1 CI2 CI3 SS1 CO1 CO2 CO3 CO4

RS-485
1 3 5 7 9 11 13 15 17 19
J1-RS-232
TB1
IRIG-B

*Location of RS-232 DTE

Module Mfg.
2 4 6
CI1 CI2
8 10 12 14 16 18
CI3 SS1 CO1 CO2 CO3 CO4
Figure 9.  Type MET electronic recloser control tester.
No. Refer to CI4 CI5 CI6
1 3 5
CI7 CI8 CI9 CI10 CI11 CO5
7 9 11 13 15 17 19
CO6
21
CO7 CO8 CO9 CO10 CO11 CO12
1 3 5 7 9 11 13
Table 3 TB3 TB4
Additional testing required
2 4 6
CI4 CI5 CI6
8 10 12 14 16 18 20
CI7 CI8 CI9 CI10 CI11 CO5 CO6
2 4 6 8 10 12
CO7 CO8 CO9 CO10 CO11CO12 apply and verify source side voltage levels per your local
Mfg. No. 6A0016010XX
RECLOSER INTERFACE CONNECTIONS
standard utility procedures.
INPUT POWER AUXILIARY POWER
FUSE + - A D F
FUSE
TB5 1 5 1 3 5 7 TB6

(10 AMP) (10 AMP) 2

-
4
+
28 VDC 2
B
4
C
6
E
Additional information
• • • • • • • • • •
TB2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

CAUTION
I(1-2) I(3-4) I(5-6) I(SEF) V(1-2) V(3-4) V(5-6) V1

This equipment requires routine inspection and

maintenance to ensure proper operation. If it is not
Figure 8.  Module mfg. No. Location on back of form 6 maintained, it can fail to operate properly. Improper
operation can cause equipment damage and possible
rack and yard mount control.
personal injury. G105.1

Testing with type MET tester

Use the Type MET electronic recloser control tester
(Figure 10) to test the following functions of the Form 6 Replacement Kits
recloser control: Replacement kits for the Form 6 recloser controls are
available through the factory Service Department. To order

testing instructions MN280083EN May 2017 8

Form 6 recloser control disassembly, reassembly, and testing instructions

these kits, refer to the Replacement Parts price list S260-01

through S280-01 for catalog numbers and pricing. Contact
your Eaton representative for additional information and
order procedures.

Factory-authorized service centers

Factory-authorized service centers are located through-out
the continental United States to provide maintenance,
repair and testing services for Eaton Cooper Power series
controls and reclosers. For further information, contact your
Eaton representative.

Factory testing and troubleshooting classes

The factory service department offers a basic testing and
troubleshooting course for the Form 6 microprocessor-based
recloser control. This course, taught by experienced
service technicians, is held at the factory’s inhouse
training facility. For additional information, contact your
Eaton representative.

Type MET recloser control tester

A 30-minute video program KSPV7 Type MET Electronic
Recloser Control Tester Operation and Testing
Procedures is available as a supplemental training aid for
service personnel.

9 testing instructions MN280083EN May 2017

Form 6 recloser control disassembly, reassembly, and testing instructions

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testing instructions MN280083EN May 2017 10

Form 6 recloser control disassembly, reassembly, and testing instructions

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11 testing instructions MN280083EN May 2017

 !
SAFETY
FOR LIFE

Eaton
1000 Eaton Boulevard
Cleveland, OH 44122
United States
Eaton.com

Eaton’s Power Systems Division

2300 Badger Drive
Waukesha, WI 53188
United States
Eaton.com/cooperpowerseries

© 2017 Eaton
All Rights Reserved
Printed in USA Eaton is a registered trademark. For Eaton’s Cooper Power series product
Publication No. MN280083EN information
KA2048-637 REV 02 All trademarks are property call 1-877-277-4636 or visit:
May 2017 of their respective owners. www.eaton.com/cooperpowerseries.