Mechanism

from Cooper Power Systems

THE ULTIMATE GAS-FREE, OIL-FREE AND

MAINTENANCE-FREE SOLUTION FOR
AUTOMATION, PROTECTION AND SWITCHING
APPLICATIONS

NOVA Technology
Kyle Distribution Switchgear
 Mechanism
NOVA Mechanism
NOVAs simple operating mechanism is designed with
utilities maintenance-free philosophy and desire for
lightweight dielectric material. It is small and light-
weight, reducing installation time and resources.
Customer Benefits
Fewer mechanical parts mean no maintenance.
Tested for a minimum of 10,000 operations to ensure
long, dependable life.
136 kilograms (300 pounds) of magnetic latching
force eliminates maintenance on triggers and align-
ment.
Visible indication of OPEN/CLOSE for safety.
Low-energy power requirement provides deadline
and bi-directional switching.
Reduced training costs via compatibility with Kyles
complete family of controls.
The mechanism uses a proven magnetic latching design
which provides accurate, reliable opening and closing
operations. Two low-voltage heaters prevent condensa-
tion and corrosion. Components are available in plated
steel and aluminum, or stainless steel.
Heater 3-Phase Mechanism
Magnetic Actuator OPEN/CLOSE
Position Indicator
View of operating mechanism with bottom cover removed.
2
Dependable Magnetic Latching
136 kilograms (300 pounds) of magnetic force ensures
complete, undeniable latching. Latching travel is less
than one inch, providing efficient response to ensure
rapid fault clearing and reclosing time. Because latch-
ing is achieved with magnetic force, there are no clos-
ing or opening springs to stretch or break.
10,000 Operations
The mechanism has been tested for a minimum of
10,000 operations with minimal component wear and
no lubrication needed.
Low-Energy Power Requirement
The mechanism can be powered from a control battery,
which is contained in all Kyle recloser controls. The
pulse energy from the battery, used to charge the mech-
anism capacitors, is only 64 watts.
Deadline and Bi-directional Switching
Deadline switching is available from any Cooper
Power Systems control equipped with dc-operated
recloser mechanisms. Several hundred deadline switch-
ing operations are available without ac power.
Distribution automation costs are reduced while pro-
viding greater operational flexibility and reliability.
Manual Open Handle Actuator Board
CT Protection Board Trip & Close Capacitors
 Mechanism

Theory of Operation At the heart of the assembly are two rare earth
A simple design assures reliable operation of the neodymium magnets. The high energy magnets pro-
NOVA mechanism by use of a magnetic actuator. vide latching forces in excess of 136 kilograms (300
Magnetic force provides faster, more efficient latching pounds), eliminating the need for closing/opening
action than mechanical force. Magnetic latching utilizes springs and mechanical latches.
fewer moving parts, which results in less wear on While at rest in the closed position, the magnetic fields
mechanism components. established by the two magnets are coupled in the iron
yoke assembly to provide latching forces for the mov-
Neodymium magnets able plunger. The magnetic forces are concentrated at
Trip Coil
the yoke-plunger interface and provide the latching
force required to keep the mechanism closed. The yoke
also houses the trip and closing coils that provide the
energy to operate the mechanism.
To open the main contacts, the trip solenoid is pulsed
with electrical current which produces an electrical
field. The electrical field, concentrated in the center of
the coil, moves the plunger assembly toward the open
position. As the plunger moves, the magnetic field
strength-density increases as the air gap decreases, due
to the difference in the relative permeability of free
Closing Coil Iron Yoke Assembly space and the ferrous yoke. The magnetic fields are re-
established in the open position to latch the unit open.
Magnetic actuator located inside the mechanism housing.

Magnetic Actuator Operation

Closed Position Trip (Open) Position

S S S
N N N

N N N
S S S

I I

Operation of the Nova magnetic actuator.

3
 Mechanism

Operation of Mechanism Linkage Manual Operation

The mechanism linkage utilizes a short travel distance Manual opening is accomplished using the manual
of approximately 19mm (0.75 inches). This short travel operating handle. When the mechanism is electrically
distance gives the NOVA recloser a fast, consistent closed, the manual opening spring is charged. Once
response time. It also reduces mechanical wear, due to charged, the spring can overcome the 406.5 Nm (300
the minimal amount of travel required to open and foot-pound) latching force of the neodymium magnets
close the device. that holds the contacts in the closed position.
The magnetic actuator is an electromechanical device
capable of extremely fast response times. This attribute
is particularly advantageous for minimizing clearing
and response time in providing instantaneous reclose.
The mechanism used in the NOVA does not use open-
ing or closing springs for electrical operation. When
electrically operating the NOVA mechanism, the reclos-
er makes use of a bi-stable linear actuator that uses two
neodymium magnets, two opposing coils and a
plunger.
Some competitive units use a single coil design in the
magnetic actuator. This coil must induce a magnetic
field which cancels the permanent magnets field dur- OPEN/CLOSE Manual
ing closing or opening operations. Since the direction position indicator operating handle
of the magnetic field must be reversed for tripping ver-
sus closing operations, and since only one coil is used, NOVA recloser manual operating handle.
the field across the magnet must be reversed. Years
ago, during Kyles evaluation of potential technologies,
this scheme was judged highly undesirable due to the
OPEN/CLOSE Position Indicator
potential of demagnetization of the permanent magnet.
Open and close operations of the NOVA mechanism
can be viewed using the indicators in the recloser con-
trols and verified with the Open/Close indicator on the
switchgear.
The contacts OPEN/CLOSE indicator is visible from
side and bottom of unit resulting in a field of vision
spanning roughly 150.

4
 Mechanism

Operational Flexibility Compatible with existing controls

Ultimate operational flexibility is provided by offering
the customer a choice of an ac or dc version of the
NOVA recloser product. Each version incorporates the
same magnetic actuator and is essentially mechanically
equivalent, but differs in electrical operation. Both
ensure reliable operation throughout all operating con-
ditions.
Application Considerations
Through 55 years of industry experience, customers
have become accustomed to the operation of the Kyle
product lines. This familiarity is the basis of the ac
operated NOVA. Today, control power is provided
from a customer-supplied potential transformer, locat-
ed on the source-side of the mechanism. This historical
investment, and complete interchangeability with all
Kyle controls, is the basis of the ac-powered NOVA.
Benefits Include:
Reliable fault clearing
Independent trip operation
Live line closing
Standardization of components such as controls and
cables
Familiar theory of operation
NOVA ac Operation
Consistent with other Kyle reclosers, both 120Vac and
240Vac closing power options are available for the
NOVA ac recloser. The ac voltage is then rectified to
48Vdc to charge the trip and close capacitors and pro-
vide the electrical pulses for the two operating coils on
the magnetic actuator. A trip operation does not require
the presence of ac voltage and recloser closing is
accomplished from the source-side low-voltage input.
Trip and closing signals are provided via the electronic
control to the mechanism through the identical 14 con-
ductor control cable used with all Kyle electronically
controlled reclosers. Retrofitting to an existing installa-
tion simply requires changeout of the switchgear.

NOVA ac

120/240Vac
Energy Source Potential
Transformer
O

NOVA ac N
E
P
(120/240Vac)

Control
Cable Electronic
Control

120Vac/240Vac
14 Pin Cable
Power Cable

NOVA ac cable connections.

5
 Mechanism

NOVA dc Benefits Include:

Customers with installations which require the capabil- Deadline and bi-directional switching
ity for numerous deadline and bi-directional switching Battery backed operation
operations can specify a newly developed NOVA dc. In
Single cable installation
these cases, NOVA operation will come primarily from
a battery contained in the control cabinet, providing Compatible with existing controls with an upgrade kit
several hundred operations. Power is supplied to
charge the control battery and provide voltage for the
mechanism heaters.
Increased use of automation or alternate feeder direc-
tion make this emerging option attractive based on
installation economics.

NOVA dc

Potential
Transformer
19 Pin Cable O

NOVA dc N
E
P
(120/240Vac)

Control
Cable Electronic
Control

120Vac/240Vac
Power Cable

NOVA dc cable connections.

6
 Mechanism
NOVA dc Operation
Trip and close operations are performed with the con-
trol battery and are independent of the ac power pro-
vided. Deadline operation is possible with the addition
of a dc-to-dc converter and interface circuit board to the
control. Retrofit kits are available which allow cus-
tomers to modify existing controls for NOVA dc opera-
tion.
The dc-to-dc converter board converts the controls
24Vdc battery supply to 53Vdc to drive the trip/close
capacitors in the NOVA mechanism. The output of the
board is separately fused and monitored with a red
LED for operator indication. The board also houses
voltage monitoring and conditioning circuits which pro-
tect the control battery from failure and provide hun-
dreds of trip/close operations without ac power.
dc-to-dc converter
board
Recloser interface board
Kyle FXB recloser control with dc-to-dc converter board.
7
A new 19 conductor cable interfaces the NOVA dc to the
control through the interface circuit board. In addition
to control functions, the cable provides ac power to the
mechanism heater. Cable lengths up to 200 feet are per-
mitted.
Upon loss of ac power, trip and close capacitors main-
tain their charge from the control battery.
NOVA Mechanism
The NOVA mechanism uses a proven magnetic latch-
ing design which provides accurate, reliable opening
and closing operations. Designed with a simple operat-
ing mechanism, NOVA is congruent with utilities
maintenance-free philosophy and desire for lightweight
dielectric material. It is small and lightweight, thus
reducing installation time and resources.
The mechanism provides customers with expanded
distribution automation opportunities with the NOVA
ac and NOVA dc. This ensures greater service continu-
ity in electrical system operation.
The magnetic actuator mechanism represents one of the
key building blocks which comprise our modular prod-
uct called NOVA.
 Mechanism

1997 Cooper Power Systems, Inc.

Kyle is a registered trademark of Cooper Industries, Inc. P.O. Box 1640
NOVA is a trademark of Cooper Industries, Inc. Waukesha, WI 53187 USA
www.cooperpower.com

Bulletin 97071 December 1997 New Issue KTM

12/97