NOJA-7478-00

USER GUIDE

RC10-OSM200
RC15-OSM200
NOJA-7478-00

Revision History
Rev Author Date Comment
0 OA 28-07-2017 Initial Release

Source: S:\Marketing-500\User Manuals\OSM-200 OSM-203 OSM-079-RC-10ES-200\NOJA-7478-00 RC-10-15-OSM200 User Guide

NOJA Power® and OSM® are registered trademarks of NOJA Power Switchgear Pty Ltd. This document
is copyright and is intended for users and distributors of NOJA Power Switchgear product. It contains
information that is the intellectual property of NOJA Power Switchgear and the document, or any part
thereof, should not be copied or reproduced in any form without written permission from NOJA Power
Switchgear.
NOJA Power® and OSM® are registered trademarks of NOJA Power Switchgear and should not be
reproduced or used in any way without written authorisation.
NOJA Power Switchgear applies a policy of ongoing development and reserves the right to change product
without notice. NOJA Power Switchgear does not accept any responsibility for loss or damage incurred as a
result of acting or refraining from action based on information in this User Manual.

© NOJA Power Switchgear Pty Ltd 2002 - 2017

www.nojapower.com.au
 NOJA-7478-00

CONTENTS
1 INTRODUCTION ..................................................................................................................................................... 1
1.1 APPLICABILITY ...................................................................................................................................................... 1
1.2 SAFETY INFORMATION .......................................................................................................................................... 1
1.2.1 Personnel Competence .................................................................................................................................................... 1
1.2.2 Hazard Statements ........................................................................................................................................................... 2
1.2.3 Safety Instructions ........................................................................................................................................................... 2
1.3 CUSTOMER ACCEPTANCE AND INITIAL INSPECTION .............................................................................................. 3
2 RECLOSER CONTROL CUBICLE ....................................................................................................................... 4
2.1 DIMENSIONS – RECLOSER CONTROL CUBICLE ...................................................................................................... 5
2.2 FUNCTIONAL DIAGRAM ......................................................................................................................................... 6
2.3 CONTROL MANAGEMENT SOFTWARE (CMS) ........................................................................................................ 7
2.4 CONTROL CABLE ................................................................................................................................................... 7
2.5 INTERFACE TEST SET............................................................................................................................................. 7
2.6 POWER SUPPLY MODULE (PSM) ........................................................................................................................... 8
2.7 COMPARISON RC01 AND RC10/15-OSM200 ........................................................................................................ 9
3 MEASUREMENT ................................................................................................................................................... 11
3.1 SAMPLING AND FILTERING .................................................................................................................................. 12
3.2 MEASUREMENT SETTINGS ................................................................................................................................... 12
3.3 PROTECTION ACCURACY ..................................................................................................................................... 13
4 INSTALLATION ..................................................................................................................................................... 14
4.1 DE–CRATING ....................................................................................................................................................... 14
4.1.1 Control Cable/Adaptor .................................................................................................................................................. 14
4.2 RC CUBICLE PREPARATION ................................................................................................................................. 14
4.2.1 Auxiliary Supply Connections........................................................................................................................................ 14
4.2.2 Initial Checks ................................................................................................................................................................. 15
4.3 LIFETIME COUNTERS ........................................................................................................................................... 17
4.4 CALCULATING NEW SWITCHGEAR COEFFICIENTS................................................................................................ 18
4.5 SITE INSTALLATION ............................................................................................................................................. 19
4.5.1 Transport to Site ............................................................................................................................................................ 19
4.5.2 Uninstall existing RC01 ................................................................................................................................................. 19
4.5.3 Installation of new control cubicle ................................................................................................................................ 19
4.5.4 Earthing ......................................................................................................................................................................... 19
4.5.5 Control Cable ................................................................................................................................................................ 21
4.5.6 Auxiliary Supply ............................................................................................................................................................ 23
4.5.7 Communications Interface ............................................................................................................................................. 23
4.5.8 Connect to the Controller with CMS ............................................................................................................................. 23
4.5.9 Update Lifetime Counters .............................................................................................................................................. 24
4.5.10 Update Switchgear Coefficients..................................................................................................................................... 25
4.5.11 Update Settings.............................................................................................................................................................. 27
5 MAINTENANCE ..................................................................................................................................................... 28
5.1 OSM RECLOSER .................................................................................................................................................. 28
5.1.1 OSM Actuator Coil Resistance Testing.......................................................................................................................... 28
5.1.2 OSM Current Sensor Resistance Testing ....................................................................................................................... 28
5.1.3 Microswitch Status Testing ............................................................................................................................................ 28
5.1.4 OSM HV Contact Resistance Testing ............................................................................................................................ 28
5.2 CONTROL CABLE ................................................................................................................................................. 29
5.3 SCHEMATICS........................................................................................................................................................ 30
5.3.1 RC General Layout ........................................................................................................................................................ 30
5.3.2 Power Supply Wiring Diagram...................................................................................................................................... 31
6 APPENDICES .......................................................................................................................................................... 32
6.1 APPENDIX A - CONVERTING THE DEFAULT MEAN COEFFICIENTS ....................................................................... 32
6.2 APPENDIX B - CALIBRATING VOLTAGE AND CURRENT MEASUREMENTS ............................................................ 33
7 INDEX ...................................................................................................................................................................... 35
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REFERENCED DOCUMENTS .................................................................................................................................... 36

 NOJA-7478-00

1 Introduction
This user guide describes the process for replacing an existing RC01 control cubicle connected to a 200 or
079 Series Recloser with a NOJA Power RC10-OSM200 or RC15-OSM200 cubicle.

The RC10-OSM200 and RC15-OSM200 cubicles provide a number of benefits over the RC01 as they
include additional protection features, advanced automation functionality and a number of additional
protocols.

Both cubicles are a slight variation of the standard control cubicles, RC10 and RC15, as they include a SIM-
03 module to connect to reclosers which use Rogowski sensors for current measurements. The RC15-
OSM200 includes Wi-Fi, GPS and Mobile Network connectivity options.

The replacement of the RC01 control cubicle is simplified by allowing the user to keep the existing control
cable by utilising an adaptor to connect to the new SIM module. NOJA Power has also developed a
spreadsheet which can be used to update the switchgear coefficients to work with the new controller.

This document provides the following information for the RC10-OSM200 and RC15-OSM200 cubicles:
 Overview
 Drawings
 Installation
 Maintenance details.
For details on the specifications and functionality provided by the RC10 and RC15 cubicles, please refer to
the standard 3-phase OSM User Manual.

1.1 Applicability
This user guide covers the following product:
 RC10-OSM200 (Recloser Controller)
 RC15-OSM200 (Recloser Controller).

1.2 Safety Information

Installation, use and servicing should only be carried out by trained and experienced personnel who are
familiar with the equipment and electrical safety requirements.

1.2.1 Personnel Competence

It is the responsibility of the purchaser to ensure the personnel installing, using and maintaining the
equipment described in this manual are competent. Minimum personnel competency requirements include:
 Familiarity with this manual and its contents.
 Training in industry accepted safe operating procedures associated with both low and medium
voltage equipment.
 Training and appropriate authorisation to energise, de-energise and earth power distribution
equipment.
 Training in the care and use of protective equipment associated with low and medium voltage
applications.

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1.2.2 Hazard Statements

This manual contains three types of hazard statements, as follows:

! DANGER: Indicates an imminently hazardous situation

that, if not avoided, will result in death or serious injury

! WARNING: Indicates a potentially hazardous situation

that, if not avoided, could result in death or serious injury

CAUTION: Indicates a potentially hazardous situation

! that, if not avoided, could result in personal injury or
equipment damage

1.2.3 Safety Instructions

Before working with equipment ensure you read, understand and follow all safety instruction contained in this
manual.

DANGER: Contact with hazardous voltage will cause death or

! severe personal injury. Contact with Recloser or Control Cubicle

terminals should only be undertaken when equipment is isolated
from applicable sources of voltage.

WARNING: This equipment is not intended to protect human life.

! Follow all locally approved safety procedures when installing or

operating this equipment. Failure to comply may result in death
or severe personal injury.

WARNING: Before working with equipment described in this

! manual carefully read and understand the contents of this manual.

Improper handling, installation, operation or maintenance can
result in death, severe personal injury or damage to equipment.

WARNING: Power distribution equipment must be properly

selected for the intended operation. It must be installed, used and
! maintained by competent personnel who have been trained in and
understand all relevant safety procedures. Failure to comply can
result in death, personal injury or equipment damage.

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1.3 Customer Acceptance and Initial Inspection

NOJA Power products are assembled, tested, inspected, packaged and dispatched from the factory meeting
all the required quality criteria.
Inspect the shipping packaging for any external signs of damage. Unpack the product and inspect it
thoroughly for any signs of transit damage. File a claim with the carrier if transit damage is found.
Product damaged by incorrect handling, installation or other misuse by the customer or carrier will not be
covered by a supplier warranty.

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2 Recloser Control Cubicle

Below is a general diagram of the Recloser Control Cubicle. The RC10-OSM200 and RC15-OSM200
cubicles include a SIM-03 module to connect to 200 and 079 series reclosers. The RC15-OSM200 includes
Wi-Fi, GPS and Mobile Network connectivity options.

Battery
GPS Battery
Breaker

Escutcheon

SIM Module

I/O Module
Operator Panel

Document
Pocket
Control Cable
Connection

Relay Module

3 Point Handle
Locking Mechanism Radio/Modem
Mounting Plate

CMS USB Auxiliary Supply

Interface Circuit Breaker

Control Cable
Entry

Power Supply
Module
General Radio Antenna
Purpose Outlet Coax Entry Hole
Auxiliary Supply
Entry Holes
Earth Stud

I/O Wiring
Entry Hole

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2.1 Dimensions – Recloser Control Cubicle

Notes:
 Dimensions in inches shown in brackets.
 RC15-OSM200 cubicle has two additional entry holes for Radio Aerial.

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2.2 Functional Diagram

The functional structure of the RC10-OSM200 and RC15-OSM200 cubicles connected to 200 and 079 series
Reclosers is illustrated in the block diagram below.

iPhone, iPad, PC with CMS

GPS Radome
SmartPhone Software

OSM RC
Recloser Cubicle Panel

Phase Vacuum Residual

CS Interrupter CS CVS
3 Phase HV Line CVS UPS & 3
Switchgear Digital
Relay
Control Inputs

Rechargeable RS232
Battery USB Ethernet Wi-Fi 4G
Trip/Close Auxiliary Ethernet
Coil switches

Comms.
SIM

Radio / I/O
modem modules
PSM
Control Cable

AC Power
Supply Remote SCADA/CMS/NOJA APP/Protocols
Power
Data
Control / Indication

RC Cubicle Internal Module and Component Function

The Operator Panel Module contains the User Interface for operator control.

The Power Supply Module (PSM) takes the auxiliary AC input and provides DC power supply to the SIM
module.

The Switchgear Interface Module (SIM) provides the power management, battery charger and incorporates
the capacitors that provide the tripping and closing energy to the OSM tank. The SIM-03 module, which is
included in the RC10-OSM200 and RC15-OSM200 cubicles, is compatible with reclosers which use
Rogowski sensors for current measurements.

The Relay Module (REL) contains the main microprocessor controller, Digital Signal Processing (DSP)
functionality, Remote Terminal Unit (RTU), communications ports and standard digital inputs.

The Communications Ports and I/O Modules provide external control and indication functions for
Supervisory Control and Data Acquisition (SCADA) or other remote control applications (Radio/Modem).

For more details on any of the above modules please refer to the standard 3-phase OSM User Manual.

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2.3 Control Management Software (CMS)

The Control Management Software (CMS) provides configuration and control of all features and functionality.
It is a comprehensive device configuration tool and allows the user to:
 configure all Relay settings
 download all settings from PC to the Relay
 upload all settings, logs, fault profile, load profile, fault counters, lifetime counters from Relay to PC
 go On-Line and view all measurements, operate the OSM, configure Protection Status Control
elements, synchronise time/date to PC clock and erase Load Profile data.
 filter logs and profile information to assist in analysis of data
 print settings and all Relay historical data
 generate graphical representations of fault and load profile data
 import and export configuration files for use by other personnel
 configure User Defined curves and standard Time Current Characteristics using a graphical interface
 ensure relay co-ordination by importing co-ordinating device characteristics from a library of
protection curves
 configure protocol settings for SCADA control.

A PC running CMS can connect to the controller directly via the local Escutcheon USB port (located below
the Operator Panel). The connection type in CMS should be configured as “USB Direct”. The USB cable
must be Type A to B and the maximum length is 3m. If a USB extension cable is used it must have a power
supply.
CMS can also be connected remotely through a Serial, Ethernet or Fibre Optic connection to provide
engineering access to the RC Control.
Refer to standard 3-phase OSM User Manual and NOJA-559 CMS Help File for more details.

2.4 Control Cable

The RC10-OSM200 and RC15-OSM200 cubicles use a different control cable interface from the RC01. The
user has the option to replace the control cable or keep the existing control cable with the use of an adaptor
to connect to the new cubicle. Using the existing control cable will reduce installation costs. Please refer to
section 4.5.5 and section 5.2.

2.5 Interface Test Set

The Interface Test Set, ITS-02 is not compatible with the RC10-OSM200 and RC15-OSM200 cubicles. An
ITS-02-200 interface test set must be used. Please contact NOJA Power for more details.

WARNING: Do not connect an ITS-02 to an RC10-OSM200 or

! RC15-OSM200 as it is not compatible and it will damage the
equipment.

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2.6 Power Supply Module (PSM)

The Power Supply Module (PSM) supplies DC power (rectified AC) filtered and surge protected, to the SIM.
The standard PSM allows for one AC input. Typically the Customer AC Input to the PSM is from a step down
Voltage Transformer (VT) or utility Low Voltage (LV) mains.
Incoming power cables from the auxiliary supply are connected to the Active (A), Neutral (N) and Earth (E)
connections as shown below. The double-pole Miniature Circuit Breaker (MCB) inputs and earth terminals
are accessed by removing a safety cover. The MCB must be set to OFF before the Voltage Selector Switch
is moved to either 110Vac or 220Vac. Please refer to section 5.3.2 for wiring diagram.
The secondary side of the power supply has a 6.3A M205 fast blow fuse located on the top.
The PSM provides additional space for fitting customer devices such as surge protection beside the MCB.

Secondary Fuse

MCB
110V

VOLTAGE
SELECT

General Purpose 220V

Outlet (GPO)

AC Input Voltage Switch

Customer AC Input
(Auxiliary Supply)

WARNING: The earth wire MUST be connected, even if in a

! workshop/testing environment. Failure to comply may result in
damage to equipment or personal injury.

WARNING: Only change the AC Input Voltage Switch when the

! MCB is set to OFF. Failure to comply may result in damage to
equipment or personal injury.

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2.7 Comparison RC01 and RC10/15-OSM200

Functionality RC01 RC10-OSM200 RC15-OSM200

Directional Overcurrent and Earth Fault Protection   

Directional Sensitive Earth Fault   
Directional Negative Phase Sequence Protection  
Dynamic Directional Change Response  
Inverse Time Protection   
User Defined Curves with 32 Time-Current Co-ordinates  
High Set Instantaneous Elements   
Inrush Restraint   
Cold Load Pickup   
Live Line Overcurrent   
LL Allow Close  
Phase Overvoltage (OV1)  
Line-to-Line Overvoltage (OV2)  
Neutral Displacement Overvoltage (OV3)  
Negative Sequence Overvoltage (OV4)  
Phase Undervoltage (UV1)   
Line-to-Line Undervoltage (UV2)   
Loss of Supply Undervoltage (UV3)   
Voltage Sag (Uv4Sag)  
Loss of Supply Detector   
Under Frequency Protection   
Over Frequency Protection  
Neutral Displacement Protection (59N)  
Admittance Protection (21Yn)  
Broken Conductor Protection (46BC)  
Synchronism Check (25)  
Auto-synchroniser (25A)  
Fault Locator (21FL)  
Live Load Blocking  
Harmonic Protection  
Automatic Backfeed Restoration   
Loss of Supply Reclosing Mode   
Automatic Change Over  
Sectionaliser  

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Functionality RC01 RC10-OSM200 RC15-OSM200

Alarm Latching  
Sequence Advance  
Advanced Programmable Logic  
DNP3 Protocol   
DNP3 Security Authentication  
IEC 60870-5-101 Protocol   
IEC 60870-5-104 Protocol  
2179 Protocol   
IEC 61850 Protocol (GOOSE Publisher and Subscriber,  
MMS)
IEC 61499 Protocol (Smart Grid Automation)  
Power Quality  
Variable Panel Fast Key Configuration  
Cellular Network Modem (2G, 3G and 4G) 
Wi-Fi wireless connectivity 
Global Positioning System (GPS) 

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3 Measurement
The RC10-OSM200 and RC15-OSM200 cubicles include the SIM-03 module which is compatible with
reclosers which use Rogowski sensors for current measurements.
The SIM Module accepts the signals originating in the OSM tank and transfers them through to the Relay
Module after filtering and scaling the signals.
The Relay Module converts the analogue signals received from the SIM Module into data as indicated in the
table below.
The measurement data is filtered for harmonic content and the RMS value of the fundamental signal is used
by Protection and Indication applications as shown in the table.
For User Configurable Analogue Values please refer to the standard 3-phase OSM User Manual.
Measured Applicability
Measured value Designation Resolution
range Protection Indication
Phase currents Ia, Ib, Ic 0 – 16000 A 1A  
Residual current (1) In 0 – 16000 A 1A  
Phase to earth voltages Ua, Ub, Uc, Ur, Us, Ut 0.5 – 22 kV 0.1 kV  
Line to line voltages Uab, Ubc, Uca, Urs, Ust, Utr 0.5 – 30 kV 0.1 kV  
Positive sequence current I1 0 – 16000 A 1A  –
Negative sequence current I2 0 – 16000 A 1A  
Positive sequence voltage U1 0.5 – 18 kV 0.1 kV  –
Negative sequence voltage U2 0.5 – 18 kV 0.1 kV  –
Residual voltage (2) Un 0.5 – 18 kV 0.1 kV  –
Phase shift between positive A1 0 – 359o 1o  –
sequence voltage and
current
Phase shift between A2 0 – 359o 1o  –
negative sequence voltage
and current
Phase shift between A0 0 – 359o 1o  –
residual voltage and current
Single and three phase total, A, B & C kVA / kW / kVAr 0 – 65535 1 – 
active and reactive power 3 phase kVA / kVAr / kW
Single and three phase total, A, B & C +/– kVAh 0 – 999999999 1 – 
active and reactive energy A, B & C +/- kWh
related to forward and
reverse power flow A, B & C +/– kVArh
directions 3 phase +/– kVAh
3 phase +/– kWh
3 phase +/– kVArh
Frequency from ABC and Fabc, Frst 46 – 65 Hz 0.01 Hz  
RST recloser sides
Phase sequence from ABC Phase seq. ABC / ACB / ? (3) NA – 
and RST sides RST / RTS / ? (3)

Single phase and three Power factor: 3phase, A 0 – 1 0.01 – 

phase power factor (4) phase, B phase, C phase
Notes:
1. Residual current, In is equal to three times the zero sequence current, I0.
2. Residual voltage is equal to three times the zero sequence voltage.
3. “?” is displayed when any phase voltage drops below 0.5 kV.
4. Signed Power Factor is determined by the quadrant the angle between voltage and current is in and is
dependent on the power flow direction. It is not dependent on the torque angle.

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Real time instantaneous measurements can be viewed on the Panel as shown below:

Panel Navigation MEASUREMENTS

>Power< 1 Phase Energy
[Turn Panel ON]  [SYSTEM STATUS] Other 3 Phase Energy
 [Measurements] 
Voltages (kV):
A 6.2 B 6.2 C 6.2
R 6.2 S 6.2 T 6.2

AB 10.7 BC 10.7 CA 10.7

RS 10.7 ST 10.7 TR 10.7

Currents (A):
A 200 B 200 C 200
N 0 I2 0

3.1 Sampling and Filtering

A sigma-delta analogue to digital converter operating at a sample rate of 409 kHz eliminates the need to
have a high order low pass filter at the front end, this reduces phase shift and distortion over the full
temperature range.
Current and voltage channels are sampled 32 times during each power frequency cycle. Each current
measurement has a low and high coefficient applied and the measurement algorithm selects the appropriate
value to provide best resolution for each sample.
First harmonic RMS values for phase and residual currents together with zero, negative and positive
sequence voltages are calculated 16 times per cycle by application of digital filtering algorithms using the
last 32 samples. The resultant fundamental RMS values are utilised by protection and indication elements.
RMS values for active and reactive power / energy values, power frequency, power direction and phase
sequence are calculated once per cycle.
Metering and display values are updated every 16 cycles.

3.2 Measurement Settings

Current sensing is carried out by Rogowski sensors. Voltage sensing is by means of Capacitive Voltage
Transformers (CVTs). An individual calibration coefficient is determined for each of the four current channels
and six voltage channels received from the OSM. These ten measurement coefficients and the OSM serial
number are also entered by the user.
The system frequency is detected automatically by the RC when it is first installed and powered up. The
system frequency is then saved into permanent memory.
Phase Configuration allows a customer the capability to re-configure default phase designations, according
to their own line connections to the Recloser. All measurements, indicators, records, protection settings and
counters operate according to the new phase designations.
All user settings can be changed from the Panel. Alternatively they can be transferred using the CMS
software package.

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3.3 Protection accuracy

Since the 200 and 079 series reclosers are fitted with Rogowski coils, the protection accuracy for the RC10-
OSM200 and RC15-OSM200 is reduced when compared with the standard RC10 and RC15 cubicles which
operate with tanks using current transformers.

The following table provides the protection accuracy for the RC10-OSM200 and RC15-OSM200:

Parameter Accuracy Accuracy Range

Operational pickup current

the greater of 2% or 2 A 0 – 800 A
– for phase overcurrent elements
±5% 800 – 16 KA

– for earth overcurrent elements the greater of 2% or 1 A 0 – 80 A

the greater of 1% or 4 A 80 – 800 A
±5% 800 – 16 KA

– for negative phase sequence elements the greater of 6% or 6 A 0 – 800 A

±10% 800 – 16 KA

All other measurement accuracies are as stated in the standard 3-phase manual.

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4 Installation
This section outlines the steps required to connect an RC10-OSM200 or RC15-OSM200 cubicle to a 200 or
079 series recloser. The user has the option to keep the existing control cable by utilising an adaptor to
connect to the new SIM module. Alternatively the control cable can be replaced. Both options are
described.

The switchgear coefficients for the voltage and current sensors inside the OSM tank will need to be
updated. Please refer to section 4.5.9 and 4.3.

4.1 De–crating
The Recloser Control (RC) Cubicle is packed in a single crate containing:
 Recloser Control Cubicle
 Routine Test Summary, standard 3-phase User Manual and RC10/15-OSM200 User Guide in the
document pocket Inside the RC Cubicle
 Control Cable for RC10/15-OSM200 (if replacing control cable)
 Control Cable adaptor for RC10/15-OSM200 (if using existing control cable).
Access into the crate is by panels fastened with tabs. The top and sides of the crate can be removed by
bending up the metal tabs with a screwdriver and hammer allowing product removal.

! CAUTION: Inappropriate lifting of the RC cubicle can result in

personal injury or equipment damage.

4.1.1 Control Cable/Adaptor

Remove the protective plastic covering the ends of the new control cable and inspect the connectors to
ensure they have not been damaged in transit. Also inspect the length of the cable to ensure it has not been
crushed or otherwise damaged.

4.2 RC Cubicle Preparation

The battery of the Control Cubicle may have discharged during transit or storage. The Control Cubicle
should have an auxiliary AC supply fitted prior to carrying out preparatory testing.

4.2.1 Auxiliary Supply Connections

The RC Cubicle requires an AC supply to be connected into the circuit breaker. The cubicle is configured for
the correct auxiliary supply voltage (110Vac or 220Vac) at the factory as requested by the customer prior to
delivery.

Refer to section 2.6 for configuration and connection details.

WARNING: Incorrect wiring of the auxiliary supply can result in

! personal injury or equipment damage. The earth wire MUST be
connected before energising the auxiliary supply.

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4.2.2 Initial Checks

The RC cubicle is shipped with default Protection settings. Prior to commissioning, the correct settings for
the intended application must be programmed. Ensure you obtain any required settings from the RC01.
Before commencing tests make sure the AC supply is connected. Next open the escutcheon panel and turn
on the battery circuit breaker. Observe the start-up message on the LCD Panel, the flashing System running
LEDs on the front panel and others on the SIM, Relay and I/O Module(s).

1. Press the Panel ON button to see the SYSTEM STATUS display.

Panel Navigation
SYSTEM STATUS
[Turn Panel ON]  [SYSTEM STATUS] 
►GENERAL◄ WARNING

Date/Time : 21/01/2011, 10:00:18

Config : 3 phase, Recloser
Status : Closed

Measurements Power Quality

Input/Output Power Supply
Protection Communications Port
Automation Protocols
Logic

Check the date and time are displayed correctly. If incorrect, adjust as illustrated in the diagram below.

Panel Navigation
[Turn Panel ON]  [SYSTEM STATUS]  [Press ESC]
 REAL TIME CLOCK SETTINGS

[MAIN MENU]
Date: 21/01/11
 [System Settings] Time: 14:12:10

 [RTC Settings] 
Date Format dd/mm/yy
Time Format 24 Hours
Time Zone (hr) +00.00

Select a parameter, enter the password (default is “NOJA”), then change the setting.
Use the arrow keys to change the settings.
Press the Enter key when finished, or ESC to cancel the change.

2. Select any Malfunction or Warning messages and press Enter for extra details.
Panel Navigation
SYSTEM STATUS
[Turn Panel ON]  [SYSTEM STATUS]
GENERAL ►WARNING◄
 [WARNING] 
21/01/2011, 14:12:18
OSM Disconnected

Press the ESC key to return to SYSTEM STATUS.

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3. Select ‘Power Supply’, select the External Load Output and change it from OFF to ON.
POWER SUPPLY STATUS
Panel Navigation
[Turn Panel ON]  [SYSTEM STATUS] Last Power Restart:
 [Power Supply] 12:01:14 16/11/2010

 [External Load Output]  AC Input OFF

Battery Voltage (Ubt) 13.8V
Battery Current (Ibt) 0.50A
Battery Capacity (%) 100
External Load Output OFF
Battery Test Initiate

Battery Test Result:

04:44:03 AM 02/10/2015
Battery Test Passed

Confirm that 12Vdc appears across the External Load terminals on the SIM module. Set the
External Load Output voltage back to OFF, press the ESC key to return to SYSTEM STATUS.

4. If any optional I/O Modules are fitted, note the Serial Number on the module case. Observe that the
I/O Modules running LEDs are flashing. I/O Module 1, one flash each second. The second I/O
Module, twice each second.
Panel Navigation INPUT/OUTPUT SETTINGS

[Turn Panel ON]  [SYSTEM STATUS] Device Mode

 [Press ESC] Local Inputs: Local
I/O 1: Local
 I/O 2: Local
[MAIN MENU]
I/O Configuration
 [Systems Settings] Serial Number I/O Number
 [I/O Settings]  0151200090407 1

Confirm that the I/O Module(s) Serial Number is displayed on the panel.

5. From the SYSTEM STATUS screen, select and view ‘Input/Output’ to confirm the I/O Modules are
indicating correctly. Note that if an I/O module is not fitted, or is disabled, NA appears next to the
input / output status.
Panel Navigation INPUT/OUTPUT STATUS
[Turn Panel ON]  [SYSTEM STATUS]
Local Inputs: Disabled
 [Input/Output]  1 2 3
Na Na Na

I/O 1 Module: Disable

1 2 3 4 5 6 7 8
In: Off Off Off Off Off Off Off Off
Out: Off Off Off Off Off Off Off Off

I/O 2 Module: Disable

1 2 3 4 5 6 7 8
In: Na Na Na Na Na Na Na Na
Out: Na Na Na Na Na Na Na Na

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General settings
Title Designation Range Resolution Factory Default
I/O1 Module I/O 1 Disable/Enable/Test1/Test2/Test3 – Disable
Note: Selection of modes (Enable/Disable/Test1/Test2/Test3/) is only applicable if the relevant module is connected
and communication is established between the module and Panel.
6. Select a ‘Test1’ mode for an I/O Module. In this mode, application of the correct operating voltage to
any input will cause ALL outputs to change state. Applying voltage to each input and confirming that
all outputs change state each time tests operation of the I/O module.
7. On completion set the module under test back to ‘Disable’ mode. Press the ESC key to return to
SYSTEM SETTINGS.

4.3 Lifetime Counters

The Lifetime counters are updated after each protection trip. To retrieve existing lifetime counters from the
RC01, follow the menu navigation below on the RC01.

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4.4 Calculating new Switchgear Coefficients

Normally the OSM tank and RC cubicle are calibrated at the factory prior to shipment. Since we are
replacing the control cubicle we need to update the switchgear coefficients.

Follow the steps below to calculate the new switchgear coefficients.

1. Record the OSM serial number which is engraved on the rating plate of the Recloser.
Note: If the serial number is not a six digit number starting with “15” or “18” please do not proceed any
further and contact NOJA Power.
2. Obtain the “Switchgear NEW Coefficients Calculator.xlsx” from NOJA Power.
3. Obtain the OLD voltage and current calibration coefficients from company records or from the RC01
control panel before dismounting the controller. To retrieve existing calibration coefficients from the
RC01, follow the menu navigation below on the RC01 HMI panel.

4. Open the “Switchgear NEW Coefficients Calculator.xlsx” provided by NOJA Power.

a. Enter the OSM 200 tank serial number in the field provided.
b. Copy and paste the OLD calibration coefficients in the cells designated as OLD
COEFFICIENT. The “Calculated NEW COEFFICIENT” should now be available.

Note: If existing calibration coefficients are not available refer to section 6.1 and 6.2.

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4.5 Site Installation

The recommendations that follow are designed to minimise installation effort and product damage.

! CAUTION: Failure to comply with installation recommendations

may result in equipment damage.

WARNING: Follow all locally approved safety procedures when

! installing or operating this equipment. Failure to comply may
result in death or severe personal injury.

4.5.1 Transport to Site

For transport to site the Recloser Control Cubicle and Control Cable should be fixed back onto the crate
base as factory supplied.
Any items which can be affected by dust, dirt, water or moisture before they are installed must be kept clean
and dry. For example, disconnected Control Cables should have the ends covered with their protective
bags as factory supplied.

4.5.2 Uninstall existing RC01

Unplug control cable and remove any other connections from existing RC01. Remove RC01 from pole using
lifting holes. Please ensure you have existing calibration coefficients, lifetime counters and any require
settings prior to dismounting (refer to section 4.2.2, section 4.3 and section 4.4).

4.5.3 Installation of new control cubicle

The RC has two lifting holes in the top section of its pole mounting bracket. The RC cubicle is secured to the
pole by bolts or coach screws with diameter up to 22mm. The top hole is keyed to allow fitting over a bolt or
nut. Once the top is secured the bottom bolt can be fitted and tightened. Refer to section 2.1 for RC cubicle
dimensions.

4.5.4 Earthing
Please check that the OSM Recloser is earthed by means of a M12 hex head bolt (earth point) positioned
on the back wall of the tank. Ensure the RC is earthed by means of an M12 stud (earth point) on the base of
the cubicle. Recommended torque for connecting the Earth Lugs is 40Nm.
There should be no earthing metal or cables between the bushing and the surge arrestor or stand-off.
Minimum recommended Earth Conductor requirement for OSM Recloser and RC cubicle:
 35mm copper conductor
2

 Crimp type Connection Lugs

 Parallel Groove Clamp be used for bonding the RC short length conductor to OSM unbroken Earth
Conductor. See the following diagrams for a typical pole mounting arrangement.

WARNING: The main earth bond from the OSM tank to the main earth

! connection at the base of the pole must be a single, unbroken run. The cubicle
earth is clamped to the main earth conductor as it runs past the cubicle without
breaking the main earth conductor.

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User Guide
NOTE
Minimum Requirement:
 All cable separation from Ground Conductor, minimum
150mm.
 Use minimum 35mm2 copper for Earth Conductors.
 Crimp type Lugs used to connect to Earth Studs.
 Parallel Groove Clamps or Line Taps used to bond RC
cubicle Earth and VT to the unbroken OSM Earth
Conductor.

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4.5.5 Control Cable

The user has two options when replacing the RC01 cubicle with an RC10-OSM200 or RC-15ES-200:
 replacing the control cable with an RC10-OSM 200 control cable (refer to section 4.5.5.1)
 keeping the existing control cable and using an RC10-OSM200 adaptor to connect to the new SIM
module (refer to section 4.5.5.2).

4.5.5.1 Replacing Control Cable

1. Unplug existing control cable from the OSM tank and remove the control cable from pole.
2. Insert and lock the new control cable into the OSM Tank.
3. Run the new control cable along the pole and feed into cubicle.
4. Connect the control cable to the socket inside the cubicle on the SIM module – make sure the plug
is aligned correctly before inserting. Secure the plug by pushing the clamping ring in and turning it
until it clicks (locks) into place (about 1/3 of a turn).
5. Secure control cable plate with wing nuts at the Cubicle Control Cable Entry hole. Care must be
taken to not apply undue strain on the Control Cable plug. Roll up excess length of cable and safely
tie to pole.

WARNING: Disconnection of the control cable when the line is

! energised must be done by Live Line crew. Follow all locally

approved safety procedures. Failure to comply may result in death
or severe personal injury.

CAUTION: The control cable has a minimum bending radius of

! 150mm. Do not bend below this value during installation as the
control cable will be damaged.

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4.5.5.2 Using existing Control Cable and adaptor

1. Connect the existing control cable into the RC10-OSM200 adaptor.
2. Secure Harting Plug to the RC10-OSM 200 adaptor. Slide cover on top of the adaptor.
3. Insert the RC10-OSM200 adaptor and cable into the new RC control cubicle.
4. Connect the RC10-OSM200 adaptor cable plug to the socket inside the cubicle on the SIM module
– make sure the plug is aligned correctly before inserting. Secure the plug by pushing the clamping
ring in and turning it until it clicks (locks) into place (about 1/3 of a turn).
5. Secure the RC10-OSM200 adaptor with wing nuts at the Cubicle Control Cable Entry hole. Care
must be taken to not apply undue strain on the Control Cable plug. Roll up excess length of cable
and safely tie to pole.

Connect to SIM
module

RC10-OSM200
Adaptor Cable

Cover

Harting
Plug

RC10-OSM200
Adaptor
Existing
Control Cable

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4.5.6 Auxiliary Supply

The Recloser Control allows connection to either an 110Vac or 220Vac configured supply. Check the power
supply input setting before connecting to ensure the correct voltage has been configured. Refer to 2.6
Power Supply Module (PSM) for connection details.

4.5.7 Communications Interface

Remote communications with the Recloser Control can be achieved by using the I/O Modules or by
connecting to the SCADA interfaces. In either case, all communications wiring must be by means of
screened cable with the screens earthed to the RC cubicle earth at one end only. Where cabling exits the
RC cubicle, it should be fitted with an appropriate RFI ferrite filter, located as close as possible to the
(inside) floor of the cubicle.
Opto or galvanic isolation and surge protection must be used on the SCADA ports if conductive twisted pair
cables are to be used as the communications medium.
Do not connect customer equipment directly to the battery under any circumstances. The External Load
Power Supply on the Sim module is provided for this purpose. Refer to standard 3-phase OSM User Manual
for details.
Note: For Wi-Fi, GPS and Mobile Network connectivity please refer to standard 3-phase OSM User Manual.

4.5.8 Connect to the Controller with CMS

Follow the steps below to connect to the controller with CMS:

1. Connect a computer to the cubicle using a USB cable plugged into the port on the front panel.
2. Start CMS and go to Device - > Device Manager.
3. The device will appear in the “Other Connected Devices” list at the bottom of the screen. Right click
on the device and click “Add as New Device”. Change Name, Description and Comments as
required.

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4. Right click on the device and click Go Online.

5. Go to the Connection Tab - > Upload Settings and then click Start Transfer.

4.5.9 Update Lifetime Counters

The Lifetime counters can be updated via the Online Operations menu in CMS (see below). To obtain
lifetime counters from the RC01 please refer to section 4.3 Lifetime Counters.

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4.5.10 Update Switchgear Coefficients

Normally the OSM tank and RC cubicle are calibrated at the factory prior to shipment. Since we are
replacing the RC01 cubicle with a new control cubicle we need to update the switchgear coefficients. For
details on obtaining new switchgear coefficients please refer to section 4.4 Calculating new Switchgear
Coefficients.

CAUTION: Incorrect Measurement coefficients may result in

! performance outside of specified accuracy for voltage and current
measurement.

Follow the steps below once you have obtained the new switchgear coefficients.

1. Update the OSM serial number using the following as an example:

2. Go to Offline Settings - > Switchgear Calibration. Enter the updated OSM serial number and the
NEW coefficients (refer to section 4.4 Calculating new Switchgear Coefficients ).

3. Click on save disk icon in the top right hand corner to save the switchgear coefficients.

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4. Go to Connection -> Download Settings -> Download. Select Switchgear Calibration and click
on Start Transfer.

Refer to NOJA-559 CMS Help file for more details.

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4.5.11 Update Settings

The correct settings for the intended application of the recloser must be programmed. Transfer any
applicable settings obtained from the RC01.

Once you have configured all settings download to the device.

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5 Maintenance
For more details on maintenance please refer to the standard 3-phase OSM User Manual.

5.1 OSM Recloser

Below are details specific to the 200 and 079 series reclosers which are required for maintenance.

5.1.1 OSM Actuator Coil Resistance Testing

The actuator coil resistance can be measured on pins 1 and 3 of the control cable if a malfunction is
suspected. The resistance measured should be 15 ohms +/-2ohms.

5.1.2 OSM Current Sensor Resistance Testing

The current sensors can be measured from the control cable pins as follows:
 I(n) – Pins 17 and 21 – 195 ohms +/-10 ohms
 I(a) – Pins 10 and 14 – 66 ohms +/-3 ohms
 I(b) – Pins 11 and 15 – 66 ohms +/-3 ohms
 I(c) – Pins 12 and 16 – 66 ohms +/-3 ohms.
See Section 5.2 Control Cable connectors to help identify pin positions.

5.1.3 Microswitch Status Testing

The OSM recloser reports its position status to the RC Cubicle using microswitches. Their status is the
opposite to the main contacts and are checked on the control cable pins 3 and 5 (or pin 5 and 7):
 When OSM is Open – microswitch is closed
 When OSM is Closed – microswitch is open
See Section 5.2 Control Cable connectors to help identify pin positions.

5.1.4 OSM HV Contact Resistance Testing

Contact resistance across a closed VI on each phase should be:
 OSM15 - 85 micro ohms or less
 OSM27 – 95 micro ohms or less.

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5.2 Control Cable

Below are the control cable connections between a 200 or 079 series recloser and an RC10-OSM200 or
RC15-OSM200 cubicle.

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5.3 Schematics

5.3.1 RC General Layout

Note:
 Wi-Fi, GPS and Mobile Network connectivity only available in RC15-OSM200 cubicle.

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5.3.2 Power Supply Wiring Diagram

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6 Appendices
6.1 Appendix A - Converting the Default Mean Coefficients
If existing calibration coefficients are not available, the default mean coefficients can be used, which
guarantee accuracy of ± 3.5% for phase current, ± 5% for neutral current and ± 15% for phase voltage .
Follow the steps below when using the default mean coefficients:
1. Record the OSM serial number which is engraved on the rating plate of the Recloser.
Note: If the serial number is not a six digit number starting with “15” or “18” please do not proceed any
further and contact NOJA Power.

2. From the table below obtain the calculated NEW Coefficients.

Calculated NEW Coefficients using Default Mean Coefficients
Serial no. starting CIa CIb CIc CIn CUa CUb CUc CUr CUs CUt
with
15yxxx 0.3832 0.3833 0.3832 0.3851 0.0148 0.0148 0.0148 0.0148 0.0147 0.0148
18yxxx 0.3832 0.3833 0.3832 0.3851 0.0279 0.0279 0.0279 0.0279 0.0278 0.0279

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6.2 Appendix B - Calibrating Voltage and Current

Measurements
If the existing calibration coefficients are not available and you don’t want to use the default mean
coefficients, HV metering device, supplied by the customer, can be used to calibrate the RC-10-200
controller once it is installed.
Ensure all equipment is earthed as described in this manual and that safety measures are taken. During
calibration process protection must be turned OFF.
Prior to commencing the calibration:
1. Complete installation of the new controller (refer to section 4 Installation)
2. Connect to the device using CMS.
3. Update the switchgear calibration coefficients using the ‘OLD’ Coefficients” in the table below.

‘OLD’ Coefficients
Serial no. starting with ‘OLD’ Current Coefficients ‘OLD’ Voltage Coefficients
15yxxx 0.4000 0.0157
18yxxx 0.4000 0.0314
Note: If the serial number is not a six digit number starting with “15” or “18” please contact NOJA Power.

4. Download the switchgear calibration settings to the controller.

Calibrating Voltage Measurements

1. Connect the HV Voltage Measurement Device to phase A and measure the primary voltage.
2. With the recloser CLOSED, on the HMI panel select ‘Measurement’ from the SYSTEM STATUS
page to monitor the line voltage for phase A.
3. The new voltage coefficients are calculated using the following: {Meter value/ HMI value * ‘OLD’
Coefficient}
where:
Meter Value = line voltage measured by the Voltage Measuring Device.
HMI Value = line voltage measured by the RC10-200 HMI panel.
‘OLD’ Coeff = corresponding ‘OLD’ coefficient.

4. Repeat steps 1 to 3 for pair bushings B/S and C/T.

5. Enter new calibration coefficients on the switchgear calibration page in CMS. Save and download
the new coefficients to the device.

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Calibrating Current Measurements

6. Connect the HV Clamp on Current Measurement Device to phase A.

7. With recloser CLOSED, on the HMI panel select ‘Measurement’ from the SYSTEM STATUS page
to monitor the primary current.
8. The new coefficient is calculated using the following: {Meter value/ HMI value * ‘OLD’ Coefficient}
where:
Meter Value = phase current measured by the Current Measuring Device
HMI Value = phase current measured by the RC10-200 HMI panel
‘OLD’ Coeff = corresponding ‘OLD’ Coefficient.

9. Repeat steps 6 to 8 for phase B and C.

10. Calculate the neutral current using the measured phase currents on all phases.
 If the imbalance is greater than 1 Amp, then calculate the new coefficient for CIn using the
following: {Calculated value/ HMI value * OLD’ Coefficient}.
 If the imbalance is smaller than 1 Amp, then use 0.3851 as the new coefficient for CIn,
which is calculated using the default mean coefficient. This guarantees accuracy of ±5% for
neutral current. Refer to section 6.1.
11. Save the new calibration coefficients on the switchgear calibration page in CMS and download the
new coefficients to the device.

Calibration verification

12. On the HMI panel, under MAIN MENU, select “Save System Data” and then press Enter. This is a
precautionary measure.
13. With the RC10-200 controller up and running, start CMS and connect to the controller
14. Upload settings and check the new switchgear coefficients are correct.
15. Check the phase voltage and current on the measurement page.

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7 Index
A M
Auto
Frequency Detection ............................................. 12
C
Calculating new Switchgear Coefficients .................. 18
CMS
Software .................................................................. 7
Communications
Ports ........................................................................ 6
Control Cable ....................................................... 21, 29
Schematics ............................................................ 29
D
Date/Time ................................................................. 15
Dimensions
RC Cubicle ................................................................ 5
E
Earthing ..................................................................... 19
OSM Recloser ........................................................ 19
RC cubicle .............................................................. 19
Unbroken Conductor ............................................. 19
External Load Supply ................................................. 23
F
Functional Overview OSM with RC10 ......................... 6
I
I/O Modules ................................................................ 6
Testing ................................................................... 17
RC10-15-OSM200 Index
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Measurement ............................................................ 11
O
Operator
Panel Module .......................................................... 6
P
Password ................................................................... 15
Phase
Configuration ........................................................ 12
Phase sequence ......................................................... 11
Power Supply Module (PSM) .................................. 6, 8
Power Supply Wiring Diagram .................................. 31
Preparation
RC Cubicle .............................................................. 14
R
Relay Module .............................................................. 6
RTU .............................................................................. 6
S
Sampling and Filtering ............................................... 12
Schematics ................................................................ 30
Settings
Measurement ........................................................ 12
Site Installation.......................................................... 19
Switchgear Interface Module (SIM) ............................ 6
T
Testing
RC Cubicle .............................................................. 15
35
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Referenced Documents

 NOJA-559 CMS Help File

 NOJA-5002 OSM15 310, OSM27 310, OSM38 300 and RC Cubicle User Manual
(standard 3-phase OSM User Manual)

36 References RC10-15-OSM200