distribution class surge arrestor

8/7/2019 Distribution Class Surge arrestor

1/15

E No.: None File Ref: 235-99CP No.: CP0804 Page: 1 of 15

September 2008 New Issue 2008 Cooper US, Inc.

UltraSIL Polymer-Housed EvolutionDistribution Class Surge Arrester

Certified Test Report


2/15


UltraSIL Polymer-Housed Evolution

Distribution-Class Surge Arrester

CERTIFICATION

Statements made and data shown are, the best of our knowledge and belief,correct and within the usual limits of commercial testing practice.

Jeff Kester Mike RamargeArrester Engineering Manager Chief Engineer


3/15


INTRODUCTION

This test report certifies that the UltraSIL polymer-housed Evolution surge arrester was successfullytested to IEEE Std C62.11-2005 standard IEEE Standard for Metal-Oxide Surge Arresters forAlternating Current Power Circuits".

TEST PROGRAMOBJECTIVE

To demonstrate the UltraSIL polymer-housed Evolution surge arrester meets all performancerequirements.

PRODEDURE

The following design tests were performed on a sufficient number of samples to demonstrate allperformance requirements are met.

DESIGN TESTS

A. Insulation Withstand ....................Per IEEE Std C62.11-2005 standard, Para. 8.1.2.1

B. Discharge Voltage Current Characteristics.......Per IEEE Std C62.11-2005 standard, Para. 8.3

C. Discharge Voltage Time Characteristics...........Per IEEE Std C62.11-2005 standard, Para. 8.3.2.2

D. Accelerated Aging Procedure .........Per IEEE Std C62.11-2005 standard, Para. 8.5

E. High Current, Short Duration.......Per IEEE Std C62.11-2005 standard, Para. 8.12

F. Low Current, Long Duration ..........................Per IEEE Std C62.11-2005 standard, Para. 8.13.2

G. Duty Cycle .............Per IEEE Std C62.11-2005 standard, Para. 8.14

H. Internal Ionization and RIV..........Per IEEE Std C62.11-2005 standard, Para. 8.10

I. Short Circuit Test.....................Per IEEE Std C62.11-2005 standard, Para. 8.18

J. Disconnector Test................Per IEEE Std C62.11-2005 standard, Para. 8.21

K. Contamination Test..............Per IEEE Std C62.11-2005 standard, Para. 8.8L. Temporary Overvoltage (TOV)...............Per IEEE Std C62.11-2005 standard, Para. 8.15

M. Accelerated Aging Tests of External Polymeric

Insulating Systems...............Per IEEE Std C62.11-2005 standard, Para. 8.6

N. Seal Integrity .............Per IEEE Std C62.11-2005 standard, Para. 8.9

O. 1000 Hours Accelerated Aging Test with Exposure

to Salt Fog........................Per IEEEStd C62.11-2005 standard, Para. 8.7 &

Per IEC 60099-4, Para. 10.8.14.2.1 Edition 2004-05

P. 5000 Hours Weather Aging Test...................Per IEEE Std C62.11-2005 standard, Annex C &

Per IEC 60099-4, Para. 10.8.14.2.2 Edition 2004-05

ADDENDUM

Q. Water Immersion TestPer IEEE C62.11-2005, Para. 8.22 &Per IEC 60099-4, Para. 10.8.13 Edition 2004-05

R. High Humidity Test Per Cooper Power Systems InternalSpecification 5A1-340-1

RESULTS

The UltraSIL polymer-housed Evolutionsurgearresters met all performance requirements.


4/15


TEST AINSULATION WITHSTAND

OBJECTIVE

To verify that assembled insulating membersof the arrester withstand impulse and powerfrequency voltage tests in accordance with IEEEStd C62.11-2005 standard, Para. 8.1.2.1.

PROCEDURE

New clean arrester housings of severalratings, including the longest and higheststressed designs were assembled overinsulator cores. The samples were mountedin several configurations, including short andlong insulating hangers with and withoutNEMA brackets and base mountings. Testsamples were subjected to positive andnegative 1.2 x 50 s voltage impulses toobtain insulation withstand levels. Testvoltages were determined by multiplying themaximum discharge voltage for a 20 kA 8/20s current impulse by a factor of 1.42.

A 60 Hertz voltage equal to 1.5 xMCOVwas applied between the arrester groundterminal and the grounded NEMA bracketwhile the hanger bracket was wet for 10seconds. This test was performed on allavailable hanger models.

RESULTSArrester samples met the requirements of the

Insulation Withstand Test by demonstrating noevidence of flashovers.

TEST BDISCHARGE VOLTAGE

CURRENT CHARACTERISTICS

OBJECTIVE

To determine maximum discharge voltagecharacteristics of the arrester at 1.5, 3, 5, 10, 20and 40 kA crest in accordance with IEEE StdC62.11-2005 standard, Para. 8.3.1.

PROCEDURE

Sample arresters were impulsed using an8 x 20 s wave shape at 1.5, 3, 5, 10, 20and 40 kA crest.

The discharge voltage crest was measured.

RESULTS

Maximum discharge voltages were establishin accordance with standards and are providedin Chart 1.


5/15


TEST CDISCHARGE VOLTAGE

TIME CHARACTERISTICS

OBJECTIVETo obtain the front-of-wave protective level

of the arrester based on an impulse that resultsin a discharge voltage cresting in 0.5 s inaccordance with IEEE Std C62.11-2005standard, Para. 8.3.2.

PROCEDURE

A classifying current of 10 kA for heavyduty/riser pole was used to determine theequivalent front-of-wave protective level.

The arresters were impulsed using fronttimes of 8 s, 2s and 1s.

The maximum discharge voltage and thetime to voltage crest were measured.

The voltage/time measurements wereplotted on linear voltage versus log timepaper and the maximum voltage at 0.5 swas determined and recorded.

RESULTS

Front-of-wave protective levels wereestablish in accordance with standards and areprovided in Chart 1.

.

TEST DACCELERATED AGING PROCEDURE

OBJECTIVE

To verify Kc and KR ratios of the arresters inaccordance with IEEE Std C62.11-2005standard, Para. 8.5.

KC = MCOV RationKR = Duty Cycle Ratio

These ratios were determined to calculate thetest values of MCOV and duty cycle voltagesused during testing.

PROCEDURE

MOV valve elements were placed in an ovenat 115C and energized at MCOV for 1,000

hours. The watts loss was measured at the MCOV

and duty cycle voltage levels within two tofive hours after the start of the test.

The watts loss wasmeasuredat 1,000hours at MCOV and duty cycle voltagelevels.

If KCand KR 1, then KC and KR areequal to 1.

RESULTS

MOV disks met requirements of theAccelerated Aging Procedure by demonstratingKC and KR < 1, which is in accordance withIEEE Std C62.11-2005 standard, Para. 8.5.

MCOVHrsLossWatts

MCOVHrsLossWattsKC

@52@

@000,1@

=

VoltageRatedHrsLossWatts

VoltageRatedHrsLossWattsKR

@52@

@000,1@

=


6/15


TEST EHIGH-CURRENT, SHORT-DURATION

OBJECTIVE

To demonstrate that arresters meet the high-current, short-duration requirements inaccordance with IEEE Std C62.11-2005standard, Para. 8.12.

PROCEDURE

Three 10 kV rated equivalent thermalsections, with isolators, were used for thistest.

Each sample was impulsed with a 100 kA(heavy duty/riser pole) crest current wavewith a wave shape of 4 x 10 s.

The samples were allowed to cool to

ambient temperature. Each sample was impulsed a second time.

Within five minutes following the secondimpulse, the samples were energized at thethermal recovery voltage per IEEE StdC62.11-2005 standard, paragraph 7.2.2(MCOV x KW x KC) for 30 minutes to verifythermal recovery.

The samples were inspected after testing tomake sure that there was not any physicaldamage.

RESULTS

Arrester samples met the requirements of theHigh-Current, Short-Duration test (HCSD) bydemonstrating the ability to handle two 100kAimpulses and undergoing thermal recovery withno physical damage.

.

TEST FLOW-CURRENT, LONG-DURATION

OBJECTIVE

To demonstrate that arresters meet the low-current, long-duration requirements inaccordance with IEEE Std C62.11-2005standard, Para. 8.13.2.

PROCEDURE

Three 10kV rated equivalent thermalsections, with isolators were used for thistest.

Each sample was impulsed with a 10 kA(heavy duty and riser pole) crest, 8 x 20 swave and the discharge voltage measured.

Each sample was impulsed using a 250 amp

(heavy duty/riser pole) by 2,000 s squarewave six times, once every 50 to 60seconds. The samples were allowed to coolto room temperature. This procedure wasrepeated two more times.

Immediately after the 18th shot, the sampleswere placed into an oven until theystabilized at 60C.

The samples were removed from the ovenand impulsed two more times.

Immediately after the 20th shot, the sampleswere energized at the thermal recoveryvoltage per IEEE Std C62.11-2005

standard, paragraph 7.2.2 (MCOV x KW xKC) for 30 minutes minimum to verifythermal recovery.

Each sample was impulsed with a 10 kA(heavy duty/riser pole) crest 8 x 20 s waveand the discharge voltage measured. Thedischarge voltage was compared to thedischarge voltage taken prior to the low-current, long-duration testing to make surethat it did not vary by more than +10%.

The samples were inspected after testing toassure that no physical damage occurred.

RESULTSArrester samples met the requirements of

the Low-Current, Long-Duration test (LCLD) bydemonstrating the ability to handle 20 impulses,undergoing thermal recovery, demonstrating


7/15


TEST GDUTY CYCLE

OBJECTIVE

To demonstrate arresters meet the duty cyclerequirements in accordance with IEEE StdC62.11-2005 standard, Para. 8.14.

PROCEDURE

Three 10 kV prorated equivalent thermalsections, with isolators were used for thistest.

Each sample was impulsed with a 10 kA(heavy duty/riser pole) crest, 8 x 20 s waveand the discharge voltage measured.

Each sample was energized at KR times theduty cycle voltage (KR=1), for the duration of

time needed to allow 20 impulses. Each sample was impulsed with a 10 kA

(heavy duty/Riserpole) crest surge of 8 x 20s wave shape.

The impulse occurred at approximately 60before the crest on the power frequency wave.

Each sample was impulsed once every 50 to60 seconds for 20 consecutive impulses.

After the 20th impulse, the samples werede-energized and placed into an oven untilthey stabilized at 60C.

Each sample was removed from the ovenand immediately energized at the thermalrecovery voltage per IEEE Std C62.11-2005 standard, paragraph 7.2.2 (MCOV xKW x KC) and impulsed twice more at a 40kA crest within one minute.

Samples remained energized at the thermalrecovery voltage for 30 minutes minimum toverify thermal recovery.

Each sample was impulsed with a 10 kA(heavy duty/riser pole) crest 8 x 20 s waveand the discharge voltage measured. Thedischarge voltage wascompared to thedischarge voltage taken prior to duty cycle tomake sure that it did not vary by more than

10%. The samples were inspected after testing to

assure that no physical damage occurred.

RESULTS

The arrester samples met the requirements of theDuty Cycle Test withstanding 22 impulses,demonstrating thermal recovery with


8/15


TEST ISHORT-CIRCUIT TEST

OBJECTIVE

To verify that failed arresters are able toconduct fault current without violentdisintegration in accordance with IEEE StdC62.11-2005 standard, Para. 8.18.

PROCEDURE

The tests were performed on a 36kVsamples with a polyester-insulating hanger.

The arresters were pre-failed by thermallyoverloading the MOV disks using excessivepower frequency voltage.

The following test currents were applied tothe arresters:

Fault CurrentAmplitude(kA rms)

Fault CurrentDuration(cylces)

0.6 12020.0 10

RESULTS

Arrester samples met the requirements of theShort-Circuit Test without ejecting any internalcomponents.

TEST JDISCONNECTOR TEST

OBJECTIVE

To verify that the disconnector can withstand,without operation, the arrester design tests andprovide a current-time characteristic operatingcurve, in accordance with IEEE Std C62.11-2005 standard, Para. 8.21.

PROCEDURE

The arrester samples in all the electricaltests, including the following tests, wereperformed with disconnectors attached:

1---High Current, Short Duration (Test E)2---Low Current, Long Duration (Test F)

3---Duty Cycle (Test G)4---Contamination Test (Test K)5---TOV (Test L)6---Seal Integrity Test (Test N)

A disconnector time-current curve wasestablished using five samples at currentlevels of 20, 80, 200, and 800 amps rms, asshown in Graph 2.

RESULTS

The disconnector samples met therequirements of the Disconnector Test bydemonstrating the arrester electrical tests did

not cause disconnector operation within thedisconnector time-current curve.


9/15


TEST KCONTAMINATION TEST

OBJECTIVE

To demonstrate the ability of the arresters towithstand the electrical stresses caused bycontamination on the housing, in accordancewith IEEE Std C62.11-2005 standard, Para.8.12.

PROCEDURE

Arrester samples were energized for aminimum of one hour at MCOV.

The watts loss at MCOV was measured atthe end of the hour.

The samples were de-energized. Within 13

minutes, a 400-500cM slurry was appliedto the housing heavily enough to form dropson the skirts.

The samples were energized at the MCOVvoltage.

The watts loss was measured after 15minutes.

The samples were de-energized again andanother slurry application was performed.

The samples were energized at MCOV for30 minute intervals and the watts loss wasmonitored to verify decreasing levelstowards the original measurement.

Once the samples were cleaned and dried,they were inspected for internal damageusing partial discharge measurements atMCOV.

RESULTS

The arrester samples met the requirementsof the Contamination Test by having stabilizedlower watts loss over time and not flashing overwith evidence of internal physical damage.

TEST LTEMPORARY OVERVOLTAGE (TOV)

OBJECTIVE

To verify what levels of 60 cycle temporaryovervoltage the arresters survive in accordancewith IEEE Std C62.11-2005 standard, Para.8.15.

PROCEDURE

Each sample was impulsed with a 10 kA(heavy duty/riser pole) crest, 8 x 20 s waveand the discharge voltage measured.

Samples were preheated to 60C.

Each sample was removed from the ovenand immediately energized at theovervoltage.

The overvoltage was removed after theguaranteed duration.

Within 1 S, each sample was energized atthe thermal recovery voltage per IEEE StdC62.11-2005 standard, paragraph 7.2.2(MCOV x KW x KC) for 30 minutes. Sampleand temperature were monitored for thermalrunaway.

Each sample was impulsed with a 10 kA(heavy duty/riser pole) crest 8 x 20 s waveand the discharge voltage measured. Thedischarge voltage was compared to thedischarge voltage taken prior to the

Temporary Overvoltage testing to make surethat it did not vary by more than 10%.

The samples were inspected after testing toassure that no physical damage occurred.

Temporary overvoltage test points wereplotted.

RESULTS

Temporary over voltage capability has beenestablished in accordance with IEEE StdC62.11-2005 standard, Para. 8.15. Resultsare provided in Chart 4 and Graph 1.


10/15


TEST MACCELERATED AGING TESTS

OF EXTERNAL POLYMERICINSULATING SYSTEMS

OBJECTIVE

To demonstrate a high performance level ofthe external polymer insulating system of thearresters when exposed to accelerated light andelectrical stress in accordance with IEEE StdC62.11-2005 standard, Para. 8.6.

PROCEDURE

The arrester housing and hanger bracketmaterials were subjected to UV testing perASTM G154-00a (Replaces G53-96) for

over 1,000 hours without any cracking of thesurfaces.

The discharge voltage of three full arrestersamples was measured using an 8 x20 simpulse with a 10 kA (heavy duty/riser pole)crest.

The hanger brackets of the samples weregrounded at their mounting hole.

Thefollowing test cycle was performed for1,000 hours:

-Dip sample into a 400-500 cm slurry bath.-Remove sample from slurry and energizefor two minutes at MCOV.

-De-energize sample and dip into 400-500cm slurry bath.

After 1,000 hours of cycling the dischargevoltage of the samples was measured usingan 8 x 20 s duration impulse with a 10 kA(heavy duty/riser pole) crest.

With the arrester samples effectivelyshorted, the maximum system voltage wasapplied across the hanger bracket for 20hours using the cycle described above.

RESULTS

The samples passed the Accelerated Aging

Test by demonstrating no evidence of flashoversor surface tracking and the arrester dischargevoltage did not change more than 10% fromthe initial value.

TEST NSEAL INTEGRITY

OBJECTIVE

To verify that the seal design of the UltraSILarrester is robust in accordance with IEEE StdC62.11-2005 standard, Para. 8.9.

PROCEDURE

Three samples were subjected to all of thefollowing tests.

The RIV and watts loss was measured atthe duty cycle rating.

An AWG No. 1 solid wire was installed onthe top and bottom terminals and torqued to20 ft Ibs.

The samples were temperature conditionedby heating them to 70C for 14 days.

Once the samples returned to ambienttemperature, they were heated to 60C forone hour.

The samples were then placed in a 4Ccold-water bath for two hours.

The 60 to 4C cycle was repeated 10 times.

Within 24 hours of the last cycle, the RIVand watts loss were measured at the dutycycle voltage to verify that the RIV did notincrease more than 20 V and the watts lossdid not increase more than 50% than theinitial value.

The samples were internally inspected toverify that there was no moisture present.

RESULTS

The arrester samples successfully met thetest requirements of the Seal Integrity Test bydemonstrating less than 20uV increase in RIVand less than 50% increase in watts loss frominitial value.


11/15


TEST O1000 HOURS ACCELERATED AGING

TEST WITHEXPOSURE TO SALT FOG

OBJECTIVE

To verify the ability of the arrester towithstand continuous salt fog conditions andendure surface arcing and heating inaccordance with IEEE Std C62.11-2005standard Para. 8.7.

PROCEDURE

One sample of the longest electrical sectionwith the highest rated voltage was subjectedto pre-test measurements as prescribed bystandards.

Sample was placed in the vertical positioninside an enclosure with salt fog mist ofspecified salinity levels and energized at Ucfor duration of 1000 hours.

Post-tests were conducted to verifymeasured values did not exceed levelsspecified by the standard.

Sample was inspected to assure that nophysical damage had occurred.

RESULTS

The arrester samples successfully met the

test requirements of the 1,000 Hour AcceleratedAging Test by demonstrating no housingpunctures or erosion of the housing, no internalbreakdowns; no surface tracking was evidencedby physical examination. Measured post-testvalues did not exceed levels specified by thestandard.

TEST P5000 HOURS WEATHERAGING TEST

OBJECTIVE

To verify the ability of the arrester to enduresurface arcing and heating while subject tohumidification, thermal cycling, rain, simulatedsolar radiation (UV) and salt fog. Testing wasperformed in accordance with IEEE StdC62.11-2005 standard, Annex C.

PROCEDURE

One sample of the longest electrical sectionwith the highest rated voltage was subjectedto pre-test measurements as prescribed bystandards.

Sample was placed in the vertical positioninside a test chamber equipped for heating,humidity, UV-radiation, artificial rain and saltfog. The sample was subject to a multi-stresscycle as defined by IEEE Std C62.11-2005standard, Annex C, and Figure C.1 forduration of 5,000 hours.

Post-tests were to verify measured values didnot exceed specified levels by the standard.

Sample was inspected to assure that nophysical damage had occurred.

RESULTS

The sample fulfilled the requirements of the5,000 Hour Weather Aging Test bydemonstrating no over current trip-out occurredduring the testing procedure. There was notracking, cracking or treeing of the externalhousing. There were no housing punctures orinternal breakdowns. Measured post-test valuesdid not exceed levels specified by the standard.


12/15


ADDENDUM

TEST QWATER IMMERSION TEST

OBJECTIVETo demonstrate the resistance of a

composite wrapped module tomoisture ingress. This test wascompleted in accordance with IEEEStd C62.11-2005 standard, Section8.22, and IEC 60099-4, Ed 2 2004.

PROCEDURE

One 36kV rated module sectionencapsulated in composite weave materialwas used for this test.

Pre-tests consisted of the followingmeasurements:o Power loss at 100% of MCOVo Partial discharge tested at 1.05xMCOVo Lightning impulse residual voltage

using 5kA, 8x20uS current impulse

Sample was immersed in deionized waterwith 1kg/m of NaCl content. Watertemperature was increased to 80 C andmaintained for 52 hours.

Sample remained immersed until water-cooled to 50 C.

Water temperature was maintained until

sample was removed. Post-test measurements were performed to

include:o Power loss at 100% of MCOVo Partial discharge at 1.05xMCOVo Lightning Impulse Residual Voltage

using 5kA, 8x20uS current impulse

RESULTS

The arrester sample met the requirements ofthe Water Immersion Test by demonstrating lessthan 20% change in power loss, less than 10pCof internal partial discharge, less than 5%

change in residual voltage and no signs ofphysical damage according to IEEE Std C62.11-2005, Section 8.22, and IEC 60099-4, Ed 22004.

TEST RHIGH HUMIDITY TEST

OBJECTIVE

The High Humidity test was designed todemonstrate proper function of the insulatinggap assembly under extreme humidityconditions.

PROCEDURE

This test was completed on two 10kVUltraSIL housing distribution arresters withmodule assemblies incorporating insulatinggap assemblies and composite weave

technology. Pre-tests consisted of the following

measurements:o Power Frequency Sparkovero Partial discharge tested at 1.05xMCOV

The top aluminum electrodes were drilledout to allow a direct path for moisture topenetrate the gap assemblies.

Samples were exposed to 95% relativehumidity while energized at an elevatedtemperature of 60 C for 1,000 hours.

Pre-tests consisted of the followingmeasurements:o Power Frequency Sparkovero Partial discharge tested at 1.05xMCOV

RESULTS

The arrester samples satisfy the criteria forthe High Humidity test by demonstrating lessthan 10% change in Power FrequencySparkover Voltage, less that 10pC internalpartial discharge tested at 1.5xMCOV and novisible signs of physical damage or dielectricbreakdown of components.


13/15


Chart 1UltraSIL Polymer-Housed Evolution Arrester Discharge Voltages

Maximum Discharge Voltage8/20 us Current Wave

(kV crest)

SwitchingSurge

(kV Crest)

ArresterRating

(kV rms)

MCOV(kV

rms)

Minimum60HZ

Sparkover(kV

Crest/2)

Front-of-Wave

ProtectiveLevel*

(kV crest)

1.5 kA

3 kA

5 kA 10 kA

20 kA 40 kA 500 A

3 2.55 4.54 20.0 8.1 8.7 9.3 10.2 11.6 13.5 7.66 5.10 9.08 23.0 16.1 17.4 18.6 20.3 23.3 27.0 15.29 7.65 13.6 32.4 18.9 20.3 21.8 23.8 27.3 31.6 17.810 8.40 15.0 32.4 20.1 21.6 23.2 25.4 29.0 33.7 19.012 10.2 18.2 52.4 25.2 27.2 29.1 31.8 36.4 42.2 23.815 12.7 22.6 55.4 30.5 32.8 35.2 38.5 44.0 51.1 28.818 15.3 27.2 64.8 37.8 40.8 43.7 47.8 54.6 63.4 35.721 17.0 30.3 64.8 40.1 43.2 46.3 50.6 57.9 67.2 37.8

24 19.5 34.7 87.8 46.4 50.0 53.6 58.6 67.0 78 43.827 22.0 39.2 97.2 53.9 58.0 62.2 68.0 78 90 50.830 24.4 43.4 117.2 58.6 63.2 67.7 74 85 98 55.333 27.0 48.1 120.2 66.6 71.7 77 84 96 112 62.836 29.0 51.6 129.6 70.4 76 81 89 102 118 66.4

** Based on a 10 kA current impulse that results in a discharge voltage cresting in 0.5 s.** Based on a 30/60 s current impulse.


14/15


Chart 4TOV Recovery Capability of UltraSIL Polymer-Housed Evolution Arresters

Per Unit of MCOVTime, Seconds Evolution

0.01 1.780.02 1.78

0.1 1.78

1 1.78

10 1.78

100 1.78

1000 1.78

10000 1.78

Graph 1

UltraSIL Polymer-Housed Evolution Arrester

TOV Curve Per ANSI C62.11

1.7801.7801.7801.7801.7801.7801.7801.780

1.000

1.100

1.200

1.300

1.400

1.500

1.600

1.700

1.800

1.900

2.000

0.01 0.1 1 10 100 1000 10000 100000

Time Duration in Seconds

Voltage(perunitofMCOV)


15/15


Graph 2Distribution Arrester Disconnector Time-Current Characteristic Plot

distribution class surge arrestor

Documents