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CP0606

UHS 10kA Arrester

Certified Test Report
IEC 60099-4 2004

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

_________________________
Michael M Ramarge
Chief Engineer

DATE:October 2006 Cooper Power Systems, Inc.

________________________
Jonathan J Woodworth
Arrester Engineering Manager

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CP0606
INTRODUCTION

This test report certifies that the UltraSIL VariSTAR arresters UHS Class 1 10kA were successfully tested
to IEC 60099-4:2004 Metal-Oxide surge arresters without gaps for a.c. systems.
TEST PROGRAM
OBJECT
To demonstrate that the UltraSIL VariSTAR Arresters Class 1 10kA meet all performance requirements.
PROCEDURE
The following design tests were performed on a sufficient number of samples to demonstrate all performance
requirements are met.
TYPE TESTS
A.

B.

C.
D.
E.
F.
G.
H.

I.

J.

K.

Insulation Withstand Test

a) Lightning Impulse Voltage Test
b) Power Frequency Voltage Test..
Residual Voltage Test
a) Steep Current Impulse Residual Voltage Test ..
b) Lightning Impulse Residual Voltage Test .
c) Switching Impulse Residual Voltage Test
Long Duration Current Impulse
Withstand Test
High Current Impulse Operating Duty Test .
Power Frequency Voltage vs. Time .
Characteristics of an Arrester Short Circuit Tests ..
Internal Partial Discharge Tests
Moisture Ingress Test
a) Terminal Torque Pre-conditioning.
b) Thermo Mechanical Pre-conditioning....
c) Water Immersion Test.
d) Verification Tests
Weather Aging Tests
a) Test Series A: 1000 hr .
b) Test Series B: 5000 hr .
Mechanical Tests
a) Test of the Bending Moment ..
b) Sulphur Dioxide Test .
c) Salt Mist Test .
Disconnector Operation .

Per IEC 60099-4 Section 8.2.6

Per IEC 60099-4 Section 8.2.8
Per IEC 60099-4 Section 8.3.1
Per IEC 60099-4 Section 8.3.2
Per IEC 60099-4 Section 8.3.3
Per IEC 60099-4 Section 8.4.2
Per IEC 60099-4 Section 8.5.4
Per IEC 60099-4 Section 6.10, Annex D
Per IEC 60099-4 Section 6.11
Per IEC 60099-4 Section 8.8
Per IEC 60099-4 Section 10.8.13.2.1
Per IEC 60099-4 Section 10.8.13.2.2
Per IEC 60099-4 Section 10.8.13.3
Per IEC 60099-4 Section 10.8.13.4
Per IEC 60099-4 Section 10.8.14.2.1
Per IEC 60099-4 Section 10.8.14.2.2
Per IEC 60099-4 Section 8.9
Per IEC 60099-4 Section 8.10.3.2
Per IEC 60099-4 Section 8.10.3.3
Per IEC 60099-4 Section 8.6.3

RESULTS
The UltraSIL VariSTAR arresters met all performance requirements of IEC 60099-4:2004.

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CP0606
TEST A:
INSULATION WITHSTAND
Test Report Number:
Certifying Laboratory:
Object:

SD-E232A/2005
LAPEM

To demonstrate the voltage withstand capability of the external insulation of the arrester
housing.

Lightning Impulse Voltage Test

Procedure:
The sample was clean and dry. The sample was subject to fifteen positive and negative 1.2
X 50 s impulses.
Results:

The sample passed with less than two discharges at the positive and negative voltage
values. No internal discharges occurred.

Power Frequency Voltage Test

Procedure:
The sample was clean and tested under wet conditions. The sample was subject to a power
frequency voltage of 1.06 times the switching impulse protection level for a period of sixty
seconds.
Results:

The sample passed with no discharges during the sixty-second period.

TEST B:
RESIDUAL VOLTAGE TESTS

Test Report Number:

Certifying Laboratory:
Object:

A6/021601
CESI

To determine the maximum discharge voltage for each discharge current.

Lightning Impulse Residual Voltage Test

Procedure:
A lightning current impulse was applied to each sample for approximately 0.5, 1, and 2
times the nominal discharge current. The current impulse had a front time between 7s to
9s and the virtual time to half-value on the tail was between 18s to 22s.
Switching Impulse Residual Voltage Test
Procedure:
One switching current impulse was applied to each sample at 125 A and 500 A. The current
impulse had a front time greater than 30s and less than 100s and a virtual time to halfvalue of approximately twice the virtual front time.
Steep Current Impulse Residual Voltage Test
Procedure:
One steep current impulse was applied to each sample with a peak value equal to the
nominal discharge current of the arrester. The current impulse had a front time between
0.9s to 1.1s and the virtual time to half-value on the tail was not longer than 20s.

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CP0606

Results:
UltraSil HD Star
1/2 Wave
8/20 Wave Forms
30/60 Switching Surge
Rating
MCOV (kV, peak) (kV, peak) (kV, peak) (kV, peak) (kV, peak) (kV, peak) (kV, peak) (kV, peak) (kV, peak)
10 kA
1.5 kA
3 kA
5 kA
10 kA
20 kA
40 kA
125 A
500 A
3
6
9
10
12
15
18
21
24
27
30
33
36

2.55
5.1
7.65
8.4
10.2
12.7
15.3
17
19.5
22
24.4
27
29

10.8
21.5
32.4
34.4
43.2
52.2
64.8
68.8
79.5
92.4
100.5
114.2
120.8

8.2
16.3
24.6
26.0
32.7
39.6
49.1
52.1
60.2
70.0
76.1
86.5
91.5

8.7
17.4
26.1
27.7
34.8
42.1
52.3
55.4
64.1
74.5
81.0
92.1
97.3

9.1
18.2
27.3
29.0
36.4
44.0
54.7
58.0
67.0
77.9
84.7
96.3
102

9.9
19.8
29.8
31.6
39.7
48.0
59.6
63.2
73.1
84.9
92.4
105
111

10.9
21.9
33.0
34.9
43.9
53.1
65.9
69.9
80.8
93.9
102
116
123

12.3
24.7
37.1
39.4
49.5
59.8
74.2
78.7
91.1
106
115
131
138

7.1
14.1
21.3
22.6
28.3
34.3
42.6
45.1
52.2
60.6
66.0
75.0
79.3

7.6
15.1
22.7
24.1
30.3
36.6
45.5
48.2
55.8
64.8
70.5
80.1
84.7

TEST C:
LONG DURATION CURRENT IMPULSE WITHSTAND TEST
Test Report Number:
Certifying Laboratory:

A6/021602
CESI

Object:

To demonstrate the ability of the arrester to meet the long duration current impulse
withstand test requirements.

Procedure:

The sample was subject to eighteen impulses, divided into six groups of three operations,
with approximately 60 seconds between impulses. The samples cooled to ambient
temperature between impulses.

Results:

The samples met test requirements with less than 5% change in residual voltage and no
physical damage.

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TEST D:
HIGH CURRENT IMPULSE OPERATING DUTY TEST
Test Report Number:
Certifying Laboratory:

A6/021603
CESI

Object:

To demonstrate the ability of the arrester to meet the high current impulse operating duty
test requirements.

Procedure:

The sample was subject to twenty 8/20 lighting current impulses with a peak value equal to
the nominal discharge current of the arrester with the sample at UC. The impulses were
divided into four groups of five impulses, with 50-60 s between impulses and 30 minutes
between groups. The sample was then subject to two 100kA + 10kA high current impulses.
Within 100ms of the second impulse, the sample shall be energized at UR for 10 s and UC
for 30 minutes.

Results:

The samples met test requirements with less than 5% change in residual voltage, achieving
thermal stability, and no physical damage.

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CP0606
TEST E:
POWER FREQUENCY VOLTAGE VS. TIME
Test Report Number:
Certifying Laboratory:

A6/021605
CESI

Object:

To determine the over voltage values and time durations for the arrester design.

Procedure:

The sample was subject to one high current impulse. The sample was then subject to each
over voltage at each specified time range. The recovery voltage of UC was applied to the
sample for thirty minutes.

Results:

UltraSIL Class 1 VariSTAR Arrester

TOV Curve Per IEC 60099-4
1.600

Voltage (per unit COV)

1.500

1.518

1.436
1.400
1.359
1.300

1.286
1.217

1.200

1.151
1.100

1.000
0.01

1.089

0.1

10

Time (sec)

100

1000

10000

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CP0606

TEST F:
CHARACTERISTICS OF AN ARRESTER: SHORT CIRCUIT TEST
Test Report Number:
Certifying Laboratory:

S1-03165A
KEMA

Object:

To verify arrester internal fault is not likely to create an explosive event.

Procedure:

Samples were thermally pre-killed using an over voltage applied for 5+3 minutes. Two
21kV arresters were then tested at full voltage and four 60kV arresters were tested at a
reduced voltage.

Results:

The 21kV arresters tested at full voltage met high current test requirements of 20kA. The
60kV arresters tested at reduced voltage met high current test requirements of 20kA. The
60kV arresters tested at reduced voltage met low current test requirements of 600A.
TEST G:
INTERNAL PARTIAL DISCHARGE TESTS

Test Report Number:

Certifying Laboratory:

A4-003926
CESI

Object:

To verify the arrester design does not generate excessive partial discharge.

Procedure:

The sample was energized to the rated voltage for 2 seconds. The voltage was then lowered
to 1.05 * UC and the partial discharge level was recorded.

Results:

The samples met test requirements with partial discharge < 10pC.

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CP0606

TEST H:
MOISTURE INGRESS TEST
Test Report Number:
Certifying Laboratory:

A4-003914
CESI

Object:

To verify the arrester design will not decrease in performance under thermo-mechanical
and moisture conditions.

Procedure:

The samples were subjected to a series of preconditioning tests including power loss,
internal partial discharge, residual voltage, terminal torque, and thermo-mechanical
preconditioning. The samples were then immersed in boiling de-ionized water with 1kg/m3
of NaCl for a period of 42 hours. The samples remained in the water until the temperature
cooled to 50 oC. After the samples reached ambient temperature they were tested for
changes in power loss, internal partial discharge and residual voltage.

Results:

All samples showed no signs of physical damage, demonstrated less than a 20% change in
power loss, the internal partial discharge did not exceed 10pC, and there was a less than 5%
deviation in residual voltage with no signs of breakdown seen in the voltage and current
oscillograms.
TEST I:
WEATHER AGING TESTS

TEST SERIES A: 1000 HR

Test Report Number:
Certifying Laboratory:

T04-1374
STRI

Object:

To verify the ability of the arrester to withstand continuous salt fog conditions and endure
surface arcing and heating.

Procedure:

The samples were placed in an enclosure filled with a salt fog mist. The samples were
energized at UC for a period of 1000 hours. The samples underwent pre and post testing
consisting of partial discharge and reference voltage.

Results:

All samples met the test requirements of: no housing punctures or housing erosion, no
internal breakdowns, no surface tracking was evidenced by physical examination, the
arrester reference voltage did not decrease by more than 5%, and the partial discharge level
did not exceed 10 pC.

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CP0606

TEST SERIES B: 5000 HR

Test Report Number:
Certifying Laboratory:

T04-1329
STRI

Object:

To verify the ability of the arrester to withstand continuous salt fog conditions and endure
surface arcing and heating.

Procedure:

One 60kV surge arrester was placed under various environmental stresses in a cyclic
manner while energized at UC for a period of 5000 hours. These stresses included solar
radiation simulation, artificial rain, dry heat, damp heat, high dampness at room
temperature, and salt fog at low concentration. The sample underwent pre and post testing
consisting of partial discharge and reference voltage.

Results:

All samples met the test requirements of: no housing punctures or housing erosion, no
internal breakdowns, no surface tracking was evidenced by physical examination, no over
current trip out, the arrester reference voltage did not decrease by more than 5%, and the
partial discharge level did not exceed 5 pC.
TEST J:
MECHANICAL TESTS

TEST OF THE BENDING MOMENT:

Test Report Number:
Certifying Laboratory:

A4-003923
CESI

Object:

To verify the arrester could withstand cantilever and environmental stresses.

Procedure:

The maximum permissible static load (180 Nm) was applied to the upright arrester for a
period of 60 90 seconds. The sample was then immersed in a vessel, boiled in de-ionized
water with 1 kg/m3 of NaCl for 42 hours. At the end of the boiling, the sample remained in
the vessel until the water cooled to 50 C. The sample underwent pre and post testing
consisting of power loss, partial discharge and residual voltage.

Results:

The sample showed no physical damage, the power loss did not increase by more than 20 %
of the initial measurement, the partial discharge did not exceed 10 pC at 1.05*Uc, and the
residual voltage at the same discharge current did not deviate by more than 5%.

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CP0606

SULPHUR DIOXIDE AND SALT MIST TESTS:

Test Report Number:
Certifying Laboratory:

13-7351-20-04-3A-rev2
Thomas A. Edison Technical Center

Object:

To verify the arrester could withstand cantilever and environmental stresses.

Procedure:

The arrester was placed in an airtight box with sulphur dioxide gas for a period of 21 days.
The sample was then placed in a chamber with a salt mist atmosphere for a period of 96
hours. The sample underwent pre and post testing of partial discharge.

Results:

The sample showed no physical damage and the partial discharge did not exceed 10 pC at
1.05*Uc.
TEST K:
DISCONNECTOR OPERATION

Test Report Number:

Certifying Laboratory:

A4-000660
CESI

Object:

To verify the disconnector was effective and permanently disconnected from arrester.

Procedure:

Five disconnectors were tested without the surge arrester at 20A, 200A, and 800 A. The
applied voltage was approximately 2700 V.

Results:

In each test, the samples disconnected and the separation was permanent.

D is c o n n e c t C u r v e

Disconnect Time (sec)

0 .1

0 .0 1

0 .0 0 1
1

10

100

C u rre n t (A m p s )

1000