E No.

: File Ref: 235

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10kA Class 2

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 Jonathan J Woodworth
Chief Engineer Arrester Engineering Manager

DATE: October 2005 © Cooper Power Systems, Inc.

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INTRODUCTION

This test report certifies that the UltraSIL VariSTAR arresters 10kA- Class 2 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 10kA– Class 2 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. Insulation Withstand Test

a) Lightning Impulse Voltage Test ……………… Per IEC 60099-4 Section 8.2.6
b) Switching Impulse Voltage Test ……………… Per IEC 60099-4 Section 8.2.7
c) Power Frequency Voltage Test….……………. Per IEC 60099-4 Section 8.2.8
B. Residual Voltage Test
a) Steep Current Impulse Residual Voltage Test .. Per IEC 60099-4 Section 8.3.1
b) Lightning Impulse Residual Voltage Test ……. Per IEC 60099-4 Section 8.3.2
c) Switching Impulse Residual Voltage Test …… Per IEC 60099-4 Section 8.3.3
C. Long Duration Current Impulse
Withstand Test ………………………………… Per IEC 60099-4 Section 8.4.2
D. Switching Surge Operating Duty Test………………. Per IEC 60099-4 Section 8.5.5
E. Power Frequency Voltage vs. Time ………………. Per IEC 60099-4 Section 6.10, Annex D
F. Characteristics of an Arrester Short Circuit Tests .. Per IEC 60099-4 Section 6.11, Annex O
G. Internal Partial Discharge Tests …………………… Per IEC 60099-4 Section 8.8
H. Moisture Ingress Test
a) Terminal Torque Pre-conditioning.…………… Per IEC 60099-4 Section 10.8.13.2.1
b) Thermo Mechanical Pre-conditioning..……….. Per IEC 60099-4 Section 10.8.13.2.2
c) Water Immersion Test.………………………… Per IEC 60099-4 Section 10.8.13.3
d) Verification Tests ……………………………… Per IEC 60099-4 Section 10.8.13.4
I. Weather Aging Tests
a) Test Series A: 1000 hr …………………………. Per IEC 60099-4 Section 10.8.14.2.1
b) Test Series B: 5000 hr …………………………. Per IEC 60099-4 Section 10.8.14.2.2
J. Mechanical Tests
a) Test of the Bending Moment ………………….. Per IEC 60099-4 Section 8.9
b) Sulphur Dioxide Test …………………………. Per IEC 60099-4 Section 8.10.3.2
c) Salt Mist Test …………………………………. Per IEC 60099-4 Section 8.10.3.3
K. Accelerated Ageing Test of the Resistor Blocks……..Per IEC 60099-4 Section 8.5.2

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

Test Report Number: 10559-RC-001-R00

Certifying Laboratory: Kinectrics

Object: 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 μs impulses.

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

Switching Impulse Voltage Test

Procedure: The sample was subject to fifteen consecutive positive and negative 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: AT-A4007446

Certifying Laboratory: CESI

Object: To determine the maximum discharge voltage for each discharge current.

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
0.9μs to 1.1μs and the virtual time to half-value on the tail was not longer than 20μs.

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 7μs to
9μs and the virtual time to half-value on the tail was between 18μs to 22μs.

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 30μs and less than 100μs and a virtual time to half-
value of approximately twice the virtual front time.
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Results:

Switching Impulse Residual Voltage

Steep Lightning Impulse Residual Voltage
Arrester Arrester (kV, crest)
Current (kV, crest)
Rating COV 30/60 Current Wave
Residual
UR UC 8/20 μs Current Wave
Voltage
(kV, rms) (kV, rms)
(kV, crest) 1.5 kA 3 kA 5kA 10kA 20kA 40kA 125 A 250 A 500 A 1000A
3 2.55 9.2 7.0 7.4 7.7 8.4 9.4 11.0 6.1 6.3 6.5 6.7
6 5.10 17.9 13.9 14.7 15.4 16.7 18.6 21.4 12.2 12.6 13.0 13.5
9 7.65 26.8 20.9 22.0 23.1 25.0 27.7 31.7 18.3 18.9 19.5 20.2
10 8.40 29.3 23.0 24.2 25.4 27.4 30.4 34.8 20.1 20.7 21.4 22.2
12 10.2 35.6 27.9 29.4 30.8 33.3 36.9 42.1 24.4 25.2 26.0 26.9
15 12.7 44.2 34.7 36.6 38.3 41.4 45.9 52.2 30.4 31.3 32.4 33.5
18 15.3 53.0 41.8 44.0 46.2 49.8 55.2 62.8 36.6 37.7 39.0 40.4
21 17.0 58.9 46.4 48.9 51.3 55.4 61.3 69.7 40.7 41.9 43.4 44.9
24 19.5 67.5 53.3 56.1 58.8 63.5 70.3 79.9 46.7 48.1 49.8 51.5
27 22.0 76.1 60.1 63.3 66.3 71.6 79.3 90.0 52.7 54.3 56.1 58.1
30 24.4 84.4 66.6 70.2 73.6 79.4 87.9 100 58.4 60.2 62.3 64.4
33 27.5 95.0 75.1 79.1 82.9 89.5 99.1 112 65.9 67.8 70.2 72.6
36 29.0 100 79.2 83.4 87.4 94.4 105 119 69.5 71.5 74.0 76.6
39 31.5 109 86.0 90.6 95.0 103 113 129 75.4 77.7 80.4 83.1
42 34.0 118 92.8 97.8 103 111 122 139 81.4 83.9 86.8 89.7
45 36.5 126 100 105 110 119 131 149 874.4 90.0 93.1 96.3
48 39.0 135 107 112 118 127 140 159 93.4 96.2 100 103
54 42.0 145 115 121 127 137 151 171 101 104 107 111
60 48.0 165 131 138 145 156 173 196 115 118 123 127
66 53.0 184 145 153 160 173 191 217 127 131 135 140
72 57.0 198 156 164 172 186 205 233 137 141 145 151
78 62.0 214 169 178 187 202 223 253 149 153 158 164
84 68.0 235 186 196 205 221 245 278 163 168 174 179
90 70.0 248 197 207 217 234 259 294 172 178 184 190
96 76.0 262 208 219 229 247 274 310 182 188 194 201
108 84.0 290 229 242 253 273 302 343 201 207 214 222
120 98.0 338 268 282 295 319 353 399 235 242 250 259
132 106 367 290 305 320 345 382 433 254 261 270 280
138 111 384 303 319 335 361 400 453 266 274 283 293
144 115 397 314 331 347 374 414 469 275 284 293 304
162 130 449 355 374 392 423 468 530 311 321 332 343
168 131 452 358 377 395 426 472 534 314 323 334 346
172 140 483 382 403 422 455 504 571 335 345 357 370
180 144 497 393 414 434 468 518 587 345 355 368 380
192 152 526 415 437 458 495 547 620 364 375 388 401
198 160 553 437 460 482 521 576 653 383 395 408 422
204 165 570 451 475 497 537 594 673 395 407 421 436
216 174 601 475 501 525 566 626 710 417 429 444 459
228 182 628 497 524 549 592 655 742 436 449 464 480
240 190 656 519 547 573 618 684 774 455 469 485 502
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TEST C:
LONG DURATION CURRENT IMPULSE WITHSTAND TEST

Test Report Number: AT-A4007437

Certifying Laboratory: 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 50-60 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:
SWITCHING SURGE OPERATING DUTY TEST

Test Report Number: AT-A4007439

Certifying Laboratory: 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 1.2 * UC’. The impulses
were divided into four groups of five impulses, with 50-60 s between impulses and 25-30
minutes between groups. The sample was then subject to two 100kA + 10kA high current
impulses. The sample was then subject to two long duration current impulses at an
elevated temperature of 60+ 3 oC with 50-60 s between impulses. Within 100ms of the
second impulse, the sample shall be energized at UR’ for 10s 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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TEST E:
POWER FREQUENCY VOLTAGE VS. TIME

Test Report Number: AT-A4007440

Certifying Laboratory: 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:
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TEST F:
CHARACTERISTICS OF AN ARRESTER: SHORT CIRCUIT TEST

Test Report Number: 53021129

Test Date: July 29, 2003
Certifying Laboratory: Hydro Quebec

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

Procedure: The samples were thermally pre-killed using an over voltage applied for 5+3 minutes. Two
60kV arresters were tested at a reduced voltage.

Results: The 60kV arrester tested at reduced voltage met high current test requirements of 40kA.
The 60kV arresters tested at reduced voltage met low current test requirements of 600A.

Test Report Number: 53021129

Test Date: July 28, 2003
Certifying Laboratory: Hydro Quebec

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

Procedure: The sample was thermally pre-killed using an over voltage applied for 5+3 minutes. One
60kV arrester was tested at a reduced voltage.

Results: The 60kV arrester tested at reduced voltage met high current test requirements of 80kA.

TEST G:
INTERNAL PARTIAL DISCHARGE TESTS

Test Report Number: AT-A4008725

Certifying Laboratory: 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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TEST H:
MOISTURE INGRESS TEST

Test Report Number: AT-A4007728

Certifying Laboratory: 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: 10613

Certifying Laboratory: Kinectrics

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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TEST SERIES B: 5000 HR

Test Report Number: T04-1326

Certifying Laboratory: 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.
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TEST J:
MECHANICAL TESTS

TEST OF THE BENDING MOMENT:

Test Report Number: AT-A4007729

Certifying Laboratory: CESI

Object: To verify the arrester could withstand cantilever and environmental stresses.

Procedure: The maximum permissible static load (680 Nm for sample 1 and 460 Nm for sample 2) 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 at 80oC with 1 kg/m3 of NaCl for 52 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%.

SULPHUR DIOXIDE AND SALT MIST TESTS:

Test Report Number: ML 169-2003-1

Certifying Laboratory: 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:
ACCELERATED AGEING TEST OF THE RESISTOR BLOCKS

Test Report Number: AT-A4007446

Certifying Laboratory: CESI

Object: To determine the voltage values UC’ and UR’ for operating duty testing.

Procedure: Samples of the resistor blocks in composite wrap material were at 115oC + 4 K for 1000
hours. Power losses were monitored for the duration of the test.

Results: The power loss ratio between the start of the test and the end power loss was less than 1.0
for all samples. No correction factor during operating duty testing must be applied.