Your Key to

Lightning Protection

ULTRASIL™ SURGE ARRESTERS

Nominal Discharge Currents: 5 kA, and 10 kA Class 1

Arrester Ratings: 3 - 60 kV
For Systems to 72 kV

ISO 90
REGIS 01
TERED
 THE KEY TO THE FUTURE IN SURGE ARRES
Now, the reduced size and weight, increased creepage distance and
non-fragmenting characteristics of polymer-housed arresters have been
further refined in the new generation of arrester design: The UltraSIL™
housed arresters from Cooper Power Systems.

The keys to the UltraSIL advantage are:

Long-Term Performance: The unique UltraSIL housing
Quality: Advanced manufacturing technology
Design Reliability: Thorough performance testing
Innovative Design Features: Solid Insulation System and More
Fast Delivery: The UltraQUIK™ System

The Key to Long-Term Performance:

The Unique UltraSIL Silicone Rubber
Housing

Our specially formulated UltraSIL silicone rubber

represents the optimum solution for long service life in
any environment due to the following properties: Wetting of a conventional
carbon-based arrester
housing. After four years of
No Tracking or Erosion outdoor exposure in a mildly
Field studies show that UV erosion of polymer contaminated environment
arrester housings will significantly reduce their
TM

water has already stopped

effective life. This damage, which partially manifests beading.
itself as color changes and surface pitting, creates
tracking paths on the housing and eventually leads to
failure. The housing damage is caused from
excessive surface current flow, known as leakage
current. All polymer housings have low leakage
currents when they are dry, however there are distinct
differences in leakage current magnitudes and
performance during wet weather.
UltraSIL silicone rubber is a hydrophobic, or
Water continues to bead
non-wetting polymer. During rain or fog, water on silicone rubber housing
droplets on the surface bead up without producing after identical exposure.
a continuous sheet of moisture. This beading action
interrupts the leakage current paths, preventing
housing damage.
Other polymers are hydrophilic; that is, they are
subject to wetting. When they are exposed to periods
of rain or fog, water on the housing flows into a
continuous conductive path. The leakage currents
will initiate arcing over small dry patches on the
housing. This dry-band arcing creates surface pitting
and tracking erosion. Surface degradation
accelerates under long-term exposure, leading to
flashover.

UltraSIL arrester
undergoing UV
testing.

2
STERS: THE ULTRASIL ARRESTER FAMILY
BOND ENERGY (kJ/mole)
450 No Chalking or Cracking
Solar ultraviolet (UV) radiation damages polymer
400
SUNLIGHT (UV ENERGY)
materials by interacting with the surface molecules.
350 If the bond energy holding these molecules together
is less than the energy of direct solar radiation, the
300 Carbon- UltraSIL bonds will break. As these bonds break, chalking and
Based Silicone
Polymers Rubber cracking occurs on the exposed surface. This visible
surface damage further increases the hydrophilic
nature of the housing.
Carbon-based polymers, such as EPR’s and
EVA’s, exhibit molecular bond energies far below the
energy of UV radiation. These weak molecular bonds
will break over time and cause visible chalking and
cracking of the arrester housing surface. Adding
silicone to these formulations does not improve their
long-term UV stability since the primary bonds are
weak.
UltraSIL silicone rubber molecules, however, have
a bond energy significantly higher than the UV energy
available from sunlight. The integrity of the surface
molecular bonds is not compromised, even in the
most demanding environments.

Mechanical Strength
UltraSIL silicone rubber, a naturally resilient
material, is routinely applied between temperature TM

extremes of -60° to 200° C — the widest range of all

polymers.

Chemical Stability
Chemical agents in the air constantly stress
polymer materials. These agents accumulate on
arrester housings, and may cause chemical
breakdown of their insulating properties.
UltraSIL silicone rubber is chemically inert and
remains unaffected by atmospheric pollutants.
UltraSIL silicone rubber will not support biological
growth, such as algae and mildew. It is also
non-flammable and will not support combustion.

THE SHAPE OF THE FUTURE IN ARRESTER TECHNOLOGY

The size, shape and internal design of the new UltraSIL

arrester were carefully chosen based on years of
experience and product analysis and confirmed by
environmental multistress life testing. Combined with
the hydrophobicity of silicone rubber, the enhanced
shed angle of the skirts shields a portion of the total
creepage distance from wet weather. It also maximizes
water run-off and enhances natural cleansing of
contaminants.

3
 THE KEY TO QUALITY: ADVANCED MANUFACTURING TECHNOLOGY

UltraSIL arresters are manufactured using highly

automated quality controlled processes at our
ISO 9001 registered Olean, New York, USA facility.

Dedicated In-House MOV Disk Fabrication

Cooper Power Systems manufactures all of the
Metal Oxide Varistor (MOV) disks used in the UltraSIL
arrester. The highly automated manufacturing
process ensures uniform physical and electrical
characteristics. This state-of-the-art process begins
with computer-controlled mixing of the proprietary
powder formulation. Once pressed and sintered into P L A S M A D E P O S I T I O N
a high density ceramic, the disk surfaces are
precision ground, then coated with conductive
electrodes using plasma deposition technology.

Arresters Assembled in a Clean Room

After rigid acceptance tests, the MOV disks and
other internal components are assembled in a
controlled clean room. This patent pending process
utilizes robotics and fluidized bed technology to form
a solid cured epoxy and fiberglass coating on the
internal components. The UltraSIL housing is then
bonded onto the internal module to form a solid high
dielectric strength insulation system.
TM

R O B O T I C F A B R I C A T I O N

F L U I D I Z E D B E D T E C H N O L O G Y

4
 THE KEY TO DESIGN RELIABILITY: THOROUGH PERFORMANCE TESTING

Automated Testing Assures Quality

Each arrester receives a battery of electrical tests
to ensure its field performance. Tests are performed
completely within a computer-directed robotic test cell
for measurement accuracy and consistent results.
To ensure a superior level of performance in
any environmental extreme, UltraSIL arresters have
been subjected to exhaustive design testing. Our
laboratory facilities feature new automated data
collection systems for rapid and accurate test results.
C L E A N R O O M E N V I R O N M E N T
IEC 60099-4 (99-4) Testing
Full certification testing has been performed in our
facilities and confirmed by independent laboratory
testing.

Outdoor Environmental Testing

Outdoor environmental tests have been conducted
on energized arrester designs for several years.
Results from these tests were a key factor in the
design of the UltraSIL arrester family.

Other Design Tests

Many other design verification tests have been
performed on the UltraSIL arrester. Please ask your
Cooper Power Systems representative for detailed
test information.

A U T O M A T E D M U L T I S T R E S S T E S T I N G

Outdoor Environmental Test

Facility

Thermal shock testing

includes temperature cycling
to -60°C. UltraSIL arrester testing includes
simulated rainstorm.

5
 INNOVATIVE DESIGN FEATURES: SOLID INSULATION SYSTEM AND MORE

Superior Solid Insulation System material. Ample protection margins are

The superior performance of the UltraSIL ensured, even in the most polluted
arrester comes from the bonding of two environments. Modularity of the manufacturing
components into a solid, void-free insulation process allows for built-in extra creepage
system: the field-proven silicone rubber used in arrester options, if needed, for demanding
the housing, and the patented internal arrester environmental conditions.
module. A unique manufacturing process
creates a single bonded structure that provides Non-Fragmenting Design
dielectric performance impervious to moisture. The UltraSIL arrester design is completely
The insulation materials were carefully chosen non-fragmenting through 20 kA of system fault
to combine exceptional dielectric characteristics current.
with physical strength. The results are a robust
electrical design which can withstand severe Universal Animal Guard
thermal cycling even under cantilever loading. Two self-adjusting “valve” openings
accommodate common wire/insulation sizes to
Optimum Creepage Housing provide protection from wildlife outages.
The UltraSIL arrester housing was designed
with creepage distances that take full advantage
of the high tracking resistance of the UltraSIL

10kV ULTRASIL™ ARRESTER

VARISTAR® CONFIGURATION

Optional
Universal
Stainless Steel Line Terminal Animal
TM

Guard
Stainless Steel Cap
w/Nameplate Information

UltraSIL™ Silicone Electrode

Rubber Housing

MOV Disk

1st Epoxy Bond

Fiberglass Reinforcing Strips

Solid Interface Bond

2nd Epoxy Bond Protected

Creepage

Spiral Wound Fiberglass 3rd Epoxy Bond

Optional Insulated Electrode

(Hidden)
Mounting Base

Auxiliary
Nameplate

Optional Isolator

Stainless Steel
Ground Terminal

6
THE KEY TO FAST DELIVERY: THE ULTRAQUIK™ SYSTEM

With the advent of the UltraSIL Arrester, we representative for a copy of catalog section
are changing the way arresters are specified. I235-35 with the Selection and Ordering Guide;
The UltraQUIK Selection and Ordering System it provides a straightforward tool to add the
builds on the modular design approach of the features and functions you require from almost
UltraSIL arrester to simplify selecting arresters 50 million available combinations. The choices
for your system. you make will “automatically” generate a unique
Ask your Cooper Power Systems arrester design and its associated catalog number.

PROTECTIVE CHARACTERISTICS
UltraSIL housed arresters provide excellent overvoltage protection for electrical equipment
throughout MV distribution systems. The protective characteristics of the UltraSIL arrester
family are shown below. All data is in accordance with IEC 60099-4 (99-4).

VariSTAR UNS IN =5kA

Ur Uc Steep Current Lightning Impulse Residual Voltage (kV crest)
Arrester Rating COV Residual Voltage 8/20 µs Current Wave
(kV rms) (kV rms) (kV crest) 1.5 kA 3 kA 5 kA 10 kA 20 kA 40 kA
3 2.55 10.9 9.0 9.7 10.4 11.4 13.0 15.1
6 5.1 21.8 17.9 19.4 20.8 22.7 26.0 30.2
9 7.65 31.4 25.8 28.0 30.0 32.8 37.4 43.5
10 8.4 32.7 26.9 29.1 31.2 34.1 38.9 45.3
12 10.2 41.1 33.8 36.5 39.2 42.9 48.9 56.9
15 12.7 51.3 42.2 45.7 49.0 53.6 61.1 71.1
18 15.3 61.6 50.6 54.8 58.8 64.3 73.4 85.3
21 17.0 65.4 53.7 58.2 62.4 68.2 77.9 90.6 TM

24 19.5 76.3 62.7 67.8 72.8 79.6 90.8 106.0

27 22.0 86.3 71.0 76.8 82.4 90.1 103.0 120.0
30 24.4 96.2 79.1 85.6 91.8 100.0 115.0 133.0
33 27.0 107.0 87.8 95.1 102.0 112.0 127.0 148.0
36 29.0 115.0 94.7 103.0 110.0 120.0 137.0 160.0

VariSTAR UHS IN =10 kA, Class 1

Ur Uc Steep Lightning Impulse Residual Voltage (kV crest) Switching Impulse
Arrester COV Current 8/20 µs Current Wave Residual Discharge
Rating (kV rms) Residual Voltage
(kV rms) Voltage (kV crest) 30/60 µs
(kV crest) Current Wave

1.5 kA 3 kA 5 kA 10 kA 20 kA 40 kA 125 A 500 A

3 2.55 11.3 8.6 9.1 9.5 10.4 11.5 13.0 7.4 7.9
6 5.10 22.6 17.2 18.2 19.1 20.8 23.0 25.9 14.8 15.9
9 7.65 32.6 24.8 26.3 27.5 30.0 33.2 37.4 21.4 22.9
10 8.40 33.9 25.8 27.4 28.6 31.2 34.5 38.9 22.2 23.8
12 10.2 42.6 32.4 34.4 35.9 39.2 43.3 48.8 27.9 29.9
15 12.7 53.2 40.4 43.0 44.9 49.0 54.2 61.0 34.9 37.4
18 15.3 63.9 48.5 51.6 53.9 58.8 65.0 73.2 41.9 44.8
21 17.0 67.8 51.5 54.7 57.2 62.4 69.0 77.7 44.4 47.6
24 19.5 79.1 60.1 63.9 66.7 72.8 80.5 90.7 51.9 55.5
27 22.0 89.5 68.0 72.3 75.5 82.4 91.1 103.0 58.7 62.8
30 24.4 99.7 75.8 80.5 84.1 91.8 101.0 114.0 65.4 70.0
33 27.0 110.8 84.2 89.5 93.5 102.0 113.0 127.0 72.7 77.8
36 29.0 119.5 90.8 96.5 101.0 110.0 122.0 137.0 78.4 83.9
39 31.5 130.3 99.1 105.0 110.0 120.0 133.0 149.0 85.5 91.5
42 34.0 141.2 107.0 114.0 119.0 130.0 144.0 162.0 92.6 99.1
45 36.5 152.1 116.0 123.0 128.0 140.0 155.0 174.0 99.7 107.0
48 39.0 162.9 124.0 132.0 137.0 150.0 166.0 187.0 107.0 114.0
54 42.0 176.0 134.0 142.0 148.0 162.0 179.0 202.0 115.0 124.0
60 48.0 197.7 150.0 160.0 167.0 182.0 201.0 227.0 130.0 139.0

7
 Arrester Manufacturing Facility, Olean, NY, USA Components & Protective Equipment
Operations Headquarters, Pewaukee, WI, USA

Product Literature for UltraSIL™ Housed VariSTAR® Surge Arresters

Catalog with UltraQUIK™ Selection and Ordering Guide — I235-35 & I235-91
Independently Certified Test Report to IEC 60099-4 — 96023
Installation and Service Information —IS235-35-1

Sales Office Locations

Athens, Greece Phone: 30-1-964-6332 Fax: 30-1-964-6336
Miami, Florida, USA Phone: 1-305-477-9400 Fax: 1-305-477-9414
Sydney, Australia Phone: 61-2-9683-1122 Fax: 61-2-9683-6840
Taipei, Taiwan Phone: 886-2-758-4530 Fax: 886-2-758-4535
Singapore Phone: 65-298-3191 Fax: 65-298-0559

Contact your Cooper Power Systems representative for more information.

UltraSIL™ and UltraQUIK™ are trademarks of Cooper Industries, Inc.

VariSTAR® is a registered trademark of Cooper Industries, Inc.

P.O. Box 1640

Waukesha, WI 53187
www.cooperpower.com

Bulletin 96201 • November 1998

©1998 Cooper Power Systems, Inc. MI5M1198