cooken (Cooper Power Systems E-No: E-9206, Rev. 02 " CP-No: CP-9208, Rev. 02 Certified Test Report File Ref: Cat. Sec. 240-40 Page: 10f 12 Design Tests for the Bay-O-Net Fuse Assembly “Tune 24, 1998 + Suporsodss 51/92 -© Cooper Power Syatoms, ne.Certified Test Report Design Tests for the Bay-O-Net Fuse Assembly 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. ak Phebe Frahk J. Muench Gordon T. Borck Engineering Manager Sr. Product EngineerE-No: £-9206, Rev. 02 CP-No:_CP-9208, Rev. 02 INTRODUCTION As part of ongoing efforts to improve and upgrade the sidewall Bay-O-Net fuse product line, the Bay-O- Net fuse holder was redesigned to provide improved mechanical and electrical characteristics. Thenew holder is molded of a thermoplastic polyester reinforced resin having excellent strength, temperature stability, heat resistance, and high dielectric properties. The fuse holder, incorporating a patented contact assembly, provides superior operating characteristics. Operating characteristic improvements include: A.) Higher interrupting ratings B.) Excellent load switching performance C.) Upgraded flange gasket seal D.) Improved pressure tight seal for the handle/fuse assembly This report details design tests conducted to verify performance of the new Bay-O-Net fuse housing in the following areas:Certified Test Report ‘REQUIREMENTS ‘The Bay-O-Not fuse assembly is required to operate and isolate other pieces of equipment on the electrical distribution system when overcurrent conditions are present. Testing will demonstrate that the Bay-O-Net fuse assembly can meet published ratings. OBIECT ‘Verify that the new Bay-O-Net fuse holder assembly can mect interrupting current ratings up to and including the following levels: + 3,500A RMS symmetrical at 8.3 kV + 2;500A RMS symmetrical at 15.5 kV + 1,000A RMS symmetrical at 23 kV PROCEDURE Bay-O-Net fuse assemblies, Cat. No. 4000361C99MC, were mounted in an oil filled tank using operating and installation instructions detailed on 5000023080 and 5000050061. The Bay-O-Net fuse assembly was tested using fuse links of the 4000353C, +4000358C, 4038108C, and 4038361C series. Circuits were created using ANSI C37.41-1981 standards as a guide. Testing was conducted at room ambient, rated voltage, with the current set at low (overload), several intermediate ranges, and atthe rated symmetric levels. Fuse links of each series type were selected and testing was conducted using ANSI C37.41-1988 as, a guide, Circuits were established for each voltage and current level. ‘The fuse was placed in the cartridge, atached to the stabber hhandle and inserted into the Bay-O-Net housing. The circuit was energized from a remote switch, the fuse melted and the current ‘was interrupted by the fuse/cartridge assembly. Following interruption, a minimum three minute voltage withstand was maintained across the specimen to verify complete interruption of the fault. RESULTS. ‘The fuses operated, cleared and withstood voltage following interruption of current up o and including the levels detailed above, CONCLUSIONS ‘The above test results verify interruption ratings of the new Bay-O-Net fuse housing.E-9206, Rev. 02 CP-No:_CP-9208, Rev. 02 REQUIREMENTS Demonstrate that the Bay-O-Net fuse assembly can be used to energize and de-cnergize load current without electrical and/or ‘mechanical deterioration to the assembly. OBLECT ‘Verify that the new Bay-O-Net fuse housing assembly can meet the following switching current ratings: ‘50 operations at 160 amps at 10.0 kV ‘50 operations at 150 amps at 15.5 kV 50 operations at 80 amps at 26.7 kV 50 operations at SO amps at 34.5 kV ‘One operation is defined as an insertion (make) of the stabber cartridge assembly into the housing and one withdrawal (break). PROCEDURE. Bay-O-Net fuse assemblies (4000361C99MC) were mounted in an oil filled tank as specified in the installation instructions. Circuits used followed ANSI C119.2 and C37.41-1988 standards asa guide. There was 10% series impedance for circuits of 26.7 KV or lower and 17% for the 34.5 KV circuit. The X/R ratio between series reactance to series resistance was in the 5-7 range. Power factors were in the 70%-80% range. The stabber/handle cartridge fuse assembly was used to make the circuit by manually closing the assembly into the housing with ahotstick. Immediately after making the circuit, the same sample was used to interrupt the circuit by manually withdrawing it, Three holders were tested at each voltage level. Fifty (50) make/break operations were performed on each of the three holders. Subsequent to switching tests the assemblies were expected to withstand system voltage. RESULTS ‘Samples tested met the ratings for both current and voltage as detailed above. The holder, contacts and cartridge assembly were in good condition following above testing. CONCLUSIONS ‘The above test results verify the switching current ratings of the new Bay-O-Net fuse assembly.Certified Test Report REQUIREMENTS ‘The Bay-O-Net fuse assembly is used in both tansformers and ul filled switchgear. These tests will verify the iemperature rise levels detailed in ANSI CS7.12.00 which allows a maximum 15°C rise above the other conductors average temperature. The worst «case condition would result nan ol temperature equal tothe average winding rise, The limit therefore, would be 15°C over average ‘winding rise temperature. ‘The continuous operating current level is the maximum current which the device can carry continuously without exceeding the ‘maximum allowable temperature rise specified in the standards. OBJECT ‘Verify both temperature rise characteristics and determine continuous operating current levels as detailed in ANSI C57.12.00 requirements. PROCEDURE Bay-O-Net fuse assemblies 4000361C99MC) were mounted in an oil filed tank as specified in the installation instructions, “Testing was performed using ANSI C37.41-1988 requirements asa guide. ‘The specimens were assembled with the cartridge and vented copper shorting bar mounted toa stabber/handie. This assembly was inserted into the Bay-O-Net housing. Thermocouples were placed at key locations to verify temperature rise levels. The oil temperature was raised to 76 °C to simulate a temperature rise of 56 °C above a 20°C ambient. Testing was conducted 81300 amperes. The test was run fora period of 24 hours to assure temperature stabilization. The maximum temperature levels of ‘current carrying parts were established at stabilization. ‘Thecontinuous current level was established when the maximum allowable temperature ise levels allowed inthe standands were reached and held, and the specimen could carry that current continuously for a period of 24 hours. RESULTS ‘The Bay-O-Net fuse assembly reached temperature stability and carried itsrated current of 300 amps continuously. Temperature rises were below levels specified in the standards. (CONCLUSIONS ‘The continuous operating current level of 300 amps was established during these tests.E-No: E-9206, Rev. 02 CP-No:_CP-9208, Rev. 02 ‘REQUIREMENTS Demonstrate thar the new Bay-O-Net fuse holder assembly has a corona (partial discharge) level of 3 pic-coulombs ur less at 29 kV and RIV voltage level below 100 microvolts at 110% rating (25.3 kV). OBIECT Determine corona and RIV levels for the new Bay-O-Net fuse holder assembly. PROCEDURE ‘The Bay-O-Net fuse assemblies (4000361C99MC) were mounted in an oil filled tank as detailed in installation instructions. ‘Testing was performed as detailed in ANSI C37.41-1988 requirements, Testing was conducted ina ste! tank filed with oi at room. ambient, The Bay-O-Net fuse holder was tested by itself and also with the stabbec/handie and cartridge assembly having both blown, and unblown fuse clements, The assemblies were tested for both corona and RIV determination. Measurements forthe RIV level ‘were made at inception, extinction fuse rating, and 110% of rating. Corona and partial discharge levels were determined at 125% of rating (29 kV). RESULTS All assemblies passed both tests with corona values less than 3 pico-coulombs at 34.5 kV. RIV levels were <2 microvolis at 11104 rating (25.3 kV) for both the holder and the complete assembly with blown and unblown fuses. CONCLUSIONS ‘All samples met corona and RIV levels as required per ANSI C37.47-1981 requirements.Certified Test Report ‘REQUIREMENTS Demonsirate thatthe Bay-O-Net fuse holder mounted in ol filled switchgear can meet a 12x50 sec 150 kV impulse at both polarities required to assure adequate ability to withstand lightning and other short time high voltage surges. OBJECT Verify the basic insulation level of the Bay-O-Net housing (4000361C99MC) as required in ANSI 57.12. PROCEDURE ‘A.1.2550 microsecond impulse test was performed on three Bay-O-Net fuse housings with blown and unblown fuse elements, ‘The units were mounted in an appropriate tank as detailed on the instalation instructions. The tank was grounded. Voltage was applied to the lower contact on the Bay-O-Net housing. Testing was performed por ANSI C37.41-1988 and C37.47-1981 requirements. RESULTS Positive polarity: 180 kV 3 shot withstand with blown fuse element. 180 KV 3 shot withstand with fuse element. ‘Negative polarity: 180V 3 shot withstand with blown fuse element, 180 kV 3 shot withstand with fuse element. CONCLUSIONS ‘The basic insulation level (BIL) of the Bay-O-Net fuse holder is adequate for use in 150 kV BIL equipment.E-No: £-9206, Rev. 02 CP-No:_CP-9208, Rev. 02 REQUIREMENTS Demonstrate that the Bay-O Net fuse holder can meet a 60 kV, 60 He. withstand per ANSI standards. OBJECT Verify 60 kV one minute hipot capability of the Bay-O-Net fuse holder. PROCEDURE ‘The Bay-O-Net fuse holder was mounted to an appropriate tank as detailed on the installation instructions. The tank was grounded. Voltage was applied to the lower contact of the Bay-O-Net housing. Testing was conducted per ANSIC3741,C37.71, €37.72 and C57.12. Three Bay-O-Net fuse assemblies were tested with normal and blown fuse links. ‘RESULTS “The Bay-O-Net fuse assembly successfully passed 60 KV, 60 Hz vollage for a minimum of one minute, CONCLUSIONS ‘The Bay-O-Net fuse holder meets ANSI standards C37.71, C37.72, C37.47 and C57.12 requirements,Certified Test Report ‘REQUIREMENTS. ‘Demonstrate that mechanical forces required toattach the Bay-O-Net housing tothe tank wall cantilever forces developed during assembly, handiing, and lead attachment will not damage the Bay-O-Net housing. OBIECT Verify that both torque and cantilever forces exerted on the Bay-O-Net housing during assembly and handling are more than adequate to meet requirements. PROCEDURE ‘The Bay-O-Net fuse holder (4037158CO1M) was atached to the tank wall as detailed on installation instructions. Fifteen (15) fuse holders were selectedat random to perform each est. The installation instruction specifies hat the Bay-O-Netholder be altached to the tank wall by tightening the retaining nut to a level of 5-10 f-Ibs to properly seat and compress the gasket for proper seal. ‘Maximum torque levels were determined by placing the specimens into the test fixture, ‘The fastening nut was tightened to 10 fi-lbs, using a digital torque wrench. Units were examined for any damage. Torque was then increased using the digital torque wrench, The force was applied at a steady rate until breakage occurred. Cantilever testing was performed by placing the test specimen into a fixture as detailed in the installation instruction, Testing. was performed on an Instron test machine. Cantilever force was applied tothe Bay-O-Net housing by administering a force tothe lower contact with the unit held inthe horizontal postion. Force was applied until breakage occurred. Testing was then performed in a similar manner on the complete assembly while mounted inthe same test fixture, A third test was performed similar to test number two, except with force applied a1 90° to determine sideward strength. RESULTS All fiften (15) test specimens exceeded a torque of 3.5x recommended maximum tightening level before breakage occurred, Cantilever forces on the Bay-O-Nethousing exhibited breakage inexcess of SO f-Ibs, The complete assembly exhibited breakage inexcess of 150 ft-lbs. CONCLUSIONS ‘The Bay-O-Net fuse housing provides excellent strength required for handling, assembly, and lead atchment procedures. 0E-No: £-9206, Rev. 02 CP-No: _CP-9208, Rev. 02 REQUIREMENTS ‘Demonstrate thatthe flange gasket and stabber handle assembly seal can meet temperature and pressure forces that willbe exerted (on the unit during extreme operating conditions. ObLECT. ‘Verify thermal cycle seal capabilities of the Bay-O-Net fuse housing, PROCEDURE ‘Ten(10) Bay-O-Net fuse assemblies (4000361C99MC) were subjected to thermal cycle seal testevaluation. Each specimen was mounted toatest fixture, which was designed to simulate the typical tank wall application. The specimens were mounted asspecified {in the instructions. For the first part of the test, the samples were placed in a pressure vessel. The vessel was filled with water and pressurized to 15 psi. The samples were held at this pressure, during which time visual examination was done to verify integrity of both seals. Phase two consisted of testing the specimens in a thermal cycle chamber in air from -30 °C to 130 °C fora total of 10 cycles. Each cycle lasted 6 hours. The units were held atthe lower and upper temperature extreme for a period of 2 hours. Following ‘conclusion of 10 cycles, the samples were again placed in the pressure vessel and pressurized to 15 psi. The samples were held at this pressure, during which time visual examination was done to verify seal integrity. RESULTS All samples passed the 15 psi pressure test after being cycled at temperature extremes of -30 °C to 130°C, verifying the seal integrity of the Bay-O-Net fuse assembly. CONCLUSIONS: ‘The Bay-O-Net fuse assembly met thermal cycle seal requirements, which it may be subjected to during extreme temperature and pressure conditions. 7Certified Test Report coofen ‘Cooper Power Systoms uaty om ecparindnte P.O. Box 1640, Waskosha, W 53187 2