NOVA Technology: Cycloaliphatic Epoxy Module Environment Tests Sales Class & Project No.: 003K91K041A Laboratory No.: ML 422-95-7 Date Written: 12/06/2002 Date Released: 12/16/2002 Study: 84-Month Desert/Tropical and 65-Month Coastal Outdoor Environment Testing of NOVA VCS Switch Units Purpose/Material Tested: Determine how resistant the Cycloaliphatic Epoxy material, used in Cooper Power Systems Type NOVA modules, is to the effects of actual outdoor weathering at the DSET Phoenix, AZ, Desert; DSET Miami, FL, Tropical; and LaQue Corrosion Services, Kure Beach, NC, Coastal test sites. The actual outdoor weathering exposure testing was conducted according to the guidelines outlined in ASTM Standard Test Method G7. Conclusion: After seven years of outdoor exposure at the DSET Phoenix, AZ and DSET Miami, FL test sites, the Cooper Power Systems Type NOVA module cycloaliphatic epoxy of Type NOVA VCS Switch units have maintained good structural integrity. No crazing, cracking, or other forms of structural deterioration have been observed. The original VCS Switch installed at the Kure Beach coastal test site was lost when Hurricane Fran struck the North Carolina coast in late August of 1996. The 58 and 65 month exposure of a second unit is included in this report. The Type NOVA module epoxy material is in excellent condition and still exhibits some slight gloss retention. No cracks, crazing, or other physical defects have developed on the surface of the NOVA epoxy. The sample plates installed at the Cooper Power Systems Franksville Technical Center have become lighter in color and have lost spectral gloss. None of these sample plates shows any signs of physical deterioration. Background: A cycloaliphatic epoxy material is being used to encapsulate the interrupter of the Type NOVA VCS Switch Module. Three VCS units and 3" x 5" sample plates are being exposed to several outdoor environments to determine how the Type NOVA module epoxy will perform. Sample plates were installed in the test racks at the Cooper Power Systems Franksville Technical Center on October 15, 1995. Three VCS Switch units were also supplied to the Franksville Technical Center. These units and sample plates were shipped to outdoor test facilities for outdoor exposure testing. Six plates and one unit were shipped to the DSET Miami, FL test site and installed in the test yard on August 31, 1995. A second unit along with six test plates were also shipped to the DSET Phoenix, AZ site and installed in the test yard on September 14, 1995. Gloss and color evaluations were conducted on the plates and the units at six-month intervals. Four sample plates remain at each test site. Two plates were removed after the six-month and one-year exposure periods were completed. The third unit and set of test plates were sent to the LaQue Corrosion Services outdoor test site located at Kure Beach, NC and installed during September 1995. In late August of 1996, Hurricane Fran struck the North Carolina coast and the VCS Switch and the plates were lost. A fourth unit was installed at Kure Beach on March 4, 1997 to continue the testing of the Type NOVA module material at a Coastal location. The following is a description of the three outdoor test sites: Phoenix, Arizona (Atlas DSET Laboratories Inc.) - At the Phoenix test site, the test specimens are exposed to a severe sunlight and thermal environment. This geographic location was used to expose the Type NOVA module epoxy to a desert environment common to the southwestern regions of the United States. The test plates were placed in unbacked racks facing south at a 45 angle to the ground, and the unit was placed on a metal support post. Miami, Florida (Atlas DSET Laboratories Inc.) - The Florida test site is located about 30 miles southwest of Miami in an agricultural area, which provides a very sunny, humid, and hot environment. This site was used to expose the samples to both the weathering conditions of the Florida sun and the corrosive high humidity conditions experienced in the southeastern states. The plates were placed in unbacked racks at a 45 angle to the ground facing south and the VCS Switch was mounted on a metal post. March 2003 New Issue Printed in USA 1
Kure Beach, North Carolina (LaQue Corrosion Services Inc.) 25 meter test site - The Kure Beach site is located on a barrier island just south of Wilmington, NC. This site is considered an extremely severe coastal installation. The VCS Switch was mounted on a 4" x 4" wooden post 25 meters from the mean tide level. Table 1 Summary of Installation Sites SPECIMEN DATE TEST OBJECTIVE INSTALLED SITE Material VCS Switch, September 1995 DSET Phoenix, AZ Desert Sample Plates Material VCS Switch, August 1995 DSET Miami, FL Tropical Sample Plates Material VCS Switch, March 1997 LaQue Corrosion Services Coastal Sample Plates Kure Beach, NC Material Sample Plates October 1995 Franksville Technical Center Seasonal Franksville, WI Results and Discussion: After seven years of outdoor exposure at the DSET Phoenix, AZ and DSET Miami, FL test sites, the Cooper Power Systems Type NOVA module epoxy of the VCS Switch units has maintained very good structural integrity. The switches have become much lighter in color. At the Phoenix site, the south exposure of the unit is lighter in color than the surfaces facing north. However, after this seven-year exposure, only slight chalking has been detected on the surface of the plastic. At both the Phoenix and Miami test sites, the units have lost most of their original spectral gloss. Neither of the two units has developed any cracking, crazing, or other forms of physical defects. The original porosity on the skirts of the Phoenix unit has not become any worse. The Miami, FL unit has developed some mildew and algae, which has previously been reported and does not appear to becoming worse. Photographs of these units have been attached to this report. The sample plates of the Type NOVA module material are reacting to the outdoor testing in a manner similar to the VCS Switch units. At the Miami site, the plates have lost 94 percent of their original gloss. Significant color and appearance changes have been reported at both test sites and slight chalking of the plates surfaces has been noted. However, no crazing, cracking, or other physical defects have been observed, except for slight pitting in Phoenix. Photographs of some of these test plates have been included in this report. None of the sample plates has exhibited any signs of physical deterioration. The sample plates installed at the Franksville Technical Center have become lighter in color and have lost all spectral gloss. None of these sample plates shows any signs of physical deterioration. The original VCS Switch installed at the Kure Beach coastal test site was lost when Hurricane Fran struck the North Carolina coast in late August of 1996. The photographs of the Kure Beach unit included in this report illustrate the 58 and 65 month exposure of a second unit. The Type NOVA module epoxy material is in excellent condition and still exhibits some slight gloss retention. No cracks, crazing, or other physical defects have developed on the surface of the plastic material. After 65 months of coastal exposure, the majority of the Type NOVA module epoxy is still in excellent condition. The electrical connector at the top of the switch has turned green, probably a reaction with chlorine. Data: See the attached tables and photographs. Key Terms: 554 Weathering/Natural 982 Cooper Power/Kyle Plant 917 Recloser/Vacuum 1898 VCS Switch 1916 Recloser/Nova 2
TYPE NOVA EPOXY SAMPLE PLATE OUTDOOR EXPOSURE TESTING Table 2 Atlas DSET Phoenix, Arizona Test Site, Plate EXPOSURE GLOSS GENERAL COLOR CHECKING CRACKING TIME K1/K2/K3 APPEARANCE CHANGE Initial.........48/45/50 6 Month........47/42/47..........9............10............10............10 12 Month.......41/34/45..........5.............5............10............10 18 Month.......37/27/45..........3.............3............10............10 24 Month.......23/17/33..........3.............3............10............10 36 Month........12/9/21...........2.............2............10............10 42 Month.......11/10/18..........2.............2............10............10 60 Month.........5/7/6............2.............1............10............10 72 Month.........3/4/3............1.............1............10............10 84 Month.........2/3/2............1.............1............10............10 Table 3 Atlas DSET Miami, Florida Test Site, Plate EXPOSURE GLOSS COLOR MILDEW CHALKING CHECKING/ TIME K7/K8/K9/K10 CHANGE CRACKING Initial........47/54/51/48 6 Month.......43/51/50/42.........10............10............10............10 12 Month......42/45/44/40.......8 Fad...........10............10............10 18 Month......26/31/31/26.......6/7 Fad..........10............10............10 24 Month......17/18/20/17.......2 Fad...........10............10............10 36 Month......10/13/12/10.......1 Fad...........10............10............10 42 Month........4/4/5/5.........1 Fad...........10............10............10 60 Month........3/3/3/3.........1 Fad...........5.............9.............10 72 Month........3/3/3/3.........1 Fad...........5............10............10 84 Month........2/3/3/2.........1 Fad...........3............10............10 Table 4 Franksville, Wisconsin Outdoor Test Rack, Plate EXPOSURE GLOSS COLOR GENERAL CHALKING CHECKING/ TIME A/B/C E APPEARANCE CRACKING Initial.........34/46/31.....60.62/-1.95/-0.3 24 Month.......32/41/27........Lighter..........10............10............10 42 Month........24/7/17.........10.18...........10............10............10 60 Month.........5/2/4..........16.69...........9.............9.............10 72 Month.........2/2/2..........18.85...........9.............9.............10 84 Month.........2/2/2..........20.39...........8.............8.............10 3
TYPE NOVA EPOXY, VCS SWITCH OUTDOOR EXPOSURE TESTING Table 5 Atlas DSET Phoenix, Arizona Test Site, Module EXPOSURE GLOSS GENERAL COLOR CRAZING CRACKING TIME APPEARANCE CHANGE Initial...........40 6 Month..........42............10............10............10............10 12 Month..........31............10............10............10............10 18 Month..........25............10............10............10............10 24 Month..........18............10............10............10............10 36 Month..........11.............9.............9............10............10 42 Month..........6.............7.............7............10............10 60 Month..........3.............5.............4............10............10 72 Month..........3.............5.............2............10............10 84 Month..........2.............5.............2............10............10 Table 6 Atlas DSET Miami, Florida Test Site, Module EXPOSURE GLOSS CHALKING CHECKING MILDEW GREEN TIME ALGAE Initial...........51 6 Month..........51............10............10............9.............10 12 Month..........35............10............10............9.............10 18 Month..........27............10............10............8.............8 24 Month..........18............10............10............8.............8 36 Month..........9.............10............10............7.............8 42 Month..........5.............10............10............7.............7 60 Month..........3.............9............10............3.............6 72 Month..........3.............7............10............3.............4 84 Month..........2.............6............10............3.............3 4
84-Month Outdoor Exposure at Phoenix, Arizona Type NOVA Epoxy, VCS Switch Unit 5
84-Month Outdoor Exposure at Phoenix, Arizona Type NOVA Epoxy, VCS Switch Unit 6
84-Month Outdoor Exposure at Miami, Florida Type NOVA Epoxy, VCS Switch Unit 7
58-Month Outdoor Exposure at Kure Beach, NC Type NOVA Epoxy, VCS Switch Unit 8
65-Month Outdoor Exposure at Kure Beach, NC Type NOVA Epoxy, VCS Switch Unit 9
84-Month Outdoor Exposure at Phoenix, Arizona Type NOVA Epoxy Sample Plates 10
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84-Month Outdoor Exposure at Miami, Florida Type NOVA Epoxy Sample Plates 2003 Cooper Power Systems, Inc. Kyle is a registered trademark of Cooper Industries, Inc. NOVA is a trademark of Cooper Industries, Inc. P.O. Box 1640 Waukesha, WI 53187 www.cooperpower.com Bulletin 03005 March 2003 New Issue KBS 3/03