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Insulators

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Insulators

Hybrid insulators consist of a highstrength ceramic core with a polymerichousing. The best features of ceramicand polymeric insulators are combined,resulting in high mechanical strengthand excellent electrical behavior underpolluted conditions. For extremely polluted environments a protectedcreepage design is available which provides outstanding electrical perfor-mance using an economical solution.

Modular lightweight insulators consistof a solid polymeric core with a poly-meric housing. Stainless steel threadscan be threaded directly into the poly-meric core without the use of bulkymetal fittings. These insulators are idealfor use in outdoor equipment and canbe designed according to specific customer requirements.

Composite insulators are based on Raychem´s 30 years experience inthe field of crosslinked polymers formedium and high voltage applications.They consist of a polymeric housingover a pultruded fiberglass rod towhich galvanized steel or aluminumend fittings are attached. By moldingdirectly over the end fitting, or by using a track resistant polyurethane,moisture ingress to the fiberglass rodis prevented. Housing materials ineither ethylene vinyl acetate or siliconeare available depending on customer preference.

Tyco Electronics Energy Division coversa wide range of polymeric, hybrid andporcelain insulators. For decades allthese products have demonstrated reliable performance in various typesof applications all over the world.

Porcelain insulators are the traditio-nal choice for distribution line, busbarand apparatus insulation. Manufacturedfrom high quality non-porous electricalporcelain, they provide a long life andcost effective solution for the majorityof applications. Porcelain insulatorsdesigned, manufactured and sold underthe brand names of Morlynn, Dulmisonand Zibo have an 80 year service expe-rience in electric power supply and rail applications.

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Composite Insulators

Composite insulators are available forapplications up to system voltages of52 kV. They provide a reliable solutionfor power utilities and railway com-panies with installations in severelypolluted environments all over theworld. The core of a composite insulatoris a pultruded fiber glass rod whichprovides a high mechanical strength. In a direct injection molding process anon-tracking, erosion and UV resistantpolymeric housing is molded directlyonto the fiberglass rod. A corrosionresistant metal end fitting is crimpedonto each end of the rod to provide ahigh mechanical strength. A new developed crimping control technologymonitors the assembly process of the metal fittings and ensures thatcrimping forces cause no damage tothe fiberglass rod while achieving acrimp that will withstand the highestpossible mechanical loads. Sealed with a tracking and erosion resistantpolyurethane barrier, the core is protected from deterioration due tomoisture ingress.

Composite insulators are available astension (suspension), line post and station post insulators. For railwayapplications, tension and strut compo-site insulators are available in a largevariety of configurations.

The maintenance free characteristics of Raychem´s EVA material have beendemonstrated during service experi-ence of more than 30 years. This historical data is supported bylong term investigations under severepollution conditions in railway tunnelsin Japan*.

High strength pultruded

fibre glass rod

Corrosion resistant

crimped end fittings

Field proven

interfacial sealing

Non tracking, UV resistant

EVA housing

*(Kunikazu Izumi, Kenzo Kadotani: „Applications of PolymericOutdoor Insulation in Japan“; IEEE Transactions on Dielectricsand Electrical Insulation, Vol. 6 No. 5, October 1999)

Composite tension insulators

Composite post insulators on anoverhead line switch

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A modular lightweight insulator is analternative form of composite insulator.It comprises a solid polymer core covered by elastomeric shedded insu-lation. A non-tracking, erosion and UVresistant housing is bonded to thepolymer core to form an excellent environmental seal. The mechanicalconnection is achieved by stainlesssteel studs which are threaded directlyinto the polymer core.

The modular lightweight insulator canbe used as a support in applicationssuch as outdoor cable terminations,busbar supports on trains and OEMapplications like disconnectors andfuseholders. Due to the modular con-struction of the insulator virtually any customer required design can bemanufactured. It therefore provides aflexible solution for a multitude ofapplications.

Solid polymer core

Proven interfacial

seal system

Stainless steel

end caps

Non tracking, UV resistant

EVA housing

Modular lightweight insulators as stand-off insulators for MV terminations

Modular lightweight insulators incombination with Raychem surgearresters in overhead line fuseholders

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Hybrid Insulators

Hybrid insulators combine the best features of ceramics and polymers. A ceramic core provides high mech-anical strength and rigidity while ahydrophobic polymeric housing offersconsiderable weight reduction andsuperior electrical performance.Available products include line postinsulators for system voltages up to 25 kV, station post insulators for systemvoltages up to 115 kV and railway catenary insulators for 15/25 kV lines.

Designed especially for highly pollutedareas, an insulator with a highly pro-tected creepage polymeric housing hasbeen developed. Its protected creepagedesign prevents both the deposition ofcontaminants and the complete wettingof the surface. Reduced leakage currentslead to a reduced flashover probabilityand therefore to significant energy savings. Compared to an equivalentporcelain insulator the hybrid insulatorhas a reduced weight and is less proneto vandalism.

The high strength porcelain core andthe cemented end fittings have themechanical strength and reliability of an equivalent porcelain insulator.Hybrid insulators combine the ceramictechnology experience of Dulmison,Morlynn and Zibo over 80 years withRaychem’s 30 years of experience inpolymeric outdoor materials. Fieldexperience in some of the worlds mostseverely polluted environments havedemonstrated the excellent performanceof this type of insulator.

High strength

porcelain core

Protected creepage

silicone housing

Corrosion resistant

galvanised steel

end fitting

Working conditions of Raybowl insulators

Raybowl insulators installed in a highpolluted area in Latin America.

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Porcelain Insulators

Trading under the names Morlynn,Dulmison and Zibo, Tyco ElectronicsEnergy Division offers a comprehen-sive range of cost effective porcelainsolutions for the electricity supply andrail industries. Experience in the designand manufacture of porcelain insulatorsexceeds 80 years.

The manufacturing processes employsome of the most advanced techno-logies in the field of ceramic insulatorproduction. A commitment to quality is evidenced by independent certifica-tion of quality systems complying withinternational standards. This is furtherreinforced by our accredited testinglaboratories which are capable of conducting a wide range of design and development tests along with type, sample and routine testing to recognized international and nationalstandards.

Insulators are made from high qualitynon porous electrical porcelain and galvanized ferrous (or non-ferrous) end fittings which provide long life andreliable performance over a wide rangeof environmental conditions. They aremade to a number of internationalstandards including ANSI, IEC, BS, AS and GB.

Line post insulators

Station post insulators

Disc and line post insulators used on overhead lines

Tension and strut insulators in railwaylines

Spool, strain, pin and disk insulators

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Mold in Place (MIP) components

Raychem offers OEM customers all thebenefits of composite insulators throughMold in Place (MIP) components whichconsist of a fiberglass rod and a moldedpolymeric housing. Mold in Place com-ponents are available for various dia-meters of fiberglass rod depending onthe mechanical requirement of the finalproduct. They can be used for insulatorsor insulating systems up to system voltages of 52 kV.

Heatshrinkable shedded components

Heatshrinkable shedded componentscan be used to protect a variety ofinner substrates against the adverseconditions of an outdoor environment.They are available in a number of sizesand shed configurations, allowingcreepage and arcing distances to betailored to customer requirements.

The components are internally coatedwith track resistant sealant which flowsduring heat recovery to prevent the formation of air voids and to produce a moisture barrier to protect the under-lying substrates. Typically they are used for surge arresters, bushings andinsulators with either ceramic or non-ceramic cores. Based on Raychem´soutdoor polymeric material they havemore than 30 years of established service in the field.

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Committed to quality

ISO 9000 series certifications for ourmanufacturing sites in both Ireland and China underline our continuingcommitment to quality, and becauseall products are subjected to a series of rigorous checks before they areshipped, customers can have completeconfidence in the products, servicesand data we supply.

Recognizing that customers oftenrequire unique solutions, our technicaland engineering capability ensures thatvirtually any custom design solutioncan be manufactured.

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Type Material Mechanical Application System rating (kN) voltage (kV)

from to

Medium voltage tension insulators

RST (PRI, EPCI) EVA up to 70 Utility, Railway 1 28

DULMISON Suspension Porcelain up to 125 Utility, Railway 1 275

Medium voltage line post insulators

RLP (PLI) EVA up to 14 Utility 1 52

HSHI Hybrid (Porcelain core up to 12.5 Utility 1 25& polymeric housing)

DULMISON Line Post Porcelain up to 12.5 Utility 1 72

Medium voltage station post insulators

RAP (PSI) EVA up to 18 Utility, OEM, Railway 1 52

EPBI EVA up to 4.5 Utility, OEM, Railway 1 36

DULMISON Station Post Porcelain up to 6 Utility, OEM, Railway 1 72

Medium voltage pin insulators

DULMISON Pin Porcelain up to 13 Utility 1 36

Spool insulators

DULMISON Spool Porcelain up to 20 Utility n.a. n.a.

Strain insulators

DULMISON Strain Porcelain 220 Utility n.a. n.a.

Insulators for railway application

RRA EVA on request Railway 15 * 25*

HCI Hybrid (Porcelain core on request Railway 15 * 25*& polymeric housing)

DULMISON Tension and StrutPorcelain on request Railway 1.5(DC) 25*

* single phase voltage

Overview of insulators

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Tyco Electronics Raychem GmbH, Energy DivisionFinsinger Feld 1, 85521 Ottobrunn/Munich, GermanyPhone: +49-89-6089-0, Fax: +49-89-6096345

Energy Division – a pioneer in the development of economical solutions forthe electrical power industry. Our product range includes: cable accessories, connectors & fittings, electrical equipment, instruments, lighting, insulators &insulation enhancement and surge arresters.

For more information and your country contact person, please visit us at: http://energy.tycoelectronics.com

All of the above information, including drawings, illustrations and graphic designs, reflects our present understanding and is to the best of our knowledge and belief correct and reliable.Users, however, should independently evaluate the suitability of each product for the desired application. Under no circumstances does this constitute an assurance of any particularquality or performance. Such an assurance is only provided in the context of our product specifications or explicit contractual arrangements. Our liability for these products is set forthin our standard terms and conditions of sale. ALR, AMP, AXICOM, B&H, BOWTHORPE EMP, CROMPTON INSTRUMENTS, DORMAN SMITH, DULMISON, GURO, HELLSTERN, LA PRAIRIE, MORLYNN, RAYCHEM, and SIMEL are trademarks.

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