35Q Integrated Insulator (with Sensor)
Product Overview
The 35Q Integrated Insulator (with Sensor) is an all-in-one insulating assembly specifically designed for 35kV-class high-voltage switchgear and other medium-voltage electrical equipment. Manufactured using integral epoxy resin cast molding, it integrates insulating support, electrical isolation, and voltage/current sensing functions, making it one of the core components for achieving intelligent and compact switchgear design. By unifying the traditional insulator and sensor unit into a single integrated design, the product significantly simplifies internal wiring, enhancing equipment operational reliability and safety.
Product Features
Integrated Design
Combines insulating support, electrical isolation, and live-line display/voltage sensing functions in a single unit. Eliminates the need for separate sensor installation, reduces the number of components inside the cabinet, optimizes internal space layout, and lowers installation complexity.
Superior Insulation Performance
Manufactured from high-weatherability, high-dielectric-strength epoxy resin using void-free integral casting. Provides excellent corona resistance and anti-tracking capability, and can reliably withstand power-frequency and lightning impulse voltages in 35kV systems over the long term.
High-Reliability Sensing Function
Built-in high-precision sensing unit enables real-time acquisition of high-voltage-side voltage and energized-state signals, providing accurate status feedback to switchgear live-line display devices, online monitoring systems, and anti-misoperation interlocking devices, ensuring safe operation and maintenance.
High Mechanical Strength and Structural Integrity
The monolithic cast structure offers excellent mechanical strength, capable of withstanding the mechanical stresses of busbars and contacts inside the switchgear. Outstanding impact and vibration resistance satisfies long-term operational mechanical stability requirements.
All-Condition Environmental Adaptability
Features moisture resistance, condensation resistance, contamination resistance, and high/low temperature tolerance, enabling stable operation in harsh indoor and outdoor environments without additional maintenance, reducing operations and maintenance costs.
Safe and Environmentally Friendly Design
Manufactured from halogen-free, environmentally compliant epoxy resin material, conforming to RoHS environmental standards. The fully sealed structure has no exposed live parts, eliminating electric shock hazards and meeting power equipment safety design requirements.
Standardized Mounting Interface
Compatible with standard mounting dimensions of 35kV high-voltage switchgear, allowing direct replacement of conventional insulators. Strong compatibility facilitates retrofitting of existing equipment and large-scale deployment.
Technical Parameters
(I) Rated Electrical Parameters
| Parameter | Specification |
|---|---|
| Rated Voltage (Un) | 40.5kV |
| Rated Frequency (fn) | 50Hz |
| Rated Power-Frequency Withstand Voltage (1 min) | 95kV (to ground / phase-to-phase) |
| Rated Lightning Impulse Withstand Voltage (peak) | 185kV (to ground / phase-to-phase) |
| Partial Discharge Level | ≤10pC (at 1.1Un/√3) |
| Creepage Distance | ≥900mm (meets Pollution Severity Class II requirements; higher classes available on request) |
| Insulation Resistance | ≥1000MΩ (tested with 5000V megohmmeter) |
| Sensor Output Characteristics | Compatible with standard live-line display devices; output signal meets GB/T 25081 requirements |
(II) Mechanical Parameters
| Parameter | Specification |
|---|---|
| Rated Mechanical Load | Longitudinal/lateral withstand ≥2000N without permanent deformation |
| Flexural Strength | ≥8kN |
| Mounting Method | Bolt-fixed; compatible with standard switchgear mounting hole patterns |
| Main Body Material | Epoxy resin (EPOXY) with toughening agent for enhanced crack resistance |
| Color | Standard red (other colors available on request) |
| Ingress Protection Rating | IP65 (main body) |
(III) Environmental Parameters
| Parameter | Specification |
|---|---|
| Ambient Temperature | -40°C ~ +70°C |
| Relative Humidity | Daily average ≤95%, monthly average ≤90% (non-condensing) |
| Altitude | ≤2000m (derating solutions available for high-altitude applications on request) |
| Pollution Severity Class | Class II (Class III/IV available on request) |
| Seismic Performance | Meets GB/T 13540 standard, seismic intensity Grade 8 requirements |
Applications
Core Application Scenarios
35kV indoor high-voltage switchgear (KYN61-40.5 and similar models), serving as the insulating support and live-line sensing component for busbars and contact boxes;
Insulating isolation and condition monitoring unit for 35kV ring main units and gas-insulated switchgear (C-GIS);
High-voltage busbar insulation and live-line display support for 35kV box-type substations and switching stations;
High-voltage-side insulation and sensing support for 35kV power transformers and reactors.
Applicable Industries
Power systems (grid companies, power generation enterprises), industrial and mining enterprises (steel, chemical, mining), rail transit, new energy (photovoltaic, wind power), and other 35kV-class power distribution systems.
Functional Compatibility
Compatible with switchgear live-line display devices, five-prevention interlocking systems, and online monitoring systems, enabling real-time monitoring of high-voltage-side energized status, anti-misoperation interlocking, and online insulation condition diagnostics.
Operating Conditions
(I) Normal Operating Conditions
Ambient temperature: -25°C ~ +40°C, daily temperature variation not exceeding 25°C;
Altitude: not exceeding 2000m;
Ambient humidity: daily average relative humidity not exceeding 95%, monthly average not exceeding 90%; no condensation, no severe contamination;
Installation location: indoors, free from severe vibration, explosion hazards, corrosive gases, and conductive dust;
Installation angle: not exceeding 5°, vertical mounting.
(II) Special Operating Conditions (Custom Order Required)
High-altitude locations (>2000m): derating design per altitude correction factor with increased insulation margin;
Extreme temperature environments (<-25°C or >+40°C): custom high/low temperature-resistant epoxy resin formulation;
High-contamination or coastal salt-mist environments: custom extended creepage distance and anti-salt-mist coating solutions;
High vibration and shock environments: optimized structural design with enhanced mechanical strength.
Installation and Maintenance
(I) Installation Requirements
Before installation, inspect the product appearance for cracks, voids, and damage; verify that sensor terminal connections are intact;
Mount vertically in accordance with switchgear drawing requirements; ensure the mounting surface is flat and bolt torque meets design specifications (recommended M8 bolt torque: 15~20 N·m);
Connect sensor signal wires in accordance with applicable standards; apply proper insulation protection and avoid contact with high-voltage components;
After installation, perform insulation resistance testing and power-frequency withstand voltage testing before commissioning.
(II) Maintenance Requirements
Periodically (every 6~12 months) inspect product appearance for contamination accumulation, condensation, and cracks;
Periodically verify live-line display device and sensor signal output to ensure accurate condition monitoring;
For cleaning, wipe with a dry soft cloth only; do not use organic solvents or high-pressure water washing;
If insulation degradation or physical damage is detected, de-energize and replace the product immediately; do not continue operation with a faulty unit.
Precautions
The product is intended solely for 35kV-class indoor high-voltage electrical equipment; operation beyond rated voltage or specified conditions is strictly prohibited;
Installation and maintenance must be performed by licensed, qualified electricians in strict compliance with electrical safety regulations and under de-energized conditions;
During transportation and storage, protect against impact and compression; store in a dry, well-ventilated environment free from corrosive gases;
Unauthorized disassembly or modification of the product is strictly prohibited; doing so will void the warranty and create safety hazards;
The product warranty period is 12 months from the date of shipment; lifetime technical support and repair services are provided.
Model Description
| Model | 35Q |
|---|---|
| Rated Voltage Class | 35kV (40.5kV) |
| Product Type | Integrated Insulator (with Sensor) |
| Customization | Creepage distance, mounting dimensions, and sensor parameters can be customized to customer requirements |
Quality Standards
The product strictly conforms to the following national and industry standards:
GB/T 20840 Instrument Transformers
GB 3906 3.6kV~40.5kV A.C. Metal-enclosed Switchgear and Controlgear
GB/T 12944.1 High-voltage Bushings
GB/T 25081 Live-line Indicators
DL/T 593 Common Clauses for High-voltage Switchgear and Controlgear Standards
Supplementary Notes
The parameters in this manual represent general specifications for standard models. Actual product parameters are subject to the factory technical drawings and test reports. For custom specifications, please contact the technical department to discuss detailed requirements.
Appendix: Product Dimensional Diagram
