550 Integrated Insulator (Sensor)
Product Overview
The 550 Integrated Insulator (Sensor) is a monolithic insulating sensor assembly specifically designed for medium- and high-voltage switchgear. Manufactured by integral epoxy resin casting, it combines electrical insulation, voltage/current sensing, and contact box functionality into a single unit. It replaces conventional split-type insulators and contact box structures to achieve compact and intelligent switchgear upgrades, and is widely applied in 10kV/24kV indoor metal-clad withdrawable switchgear and other power equipment.
Product Features
Integrated Design
Combines insulating support, contact sealing, and voltage/current sensing functions into a single component, substantially simplifying the internal structure of switchgear, reducing installation steps, decreasing cabinet volume, and improving space utilization.
The monolithic cast structure eliminates joint gaps, completely preventing partial discharge, moisture ingress, and creepage hazards; insulation reliability is significantly higher than that of split-type structures.
Superior Insulation and Mechanical Performance
Formulated with high-purity epoxy resin and nano-scale inorganic fillers, vacuum-cast and thermally cured, providing high dielectric strength, high mechanical strength, aging resistance, and arc resistance.
The shed profile design optimizes electric field distribution, effectively raising the surface flashover voltage and meeting the long-term insulation requirements of medium- and high-voltage systems.
High mechanical strength allows the component to withstand contact insertion/withdrawal forces, busbar stresses, and short-circuit electromagnetic forces without risk of cracking or deformation, ensuring a long service life.
Intelligent Sensing Function
Built-in high-accuracy voltage/current sensing units enable real-time acquisition of busbar voltage and current signals within the switchgear, providing data support for intelligent monitoring, condition assessment, and fault early warning.
High sensing accuracy, good linearity, and strong anti-interference capability meet the requirements of power system automation and intelligent operation and maintenance.
Safety and Environmental Features
Fully sealed structure with no exposed live parts, effectively preventing accidental contact, condensation, and dust ingress, enhancing switchgear operational safety.
Epoxy resin material is environmentally friendly and non-toxic, compliant with RoHS standards, free of SF6 and other greenhouse gases, satisfying green power equipment requirements.
Excellent flame retardancy, achieving the V-0 flame retardancy rating specified in GB/T 20641.1, enhancing protection against electrical fires.
Convenient Installation and Maintenance
Standardized interface design compatible with mainstream 10kV/24kV switchgear structures; simple installation requiring no complex commissioning.
Maintenance-free design eliminates the need for periodic inspection during service, reducing operation and maintenance costs.
Technical Parameters
| Parameter Category | Item | Technical Specification |
| Rated Electrical Parameters | Rated Voltage | 12kV / 24kV (optional) |
| | Rated Frequency | 50Hz | |
| | Rated Current | 630A / 1250A / 1600A / 2000A (optional) | |
| | Rated Short-Time Withstand Current | 20kA / 25kA / 31.5kA / 40kA (4s, optional) | |
| | Rated Peak Withstand Current | 50kA / 63kA / 80kA / 100kA (optional) | |
| | 1min Power-Frequency Withstand Voltage | 42kV (12kV class) / 65kV (24kV class) | |
| | Lightning Impulse Withstand Voltage | 75kV (12kV class) / 125kV (24kV class) | |
| Insulation Performance | Partial Discharge Level | ≤5pC (at 1.1Um/√3) |
| | Dielectric Dissipation Factor | ≤0.002 (at power frequency) | |
| | Volume Resistivity | ≥1×10¹² Ω·cm | |
| | Surface Resistivity | ≥1×10¹¹ Ω | |
| Mechanical Performance | Flexural Strength | ≥120MPa |
| | Compressive Strength | ≥150MPa | |
| | Contact Insertion/Withdrawal Force | Compliant with GB/T 11022; insertion/withdrawal endurance ≥2000 operations | |
| Sensing Performance | Voltage Sensing Accuracy | Class 0.5 / Class 0.2 (optional) |
| | Current Sensing Accuracy | Class 0.5 / Class 0.2 (optional) | |
| | Linearity | ≤±0.2% | |
| | Temperature Drift | ≤±0.1%/°C | |
| Environmental Adaptability | Operating Temperature | -40°C to +70°C |
| | Relative Humidity | ≤95% (at +25°C) | |
| | Altitude | ≤2000m (customizable above 2000m) | |
| Materials and Process | Primary Material | Epoxy Resin (EP) |
| | Flame Retardancy Rating | V-0 (GB/T 20641.1) | |
| | Protection Degree | IP65 (internal live parts) | |
| | Applicable Standards | GB/T 11022, GB/T 3906, DL/T 404, JB/T 10686 |
Note: Special parameters (e.g., higher current ratings, voltage levels, customized sensing accuracy) can be tailored to user requirements.
Application Scope
Applicable Scenarios
10kV/24kV indoor metal-clad withdrawable switchgear (KYN28, KYN61, and similar series)
Ring main units, gas-insulated switchgear, solid-insulated switchgear, and other medium-voltage distribution equipment
Intelligent switchgear, modular substations, and renewable energy grid-connection cabinets (photovoltaic, wind power)
Industrial power distribution systems, rail transit power supply systems, and data center power distribution systems
Functional Applications
Serves as the insulating connection component between the switchgear busbar and the circuit breaker truck, providing electrical isolation and mechanical support
Integrated voltage/current sensing functions supply data acquisition for online monitoring and intelligent operation and maintenance of switchgear
Replaces conventional split-type contact boxes and insulators, enabling compact and intelligent switchgear upgrades
Improves switchgear insulation reliability, preventing condensation, creepage, partial discharge, and related faults
Operating Conditions
Normal Operating Conditions
Ambient temperature: -40°C to +70°C; daily average temperature not exceeding +35°C
Altitude: not exceeding 2000m (correction required above 2000m per GB/T 11022; high-altitude variants available on request)
Ambient humidity: relative humidity not exceeding 95% (at +25°C), no condensation, no severe pollution
Installation site: indoors, free from severe vibration, corrosive gases, flammable/explosive media, and heavy dust contamination
Installation angle: vertical mounting; tilt angle not exceeding 5°
Power supply system: three-phase AC 50Hz, with isolated neutral, arc suppression coil grounding, or low-resistance grounding
Special Operating Conditions (Customization Required)
High-altitude locations (>2000m): insulation structure optimization and enhanced external insulation strength required
High-humidity and condensation environments: anti-condensation coating and optimized shed profile required
Heavily polluted areas: anti-pollution structure with increased creepage distance required
Extreme high/low temperature environments: customized high/low temperature-resistant epoxy resin formulation required
High-vibration environments: reinforced mechanical structure with enhanced impact resistance required
Installation and Maintenance
Installation Requirements
Before installation, inspect the product appearance for cracks, damage, voids, and deformation; verify sensor wiring integrity
Position and install according to the switchgear engineering drawings, ensuring coaxial alignment with busbars and contacts to avoid stress concentration
Tighten fastening bolts to the specified torque; avoid over-tightening (risk of cracking insulation) or under-tightening (risk of poor contact)
Connect sensor unit wiring in accordance with the instruction manual, apply proper insulation protection, and prevent short circuits and miswiring
After installation, perform insulation resistance testing, power-frequency withstand voltage testing, and partial discharge testing; commission only upon satisfactory results
Maintenance Requirements
The product is maintenance-free by design; no periodic disassembly or overhaul is required during normal operation
Conduct periodic visual inspections (every 1 to 2 years): clean surface dust and contamination, and check for cracks or discharge marks
Periodically calibrate sensor unit accuracy to ensure monitoring data integrity
If damage or degraded insulation performance is detected, de-energize and replace the unit immediately; operation with known defects is prohibited
Precautions
During transport and storage, protect the product from impact, compression, and direct sunlight; storage environment must be dry and ventilated, at temperatures between -10°C and +40°C
Installation and maintenance must be performed in a de-energized state, strictly following electrical safety operating procedures
Drilling, cutting, or striking the product surface is prohibited to avoid damage to the insulation structure
Installation and commissioning must be performed by qualified electrical engineers; operation by non-qualified personnel is prohibited
If product parameters do not match the actual service conditions, forced use is prohibited; contact the manufacturer for customized products
Standards and Certifications
GB/T 11022 Common Specifications for High-Voltage Switchgear and Controlgear Standards
GB/T 3906 3.6kV~40.5kV AC Metal-Enclosed Switchgear and Controlgear
DL/T 404 3.6kV~40.5kV AC Metal-Enclosed Switchgear and Controlgear
JB/T 10686 Epoxy Resin Insulating Parts for High-Voltage Switchgear
GB/T 20641.1 Low-Voltage Switchgear and Controlgear, Part 1: General Rules (Flame Retardancy)
The product has passed type testing by the National High-Voltage Electrical Apparatus Quality Supervision and Inspection Center and complies with ISO 9001 quality management system requirements.
After-Sales Service
Product warranty period: 18 months from the date of commissioning, or 24 months from the date of shipment, whichever comes first
The manufacturer provides technical support, installation guidance, and customized design services
Non-human-induced defects within the warranty period: free repair or replacement; lifetime maintenance service provided beyond the warranty period
Appendix: Product Outline Drawing
