35kV Integrated Insulator Product Manual
Product Overview
The 35kV integrated insulator is a core insulating component designed specifically for 35kV high-voltage switchgear and other medium-voltage switchgear assemblies. Manufactured using integral epoxy resin vacuum casting, it consolidates insulating support, conductor fixing, and electrical isolation functions into a single unified structure, replacing conventional split-type insulating configurations. This design significantly enhances insulation reliability and structural compactness, and is widely applied in indoor high-voltage power distribution systems.
Product Features
Integrated Insulation Design
Produced via integral vacuum epoxy resin casting with no joints and no voids, delivering superior insulation performance. This design eliminates the weak insulation points inherent in split-type structures and provides effective resistance against power-frequency and lightning impulse overvoltages in 35kV systems.
High Mechanical Strength and Stability
The epoxy resin material provides exceptional mechanical strength, capable of withstanding the sustained gravitational load of high-voltage conductors and short-circuit electromagnetic force impacts. The rigid structure exhibits no deformation or loosening, ensuring long-term structural stability during equipment operation.
Superior Electrical Performance
High insulation resistance, low dielectric loss, and minimal partial discharge (≤5pC) meet the insulation requirements of high-voltage equipment, effectively preventing corona and flashover phenomena and enhancing system operational safety.
Environmental Aging Resistance
Excellent weathering resistance, ozone resistance, and chemical corrosion resistance allow adaptation to complex indoor electrical environments. The product shows no aging or cracking over extended service life.
Compact Structure and Easy Installation
The integrated structure incorporates insulating sheds and mounting base in a single unit, eliminating the need for additional insulating accessories. The small installation footprint is compatible with the compact design of 35kV switchgear, simplifying installation procedures and reducing maintenance costs.
Safety and Protection Performance
The shed structure increases creepage distance to enhance resistance to pollution-induced flashover. The enclosed base design effectively isolates live parts, preventing accidental contact and ensuring safe operation and maintenance.
Technical Parameters
| Parameter Category | Item | Technical Specification |
| Rated Electrical Parameters | Rated Voltage | 35kV |
| | Rated Frequency | 50Hz | |
| | Rated Power-Frequency Withstand Voltage (1 min) | 95kV | |
| | Rated Lightning Impulse Withstand Voltage (Peak) | 185kV | |
| | Creepage Distance | ≥900mm (satisfies Pollution Severity Class II requirements; higher classes available on request) | |
| | Partial Discharge | ≤5pC (tested at 1.1Un) | |
| | Insulation Resistance | ≥1×10¹²Ω | |
| | Dielectric Dissipation Factor (tan δ) | ≤0.003 | |
| Mechanical Parameters | Flexural Strength | ≥12kN |
| | Compressive Strength | ≥30kN | |
| | Short-Circuit Electromagnetic Force Withstand | Meets 40kA/4s short-circuit requirements | |
| Materials and Process | Base Material | Epoxy resin (with toughening and flame-retardant additives) |
| | Color | Standard red (other colors available on request) | |
| | Forming Process | Integral vacuum casting | |
| | Flame Retardancy Rating | UL94 V-0 | |
| Environmental Parameters | Operating Temperature Range | -40°C to +70°C |
| | Relative Humidity | ≤95% (at 25°C) | |
| | Altitude | ≤1000m (high-altitude customization available) | |
| | Pollution Severity Class | Class II (Class III/IV available on request) |
Note: Customized parameters are available for special operating conditions (e.g., high altitude, heavy pollution); refer to the technical agreement for specifics.
Application Scope
Applicable Scenarios
35kV indoor high-voltage switchgear (e.g., armored withdrawable switchgear, fixed-mounted switchgear)
35kV ring main units and compact substations (European-type and American-type pad-mounted transformers)
35kV high-voltage switchgear assemblies and gas-insulated switchgear
35kV busbar insulating supports and conductor fixing/isolation
Insulating support components for other 35kV indoor high-voltage electrical equipment
Applicable Systems
Suitable for three-phase AC power systems operating at AC 50Hz with a rated voltage of 35kV, for use in indoor high-voltage equipment in power generation, transmission, distribution, and transformation applications.
Operating Conditions
(I) Normal Operating Conditions
Ambient temperature: -40°C to +70°C; daily average temperature not exceeding +35°C
Altitude: not exceeding 1000m (above 1000m, altitude correction per GB/T 11022 is required, or high-altitude custom products must be selected)
Ambient humidity: daily average relative humidity not exceeding 95%, monthly average not exceeding 90% (at 25°C), no condensation
Environmental conditions: indoor use; free from severe vibration, explosion hazards, heavy pollution, corrosive gases, and conductive dust
Mounting orientation: vertical installation; tilt angle not exceeding 5°
Seismic intensity: not exceeding Intensity 8
(II) Special Operating Conditions
If the operating environment exceeds normal conditions (e.g., high altitude, heavy pollution, high temperature, high humidity, strong vibration), this must be specified at the time of ordering. The manufacturer will perform customized design and parameter adjustment to ensure the product meets application requirements.
Installation and Maintenance
(I) Installation Requirements
Pre-installation inspection: verify that the product exterior is free of cracks, damage, and voids; confirm dimensions conform to drawing specifications; ensure the insulating surface is clean and free of foreign matter
Installation method: bolt-fix through pre-drilled mounting holes in the base, ensuring secure installation with no looseness
Conductor connection: reliably connect the top terminal to the high-voltage conductor; verify contact resistance meets requirements and prevent overheating
Insulation protection: avoid scratching the insulating surface with sharp objects during installation to prevent degradation of insulation performance
Post-installation inspection: verify that insulation clearances and creepage distances conform to design requirements, and that no foreign matter obstructs the sheds
(II) Maintenance Requirements
Routine inspection: inspect product exterior monthly for cracks, discharge marks, and contamination deposits
Cleaning and maintenance: periodically clean the insulating surface with a dry soft cloth to remove dust and pollution; use of organic solvents is strictly prohibited
Insulation testing: perform annual insulation resistance and partial discharge testing to verify performance compliance
Replacement criteria: if cracks, damage, or degraded insulation performance are detected, replace the product immediately; continued use is strictly prohibited
Precautions
This product is a high-voltage insulating component intended solely for 35kV indoor systems; operation beyond rated voltage or outside specified conditions is strictly prohibited
Installation and maintenance must be performed by qualified personnel holding high-voltage working certifications, in strict compliance with high-voltage safety operating procedures
During transportation and storage, protect the product from impact, compression, and moisture exposure; storage environment must be dry, well-ventilated, and free of corrosive gases
Unauthorized modification or structural alteration of the product is strictly prohibited; doing so will void the product warranty and create safety hazards
The product warranty period is 12 months from the date of shipment; non-human-induced defects within the warranty period are eligible for free repair or replacement
Ordering Information
The following must be specified when placing an order: product model number, rated voltage, creepage distance, mounting dimensions, color, and quantity
For special operating conditions (high altitude, heavy pollution, custom dimensions), detailed technical requirements must be provided and a technical agreement must be signed
Products are packaged with moisture-proof and shock-resistant packaging; each shipment includes a product certificate of conformance, test report, and user manual
Appendix: Applicable Standards
This product complies with the following national and industry standards:
GB/T 11022 Common Specifications for High-Voltage Switchgear and Controlgear Standards
GB/T 19519 Insulators — Epoxy Resin Insulating Parts for High-Voltage AC Bushings
DL/T 593 Common Specifications for High-Voltage Switchgear and Controlgear
IEC 60660 Insulators — Resin-bonded Fibre for Indoor Applications at Voltages Greater than 1000 V
Appendix: Product Outline Drawing
