Busbar Insulation and Covers
S1 Busbar Insulation Heat Shrink Tube 1 kV to 35 kV
The general purpose busbar insulation family covering 1 kV to 35 kV with UL 224 recognition under file E341796
- Operating temperature: -40 to 105°C
- Minimum full recovery temperature: 125°C
- Products available for various voltage ratings (S1-1, S1-10, S1-35)
- Environmental friendly, RoHS compliant
- Shrink ratio: 2:1 & 2.5:1 & 3:1
- Standard Color: Black, other colors also available
S1 · Busbar Insulation and Covers
Product Overview
What S1 Does
Environmental friendly flame retardant polyolefin material, can be applied in power switchgear from 1kv to 35kv, providing insulation enhancement, protection against flashover or accidental discharge. It can be used for circular and rectangular copper or aluminum busbars.
The general purpose busbar insulation family covering 1 kV to 35 kV with UL 224 recognition under file E341796 It is manufactured by Dalian United Polymer Material Co., Ltd. in Dalian China where radiation cross linking extrusion and molding are all performed in house under one quality system.
Key Benefits
- One family spanning 1 kV to 35 kV with three voltage ratings
- UL 224 recognition under file E341796 for export and North American projects
- Shrink ratios of 2:1 2.5:1 and 3:1 which is the widest range in the busbar family
- Environmentally friendly and RoHS compliant
- Black as standard with other colours available on a production run
Who It Is For
Who Benefits Most from S1
The buyers and site teams this product was designed around
OEMs Needing a UL Recognised Material
Export switchgear and equipment builders whose customers require UL recognised components.
Low Voltage Switchboard Manufacturers
The S1-1 rating covers 1 kV busbar insulation in LV boards.
Distributors and Stockists
One family that spans the whole voltage range simplifies a stock list.
Electric Vehicle and Battery System Integrators
High voltage copper bar protection in traction and storage systems.
Problems It Solves
Problems This Product Removes
Every one of these is a failure mode we have seen on real networks
Export Markets Demand Recognised Component Approvals
UL 224 recognition under file E341796 satisfies the common North American requirement.
Three Separate Voltage Ratings Means Confusing Part Numbers
S1-1 S1-10 and S1-35 share one product family one installation method and one datasheet.
A 2:1 Ratio Does Not Always Cover a Bolted Section
A 3:1 option is available where the entry diameter must be much larger than the finished diameter.
Bare Bar in Any Assembly Is a Flashover Risk
Insulating the bar raises withstand and removes the animal and condensation bridging path.
Application Scenarios
Where It Is Used
LV Switchboard Busbar
1 kV main and distribution bar insulation.
MV Switchgear Busbar
10 kV and 35 kV rated bar insulation.
Battery and Traction Bar
High voltage copper bar in storage and vehicle systems.
Export Equipment Builds
Assemblies requiring a UL recognised insulation material.
General Equipment Insulation
Any exposed conductor requiring an insulating cover.
Technical Data
Specifications and Dimensions
Test methods and requirements taken directly from the manufacturing specification
Technical Data
| Property | Test Method | Requirement |
|---|---|---|
| Tensile Strength | ASTM D2671 | ≥10.4 MPa |
| Ultimate Elongation | ASTM D2671 | ≥200% |
| Heat Aging (136°C/168h) Tensile Strength Ultimate Elongation | ASTM D2671 | ≥7.3 MPa ≥100% |
| Water absorption (23°C/24h) | ASTM D2671 | ≤1.0% |
| Low-temperature flexibility (-40°C/4h) | ASTM D2671 | No cracking |
| Heat shock (200°C/4h) | ASTM D2671 | No cracking, dripping or flowing |
| Dielectric strength Thickness less than 1.0mm Thickness 1.0mm to less than 2.0mm Thickness 2.0mm to less than 3.0mm | ASTM D2671 | ≥20 kV/mm ≥16 kV/mm ≥12 kV/mm |
| Volume resistivity | ASTM D2671 | ≥1.0×1013Ω·cm |
| Tracking and erosion resistance | ASTM D2303 | After 1hr at 2.5kV, and 1hr at 2.75kV, No burn penetration, no sustained burning |
| Flammability | ANSI C37.20 IEEE-27 | No continuous combustion phenomenon and Self-extinguishing within 60S |
| Smoke index | IEC 61034 | ≤120 |
| Copper corrosion (150°C/168h) | IEC 60684-3-283 | No corrosion |
Dimensions
| Size S1-1 | As supplied(mm) Inner diameter D (min.) | After recovered (mm) Inner diameter d (max.) | Wall thickness t (nom.) | Standard length (m) | Applicable rectangular busbar(mm) L+T | Applicable round busbar(mm) D | ||
|---|---|---|---|---|---|---|---|---|
| 2.5:1 | ||||||||
| 15/6 | 15 | 6 | 1.5 | 30 | 12 | 18 | 6.5 | 12 |
| 30/12 | 30 | 12 | 1.6 | 30 | 17 | 39 | 11 | 25 |
| 50/20 | 50 | 20 | 1.6 | 30 | 36 | 65 | 22 | 43 |
| 75/30 | 75 | 30 | 1.7 | 30 | 39 | 86 | 27 | 55 |
| 100/40 | 100 | 40 | 1.8 | 30 | 59 | 117 | 38 | 75 |
| 120/50 | 120 | 50 | 1.9 | 30 | 70 | 150 | 44 | 90 |
| 150/60 | 150 | 60 | 2 | 30 | 89 | 157 | 55 | 100 |
| 175/70 | 175 | 70 | 2.5 | 30 | 117 | 190 | 75 | 120 |
| 235/105 | 235 | 105 | 2.5 | 30 | 190 | 280 | 120 | 180 |
| 3:1 | ||||||||
| 30/10 | 30 | 10 | 1.8 | 30 | 17 | 39 | 11 | 25 |
| 75/25 | 75 | 25 | 2.0 | 30 | 39 | 86 | 27 | 55 |
| 100/35 | 100 | 35 | 2.3 | 30 | 59 | 117 | 38 | 75 |
| 120/40 | 120 | 40 | 2.5 | 30 | 70 | 150 | 44 | 90 |
| 150/50 | 150 | 50 | 2.5 | 30 | 89 | 157 | 55 | 100 |
CROSS REFERENCE · Tyco-Raychem: LVIT
Manufacturing and Quality
How It Is Made and Checked
Compounding extrusion radiation cross linking expansion and test all under one roof in Dalian
-
01
Compounding
Base polyolefin antioxidants flame retardants and functional fillers are mixed to a recipe held under our own formulation control rather than bought as a masterbatch.
-
02
Extrusion
The compound is extruded to the required wall and diameter. Co extruded products form two or three layers in a single pass so no interface can trap air.
-
03
Radiation Cross Linking
Electron beam irradiation creates the cross linked network that gives the material its shape memory. This step is what makes the product heat shrinkable.
-
04
Expansion
The cross linked part is heated expanded to its supplied diameter and cooled under tension so the expanded shape is locked in until heat is applied again.
-
05
Test and Inspection
More than 90 percent of product performance tests are carried out in our own laboratory including tensile elongation heat aging dielectric strength and tracking resistance.
-
06
Packing and Traceability
Each batch carries a production record so a delivered part can be traced back to its compound lot and process parameters.
Certification
ISO 9001:2015
Quality management system
IATF 16949:2016
Automotive quality management
ISO 14001:2015
Environmental management
ISO 45001:2018
Occupational health and safety
GJB 9001C-2017
Defence quality management
UL 224 E341796
Extruded insulating tubing
CE / RoHS
European conformity and restricted substances
CCS / ABS / DNV
Marine classification society approvals
Comparison
How S1 Compares
An honest comparison so you can rule this product in or out quickly
| Rating | Voltage | Typical Application |
|---|---|---|
| S1-1 | 1 kV | LV switchboards battery and traction bar |
| S1-10 | Up to 24 kV | MV switchgear in the 6 to 24 kV range |
| S1-35 | Up to 36 kV | MV switchgear in the 6 to 36 kV range |
Use Guide
How to Select and Install S1
The sequence our engineers walk customers through on every first installation
-
01
Select the Voltage Rating
S1-1 for 1 kV S1-10 to 24 kV and S1-35 to 36 kV. Do not use a lower rating on a higher voltage bar.
-
02
Choose the Shrink Ratio
2:1 for a close fit 2.5:1 for a moderate step and 3:1 where the entry must be much larger than the finished size.
-
03
Deburr the Bar
Break every edge before fitting or the recovering tube will be cut.
-
04
Degrease
Remove oil oxide and machining residue.
-
05
Shrink from the Middle Outward
Trapped air escapes at both ends.
-
06
Handle Joints Separately
Bolted lap joints need S1-B molded covers not tube.
FAQ
S1 Frequently Asked Questions
The questions buyers ask before they place an order
What does UL 224 recognition mean
Which rating do I need
Is S1 halogen free
Can I use it on electric vehicle high voltage bar
What colours are available
Is the UL file number printed on the tube
Still need an answer ask our engineers on WhatsApp
Related
Related Products
S1-10 Busbar FR 24 kV
Flame retardant busbar insulation available in red yellow green and blue for phase identification up to 24 kV
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S1-35 Busbar FR 36 kV
The 36 kV flame retardant busbar grade in four phase colours for compact switchgear and collector substations
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S1(n)-10 Busbar HF 24 kV
Halogen free red tubing that insulates round and rectangular copper or aluminium busbar inside 6 to 24 kV switchgear
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S1-B Lap Joint Cover
Molded clip open covers that insulate bolted busbar joints and still allow inspection without damaging the connection
VIEW DETAILSGet a Quotation for S1
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