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Solution

Switchgear and Busbar Insulation

Raising internal clearance inside compact switchgear and covering the joints a tube cannot reach

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Switchgear and Busbar Insulation

The Problem

Why This Is Harder Than It Looks

Insulated busbar is what allows a switchgear cubicle to be small. It also removes the bridging path that small animals condensation and dust use to destroy a switchboard. The difficulty is never the straight bar runs. It is the bolted lap joints that a tube cannot conform to and that maintenance has to be able to open.

Process

From Requirement to Delivered Product

Design material selection prototyping production quality control packing logistics and after sales

  1. 01

    Design

    We work from the busbar drawing. Bar section length joint geometry bolt count and the required voltage class set every part in the package.

  2. 02

    Material Selection

    Halogen free for occupied and critical buildings. Flame retardant where phase identification colours are wanted. UL 224 recognised where the assembly is exported.

  3. 03

    Prototyping

    Molded lap joint covers are tooled to your joint geometry with a first article supplied for fit approval before production.

  4. 04

    Production

    Tube extruded and irradiated in our own plant. Covers molded in our own tooling. Cut lengths and labelling done before despatch.

  5. 05

    Quality Control

    Dielectric strength volume resistivity heat aging and low temperature flexibility tested per lot. Cover fit checked against the approved first article.

  6. 06

    Packing

    Tube cut to length and labelled per position so the assembly line does not have to measure. Covers packed per joint.

  7. 07

    Logistics

    Delivery timed to the switchboard build programme. Repeat orders from existing tooling ship fast.

  8. 08

    After Sales

    Spares holding for future maintenance and modifications quoted at handover.

Products

Products Used in This Solution

S1(n)-10 Halogen Free Busbar Insulation Heat Shrink Tube 6 to 24 kV
S1(n)-10

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(n)-35 Halogen Free Busbar Insulation Heat Shrink Tube 6 to 36 kV
S1(n)-35

S1(n)-35 Busbar HF 36 kV

The 36 kV halogen free busbar grade for switchgear where clearance is tight and smoke toxicity is regulated

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S1-10 Flame Retardant Busbar Insulation Heat Shrink Tube 6 to 24 kV
S1-10

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 Flame Retardant Busbar Insulation Heat Shrink Tube 6 to 36 kV
S1-35

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 Busbar Insulation Heat Shrink Tube 1 kV to 35 kV
S1

S1 Busbar Tube

The general purpose busbar insulation family covering 1 kV to 35 kV with UL 224 recognition under file E341796

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S1-A Wrap Around Overhead Line Cover 380 V to 110 kV
S1-A

S1-A Overhead Line Cover

A wrap around insulating cover with a built in creepage device that clips onto a live route conductor without disconnection

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S1-B Busbar Lap Joint Insulation Cover 1 kV to 36 kV
S1-B

S1-B Lap Joint Cover

Molded clip open covers that insulate bolted busbar joints and still allow inspection without damaging the connection

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Outcomes

What You Get

  • A compact cubicle that meets its power frequency withstand without growing
  • The animal and condensation bridging path removed from the whole bar system
  • Bolted joints insulated and still openable for torque check and thermographic survey
  • Tube cut and labelled per position which removes measuring and waste from assembly
  • One bill of materials covering straight runs joints and any live overhead sections

FAQ

Switchgear and Busbar Insulation Frequently Asked Questions

Can a shrink tube cover a bolted lap joint
No. The stepped profile with bolt heads cannot be conformed to by a tube. S1-B molded covers are made to the joint geometry and clip open with a buckle.
Which grade do I need at 36 kV
S1(n)-35 for halogen free or S1-35 for flame retardant with phase colours. The 24 kV grades do not give the required withstand margin at 36 kV.
Do you supply covers to our drawing
Yes. Send a dimensioned sketch or a photograph with a rule across the joint and we will quote tooling and unit price.
Can bar be insulated after it is installed
Only if it can be disconnected at one end so the tube can be slid on. For a live installed conductor use S1-A wrap around cover.
Is the colour through the wall or only on the surface
The colour is compounded through the full wall thickness so surface abrasion does not change the phase identification.
What about the transition from switchgear to an overhead line
S1-A wrap around cover handles the overhead conductor section including the transition lead into a main transformer station.

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Other Solutions

Explore the Rest

Medium Voltage Cable Jointing

Rebuilding insulation screen and sealing across a jointed conductor from 6 kV to 36 kV

Cable Termination Indoor and Outdoor

Field grading anti tracking insulation and creepage from 0.6/1 kV to 26/35 kV

Emergency Cable Repair

Restoring a damaged jacket in place without cutting the cable or disturbing the terminations

OEM and Private Label Kits

Kits packed to your bill of materials with your brand on the carton the instruction sheet and every bag

Custom Formulation and Tooling

Changing a wall thickness a shrink ratio a colour or a molded shape when the catalogue does not fit

Start a Conversation About Switchgear and Busbar Insulation

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