AXICOM
COMPOSITE
INSULATORS HTV
DESIGN BOOK
ENERGY /// AXICOM COMPOSITE INSULATORS HTV
2
Table of contents
I
Design Book
Presentation
3
How to design your own AXICOM Hollow Insulator HTV ?
6
Design Guide Step 1
6
Design Guide Step 2
7
Design Guide Step 3
8
Design Guide Step 4
9
Standards
Specification Sheet for AXICOM Composite Insulators
ENERGY /// AXICOM COMPOSITE INSULATORS HTV
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11
Design
Book
3
Presentation
Since more than 25 years AXICOM Composite Insulators
from TE Connectivity have been in service worldwide
as important components of high voltage apparatuses,
modern circuit breakers, instrument transformers, cable
terminations, bushings, station post insulators and other
components in high voltage substations. Utilize this
advanced technology for voltage up to 1100 kV AC and
800 kV DC.
Far more than 250.000 insulators were produced in
our plant in Wohlen, Switzerland. Excellent reliability,
zero maintenance and great safety bring tremendous
benefits to our customers worldwide. HV equipment
manufacturers capitalize on their low weight, short
lead-times, easy handling and support of development
for new and more economical HV solutions.
All our experience is implemented in our new state of the
art factory located in Kunshan, China. According to the
expanding requirements worldwide the factory deals with
highly developed technical equipment and engineering tools.
The silicone material in Kunshan was changed to HTV, this
helps us to increase our competitiveness, and in the same
time remain our highest quality of insulators. At Kunshan
factory we have a full range of test equipments for testing of
design criteria, e.g. mechanical loads, tightness testing, burst
pressure and electrical behaviour according to IEC 61462
and IEC 62217. With regard to this, the HV Test laboratory
can test up to 1200 kV AC and 1800 kV impulse voltage.
This new factory will increase our flexibility on the market
to be able to meet very different requirements from our
customers.
ENERGY /// AXICOM COMPOSITE INSULATORS HTV
4
Design Book
How to design your own AXICOM
Hollow Insulator HTV ?
How to design your own AXICOM Hollow Insulator HTV ?
The following pages give you an overview of our insulators and the ability to design your own composite hollow core insulator for your
electrical apparatus. On the basis of a few inputs, all requirements can be fixed and TE can start to design.
Step 1
Select the needed inner diameter of the insulator

Step 2
Select the mechanical requirements, e.g. MSP, MML, filling medium etc. for the
needed tube material

Step 3
Select dimensions like creepage and arcing distance, shed form, overall length
etc.

Step 4
Select the required flanges
ENERGY /// AXICOM COMPOSITE INSULATORS HTV
How to design your own AXICOM
Hollow Insulator HTV ?
Design Book
5
Step 1
Step 1
Inner diameter of an insulator
Cylindrical
The tube of a composite insulator is an internal insulating part and is designed to ensure the mechanical characteristics. The tube is
generally manufactured of resin-impregnated glass fibres. The impregnation resin is an epoxy resin with properties, which adapts to
the requirements of high voltage and outdoor applications. The endless fibres are arranged in different manners to achieve a specified
mechanical strength and guarantee the lowest deflection under cantilever load.
Inner Diameter ID (mm)
Outer Diameter OD (mm)
130
142
154
166
198
206
248
257
300
312
358
374
486
510
586
610
The different diameters fulfil all requirements. With both cylindrical and conical designs, insulators of up to 12 m in length can be
produced. On the left, you see an overview of the complete range of tubes. Other inner diameters are available if needed.
Without protection layer
against SF
With protection layer
against SF
MML
MSP
Stiffness
A2312
A2313
*
***
*
A2314
A2315
**
**
**
A2316
A2317
**
*
***
A2318
A2319
***
*
***
TE Connectivity established four standard Cevolit tube systems, which are selectable in Step 2.
ENERGY /// AXICOM COMPOSITE INSULATORS HTV
Design
Book
6
How to design your own AXICOM
Hollow Insulator HTV ?
Design Book
Step 2
Step 2
Selection of tube material
TE Connectivity develops different tube materials to fulfil
all required mechanical strengths. Additionally, a protection
layer against SF6 can be implemented. The wet winding tubes
with endless fibres are produced under strict strength quality
standards and control. Special tube materials can be produced
on request. The following overview shows some typical
references.
Inner criteria:
• Filling medium
• Pressurized Y/N?
• Bending Load
Cevolit A2312/2313
Type
max.
mechanical
load, MML
[kNm]
max.
service
pressure,
MSP [Mpa]
Cevolit A2314/2315
max.
Specific
deflection, mechanical
3
[mm/kN/m ] load, MML
[kNm]
max.
service
pressure,
MSP [Mpa]
Cevolit A2316/2317
Specific
max.
deflection, mechanical
3
[mm/kN/m ] load, MML
[kNm]
max.
service
pressure,
MSP [Mpa]
Cevolit A2318/2319
Specific
max.
deflection, mechanical
3
[mm/kN/m ] load, MML
[kNm]
max.
service
pressure,
MSP [Mpa]
Specific
deflection,
[mm/kN/m3]
142
2,4
2,8
4,3
4,1
2,3
2,9
5,4
1,6
2,3
5,6
1,2
2,1
166
3,4
2,4
2,6
5,8
2,0
1,8
7,1
1,3
1,4
7,3
1,0
1,2
206
3,7
1,2
1,9
6,2
1,0
1,3
7,8
0,7
1,1
8,1
0,5
0,91
257
6,6
1,1
0,88
11
0,9
0,61
14,5
0,6
0,48
16,6
0,5
0,41
312
12,9
1,2
0,37
21,6
1,0
0,25
24,6
0,7
0,2
25,6
0,5
0,17
374
24,7
1,4
0,16
39,9
1,1
0,11
42,5
0,7
0,09
44,1
0,6
0,07
510
68,4
1,5
0,04
93,2
1,3
0,03
98,8
0,8
0,02
102,5
0,6
0,02
610
99,1
1,3
0,02
150,9
1,0
0,02
160,8
0,7
0,01
167,1
0,5
0,01
Note
ENERGY /// AXICOM COMPOSITE INSULATORS HTV
deflection [mm] = specific deflection x bending load [kN] x (insulator length
[m])3
How to design your own AXICOM
Hollow Insulator HTV ?
Design Book
7
Step 3
Step 3
Shed profile
With regard to the outer design, different
components are important for the overall
dimensions of an insulator:
Design
Book
• Arcing distance
• Creepage distance
• Pollution class
• Shed form
• Service temperature
Ø ≤ 257 mm
Ø ≤ 312 mm
AXICOM China Hollow Core Insulators are moulded directly on the tube with different shed forms. To fulfil the specified creepage
distance, the shed forms were designed and optimized according to IEC 60815-3.
Alternating sheds
Type
Outer Ø
Insulator, E
(mm)
Shed
spasing, T
(mm)
Alternating
shed step,
Tk (mm)
Creepage
factor, Cv
(mm)
Top interval to
flange, O
(mm)
Bottom
interval to
flange, U
(mm)
142
256
50
23
207
55
55
166
280
50
23
207
55
55
206
320
50
23
207
55
55
257
371
50
23
207
55
55
312
452
65
30
277
55
55
374
514
65
30
277
55
55
510
650
65
30
277
55
55
610
750
65
30
277
55
55
Note
Number of sheds = n
Arching distance alternating sheds SW = O + (n - 1) x T + Tk + U
Creepage distance L = O - T + Tk + (n x Cv) + U
ENERGY /// AXICOM COMPOSITE INSULATORS HTV
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How to design your own AXICOM
Hollow Insulator HTV ?
Design Book
Step 4
Step 4
Flange Design
A great range of standard flanges is available at TE Connectivity. The following overview shows you the capability of aluminium alloy
flanges. The end-flanges are part of the insulator and they are assembled with the tube using AXICOM China´s special gluing technology.
This is done to transmit the mechanical loads and seal the adjacent structure.
Standard Flanges Data
Diameter
142
166
206
257
312
Pos.
FA
(mm)
FB
(mm)
ØF5
(mm)
ØFT
(mm)
n x Ød
(mm)
Pos. 21
55
8
205
185
12 x Ø11
Pos. 22
65
12
205
185
12 x Ø11
Pos. 23
85
12
205
185
12 x Ø11
Pos. 24
110
15
205
185
12 x Ø11
Pos. 31
55
8
232
212
16 x Ø11
Pos. 32
65
10
232
212
16 x Ø11
Pos. 33
85
12
240
220
16 x Ø11
Pos. 34
110
15
240
220
16 x Ø11
Pos. 41
55
8
286
260
16 x Ø11
Pos. 42
65
10
286
260
16 x Ø11
Pos. 43
85
12
286
260
16 x Ø11
Pos. 44
110
15
286
260
16 x Ø11
Pos. 51
65
10
344
314
16 x Ø11
Pos. 52
85
12
344
314
16 x Ø11
Pos. 53
110
15
344
314
16 x Ø13.5
Pos. 54
150
20
344
314
16 x Ø13.5
Pos. 61
65
10
380
360
24 x Ø11
Pos. 62
85
12
380
360
24 x Ø11
Pos. 63
110
15
400
370
24 x Ø13.5
Pos. 64
150
20
410
380
24 x Ø13.5
Pos. 71
65
10
442
422
24 x Ø11
Pos. 72
85
12
442
422
24 x Ø11
Pos. 73
110
15
462
432
24 x Ø13.5
Pos. 74
130
15
462
432
24 x Ø13.5
Pos. 75
160
20
462
435
24 x Ø13.5
Pos. 81
85
15
598
568
24 x Ø13.5
Pos. 82
110
15
598
568
30 x Ø13.5
Pos. 83
130
20
602
572
30 x Ø13.5
Pos. 84
160
20
602
572
30 x Ø13.5
Pos. 91
145
30
715
680
32 x Ø13.5
374
510
610
Additionally to these standard flanges, we are able to produce any kind of metal flanges that are required.
There are different kinds of production possibilities:
• Die cast
• Sand cast
• Solid material
• Forged flanges
• Varnished flanges
• Anodized flanges
All flanges feature a high quality standard to realize a high performance and corrosion resistance.
Please ask for more details.
ENERGY /// AXICOM COMPOSITE INSULATORS HTV
Design Book
9
Standards
Standards
Design and Type tests according to IEC 61462
Design
Book
Design tests 7.0
Type tests 8.0
Tests on interfaces and connections of end fittings 7.2
Reference
dry
power
frequency
flashover
test 7.2.2
Thermalmechanical
pre-stressing
test 7.2.3
Water
immersion
pre-stressing
test
7.2.4
Verification tests 7.2.5
Visual examination 7.2.5.1
Steep-front impulse
voltage test 7.2.5.2
Dry power frequency
voltage test 7.2.5.3
Internal pressure test
7.2.5.4
Tests on shed and housing material 7.3
Hardness
test 7.3.1
Mechanical type tests according to IEC 61642
Bending
Tube in phase
1.0 x MML
Reversible elastic
1.5 x MML, residual strain ≤ ±5%
Reversible elastic
2.5 x MML, no visible damages
Irreversible plastic
SML ≥ 2.5 x MML, breaking value
Irreversible plastic
Internal pressure
Tube in phase
1.0 x MSP
Reversible elastic
2.0 x MSP, residual strain ≤ ±5%
Reversible elastic
4.0 x MSP, no visible damages
Irreversible plastic
SIP ≥ 4.0 x MSP, breaking value
Irreversible plastic
Definitions
MML
Maximum Mechancial Load
which is the design load for the
equipment manufacturer
SML
Specified Mechanical Load,
a load specified by the
manufacturer that is used
MSP
Maximum Service Pressure
which is the design pressure
for the equipment manufacturer
SIP
Specified Internal Pressure,
an internal pressure specified
by the manufacturer
ENERGY /// AXICOM COMPOSITE INSULATORS HTV
Accelerated
weathering
test 7.3.2
Tracking and
erosion test
7.3.3
Flammability
test 7.3.4
Tests on tube
material 7.4
Dye
penetration
test 7.4.1
Water
diffusion
test 7.4.2
Internal
pressure
test 8.4
Bending
test 8.5
Design Book
Specification Sheet for AXICOM
Composite Insulators
Specification Sheet for AXICOM Composite Insulators
Customer
Contact person
Apparatus
Quantity per year / batch size
Req.
unit
Outer Criteria Step 3
Inner Criteria Step 1 and 2
Inner tube diameter in mm
Tube material
SF6
 Oil
 other.
Cevolit
Pressurized
Yes 
Maximum Service Pressure (MSP)
MPa.
Maximum mechanical load (MML)
kN
Specified mechanical load (SML)
kN
Deflection@MML
mm
Nominal Service Voltage
kV
BIL
kV
Pollution level according to IEC 60815
/ Creepage distance
mm
Service temperature range
°C
min. arcing distance
mm
min. creepage length
mm
Insulator length
mm
No 
Top
Bottom
Top
Bottom
Standard designation
Special Flanges
Bolt Cicle Diameter (BCD)
mm
Outer Flange Diameter
mm
Number and size of holes
mm
Remarks
Flanges Step 4
Customer's Needs
mm
Insulating medium
Standard Flanges
Contact details customer (first name, last name, company, email addres, phone number).
Contact
10
ENERGY /// AXICOM COMPOSITE INSULATORS HTV
Design Book
Notes
11
Notes
Design
Book
ENERGY /// AXICOM COMPOSITE INSULATORS HTV
TE Connectivity (NYSE: TEL) is a $14 billion global technology leader. Our connectivity and sensor solutions are essential
in today’s increasingly connected world. We collaborate with engineers to transform their concepts into creations –
redefining what’s possible using intelligent, efficient and high-performing TE products and solutions proven in harsh
environments. Our 80,000 people, including 7,500 design engineers, partner with customers in over 150 countries
across a wide range of industries. We believe EVERY CONNECTION COUNTS - www.TE.com
•Mining
•Substations
• Nuclear power plants
• Transmission lines
•OEMs
• Underground distribution
• Overhead distribution
•Windfarms
• Petrochemical plants
•Solar
•Railways
•Hydro-electric
• Street lighting
WHEREVER ELECTRICITY FLOWS, YOU’LL FIND TE ENERGY
te.com/energy
FOR MORE INFORMATION:
EMEA and Americas Market
Asia Market
Plant AXICOM Wohlen
TE Connectivity (Shanghai) Co., Ltd.
Industriestrasse 14 5610 Wohlen
QinJiang Road 307, Shanghai
Switzerland
200233 China
Tel: +41 56 6188700
Tel: +86 021 61 067 000
Fax:+41 56 6188701
Fax:+86 021 54 270 322
productsupport-axicom@te.com
www.te.com.cn/zh/industries/energy.html
te.com/energy
® 2014 TE Connectivity Ltd. family of companies. All Rights Reserved. 1773451-7 EPP-2367-10/14
AXICOM, Raychem, TE Connectivity and the TE connectivity (logo) are trademarks of the TE Connectivity Ltd. family of companies. Other logos, product
and Company names mentioned herein may be trademarks of their respective owners. While TE has made every reasonable effort to ensure the accuracy
of the information in this brochure, TE does not guarantee that it is error-free, nor does TE make any other representation, warranty or guarantee that the
information is accurate, correct, reliable or current. TE reserves the right to make any adjustments to the information contained herein at any time without
notice. TE expressly disclaims all implied warranties regarding the information contained herein, including, but not limited to, any implied warranties of
merchantability or fitness for a particular purpose. The dimensions in this brochure are for reference purposes only and are subject to change without notice.
Specifications are subject to change without notice. Consult TE for the latest dimensions and design specifications.
ENERGY /// AXICOM COMPOSITE INSULATORS HTV