Hexagonal copper busbar insulators are support posts that mechanically secure copper busbars and provide essential electrical isolation inside electrical panels. They are typically red components made from robust plastics.
Here’s a summary of common technical specifications and applications for these insulators:
| Feature | Typical Specifications / Details | Sources |
|---|---|---|
| Primary Material | DMC (Dough Moulding Compound) or BMC; a fiberglass-reinforced thermoset polyester offering high strength, flame retardancy (e.g., UL94 V-0), and low water absorption. | -2-5-6 |
| Typical Voltage Range | 660V to 4500V for low-voltage applications (common in LV switchgear). | -2-4-8 |
| Standard Colors | Commonly red, but can be customized (brown, other colors). | -2-5 |
| Operating Temperature | Typically between -40°C to +140°C, with common ranges of -30°C to 120°C or 30°C to 140°C. | -2-5-7 |
| Thread Inserts | Brass or steel (zinc-coated); standard thread sizes like M6, M8, up to M12. | -1-2-5 |
| Height Range | Commonly available from 16mm to 100mm, with 25mm, 30mm, 35mm being very common sizes. | -1-2-5 |
| Key Functions | Fix busbars, withstand short-circuit forces, maintain safe creepage & clearance distances. | -1-2-7 |
| Main Applications | Low-voltage distribution cabinets, switchgear, control panels, inverters, UPS systems, EV charging cabinets. | -2-5-6 |
???? How to Select the Right Insulator
Choosing the correct insulator is critical for safety and reliability. Consider these key parameters:
Voltage Rating & Clearances: The insulator's rated voltage must meet or exceed your system's maximum voltage. Pay special attention to the creepage distance (the shortest path along the insulator's surface between conductors), which depends on the system voltage and the pollution degree of the environment (e.g., a clean vs. a dusty or humid panel) -7.
Mechanical Requirements: Consider the weight of the busbar and the potential electrodynamic forces during a short-circuit. Ensure the insulator's mechanical strength and thread type (e.g., M6, M8) are sufficient. Use a calibrated torque wrench to tighten to the manufacturer's specified value to avoid damage -1-7.
Environmental Conditions: Match the material to the operating environment. DMC/BMC is suitable for most general industrial applications due to its broad temperature tolerance and flame retardancy. For outdoor or high UV/chemical exposure, other materials like epoxy or porcelain might be specified -7.
Physical Dimensions: The height determines the insulation distance from the panel. The hexagonal width (often 26mm, 33mm, or 41mm across flats) and internal slot size (e.g., for a 25mm x 6mm busbar) must match your busbar and mounting hole layout. https://store.unigulfsupply.com/product/insulation-column-sb-20-x-30mm-polyester-standoff-insulators/