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1、 Overview
Copper bar is used for insulated cast busbar conductor, and composite insulating material is used for the outer surface of conductor. The composite insulating material is made of epoxy resin, quartz sand and other inert inorganic mineral materials, which is accurately prepared according to the specific formula and process requirements. It has excellent electrical and gas insulation performance, mechanical properties and good heat dissipation performance, and it is waterproof, fireproof, explosion-proof and anti-corrosion erosion.

2、 Product features
1. Fire protection: the composite insulation material is not easy to burn and has self extinguishing, low smoke and non-toxic, and can meet the 3-hours combustion test at 750 ℃. It can be used in high fire safety requirements.
2. Waterproof: the fully insulated cast busbar conductor is casting with composite insulating material, and the connection between sections is casting on site. After the busbar is installed, the protection grade of the system can reach IP68, which is suitable for outdoor high tide and humidity, cable trench and other harsh environments.
3. Explosion proof: the insulation after integral casting of epoxy resin has high sealing performance, which can isolate live parts from contacting with combustible gas.
4. Anti corrosion: good resistance to acid and alkali substances or grease, liquid corrosion, anti mold, can be in high pollution, high corrosion environment long-term safe operation.
5. High overall mechanical strength and good anti-collision performance: the cured composite insulation material has high mechanical strength, wear resistance and impact resistance, and the anti-collision grade of the product is as high as ik10.
6. Small size, easy to layout and installation: the structure of fully insulated cast busbar is compact, its volume is only 17% of the traditional air insulated busbar, occupying small space, convenient for on-site layout. Before the busbar leaves the factory, the corresponding straight section, turning section, T-connection section and pan head have been made according to the specific engineering layout requirements, so the on-site installation is convenient.
7. Good heat dissipation, aging resistance and anti cracking: the composite insulation material is made of a variety of inert inorganic minerals and a small amount of special epoxy resin by vacuum mixing and casting, with high thermal conductivity and good heat dissipation; the unique composite insulation material formula design ensures that the thermal expansion coefficient of the insulation material is consistent with that of the conductor, and effectively prevents the insulator from cracking.
8. Maintenance free: once the product is in operation, it can be maintenance free for life.

3、 Structural features
1. Properties of insulating materials
There are many kinds of epoxy resins. According to different performance requirements and process performance requirements, targeted configuration and process scheme can be designed. Curing principles of epoxy resins with different formulations are not the same. The performance of related castables varies greatly. Meanwhile, the pouring process conditions have a great impact on the structure and performance of castables. The technology and process of this product are constantly improved on the basis of European application technology. The formula insulation material can not only meet the electrical performance, but also has good thermal conductivity and mechanical properties.
2. Raw materials
The performance of conductors and fillers will directly determine the performance of products. Our conductors are purchased from regular manufacturers, and the performance is better than the national standard. We have strict inspection control procedures. The key of insulating materials is epoxy resin and curing agent. Our epoxy resin and curing agent are imported from Europe, which has absolute advantage in quality.
3. Key technology
Good product quality is inseparable from strict process and equipment. The proportion of insulating materials must be mixed and poured in strict accordance with the formula. At the same time, in order to reduce the steam drum in the pouring materials, it must be poured in a certain vacuum environment, otherwise the performance of insulating materials will be seriously affected. We use the vacuum pouring equipment imported from Germany, which has the accurate measurement and vacuum mixing system. The whole pouring ingredients and vacuum mixing are automatically completed by the equipment, which can effectively avoid the product quality problems caused by human factors.
Casting busbar production has certain requirements for the environment, temperature and humidity must be controlled within a certain range, our casting workshop has strict control of temperature and humidity air conditioning system, which can effectively ensure the quality of products.
4. Cast on site
The joint between segments is poured on site, and the joint position is the fault prone area. Field connection we control the contact resistance through the contact resistance tester to ensure the temperature rise of the joint. The insulation materials are mixed by small vacuum equipment on site to fully ensure the joint performance.

4、 Use environment
Altitude: 1000 m
The highest ambient temperature is + 55 ℃
Minimum ambient temperature: - 40 ℃
Relative humidity: no more than 90% (+ 20 ℃)
Sunshine intensity: 0.1w/cm2 (wind speed: 0.5m / s)
Maximum daily temperature difference: 25K
Indoor relative humidity: daily average ≤ 95%, monthly average ≤ 90%
Maximum wind speed: 35m / S (Note: wind speed refers to the average wind speed of 10min at the height of 10m above the ground) the load has a wind speed of 10mm icing and 17.5m/s at the same time
Earthquake resistance: ground horizontal acceleration 0.2g; vertical acceleration 0.1g simultaneously. Resonance, sine wave and beat wave test methods were used; 5 times of excitation, 5 waves each time, with an interval of 2 s. The safety factor is not less than 1.

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