DESIGN FEATURES

The structural design of TONLY^© composite insulator consists of these basic parts:
CORE – is fiberglass reinforced epoxy resin rod that produced from the highest quality materials. It is the component to bear mechanical load and has minimum tension strength at 1000Mpa.
END FITTINGS – are made of steel with hot-dip galvanized. They are compressed directly to the rod by a special process.
SHEATH & WEATHERSHEDS – are produced with High Temperature Vulcanized silicone rubber compound that exhibit high, long-term hydrophobicity, high aging resistance, high corona resistance and low permeability to moisture.
INTERFACES – between the fiberglass rod, rubber sheath, and rubber sheds are laid on a special adhesive that compound on the basis of silicone rubber and then vulcanized. This firmly bonds the rubber to the rod and bonds the rubber sheds to the rubber sheath so that the joint between sheds and sheath is stronger than the rubber.
For suspension insulator with SML on or above 120kN, the interface between the metal fittings and the sheath is fitted on an additional o-ring seal beside of the special sealant.
CORONA RINGS – is made of aluminum. The corona ring is necessary at 220kV system and above. For application at 220kV and 230kV, one corona ring should be assembled at the line end of the suspension insulator; For application at 345kV and greater, two corona rings should be assembled at both end of insulators. There are three types of corona rings for options: R250, R305, R380.
Normal Applications:
Top Grounded, Bottom Energized

CONFIGURATION OF END-FITTINGS:
The designation of the above end-fittings are in accordance with IEC61466-1) Composite string insulator units for overhead lines with a nominal voltage greater than 1000 V – Part 1: Standard strength classes and end fittings); The ANSI classes are also available.
CATALOF NUMBER DEFINITION:



TONLY^© SUSPENSION INSULATORS
Note:
1. All tests are in accordance with IEC61109;
2. Maximum RIV is 100 μm when tested at 1 MHz and 10% over nominal line-ground voltage for indicated system voltage.
3. All units for 220kV system voltage should be assembled one corona at the line end.
4. For other fittings, use the suffixes indicated above. Specify the top fitting first. For example: for clevis top and tongue bottom, add the suffix CT instead of the suffix SB. If both end fittings are to be same, just specify one letter.
Example: for clevis at both end, just add C suffix instead of the suffix SB.


TONLY^© SUSPENSION INSULATORS
Note:
1. All tests are in accordance with IEC61109;
2. Maximum RIV is 100 μm when tested at 1 MHz and 10% over nominal line-ground voltage for indicated system voltage.
3. All units for 220kV and 230kV system voltage should be assembled one corona at the line end.
4. All units for 345kV or greater system voltage should be assembled with two corona rings, one at each end.”
5. For other fittings, use the suffixes indicated above. Specify the top fitting first. For example: for clevis top and tongue bottom, add the suffix CT instead of the suffix SB. If both end fittings are to be same, just specify one letter.
Example: for clevis at both end, just add C suffix instead of the suffix SB.


TESTING
TONLY^© composite suspension insulators have been subject to the tests as below:
Tests on core material
Flammability test
Accelerated electric- environmental ageing test (5000 hours)
Power arc test
Verification of salinity withstand voltage with salt fog method
Tests for the control of the slope of the curve” tensile failure load- time” for the core and its end fittings
Long duration tensile test for verification of the specified mechanical load (SML) and of tightness of the interface between metal end fitting and housing
Fatigue mechanical tensile test
Visual examination
Verification of dimension
Verification of the locking system
Verification of tightness of the interface between metal end fitting and housing and of the specified mechanical load
Verification of zinc -coating
Testing on interfaces and on metal end fitting connections