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Only a company that develops, produces and delivers products worldwide can provide the optimal solution for your requirements. The specialists of PPC Insulators are dedicated to supplying you with superior advice and global support. PPC Insulators quality products and service provide time-tested value to fulfill your needs! Please visit us on the web at www.ppcinsuators.com

Revision 1/2003

We produce a comprehensive range of products for overhead transmission lines up to highest system voltages of 525 kV with the most progressive technology. Electrical Values Shed Profiles Creepage Distances PAGE PAGE PAGE 6 6 7 > Production Insulating Material Insulator Cap Material (Fittings) Cementing Marking Inspection and Testing PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE 8 8 8 8 9 10 12 14 16 > > > > > Application and Advantages Ball and Socket Couplings Locking Devices Clevis and Tongue Couplings Long Rod Insulators with Ball and Socket Couplings > Long Rod Insulators with Clevis and Tongue Couplings PAGE 18 PAGE 19 Introduction Long Rod Insulators .Long Rod Insulators Best Performance in Engineering Your Request is our Challenge > ISO 9001 > IEC > DIN > ÖNORM Index Introduction Excellent design with extra high strength > Standards High Voltage Overhead Transmission Lines IEC Publications DIN ÖNORM Couplings Locking Device PAGE PAGE PAGE PAGE PAGE PAGE 4 4 4 4 5 5 > Design PPC Insulators is a specialist in long rod insulators with a 60 year history of experience and development of these porcelain insulators. engineering and in-service life.

DIN 48063 (1978) = ÖNORM E4130 (1988) ÖNORM E4131 (1988) ÖNORM E4104 (1988) IEC 60433 a porcelain long rod insulator is. split pins conforming to are normally used. the following characteristics have to be defined: St andards Locking Devices For ball and socket couplings. defined as follows: L 160 B 550 L long rod insulator 160 B C 550 specified mechanical failing load (kN) ball and socket coupling clevis coupling (when B is replaced by C) standard lightning impulse withstand voltage [kV) The clevis coupling is locked by a corresponding connecting bolt with grooved nut and cotter pin according to These connecting bolts are not part of regular supplies. for example. ÖNORM E4104 (1988) According to the former Austrian standards ÖNORM a long rod insulator was defined as shown in the following example: L 60/15-125 L porcelain long rod insulator with normal shed spacing 60 15 125 core diameter (mm) number of sheds mechanical failing load. but upon customer request. IEC 60120 (1987) = DIN 48064 (1982) = ÖNORM E4125 (1988) 2. According to For ball and socket couplings complying to the locking is performed by a corresponding split pin. average value (kN) Clevis couplings conforming to IEC 60471 (1977) = DIN 48073 (1975) = DIN 48074 (1990) = ÖNORM E4126 (1984) Variations are made by changes in the initial letter as shown: L LH VL NL WL standard design with normal creepage distance normal creepage distance with higher strength anti-pollution type fog type with alternating sheds PAGE 4 PAGE 5 Standards > > > > > > specified mechanical failing load minimum nominal creepage distance environmental conditions and grade of pollution type of coupling standard lightning impulse withstand voltage IEC 60372 (1984) Long Rod Insulators . Most of these pins also comply with Standards wet power frequency withstand voltage Designation PPC Insulators manufactures long rod insulators according to IEC 60433 (1998) (including the former German standard DIN 48006 (1986)). PPC can procure these connecting bolts. DIN 48073 According to the former German standard DIN 48006 the same insulator was defined as: LP 75/22/1250 LP porcelain long rod insulator with ball LG 75 22 1250 and socket coupling porcelain long rod insulator with clevis coupling (when LP is replaced by LG) core diameter (mm) number of sheds total length of the long rod insulator (mm) Couplings Three types of couplings for porcelain long rod insulators are available: Ball and socket couplings conforming to 1.Long Rod Insulators Long Rod Insulators High Voltage Overhead Transmission Lines To specify the correct porcelain long rod insulator.

to DIN protected creepage distance Alternating shed The recommendations of standard IEC 60815 (1986) are valid for the design of the shed profiles of porcelain insulators and for the determination of the adequate tolerances. It should be noted that to provide an accurate picture of all electrical relationships.Long Rod Insulators Shed Profiles according to Standard IEC 60815 Long Rod Insulators Design Plain shed Design Creepage Distances Porcelain long rod insulators are produced with different shed profiles to optimize performance according to environmental conditions and the grade of pollution. this includes Desert shed > Fog and Salt Pollution shed profiles for coastal areas (fog and salt pollution) which require a high > Dust Pollution aerodynamic shed profiles for areas with desert conditions (dust pollution) > Industrial Pollution shed profiles for areas with heavy industrial pollution Standard shed acc. For example. creepage and arcing distance of the insulating part and follows the standard IEC 60071 (1982-1996). arcing horns and protective devices. a real tower should be constructed with all relevant distances to earth in conjunction with insulators. The insulation performance of a long rod insulator is a function of the length. Electrical Values Electric Arc Discharge along a Long Rod Insulator with Protective Fittings PAGE 6 PAGE 7 Design Long Rod Insulators .

Inspection and Testing of Porcelain Long Rod Insulators according to Standard IEC 60383 Test programme Dry lightning impulse withstand voltage test Wet power-frequency withstand voltage test Mechanical failing load test Thermal-mechanical performance test Verification of the dimensions Verification of the displacements Type tests Sample tests Routine tests               Insulator Cap Material (Fittings) Insulator caps are manufactured in malleable cast iron. By customer request. C-130. however grey can also be provided upon request. Glazing is normally brown in color. according to standard DIN EN 1562 (1997). we can also manufacture from aluminum oxide porcelain. Cementing Cementing is provided with a lead-antimony alloy as standard although it is also possible to provide Portland cement or sulfur cement. which conforms to IEC 60672 (1995-1999). Inspection and Testing Porcelain long rod insulators are tested according to standard IEC 60383 (1993).Long Rod Insulators Long Rod Insula tors Insulating Material The insulator body of the unit is made from high quality aluminum oxide porcelain. Production Production Marking Each porcelain long rod insulator carries the trademark of the PPC Insulators and of the manufacturing factory and the date of manufacture as well as the type designation and the specific mechanical failing load in accordance with standard IEC 60433. 85 µ m) average value. Glazing provides a dirt repellent surface. in minimum EN-GJMB-550-4 or EN-GJMW-450-7. Verification of the locking system Temperature cycle test Porosity test Galvanizing test Routine visual inspection Routine mechanical test PAGE 8 PAGE 9 Production Long Rod Insulators . C-120. The caps are hot dip galvanized according to standard DIN EN ISO 1461 (1999) with a zinc weight of min. 600 g/m 2 (min.

which minimizes corrosion problems and also provides > lower weight for a complete insulator set > simpler mounting of strings > low level of HF interference to radio and television transmissions long rod insulators are recommended for use in direct current applications because there is > no pin corrosion > no ion migration > no problems with thermal runaway effects minimum total life cycle costs through high reliability long rod insulators can be used for tension and compression loads low surface leakage current resulting puncture proof Long rod insulators are solid core and the theoretical puncture path through the porcelain body is almost equal to the dry arcing distance. self-fractures of long rod insulators made of aluminum oxide porcelain are not known in reduced transmission losses the creepage distance is comprised of sheds and core parts which have > good self-cleaning properties with respect to climatic conditions > better insulation performance under pollution conditions packaging in crates offers the maximum protection during shipping and storage insulator body made of aluminum oxide porcelain > high mechanical strength > free of internal stresses > no measurable aging > resistant to salt pollution > high resistance to temperature variations lowest maintenance costs > high resistance to vandalism PAGE 10 PAGE 11 Application and Advantages Long Rod Insulators . if any. always occurs in the air outside the porcelain body.Long Rod Insulators Long Rod Insulators Application and Advantages underribs on sheds not required as the core parts between the sheds contribute to insulation long rod insulators can be checked ultrasonically for mechanical soundness Application and Advantages protection against power arcs is achieved by the addition of protective fittings > cascade flashovers are not possible > immune to thermal puncture electrically and mechanically stressed zones are separated routine test load = 80% of the specified mechanical failing load minimum use of metal parts. flashover. Since porcelain has several times the dielectric breakdown strength of air.

5 5 + 1 .2 1.5 +0 .0 2.5 3 3.8 33.6 2.0 + 1.5 +0 . The pin ball in the socket interior.5 34.5 51 59 67.2 1.0 + 2.5 34.d1 Min.1 h1 (mm) 9.2 23 27 32 36 + 1.1 +0 + 2.5 2.0 2.0 + 2.0 8.2 +0 .0 * minimal value ** minimal value of the thickness of the locking device PAGE 12 h4 .6 .3.5 5 R5 (mm) 4 5 5 7 10 12 14 T ** (mm) 4.6 8 10 r4 (mm) 1.1.5 14.5 20.7 1.3.3 .5 + 0 . 3.3.1 d d 2 2 D D 2 3 The pin ball in the socket entry.8 3.0 2.9 4.0 3.5 34.2.0 +0 +0 .9 .3 .d2 Min.0 5.2 1.9 +0 .4 6.5 3 5. 1.0 2.Long Rod Insulators Long Rod Insulators Ball and Socket Couplings Standard IEC 60120 Clearance between the Pin Ball and the Socket End D 1 Ball and Socket Couplings d 1 Designated size of coupling 11 16 20 24 28 32 * given for guidance d1 (mm) 11.2 Q* Min.0. 0.1.8 +0 .5 .5 26 30 + 1.0 + 1.5 19.5 42.2 19.1.5 .3 + 0 .3 .2.0 6.1.5 D 3* (mm) 24.1 + 0 .4.5 .6 .4 +0 .5 21 23.9 .0 + 2.0 5.6 .5 2.5 3.6 3.1 .5 H 2* (mm) 15.1.2 + 0 .1.3 .5 42 R1 (mm) 35 23 23 27 40 55 70 R3 (mm) 4 3 3 6 5 8 10 R4 (mm) 1.1.4 1.7 +0 .1 3.1.0 5.9 D2 .9 r1 (mm) 35 23 27 40 55 70 r2 (mm) 35 50 60 70 80 90 r 3* (mm) 3.5 42.6 1.0 D1 (mm) 12.1. 3.7 7.6 .1.5 4 4.8 5.9 17 21 25 29 33 + 0 .5 4.5 7.1.1 + 1. 1.0 P Max.5 .5 * clearance between the pin ball and the locking device Dimensions of the Socket End Designated size of coupling 11 16A 16B 20 24 28 32 Dimensions of the Twin-Balled Pins H1 (mm) 10.1.0 2.8 +0 .5 1.6 +0 .0 3.4 7.5 Designated size of coupling h4 (mm) 11 16 20 24 28 32 47 63 83 90 97 120 +0 .4 + 0 .5 11. Designated size of coupling 11 16A 16B 20 24 28 32 D1 .0 P Q + 1 .2 2.0 Max.1.5 6.0 + 3.9 7.5 D3 .d2 Min.1 + 1.2 8.1.5 17 20.3.1 + 1.5 4 4.1. 1.6 1.1.5 34.6 d2 (mm) 22.5 51 59 67.3 41 49 57 65 +0 .5 .5 23.1 13.5 + 1 .0 + 2.0 2.5 +0 .2 1.5 3 3 3.7 1.7 6.4 7.4 19.0 + 3.3 +0 .7 2.5 33.0 + 1.5 27 +0 .2 2.0 + 2.0 + 1.5 2.5 +0 .0 D 2* (mm) 24.3 +0 .5 25 28.2 PAGE 13 Ball and Socket Couplings Dimensions of the Pin Ball D 1 d 1 Long Rod Insulators .5 36.7 10.0 2.5 3.1.

7 11.8 4.0 + 0.5 2.5 ± 0.7 9.0 3.0 3.2 .6 + 0.2 ± 0.0 * all the dimensions are the same as for standard split-pins.2 .X F3 F4 F5 R F2 X X T R 2 T Designated size of standard coupling Standard V-type split-pin Alternative V-type split-pin * Designated size of standard coupling F1 F2 F3 F4 F5 F6 L1 L2 L3 L4 L5 R1 R 2 R 3 max S T S (mm) 11 16A 16B 20 24 28 32 2.0 + 0.9 7.2 .5 10.5 10.0 2.5 3.0 + 0.0 +1 -0 + 0.2 ± 0.2 .0 5.0 18.8 R min (mm) 2.2 .5 42 ± 1.9 7.5 7.5 62 ± 1.5 L min (mm) 29 38 38 49 60 71 81 F' 2 max (mm) 7.5 (mm) 8.5 15.6 -0 (mm) 37 ± 1.0 + 0.0 (mm) 1.2 10.5 + 0.3 .2 .5 16.3 9.5 72 ± 1.5 10.8 5.5 16.2 .5 50 ± 1.0 (mm) 1.5 3.0 14.5 2.5 15.7 24 11 16A 16B 20 (mm) (mm) (mm) (mm) (mm) (mm) 15 22 22 22 22 24 26 20 28 28 30 30 32 36 4 5 5 5 5 6 6 13 19 19 19 19 21 24 19 24 24 24 25 28 33 4 5 5 5 5 6 7 + 0.5 1.5 2.0 + 0.5 2.0 15.0 4.0 7.1 3.0 + 0.2 .0 8.7 + 0.1 4.1 3.2 .5 (mm) 12.2 .5 36 ± 1.0 10.5 50 ± 1. V-Type Split-Pin in Locking and in Coupling Positions W-Clip in Locking and in Coupling Positions A Socket entry Socket entry Socket entry Socket entry A Split-pin in locking position Split-pin in coupling position W-clip in locking position W-clip in coupling position PAGE 14 PAGE 15 Locking Devices Long Rod Insulators R3 L2 L3 L4 R2 S S . except the value F 2 replaced by F' 2 The dimension L max shall be specified by the purchaser of the split-pin.5 2.5 12.0 6.5 50 ± 1.3 10.7 10.0 (mm) 4.8 5.0 + 0.5 2.0 (mm) 3.0 +1 -0 + 0.0 8.0 +1 -0 + 0.5 71 ± 1.0 2.3 3.5 96 ± 1.0 + 0.0 11.5 12.2 .5 2.0 + 0.5 2.5 3.2 ± 0.3 0 R2 (mm) 3.2 .5 62 ± 1.2 .5 7.2 9.0 + 0.2 .0 + 0.1 T (mm) 4.2 F 2min (mm) 8.5 2.1 11.0 4.8 4.2 .2 7.0 3.2 .7 12.0 3.0 (mm) 3 3 3 3 3 4 4 (mm) 2.5 3.2 2.5 15.1 10.7 6.5 3.2 .5 5.2 ± 0.1 3.0 3.5 4.8 5.0 + 0.2 .7 32 +1 -0 + 0.0 3.7 10.0 +1 -0 + 0.0 ± 0.Pin (V-Type) for Ball and Socket Couplings Dimensions of the W-Clip for Ball and Socket Couplings F1 F6 F2 L5 R1 L1 Locking Devices R 1 L Section X .8 15.7 28 +1 -0 + 0.0 (mm) 24 ± 1.2 ± 0.2 1.5 36 ± 1.8 13.5 83 ± 1.2 .Long Rod Insulators Long Rod Insulators Locking Devices Standard IEC 60372 Dimensions of the Split .

4 . Designation d1 (mm) l + 2* (mm) 28.2 32 32.5 17. 145.6 31.8 22 22.4 23 24 24.5 29 33 F (mm) 32 34.5 19 19. to DIN 94 (mm) 5 6 6 6 8 8 - N 13 S 13 N 19 S 19 N 22 S 22 N 25 S 25 N 28 S 28 N 32 S 32 13 19 22 25 28 32 + 0.5 1. 52.5 1. 215.5 19 19.6 27.5 22 25 18 23 26. Nom. 52. 38. Max. 130. Min. 43. 65.5 .5 2 2 15 21 23 26 29 33 - 4 x 25 5 4 5 4 x x x x 45 40 45 40 5 x 50 5 x 50 5 x 71 * Section of the length depending on outside distance of clevis PAGE 16 PAGE 17 Clevis and Tongue Couplings l e H h l Long Rod Insulators . to DIN 1441 Cotter pin acc.5 B (mm) 14 14 15.5 60 67 69. 52.5 57. 335 43.0.5 H (mm) 15 22 25 26. Nom. Min. 48. 295. 275. 210. 48.5 26 30 24. 230.6 + 0.6 26 27 28 29 30 31 33 34 35 n (mm) 12 13 13. Nom.8 1.8 + 0.5 23 24 25.0. 225 34. 45 34. 335 d2 (mm) 5* 5 6 5 6 5 6 6 6 d3 (mm) M12 M16 x M18 x M22 x M24 x M27 x e + s d2 cotter pin 2 h ± 2 Width of flats s (mm) 14 16 16 16 20 20 (mm) 19 24 27 32 36 41 Disk acc. 185. Nom. 38.5 46 48.5 77 79. 315. Max. Nom. 290.5 .3 .6 d2 (mm) 14 14 15 19.4 21. 48.8 + 0. 215. 83. 255.8 13 13. Max.2 25 25. 205. 60.5 23 24 25.5 30 33 l (mm) 45 65 75 80 90 100 - blind holes 13L 19L 22L 25L 28L 32L Min. 150. Min.0. 105.6 19 19. 40. 235. 125.0.5 18 22 17. 315. 83. 48.3 + 0. 60. 165. 57. Min. 57. 270. 310. Min.6 + 0.5 21. 170.Long Rod Insulators Long Rod Insulators Clevis an d Tongue Couplings Standard DIN 48 073 Dimensions of Connecting Bolts Standard IEC 60471 Shape N Shape S with grooved nut and cotter pin marking width of flats with cotter pin and disk Clevis and Tongue Couplings Dimensions of Clevis and Tongue Coupling B n A Tongue d1 d1 thread Bolt d1 l d2 d2 F d3 cotter pin h d2 m d2 A Clevis Section A .0.8 20 21.3 .6 24. 110. 66 48.2 28 28. 75.3 . 43. 295. 190. Max. 330 43. Max.5 20 20 22 20 20 22 26 26 28 26 26 28 26 26 28 m (mm) 10 13 15 14.5 18. 32. 52. 235.5 53 55.5 23 24 25.5 17.A Designation d1 (mm) 12. Max. Nom.0. 250. 275. 57. 255.

5 123 123 145 72.5 123 123 145 72.5 123 123 145 72.5 123 123 72.5 123 123 72.Long Rod Insulators Long Rod Insulators Long Rod Insulators with Ball and Socket Couplings with Clevis and Tongue Couplings d2 Ball and Socket Couplings d1 Characteristics of Long Rod Insulators with Ball and Socket Couplings "B" according to the Standard IEC 60433 (1998) and according to the former German Standard DIN 48006 / Part 1 Designation according according to to former Core Highest Standard Wet Specified Routine Minimum Maximum Standard diameter system lightning power mechanical mechanical nominal nominal coupling d2 voltage impulse frequency failing test creepage length size Um withstand withstand load load distance L (pin voltage voltage (16 mm/kV) diameter) d1 (mm) (kV) (kV) (kV) (kN) (kN) (mm) (mm) (mm) Characteristics of Long Rod Insulators with Clevis and Tongue Couplings "C" according to the Standard IEC 60433 (1998) and according to the former German Standard DIN 48006 / Part 2 Designation according according to to former Core Highest Standard Wet Specified Routine Minimum Maximum Standard diameter system lightning power mechanical mechanical nominal nominal coupling d2 voltage impulse frequency failing test creepage length size (conUm withstand withstand load load distance L necting bolt voltage voltage (16 mm/kV) diameter) d1 (mm) (kV) (kV) (kV) (kN) (kN) (mm) (mm) (mm) IEC 60433 DIN 48006/1 L 40 B 170 L 60 B 170 L 100 B 170 L 100 B 250 L 100 B 325 L 100 B 450 L 100 B 550 L 120 B 325 L 120 B 450 L 120 B 550 L 120 B 650 L 160 B 325 L 160 B 450 L 160 B 550 L 160 B 650 L 210 B 325 L 210 B 450 L 210 B 650 L 250 B 550 L 250 B 650 L 300 B 650 LP 60/5/380 LP 60/5/390 LP 60/19/870 LP 60/30/1240 LP 60/19/870 LP 60/30/1240 LP 75/14/870 LP 75/22/1250 LP 85/14/900 LP 95/22/1300 - 60 60 36 36 36 52 170 170 170 250 325 450 550 325 450 550 650 325 450 550 650 325 450 550 650 550 650 550 650 70 70 70 95 140 185 230 140 185 230 275 140 185 230 275 140 185 230 275 230 275 230 275 40 60 100 100 100 100 100 120 120 120 120 160 160 160 160 210 210 210 210 250 250 300 300 32 48 80 80 80 80 80 96 96 96 96 128 128 128 128 168 168 168 168 200 200 240 240 576 576 576 832 1160 1968 1968 1160 1968 1968 2320 1160 1968 1968 2320 1160 1968 1968 2320 1968 2320 1968 2320 380 400 450 580 870 1085 1240 870 1085 1240 1430 885 1100 1255 1445 905 1120 1275 1465 1305 1500 1330 1520 11 IEC 60433 DIN 48006/2 L 100 C 170 L 100 C 250 16 L 100 C 325 L 100 C 450 L 100 C 550 L 120 C 325 16 L 120 C 450 L 120 C 550 L 120 C 650 L 160 C 325 20 L 160 C 450 L 160 C 550 L 160 C 650 L 210 C 325 20 L 210 C 450 L 210 C 550 L 210 C 650 24 24 L 250 C 550 L 250 C 650 L 300 C 650 LG 60/14/860 LG 60/30/1270 LG 60/19/900 LG 60/30/1270 LG 75/14/900 LG 75/22/1270 LG 85/14/940 LG 85/22/1310 LG 95/22/1340 95 105 85 75 60 60 36 52 72.5 123 123 145 123 145 123 145 60 75 L 210 B 550 LP 85/22 /1270 85 95 105 L 300 B 550 LP 105/22/1330 L 300 C 550 LG 105/22/1370 PAGE 18 PAGE 19 Clevis and Tongue Couplings d2 L L Long Rod Insulators .5 123 123 145 123 145 123 145 170 250 325 450 550 325 450 550 650 325 450 550 650 325 450 550 650 550 650 550 650 70 95 140 185 230 140 185 230 275 140 185 230 275 140 185 230 275 230 275 230 275 100 100 100 100 100 120 120 120 120 160 160 160 160 210 210 210 210 250 250 300 300 80 80 80 80 80 96 96 96 96 128 128 128 128 168 168 168 168 200 200 240 240 d1 576 832 1160 1968 1968 1160 1968 1968 2320 1160 1968 1968 2320 1160 1968 1968 2320 1968 2320 1968 2320 475 605 900 1120 1270 905 1120 1275 1465 920 1135 1290 1465 940 1155 1310 1500 1335 1530 1365 1560 22 25 22 19 19 19 60 72.5 123 123 145 72.