Insulators & Capacitive Sensors (12kV-40.5kV)
XBRELE’s Epoxy Post Insulators (ZJ Series) ensure robust mechanical support for busbars, while our Capacitive Sensors (CG5 Series) provide precise voltage indication signals. Manufactured via APG technology for superior dielectric strength and zero partial discharge.
Advanced Epoxy Post Insulators & Sensors for MV Switchgear
XBRELE provides a comprehensive range of Indoor Epoxy Post Insulators (ZJ Series) and high-precision Capacitive Voltage Sensors (CG5 Series). These components are critical for medium voltage (12kV-40.5kV) distribution systems, ensuring safe busbar support and accurate voltage monitoring within compact switchgear environments.
Unlike traditional porcelain, our epoxy resin insulators are manufactured using APG (Automatic Pressure Gelation) technology. This guarantees high mechanical bending strength (up to 12kN) and superior dielectric properties with a Partial Discharge (PD) < 5pC. The integrated capacitive sensors in our CG5 series enable reliable connection to Voltage Presence Indicating Systems (VPIS), enhancing operator safety.
Designed for KYN28, XGN, and UniGear cabinets, our products strictly comply with IEC 60660 (Tests on indoor post insulators) and IEC 61243-5 (Voltage detecting systems). Whether you need standard support insulators or advanced sensor-integrated units, XBRELE delivers factory-direct quality.
For other essential components like wall bushings or contact boxes, explore our complete Switchgear Parts & Accessories Directory .
Insulators & Capacitive Sensors
High-precision CG5 sensors for VPIS and robust ZJ epoxy insulators for busbar support.
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Reliability of XBRELE Insulation Components
XBRELE utilizes advanced APG technology to manufacture high-strength Indoor Epoxy Post Insulators and precision sensing devices. Designed to withstand mechanical bending loads (up to 12kN) and ensure accurate monitoring in 12kV-40.5kV switchgear.
APG Epoxy Resin Casting
The integrity of a dielectric body depends on its density. We utilize Automatic Pressure Gelation (APG) to eliminate internal voids.
- Void-Free Structure: Ensures high insulation resistance for epoxy components in critical substations.
- Mechanical Strength: ZJ series supports withstand high bending loads (4kN - 12kN) during short circuits.
- Thermal Stability: Premium resin maintains performance under high temperatures. View all our switchgear parts.
Precision VPIS Monitoring
Safety relies on accurate indication. Our CG5 sensing units integrate high-stability ceramic capacitors.
- Reliable Signal: Provides precise output for Voltage Presence Indicating Systems (VPIS) (DXN displays).
- Low Partial Discharge: 100% testing ensures PD is less than 5pC, preventing internal breakdown.
- Dual Function: Combines mechanical support with live line indication, saving space in compact cabinets.
X-Ray & Bending Tests
We employ X-Ray inspection and mechanical load testing on every batch of products to ensure structural integrity.
- Non-Destructive Testing: X-Ray detects hidden micro-cracks inside the solid insulation.
- Torque Strength: Brass inserts are tested to withstand high torque during busbar installation.
- Standards: Verified against IEC 60660 requirements for indoor supports.
Manufacturing & Testing of Epoxy Insulators & Sensors
From raw resin mixing to final X-Ray inspection, XBRELE ensures every indoor post insulator (ZJ) and capacitive sensor (CG5) delivers zero-defect performance for MV switchgear.
APG Casting & Precision Assembly
Our production line for epoxy resin components utilizes advanced APG technology to eliminate internal voids, ensuring high mechanical strength for busbar support.
- 01
Mold Preparation
Molds are pre-heated. Brass inserts for post insulators are positioned with high accuracy to ensure alignment.
- 02
APG Vacuum Casting
Epoxy resin is injected under vacuum using APG technology, creating a dense, void-free dielectric body.
- 03
Curing & Demolding
Controlled curing cycles prevent micro-cracking in the insulator body. Parts are inspected for surface finish.
- 04
X-Ray Flaw Detection
Verifying the bonding between inserts and the epoxy matrix to ensure no hidden defects in the sensor body.
- 05
Final Testing
Routine tests for withstand voltage, PD, and capacitance are conducted before the switchgear components are packed.
Routine & Type Tests
All insulators and sensors are tested per IEC 60660 / IEC 61243 to guarantee reliability in critical power networks.
Dielectric Performance
- Power Frequency Withstand: 42kV (12kV units), 95kV (40.5kV).
- Partial Discharge (PD): < 5pC at 1.1x rated voltage prevents epoxy insulation aging.
- Impulse Voltage (BIL): Verified up to 75kV / 185kV for medium voltage systems.
Mechanical & Functional
- Bending Load Test: Verifies strength (4kN-12kN) to withstand busbar stress.
- Capacitance Check: Ensures voltage sensors provide accurate signals for VPIS.
- Test procedures align with standards for solid electrical insulation.
Dimensional Verification
- Precision check of mounting holes and insert threads.
- Verification of conductor terminal alignment.
- Surface creepage distance measurement for safety.
Global Delivery for Insulation Components
XBRELE ensures rapid supply of indoor post insulators and capacitive sensors to switchgear manufacturers globally. We offer flexible customization for non-standard voltage ratings (e.g., 17.5kV) and secure export packaging.
Stock Availability for ZJ & CG5
We maintain strategic inventory of standard models like ZJ-10kV/Φ65 and CG5-24kV/Sensor to support urgent retrofitting.
- In-Stock Dispatch: Standard 12kV/24kV units ship within 3-5 days.
- Bulk Production: 15-day lead time for large orders (>1000 pcs).
- Spare Parts: Quick replacement for damaged busbar supports.
- Sample Service: Prototype sensors available for VPIS testing.
Custom Mold Design
XBRELE offers mold customization to fit unique cabinet geometries or special high-altitude insulation requirements.
- Dimensional Adaptation: Custom height and diameter for tight spaces.
- Insert Customization: M10/M12/M16 thread options for post insulators.
- Voltage Ratings: Special designs for 17.5kV (Export) or 40.5kV.
- Private Labeling: Laser marking for OEM switchgear brands.
Secure Transport for Epoxy
Epoxy resin components require careful handling. We use multi-layer packaging to prevent chipping during sea or air freight.
- Foam Protection: Individual wrapping for each sensor and insulator.
- Reinforced Cartons: Heavy-duty boxes stacked on fumigated pallets.
- Shock Absorption: Internal cushioning to withstand transit impact.
- Documents: Test reports and compliance certs included.
Common Questions About Insulators & Sensors
Technical answers regarding post insulators, sensor capacitance, creepage distance, and compatibility with KYN28 switchgear.