FXBW4-110/120 Composite Suspension Insulator
The FXBW4-110/120 composite suspension insulator is a long-rod polymer insulator designed for 110 kV overhead transmission-line suspension and tension applications. It provides electrical insulation between energized conductors and grounded tower structures while transferring the specified mechanical load through the insulator string.
The insulator consists of a load-bearing fiberglass-reinforced resin core rod, a polymeric housing with multiple sheds and permanently attached metal end fittings. The silicone rubber housing protects the core from moisture, ultraviolet radiation, contamination and outdoor weathering.
Compared with conventional porcelain and glass insulators, the composite construction offers lower weight, easier handling and good resistance to impact and vandalism. The shed profile and creepage distance can be selected according to the system voltage, site pollution severity, installation altitude and environmental conditions.
Model note: The designation FXBW4-110/120 normally indicates a 110 kV composite suspension insulator with a specified mechanical load of approximately 120 kN. The actual rating must be verified against the approved drawing and test report.
Key Features
- Long-rod composite construction for overhead transmission lines
- High-strength fiberglass-reinforced resin core
- Weather-resistant silicone rubber housing and sheds
- Hydrophobic surface helps limit contamination-related leakage current
- Lightweight design simplifies transport and tower installation
- High resistance to impact, breakage and handling damage
- Galvanized or corrosion-protected metal end fittings
- Different shed profiles and connection fittings available
- Electrical and mechanical parameters customizable to project requirements
Typical Technical Specifications
| Model | FXBW4-110/120 |
|---|---|
| Product Type | Composite Suspension / Tension Insulator |
| System Voltage | 110 kV, subject to system design |
| Specified Mechanical Load | 120 kN, subject to approved test data |
| Insulator Construction | Composite long-rod type |
| Core Material | Fiberglass-reinforced resin rod |
| Housing Material | Silicone rubber or specified polymeric material |
| Shed Color | Red, grey or customized |
| End Fitting Material | Forged or cast steel with corrosion-protective coating |
| End-Fitting Options | Socket, ball, clevis, tongue or project-specific combination |
| Application | Suspension and tension insulation for overhead transmission lines |
| Installation | Outdoor insulator string assembly |
| Reference Standards | IEC 61109:2025 and IEC 62217:2025 |
| Customization | Creepage distance, section length, shed profile, fittings, color and marking |
Electrical dimensions and withstand values must be taken from the approved manufacturer drawing. Representative market data must not replace the test report for the supplied model.
Product Construction
Fiberglass Core Rod
The fiberglass-reinforced resin core is the main load-bearing component. It transfers the tensile load between the metal end fittings and must provide the required mechanical strength and resistance to stress corrosion.
Silicone Rubber Housing
The polymeric housing and sheds protect the core rod and increase the creepage distance. Silicone rubber is commonly selected for its hydrophobic properties and outdoor weathering performance.
Metal End Fittings
The end fittings provide the mechanical interface with tower hardware, conductor fittings and insulator-string components. Connection dimensions and strength class must match the complete line-hardware assembly.
Sealing Interface
The interfaces between the housing, core rod and metal fittings must be properly sealed to prevent moisture ingress. Interface integrity is a critical part of composite-insulator design and testing.
Applications
- 110 kV overhead transmission lines
- Suspension insulator strings
- Tension and dead-end insulator strings
- Transmission towers in polluted environments
- Coastal, industrial and high-humidity regions
- Grid construction and line-upgrade projects
Selection Considerations
- Highest system voltage and insulation coordination
- Specified mechanical load and safety factor
- Required creepage distance
- Site pollution severity
- Installation altitude and atmospheric conditions
- Lightning and switching impulse requirements
- Power-frequency withstand voltage
- End-fitting type and coupling dimensions
- Electric-field grading requirements
The number and geometry of the sheds must not be selected from voltage rating alone. Pollution level, altitude, rainfall, icing and local utility requirements must also be considered.
Quality Inspection
- Visual and dimensional inspection
- Core-rod and housing-material verification
- End-fitting and coupling-dimension inspection
- Mechanical load testing
- Electrical withstand and impulse testing
- Interface and sealing inspection
- Galvanized-coating inspection where applicable
- Routine, sample and type tests according to the agreed standard
Reference Standards
- IEC 61109:2025 – Composite suspension and tension insulators for overhead lines
- IEC 62217:2025 – General definitions, test methods and acceptance criteria for polymeric high-voltage insulators
- IEC 61466-1 – Standard strength classes and end fittings for composite string insulator units
- IEC TS 60815 series – Selection and dimensioning of high-voltage insulators for polluted conditions
- Applicable national standards, utility specifications and approved project drawings
Reference to an IEC standard does not constitute certification. Compliance must be supported by valid reports covering the exact design, materials, dimensions and manufacturing process of the supplied insulator.
Ordering Information
Please provide the following information when requesting a quotation:
- System nominal voltage and highest system voltage
- Specified mechanical load
- Section length and dry arcing distance
- Minimum creepage distance
- Required shed profile and housing color
- Upper and lower end-fitting types
- Pollution severity and installation altitude
- Required electrical withstand levels
- Applicable standard and test-report requirements
- Quantity, marking and packaging requirements
Frequently Asked Questions
Is FXBW4-110/120 suitable for every 110 kV line?
No. The model must also satisfy the required highest system voltage, insulation coordination, creepage distance, mechanical load, fitting dimensions and local environmental conditions.
Does “120” mean the insulator is rated at 120 kV?
Normally, no. In this model designation, 110 generally identifies the voltage class and 120 generally identifies the mechanical load class in kilonewtons. The manufacturer’s model table must be checked.
Can it be used in heavily polluted areas?
A composite insulator can provide good pollution performance, but the shed profile and creepage distance must be selected according to the measured or specified site pollution severity.
Are corona or grading rings included?
They may be required depending on voltage level, insulator design and electric-field analysis. Their inclusion and installation position must be confirmed in the quotation and approved drawing.
