H1: XZP-160 DC Suspension Insulator (U160BL) — 160kN, 545mm Creepage, 140kV DC Dry Withstand, Zinc Sleeve Protection, Brown/Light Gray Glaze, IEC 60383
The XZP-160 DC Suspension Insulator (U160BL) is a premium cap‑and‑pin disc insulator specifically engineered for high‑voltage direct current (HVDC) overhead transmission lines. Designed to meet the unique challenges of DC transmission — including DC ageing and electrolytic corrosion — this insulator delivers exceptional performance in heavy pollution areas with its advanced shed profile design and specialized material composition.
Manufactured in compliance with IEC 60383 international standards, this DC insulator features a robust porcelain body with superior characteristics to resist DC ageing. The pins are equipped with zinc sleeves to prevent DC electrolytic corrosion, ensuring long‑term reliability in HVDC applications. The unit is available in either brown (standard) or light gray (optional) glaze, both offering identical mechanical and electrical performance.
With a combined mechanical and electrical (M&E) failing load of 160kN and a nominal creepage distance of 545mm, the XZP-160 delivers dependable performance on ±400 kV to ±800 kV HVDC transmission lines in the most challenging environments. The large 320mm diameter and 170mm spacing provide excellent pollution flashover performance and mechanical stability.
The advanced DC‑optimized shed design incorporates a specialized profile that maximises creepage length while maintaining superior self‑cleaning properties. The porcelain material’s superior DC ageing resistance, combined with zinc sleeve protection against electrolytic corrosion, ensures decades of reliable service in HVDC applications where AC insulators would fail prematurely.
Whether you are designing new HVDC transmission corridors, upgrading existing DC lines, or expanding national grid interconnections, the XZP-160 DC suspension insulator offers a durable, high‑performance choice for your HVDC infrastructure, with the flexibility to select your preferred glaze colour.
H2: XZP-160 DC Suspension Insulator — Technical Specifications (Brown & Light Gray Glaze)
The XZP-160 DC suspension insulator is rated with a combined mechanical and electrical (M&E) failing load of 160kN, making it suitable for tangent suspension, light‑tension, strain, and dead‑end applications on ±400 kV to ±800 kV HVDC transmission lines.
Its nominal creepage distance of 545mm — significantly longer than standard AC designs — provides superior pollution flashover performance in heavy industrial, coastal, and desert environments. The DC dry withstand voltage reaches 140kV, and the DC wet withstand voltage is 55kV. The dry lightning impulse withstand voltage is 140kV (positive) and 150kV (negative).
The nominal diameter is 320mm, with a unit spacing (height) of 170mm. These larger dimensions provide increased surface area for improved pollution performance and enhanced mechanical stability. The advanced DC‑optimized shed profile is specifically designed to resist DC ageing and maintain insulation integrity.
The coupling hardware is the 20R ball‑and‑socket type, ensuring full interchangeability with existing HVDC fittings per IEC dimensional requirements. The “R” designation indicates the heavy‑duty rotary coupling design.
The pins are equipped with zinc sleeves to prevent DC electrolytic corrosion — a critical feature for HVDC applications where standard galvanised pins would degrade due to unidirectional current flow.
The glaze is available in both brown (standard) and light gray (optional). All other technical parameters — mechanical, electrical, and dimensional — are identical between the two colour options.
Every unit undergoes a routine tension load test of 80kN to verify mechanical integrity prior to dispatch. The SF₆ puncture withstand voltage reaches 210kV, demonstrating exceptional dielectric robustness.
H2: XZP-160 DC Suspension Insulator — Complete Technical Data (Brown vs. Light Gray Glaze)
The following table lists all technical parameters for both glaze colour options. All values are identical except for the glaze colour.
| Parameter | XZP-160 (Brown Glaze) | XZP-160 (Light Gray Glaze) |
| Glaze Color | Brown | Light Gray |
| Type Designation | XZP-160 (U160BL) | XZP-160 (U160BL) |
| Figure No. | 1 | 1 |
| Diameter D (mm) | 320 | 320 |
| Unit Spacing H (mm) | 170 | 170 |
| Nominal Creepage Distance L (mm) | 545 | 545 |
| Coupling Size | 20R | 20R |
| Rated M&E Failing Load (kN) | 160 | 160 |
| Routine Tension Load (kN) | 80 | 80 |
| Impact Load (N·m) | 10 | 10 |
| DC Dry Withstand Voltage (kV) | 140 | 140 |
| DC Wet Withstand Voltage (kV) | 55 | 55 |
| Dry Lightning Impulse Withstand (Positive) (kV) | 140 | 140 |
| Dry Lightning Impulse Withstand (Negative) (kV) | 150 | 150 |
| SF₆ Puncture Withstand Voltage (kV) | 210 | 210 |
| Net Weight, Approximate (kg) | 13.2 | 13.2 |
| Applied Standard | IEC 60383 | IEC 60383 |
Note: The XZP-160 DC suspension insulator is specifically engineered for HVDC applications with DC‑optimized shed design, superior DC ageing resistance, and zinc sleeve protection against electrolytic corrosion.
The 545mm creepage distance provides superior pollution flashover performance in heavy contamination areas. Both brown and light gray glazes offer the same outstanding performance.
H2: XZP-160 DC Suspension Insulator — DC‑Specific Design Features
The XZP-160 DC suspension insulator incorporates several design features specifically developed for HVDC transmission that set it apart from conventional AC insulators:
- Zinc sleeve protection — The pins are equipped with zinc sleeves that prevent DC electrolytic corrosion. In HVDC applications, unidirectional current flow can cause accelerated corrosion of standard galvanised components. The zinc sleeves act as a sacrificial anode, protecting the critical pin components and ensuring long‑term mechanical integrity.
- DC‑optimized porcelain material — The high‑grade porcelain body is formulated with superior characteristics to resist DC ageing. Unlike AC insulators, DC insulators are subject to continuous unidirectional voltage stress that can accelerate dielectric ageing. Our special porcelain formulation maintains consistent dielectric strength throughout the insulator’s service life.
- Advanced shed profile — The DC‑optimized shed geometry is specifically designed to maximise the 545mm creepage distance while maintaining effective self‑cleaning properties. The optimized profile enhances pollution flashover performance in heavy contamination areas where DC insulators are particularly vulnerable.
- Robust mechanical design — The 160kN rating with 20R coupling ensures reliable mechanical performance under the extreme conditions of long‑span HVDC river crossings, heavy icing, and seismic zones.
- IEC 60383 compliance — Full compliance with international standards ensures global interchangeability and quality assurance.
Each XZP-160 DC suspension insulator is produced from high‑grade porcelain, fired at over 1,300 °C using the wet process, achieving maximum density and near‑zero porosity. The zinc sleeves are precision‑applied to ensure optimal corrosion protection throughout the insulator’s service life.
The cement bonding between the porcelain body and metal parts uses high‑quality Portland cement, guaranteeing mechanical stability across extreme thermal cycling from ‑70 °C to +105 °C.
The hard, glossy glaze — available in brown or light gray — further enhances self‑cleaning and maintains surface integrity over decades of service. Both glaze colours are applied using the same high‑quality process, ensuring identical durability, hardness, and electrical performance.
H2: XZP-160 DC Suspension Insulator — Applications and Installation
The XZP-160 DC suspension insulator is widely deployed on ±400 kV to ±800 kV HVDC transmission lines, as well as HVDC converter station entries, back‑to‑back HVDC interconnections, and long‑distance bulk power transmission corridors where DC technology is the preferred solution.
The 160kN mechanical rating combined with the 545mm creepage distance, 320mm diameter, and DC‑specific design features makes it particularly suitable for:
- ±400 kV to ±800 kV HVDC transmission lines – Where the highest reliability is required for bulk power transmission over long distances.
- Heavy pollution areas – Industrial zones, coastal regions, and desert environments where pollution flashover is a significant risk for DC lines.
- Long‑span river crossings and mountain passes – Where mechanical loads are extreme and DC insulators must maintain reliable performance.
- HVDC converter stations – Strain and dead‑end towers at converter station entries where DC‑specific insulators are essential.
- National grid interconnections – Back‑to‑back HVDC links and transmission corridors where bulk power must be transmitted efficiently.
- Renewable energy integration – Offshore wind HVDC connections and long‑distance renewable energy transmission.
The 20R coupling with zinc sleeves ensures compatibility with existing HVDC hardware and provides protection against electrolytic corrosion. The DC‑optimized shed design facilitates hot‑stick handling for live‑line maintenance.
Typical application scenarios include:
- ±400 kV HVDC lines – Suspension and strain applications where DC‑optimized design is required.
- ±500 kV HVDC lines – Heavy‑duty strain and dead‑end towers requiring maximum mechanical strength and pollution performance.
- ±800 kV UHVDC lines – Ultra‑high‑voltage DC transmission where only the highest performance insulators are acceptable.
The 20R ball‑and‑socket coupling ensures compatibility with existing HVDC clevis pins, yokes, and socket hardware. The DC‑specific design features — zinc sleeves, DC‑optimized shed profile, and special porcelain formulation — ensure maximum reliability in HVDC applications.
For higher voltage requirements, multiple units of the XZP-160 DC suspension insulator can be assembled in strings. Explore our full range of suspension insulators and transmission hardware for more options.
H2: XZP-160 DC Suspension Insulator — Quality and Performance Advantages
The XZP-160 DC suspension insulator offers the highest level of quality and performance for HVDC transmission applications, with several advantages over conventional AC insulators:
- DC‑optimized porcelain formulation – Superior resistance to DC ageing, ensuring decades of reliable dielectric performance.
- Zinc sleeve protection – Prevents DC electrolytic corrosion, extending mechanical service life significantly compared to standard galvanized pins.
- 545mm creepage distance – Provides superior pollution flashover performance in heavy contamination environments.
- 320mm diameter – Large surface area for improved pollution performance and self‑cleaning.
- DC wet withstand voltage 55kV – Enhanced wet performance for reliable operation in rain, fog, and high‑humidity conditions.
- SF₆ puncture withstand 210kV – Exceptional dielectric robustness demonstrating the quality of the porcelain and DC‑optimized design.
- 20R coupling with zinc sleeves – Heavy‑duty rotary coupling design with corrosion protection for HVDC applications.
- IEC 60383 compliance – Manufactured to international standards for global quality assurance.
At 13.2kg, the XZP-160 offers a competitive strength‑to‑weight ratio for a 160kN DC insulator while incorporating all essential DC‑specific design features.
With an expected service life exceeding 50 years under normal HVDC operating conditions, the XZP-160 requires minimal routine maintenance. Every unit undergoes 100% routine testing before dispatch, including:
- Visual and dimensional inspections.
- Routine tension load verification (80 kN).
- DC dry and wet withstand voltage tests.
- Porosity and temperature‑cycle prototype testing per IEC 60383.
Each insulator is individually foam‑cushioned and securely packed in durable wooden crates or corrugated cartons. This prevents damage during transit. We offer flexible shipping arrangements (FOB, CIF, EXW) with lead times of 15–30 days, depending on order quantity.
For detailed product datasheets, CAD drawings, or competitive pricing on the XZP-160 DC suspension insulator (brown or light gray), please contact our sales team via the inquiry form below.
We also provide OEM services and complimentary technical consultation for HVDC string assembly design. For installation guidance, refer to our insulator string assembly guide.
H2: XZP-160 DC Suspension Insulator — Why Choose Our Product?
Selecting the right DC suspension insulator for your HVDC infrastructure is critical to long‑term grid reliability — especially in heavy pollution areas where AC insulators would fail prematurely due to DC ageing and electrolytic corrosion. Our XZP-160 DC suspension insulator is manufactured under stringent quality control protocols at every production stage.
From raw material sourcing (DC‑optimized high‑grade porcelain clay) to final high‑voltage DC testing, every step aligns with IEC 60383. We understand that HVDC transmission projects require specialized insulators that address the unique challenges of DC technology — challenges that standard AC insulators are not designed to meet.
That is why the XZP-160 DC suspension insulator is specifically engineered with zinc sleeve protection against DC electrolytic corrosion, DC‑optimized porcelain with superior resistance to DC ageing, a DC‑optimized shed profile with 545mm creepage distance, and 20R heavy‑duty coupling to deliver maximum performance in the most demanding HVDC applications. Additionally, we offer both brown and light gray glaze options to match regional preferences or project specifications.
With over a decade of experience in porcelain insulator production — including specialized DC insulator manufacturing — we offer competitive factory pricing, prompt delivery, and dedicated after‑sales technical support.
Whether you require a small sample batch for project validation or a full container shipment, the XZP-160 DC suspension insulator (brown or light gray) is available with short lead times. Contact us today to discover how the XZP-160 DC suspension insulator can strengthen your HVDC grid reliability with its specialized DC‑optimized design.
XZP-160 DC Series — Key Specifications Summary
| Parameter | XZP-160 (U160BL) |
| M&E Failing Load | 160 kN |
| Nominal Diameter D | 320 mm |
| Unit Spacing H | 170 mm |
| Creepage Distance L | 545 mm |
| Coupling Size | 20R |
| DC Dry Withstand Voltage | 140 kV |
| DC Wet Withstand Voltage | 55 kV |
| Lightning Impulse (+/-) | 140 / 150 kV |
| SF₆ Puncture Withstand | 210 kV |
| Zinc Sleeve Protection | ✓ |
| DC Ageing Resistance | ✓ |
| Net Weight | 13.2 kg |
| Glaze Options | Brown / Light Gray |
| Best Application | ±400kV – ±800kV HVDC lines / Heavy pollution areas |
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