POWER COMPOSI TES

ReCoTec

ROTAFIL

COMPOSITE MATERIALS
FOR HIGHEST ELECTRICAL
AND MECHANICAL REQUIREMENTS.
INSULATING TUBES AND
HOLLOW COMPOSITE INSULATORS
MADE IN GERMANY.
ReCoTec

. ROTAFIL

2
3
Meanwhile a signicant part of the tube production is
sold under the brand ROTAFIL

to external customers with

similar high quality standards. Examples of applications:
insulating housings for high voltage apparatus, bobbins for
coils in medical equipment as well as in reactors and
transformers and insulating shafts of rotating machines.
Based on this know-how and experience it was a logical
step to expand the business eld of insulation material
and ofer hollow composite insulators in MR quality to
the market. Under the brand name ReCoTec

(Reinhausen
Composite Technology) a continuously growing range of
hollow insulators with silicone rubber sheds for outdoor
applications as well as without sheds for indoor use is
available.
The Reinhausen Power Composites (RPC) success story began over 30 years ago
when Maschinenfabrik Reinhausen (MR) needed insulating tubes made from
fiberglass-reinforced epoxy resin in order to produce MR on-load tap-changers.
The products available on the market at that time were not able to meet the
stringent quality requirements of MR. So the solution was to design, produce and
process them in-house. The results were composite materials of a unique quality
which also proved to be the cornerstone for a new company division.
Due to the success and rapid growth of the new business
eld, all activities of MR regarding composite materials and
insulators have been organized as a legally independent
entity since August 1
st
, 2009. The company with the trade
name Reinhausen Power Composites GmbH is a 100%
subsidiary of Maschinenfabrik Reinhausen GmbH.
BECAUSE GOOD IS
NOT GOOD ENOUGH.
HOLLOW COMPOSITE
INSULATORS.
ReCoTec

4
ReCoTec

hollow composite insulators ofer a number of

advantages compared to conventional porcelain insulators.
They are substantially lighter, extremely durable and
earthquake resistant. They maintain their water-repellent
characteristics, and thus their excellent insulating proper-
ties, even under extreme environmental conditions. In the
event of failure or external damage, they are explosion-
proof and do not scatter hazardous parts.
30 years of experience in dimensioning, producing and
processing berglass-reinforced tubes and state-of-the-
art production equipment is your guarantee of a very high
level of reliability. To achieve these goals at the develop-
ment stage, the insulators are designed with CAD systems
and programs for mechanical and electrical FEM calcula-
tions. Our operation is also DIN EN ISO 9001:2000 and
DIN EN ISO 14001:1996 and certied for health and safety
management in accordance with OHRIS which is equiva-
lent to ILO-OSH-2001 / DIN ISO 18001. Ultra-modern test
equipment and regular inspection of all materials and pro-
duction processes far beyond the requirements of relevant
standards ensure this quality. Additionally, all of this is
done in a very short delivery period (usually delivery in
4 weeks ex works for insulators with estab-lished designs).
I All requirements of IEC 61462 and IEC 62217 fullled
I Salt fog test passed with increased salinity above the
standard requirement
I Mechanical and tightness test passed at -60C and
+110C
I Resistance against various insulation uids and SF6
decomposition products proven
Advanced materials and processes:
I FRP manufactured with e-glass and epoxy resin
I Glass content approximately 80%
I Glass transition temperature (T
g
) of resin and glue 128C
I Ozone and UV resistant liquid silicone rubber (LSR)
I Tracking and erosion resistance 4.5 kV in class 1a
I Proven hydrophobicity recovery within 24 hours
I Flammability classication V0
Sheds:
I Shed prole optimized under IEC 60815-3
I All sheds with inclined underside
I Optimal creepage distances
I Low leakage currents
I Special HVDC prole available
Under the ReCoTec

(Reinhausen Composite Technology)

brand name, we manufacture hollow composite insulators
with silicone shielding based on our ROTAFIL

cylinders.
5
ReCoTec

TECHNICAL DATA.
Picture 1: Normal Shed profile,
creepage factor approx. 2.75
Picture 2: Alternating Shed profile,
creepage factor approx. 3.9
p
p 1
p 2
s
s
Inner tube diameter
Outer tube
diameter
Outer shed
diameter
Normal shed prole* Alternating shed prole
2)
d [mm] d [mm] d [mm] p [mm] s [mm] p1 [mm] p2 [mm] s [mm]
80/85 90 198 50 35 50
98/100/107 112 230 55 40 50
100/107/110/120 132 240 50 35 50
110/120/130 142 250 50 35 50
135/150/158/160 172 280 50 35 50
180/190/198/200 210 318 50 50 50 35 50
200/205/220 232 340 50 35 50
230/240/248/250 260 368 50 50 50 35 50
273/290/298/300 310 434 58 60 58 43 60
320/330/340/350 362 486 58 60 58 43 60
479/486/496/500 510 634 58 60 58 43 60
560/580/586/595 615 753 65 50 70
710/770 790 928 65 50 70
Table 1: Available insulator dimensions. Maximum length 11,500 mm.
For current information about available dimensions and standard flanges, please visit www.reinhausen.com/pc.
Filament winding tubes are available in the following standard designs:
PFWL pressure tube with inner liner
PBFWL combined pressure and bending tube with inner liner
BFWL bending tube with inner liner
TFWL torsion tube with inner liner
Laminates for special applications on request.
2)
Special shed proles on request
6
Conical ReCoTec

insulators
I For bushing & cable termination
I Reduce insulation medium use by up to 50%
(oil or gas)
I Reduce the size of equalizing tanks
I Increase the phase to phase distance
ReCoTec

INNOVATIONS.
Our innovations, such as conical ReCoTec

insulators, ReCoTec

with integrated ber-optic cables and ReCoTec

with anges made of FRP

material, help our customers expand and secure their market leadership.
ReCoTec

D
o
D
i d
o
d
i
L
t
L
c
L
b
L
total
d
o

mm
d
i

mm
D
o

mm
D
i

mm
L
t min

mm
L
t max

mm
L
c

mm
L
b min

mm
L
b max

mm
L
total
mm
132 app. 100 362 350 100 1100 1495 100 2500 5095
132 app. 90 510 496 100 1050 2465 100 1500 5015
172 app. 145 362 350 100 1200 1245 100 2700 5145
172 app. 135 510 496 100 1150 2215 100 1700 5065
210 app. 195 362 350 100 1700 995 100 2600 5295
210 app. 186 510 496 100 1200 1965 100 2050 5215
7
ReCoTec

without silicone
Primarily for use in indoor applications and
GIS systems. Diferent protecting layers
(lacquering) possible on customer request.
ReCoTec

with
integrated optical fibers
The integrated ber-optic cables can be
used for current and voltage transformers
and support insulators for exchanging
measurement and optical signals between
high-voltage and ground.
Primary characteristics:
I Up to 24 individual bers possible
I Connections based on customer
specications
I Hollow or with gas or gel lling
ReCoTec

post insulators
I For HVDC Projects and
I For high-voltage substations
Features:
I Ready for assembly
I Filled with SF
6
or N2
I Available in one or two parts
for easier transportation and
handling
ReCoTec

with FRP flanges

This insulator can be used for all
types of applications.
Primary characteristics:
I Increased arcing distance
I No Foucault currents in case
of high magnetic eld
I Enhanced exibility of ange
geometry design
I Delivery time reduction
Insulating drive shafts
for wind turbines
ReCoTec

products also perform very well in insulating

drive shafts for wind turbines. Produced with metal
anges as mechanical interfaces, the tube insulates the
electrical part of the turbine from lightning strikes and
static electricity. The tube and the gluing connection to
the anges transmit high and varying torques.
8
ReCoTec

HIGH QUALITY MADE BY MR.
ReCoTec

9
MORE POWER,
MORE VALUE.
ReCoTec

hollow composite insulators for high voltage apparatus insulators

offer a number of advantages over traditional porcelain housings:
Cost reduction in equipment manufacturing
and installation
I Low weight eases handling, transport and installation
I High impact and shock resistance avoids damage caused by
handling errors and vandalism, no additional costs and delays
caused by damaged insulators
Quick and reliable
I Short and reliable process times for insulators, equipment
and substations
I Flexible adjustment to different operating conditions because
mechanical properties can be widely inuenced by design
I Low manufacturing tolerances enable precise adjustment to
the installed device
Safety
I High mechanical strength and adjustable exibility for optimal
seismic performance and low risk of damage by vandalism
I No dangerous fragments result if the housing is destroyed by
internal or external inuences, no secondary damage to
surrounding equipment and no danger for persons in the vicinity
Maximum operational reliability
I Excellent ash-over resistance under contamination and
humidity conditions due to hydrophobicity and hydrophobicity
transfer, superior insulating abilities in difcult environments
I Extremely good bonding of tube-ange interface, better leakage
properties
ROTAFIL

THE FUTURE OF
FILAMENT WINDING TECHNOLOGY.
ROTAFIL

10
ROTAFIL

tubes are manufactured using the lament

winding technology. Numerically controlled (NC) winding
machines wind the resin-impregnated glass bers on to
a mandrel. The winding angles are varied from 5 to 88
depending on the mechanical requirements. After winding,
the epoxy resin is cured in temperature controlled conveyor
furnaces. Until the resin is completely cured, the mandrels
are kept rotating to avoid displacement of the resin. Finally,
the material is cooled to room temperature and the mandrel
is pulled out of the tube.
Materials
To meet high electrical and mechanical requirements,
RPC uses only e-glass bers and high-temperature curing-
epoxy resins from renowned suppliers for the production
of ROTAFIL

tubes. The glass content is approximately 80%.

For applications with diferent operation temperatures
two resin systems are available, with glass transition
temperatures (T
g
) of >128C and >156C.
Surfaces
As a standard, ROTAFIL

tubes are equipped with a polyester

liner on the inner and outer surface. The polyester eece
is saturated with epoxy resin before winding. Thus, it
provides a layer of resin below and above the FRP material.
This layers provide smooth surfaces which need no further
treatment. Furthermore, the inner layer protects the glass
bers against the decomposition products of SF
6
in
switching devices. This ability has been proven in special
tests performed by circuit breaker manufacturers. Test
reports can be provided on request.
On special request, the tubes can also be supplied without
the liners on one or both surfaces and the surfaces can be
grinded and varnished.
Pressure tube (PFW):
winding angle
Bending tube (BFW):
winding angle
Design & dimensions
At present, ROTAFIL

tubes are available in diameters

from 28 mm to 1000 mm and in lengths up to approximately
5700 mm. The usable length depends on the winding angle.
The winding angle is the angle between the glass bers and the
axis of the tube. It can be varied from less than 5 up to 88.
Small winding angles result in tubes with high bending strength
(BFW) and large angles in pressure resistant tubes (PFW).
Diferent angles can also be combined to produce tubes which
can withstand high bending forces as well as high internal
pressure (PBFW).
outer
diameter
Polyester eece
saturated with
epoxy resin
(optional)
inner
diameter
berglass
reinforced epoxy resin
Certied tubes of Reinhausen Power Composites
for the highest electrical and mechanical requirements.
Certified quality
From each batch of materials used for production, samples are taken
and tested in a special testing lab. Glass content, glass transition
temperature (Tg) and electrical puncture voltage are regularly meas-
ured on samples of nished products in accordance with a test plan.
Of course, Reinhausen Power Composites is certied according
to ISO 9001:2000, ISO 14001:2004 and OHRIS equivalent to
ILO-OSH-2001 / DIN ISO 18001. In 2008, one of our longest term
customers for machined FRP tubes, Siemens Medical Solutions,
awarded us the title Supplier of the Year.
Frequent Quality Controls and 100% traceability
of the materials used.
11
ROTAFIL

TECHNICAL DATA.
12
ROTAFIL

Winding angle
1)
Mechanical properties (material) Norm Unit PFW (54) BFW (25) PBFW (25/54)
Flexural strength tangential ISO 178 MPa 476 138 398
Flexural strength axial ISO 178 MPa 211 302 294
Mechanical properties (tube) PFW (54) BFW (25) PBFW (25/54)
Flexural strength IEC 61462 MPa 120 350 310
Flexural modulus axial IEC 61462 MPa 12000 28000 25000
Flexural modulus tangential IEC 61462 MPa 18200 14000 16700
Max. axial stress during internal pressure IEC 61462 MPa 60 35 40
Max. tangential stress during internal pressure IEC 61462 MPa 120 70 80
Initial ring stifness
(depending on wall thickness)
DIN EN 1228 N/m
2

25150
(5.5 mm)
24140
(5.5 mm)
31400
(6.5 mm)
Electrical properties PFW (54) BFW (25) PBFW (25/54)
Dielectric loss factor tan at 23C, 50 Hz VDE 303-4 10
-3
approx. 2
Dielectric loss factor tan at 23C, 1 kHz VDE 303-4 10
-3
approx. 4.2
Dielectric loss factor tan at 23C, 1 MHz VDE 303-4 10
-3
approx. 11.5
Dielectric strength VDE 303-21 kV/cm 113 113 90
Creepage current strength IEC 60112 CTI 600
Rel.permittivity
R
at 23C, 50 Hz VDE 303-4 approx. 5.2
Rel.permittivity
R
at 60C, 50 Hz VDE 303-4 approx. 5.2
Rel.permittivity
R
at 100C, 50 Hz VDE 303-4 approx. 5.2
Water difusion test IEC 61462 mA rms < 1
Volume resistivity (500 V, 23C) IEC 60093 m 3.9 10
12
Arc resistance IEC 6161 s 177
High current dielectric strength (30C) VDE 0441-1 HD2
High voltage creepage current strength IEC 60587 1A0
Surface resistance IEC 60167 1.5 10
12
Other properties PFW (54) BFW (25) PBFW (25/54)
Density ISO 1183 g/cm
3
2.06 2.02 2.04
Glass content ISO 1172 wt.-% 79.5 79.2 77.7
Glass transition temperature Tg IEC 61006 C 128 (ROTAFIL

50X1X) or 156 (ROTAFIL

51X1X)
Temperature class IEC 60085 B (ROTAFIL

50X1X) or H (ROTAFIL

51X1X)
Linear thermal expansion coefcient axial
(-60...100C)
ISO 11359-2 10
-5
K
-1
1.55 0.94 1.09
Linear thermal expansion coefcient tangential
(-60...100C)
ISO 11359-2 10
-5
K
-1
0.94 1.68 1.23
Flame resistance IEC 60695-11-10 V0
Flame resistance (glow wire) IEC 60695-2-12 C 960
Thermal conductivity DIN 52612 W/mK 0.5 0.6
Water absorption (until weight constance) ISO 62 Method 2 % 0.1
Properties of GFRP Tubes
1)
further winding angles available upon request
PFW: Pressure lament winding
BFW: Bending lament winding
PBFW: Pressure/Bending lament winding
ROTAFIL

INNOVATIONS.
13
High-temperature resin
Since the temperature in electrotechnical devices is very
often the dominant aging factor, we ofer a high-tempera-
ture resin system with a glass transition temperature Tg of
156C (thermal class H). This system has almost the same
characteristics as the standard resin system with a Tg of
128C. Additional technical details can be seen in the table
on the left.
Assembly competence
For 30 years, our skilled workers have assembled metallic
and plastic parts on diferent GFRP tubes. This process is
mainly used for the high quality tap changers of MR. For
more than 20 years, we have also used our competence
to pre-assemble products for other customers.
Machining center
In addition to manufacturing FRP tubes, Reinhausen
Power Composites has extensive abilities and experience
in machining these tubes. Our production is equipped
with various NC machining centers to perform all
relevant operations:
I Saws with diamond-equipped blades for cutting to
the designed length
I Machines for drilling, milling, turning and grinding
I Lathes of diferent sizes mainly for processing the
ends of the tubes
I Several manual work stations for nishing and
quality control
All machines and work stations are operated by skilled
workers who are regularly trained.
14
ROTAFIL

is always the product of choice if high electrical, mechanical and

precision requirements are to be fullled continuously and consistently.
ROTAFIL

APPLICATIONS.
ROTAFIL

On-load tap-changers
For about 30 years ROTAFIL

tubes have been used in

various functions in MRs tap changers. The tubes serve
as housings, drive shafts, contact carriers, and more. The
electrical as well as mechanical requirements are very high
in this application and the tubes need to be machined in
many diferent ways.
Transformer production
Various transformer manufactures are replacing old-
fashioned hard-paper cylinders with modern GFRP tubes.
This ensures higher quality in electrical and mechanical
behavior. Most common applications are arc surpression
coils or cylinders for transformer windings. Additionally,
various applications are possible to increase the quality
and reliability of transformers.
Bobbins for high frequency coils in computer
and magnetic resonance tomography
Another long-term and very successful application is in
the use of bobbins for high frequency coils in computer
and magnetic resonance tomography. For this eld of use,
very precise production and machining is essential to
maintain all dimensions and properties within extremely
low tolerances.
Hollow composite insulators (ReCoTec

)
For many years ROTAFIL

tubes have been used as support

tubes for hollow composite insulators by several customers.
In 2007 RPC started its own manufacturing of this modern
type of high-voltage outdoor and indoor insulators under
the brand name ReCoTec

.
Other applications
Other common applications include winding supports for
reactors, insulating spacers and housings in high-voltage
testing equipment and insulating pipes for measuring
devices, among others.
Magnetic Resonance Tomography
application for customer SIEMENS
Transformer bushings On-load tap-changer
VACUTAP

VV

GFRP tube with machined

cooling chanels
15
MORE POWER,
MORE VALUE.
Leading technology products from Power Composites are
the perfect solution for meeting the highest requirements.
Quick and reliable
I Decades of experience in the production and processing of tubes
made from berglass-reinforced epoxy resin
I The winding angles vary between 5 and 88 depending on the
mechanical requirements
I Low manufacturing tolerances enable precise adjustment to the
installed device
I For applications with varying operating temperatures, two resin
systems are available with glass transition temperatures (T
g
) of
>128C and >156C
I Certied in accordance with ISO 9001:2008, ISO 14001:2009 and
OHRIS which is equivalent to ILO-OSH-2001 / DIN ISO 18001.
Maximum operational reliability
I RPC uses only e-glass bers and high-temperature curing-epoxy
resins from renowned suppliers for the production of ROTAFIL

tubes
I The glass content is approximately 80%
THE POWER BEHIND POWER.
Reinhausen Power Composites GmbH
Weidener Strasse 20
93057 Regensburg, Germany
Phone: +49 941 4090-2860
Fax: +49 941 4090-500
Email: rpc@reinhausen.com
www.reinhausen.com
Please note:
The data in our publications may differ from
the data of the devices delivered. We reserve
the right to make changes without notice.
IN3534366/00 EN RECOTEC / ROTAFIL
F0311800 07/13 uw
Maschinenfabrik Reinhausen GmbH 2013