Introducing Insulect’s New SF₆-Free Load Break Switch

Insulect recently launched its new epoxy-insulated, SF₆-free vacuum load break switch—an important step toward more sustainable switching equipment for 12 kV and 24 kV distribution networks.

The switch combines vacuum interruption technology with solid epoxy insulation, eliminating the need for SF₆ gas while still meeting the performance requirements of IEC 62271-103. Designed for real-world field environments, it supports both manual operation and SCADA-enabled remote control, giving utilities flexibility in how they deploy and operate the equipment.

Why This Product Was Developed

The primary driver behind the new design is the power industry’s gradual shift away from SF₆ (sulphur hexafluoride). Although widely used in switchgear, SF₆ is a potent greenhouse gas, and tightening environmental regulations are pushing utilities to adopt alternatives that reduce lifecycle risk and compliance requirements.

Engineers working on the project focused on creating a solution that could maintain the reliability and performance expected in distribution networks—without the operational complexities associated with gas-insulated equipment.

As Andres Rambal, the Product Applications Engineer involved in the development, explained:

“Remote-operated models include both DNP3 and IEC 61850-compatible control, local/remote selection, and waterproof connectors to simplify field wiring and integration into existing SCADA systems.”

By integrating vacuum interruption within a fully sealed epoxy-insulated system, the switch removes the need for gas handling, leak monitoring, and specialised servicing.

What Problems It Solves

Traditional load break switches that rely on SF₆ come with additional operational responsibilities, including gas monitoring, regulatory reporting, and end-of-life management. The new epoxy-insulated design removes these requirements entirely.

The switch also addresses several practical challenges associated with outdoor distribution equipment. A stainless-steel enclosure, sealed insulation system, and polymer bushings help improve performance in harsh environments where moisture, dust, or corrosive conditions can affect long-term reliability.

From an operational perspective, the unit is designed to remain simple for field crews while still enabling modern network control capabilities. Eric Koutoulas, the Business Development Manager involved in the rollout, summarised the intent:

“Network operators wanted a solution that was dependable and didn’t create ongoing operational overhead. This design keeps day‑to‑day management simple and minimises the number of components that require regular attention.”

A Practical Solution for the Field

The new load break switch is rated for 630 A continuous current, with 16 kA short time withstand current for one second and 40 kA peak making current capability.

It is designed to handle cable-charging and line-charging duties and has been tested for 5,000 mechanical operations, supporting long-term field use.

Several configuration options are available to suit different installation requirements, including:

• Factory-fitted cable leads

• Surge arresters

• Mid-pole or pole-top mounting arrangements

Remote-operated models include IEC 61850-compatible control, local/remote selection, and waterproof connectors to simplify field wiring and integration into existing SCADA systems.

See It at EN26

Insulect will be showcasing the new SF₆-free, epoxy-insulated load break switch at the EN26 event (Stand #14) in Adelaide from March 17–19, 2026. Visitors will be able to see the equipment up close and speak with the sales team about its design, development, and field applications. Claim your free access now or contact us today to learn more.