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Busbar Design Basics

Busbar materials must have high electrical conductivity like copper, be strong at working temperatures to withstand short circuits, and be resistant to corrosion. Busbar ratings depend on working and ambient temperatures as well as how much heat is generated and lost through convection, radiation, and the emissivity of the copper surface. The minimum size of a busbar is calculated using the current density, temperatures, heat generated, and heat lost until heat generated is less than or equal to heat lost.

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Lakshmanan Sivalingam
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366 views9 pages

Busbar Design Basics

Busbar materials must have high electrical conductivity like copper, be strong at working temperatures to withstand short circuits, and be resistant to corrosion. Busbar ratings depend on working and ambient temperatures as well as how much heat is generated and lost through convection, radiation, and the emissivity of the copper surface. The minimum size of a busbar is calculated using the current density, temperatures, heat generated, and heat lost until heat generated is less than or equal to heat lost.

Uploaded by

Lakshmanan Sivalingam
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Busbar Design Basics

Materials for Busbar Systems


High electrical conductivity
only silver is better than copper

Good thermal conductor


heat reaches surface quickly

Strong (at working temperature)


to withstand short circuit stresses
low creep

Easy to joint
resistant to corrosion

Busbar System Current Ratings


Busbar ratings are determined only by the
maximum desired working temperature

At working temperature:
heat generated = heat lost

Busbar System Current Ratings


Busbar ratings depend on:

Working and ambient temperatures

Heat lost from the busbar


by convection
by radiation

Heat generated in the busbar

Busbar System Current Ratings


Bright copper has an emissivity of about 0.1
During use, the emissivity of the copper
surface increases - and the current rating
increases - as the copper darkens to reach an
emissivity value of about 0.7
Tin plated copper has an emissivity of about
0.3 to 0.5
But painting bars reduces the current rating!

Minimum size calculation


Calculation method:
1

Select working and ambient temperatures

Assume initial current density of 8 amps/mm2

Find appropriate size in standard range

Calculate heat generated due to current

Calculate heat loss at working temperature

If 4>5, increase size and return to 4


When 4=<5, this is smallest possible size

Best economic sizing


The most economic size gives the lowest lifetime
cost. It is the minimum total cost of
material
installation and
energy costs
over the circuit lifetime.

Higher purchase cost - lower running costs

Further considerations
Having calculated the size of the bar, there are
three further considerations:
voltage drop
skin effect
increases apparent resistance by reducing
effective area - important for:
thick busbars
high frequencies
harmonics generated by non-linear loads

short circuit current

Summary of Busbar Material


Characteristics
High Conductivity
low loss, low voltage drop

Easy Formability
due to small grain size and advanced production technology
easy to bend without surface deformation

Good Flatness
simple reliable jointing

Good Straightness
easy installation, lower joint stress

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