Panel Design & Calculate Size of Bus Bar - Electrical Notes & Articles

3/1/2017 Panel Design & Calculate Size of Bus bar | Electrical Notes & Articles
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Panel Design & Calculate Size of Bus bar
AUGUST 5, 2014 57 COMMENTS (HTTPS://ELECTRICALNOTES.WORDPRESS.COM/2014/08/05/PANEL‑DESIGN‑
CALCULATE‑SIZE‑OF‑BUS‑BAR/#COMMENTS)
Example: Calculate Size of Bus bar having Following Details
Bus bar Current Details:
Rated Voltage = 415V,50Hz ,
Desire Maximum Current Rating of Bus bar =630Amp.
Fault Current (Isc)= 50KA ,Fault Duration (t) =1sec.
Bus bar Temperature details:
Operating Temperature of Bus bar (θ)=85°C.
Final Temperature of Bus bar during Fault(θ1)=185°C.
Temperature rise of Bus Bar Bar during Fault (θt=θ1‑θ)=100°C.
Ambient Temperature (θn) =50°C.
Maximum Bus Bar Temperature Rise=55°C.
Enclosure Details:
Installation of Panel= Indoors (well Ventilated)
Altitude of Panel Installation on Site= 2000 Meter
Panel Length= 1200 mm ,Panel width= 600 mm, Panel Height= 2400 mm
Bus bar Details:
Bus bar Material= Copper
Bus bar Strip Arrangements= Vertical
Current Density of Bus Bar Material=1.6
Temperature Co efficient of Material Resistance at 20°c(α20)= 0.00403
Material Constant(K)= 1.166
Bus bar Material Permissible Strength=1200 kg/cm2
Bus bar Insulating Material= Bare
Bus bar Position= Edge‑mounted bars
Bus bar Installation Media= Non‑ventilated ducting
Bus bar Artificial Ventilation Scheme= without artificial ventilation
Bus bar Size Details:
Bus bar Width(e)= 75 mm
Bus bar Thickness(s)= 10 mm
Number of Bus Bar per Phase(n)= 2 No
Bus bar Length per Phase(a)= 500 mm
Distance between Two Bus Strip per Phase(e)= 75 mm
Bus bar Phase Spacing (p)= 400 mm
Total No of Circuit= 3 No.
Bus bar Support Insulator Detail:
Distance between insulators on Same Phase(l)= 500 mm
Insulator Height (H)= 100 mm
Distance from the head of the insulator to the bus bar center of gravity (h)= 5 mm
Permissible Strength of Insulator (F’)=1000 Kg/cm2
https://electricalnotes.wordpress.com/2014/08/05/paneldesigncalculatesizeofbusbar/ 1/12
Calculation:
(1) De rating Factors for Bus bar:
(1) Per Phase Bus Strip De rating Factor (K1):
Bus bar Width(e) is 75mm and Bus bar Length per Phase(a) is 500mm so e/a is 75/500=0.15
No of Bus bar per phase is 2 No’s.
From following table value of de rating factor is 1.83
Number of Bus Bar Strip per Phase (K1)
No of Bus Bar per Phase
e/a
1 2 3
0.05 1 1.63 2.4
0.06 1 1.73 2.45
0.08 1 1.76 2.5
0.1 1 1.8 2.55
0.12 1 1.83 2.6
0.14 1 1.85 2.63
0.16 1 1.87 2.65
0.18 1 1.89 2.68
0.2
1 1.91 2.7
(2) Bus bar Insulating Material De rating Factor (K2)
Bus bar having No insulating material. It is Bare so following Table
De rating Factor is 1.
Bus Bar Insulating Material
De rating Factor
(K2):
Bare 1
PVC Sleeving 1.2
Painted 1.5

(3) Bus bar Position De rating Factor (K3)
Bus bar Position is Edge‑mounted bars so following Table
Bus bar Position is Edge‑mounted bars so following Table
De rating Factor is 1
Bus Bar Position(K3): De rating Factor
Edge‑mounted bars 1
1 bar base‑mounted 0.95
several base‑mounted bars 0.75

(4) Bus bar Installation Media De rating Factor (K4)
Bus bar Installation Media is Non‑ventilated ducting so following Table
De rating Factor is 0.8
Bus Bar Installation Media(K4): De rating Factor
Calm indoor atmosphere 1
Calm outdoor atmosphere 1.2
Non‑ventilated ducting 0.8

(5) Bus bar Artificial Ventilation De rating Factor (K5)
Bus bar Installation Media is Non‑ventilated ducting so following Table
Bus Bar Artificial Ventilation Scheme De rating
(K5): Factor
without artificial ventilation 0.9
with artificial ventilation 1

(6) Enclosure & Ventilation De rating Factor (K6)
Bus bar Area per Phase = Bus width X Bus Thickness X Length of Bus X No of Bus bar per Phase
Bus bar Area per Phase = 75x10xX500X2= 750000mm
Total Bus bar Area for Enclosure= No of Circuit X( No of Phase + Neutral )X Bus bar Area per Phase
Here we used Size of Neutral Bus is equal to Size of Phase Bus
Total Bus bar Area for Enclosure=3X(3+1)X750000mm
Total Bus bar Area for Enclosure=9000000 Sq.mm
Total Enclosure Area= width X Height X Length
Total Enclosure Area=1200x600x2400=1728000000 Sq.mm
Total Bus bar Area for Enclosure / Total Enclosure Area =9000000/1728000000
Total Bus bar Area for Enclosure / Total Enclosure Area=0.53%
Bus bar Artificial Ventilation Scheme is without artificial ventilation so following Table
Volume of Enclosure & Ventilation De rating Factor (K6)
cross Section area of
Indoors ( Panel is Indoors ( Panel is
Bus bar/Total Bus Bar Outdoor
well Ventilated) Poorly Ventilated)
Area
0% 0.95 0.85 0.65
1% 0.95 0.85 0.65
5% 0.9 0.7 0.6
10% 0.85 0.65 0.5

(7) Proxy Effect De rating Factor (K7)
Bus bar Phase Spacing (p) is 400mm.
Bus bar Width (e) is 75mm and Space between each bus of Phase is 75mm so
Total Bus length of Phase with spacing =75+75+75+75+75=225mm
Bus bar Phase Spacing (p) / Total Bus length of Phase with spacing
https://electricalnotes.wordpress.com/2014/08/05/paneldesigncalculatesizeofbusbar/ = 400 / 225 =2 3/12
Bus bar Phase Spacing (p) / Total Bus length of Phase with spacing = 400 / 225 =2
From following Table De rating factor is 0.82
De rating
Proxy Effect (K7):
Factor
1 0.82
2 0.82
3 0.82
4 0.89
5 0.95
6 0.99
7 1

(8) Altitude of Bus Bar installation De rating Factor (K8)
Altitude of Panel Installation on Site is 2000 meter so following Table
Altitude of installation site (Meter) De rating
(K8) Factor
2200 0.88
2400 0.87
2500 0.86
2700 0.85
2900 0.84
3000 0.83
3300 0.82
3500 0.81
4000 0.78
4500 0.76
5000 0.74
Total De rating Factor= K1XK2XK3Xk4Xk5Xk6Xk7Xk8
Total De rating Factor =1.83x1x1x0.8×0.9×0.95×0.82×0.88
Total De rating Factor =0.90
(2) Bus bar Size Calculation:
Desire Current Rating of Bus bar (I2) =630 Amp
Current Rating of Bus bar after De rating Factor (I1)= I2 X De rating Factor or I2 / De rating Factor
Current Rating of Bus bar after De rating Factor (I1)=630×0.9
Current Rating of Bus bar after De rating Factor (I1)=697Amp
Bus bar Cross Section Area as per Current= Current Rating of Bus bar / Current Density of Material
Bus bar Cross Section Area as per Current= 697 / 1.6
Bus bar Cross Section Area as per Current= 436 Sq.mm
Bus bar Cross Section Area as per Short Circuit= Isc X√ ((K/( θtx100)x(1+ α20xθ) xt
Bus bar Cross Section Area as per Short Circuit= 50000X√ ((1.166/( 100×100)x(1+ 0.00403×85) x1
Bus bar Cross Section Area as per Short Circuit=626 Sq.mm
Select Higher Size for Bus bar Cross section area between 436 Sq.mm and 626 Sq.mm
Final Calculated Bus Bar Cross Section Area =626 Sq.mm
Actual Selected Bus bar size is 75×10=750 Sq.mm
We have select 2 No’s of Bus bar per Phase hence.
Actual Bus bar cross section Area per Phase =750×2= 1500 Sq.mm
Actual Bus bar cross section Area per Phase =750×2= 1500 Sq.mm
Actual Cross Section Area of Bus bar =1500 Sq.mm
Actual Bus bar Size is Less than calculated Bus bar size.
(3) Forces generated on Bus Bar due to Short Circuit Current
Peak electro‑magnetic forces between phase conductors (F1) = 2X(l/d)X(2.5xIsc)2/100000000
Total width of Bus bar per Phase(w)=75+75+75=225mm =2.25cm
Bus bar Phase to Phase Distance (d)=400+225=625mm=6.25cm
Peak electro‑magnetic forces between phase conductors (F1) =2x(50/63)x(2.5×50000)2/100000000
Peak electro‑magnetic forces between phase conductors (F1)=250 Kg /cm2
Peak electro‑magnetic forces between phase conductors (F1)=2.5 Kg /mm2
Actual Forces at the head of the Supports or Bus Bar (F)=F1X(H+h/H)
Actual Forces at the head of the Supports or Bus Bar (F)=2.5x(100+5/100)
Actual Forces at the head of the Supports or Bus Bar (F)= 3 Kg /mm2
Permissible Strength of Insulator (F’) is 10 Kg/mm2
Actual Forces at the head of the Supports or Bus Bar is less than Permissible Strength
Forces on Insulation is in within Limits
(4) Mechanical strength of the bus bars
Mechanical strength of the bus bars=(F1X i /12)x(1/ Modulus of inertia of a bus bar )
Value of Modulus of inertia of a bus bar or of a set of bus bars (i/v)
No of Bus Strip per Phase Vertical Bus Bar (cm3) Horizontal Bus Bar (cm3)
1 1.66 16.66
2 14.45 33.33
3 33 50

From above table Value of Modulus of inertia of a bus bar=14.45
Mechanical strength of the bus bars=(250×50/12)X(1/14.45)
Mechanical strength of the bus bars= 72 Kg/cm2
Mechanical strength of the bus bars= 0.72 Kg/mm2
Permissible Bus bar Strength is 12 Kg/mm2
Actual Mechanical Strength is less than Permissible Strength
Mechanical strength of Bus bar is in within Limit
(5) Temperature Rise Calculation
Specified Maximum Temperature Rise (T1) is 35°c
Calculated Maximum Temperature Rise (T2)=T/(log(I1/I2)1.64)
Calculated Maximum Temperature Rise (T2)=35/(Log(697/630)1.64)
Calculated Maximum Temperature Rise (T2)= 30°c
Calculated Bus bar Temperature rise is less than Specified Max Temperature rise
Temperature Rise is in within Limit
Results:
Size of Bus bar = 2No’s 75x10mm per Phase.
Total No of Feeder =3 No’s
Total No’s of Bus bar = 6 No’s 75x10mm for Phase and 1No’s 75x10mm for Neutral.
Forces at the head of the Supports or Bus Bar (F)= 3kg/mm2
Mechanical strength of the bus bars= 0.7 Kg/mm2
Maximum Temperature Rise=30°c
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About Jignesh.Parmar
Jignesh Parmar has completed M.Tech (Power System Control), B.E(Electrical) from Gujarat University. He has more than 13 years
experience in Power Transmission‑Power Distribution‑Electrical energy theft detection‑Electrical Maintenance‑Electrical
Projects(Planning‑Designing‑coordination‑Execution). He is Presently associate with one of the leading business group as a Deputy
Manager at Ahmedabad,India. He is Freelancer Programmer of Advance Excel and design useful Excel Sheets of Electrical
Engineering as per IS,NEC,IEC,IEEE codes. He is technical Author for ʺElectrical Mirrorʺ and ʺElectrical Indiaʺ Magazines. He is
Technical Blogger and Familiar with English, Hindi, Gujarati, French languages. He wants to Share his experience & knowledge and
help technical enthusiasts to find suitable solutions and updating themselves on various Engineering Topics.
57 Responses to Panel Design & Calculate Size of Bus bar
Felix Jr San Buenaventura says:
August 7, 2014 at 5:41 am
THIS IS GOOD REFERENCE FOR LV AND MV SWGR. DESIGNERS.
Reply
atmakur murali Krishna says:
August 7, 2014 at 11:06 am
Extremely useful information
Reply
Reply
RAMACHANDRAN S says:
August 14, 2014 at 3:43 am
Thank u for this useful information.Great
Reply
ganapathy sadayan says:
September 13, 2014 at 3:08 am
Hi, Mr. Jignesh Parmar,
The above information is really useful for us who ever doing the design and selection of busbar for panel engineering.
Thanks for this information, kindly share electrical technical information to us.
Ganapathy.
Reply
Ibrahim says:
October 27, 2014 at 5:46 am
thank alot for this valuable information however, I notice that you are considering derating factor for busbar calcualtion is 0.9
then after derating current rating shall be reduced but in your calculation it is increasing. can you please explain why it is so or it
is only a typing mistake.
Reply
P S N RAJU says:
December 21, 2015 at 11:33 am
CAN I USE HALF GRADE COPPER BUS BAR 15X100 MM FOR 2500AMPS AC 50HZ
Reply
karan says:
November 20, 2014 at 11:51 am
thank u sir, for this information
Reply
P.Ramesh kanna says:
November 21, 2014 at 1:33 pm
useful information
Reply
Hitesh parikh says:
November 24, 2014 at 6:39 am
Dear sir,
This information very much use to new design Engineer.
Hitesh parikh
Design Engineer in MV SWGR company
Reply
Biswanath Hazra says:
Truly useful. Thanks for sharing.
Reply
indrajit says:
Dear Sir,
thanks for your above article, I also want the same type of calculation for Earthing bus bar(Conductor) for electrical panel.
Reply
Daa says:
December 11, 2014 at 1:20 pm
Thanks Sir,
I need more elaboration on the temperature rise calculation. I am not able to get the answer 30 in the given example. Deg cel with
the given formula. My T1= 40 Deg cel, I1= 4055 Amp, I2= 4000 Amp , T2= ?
: Calculated Maximum Temperature Rise (T2)=35/(Log(697/630)1.64)
: Calculated Maximum Temperature Rise (T2)=35/(Log(697/630)1.64)
Pl help,
Thx,
Daa
Reply
Faizal Ruzley says:
Good Info,
Thanks for detail and calculation,good for RMU and CSU design.
Reply
phaneendra kumar says:
Thank you for your information.I am doing Air core reactor designs myself.I know the temperature rise of the conductor.It is
R&D ..I am not geing Economical Designs…They are going very large size for smaller current and impedance… Will you pleas
help to do learn reactor design….I am doing this research my self from last one year..
Reply
Vinodkumar says:
Dear Sir,
Very use ful information you have given to us. Thank you . I have one doubt . Can you please tell me why we choose 2nos of
75X10 bus bar for each phase when one is enough for the Isc rating. Is there anything else we have to know.
Reply
Nani says:
sir,
i want to learn more from u……
Reply
Paulraj says:
January 28, 2015 at 5:46 am
Ji,
Let me know the factors reference for PVC sleeve & ma black painted busbar.
Reply
Chaakis Zacharias says:
February 3, 2015 at 9:05 am
hi,
nice info indeed.
i’d also like to know how you chose the above bus bar size and please post the board with the bus bar dimensions.
thanks
Reply
rajeev says:
February 19, 2015 at 4:59 pm
thank
you sir
Reply
mourad says:
March 8, 2015 at 3:50 pm
Thanks a lot brother
Reply
vipin khandelwal says:
March 8, 2015 at 6:28 pm
Hello Sir,
Thanks for the information but I have one doubt . Can you please tell me why we choose 2 nos of 75X10 bus bar for each phase 8/12
https://electricalnotes.wordpress.com/2014/08/05/paneldesigncalculatesizeofbusbar/
Thanks for the information but I have one doubt . Can you please tell me why we choose 2 nos of 75X10 bus bar for each phase
when one is enough for the Isc rating. Is there anything else we have to know.
Which standard reference you have considered ?
Thanks,
Vipin
Reply
eqsgroups says:
April 2, 2015 at 6:45 am
Dear Sir,
Please provide following information given below‑
1‑ How to select Al Bus bar (Info of Al Bus bar Material )
2‑How to compare Al and Cu Bus bar to select for same rating.
3‑Any thumb rule is there to select bus bar size quickly.
4‑Please provide bus bar selection chart for AL and Cu Both.
5‑How to select no, of Bus bar per phase.
Reply
Subhadeep Banerjee says:
April 3, 2015 at 4:04 pm
Thank u sir, this will help me a lot in my field of job…
Reply
Girisha CD says:
April 25, 2015 at 4:57 am
Very Usefull document….
Reply
ron says:
May 14, 2015 at 3:54 pm
Power distribution load centers generally have 2 methods of current supply. Source current is either introduced at one end of the
bus (top fed) with branch circuit loads distributed through taps and over‑current devices along the bus. Many smaller capacity
load centers (100‑225 amperes) have current supplied through a main breaker connected to the mid‑section of a bus. How is bus
design affected with a center fed approach as opposed to a top fed approach? Did your calculation assume the top fed design
approach? Thank you
Reply
K. Sivakumar says:
May 14, 2015 at 4:20 pm
Can you refer to relevant IS/IEEE/IEC Standard that you followed for these calculations? You may mail me at:
“[email protected]”
Reply
sandeep tawade says:
June 17, 2015 at 9:31 am
can provide bus bar size calculation for 3sec
Reply
dinesh says:
June 24, 2015 at 4:58 am
hello sir i have 63 A mcb 24 nos out going. so what would be a main incommer.
Reply
rahul says:
June 25, 2015 at 2:00 pm
Very thankful to you
Dear Sir,
Please provide following information given below‑
1‑ How to select Al Bus bar (Info of Al Bus bar Material )
2‑How to compare Al and Cu Bus bar to select for same rating.
3‑Any thumb rule is there to select bus bar size quickly.
4‑Please provide bus bar selection chart for AL and Cu Both.
5‑How to select no, of Bus bar per phase.
Reply
Reply
Zee says:
July 2, 2015 at 11:04 am
Jignesh .Parmar,
Its a blessing that you are maintaining this site……
Reply
TranMinh says:
July 8, 2015 at 2:15 pm
Someone explains to me: Number of Bus Bar Strip per Phase (K1)..What is bus bar strip
Reply
Mahesh says:
July 9, 2015 at 3:15 pm
Please tell me what is the formula for determine MCCB maximum working temperature..?
Reply
Mushtaq Ahmad says:
August 24, 2015 at 7:30 am
Thanks a lot for sharing such a useful article
Reply
Nandarathana says:
August 26, 2015 at 9:27 am
Dear Sir,
Please explain why did u take 50 deg. C as ambient temperature? Is it actual ambient temperature of seled value after
temperature has risen due to heat emied?
Thanks
Reply
BAMBANG Yuwono says:
Thankyou for all your usefull refference. And 1 question Ihave small power plant with 1 set 500 kva cat,365 kva cat, n 100 kva
cummin eng I want to built synchronize both of thre genset for safe operation and load sharing….best regard Bambaang
Yuwono.
Reply
Ramesh says:
October 23, 2015 at 9:31 am
Dear Sir,
I want to design a Bus bar of rating 700V, 130A DC supply , then what is thinkness of bus bar size when it is a copper material
Reply
BAMBANG yu says:
Thankyou for all your usefull refference. And 1 question Ihave small power plant with 1 set 500 kva cat,365 kva cat, n 100 kva
cummin eng I want to built synchronize both of thre genset for safe operation and load sharing….best regard Bambaang
Yuwono.
Reply
Ravindra says:
how to select busbar as per rating changes of panel… for eg.. 1000A ACB, 2500A ACB … WHICH SIZE OF BUSBAR
WE HAVE SELECT
Reply
Nur.Md.Badsha says:
Please let me know about I/d(50/63) for F1
N.M.badsha
Electrical & Electronic Engineer,KUET
Experience on power Distribution,pharmaceutical,Food & Beverage Production Machineries.
Reply
Reply
Rajan says:
Hi – is there any reference document to substantiate the consideration of current density 1.6A/mm2
Reply
abhinav shukla says:
thank you sir for sharing your valuable knowledge
Reply
S.Selvam says:
Sir,
Pl.provide us design calculation for AMF Panel bus bar size – Both three phases & one neutral ,we have three DG Set which are
500KVA each and controlled by 800A / 1600A ACB with protection
Reply
gulshad khan says:
March 8, 2016 at 7:07 am
MD GULSHAD KHAN
IT IS A VERY USEFUL CALCULATION FOR SELECTING THE BUSBAR
Reply
NAGA CHAITANYA VEMURI says:
March 14, 2016 at 6:02 am
can you please clarify me, for HIGH RISE Buildings , Bus bars are used instead of only using armored cables . Is this because of
economical factor or any technical advantage is there.?
Reply
Amita says:
May 1, 2016 at 11:13 am
Tanks, it is very useful
If it is possible for you, please tell us about your standard or document reference.
Best regards.
Reply
zillur rahman says:
May 25, 2016 at 8:19 am
can i use half grade copper bus bar for 1000amps cos formula
Reply
Papoo Sankaran says:
May 26, 2016 at 5:47 pm
Greetings to you Mr.Jignesh Parmar.
You are doing a great service yo practicing engineers.After all, teaching is a noble way of serving the people.
Reply
zillur rahman says:
May 28, 2016 at 10:01 am
can iuse half grade copper bas bar 500&1000amps change over switch formula?
Reply
SUNNY KUMAR says:
June 13, 2016 at 5:07 am
thanks for this useful information. which standards are applicable to this calculation.
Reply
amitkumar says:
June 15, 2016 at 8:47 am
Thanks for bus bar information
Reply
Papoo Sankaran says:
June 17, 2016 at 9:05 am
June 17, 2016 at 9:05 am
Item(6) De‑rating Factor K6:
Area of Busbar is mentioned as Width x Thickness x Length.x No.of busbars. How can the product of these three dimensions be
“area”, it can be only “volume”; Please clarify.
Reply
lohit says:
July 5, 2016 at 5:17 am
thanks for the information
Reply
Vasu says:
July 8, 2016 at 10:41 am
you want panel board design for LT switchgear & current rating busbar calculation (copper & Aluminium)
Reply
Sonia says:
July 14, 2016 at 1:02 pm
According to which IEC standard is performed this calculation?
Reply
Rohith says:
August 22, 2016 at 5:56 am
any one knows how to find bus bar size with a only amps rating. because i dont know about the bus bar size mean, how could i
find the bus bar rating with a only amps. any one know the formulas ?????
Reply
Palwe Babasaheb says:
August 31, 2016 at 9:14 am
it will be gr8 if you provide backup sheet (All table source))for above calculations.
Reply
D.VAMSI KRISHNA says:
September 5, 2016 at 7:06 pm
thnks for the information sir,, can you post a quick thumb rule to check the size of busbar with respect to CB used (ex.800A
MCCB/ACB etc)
Reply
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