Busbar size and calculation

Busbar

Bus bar 

A bus bar (also spelled busbar, buss bar or busbar), is a strip or bar of copper, brass or aluminum that cond
Busbars are typically either flat strips or hollow tubes as these shapes allow heat to dissipate more efficient
A busbar may either be supported on insulators, or else insulation may completely surround it. Busbars are
Busbars may be connected to each other and to electrical apparatus by bolted, clamp, or welded connection
Busbars are typically contained inside switchgear, panel boards, or busway. Distribution boards split the el
Advantag
es
Following are some advantages of Bus bar trunking system over normal cabling system:-
1.      On-site installation times are reduced compared to hard-wired systems, thus leading to cost savings.
2.      It provides increased flexibility in design and versatility with regard to future modifications.
3.      Greater safety and peace of mind for specifiers, contractors and end-users.
4.      Because of the simplicity of busbar, it is easy to estimate costs from the design/estimating stage throug
5.      It is short sighted to compare the cost of busbar against that of a length of cable — and not the real cos
6.      Distribution busbar distributes power along its length through tap-off points along the busbar at typical
7.      Installed vertically the same systems can be used for rising-mains applications, with tap-offs feeding in
8.      Very compact so provides space savings.
9.      Where aesthetics have to be considered, busbar trunking can be installed with natural galvanized, alum
10.  Busbar trunking has several key advantages over conventional forms of power distribution including: -
11.  (a) Reduced, onsite installation times when compared to hard-wired systems thus leading to cost saving
a.       Increased flexibility in design and versatility with regard to future modifications.
b.      Increased safety features brought about by the use of high quality, manufactured components, which p
12.  Uneven distribution of current takes place where multiple runs of cables are used in parallel.
13.  Busbar trunking has tap-off points at regular intervals along each length to allow power to be taken off
14.  For higher ratings of power distribution we need to have multiple runs of cable. In such conditions unb
15.  When multiple runs of cables are used it often leads to improper end connections thereby causing overh
Current carrying capacity
The current-carrying capacity of a busbar is usually determined by the maximum temperature at which the
BS 159 stipulates a maximum temperature rise of 50°C above a 24 hour mean ambient temperature of up to
ANSI C37.20 alternatively permits a temperature rise of 65°C above a maximum ambient of 40°C, provide
A very approximate method of estimating the current carrying capacity of a copper busbar is to assume a cu
The more popular thumb rule being followed in India is to assume current density of 1.0 Amps / Sq.mm fo
Standard size of bus bar
Sr. Application area Cable
 One circuit per floor. Hence for a 20-floor building,
1 Number of circuits
you need 20 circuits.

Need 1 outgoing for each circuit. Hence 20 nos.

2 Main Switchboard MCCB outgoings. Higher cost and larger space
requirement in electrical room

Using 4 core cables, and considering 1 cable per

3 Shaft Size feeder, you need 20 cables on the lowest floor. Large
space required for cables/ cable tray.

The high concentration of insulating materials used

4 Fire & safety in cables and conductors involves a very high level
of combustive energy.

load on any floor exceeds initial plan, owner has to

5 Future expansion run an additional cable from a spare feeder on main
board to that floor.

6 Fault withstand levels Limited by conductor size of each circuit.

7 Installation time Much longer

High impedance if you choose cable size based on

8 Voltage drop
each floor current rating.

Busbars Reduce System Costs

A laminated busbar will lower manufacturing costs by decreasing assembly time as well as internal materia
Bus bars Improve Reliability
Laminated bus bars can help your organization build quality into processes. The reduction of wiring errors
Bus bars Increase Capacitance
Increased capacitance results in decreasing characteristic impedance. This will ultimately lead to greater ef
Eliminate Wiring Errors
By replacing a standard cable harnesses with bus bars, the possibility for miss-wirings is eliminated. Wirin
Bus bars Lower Inductance
Any conductor carrying current will develop an electromagnetic field. The use of thin parallel conductors
Bus bars Lower Impedance
Increasing the capacitance and reducing the inductance is a determining factor in eliminating noise. Keepin
Bus bars Provide Denser Packaging
The use of wide, thin conductors laminated together led to decreased space requirements. Laminated bus b
Bus bars Provide Wider Variety of Interconnection Methods
The flexibility of bus bars has allowed an unlimited number of interconnection styles to choose from. Bush
Bus bars Improve Thermal Characteristics
The wide, thin conductors are favourable to allowing better airflow in systems. As package sizes decrease,
Material: The copper will be of ETP grade as per DIN 13601-2002 and with oxygen free copper.
Chemical composition: Purity of copper will be as per DIN EN 13601:2002. Copper + Silver 99.90% min.
Typical example
Rating Current: 3200Amp.
System:415Vac, TPN, 50Hz.
Fault Level: 50KA. For 1 Sec.
Operation Temp:40° C rise over 45 ° C ambient.

CONSIDERATION
Enclosure size: 1400 mm. wide X 400mm. height
Bus bar Size: 2:200x10 per Ph., 1:200x10 for Neutral.
Bus bar material: Electrolytic gr. Al. (IS 63401/AA6101)

Short Circuit Rating

-upto 400A rated current: 25KA for 1 sec.
-600 to 1000A rated current: 50KA for 1 sec.
-1250 to 2065-100KA for 1 sec.
-2500 to 50100-225KA for 1 sec.

The minimum cross section needed in sqmm for busbar in various common cases can be listed as below-

Material Fault level (KA) Withstand time

1 sec.
35 443
Aluminiu
50 633
m
65 823

35 285
Copper
 Copper 50 407
65 528

Let us select a busbar with an example:

1) Aluminium busbar for 2000A, 35 kA for 1 sec withstand – From the table the minimum cross-section n

2) Copper busbar for 2000A, 35 kA for 1 sec withstand – From the table the minimum cross-section need

Thus, by using the above formula and table, we can easily select busbars for our switchboards.

Size in mm Area sqmm Weight/ km

12X2 24 0.209

15X2 30 0.262

15X3 75 0.396

20X2 40 0.351

20X3 60 0.529

20X5 100 0.882

25X3 75 0.663

25X5 125 1.11

30X3 90 0.796

30X5 150 1.33

40X3 120 1.06

40X5 200 1.77

40X10 400 3.55

50X5 250 2.22

50X10 500 4.44

60X5 300 2.66

60X10 600 5.33
80X5 400 3.55
80X10 800 7.11
100X5 500 4.44
100X10 1000 8.89
120X10 1200 10.7
160X10 1600 14.2
200X10 2000 17.8

Temperature rise

During the short circuiting, the bus bar should be able to withstand the thermal as well as mechanical stress

T = K (I/A) 2 (1+αθ) 10-2

T=temperature rise per second
A= conductor cross section area
α = temperature coefficient of resistivity at 20 deg.C/deg.C
= 0 .00393 for copper
= 0 .00386 for aluminium
K = constant
=0.52 for copper
=1.166 for aluminium
θ = temperature of the conductor at the instant at which the temperature rise is being calculated.

Typical calculation

Rated current = 1000A

Fault current = 50KA for 1 sec
Permissible temperature rise= 40 deg.C
Busbar material =aluminium ally E91E
De-rating factor due to material =1
De-rating factor due to temperature rise =0.86
De-rating factor due to enclosure =0.75
Total de-rating factor = 1x0.75x0.86=0.66
Minimum cross section area required to withstand short circuit for 1 sec.
= (Ifc x√t
)/0.08
Where, Ifc = fault level current in KA
t= 1 second
Area A =
(50x√1

)/0.08 = 625 sqmm

Considering all de-rating factor, A = 625/0.66 =946.97
Say, cross sectional area per phase = 1000 sqmm
For neutral, cross sectional area per phase = 500 sqmm
r, brass or aluminum that conducts electricity within a switchboard, distribution board, substation, battery bank or other electrical
heat to dissipate more efficiently due to their high surface area to cross-sectional area ratio. A hollow section has higher stiffness
letely surround it. Busbars are protected from accidental contact either by a metal earthed enclosure or by elevation out of norma
d, clamp, or welded connections. Often joints between high-current bus sections have matching surfaces that are silver-plated to r
Distribution boards split the electrical supply into separate circuits at one location. Busways, or bus ducts, are long busbars with

ling system:-
hus leading to cost savings.
uture modifications.

design/estimating stage through to installation on site. This is because the technical characteristics and price of each component
f cable — and not the real cost of a cable installation to include multiple runs of cable, tray and fixing, let alone the protracted tim
ints along the busbar at typically at 0.5 or 1 m centers. Tap-off units are plugged in along the length of the busbar to supply a loa
ations, with tap-offs feeding individual floors. Certified fire barriers are available at points where the busbar passes through a flo

with natural galvanized, aluminium, or painted finish. Special colours to match switchboards or a specific colour scheme are als
power distribution including: -
ems thus leading to cost savings.

ufactured components, which provide greater safety and peace of mind for specifies, contractors and end-users.
are used in parallel.
to allow power to be taken off and distributed to where it is needed. Because it is fully self-contained it needs only to be mechan
f cable. In such conditions unbalanced distribution of current takes place and causing overheating of some cable. This is complet
nections thereby causing overheating of contacts, burning of cables ends, and is a major cause of fire. This is completely avoided

mum temperature at which the bar is permitted to operate, as defined by national and international standards such as British Stand
n ambient temperature of up to 35°C, and a peak ambient temperature of 40°C.
mum ambient of 40°C, provided that silver-plated (or acceptable alternative) bolted terminations are used. If not, a temperature ri
copper busbar is to assume a current density of 2 A/mm2 (1250 A/in2) in still air. This method should only be used to estimate a
ensity of 1.0 Amps / Sq.mm for Aluminium and 1.6 Amps for Copper for any standard rectangular conductor profile.

busbar
 Just one circuit can cover all floors.

Need only 1 outgoing for each riser. Lower cost and

size of main panel.

Typical size of 1600A riser is 185mm x 180mm.

Leads to big savings on riser shaft size, and hence
more usable floor area on every floor.

The volume of insulating materials used in trunking

is reduced to a minimum so combustive energy is
considerably lower than cables. The insulating
materials used do not release corrosive or toxic gases
in the event of a fire. Once the source of the fire is
removed, these materials are extinguished in a few
seconds so that the effect of the fire is minimised

By providing extra tap off slots on each floor at the

design stage, owner only has to procure a tap off box
and plug it in wherever additional load is required.
As the plug in can be done live, there is no shut
down required for any of the existing clients /
circuits. Future Flexibility.

Much higher – typically a 1600 A riser has a fault

withstand capability of 60 to 70 kA. Safer in an
electrical fault.

Each riser on a 20-floor building can be installed in

approximately 2 to 3 days.

Much lower impedance. Hence substantially lower

voltage drop.

time as well as internal material handling costs. Various conductors are terminated at customer specified locations to eliminate th

The reduction of wiring errors results in fewer reworks, lower service costs and lower quality costs.
will ultimately lead to greater effective signal suppression and noise elimination. Keeping the dielectrics thin and using dielectrics

s-wirings is eliminated. Wiring harnesses have high failure rates relative to bus bars, which have virtually none. These problems

use of thin parallel conductors with a thin dielectric laminated together minimizes the effect of inductance on electrical circuits. M

or in eliminating noise. Keeping the dielectric thickness to a minimum will accomplish the highly desired low impedance.

requirements. Laminated bus bars have helped decrease total system size and cost.

ion styles to choose from. Bushings, embossments, and fasten tabs are most commonly used.

ms. As package sizes decrease, the cost of removing heat from systems has greatly increased. A bus bar cannot only reduce the o
oxygen free copper.
Copper + Silver 99.90% min.

cases can be listed as below-

Withstand time
200 msec. 40 ms. 10 ms.
198 89 44
283 127 63
368 165 82

127 57 28
 182 81 41
236 106 53

le the minimum cross-section needed would be 443 mm2. Thus we can select a 100mm x 5mm busbar as the minimum cross-sec

e minimum cross-section needed would be 285 mm2. Thus we can select a 60mm x 5mm busbar as the minimum cross-section.

our switchboards.
current carrying capacity in amp ( copper ) at 35 deg.C
AC ( no. of bus) DC ( no. of bus)
I II III II II I II

110 200 115 205

140 200 145 245

170 300 175 305

185 315 190 325

220 380 225 390

295 500 300 510

270 460 275 470

350 600 355 610

315 540 320 560

400 700 410 720

420 710 430 740

520 900 530 930

760 1350 1850 2500 770 1400

630 1100 1650 2100 650 1150

920 1600 2250 3000 960 1700

760 1250 1760 2400 780 1300

1060 1900 2600 3500 1100 2000
 970 1700 2300 3000 1000 1800
1380 2300 3100 4200 1450 2600
1200 2050 2850 3500 1250 2250
1700 2800 3650 5000 1800 3200
2000 3100 4100 5700 2150 3700
2500 3900 5300 7300 2800 4800
3000 4750 6350 8800 3400 6000

mal as well as mechanical stress. When a sort circuiting takes place, the temperature rise is directly proportional to the squire of th

is being calculated.
bank or other electrical apparatus. Its main purpose is to conduct electricity, not to function as a structural member.
on has higher stiffness than a solid rod of equivalent current-carrying capacity, which allows a greater span between busbar supp
elevation out of normal reach. Power Neutral busbars may also be insulated. Earth (safety grounding) busbars are typically bare
at are silver-plated to reduce the contact resistance. At extra-high voltages (more than 300 kV) in outdoor buses, corona around t
are long busbars with a protective cover. Rather than branching the main supply at one location, they allow new circuits to branc

ce of each component are always known.

alone the protracted time and effort of pulling cables.
busbar to supply a load; this could be a sub distribution board or, in a factory, to individual machines. Tap-offs can normally be
ar passes through a floor slab. Protection devices such as fuses, switchfuses or circuit breakers are located along the busbar run, r

colour scheme are also available on request.

eds only to be mechanically mounted and electrically connected to be operational.

cable. This is completely avoided in the BTS systems.
is completely avoided in Bus Bar Trunking systems.

s such as British Standard BS 159, American Standard ANSI C37.20, etc. These standards give maximum temperature rises as w

If not, a temperature rise of 30°C is allowed.

y be used to estimate a likely size of busbar, the final size being chosen after consideration has been given to the calculation meth
ocations to eliminate the guesswork usually associated with assembly operating procedures. A reduced parts count will reduce or
n and using dielectrics with a high relative K factor will increase capacitance.

none. These problems are very costly to repair. Adding bus bars to your systems is effective insurance.

on electrical circuits. Magnetic flux cancellation is maximized when opposing potentials are laminated together. Laminated bus b

low impedance.

nnot only reduce the overall size required, but it can also improve airflow with its sleek design.
he minimum cross-section. Considering a current density of 1A/ mm 2 by considering temperature as well as skin effect, we shal

nimum cross-section. Considering a current density of 1.6A/ mm2 by considering temperature as well as skin effect, we shall req

DC ( no. of bus)
III II II

2000

1750

2500

1900 2500
2800 3600
 2500 3200
3700 4800
3150 4050
4500 5800
5200 6700
6900 9000
8500 10000

onal to the squire of the rms value of the fault current. The duration of short circuiting is very small i.e. one second till the breake
an between busbar supports in outdoor switch yards.
sbars are typically bare and bolted directly onto any metal chassis of their enclosure. Busbars may be enclosed in a metal housin
r buses, corona around the connections becomes a source of radio-frequency interference and power loss, so connection fittings d
ow new circuits to branch off anywhere along the route of the busway.

ap-offs can normally be added or removed with busbar live, eliminating production down time.
d along the busbar run, reducing the need for large distribution boards and the large quantities of distribution cables running to a

m temperature rises as well as maximum ambient temperatures.

n to the calculation methods. Refer catalogue of manufacturers.

arts count will reduce ordering, material handling and inventory costs.
gether. Laminated bus bars have been designed to reduce the proximity effect in many semiconductor applications as well as app
ll as skin effect, we shall require 4 x 100mm x 5mm busbars for this case.

skin effect, we shall require 4 x 60mm x 5mm busbars for this case.
one second till the breakers opens and clears the fault. The heat dissipation through convection and radiation during this short dur
closed in a metal housing, in the form of bus duct or busway, segregated-phase bus, or isolated-phase bus.
s, so connection fittings designed for these voltages are used.

ution cables running to and from installed equipment.

pplications as well as applications that involve high electromagnetic interference (EMI).
ion during this short duration is negligible and all the heat is observed by the busbar itself. The temperature rise due to the fault c
ure rise due to the fault can be calculated by applying the formulae.