Busbar Design

Busbar Design Basics
David Chapman Copper Development Association david.chapman@copperdev.co.uk
Copper Development Association
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
www.leonardo-energy.org www.cda.org.uk
Busbar System Current Ratings

Busbar ratings are determined only by the maximum desired working temperature
At working temperature: heat generated = heat lost


Busbar ratings depend on: Working and ambient temperatures Heat lost from the busbar by convection by radiation Heat generated in the busbar


Power dissipated by convection is given by:
1.25
Pcv2 Pcv1 v
7.66 U Pcv ! 0.25 v
where U is the temperature rise above ambient v is the vertical height of the surface


Convection (for 80 C temperature rise)
Power dissipation per metre length v Vertical height 160 Power dissipation per metre length (W)
120
80
40
0 0 50 100 Vertical height (mm) 150 200


Power dissipated by radiation is given by:
Pr
Pr ! 5.7I
4 T2
4 T1
v10
8
Pr
where Pr is the power dissipated per square metre T2 is the working temperature, K T1 is the ambient temperature, K I is the emissivity

The emissivity, I, describes how effectively the surface radiates heat For a perfectly polished surface, the value is close to zero - a very poor radiator For a matt black surface, the value is close to 1 - a very good radiator


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!

Pr Pr
Pr
Pr
Pr
Pr
No radiation heat loss from internal surfaces


Radiation (for 30 C ambient)
Ra iation po er issipation v orkin temperature
o er issipation (
per sqm)
73
3 3 Absolute orkin Temperature (K)
373


for 100 mm vertical height, 30 C ambient
Total power dissipation v Working temperature
1000 900 Power dissipation (W per sqm) 800 700 600 500 400 300 200 100 0 40 60 80 100 120 140 Working temperature (C)
Convection Radiation Total


The power generated by current in the busbar is:
P!I R
where
Vl P!I a
2
V is the resistivity of the material
a is the cross sectional area l is the length


At some temperature, the heat generated in the busbar is equal to the total heat lost by convection and radiation.
Pi ! ?Pc A ?Pr A

Minimum size calculation

Calculation method: 1 2 3 4 5 6 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


Cost of bar 15
Cost of bar per metre ($)
10
0 0 100 200 00 400 500 600 Cross sect onal area (sqmm)


Cost of losses - 5 yea s 0
Cost of losses over 5 years ($)
20
10
0 0 100 200 00 400 500 600 Cross sect onal area (sqmm)

Economic Sizing of Busbars

Total cost - 5 years 30
Cost of bar Cost of loss Total

Lifetime cost per metre ($) 20
10
0 0 100 200 300 Cross sectional area (sqmm) 400 500 600

Busbar calculation software



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 >101.5 % IACS
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
David Chapman Copper Development Association david.chapman@copperdev.co.uk

Busbar Design

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Busbar Design

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Busbar Design Basics

David Chapman Copper Development Association david.chapman@copperdev.co.uk

Copper Development Association

Materials for Busbar Systems

 Good thermal conductor

 Strong (at working temperature)

Busbar System Current Ratings

At working temperature: heat generated = heat lost

Copper Development Association

Busbar System Current Ratings

Copper Development Association

Busbar System Current Ratings

7.66 U Pcv ! 0.25 v

Copper Development Association

Busbar System Current Ratings

0 0 50 100 Vertical height (mm) 150 200

Copper Development Association

Busbar System Current Ratings

Busbar System Current Ratings

Copper Development Association

Busbar System Current Ratings

Busbar System Current Ratings

No radiation heat loss from internal surfaces

Copper Development Association

Busbar System Current Ratings

3 3 Absolute orkin Temperature (K)

Copper Development Association

Busbar System Current Ratings

Copper Development Association

Busbar System Current Ratings

V is the resistivity of the material

a is the cross sectional area l is the length

Busbar System Current Ratings

Copper Development Association

Minimum size calculation

Copper Development Association

Best economic sizing

Higher purchase cost - lower running costs

Copper Development Association

Best economic sizing

Cost of bar per metre ($)

Copper Development Association

Best economic sizing

Cost of losses over 5 years ($)

Copper Development Association

Economic Sizing of Busbars

Cost of bar Cost of loss Total

Copper Development Association

Busbar calculation software

Copper Development Association

Busbar calculation software

Copper Development Association

Busbar calculation software

Copper Development Association

thick busbars high frequencies harmonics generated by non-linear loads

short circuit current

Summary of Busbar Material Characteristics

David Chapman Copper Development Association david.chapman@copperdev.co.uk

Copper Development Association

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Good thermal conductor

Strong (at working temperature)