SWITCHGEAR

Busbar Systems
Overview
Medium voltage busbar systems consist of two general arrangements. The main switchgear distribution bus has
three busbar sets (one set per phase) which run horizontally through all the panels in a line-up. These distribution
busbars run through a dedicated chamber within each metal-enclosed panel. Segregation of busbar chambers,
between adjacent panels, is provided by using insulated through-bushings. Inside the horizontal busbar chamber of
each panel, a vertical feeder busbar system can be tapped off the main horizontal system, for incomer, feeder,
bus-coupler, bus-riser, metering or motor starter circuit.

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Ratings
The nominal current rating (Ir) of an incomer busbar system usually matches the rating of the main busbar system it
is feeding. Likewise, bus-coupler and bus-riser systems have the same current rating as the main busbar system they
are connecting. A feeder circuit busbar system has a nominal current rating to match the expected load.

The nominal current rating is determined by the cross sectional area, shape and configuration of the
individual phase bars.

The short-time withstand current rating (Ik) of the busbar system must be greater than the highest expected
symmetrical fault current at the point of installation. This rating is for a short-time withstand period of 1 or 3
seconds (tk). All busbar systems installed in the same switchgear line-up usually have the same short-time withstand
current/time rating.
The nominal voltage rating (Ur) of a busbar system must be greater than the installation's operating voltage. This
voltage rating determines the minimum phase-to-phase and phase-to-earth busbar clearances.
The nominal frequency rating (fr) of a busbar system must match the installation's operating frequency.

NOTE
The nominal current must be derated for high ambient temperatures (usually above 40 °C).
The nominal voltage and insulation ratings of a busbar system must be adjusted for altitudes over 1000
metres.

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Design
Busbar system design must consider:
 adequate minimum required clearance between phases and phase to earth
 selection of adequate busbar insulator standoffs
 bolting arrangements for continuous busbar connections
 thermal effects on busbar and insulator standoffs under normal and fault conditions
 electrodynamic forces applied to busbars and insulator standoffs under fault conditions
 avoidance of mechanical resonance under normal operating and fault conditions
Voltage ratings and clearance
IEC 62271-1 gives typical voltage ratings for busbar systems and insulator standoffs.

Typical voltage ratings and minimum clearances for busbar systems and insulator standoffs
Rated voltage Power frequency withstand Lightning impulse withstand Clearance –
voltage voltage recommended
Ur (kV) Ud (kV) Up (kV) P-P and P-E (mm)
7.2 20 60 70~90
12 28 75 120
17.5 38 95 160
24 50 125 220
36 70 170 320
Source: derived from IEC 62271-1
Current ratings and dimensions
The nominal current rating of a busbar is determined by the type of material, shape and cross sectional area of the
bar and the maximum permissible temperature rise of the material. If the busbar is carrying AC current, the
operating frequency has a slight effect on the busbar rating due to magnetic skin effect.
A busbar system has a short-time withstand current rating. The temperature rise in the event of a short circuit
condition must not exceed the thermal limits of busbar standoffs.

Typical current ratings and nominal dimensions for medium voltage busbar systems

NOTE
Dimensions should be used as a guideline only and may vary.
The dimensions stated in this table are based on bare copper at ambient temperature of 40 °C,
maximum permissible temperature rise of 50 °C, operating at 50 Hz.
Rated current Bar dimensions - Rated short-time withstand Rated short-time withstand
per phase current 1 period 1
(A) W x D (mm) Ik (kA) tk (seconds)
630 50 x 6
1250 80 x 10
1600 100 x 10 12.5/16/20/25/31.5/40/50 0.5/1/2/3
2000 100 x 6 (2 bars)
2500 100 x 10 (2 bars)
3150 100 x 3 (3 bars)
Source: current rating information is derived from IEC 62271-1
1
Most medium voltage switchgear including busbar systems have short-time withstand ratings of 16 kA, 20 kA,
25 kA or 31.5 kA for 3 seconds.

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Temperature rise
During short circuit conditions the busbar will rise in temperature, depending on the level of short circuit current and
time duration. This temperature rise must not exceed the thermal limits of any equipment in contact with the
busbar.

Maximum permissible temperature rise for bolt-connected devices, including busbars

Material and dielectric medium Maximum permissible Temperature rise
temperature (°C) above 40 °C ambient
(°C)
Bolted connection (or equivalent)
Bare copper, bare copper alloy or bare aluminium alloy
In air 90 50
In sulphur hexafluoride (SF6) 115 75
In oil 100 60
Silver or nickel coated
In air 115 75
In sulphur hexafluoride (SF6) 115 75
In oil 100 60
Tin-coated
In air 105 65
In sulphur hexafluoride (SF6) 105 65
In oil 100 60
Source: derived from IEC 62271-1

NOTE
When engaging parts with different coatings, or where one part is of bare material, the permissible
temperature and temperature rise shall be those of the surface material having the lowest permitted
value.

Electrodynamic withstand
During short circuit conditions, the peak current associated with the first loop of the fault current produces
electrodynamic forces which stress the busbar and insulator standoff supports. Stress on the busbars must not
exceed the limits of the material used. Bending forces must not exceed the mechanical limits of the insulator
standoffs.

Electrodynamic forces
Busbars (parallel) Support
Ip Ip F1
h = e2
F

F1 H
F1 l
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d
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d Distance between phases (cm) H Insulator height

l Distance between insulators on a single phase
(cm)
F1 Force on busbar centre of gravity (daN)
Ip Peak value of short circuit current (kA)
NOTE: 1 daN (dekanewton) is equal to 10 newtons.
h Distance from head of insulator to busbar
centre of gravity
F Force on head of insulator stand-off (daN)

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Resonant frequency
The busbar system must be checked for potential resonance under normal operating conditions and fault conditions.
This is done by calculating the natural resonant frequency of the system, which must meet the following criteria:
 50 Hz supply: not within the ranges 48 Hz to 52 Hz and 96 Hz to 104 Hz
 60 Hz supply: not within the ranges 58 Hz to 62 Hz and 116 Hz to 124 Hz
Calculation requirements
Busbar systems are subjected to thermal and electrodynamic stresses under normal operating conditions, but more
so under short circuit fault conditions. It is important to ensure the busbar system will function safely under all
known conditions. When checking the design, the most important considerations are the nominal operating
current, expected fault current at the point of installation, average ambient temperature and the altitude of the
installation.
To check the safety of a busbar system:
 Check that the current rating of the busbar system (Ir) exceeds the expected nominal current. Main
factors affecting the busbar rating are busbar material and configuration, ambient temperature and
maximum permissible temperature rise.
 Check the maximum expected temperature rise of the busbar during a short circuit fault. In the event of
short circuit current flow (Ith), the surface temperature of a busbar must not exceed the thermal limits of
any material coming in contact with it (ie insulator standoffs).
 Check the maximum expected electrodynamic forces imparted on the busbars and insulator standoffs, due
to the peak short circuit fault current (Idyn). Do not exceed the mechanical limitations of the material.
 Check that the busbar system will not resonate under normal operating and fault conditions.
Refer to Busbar Calculations on page 149 for calculation details and examples.

Busbar bolting arrangements

Typical busbar bolting details for single overlap copper bar

Bar width Joint Joint area Number of Metric bolt size Bolt Hole size Washer Washer
(mm) overlap (mm2) bolts1 (coarse thread) torque (mm) diameter thickness
(mm) (Nm) (mm) (mm)
16 32 512 2 M6 7.27 14 1.8
20 40 800 2 M6 7.27 14 1.8
25 60 1500 2 M8 1710 21 2
30 60 1800 2 M8 1710 21 2
40 70 2800 2 M10 28
11.5 24 2.2
50 70 3500 2 M12 4514 28 2.7
60 60 3600 4 M10 28
11.5 24 2.2
80 80 6400 4 M12 4514 28 2.7
100 100 10000 5 M12 4515 28 2.7
120 120 14400 5 M12 4515 28 2.7
160 160 25600 6 M16 9120 28 2.7
200 200 40000 8 M16 9120 28 2.7
Source: Copper for Busbars http://www.copperinfo.co.uk/busbars/pub22-copper-for-busbars/homepage.shtml
1
Number of bolts based on using high-tensile steel or bronze (CW307G, formerly C104)

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