Busbar Design

David Chapman
Copper Development Association

david.chapman@copperdev.co.uk
Busbar Design Basics
www.leonardo-energy.org
www.cda.org.uk
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
Materials for Busbar Systems
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
www.cda.org.uk
Busbar ratings depend on:
Working and ambient temperatures
Heat lost from the busbar
by convection
by radiation
Heat generated in the busbar
www.cda.org.uk
25 . 0
25 . 1
66 . 7
v
P
cv
u
=
Power dissipated by convection is given by:
where
u is the temperature rise above ambient
v is the vertical height of the surface
P
cv1
P
cv2

v
www.cda.org.uk
Power dissipation per metre length v Vertical height
0
40
80
120
160
0 50 100 150 200
Vertical height (mm)
P
o
w
e
r

d
i
s
s
i
p
a
t
i
o
n

p
e
r

m
e
t
r
e

l
e
n
g
t
h

(
W
)
Convection (for 80 C temperature rise)
www.cda.org.uk
Power dissipated by radiation is given by:
( )
8 4
1
4
2
10 7 . 5

= T T P
r
c
where
P
r
is the power dissipated per square metre
T
2
is the working temperature, K
T
1
is the ambient temperature, K
c is the emissivity
P
r

P
r

www.cda.org.uk
The emissivity, c, 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
www.cda.org.uk
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!

www.cda.org.uk
P
r

P
r

P
r

P
r

P
r
P
r

No radiation heat loss
from internal surfaces
www.cda.org.uk
Radiation power dissipation v Working temperature
0
20
40
60
80
100
273 323 373
Absolute Working Temperature (K)
P
o
w
e
r

d
i
s
s
i
p
a
t
i
o
n

(
W

p
e
r

s
q
m
)
Radiation (for 30 C ambient)
www.cda.org.uk
for 100 mm vertical height, 30 C ambient
Total power dissipation v Working temperature
0
100
200
300
400
500
600
700
800
900
1000
40 60 80 100 120 140
Working temperature (C)
P
o
w
e
r

d
i
s
s
i
p
a
t
i
o
n

(
W

p
e
r

s
q
m
)
Convection
Radiation
Total
www.cda.org.uk
R I P
2
=
a
l
I P

2
=
The power generated by current in the busbar is:
where
is the resistivity of the material
a is the cross sectional area
l is the length
www.cda.org.uk
At some temperature, the heat generated in the
busbar is equal to the total heat lost by convection
and radiation.
| | | |
r c i
P P P + =
www.cda.org.uk
Calculation method:
1 Select working and ambient temperatures
2 Assume initial current density of 8 amps/mm
2
3 Find appropriate size in standard range
4 Calculate heat generated due to current
5 Calculate heat loss at working temperature
6 If 4>5, increase size and return to 4
When 4=<5, this is smallest possible size
Minimum size calculation
www.cda.org.uk
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
Best economic sizing
www.cda.org.uk
Cost of bar
0
5
10
15
0 100 200 300 400 500 600
Cross sectional area (sqmm)
C
o
s
t

o
f

b
a
r

p
e
r

m
e
t
r
e

(
$
)
www.cda.org.uk
Cost of losses - 5 years
0
10
20
30
0 100 200 300 400 500 600
C
o
s
t

o
f

l
o
s
s
e
s

o
v
e
r

5

y
e
a
r
s

(
$
)
www.cda.org.uk
Economic Sizing of Busbars
Total cost - 5 years
0
10
20
30
0 100 200 300 400 500 600
L
i
f
e
t
i
m
e

c
o
s
t

p
e
r

m
e
t
r
e

(
$
)
Cost of bar
Cost of loss
Total
www.cda.org.uk
Busbar calculation software
www.cda.org.uk
www.cda.org.uk
www.cda.org.uk
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
www.cda.org.uk
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
david.chapman@copperdev.co.uk

Busbar Design

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David Chapman

Copper Development Association

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