Busbar Design

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

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- 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:
7.66 θ 1.25
Pcv = 0.25
Pcv2 Pcv1 v
v
where
θ 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 50 100 150 200
Vertical height (mm)

Power dissipated by radiation is given by:
Pr
Pr = 5.7ε ( T24
− T14
) ×10 −8
Pr
where
Pr is the power dissipated per square metre
T2 is the working temperature, K
T1 is the ambient temperature, K
ε is the emissivity

The emissivity, ε, 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)
Radiation power dissipation v Working temperature
100
80
Power dissipation (W per sqm)
60
40
20
0
273 323 373
Absolute Working Temperature (K)
for 100 mm vertical height, 30 C ambient
Total power dissipation v Working temperature
1000
900 Convection
800
Power dissipation (W per sqm)
Radiation
700 Total
600
500
400
300
200
100
0
40 60 80 100 120 140
Working temperature (C)

The power generated by current in the busbar is:
2 ρl 2
P=I R P=I
a
where
ρ 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 ] + [ Pr ]

Minimum size calculation
Calculation method:
1 Select working and ambient temperatures
2 Assume initial current density of 8 amps/mm2
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

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
10
Cost of bar per metre ($)
0
0 100 200 300 400 500 600
Cross sectional area (sqmm)

Cost of losses - 5 years
30
Cost of losses over 5 years ($)
20
10
0
0 100 200 300 400 500 600

Economic Sizing of Busbars
Total cost - 5 years
30
Cost of bar
Cost of loss
Total
Lifetime cost per metre ($)
20
10
0
0 100 200 300 400 500 600

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
david.chapman@copperdev.co.uk

Busbar Design

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Busbar Design Basics

Copper Development Association

 Good thermal conductor

 Strong (at working temperature)

Copper Development Association

Busbar ratings are determined only by the

maximum desired working temperature

heat generated = heat lost

Copper Development Association

Busbar ratings depend on:

• Working and ambient temperatures

• Heat lost from the busbar

• Heat generated in the busbar

Copper Development Association

Copper Development Association

Copper Development Association

Copper Development Association

The emissivity, ε, describes how effectively

For a perfectly polished surface, the value is

For a matt black surface, the value is close to

Copper Development Association

Bright copper has an emissivity of about 0.1

During use, the emissivity of the copper

Tin plated copper has an emissivity of about

But painting bars reduces the current rating!

Copper Development Association

No radiation heat loss

Copper Development Association

Copper Development Association

Copper Development Association

At some temperature, the heat generated in the

Copper Development Association

1 Select working and ambient temperatures

2 Assume initial current density of 8 amps/mm2

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

Copper Development Association

Higher purchase cost - lower running costs

Copper Development Association

Copper Development Association

Copper Development Association

Copper Development Association

Copper Development Association

Copper Development Association

Copper Development Association

◊ harmonics generated by non-linear loads

• short circuit current

Copper Development Association

Copper Development Association

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