Flexible insulated busbars consist of several layers of uncoated or tinned copper strips and are insulated with highly flexible PVC compound with extrusion technology. They are excellently suitable for high current connections inside switchgears, switchboards or other electrical installations.
Technical data of electrical conductor:
Copper strips (≥99.9%Cu).
Surface: uncoated or tinned.
Electrical conductivity: ≥56Sm/mm2.
Tensile strength: ≥200N/mm2.
Technical data of insulation:
Color: black (other colors are also possible on request).
Shore hardness: A70-80.
Electrical strength: ≥23kV/mm.
Oxygen index: 30%.
Flame retardant; self-extinguishing.
Elasticity: ≥180% after 7-day aging-test with 135℃.
Tensile strength: ≥20MPa.
Technical data of flexible insulated busbars:
SGS certified: RoHS compliant.
Operating temperature: -30℃ to +105℃.
Voltage withstand performance wiith 15min / 50Hz AC: between flexible insulated busbar and earth: ≥15kV; between two flexible insulated busbars: ≥30kV.
Main features of flexible insulated busbars:
Easy assembly: it could be easily bended and fixed with hands or easy tools.
Possibility of reducing sizes of the equipment.
Lower temperature rise on the flexible insulated busbars than on normal copper bars.
High flexibility: no problem with vibrations or thermal expansions.
Application offlexible insulated busbars:
The flexibility of the bars makes it possible to install into difficult equipment or small places very easily. They can be particularly well used as connectors in switchgears and between transformers, switching devices and prefabricated power networks.
Dimensions and ampacity
Standard length: 2m or 3m (for 1-layer busbar, 25m in roll is possible).
Cross-section: up to 1200mmm2.
Ampacity: values in the table are only for reference because the actual ampacity is related to the application conditions.
We can produce pre-formed flexible insulated busbars according to customer drawings.
Guidance for selecting the correct dimensions
The ampacities are related to the cross-sections and operating ambient temperature, as shown in above table. Therefore, three factors should be considered for deciding the dimensions:
Allowed temperature-rise on the flexibars
Width of the flexibars
The temperature-rise ΔT can be calculated with formula:
ΔT=Tr – Ta
Ta: ambient temperature
Tr: temperature of bars at rated current (pay attention: for general electrical apparatus, Tr should be<105℃).
Example (just for reference):
If operating ambient temperature is 40℃, and you need ampacity 510A with bar width < 40mm, you could get allowed highest temperature-rise 65K (105℃-40℃=65K), so you could decide dimension 32×1×4. With this bar, the highest temperature-rise will be 50K with current 520A.