1 bimetal technology-contact busway

Copper Contact Busway

SBGMar 2011Rev 6.2

- New Copper Solution

Schneider Electric 2- SBG – Exp – CCB rev6.2 - Mar 2011

General Introduction

Schneider Electric 3- SBG – Export – May 2010

Background of Aluminum

● Unlike Oil and Copper (limited resource), Aluminum is the most abundant (8%) metallic element, the 3rd most abundant of all elements (after oxygen and silicon)

● Aluminum is a good thermal and electrical conductor, by weight better than copper (65% of conductivity by volume, 50% by weight)

● Price of aluminum more stable than copper - 100% increase over past 5 years, compared with 300% increase of copper!


Problems of traditional aluminum busway (1)

● Aluminum oxide (alumina or aloxite) forms when the metal exposed to air, responsible for metallic aluminum’s resistance to weathering. Therefore an electrical insulator (overheat).

● Fretting corrosion happens at contact between PIU jaw and busbar(Fretting corrosion refers to corrosion damage at the asperities of contact

surfaces. This damage occurs under load and in the presence of repeated relative surface motion, as often induced by vibration).


Problems of traditional aluminum busway (2)

● Fretting corrosion results from:● Contact between busbar and PIU jaw under load● Vibration (50Hz)● Repeated relative motion ● Deformation on surface (hardness aluminum << copper)

● Fretting corrosion results in:● Silver/tin plating and small fragments of aluminum removed, oxidation forms, build-

up of oxide residue (insulator) ● Contact pressure drops, increasing temperature, increasing resistance● Failure (explosion) happens at the contact● More critical on IEC than UL busway because smaller allowable conductor cross

section (higher current density)


Our solution: Copper Contact (laminated bimetal)●Silver plated bimetal plate cladding on

aluminum conductor at all connection contacts, through high current and high pressure● Outer contact surface of the connection plate is

silver-plated copper, the inside surface is Aluminum

● All of busway connection zone are silver to silver contact

● Copper placed only at where it is required… at contacts

● Fretting corrosion does not happen as hardness of copper is much higher than aluminum

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Copper Contact Busway Offers● Medium Power (100A-800A) : Canalis KSA● High Power (800A-5000A): I-LINE II BFC

Canalis KSA (100A - 800A) Canalis KT/KHF more than 20 years

I-LINE BFC (800A - 5000A) - new

● More than 30 years application experience in Europe● 26 millions meters installed worldwide

● 9 millions of energized joint packs● 9 millions of energized plug-in units

● Laminated Bimetal Technology introduced to High Power I-LINE II series from Medium Power Canalis series

20 yearsMore than30 years


Advantages of



A safer, more reliable and economical solution

●Safety and Reliability – thanks to the laminated bimetal technology, copper contact solution removes all doubts and uncertainties of past experience on application of aluminum for power distribution

●Durability – service life of copper contact busway is longer than aluminum busway, and matches that of copper busway

●Economical – copper contact busway retains many features of copper busway, yet far more economical and price stable than copper busway

Aluminum Copper Contact Copper

safety and reliability level (IEC range)


service life level (IEC range)


price level (IEC range)


Green and Environmental Friendly

●Reduce pollution – pollution during plating process reduced by 95%. Silver plating applied at only contact areas instead of entire length of conductor.

●RoHS compliant - eliminate the use of hazardous substances and reduce the pollution*RoHS (Restriction of Hazardous Substances) directive restricts the use of some hazardous materials (like Lead, Mercury, Cadmium andHexavalent chromium etc), firstly implemented in EU in 2006, andsimilar directives are introduced in Asia.

● The insulation material is halogen free and no toxic emission in case of fire (DuPont Mylar)

● Product at end of service life can be recycled● insulation easily separated from busbar● Bimetal clads removable from busbar

RoHS Compliant

Green


Energy Efficiency

●Achieved Green Leaf Energy Efficiency mark by Intertek, an equivalent level of Energy Star / LEED.

●Schneider Electric is conservative on optimisation of cross section, which is designed in such a way that no additional cooling (e.g. cooling fins) required on housing. Busway serving the purpose of electrical distribution

●Resistance and power consumption is lower than the industrial average.


Lower contact resistance

●Silver- silver contact reduces the contact resistance

● The thermal imaging test shows the temperature of the connection plate is far lower than the temperature of cable when running at full load

4.5%38.31Ni-Cu alloy

15%11.49Pure tin

61.8%2.901100 aluminum

100%1.722# pure copper

105%1.642# pure silver

Conductivity (IACS)Resistance（m）


All features and benefits of

I-Line and Canalisretained!!!


SEISMIC COMPLIANCE

Schneider Busway System passed the seismic tests and complies with Zone-4, most severe, seismic requirements


Seismic compliance

●Full range of standard products of I-Line and Canalistested and certified to UBC zone 4, more severe, condition

●Tests carried out in EERTC (Earthquake Engineering Research & Test Centre), witnessed and results agreed by seismic experts of Shimizu Corporation Japan

●Both mechanical (bending and twisting) and dynamictests (simulation of several historical earthquakes including Kobe Japan 1995, Ojiya Japan 2004, El Centro USA 1940, Building ConstructionWave Japan) performed and passed●Learning points achieved on recommendation of

supports – consult factory for further info


Full 14 type tests in

IEC60439-1/2 ed.3.1 2005


14 type tests in IEC 60439-2 ed.3.1: 2005

Note:

1) Edition 3.1 2005, 8.2.9 requires the glow-wire test at a temperature of 960C instead of 850C in Edition 3.0 2000

2) Edition 3.1 2005, 8.2.4 has more clear regulation that the resistance phase to PE measured after the short circuit withstand test shall not exceed by more than 10% the value before test. Ed.3.0 ask to compare the resistance before and after the test as indication in the remark.

3) 8.2.11 is not applicable


3 fire-related type tests (IEC60439-1/2)

● 8.2.9 - Verification of the resistance of insulating materials to abnormal heat and fire

● Purpose and importance of this test● To verify the insulating material of busway will not burn or cause the burning when affected by abnormal heat or by fire with the degree of 9600C (the insulating material need to retain current-carrying parts) or 6500C(other than former material).

● Test arrangement● Use glow-wire to approach the sample, the duration is 30 seconds. There shall be no obvious and continuous flame or the flame shall extinguish within 30 seconds when moving away the glow-wire.



● 8.2.14 - Verification of resistance to flame-propagation

● Purpose and importance of this test● To verify the resistance to flame propagation. The fire resistant busway helps to prevent the flame propagation and fire spread, save time for people to run away from the fire

● Test arrangement● Three standard busbar trunking units of the same type are placed at regular intervals on a vertical ladder into a fire test rig; every busbar trunking shall present a different side orientation to the burner flame impact. After burning has ceased, the busbar trunking enclosures should be wiped clean. All soot is to be ignored if, when wiped off, the original surface is undamaged. If it does not ignite or the maximum extent of the charred portion (external or internal) of the busbar trunking has not reached a height exceeding 2.5m above the bottom edge of the burner, the system is deemed has having passed the test.



● 8.2.15 - Verification of fire resistance in building penetrations

● Purpose and importance of this test● Verify the fire resistance in building penetration. The fire resistant busway can resist the smoke spread and penetration; prevent the further spread of fire, save time for people to run away from the fire. Suitable for the busway designed to prevent the spread of fire with specified time (60min, 120min, 180min, 240min)● Test is performed according to ISO834

● Test arrangement● A representative busbar trunking fire-proof unit sample shall be mounted as used in building practice on a test floor, made of concrete. A fire seal shall be used to fill the void around the busbar trunking enclosure passing through the hole of the test floor. When performing the test, a set of thermocouples shall be located on the unexposed side of the sample to record the surface temperatures of the busbar trunking enclosure ● Required no smoke & temperature rise on unexposed surface couldn’t exceed 180K (Maximum) and 140K (Average)


KEMA KEUR and

ASTA Diamond(1)

listed

(1) ASTA Diamond license being approved by ASTA


KEMA KEUR and ASTA Diamond●Full range of I-Line and Canalis carries KEMA KEUR and

ASTA Diamond safety marks

●A product carrying the marks is ensured by KEMA / ASTA that it is safe and is produced identical to those originally tested. Product and production location under surveillanceof KEMA / ASTA

●Critical for busway than other electrical product as semi-standard, variety of lengths

●General KEMA or ASTA type test is a one-time test on a single specimen of sample. KEMA or ASTA is not responsible for the conformity of the production with the specimen tested. No safety marks

●Full type tests in accordance with latest (2005) IEC version


Mylar® Insulation


Mylar® insulation

●Mylar®, sourced from USA/Europe, is a registered brand of Dupont, so popular and widely used that it is regarded as one category of insulation material (Coca-Cola = Coke)

●Over 40+ years of installation of I-Line and Canalis still in use. Quality and performance guaranteed by BOTH Schneider Electric and Dupont

●Properties and performance controlled by Dupont, not played around at busbar factory

●Environmentally friendly, detachable and recyclable after service life

●Halogen free and self-extinguished. IEC60439-1/2, 8.2.9 is a dedicated test “Verification of the resistance of insulating materials to abnormal heat and fire”


Epoxy insulation (1)

●Epoxy is not a brand but a type of material - insulation is the most critical material for sandwich busway (c.f. engine for aircraft)

●1 layer. “pin hole” is common with epoxy technology, covered by PVC/PET tapes

●Not recommended by IEC60439-2:"7.4.2.1 Protection by insulation of live parts

.… NOTE Examples are electrical components embedded in insulation,cables. Paints, varnishes, lacquers and similar products alone are generally not considered to provide an adequate insulation for protection against electric shock in normal service.“

● For sandwich type busway, there is no air between the conductors, meaning epoxy or mylar are used as a primary insulation. Since Epoxy belongs to the family mentioned in the "NOTE" of IEC60439, IEC recommends not to use this

● Schneider Electric uses a lot of epoxy for a lot of electrical equipment, but only as a secondary insulation (primary insulation can be air between conductors)

●Non recyclable, non environmentally friendly


Epoxy insulation (2)

●Special service condition (on specification of a world-leading, epoxy-pioneered busway manufacturer in USA)


Complete Schneider Electric Solutionfrom

transformer to sub main distribution,fully coordinated using our

ACB and MCCB


Complete Schneider Electric Solution

Trihal transformerI-Line-Trihal transformer tap

RM6 + T200IRemote control modular cubicles

PrismaBlokset

Okken NSX Circuit Breaker

Busway Plug-in unit equipped with Power Meter


Major Project Referencesof



More than 30 years application experience worldwide● The Molecular fusion technology is applied on the busway of

which amp rating more than 250A● In Europe, 90% high power busway utilize Molecular fusion

technology.


Nord Villepinte Convention center

●Project Name: Nord Villepinte Convention center

● Location : North Paris

●Area: 210,000m2

●General information: one of the biggest exhibition centers in Europe. Schneider copper contact busway have been installed and operated for more than 25 years.

●Completion date: 1982 December

●Scheme: double fishbone

●Maximum capacity: 3200A

●Single run: 183 meter


Moscow Ostankino Tower●Project Name: Moscow Ostankino tower

● Location : Moscow

●General information: tallest TV tower in Europe, the biggest swing is more than 20 meters. In the year 2000, Aug, a serious fire accident occurred because of the cable overload. From that day on, they all use Schneider new copper contact busway.

●Completion date: 2002, September

●Scheme: double main trunking

●Maximum capacity: 1600A

● Total length: 540 meter (270m x 2)