1 Bimetal Technology
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Copper Contact Busway
SBGMar 2011Rev 6.2
- New Copper Solution
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Schneider Electric 2- SBG Exp CCB rev6.2 - Mar 2011
General Introduction
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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 ofcopper!
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Schneider Electric 4- SBG Export May 2010
Problems of traditional aluminum busway (1)
Aluminum oxide (alumina or aloxite) forms when the metal exposed to
air, responsible for metallic aluminums 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).
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Schneider Electric 5- SBG Export May 2010
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
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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 thanaluminum
>
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7/32Schneider Electric 7- SBG Exp CCB rev6.2 - Mar 2011
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 yearsI-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 than
30 years
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Advantages
of
Copper Contact Busway
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A safer, more reliable and economical solution
Safety and Reliability thanks tothe laminated bimetal technology, copper
contact solution removes all doubts and
uncertainties of past experience onapplication of aluminum for power
distribution
Durability service life of coppercontact busway is longer than aluminum
busway, and matches that of copper
busway
Economical copper contact buswayretains many features of copper busway,
yet far more economical and price stablethan copper busway
Aluminum Copper Contact Copper
safety and reliability level (IEC range)
Aluminum Copper Contact Copper
service life level (IEC range)
Aluminum Copper Contact Copper
price level (IEC range)
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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, and
similar 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
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Schneider Electric 11- SBG Exp CCB rev6.2 - Mar 2011
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 noadditional 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.
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Schneider Electric 12- SBG Exp CCB rev6.2 - Mar 2011
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 cablewhen 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
Conductivi ty (IACS)Resistancem
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Schneider Electric 13- SBG Exp CCB rev6.2 - Mar 2011
All features and benefitsof
I-Line and Canalisretained!!!
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Schneider Electric 14- SBG Exp CCB rev6.2 - Mar 2011
SEISMIC COMPLIANCE
Schneider Busway System passed the seismic tests andcomplies with Zone-4, most severe, seismic requirements
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Schneider Electric 15- SBG Exp CCB rev6.2 - Mar 2011
Seismic compliance
Full range ofstandard products of I-Line and Canalis
tested 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 ofShimizu Corporation Japan
Both mechanical (bending and twisting) and dynamic
tests (simulation of several historical earthquakes
including Kobe Japan 1995, Ojiya Japan 2004, ElCentro USA 1940, Building Construction
Wave Japan) performed and passed
Learning points achieved on recommendation of
supports consult factory for further info
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Schneider Electric 16- SBG Exp CCB rev6.2 - Mar 2011
Full 14 type tests
in
IEC60439-1/2 ed.3.1 2005
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Schneider Electric 17- SBG Exp CCB rev6.2 - Mar 2011
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
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Schneider Electric 18- SBG Exp CCB rev6.2 - Mar 2011
3 fire-related type tests (IEC60439-1/2)
8.2.9 - Verif ication of the resistance ofinsulating 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.
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Schneider Electric 19- SBG Exp CCB rev6.2 - Mar 2011
3 fire-related type tests (IEC60439-1/2)
8.2.14 - Verif ication of resistance to flame-propagation
Purpose and importance of this test
To verify the resistance to flame propagation. Thefire 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, theoriginal 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.
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Schneider Electric 20- SBG Exp CCB rev6.2 - Mar 2011
3 fire-related type tests (IEC60439-1/2)
8.2.15 - Verif ication of fire resistance inbuilding penetrations
Purpose and importance of this test
Verify the fire resistance in building penetration. The
fire resistant busway can resist the smoke spread andpenetration; 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 fillthe 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 unexposedsurface couldnt exceed 180K (Maximum) and 140K
(Average)
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Schneider Electric 21- SBG Exp CCB rev6.2 - Mar 2011
KEMA KEUR
andASTA Diamond (1)
listed
(1) ASTA Diamond license being approved by ASTA
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Schneider Electric 22- SBG Exp CCB rev6.2 - Mar 2011
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 / ASTAthat it is safe and is produced identical to those originally
tested. Product and production location undersurveillance
of 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 asingle 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
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Schneider Electric 23- SBG Exp CCB rev6.2 - Mar 2011
Mylar Insulation
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Schneider Electric 24- SBG Exp CCB rev6.2 - Mar 2011
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 abnormalheat and fire
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Schneider Electric 25- SBG Exp CCB rev6.2 - Mar 2011
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 l ive 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
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Schneider Electric 26- SBG Exp CCB rev6.2 - Mar 2011
Epoxy insulation (2)
Special service condition (on specification of a world-leading, epoxy-
pioneered busway manufacturer in USA)
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Schneider Electric 27- SBG Exp CCB rev6.2 - Mar 2011
Complete Schneider Electric Solution
from
transformer to sub main distribution,
fully coordinated using ourACB and MCCB
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Schneider Electric 28- SBG Exp CCB rev6.2 - Mar 2011
Complete Schneider Electric Solution
Trihal transformer
I-Line-Trihal transformer tap
RM6 + T200I
Remote control modular
cubicles
Prisma
Blokset
Okken NSX Circuit Breaker
Busway Plug-in unit
equipped with
Power Meter
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Schneider Electric 29- SBG Exp CCB rev6.2 - Mar 2011
Major Project References
of
Copper Contact Busway
M th 30 li ti i
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Schneider Electric 30- SBG Exp CCB rev6.2 - Mar 2011
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.
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Schneider Electric 31- SBG Exp CCB rev6.2 - Mar 2011
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
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Moscow Ostankino Tower
Project Name: Moscow Ostankino tower
Location : Moscow
General information: tallest TV tower in
Europe, the biggest swing is more than 20meters. 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)