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Parameters of the main busbar of the low-voltage switchgear

The main busbar in low-voltage switchgear must be designed for rated current, short-circuit withstand, thermal stability, mechanical strength, and compliance with IEC 61439 standards.Key Electrical Parameters
  • Rated Current (Ir): The continuous current the busbar can carry without exceeding permissible temperature rise. This is calculated considering the diversity factor of connected loads, e.g., a total equipment requirement of 2700 A with a diversity factor of 0.6 results in a main busbar current rating of 1620 A according to IEC 61439-1 .
  • Short-Circuit Withstand Capacity (Icw): The busbar must withstand prospective short-circuit currents without mechanical or thermal damage. This depends on material, cross-sectional area, and busbar geometry .
  • Voltage Rating: Typically up to 1000 V AC or 1500 V DC for low-voltage assemblies .
  • Temperature Rise: IEC 61439-1 sets the maximum permissible busbar temperature at 140°C (105 K above ambient 35°C) under full load conditions .
Mechanical and Material Considerations
  • Material: Copper or aluminum are commonly used. Copper offers higher conductivity and better thermal performance, while aluminum is lighter and cost-effective .
  • Busbar Geometry: Width, thickness, layering, and spacing are optimized to balance current-carrying capacity, heat dissipation, and space efficiency. Thinner, wider bars can reduce AC resistance effects and improve thermal performance .
  • Mechanical Strength: Busbars must resist short-circuit forces and maintain structural integrity. Proper support and joint quality are critical .
Thermal and Environmental Parameters
  • Insulation Coordination: Busbars must be insulated to prevent electrical faults and ensure safety.
  • Heat Dissipation: Arrangement of horizontal and vertical busbars affects airflow and temperature distribution within the switchgear .
  • Corrosion Resistance and EMC: Busbars are tested for corrosion, electromagnetic compatibility, and degree of protection (IP rating) according to IEC 61439 .
Design and Verification
  • Standards Compliance: IEC 61439-1 and IEC 61439-2 define construction, verification, and testing requirements for low-voltage switchgear busbars .
  • Testing: Includes thermal tests, short-circuit tests, mechanical operation cycles, and verification of insulation and protection degrees .
  • Optimization: Designers often standardize busbar families and adjust thickness or layering for different current ratings to balance cost, space, and performance .
Summary

The main busbar in low-voltage switchgear is a critical component that must be sized and designed to handle continuous current, short-circuit stresses, and thermal limits while maintaining mechanical integrity and compliance with IEC 61439 standards. Proper material selection, geometry, and verification ensure reliable, efficient, and safe power distribution within the switchgear assembly .

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