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Copper Contact Busway
SBG
Mar 2011
Rev 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 ...
Schneider Electric 4- SBG – Export – May 2010
Problems of traditional aluminum busway (1)
● Aluminum oxide (alumina or alo...
Schneider Electric 5- SBG – Export – May 2010
Problems of traditional aluminum busway (2)
● Fretting corrosion results fro...
Schneider Electric 6- SBG – Export – May 2010
Our solution: Copper Contact (laminated
bimetal)
● Silver plated bimetal pla...
Schneider Electric 7- SBG – Exp – CCB rev6.2 - Mar 2011
Copper Contact Busway Offers
● Medium Power (100A-800A) : Canalis ...
Schneider Electric 8- SBG – Exp – CCB rev6.2 - Mar 2011
Advantages
of
Copper Contact Busway
Schneider Electric 9- SBG – Exp – CCB rev6.2 - Mar 2011
A safer, more reliable and economical solution
●Safety and Reliabi...
Schneider Electric 10- SBG – Exp – CCB rev6.2 - Mar 2011
Green and Environmental Friendly
● Reduce pollution – pollution d...
Schneider Electric 11- SBG – Exp – CCB rev6.2 - Mar 2011
Energy Efficiency
● Achieved Green Leaf Energy Efficiency
mark by...
Schneider Electric 12- SBG – Exp – CCB rev6.2 - Mar 2011
Lower contact resistance
● Silver- silver contact reduces
the con...
Schneider Electric 13- SBG – Exp – CCB rev6.2 - Mar 2011
All features and benefits
of
I-Line and Canalis
retained!!!
Schneider Electric 14- SBG – Exp – CCB rev6.2 - Mar 2011
SEISMIC COMPLIANCE
Schneider Busway System passed the seismic tes...
Schneider Electric 15- SBG – Exp – CCB rev6.2 - Mar 2011
Seismic compliance
●Full range of standard products of I-Line and...
Schneider Electric 16- SBG – Exp – CCB rev6.2 - Mar 2011
Full 14 type tests
in
IEC60439-1/2 ed.3.1 2005
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 20...
Schneider Electric 18- SBG – Exp – CCB rev6.2 - Mar 2011
3 fire-related type tests (IEC60439-1/2)
● 8.2.9 - Verification o...
Schneider Electric 19- SBG – Exp – CCB rev6.2 - Mar 2011
3 fire-related type tests (IEC60439-1/2)
● 8.2.14 - Verification ...
Schneider Electric 20- SBG – Exp – CCB rev6.2 - Mar 2011
3 fire-related type tests (IEC60439-1/2)
● 8.2.15 - Verification ...
Schneider Electric 21- SBG – Exp – CCB rev6.2 - Mar 2011
KEMA KEUR
and
ASTA Diamond(1)
listed
(1) ASTA Diamond license bei...
Schneider Electric 22- SBG – Exp – CCB rev6.2 - Mar 2011
KEMA KEUR and ASTA Diamond
● Full range of I-Line and Canalis car...
Schneider Electric 23- SBG – Exp – CCB rev6.2 - Mar 2011
Mylar® Insulation
Schneider Electric 24- SBG – Exp – CCB rev6.2 - Mar 2011
Mylar® insulation
●Mylar®, sourced from USA/Europe, is a register...
Schneider Electric 25- SBG – Exp – CCB rev6.2 - Mar 2011
Epoxy insulation (1)
●Epoxy is not a brand but a type of material...
Schneider Electric 26- SBG – Exp – CCB rev6.2 - Mar 2011
Epoxy insulation (2)
●Special service condition (on specification...
Schneider Electric 27- SBG – Exp – CCB rev6.2 - Mar 2011
Complete Schneider Electric Solution
from
transformer to sub main...
Schneider Electric 28- SBG – Exp – CCB rev6.2 - Mar 2011
Complete Schneider Electric Solution
Trihal transformer
I-Line-Tr...
Schneider Electric 29- SBG – Exp – CCB rev6.2 - Mar 2011
Major Project References
of
Copper Contact Busway
Schneider Electric 30- SBG – Exp – CCB rev6.2 - Mar 2011
More than 30 years application experience
worldwide
● The Molecul...
Schneider Electric 31- SBG – Exp – CCB rev6.2 - Mar 2011
Nord Villepinte Convention center
● Project Name: Nord Villepinte...
Schneider Electric 32- SBG – Exp – CCB rev6.2 - Mar 2011
Moscow Ostankino Tower
● Project Name: Moscow Ostankino tower
● L...
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1 bimetal technology-contact busway

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1 bimetal technology-contact busway

  1. 1. Copper Contact Busway SBG Mar 2011 Rev 6.2 - New Copper Solution
  2. 2. Schneider Electric 2- SBG – Exp – CCB rev6.2 - Mar 2011 General Introduction
  3. 3. 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!
  4. 4. 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 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).
  5. 5. 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 << 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)
  6. 6. Schneider Electric 6- SBG – Export – May 2010 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 >
  7. 7. Schneider 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 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 years More than 30 years
  8. 8. Schneider Electric 8- SBG – Exp – CCB rev6.2 - Mar 2011 Advantages of Copper Contact Busway
  9. 9. Schneider Electric 9- SBG – Exp – CCB rev6.2 - Mar 2011 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) Aluminum Copper Contact Copper service life level (IEC range) Aluminum Copper Contact Copper price level (IEC range)
  10. 10. Schneider Electric 10- SBG – Exp – CCB rev6.2 - Mar 2011 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 and Hexavalent 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
  11. 11. 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 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.  
  12. 12. 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 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)
  13. 13. Schneider Electric 13- SBG – Exp – CCB rev6.2 - Mar 2011 All features and benefits of I-Line and Canalis retained!!!
  14. 14. Schneider Electric 14- SBG – Exp – CCB rev6.2 - Mar 2011 SEISMIC COMPLIANCE Schneider Busway System passed the seismic tests and complies with Zone-4, most severe, seismic requirements
  15. 15. Schneider Electric 15- SBG – Exp – CCB rev6.2 - Mar 2011 Seismic compliance ●Full range of standard 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 of Shimizu Corporation Japan ●Both mechanical (bending and twisting) and dynamic tests (simulation of several historical earthquakes including Kobe Japan 1995, Ojiya Japan 2004, El Centro USA 1940, Building Construction Wave Japan) performed and passed ●Learning points achieved on recommendation of supports – consult factory for further info
  16. 16. Schneider Electric 16- SBG – Exp – CCB rev6.2 - Mar 2011 Full 14 type tests in IEC60439-1/2 ed.3.1 2005
  17. 17. 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
  18. 18. Schneider Electric 18- SBG – Exp – CCB rev6.2 - Mar 2011 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.
  19. 19. Schneider Electric 19- SBG – Exp – CCB rev6.2 - Mar 2011 3 fire-related type tests (IEC60439-1/2) ● 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.
  20. 20. Schneider Electric 20- SBG – Exp – CCB rev6.2 - Mar 2011 3 fire-related type tests (IEC60439-1/2) ● 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)
  21. 21. Schneider Electric 21- SBG – Exp – CCB rev6.2 - Mar 2011 KEMA KEUR and ASTA Diamond(1) listed (1) ASTA Diamond license being approved by ASTA
  22. 22. 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 / ASTA that it is safe and is produced identical to those originally tested. Product and production location under surveillance 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 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
  23. 23. Schneider Electric 23- SBG – Exp – CCB rev6.2 - Mar 2011 Mylar® Insulation
  24. 24. 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 abnormal heat and fire”
  25. 25. 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 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
  26. 26. 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)
  27. 27. Schneider Electric 27- SBG – Exp – CCB rev6.2 - Mar 2011 Complete Schneider Electric Solution from transformer to sub main distribution, fully coordinated using our ACB and MCCB
  28. 28. 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
  29. 29. Schneider Electric 29- SBG – Exp – CCB rev6.2 - Mar 2011 Major Project References of Copper Contact Busway
  30. 30. 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.
  31. 31. 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
  32. 32. Schneider Electric 32- SBG – Exp – CCB rev6.2 - Mar 2011 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)

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