Using my current bussing, what are my limits on DC Amperage, and what is the temperature rise above ambient that I should factor in? Old bus bars are 52 x 14 mm (installed maybe 40 years ago). I have a rectifier it gives output 24 volts DC and 15000 amps at source to load in distance 6 m, 5 m, 2 m, 1 m. At what size of busbar(or) cables are taken my application and what type of insulation I prefer to the bus bus at safe conditions. =(3.ye!|q& B/PxX I think you may need to retain an experienced electrician, electrical engineer, or plating consultant -- someone who has worked with this stuff and is familiar with the concepts being discussed. Don't forget to check the ampacity of the anode rod when you fix the cathode rod. R = 1.05 x 10-3 Ω Sorry that it's hard to be of much more help from such a distance.

0000014459 00000 n Regards, P Marek. Q. A. Hi Drew. 0000009080 00000 n

30E&J@1"+O'+=J Good luck. 0000002007 00000 n %PDF-1.3 % Thanks and Warm Regards Also do you have an example of how long peak would be measured using your calculations? This gives you measurable but not excessive voltage drops, and warm but not hot bus bars. For example: A DC busbar with 38000A current, 200 v dc I think the correct answer will be slightly more than 1/10 of a square inch for a peak load for only one second, but I can't say for sure, and feel that the codes probably want you to size things based on maximum-ever loads for safety, not usual loads. For DC bussing for a rectifier, however, I think the standard number used for decades, 1000 amps/square inch for open air bussing, is an easier and safer approach. Huh? A. Hi Ajay. And V = I x R, so I get: How to calculate copper bus size for the Continuous DC load of 100A & a peak load of 200A for 1 Sec. Are there any tables of recommended solid conductor sizes for dc current similar to what is used for home wiring? Drew, "No-Ox-Id" Compound As you see, we appended your inquiry to a thread which I think will answer it for you: the copper needs 1 inch of cross sectional area for every 1000 amps. CapitalEquipment The bars are run with their long axis vertical. That is, we have a macro thumb-rule that a square inch of copper can carry 1000 Amps, and we don't apply that macro rule to a micro situation. We still say the ampacity is 1000 Amps; we don't calculate a reduced capacity based on the smaller contact area we see in the microscope. 0000003969 00000 n Q. We electroplate zinc onto ordinary Link chain at 9 VDC @ 3000A. 0000007519 00000 n So you would need 645 * 400/1000 = 258 square millimeters, and you've only got 228. We use rectifiers that generally operate 7-9 V and about 1500-2000 A. I don't have any knowledge of busbar size calculation; please send me choice of a correct busbar sizes for required current rating.

Closely related historical postings, oldest first: Q. Hello all,

For example, For 1500 Amps Which size Copper Bars I have to use Terminal box i.e. Q. Cables are widely used in plating shops. Q. free & open in air. That's a lot, and it would apply to each pole if they're both 100 m long. 0000000998 00000 n I've used 1000 Amps / square inch (in open air) in plating and anodizing shops for many decades, so I think 1/10 of a square inch would be correct for 100 Amps continuous load. Hi, Sujin. 54 24 0000005512 00000 n A. Hi, Hitendra. This would be for a DC combiner with a positive and negative bus to combine lithium battery banks and which would be the common point to power a whole lot of 48V inverters as a large energy storage system/UPS. 0000023480 00000 n

Did you wire brush the joints and apply conductive joint compound?

How to calculate the copper busbar size for a given DC current rating ? I have always understood that the Rise in Celsius is the rise over ambient or resting temperature. Copyright 2022 Copper Development Association Inc. All Rights Reserved. My question was very simple: And I understand that a 1/4 x 4 bar has greater surface area and cooling, and consequently higher current carrying capacity, than a 1/2 by 2 bar. I would, however, like to make a suggestion. in has proven itself for decades. The minimum bending radius for copper is equal to the thickness of the bar. Disclaimer: It's not possible to fully diagnose a finishing problem or the hazards of an operation via these pages. To measure the resistance of a bus bar you can use Ohm's Law. A 1/4" x 4" buss however is at 1250 amps. A. Hi, Naresh. @ |Kj ;!EGK#&0l"W^Ui0o?wYlnd)Ffvk3mm3;0UE$00b-+fBf[ mKnw'k1Ke/e{SE(Y9k>.VE/xqEaBIM}y7:7"{88Q(Q.PrC(!y$-?^DR You can measure the amperage along the length of the cathode bar on each rack/fixture with a tong tester/ammeter to verify the amperage is consistent.

Please advise criterion for the selection of DC bus size for the peak loads. 3bi50PK k`eiWj. How to calculate DC bus bar current carrying capacity with respect to temperature. 0000008384 00000 n You can choose the type of busbar, either aluminium or copper or galvanized bars or iron busbar or silver in the results. 0000011129 00000 n

I think that we can see from Ohm's Law that the knife-edge contact is not causing a significant resistance, and we can see (with a thermal scanner if not by hand) that there is no dangerous heat buildup at the knife edge. Are there ways to make the corrosion more manageable. 0000001854 00000 n

1. I feel you can proceed with what you have. Q. Hi. Sorry, I don't know the answers for your situation.

I dont think the busbars are sufficient to carry that current but these are the standard busbars they send to everyone?? There is a resistance due to the contact of the two pieces (header bar-busbar) and this can be calculated using Holm's equation (is an inverse function of the square root of load), however I have differing ideas in how to calculate the resistance through the buswork (through the triangular bar) as the contact is initially on the edge, rather than the end of the triangle. (30s, 1m, 3m?). Now I have a rectifier which the rating the output rating is 12VDC, 4000A. 0000001800 00000 n The current size of copper busbar which link from rectifier to chrome tank is 12 mm x 100 mm. Q. DC resistance of copper bus bar. I want to measure the end resistance and inductance of a bus bar.

: I have copper bus bar width = 14 mm, thickness= 6 mm, temperature 100 degrees -- so how to calculate current carrying capacity. 0000083756 00000 n 0000005026 00000 n 0000008826 00000 n Q. Hello dear Ted, I know that the surface corrosion will have a very small impact but that the connections could be significant. Architecural Manufacturers & Distributors, Architectural Installation Contractors Database, UNS Standard Designation for Wrought and Cast Copper, ASTM Standard Designation for Wrought and Cast Copper and Copper Alloys, European Numbering System for Non-Ferrous Metals, The U.S. Copper Industry: Critical to Keeping the U.S. All joints (male/female ) are firm and good contact. Thanks, Kurt.

But the fact is, 1000 Amps/sq. 0000034399 00000 n How can I determine the resistance of the fixture when I have no idea about its temperature? resistance specific dc formula wire physics conductor current solving volume circuits electric Are all components at least 1/4" x 3/4"? A quick study of their ampacity tables complicates the issue even more. I am building a LiFePO4 battery with 280aH cell (8s configuration 24V) and they sent me tinned clad busbar (copper inside) of 2mm thick and 20mm wide by 90 mm length ( I know length does not matter). Length here absolutely doesnt make any difference when comes to calculations? But figure it is about 10 percent of copper. Also, How many carbon brushes to be used at each side. And if this loss of performance is enough to change or clean the buss bar. 0000037369 00000 n V = 2000 A x 1.05 x 10-3 Ω = 2.1 Volts. 0000003825 00000 n How to size this stuff has been explained numerous times just on this one thread alone, and if you can't follow it sufficiently to do the arithmetic yourself, you don't understand enough to install bus bar without guidance. I have been going back and forwards with this for weeks.

A. Hi Danny. Is this a manually operated installation? Back when I was in school it was R = E / I, today you probably hear it as R = V / A.

I have never claimed to be an electrical engineer, but have run a lot of wire in my day. 0000004706 00000 n 0000004684 00000 n 4. Here in the USA and in the electroplating industry, the nice round number of 1000 Amps per square inch for open bus bar was universally accepted long before I entered the industry, and that was over 60 years ago :-) endstream endobj 31 0 obj << /Type /FontDescriptor /Ascent 1005 /CapHeight 734 /Descent -209 /Flags 32 /FontBBox [ -50 -207 1447 1000 ] /FontName /AAMONO+Verdana /ItalicAngle 0 /StemV 96 /XHeight 546 /FontFile2 57 0 R >> endobj 32 0 obj << /Type /FontDescriptor /Ascent 891 /CapHeight 656 /Descent -216 /Flags 34 /FontBBox [ -568 -307 2000 1007 ] /FontName /AAMOPA+TimesNewRoman /ItalicAngle 0 /StemV 94 /XHeight 0 /FontFile2 61 0 R >> endobj 33 0 obj << /Type /Font /Subtype /Type0 /BaseFont /AAMOMK+Cambria /Encoding /Identity-H /DescendantFonts [ 54 0 R ] /ToUnicode 30 0 R >> endobj 34 0 obj [ /ICCBased 59 0 R ] endobj 35 0 obj << /Type /Font /Subtype /TrueType /FirstChar 32 /LastChar 176 /Widths [ 250 0 0 0 0 0 0 0 333 333 500 0 250 0 250 278 500 500 500 500 500 500 500 500 500 500 0 0 0 0 0 0 0 722 0 667 722 611 556 0 722 333 0 0 611 889 0 0 556 0 667 556 611 0 0 944 0 0 0 0 0 0 0 0 0 444 500 444 500 444 333 500 500 278 0 500 278 778 500 500 500 500 333 389 278 500 0 0 500 500 444 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 400 ] /Encoding /WinAnsiEncoding /BaseFont /AAMOPA+TimesNewRoman /FontDescriptor 32 0 R >> endobj 36 0 obj << /Type /FontDescriptor /Ascent 1005 /CapHeight 734 /Descent -209 /Flags 96 /FontBBox [ -166 -208 1705 1000 ] /FontName /AAMONM+Verdana-BoldItalic /ItalicAngle -15 /StemV 184.396 /FontFile2 60 0 R >> endobj 37 0 obj 3600 endobj 38 0 obj << /Filter /FlateDecode /Length 37 0 R >> stream Ceiling Fan Power Consumption Calculation, Power Saving Tips, What is Busbar Current Carrying Capacity Calculation 5 Types of Busbar, AP Electricity Bill Calculator & Rate Per unit Cost 2022, Karnataka Bescom electricity bill calculator & Latest Tariff 2022, DHBVN Electricity Calculator & Per Unit Rate DHBVN, IDMT Tripping Time Calculator, Formula, Calculation, Battery Life Calculator, Formula, Example, Formula, Torque conversion Calculation, Formula, Example, T-Match Impedance Matching Calculation, Formula, Example, Strip line Trace Width Calculation, Formula, Example, Circular Waveguide Calculation, Formula, Example, VSWR Return Loss Calculation, Formula, Example, Trace resistance Calculation, Formula, Example, Tank circuit resonance Calculation, Formula, Example, T-Pad Attenuator Calculation, Formula, Example, Skin Depth Calculator, Calculation With Example, ITI Electrician Whatsapp Group Links Join, 1500+ Active Electrical Engineering WhatsApp Group Links Join, Top 10 Electrical Website for Electrical Engineering Students, Copper bar carries 4500Amps (1.2 x 150 x 25) current, Aluminium Carries 3000 Amps (0.8 x 150 x 25) Current, GI Bus Bar Carries 2250 Amps (0.6*150*25) Current. If you are seeking a product or service related to metal finishing, please check these Directories: Jobshops

At 200 amps the joints are heating to 70+ C. DC causes greater heating of the bus. It is enough dimension for new copper ? I will appreciate any help you can provide. Then again, 100 m is pretty long for a DC bus run. If you wish to purchase a copy of the complete Standard, please visit the ATIS Document Center.

0000037582 00000 n e.g. In any case, you obviously should minimize potential exposure to live circuits even though they are only 24 V, and people in the area should clearly understand the situation. This is specifically regarding hard chrome plating but can be applied to other types of plating as well. HWiF. Are these busbars going to be okay for connecting the cells together??

%%EOF 0000001731 00000 n

The rectifier terminal often implies what size bus bar the rectifier manufacturer feels is appropriate. Apex Tool Group - York, Pennsylvania USA, (your purchases make finishing.com possible). 56 0 obj<>stream 0000003221 00000 n

Steel is an alloy, and the conductivity of alloys varies very widely, with some stainless steels being only 3 percent as conductive as copper, and some plains steels close to 15 percent, so it's hard to put a perfect number on this. Your busing is 12% short of IDEAL calculations. The surface roughening that may occur at the bend is not serious as long as it is only a surface condition. I've been sizing DC bus bar the same way for 40 years, so I would dearly love to get out of that rut and hear a newer and better way. (your purchases make finishing.com possible). Best Regards

Good afternoon. Will connecting both ends of the cathode bar decrease the resistance through the cathode bar to the 40 plating racks evenly spaced on the bar? 0000051896 00000 n 0000023458 00000 n

0000070357 00000 n I visited a GE or Westinghouse bus bar plant decades ago where they hung bus bar vertically and dipped it 4"-6" deep into the plating solution to plate the ends. Please get tables from suppliers like stormcopper or consult the National Electrical Code. 3) Will the size be different for DC and AC 50 Hz? You need at least two, not one, 12 mm x 100 mm busbars, although most experienced installers would probably use four or five 6 mm x 100 mm bars instead. 0000026542 00000 n 0000002904 00000 n My existing plating tanks have undersized cathode bars (3"x .75", 4000A rectifier) which cannot be upsized. A.

24 0 obj << /Linearized 1 /O 26 /H [ 1240 353 ] /L 177436 /E 115625 /N 4 /T 176838 >> endobj xref 24 40 0000000016 00000 n

If you are leading each end of your cathode/anode bars from the MAIN busbar, I found that these leads from the MAIN busing should be of the same length. But the voltage has little to do with it (in this limited context of bussing a plating tank that operates at the usual industrial levels). But I have not found a chart stating whether that is AC or DC. The minimum bending radius for aluminum is equal to twice the thickness of the bar. The ampacity rating is based on a 30C rise above a 40C ambient. Sunny. Hopefully someone who knows will help us. I am long familiar with open bus bar systems which have no insulation at all, and which have been used for many decades in plating shops -- but I've also seen movement toward people no longer accepting open bus bar systems as being safe, especially as we get to higher voltages like 24 V. Welding cable sized at 1000 Amps/square inch can be used as an alternative to open bus bar, but doesn't fully address the issue of people working with live 24 v systems. xref Then press the calculate button, you get the aluminium or copper busbar current carrying capacity in amps. Which methods I can apply to do the same. 0000020501 00000 n

Maximum current 400 A on 8 ~ 10 V DC. EKj#NdUN${{iU'G@{$5OB4|Es\o2zl_*&\;5n1$O|]PD8$R} t&qNWY|_xt7@y WZzb06FtU%O\]I JF)I"if=P|*mu&_)nuc8." Rv3)BC/L6j0Uf!TMpgZAlks[ The number of sizes shown are not as extensive as those in the tables of AC ampacities, and there may be slight discrepancies between the ampacities shown here and those obtained by calculations derived from AC ampacities. My opinion, and that's all it is, is that you should have ordered 6 mm x 52 mm (1/4" x 2") bars. But please keep the discussion moving forward by trying your very best to phrase ongoing questions in terms of the answers that have already been offered. Q. You simply measure the voltage drop while the bar is carrying a known current. ! I believe de-rate AC values around 30%.

0000003864 00000 n

Good Morning i. Ted note: Please! trailer << /Size 64 /Info 22 0 R /Root 25 0 R /Prev 176828 /ID[<0106a25d7d8876649a4975b7d4d938f4><263729f7b2ee924bb0cf4b5d40b4daf1>] >> startxref 0 %%EOF 25 0 obj << /Type /Catalog /Pages 21 0 R /Metadata 23 0 R /PageLabels 20 0 R >> endobj 62 0 obj << /S 170 /L 285 /Filter /FlateDecode /Length 63 0 R >> stream My amperage requirement is only 1500A, but I've overspec'd for heat, losses etc in the system. What could the heating be due to? I understand resistivity of metals increases with temperature and that I can decrease resistance by increasing the cross section of the conductor, but how do I know at what temperature (resistivity) will the conductor arrive if I send a given current through it? 0000073034 00000 n The minimum bend radii may be reduced only if specifically allowed by the conductor manufacturer.

Sitemap 2