ELINS SWITCHBOARDS PVT. LTD.

BANGALORE Theoretical Calculation of Current carrying capacity of Aluminium Busbars

I.

400A Aluminium Busbars with 1 Run of rectangular busbars :-

1. We use Electrical Conductivity Grade, WP/T6 (Range 1) 56.5% of IACS Aluminium Busbars. 2 . Size of the Bus bars used for 400 A rating is 1RX50X10 mm. Formula: I = 1.02 x A 0.5 x p 0.39 x 0.61 [(1+ )] 0.5 Where: I = Current in Amps A = Cross sectional area of busbars in sq.mm = 50 X 10 =500sq.mm p = Perimeter of bus bar in mm. = (50+10)2 =120 mm. = Temperature difference between conductor and the ambient air at 35o C = 45 deg C = Resistance Temperature co-efficient of Aluminium at the ambient Temperature / degC = 0.00364 = Resistivity of Aluminium at the ambient Temperature-cm = 3.133 I = 1.02 x 500 0.5 x 120 0.39 x 45 0.61 [(1+0.00364 x 45)3.133] 0.5 = 1504.62 1.909 = 788.17 Amps For calculation purpose parameters are considered for D50S WP grade busbar, the conductivity of which is of 55%. Where as we are using busbar of WP/T6 (Range 1) Hindalco busbar, the conductivity of which is of 56.5%. Therefore % of increase in conductivity is 100 x 56.5 = 102.72% 55 Hence extra % of conductivity for the bus bars used = 2.72 % Therefore the total current carrying capacity for WP/T6 (Range 1 ) Hindalco busbars = 788.17+{2.72 x 788.17}= 809.61 A 100 Current carrying capacity of single 50 x 10 mm. busbar is = 809.16 A Enclosure correction factor is applicable only for enclosures of Non Magnetic Materials. However to be on safer side a correction factor of 0.8 can be considered. Therefore current carrying capacity of 1RX50X10 mm. Al busbars = 809.61 X 0.8 = 647.69 Amps. Hence the Busbars provided by us (ie; 1Rx50x10mm) are more than adequate as per the above design calculations.

Project: Wipro DC Pune.

Page: 1 of 8

ELINS SWITCHBOARDS PVT. LTD.

BANGALORE

II.

600A Aluminium Busbars with 1 Run of rectangular busbars :-

1. We use Electrical Conductivity Grade, WP/T6 (Range 1) 56.5% of IACS Aluminium Busbars. 2 . Size of the Bus bars used for 600 A rating is 1RX75X10 mm. Formula: I = 1.02 x A 0.5 x p 0.39 x 0.61 [(1+ )] 0.5 Where: I = Current in Amps A = Cross sectional area of busbars in sq.mm = 75 X 10 =750sq.mm p = Perimeter of bus bar in mm. = (75+10)2 =170 mm. = Temperature difference between conductor and the ambient air at 35o C = 45 deg C = Resistance Temperature co-efficient of Aluminium at the ambient Temperature / degC = 0.00364 = Resistivity of Aluminium at the ambient Temperature-cm = 3.133 I = 1.02 x 750 0.5 x 170 0.39 x 45 0.61 [(1+0.00364 x 45)3.133] 0.5 = 2110.89 1.909 = 1105.76 Amps For calculation purpose parameters are considered for D50S WP grade busbar, the conductivity of which is of 55%. Where as we are using busbar of WP/T6 (Range 1) Hindalco busbar, the conductivity of which is of 56.5%. Therefore % of increase in conductivity is 100 x 56.5 = 102.72% 55 Hence extra % of conductivity for the bus bars used = 2.72 % Therefore the total current carrying capacity for WP/T6 (Range 1 ) Hindalco busbars = 1105.76+{2.72 x 1105.76}= 1135.84 A 100 Current carrying capacity of single 75 x 10 mm. busbar is = 1135.84 A Enclosure correction factor is applicable only for enclosures of Non Magnetic Materials. However to be on safer side a correction factor of 0.8 can be considered. Therefore current carrying capacity of 1RX75X10 mm. Al busbars = 1135.84 X 0.8 = 908.67 Amps. Hence the Busbars provided by us (ie; 1Rx75x10mm) are more than adequate as per the above design calculations.

Project: Wipro DC Pune.

Page: 2 of 8

ELINS SWITCHBOARDS PVT. LTD.

BANGALORE

III.

800A Aluminium Busbars with 1 Run of rectangular busbars :-

1. We use Electrical Conductivity Grade, WP/T6 (Range 1) 56.5% of IACS Aluminium Busbars. 2 . Size of the Bus bars used for 800 A rating is 1RX100X10 mm. Formula: I = 1.02 x A 0.5 x p 0.39 x 0.61 [(1+ )] 0.5 Where: I = Current in Amps A = Cross sectional area of busbars in sq.mm = 100 X 10 =1000sq.mm p = Perimeter of bus bar in mm. = (100+10)2 =220 mm. = Temperature difference between conductor and the ambient air at 35o C = 45 deg C = Resistance Temperature co-efficient of Aluminium at the ambient Temperature / degC = 0.00364 = Resistivity of Aluminium at the ambient Temperature-cm = 3.133 I = 1.02 x 1000 0.5 x 220 0.39 x 45 0.61 [(1+0.00364 x 45)3.133] 0.5 = 2695.29 1.909 = 1411.51 Amps For calculation purpose parameters are considered for D50S WP grade busbar, the conductivity of which is of 55%. Where as we are using busbar of WP/T6 (Range 1) Hindalco busbar, the conductivity of which is of 56.5%. Therefore % of increase in conductivity is 100 x 56.5 = 102.72% 55 Hence extra % of conductivity for the bus bars used = 2.72 % Therefore the total current carrying capacity for WP/T6 (Range 1 ) Hindalco busbars = 1411.51+{2.72 x 1411.51}= 1449.91 A 100 Current carrying capacity of single 100 x 10 mm. busbar is = 1449.91 A Enclosure correction factor is applicable only for enclosures of Non Magnetic Materials. However to be on safer side a correction factor of 0.8 can be considered. Therefore current carrying capacity of 1RX100X10 mm. Al busbars = 1449.91 X 0.8 = 1159.93 Amps. Hence the Busbars provided by us (ie; 1Rx100x10mm) are more than adequate as per the above design calculations.

Project: Wipro DC Pune.

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ELINS SWITCHBOARDS PVT. LTD.

BANGALORE

IV.

1000A Aluminium Busbars with 1 Run of rectangular busbars :-

1. We use Electrical Conductivity Grade, WP/T6 (Range 1) 56.5% of IACS Aluminium Busbars. 2 . Size of the Bus bars used for 1000 A rating is 1RX125X10 mm. Formula: I = 1.02 x A 0.5 x p 0.39 x 0.61 [(1+ )] 0.5 Where: I = Current in Amps A = Cross sectional area of each busbar in sq.mm = 125 X 10 =1250sq.mm p = Perimeter of bus bar in mm. = (125+10)2 = 270 mm. = Temperature difference between conductor and the ambient air at 35o C = 45 deg C = Resistance Temperature co-efficient of Aluminium at the ambient Temperature / degC = 0.00364 = Resistivity of Aluminium at the ambient Temperature-cm = 3.133 I = 1.02 x 1250 0.5 x 270 0.39 x 45 0.61 [(1+0.00364 x 45)3.133] 0.5 = 3263.97 1.909 = 1709.78 Amps For calculation purpose parameters are considered for D50S WP grade busbar, the conductivity of which is of 55%. Where as we are using busbar of WP/T6 (Range 1) Hindalco busbar, the conductivity of which is of 56.5%. Therefore % of increase in conductivity is 100 x 56.5 = 102.72% 55 Hence extra % of conductivity for the bus bars used = 2.72 % Therefore the total current carrying capacity for WP/T6 (Range 1 ) Hindalco busbars = 1709.78 +{2.72 x 1709.78}= 1756.28 A 100 Current carrying capacity of single 125 x 10 mm. busbar is = 1756.28 A Enclosure correction factor is applicable only for enclosures of Non Magnetic Materials. However to be on safer side a correction factor of 0.8 can be considered. Therefore current carrying capacity of 1RX125X10 mm. Al busbars = 1756.28 X 0.8 = 1405.02 Amps. Hence the Busbars provided by us (ie; 1Rx125x10mm) are more than adequate as per the above design calculations.

Project: Wipro DC Pune.

Page: 4 of 8

ELINS SWITCHBOARDS PVT. LTD.

BANGALORE

V.

1600A Aluminium Busbars with 2 Runs of rectangular busbars :-

1. We use Electrical Conductivity Grade, WP/T6 (Range 1) 56.5% of IACS Aluminium Busbars. 2 . Size of the Bus bars used for 1600 A rating is 2RX100X10 mm. Formula: I = 1.02 x A 0.5 x p 0.39 x 0.61 [(1+ )] 0.5 Where: I = Current in Amps A = Cross sectional area of busbars in sq.mm = 100 X 10 =1000sq.mm p = Perimeter of bus bar in mm. = (100+10)2 =220 mm. = Temperature difference between conductor and the ambient air at 35o C = 45 deg C = Resistance Temperature co-efficient of Aluminium at the ambient Temperature / degC = 0.00364 = Resistivity of Aluminium at the ambient Temperature-cm = 3.133 I = 1.02 x 1000 0.5 x 220 0.39 x 45 0.61 [(1+0.00364 x 45)3.133] 0.5 = 2695.29 1.909 = 1411.51 Amps For calculation purpose parameters are considered for D50S WP grade busbar, the conductivity of which is of 55%. Where as we are using busbar of WP/T6 (Range 1) Hindalco busbar, the conductivity of which is of 56.5%. Therefore % of increase in conductivity is 100 x 56.5 = 102.72% 55 Hence extra % of conductivity for the bus bars used = 2.72 % Therefore the total current carrying capacity for WP/T6 (Range 1 ) Hindalco busbars = 1411.51+{2.72 x 1411.51}= 1449.91 A 100 Current carrying capacity of single 100 x 10 mm. busbar is = 1449.91 A Therefore current carrying capacity of two busbars with air gap space equal to the Busbar thickness, considering multiplying factor of 1.8, for 2 lamination = 1449.91 x 1.8 = 2609.84 Amps. Enclosure correction factor is applicable only for enclosures of Non Magnetic Materials. However to be on safer side a correction factor of 0.8 can be considered. Therefore current carrying capacity of 2RX100X10 mm. Al busbars = 2609.84 X 0.8 = 2087.87 Amps. Hence the Busbars provided by us (ie; 2Rx100x10mm) are more than adequate as per the above design calculations.

Project: Wipro DC Pune.

Page: 5 of 8

ELINS SWITCHBOARDS PVT. LTD.

BANGALORE

VI.

3200A Aluminium Busbars with 4 Runs of rectangular busbars :-

1. We use Electrical Conductivity Grade, WP/T6 (Range 1) 56.5% of IACS Aluminium Busbars. 2 . Size of the Bus bars used for 3200 A rating is 4RX100X10 mm. Formula: I = 1.02 x A 0.5 x p 0.39 x 0.61 [(1+ )] 0.5 Where: I = Current in Amps A = Cross sectional area of busbars in sq.mm = 100 X 10 =1000sq.mm p = Perimeter of bus bar in mm. = (100+10)2 =220 mm. = Temperature difference between conductor and the ambient air at 35o C = 45 deg C = Resistance Temperature co-efficient of Aluminium at the ambient Temperature / degC = 0.00364 = Resistivity of Aluminium at the ambient Temperature-cm = 3.133 I = 1.02 x 1000 0.5 x 220 0.39 x 45 0.61 [(1+0.00364 x 45)3.133] 0.5 = 2695.29 1.909 = 1411.51 Amps For calculation purpose parameters are considered for D50S WP grade busbar, the conductivity of which is of 55%. Where as we are using busbar of WP/T6 (Range 1) Hindalco busbar, the conductivity of which is of 56.5%. Therefore % of increase in conductivity is 100 x 56.5 = 102.72% 55 Hence extra % of conductivity for the bus bars used = 2.72 % Therefore the total current carrying capacity for WP/T6 (Range 1 ) Hindalco busbars = 1411.51+{2.72 x 1411.51}= 1449.91 A 100 Current carrying capacity of single 100 x 10 mm. busbar is = 1449.91 A Therefore current carrying capacity of four busbars with air gap space equal to the Busbar thickness, considering multiplying factor of 3.2, for 4 lamination = 1449.91 x 3.2 = 4639.71 Amps. Enclosure correction factor is applicable only for enclosures of Non Magnetic Materials. However to be on safer side a correction factor of 0.8 can be considered. Therefore current carrying capacity of 4RX100X10 mm. Al busbars = 4639.71 X 0.8 = 3711.77 Amps. Hence the Busbars provided by us (ie; 4Rx100x10mm) are more than adequate as per the above design calculations.

Project: Wipro DC Pune.

Page: 6 of 8

ELINS SWITCHBOARDS PVT. LTD.

BANGALORE

VII.

4000A Aluminium Busbars with 4 Runs of rectangular busbars :-

1. We use Electrical Conductivity Grade, WP/T6 (Range 1) 56.5% of IACS Aluminium Busbars. 2 . Size of the Bus bars used for 4000 A rating is 4RX125X10 mm. Formula: I = 1.02 x A 0.5 x p 0.39 x 0.61 [(1+ )] 0.5 Where: I = Current in Amps A = Cross sectional area of busbars in sq.mm = 125 X 10 =1250sq.mm p = Perimeter of bus bar in mm. = (125+10)2 =270 mm. = Temperature difference between conductor and the ambient air at 35o C = 45 deg C = Resistance Temperature co-efficient of Aluminium at the ambient Temperature / degC = 0.00364 = Resistivity of Aluminium at the ambient Temperature-cm = 3.133 I = 1.02 x 1250 0.5 x 270 0.39 x 45 0.61 [(1+0.00364 x 45)3.133] 0.5 = 3263.97 1.909 = 1709.78 Amps For calculation purpose parameters are considered for D50S WP grade busbar, the conductivity of which is of 55%. Where as we are using busbar of WP/T6 (Range 1) Hindalco busbar, the conductivity of which is of 56.5%. Therefore % of increase in conductivity is 100 x 56.5 = 102.72% 55 Hence extra % of conductivity for the bus bars used = 2.72 % Therefore the total current carrying capacity for WP/T6 (Range 1 ) Hindalco busbars = 1709.78 +{2.72 x 1709.78}= 1756.29 A 100 Current carrying capacity of single 125 x 10 mm. busbar is = 1756.29 A Therefore current carrying capacity of four busbars with air gap space equal to the Busbar thickness, considering multiplying factor of 3.2, for 4 lamination = 1756.29 x 3.2 = 5620.13 Amps. Enclosure correction factor is applicable only for enclosures of Non Magnetic Materials. However to be on safer side a correction factor of 0.8 can be considered. Therefore current carrying capacity of 4RX125X10 mm. Al busbars = 5620.13 X 0.8 = 4496.10 Amps. Hence the Busbars provided by us (ie; 4Rx125x10mm) are more than adequate as per the above design calculations.

Project: Wipro DC Pune.

Page: 7 of 8

ELINS SWITCHBOARDS PVT. LTD.

BANGALORE

VIII.

6000A Aluminium Busbars with 4 Runs of rectangular busbars :-

1. We use Electrical Conductivity Grade, WP/T6 (Range 1) 56.5% of IACS Aluminium Busbars. 2 . Size of the Bus bars used for 6000 A rating is 4RX200X10 mm. Formula: I = 1.02 x A 0.5 x p 0.39 x 0.61 [(1+ )] 0.5 Where: I = Current in Amps A = Cross sectional area of each busbar in sq.mm = 200 X 10 = 2000sq.mm p = Perimeter of bus bar in mm. = (200+10)2 = 420 mm. = Temperature difference between conductor and the ambient air at 35o C = 45 deg C = Resistance Temperature co-efficient of Aluminium at the ambient Temperature / degC = 0.00364 = Resistivity of Aluminium at the ambient Temperature-cm = 3.133 I = 1.02 x 2000 0.5 x 420 0.39 x 45 0.61 [(1+0.00364 x 45)3.133] 0.5 = 4905.03 1.909 = 2569.42 Amps For calculation purpose parameters are considered for D50S WP grade busbar, the conductivity of which is of 55%. Where as we are using busbar of WP/T6 (Range 1) Hindalco busbar, the conductivity of which is of 56.5%. Therefore % of increase in conductivity is 100 x 56.5 = 102.72% 55 Hence extra % of conductivity for the bus bars used = 2.72 % Therefore the total current carrying capacity for WP/T6 (Range 1 ) Hindalco busbars = 2569.42 +{2.72 x 2569.42 }= 2639.30 A 100 Current carrying capacity of single 200 x 10 mm. busbar is = 2639.30 A Therefore current carrying capacity of Four busbars with air gap space equal to the Busbar thickness, considering multiplying factor of 3.2 for 4 laminations = 2639.30 X 3.2 = 8445.79 Amps. Enclosure correction factor is applicable only for enclosures of Non Magnetic Materials. However to be on safer side a correction factor of 0.8 can be considered. Therefore current carrying capacity of 4RX200X10 mm. Al busbars =8445.79 X 0.8 = 6756.62 Amps. Hence the Busbars provided by us (ie; 4Rx200x10mm) are adequate as per the above design calculations.

Project: Wipro DC Pune.

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