KLD-TM Series Copper Busbar Trunking System

Product Selection

Example: TM-T-Q-10KV/4000A: Copper busbar, copper tube conductor, fully insulated, rated voltage 10KV, rated current 4000A.

Scope of application

The TM-series copper busbar utilizes hollow copper (or aluminum) tubes as conductors, encased in insulation—a type of busbar product commonly referred to as “tubular cables” overseas. Copper busbars boast features such as high current-carrying capacity (up to 12,000 A), high mechanical strength, excellent insulation performance, and a wide range of applications, which is why they are increasingly recognized and adopted by more and more customers. Abroad, this type of product has already accumulated several decades of operational experience. In China, however, due to relatively recent entry into this field, as well as limitations in technological R&D capabilities and insulating materials, currently only products rated at 35 kV and below can be manufactured. These products are suitable for use in large-scale enterprises and substations.

Product Features

1. High current-carrying capacity: The main body of the copper busbar consists of hollow copper or aluminum alloy tubes with a large surface area. Compared to conventional rectangular busbars, it features a uniform distribution of current density across the conductor’s surface, enabling a maximum rated current of up to 12,000 A.

2. Excellent insulation performance: The copper busbar adopts a sealed and shielded insulation design, with the enclosure grounded at zero potential. The electric field distribution on the busbar surface is uniform, ensuring strong electrical insulation performance. It can be directly routed through cable trenches and cable interlayers.

3. High mechanical strength: The main body of the copper busbar has a permissible stress that is four times greater than that of rectangular busbars, enabling it to withstand large short-circuit currents and offering high mechanical strength. As a result, the maximum span between busbar supports can reach up to 8 meters.

4. Excellent heat dissipation and low temperature rise: The copper busbar is a hollow conductor with ventilation holes at both ends. The internal duct naturally facilitates convection of hot air, providing superior heat dissipation performance compared to conventional busbars.

5. Low Loss: The shape of the copper busbar determines that its skin-effect coefficient on the surface is low, with Kf ≤ 1, resulting in low AC resistance and thus minimizing power loss in the busbar. The dielectric loss of the insulation layer of the copper busbar is less than 0.01%.

6. High thermal resistance of insulating materials: The primary insulating material used in tubular busbars is polytetrafluoroethylene, which boasts excellent electrical performance and chemical stability. It can operate normally within a temperature range of -200°C to +200°C, with low dielectric loss, flame retardancy, and resistance to aging. When combined with other insulating materials, the service life of the product is ≥30 years.

7. Strong resistance to electrical vibrations: The results of dynamic stability tests show that a copper busbar with a rated voltage of 10 kV and a rated current of 400 A can withstand a short-circuit current surge of 63 kA (for 4 seconds). This busbar can be directly fixed to steel frameworks or concrete supports, eliminating the need for wall bushings and pillar insulators, thus providing enhanced resistance to vibrations.

8. Immune to environmental interference and highly reliable: Each phase of the insulated copper busbar is enclosed and shielded with insulation, preventing condensation from forming inside. It also eliminates ground faults and phase-to-phase short circuits caused by external moisture, dust, and foreign objects, ensuring highly reliable operation.
9. The busbar structure is concise, with a clear layout, easy installation, and minimal maintenance requirements: the product can be successfully installed once and requires no maintenance throughout its entire service life.

Main Technical Parameters

1. Rated frequency: 50 Hz; Rated voltage: 0.4 kV to 110 kV; Rated current: 1,000 A to 12,000 A; Busbar temperature rise: ≤40 K

2. Altitude: Below 1000m (special cases above 1000m altitude)

3. Ambient temperature: -30℃ to +45℃; maximum daily temperature difference: 30℃; solar irradiance: 0.1 W/cm²

4. Maximum wind speed: 35 m/s; maximum relative humidity: 95%; ice thickness: 10 mm

5. Seismic intensity: Grade V, horizontal acceleration 0.25g, vertical acceleration 0.125g

6. Pollution degree: Level IV

7. Creepage Distance: 3.1 cm/kV