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KLD-C Densely Packed Busbar System
The KLD-C series low-impedance compact busbar trunking system features a typical sandwich structure internally. It is a flexible and reliable power distribution system characterized by a well-designed layout, superior performance, and numerous advantages such as stable and dependable operation, high power distribution efficiency, excellent heat dissipation, reduced voltage drop, resistance to mechanical impacts, and easy installation. This system is suitable for three-phase three-wire, three-phase four-wire, and three-phase five-wire AC systems operating at frequencies of 50 to 60 Hz, with rated working voltages up to 1000 V, rated insulation voltages up to 1500 V, and rated working currents ranging from 100 to 6300 A.
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System Overview
The KLD-C series low-impedance compact busbar system features a typical sandwich structure inside, making it a flexible and reliable power distribution system. With its rational design and superior performance, this system boasts characteristics such as stable and dependable operation, high power distribution efficiency, excellent heat dissipation, reduced voltage drop, resistance to mechanical impacts, and easy installation. It is suitable for AC three-phase three-wire, three-phase four-wire, and three-phase five-wire systems operating at frequencies of 50 to 60 Hz, with rated working voltages up to 1000 V, rated insulation voltages up to 1500 V, and rated working currents ranging from 100 to 6300 A.
The KLD-C series low-impedance, compact busbar system can be used in large-scale commercial and real estate projects as a high-efficiency power distribution system for high-current applications. To meet user needs, the KLD-C busbar system has been designed to reduce its own weight, while fully taking into account the stringent stability requirements for busbars during shaft installation, thereby enhancing the system’s reliability and versatility.
Given the high demands of industrial and mining enterprises on busbar trunking systems—such as short-time withstand current and low impedance—as well as the potential presence of various electromagnetic interferences, the KLD-C busbar trunking system offers an optional neutral conductor (100% or 200%) to meet the harmonic elimination requirements in diverse power systems. The enclosure, made entirely of non-magnetic materials (aluminum and aluminum-magnesium alloy), ensures that large currents will not induce eddy-current hysteresis losses that could affect the busbar trunking system.
The KLD-C series busbar trunking system, as a low-cost, high-efficiency power distribution solution for industrial plants, hospitals, shopping malls, high-rise buildings, or high-tech environments, will bring you a perfect combination of superior performance.
Product Structure Features
Small in size, highly flexible.
The compact “sandwich” structure not only saves space but also boasts excellent voltage characteristics. Various functional units can be adapted to changes in both corner angles and heights, making them suitable for installation in any architectural space—such as mezzanines or along walls.
The conductor with a “sandwich” structure, combined with a fully enclosed housing, together form an integrated thermal propagation path, resulting in improved heat dissipation performance.
Safe and reliable plug-in box
The operating handle for the plug-in connection can be mounted on the door panel of the enclosure and is equipped with precise trip and close indicators.
The padlock mechanism is used to prevent the plug-in box from being accidentally closed and to block unauthorized access to the power grid.
The fuse-equipped junction box is equipped with a dedicated fuse-pulling tool.
The socket-molded cover prevents fingers from accidentally coming into contact with live conductors.
Internal grounding and enclosure grounding employ a plug-in connection. The pins feature a rationally designed structure and are silver-plated to ensure reliable contact in the system.
The internal connection mechanism of the plug-in box prevents the door from being opened when the power is on, further ensuring the personal safety of operators.
Rugged and lightweight all-aluminum housing
The busbar trunking system uses lightweight, molded, fully enclosed aluminum alloy profiles as its enclosure. Its unique structure provides high adaptability and safety and reliability, enabling it to easily handle a variety of special application conditions.
The all-aluminum housing, after being coated by spraying, can withstand a salt-spray test lasting 1,000 hours.
The all-aluminum enclosure boasts excellent corrosion resistance, heat dissipation performance, and electrical conductivity. The entire enclosure features 100% grounding capacity.
High-performance materials
Busbar systems use high-quality tin-plated or silver-plated copper or aluminum busbars as conductive materials, and the outer surfaces of these conductive bars are all equipped with excellent corrosion protection.
The busbar is entirely wrapped with Class B (130℃) thermally formed polyester film insulation, which significantly enhances the busbar's insulation strength and impact resistance.
It uses environmentally friendly insulation materials and has passed SGS’s six physical property tests required by ROHS, as well as CE certification.
Easy and quick connection
The conical insulating plate enhances mechanical strength, and the molded housing ensures that there is no warping under pressure.
Wide-flange manganese steel washers ensure even pressure distribution across the contact surface.
A standard #19 wrench is all you need to tighten the double-ended single bolt with the red indicator. When the indicator mark naturally falls off, no further action is required.
Any detection tool can determine whether the connector is securely fastened.
The bolts can be reused during maintenance.
To compensate for the impact of installation errors on the connection, the connector features an adjustable tolerance of ±4 mm along the length of the busbar.
The precision CNC sawing machine ensures a smooth cut surface of the busbar, minimizing contact resistance at the busbar connection points.
The wide lead-manganese steel washer ensures a reliable connection for the connector. The double-ended bolt, which eliminates the need for a torque wrench, maximizes connection efficiency and effectiveness.
The unique temperature-indication module ensures that maintenance personnel are alerted in the event of a system failure or overheating.
The KLD-C busbar plug-in box features a unique mechanically assisted pushing mechanism, enhancing the efficiency and reliability of connections.
Reference standard
The KLD-C busbar trunking system complies with the following standards:
IEC 60947.2-1997 GB7251.1-2005
IEC 60439.1-2001 GB7251.2-2006
IEC 60439.2-2000
IEC60529
JB/T 9662-1999
Protection level
Depending on the application scenario, the busbar trunking system can achieve a protection rating of up to IP65.
Note: IP40—The “40” indicates that the enclosure is protected against solid objects with a diameter of at least 1 mm, and the “0” indicates no additional protection.
IP42—The “42” indicates that the enclosure is protected against solid objects with a diameter of at least 1 mm, and the “2” indicates that it is protected against water dripping at an angle of 15°.
IP54—“5” indicates dust resistance, and “4” indicates splash water resistance.
IP65—“6” indicates dust-tight, and “5” indicates protection against water jets.
Grounding resistance of the KLD-C busbar system (ambient temperature 20°C)
KLD-C busbar grounding strip resistance (Cu) 50% internal grounding
Serial number
Rated current (A)
Resistance (10⁻⁰ Q/m)
1
250
308.6
2
400
208.1
3
630
179.1
4
800
141.1
5
1000
108.1
6
1250
94.2
7
1600
84.3
8
2000
55.8
9
2500
37.6
10
3150
28.9
11
4000
23.3
12
5000
17.4
13
6000
15.1
Form 5-1
KLD-C busbar grounding strip resistance (AI) 50% internal grounding
Serial number
Rated current (A)
Resistance (10⁻⁰ Q/m)
1
250
308.6
2
400
208.1
3
630
179.1
4
800
141.1
5
1000
108.1
6
1250
94.2
7
1600
84.3
8
2000
55.8
9
2500
37.6
10
3150
28.9
11
4000
23.3
12
5000
17.4
13
6000
15.1
Form 5-2
Technical Parameters
Short-circuit current rating
The KLD-C busbar system provides stable and efficient power transmission and boasts extremely high short-circuit withstand capability.
The KLD-C busbar trunking system has passed the third-party verification by CCC for its short-circuit withstand capability.
Copper conductor
Rated current (A)
Rated short-time withstand current (kA)
Rated Peak Withstand Current (kA)
100~630
30
63
630~1600
50
105
1600~3150
65
143
4000~6300
100
220
Form 6-1
Aluminum conductor
Rated current (A)
Rated short-time withstand current (kA)
Rated Peak Withstand Current (kA)
100~250
10
17
400~800
30
63
1000~2500
50
105
3150~4000
80
176
Form 6-2
Technical Parameters
The impact of ambient temperature on usage
At an ambient temperature of 40°C, the KLD-C busbar system can operate continuously under rated current load, with a shell temperature rise not exceeding 30K.
If the busbar trunking system operates continuously in a high-temperature environment, a derating design is required. The rated current after derating = rated operating current × derating factor (see the table below).
Ambient temperature ℃
Capacity reduction factor
40
1.00
45
0.95
50
0.90
55
0.85
60
0.80
65
0.74
70
0.67
Form 7-1
Resistance, Reactance, Impedance, and Voltage Drop
The KLD-C busbar system features low voltage drop characteristics. Its high-purity copper conductors provide extremely low resistance. The compact sandwich structure and the aluminum enclosure made of weak-magnetic materials minimize conductor reactance. Below are the impedance and voltage drop data for the straight sections of the busbar.
Copper busbar (50 Hz, temperature 20°C)
Rated current (A)
Resistance
Reactance
Impedance
Voltage drop (V/m)
Power factor
10⁻⁶ Ω/m
0.8
0.9
1.0
250
154.4
44.8
160.8
0.065
0.069
0.067
400
104.0
35.3
109.8
0.072
0.076
0.072
630
89.6
32.1
95.1
0.099
0.103
0.098
800
70.5
27.4
75.1
0.101
0.105
0.098
1000
58.9
24.1
63.7
0.107
0.110
0.102
1250
47.1
20.7
51.4
0.108
0.112
0.102
1600
35.3
16.6
39
0.106
0.108
0.098
2000
27.9
14.2
31.3
0.107
0.109
0.097
2500
18.8
10.7
21.6
0.093
0.094
0.081
3150
14.4
9.5
17.3
0.094
0.094
0.079
4000
11.7
6.3
13.3
0.091
0.092
0.081
5000
9.4
5.4
10.8
0.084
0.084
0.073
6300
8.7
5.0
10.0
0.086
0.087
0.075
Form 8-1
Aluminum busbar (50 Hz, temperature 20°C)
Rated current (A)
Resistance
Reactance
Impedance
Voltage drop (V/m)
Power factor
10⁻⁶ Ω/m
0.8
0.9
1.0
100
171.3
35.3
174.9
0.027
0.029
0.030
160
171.3
35.3
174.9
0.044
0.047
0.047
200
171.3
35.3
174.9
0.055
0.059
0.059
250
171.3
35.3
174.9
0.069
0.073
0.074
400
129.3
29.5
133.2
0.084
0.090
0.090
500
105.3
25.6
108.4
0.086
0.073
0.091
630
89.0
22.8
91.9
0.093
0.090
0.096
800
69.0
19.1
71.6
0.092
0.092
0.096
1000
59.7
17.1
62.1
0.100
0.098
0.103
1250
47.6
14.5
49.8
0.101
0.098
0.103
1600
38.5
12.5
40.4
0.106
0.106
0.107
2000
31.7
10.9
33.5
0.110
0.107
0.110
2500
26.3
9.5
28.0
0.116
0.111
0.114
3150
17.5
5.8
18.5
0.095
0.115
0.096
4000
12.6
4.8
13.5
0.090
0.093
0.087
Form 8-2
Functional unit
Feed-in linear segment
The feed-in busbar trunking system carries current from the power source and does not feature plug-in interfaces.
The standard length is 3000 mm or 4000 mm, with a minimum length of 400 mm.Dimensions and weight
Copper busbar
Rated current (A)
Width (mm)
Height H (mm)
See the attached figure.
Four-line 100% N
5-thread 100% N, 50% PE
250
128
95
8.54
9.34
8-2
315
128
95
9.57
10.42
400
128
95
10.60
11.50
500
128
105
12.40
13.52
630
128
115
14.20
15.54
800
128
130
17.20
18.94
1000
128
150
20.10
22.24
1250
128
170
24.00
26.67
1600
128
210
29.84
33.31
2000
128
243
35.68
39.95
2500
128
280
43.40
48.74
3200
128
420
59.58
66.52
8-3
4000
128
490
83.33
92.68
5000
128
560
102.45
114.20
6300
128
744
134.60
149.80
Form 9-1
Aluminum busbar
Rated current (A)
Width (mm)
Height H (mm)
See the attached figure.
Four-line 100% N
5-thread 100% N, 50% PE
315
128
95
7.05
7.76
8-2
400
128
105
7.78
8.15
500
128
120
8.87
9.32
630
128
130
10.09
10.66
800
128
150
10.90
11.55
1000
128
175
12.52
13.33
1250
128
200
14.95
16.01
1400
128
220
16.06
17.26
1500
128
230
17.85
19.13
1600
128
240
19.39
20.89
2000
128
285
23.05
24.91
2500
128
400
34.77
37.37
3200
128
520
44.48
48.04
8-3
4000
128
570
49.34
53.39
Form 9-2
Note: The above data is for reference only. Our company reserves the right to modify the above data without further notice.
Insertable Straight Segment
The plug-in busbar trunking system features flexible socket arrangements, with sockets available on both sides. A standard 3-meter section can accommodate up to four sockets on a single side. Users can reserve additional sockets based on specific requirements, allowing for easy reconfiguration when equipment loads are relocated or when expansion is needed in the future.
Each socket outlet is equipped with a socket base plate and a socket cover plate. The socket base plate prevents accidental contact of fingers with live conductors (IP2X), while the phase sequence of the conductors is clearly marked on the socket base plate. The socket cover plate helps prevent contamination of the conductive contact surfaces; when paired with gaskets, it can provide dustproof or moisture-proof capabilities. The standard lengths are 3000 mm or 4000 mm, with a minimum length of 1000 mm. The minimum dimension for L1—the distance from the center of the socket outlet to the standard end—is 400 mm, and the minimum dimension for L2—the distance between the centers of two adjacent socket outlets—is 610 mm.
Connector
The KLD-C busbar system employs a specialized connector equipped with dual-head torque-shear bolts. When the correct torque value is reached, the top bolt head will shear off, ensuring a tight and reliable connection at the joint.
For convenient connection, the connector provides an adjustment range of ±4 mm. The connecting cover plate prevents over-adjustment of the connector; the connector is allowed to make its maximum adjustment only when the connecting cover plate has been removed. The connector can be safely removed without interfering at all with adjacent busbar trunking systems, enabling maintenance of a specific section of busbar trunking or the removal of an entire section.
Double-head torque shear bolt
When the correct torque value is reached and the connector is tightened, the top bolt head will break off, causing the red tag to fall off immediately, thus facilitating inspection.
*The initial installation can be completed without a torque wrench.
*After the first nut falls off, the bolt can still be reused with the help of a torque wrench.
* The standard tightening torque is 68 N·m.
Bent conduit
The KLD-C busbar system offers a complete range of bend units to meet all installation requirements. Special bends, such as those with non-standard angles or dimensions, can be custom-made.
Starting busbar
The busbar at the starting end and the starting-end enclosure can be matched with switchgear and transformers of any model. Users can also independently determine the phase spacing of the busbar at the starting end according to their specific needs.
Note: 1. For standard busbars at the beginning of the system, when the busbar current ≤ 1600 A, K = 100 mm. When the busbar current ≥ 1600 A, K = 120 mm.
2. All data provided are for standard products. If you have any customization requirements, please contact our engineers.
Terminal busbar connection parameters
Copper busbar Dimensions: mm
Rated current
A
B
C
K
M
Type
100
~
~
~
~
~
~
160
~
~
~
~
~
~
200
~
~
~
~
~
~
250
20
40
~
100
Φ11
A
400
20
40
~
100
Φ11
A
500
~
~
~
~
~
~
630
20
40
~
100
Φ11
A
800
20
40
~
100
Φ11
A
1000
25
50
40
100
Φ13
A
1250
25
50
40
100
Φ13
B
1600
25
50
60
100
Φ17
B
2000
30
60
60
120
Φ17
C
2500
30
60
60
120
Φ17
C
3150
30
60
60
120
Φ17
B
4000
25
50
50
120
Φ17
C
5000
30
60
60
120
Φ17
C
6300
30
60
60
120
Φ17
C
Form 15-1
Aluminum busbar Dimensions: mm
Rated current
A
B
C
K
M
Type
100
20
40
~
100
Φ11
A
160
20
40
~
100
Φ11
A
200
20
40
~
100
Φ11
A
250
20
40
~
100
Φ11
A
400
20
40
~
100
Φ11
A
500
25
50
~
100
Φ13
A
630
25
50
~
100
Φ13
A
800
20
40
40
100
Φ13
B
1000
20
40
40
100
Φ13
B
1250
30
60
60
100
Φ17
B
1600
25
50
50
100
Φ17
C
2000
30
60
60
120
Φ17
C
2500
30
60
60
120
Φ17
C
3150
25
50
50
120
Φ17
C
4000
30
60
60
120
Φ17
C
5000
~
~
~
~
~
~
Form 15-2
Note: Busbars with a current rating ≥ 3150A adopt a parallel double-row design, and both rows are equipped with openings for the busbar at the starting end.
Terminal box
The terminal box is used to protect the incoming line interface of the busbar at the terminal end, completely enclosing all exposed busbars in the incoming line section. The standard dimensions of the terminal box are (500mm × 500mm × 500mm), and we can determine the exact dimensions of the terminal box based on site conditions and according to customer requirements.
All data are for standard products. If you have any customization requirements, please contact our engineers.
Terminal cover
The terminal cover is installed at the end of the busbar (or branch busbar), preventing external access to live parts and thereby fully enclosing the entire busbar system.
Plug-in box
The KLD-C plug-in box distributes electrical power from the busbar trunking system to the loads and serves as a mechanism for switching and disconnecting branch currents. As such, the plug-in box is the most frequently used component by users and plays a critical role in protecting branch currents.
When designing the KLD-C, full consideration was given to user requirements, offering a variety of options that include internal circuit breakers or fuses for protection.
Plug-in box with circuit breaker
The circuit breaker protection standard adopts a rated current range of 16A to 630A.
One can install a 3-pole or 4-pole circuit breaker in the junction box to protect the load.
An optional accessory for circuit breakers, such as operating handles, shunt trip releases, and residual current protection modules.
Plug-in box with circuit breaker
The plug-in box with fuse is manufactured according to the specifications provided by the customer.
A unique anti-misconnection plug-in: The plug-in box is equipped with a self-made positioning device that effectively prevents incorrect phase connections.
One-pin connector: All pins are silver-plated to enhance conductivity.
Plug-in box external dimensions (L×W×H) mm
*For non-standard sizes and high-current-rated plug-in boxes, please contact the manufacturer.
Operation method
Current rating (A)
Connector box dimensions (L x W x H) mm
Manual operation
100
450x240×260
160~250
550×260×260
400
650×300×300
630
750×340×320
800
950×370×340
Rotary operating mechanism
100
450 × 240 × (300 + 70)
160~250
550 × 260 × (320 + 70)
400
650 × 300 × (340 + 70)
630
750 × 340 × (360 + 70)
800
950 × 370 × (360 + 70)
Form 19-1
Note: 1. The dimensions in Table 19-1 are determined based on the standard dimensions of 3p/4p circuit breakers, with an additional 70 mm factored in to accommodate the installation space for the rotating handle.
2. All data are for standard products; special requirements can be customized.
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Address: No. A2-6, Enclosure Area, No. 299 Zongbao Road, Guiyang Comprehensive Bonded Zone, Guiyang, China
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