YuyaoKLD-C Densely Packed Busbar System

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

Form 5-1

KLD-C busbar grounding strip resistance (AI) 50% internal grounding

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

Form 6-1

Aluminum conductor

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).

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)

Form 8-1

Aluminum busbar (50 Hz, temperature 20°C)

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

Form 9-1

Aluminum busbar

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

Form 15-1

Aluminum busbar Dimensions: mm

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.

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.