Bus Bar Calculation - Requirement

INDAL CHART
Dimension of Al.
Bus bar
Total Cross Section Per Phase ( sq. mm)
AC Current at an ambient of 35 deg & rise Correctio

50 deg.
n Factor
Derated current considering correction

factor as .667
Width
(mm)
Thickness
(mm)
25.4
6.35
161.29
322.58
483.87
645.16
355
705
970
1100
0.667
236.785
470.235
646.99
733.7
38.1
6.35
241.94
483.87
725.81
967.74
520
1020
1350
1535
0.667
346.84
680.34
900.45
1023.845
50.8
6.35
322.58
645.16
967.74
1290.32
670
1290
1705
1940
0.667
446.89
860.43
1137.235
1293.98
63.5
6.35
403.23
806.45
1209.68
1612.90
810
1510
2000
2260
0.667
540.27
1007.17
1334
1507.42
76.2
6.35
483.87
967.74
1451.61
1935.48
960
1740
2310
2620
0.667
640.32
1160.58
1540.77
1747.54
101.6
6.35
645.16
1290.32
1935.48
2580.64
1235
2140
2800
3200
0.667
823.745
1427.38
1867.6
2134.4
127
6.35
806.45
1612.90
2419.35
3225.80
1505
2510
3240
3700
0.667
2161.08
2467.9
152.4
6.35
967.74
1935.48
2903.22
3870.96
1780
2860
3680
4240
0.667
1187.26
1907.62
2454.56
2828.08
50.8
9.53
484.12
968.25
1452.37
1936.50
830
1500
1970
2260
0.667
553.61
1000.5
1313.99
1507.42
76.2
9.53
726.19
1452.37
2178.56
2904.74
1180
2050
2660
3030
0.667
787.06
1367.35
1774.22
2021.01
101.6
9.53
968.25
1936.50
2904.74
3872.99
1495
2480
3150
3560
0.667
997.165
1654.16
2101.05
2374.52
127
9.53
1210.31
2420.62
3630.93
4841.24
1860
2930
3660
4200
0.667
1240.62
1954.31
2441.22
2801.4
152.4
9.53
1452.37
2904.74
4357.12
5809.49
2120
3340
4080
4680
0.667
1414.04
2227.78
2721.36
3121.56
203.2
9.53
1936.50
3872.99
5809.49
7745.98
2750
4150
4900
5740
0.667
1834.25
2768.05
3268.3
3828.58
76.2
12.7
967.74
1935.48
2903.22
3870.96
1355
2240
2830
3240
0.667
903.785
1494.08
1887.61
2161.08
101.6
12.7
1290.32
2580.64
3870.96
5161.28
1740
2720
3360
3900
0.667
1160.58
1814.24
2241.12
2601.3
127
12.7
1612.90
3225.80
4838.70
6451.60
2080
3120
3900
4550
0.667
1387.36
2081.04
2601.3
3034.85
152.4
12.7
1935.48
3870.96
5806.44
7741.92
2420
3500
4400
5100
0.667
1614.14
2334.5
2934.8
3401.7
203.2
12.7
2580.64
5161.28
7741.92
10322.56
3060
4450
5300
6150
0.667
2041.02
2968.15
3535.1
4102.05
254
12.7
3225.80
6451.60
9677.40
12903.20
3640
5000
6000
6850
0.667
2427.88
3335
4002
4568.95
No. of bars
No. of bars
0.667
No. of bars
1003.835 1674.17
CALCULATION OF ALUMINIUM dropper for 800A
PARAMETERS
Feeder Rating
800 A
Size of Aluminium Bus Bar considered
2x50x10 mm2
i.e. Runs/Phase
2 mm
Width
50 mm
Thickness
10 mm
Current rating as per INDAL Aluminium ( E91)=0.97*EIE M

grade current
1455 A
Design Ambient Temperature
50 C
Rise in Temperature allowed
40 oC
Final Temperature Permitted

Size of Bus Bar enclosure
i.e. Height
Depth
Fault current (for 1 sec)
Duration of Fault
Grade of Al. dropper
A.
for EIE-M grade (Amp)
90
175 x 800
175
800
50000
C
sq.mm
mm
mm
A
o
1 s
E91-E
MINIMUM CONDUCTOR SIZE

Formula
to determine the minimum size of conductor for any fault level:
t = (k/100) x ( Isc/A)2 x (1+ 20 . ) x t
( Ref: Industrial Power Engineering and Application Handbook, Page 865)
t= temperature rise above operating temp. in deg. C
100 oC
(190-90)oC
95 oC
(185-90)oC
Isc= symmetrical fault current in r.m.s in Amps.
A= cross sectional area of conductor in mm 2
20= temperature coefficient of resistence at 20 deg C/deg C
0.00403 for pure Aluminium
0.00363 for Aluminium alloy
0.00393 for pure copper
= operating temperature of the conductor at which the fault occurs
k=
1.166 for aluminium
0.52 for copper
t= duration of fault in seconds
Aluminium starts softening at a temperature of around 180-200 deg.As a rule of thumb for
Al conductor,on a fault a safe temperature rise of 100 deg above the allowable end temperature
of 90 deg of the conductor during normal condition has been considered & taken as the basis
to determine the minimum size of the conductor
Final temp. allowed for busbar after short circuit is 190 deg C
By putting all values in the above equation
1500
100 = (1.166/100) ( 50000/A)2 (1+ 0.00363 x 90) x 1

A=
630.26 sq.mm
for pure Al.
621.88 sq.mm
for Al alloy
646.63 sq.mm
638.03 sq.mm
( final temp 190 i.e. 90+100)

( final temp 190 i.e. 90+100)
for pure Al.

for Al alloy
( final temp 185 i.e. 90+95)

( final temp 185 i.e. 90+95)
B.
THERMAL RATING
I.
DERATING FACTOR ON ACCOUNT OF HIGHER AMBIENT

TEMPERATURE
50 oC
40 oC
Derating Factor k1 :
0.88
( Ref: Industrial Power Engineering and Application Handbook, Page 870,871)
II.
DERATING DUE TO ENCLOSURE

Cross sectional area of busbar
cross sectional area of enclosure
= No. of Phase x (Cross Section per Phase) x 100

= 300000
140000
As per table 5(enclosed) of INDAL paper on INDAL Al. Bus Bar,
the derating factor, k2 :
if ratio is less than 5%
0.75
2.1428571429
III. DERATING DUE TO PROXIMITY EFFECT

Busbar rating is lower than 1600A
So,the derating due to proximity effect will be , k3 :
IV.
DERATING DUE TO BUSBAR MATERIAL

Grade :
Electrolytic gr. Al.(D50SWP)
Derating Factor , k4 :
V.
0.95
i.e. E91-E
( INDAL ALLOY)
TOTAL DERATING FACTOR

Total derating = derating due to ambient x derating due to enclosure x derating due
to proximity effect x derating due to busbar material
= k1 x k2 x k3 x k4
0.627
So, the cross section of dropper required for 630 A out going ACB shall cary 630A after
considering all derating factors = (Combined derating factor) x ( Current from Indal Data Sheet)
=(k1 x k2 x k3 x k4) x ( Current from Indal Data Sheet)
912.285
So,the busbar size choosen from Indal sheet shall be capable of

carrying
912.285 A
CALCULATION OF ALUMINIUM dropper for 1000/1250A
PARAMETERS
Feeder Rating
1000/1250
3x50x10 mm2
i.e. Runs/Phase
3 mm
Width
50 mm
Thickness
10 mm

grade current
1998.2 A
50 C
40 oC

i.e. Height
Depth
Duration of Fault
A.
for EIE-M grade (A)
90
175 x 800
175
800
50000
C
sq.mm
mm
mm
A
o
1 s
E91-E

Formula
t = (k/100) x ( Isc/A)2 x (1+ 20 . ) x t
100 oC
(190-90)oC
95 oC
(185-90)oC
k=
1.166 for aluminium
0.52 for copper
2060
100 = (1.166/100) ( 50000/A)2 (1+ 0.00363 x 90) x 1

A=
630.26 sq.mm
for pure Al.
621.88 sq.mm
for Al alloy
646.63 sq.mm
638.03 sq.mm
( final temp 190 i.e. 90+100)

( final temp 190 i.e. 90+100)
for pure Al.

for Al alloy
( final temp 185 i.e. 90+95)

( final temp 185 i.e. 90+95)
B.
THERMAL RATING
I.

TEMPERATURE
50 oC
40 oC
0.88
II.


= 450000
140000
0.75
3.2142857143

IV.

Grade :
V.
0.95
i.e. E91-E
( INDAL ALLOY)

= k1 x k2 x k3 x k4
0.627
1252.8714

carrying
1252.8714 A
CALCULATION OF ALUMINIUM dropper for 1250/1600A
PARAMETERS
Feeder Rating
1250/1600
4x50x10 mm2
i.e. Runs/Phase
4 mm
Width
50 mm
Thickness
10 mm

grade current
2429.85 A
50 C
40 oC

i.e. Height
Depth
Duration of Fault
A.
for EIE-M grade (A)
90
175 x 800
175
800
50000
C
sq.mm
mm
mm
A
o
1 s
E91-E

Formula
t = (k/100) x ( Isc/A)2 x (1+ 20 . ) x t
100 oC
(190-90)oC
95 oC
(185-90)oC
k=
1.166 for aluminium
0.52 for copper
2505
100 = (1.166/100) ( 50000/A)2 (1+ 0.00363 x 90) x 1

A=
630.26 sq.mm
for pure Al.
621.88 sq.mm
for Al alloy
646.63 sq.mm
638.03 sq.mm
( final temp 190 i.e. 90+100)

( final temp 190 i.e. 90+100)
for pure Al.

for Al alloy
( final temp 185 i.e. 90+95)

( final temp 185 i.e. 90+95)
B.
THERMAL RATING
I.

TEMPERATURE
50 oC
40 oC
0.88
II.


= 600000
140000
0.75
4.2857142857

IV.

Grade :
V.
0.95
i.e. E91-E
( INDAL ALLOY)

= k1 x k2 x k3 x k4
0.627
1523.51595

carrying
1523.51595 A
CALCULATION OF ALUMINIUM BUS LINK for 800A
PARAMETERS
Feeder Rating
800 A
2x76.2x6.35 mm2
i.e. Runs/Phase
2 mm
Width
76.2 mm
Thickness
6.35 mm

grade current
1740 A
50 oC
40 oC

i.e. Height
Depth
Duration of Fault
A.
90
175 x 800
175
800
50000
C
sq.mm
mm
mm
A
o
1 s
E91-E

Formula
t = (k/100) x ( Isc/A)2 x (1+ 20 . ) x t
100 oC
(190-90)oC
95 oC
(185-90)oC
k=
1.166 for aluminium
0.52 for copper
100 = (1.166/100) ( 50000/A)2 (1+ 0.00363 x 90) x 1

A=
630.26 sq.mm
for pure Al.
621.88 sq.mm
for Al alloy
646.63 sq.mm
638.03 sq.mm
( final temp 190 i.e. 90+100)

( final temp 190 i.e. 90+100)
for pure Al.

for Al alloy
( final temp 185 i.e. 90+95)

( final temp 185 i.e. 90+95)
B.
THERMAL RATING
I.

TEMPERATURE
50 oC
40 oC
0.88
II.


= 290322
140000
0.75
2.0737285714

IV.

Grade :
V.
0.95
i.e. E91-E
( INDAL ALLOY)

= k1 x k2 x k3 x k4
0.627
1090.98

carrying
1090.98 A
CALCULATION OF ALUMINIUM BUS LINK f for 1000/1250A
PARAMETERS
Feeder Rating
1000/1250
3x76.2x6.35 mm2
i.e. Runs/Phase
3 mm
Width
76.2 mm
Thickness
6.35 mm

grade current
2310 A
50 oC
40 oC

i.e. Height
Depth
Duration of Fault
A.
90
175 x 800
175
800
50000
C
sq.mm
mm
mm
A
o
1 s
E91-E

Formula
t = (k/100) x ( Isc/A)2 x (1+ 20 . ) x t
100 oC
(190-90)oC
95 oC
(185-90)oC
k=
1.166 for aluminium
0.52 for copper
100 = (1.166/100) ( 50000/A)2 (1+ 0.00363 x 90) x 1

A=
630.26 sq.mm
for pure Al.
621.88 sq.mm
for Al alloy
646.63 sq.mm
638.03 sq.mm
( final temp 190 i.e. 90+100)

( final temp 190 i.e. 90+100)
for pure Al.

for Al alloy
( final temp 185 i.e. 90+95)

( final temp 185 i.e. 90+95)
B.
THERMAL RATING
I.

TEMPERATURE
50 oC
40 oC
0.88
II.


= 435483
140000
0.75
3.1105928571

IV.

Grade :
V.
0.95
i.e. E91-E
( INDAL ALLOY)

= k1 x k2 x k3 x k4
0.627
1448.37

carrying
1448.37 A
CALCULATION OF ALUMINIUM BUS LINK for 1250/1600A
PARAMETERS
Feeder Rating
1250/1600
4x76.2x6.35 mm2
i.e. Runs/Phase
4 mm
Width
76.2 mm
Thickness
6.35 mm

grade current
2620 A
50 oC
40 oC

i.e. Height
Depth
Duration of Fault
A.
90
175 x 800
175
800
50000
C
sq.mm
mm
mm
A
o
1 s
E91-E

Formula
t = (k/100) x ( Isc/A)2 x (1+ 20 . ) x t
100 oC
(190-90)oC
95 oC
(185-90)oC
k=
1.166 for aluminium
0.52 for copper
100 = (1.166/100) ( 50000/A)2 (1+ 0.00363 x 90) x 1

A=
630.26 sq.mm
for pure Al.
621.88 sq.mm
for Al alloy
646.63 sq.mm
638.03 sq.mm
( final temp 190 i.e. 90+100)

( final temp 190 i.e. 90+100)
for pure Al.

for Al alloy
( final temp 185 i.e. 90+95)

( final temp 185 i.e. 90+95)
B.
THERMAL RATING
I.

TEMPERATURE
50 oC
40 oC
0.88
II.


= 580644
140000
0.75
4.1474571429

IV.

Grade :
V.
0.95
i.e. E91-E
( INDAL ALLOY)

= k1 x k2 x k3 x k4
0.627
1642.74

carrying
1642.74 A
Operating temperature 90 deg C

Ambient temp
Permissible Bar temp rise
C
35
40
45
50
C
55
50
45
40
Derating Factor
1.05
1
0.945
0.88
55
60
35
30
0.815
0.75
Operating temperature 85 deg C

Ambient temp
Permissible Bar temp rise
C
30
35
40
45
50
55
C
55
50
45
40
35
30
Derating Factor
1.05
1
0.945
0.88
0.815
0.75
Derating Factor due to material

Electrolytic Grade i.e. E91-E
0.94
Derating Factor due to Proximity Effect

0.95
Derating Factor due to enclosure

Enclosure
1.Outdoor
2.Indoor where the enclosure
itself is in a well ventillated
room
2.Indoor where the enclosure
itself is in a poorly ventillated
room & room temp is high
Ratio
<1%
5%
10%
Derating Factor
0.95
0.9
0.85
<1%
5%
10%
<1%
5%
0.85
0.75
0.65
0.65
0.6
10%
0.5

Bus Bar Calculation - Requirement

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Bus Bar Calculation - Requirement

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INDAL CHART

Total Cross Section Per Phase ( sq. mm)

AC Current at an ambient of 35 deg & rise Correctio

Derated current considering correction

CALCULATION OF ALUMINIUM dropper for 800A

Size of Aluminium Bus Bar considered

Current rating as per INDAL Aluminium ( E91)=0.97*EIE M

Design Ambient Temperature

Rise in Temperature allowed

Final Temperature Permitted

for EIE-M grade (Amp)

MINIMUM CONDUCTOR SIZE

100 = (1.166/100) ( 50000/A)2 (1+ 0.00363 x 90) x 1

( final temp 190 i.e. 90+100)

for pure Al.

( final temp 185 i.e. 90+95)

DERATING FACTOR ON ACCOUNT OF HIGHER AMBIENT

Rise in Temperature allowed

DERATING DUE TO ENCLOSURE

= No. of Phase x (Cross Section per Phase) x 100

the derating factor, k2 :

if ratio is less than 5%

III. DERATING DUE TO PROXIMITY EFFECT

DERATING DUE TO BUSBAR MATERIAL

TOTAL DERATING FACTOR

So,the busbar size choosen from Indal sheet shall be capable of

CALCULATION OF ALUMINIUM dropper for 1000/1250A

Size of Aluminium Bus Bar considered

Current rating as per INDAL Aluminium ( E91)=0.97*EIE M

Design Ambient Temperature

Rise in Temperature allowed

Final Temperature Permitted

for EIE-M grade (A)

MINIMUM CONDUCTOR SIZE

100 = (1.166/100) ( 50000/A)2 (1+ 0.00363 x 90) x 1

( final temp 190 i.e. 90+100)

for pure Al.

( final temp 185 i.e. 90+95)

DERATING FACTOR ON ACCOUNT OF HIGHER AMBIENT

Rise in Temperature allowed

DERATING DUE TO ENCLOSURE

= No. of Phase x (Cross Section per Phase) x 100

the derating factor, k2 :

if ratio is less than 5%

III. DERATING DUE TO PROXIMITY EFFECT

DERATING DUE TO BUSBAR MATERIAL

TOTAL DERATING FACTOR

So,the busbar size choosen from Indal sheet shall be capable of

CALCULATION OF ALUMINIUM dropper for 1250/1600A

Size of Aluminium Bus Bar considered

Current rating as per INDAL Aluminium ( E91)=0.97*EIE M

Design Ambient Temperature

Rise in Temperature allowed

Final Temperature Permitted

for EIE-M grade (A)

MINIMUM CONDUCTOR SIZE

100 = (1.166/100) ( 50000/A)2 (1+ 0.00363 x 90) x 1

( final temp 190 i.e. 90+100)

for pure Al.

( final temp 185 i.e. 90+95)

DERATING FACTOR ON ACCOUNT OF HIGHER AMBIENT

Rise in Temperature allowed

DERATING DUE TO ENCLOSURE