Busbar

P ro d u c t D a t a S h e e t
 Product Data Sheet
Busbar IS 2120-0004

Technical Data Sheet

Busbar
For the high-voltage area, in locations where cable connections are unsuitable due to their
outer dimensions

Material of conductor Cu-OF-E or Al 99,7

Material of insulation Polyamide layer

12 x 2,2 (25 mm²) - Cu

16 x 2 (32mm²) - Cu
12 x 3 (35 mm²) - Cu or Al
Dimension of cross-section [mm]
15,5 x 3,5 (50 mm²) - Cu or Al
17 x 4.5 (70 mm²) - Cu or Al
19,5 x 5 (90 mm²) - Cu or Al

Possible bending radii [mm] See Section 2.2

Nominal voltage [V] 600 AC / 1000 DC

Dielectric strength [VDC] > 5000

Operating temperature [°C] -40 to 105° (temporary 125°)

 Product Data Sheet
Busbar IS 2120-0004

Busbar
Version 5.0

Change reference:

Issue date Issue Changed pages Type and reason for the change

11.10.2017 1.0 Initial issue

02.11.2017 2.0 9 Bending radii revised

9 & 10 Bending radii and minimum distances re-

26.02.2018 3.0
vised

Added new busbar sizes and material:

11.12.2018 4.0 2 32mm² Cu,
35²-50²-70²-90mm² Al

08.07.2019 5.0 Completely revised

This directive has been released for use:

Org. Name Signature

Created/changed TK Daniel Gutwenger Daniel Gutwenger

(Prozessverantwor-
Reviewed VE Daniel Gutwenger Daniel Gutwenger
tung)

Released VE Dr. Claudia Stern Dr. Claudia Stern

 Product Data Sheet
Busbar IS 2120-0004

Preface:

This document provides an overview of Intercable’s product line of High Voltage extruded
Busbars, the applicable geometry, attachment components as well as a summary of tests
conducted per customer product validations.

Also-applicable documents:

DIN EN 60695-11-10
ISO 6722-1
VW 60306
DIN EN ISO 14270
DIN EN ISO 14273
 Product Data Sheet
Busbar IS 2120-0004

Table of Contents

Technical Data Sheet ...............................................................................................ii

1 Introduction ..................................................................................................... 6

2 Bar .................................................................................................................. 7
2.1 Cross-sections ...................................................................................................... 7
2.2 Bar Structure ......................................................................................................... 8
2.3 Bending Geometry ................................................................................................ 9
2.4 Stripping & Welding ............................................................................................ 10
2.5 Deratingcurve...................................................................................................... 11

3 Flex Area ........................................................................................................16

4 Fastening Parts ...............................................................................................17

5 Attachments ...................................................................................................18
5.1 Attachment Clip .................................................................................................. 18
5.2 Spacers ............................................................................................................... 19
5.3 Weld-on elements ............................................................................................... 19
5.4 Caps .................................................................................................................... 20

6 Customer validation ........................................................................................21

 Product Data Sheet
Busbar FM 11009-007
© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-

1 Introduction

Fastening
element
Polyamide cap Screw
sible to any third parties!

Busbar
Flex Area

Figure 1-1 Busbar with different attachments

Busbars are used for high-voltage current transmission, in locations where cable connections
are unsuitable due to their outer dimensions. The solid flat conductor used permits a smaller
cross-section while preserving conductivity.

The busbars can be delivered in different sizes (see table 2.1). A flexible cable area is used in
the relevant locations to compensate for tolerances and prevent vibration damage. Holes are
punched in the ends or mounting elements, which are protected from corrosion through tin-
ning, are welded on to permit simple mounting on the poles with screws. Polyamide caps are
used as contact protection above the welding points. They serve as protection against loss
at the same time. Figure 1-1 shows the schematic of such a bus bar with different attach-
ments.

V5.0 / 06.08.2019 IS 2120-0004 6 / 28

 Product Data Sheet
Busbar FM 11009-007

2 Bar
© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-

2.1 Cross-sections
Busbar insulated with a polyamide layer

Dimensions (AxB) Cu Al
Cross-sec-
Article Article
tion A B
No. No.
25mm² 13 3,2 381329 -
32mm² 17 3 388564 -
35mm² 13 4 380967 502088
50mm² 16,5 4,5 501798 502089
70mm² 18 5,5 501904 502090
B
90mm² 20,5 6 501802 502091
sible to any third parties!

Figure 2-1 Busbar insulated

Braided copper tapes with silicone jacket

Dimensions (AxB) Article
Cross-section
A B No.
25mm² 15,6 7,3 501384
35mm² 17,2 8 501383

B
Figure 2-2 Braided copper tape with silicone jacket

V5.0 / 06.08.2019 IS 2120-0004 7 / 28

 Product Data Sheet
Busbar FM 11009-007

2.2 Bar Structure

© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-

Long edge
Conductor
(Cu OF-E or Al 99,5)
Short edge

PA12-insulation

Figure 2-3 Structure of a busbar

sible to any third parties!

The busbar is made of highly conductive copper (Cu-OF-E) or aluminum (Al 99,7 EN AW 1070A
H112), which is protected against mechanical damage and corrosion by a high-quality poly-
amide layer (PA12). The insulation is extruded onto the flat conductor in order to maintain
adhesion even after twisting and bending. The ends of the busbar are stripped outwards by
a laser using a special process that ensure there is no notch left on the busbar. The longer
one of the two edges is usually called the long edge (or high edge), the shorter one the short
edge. The busbars can be designed in different thicknesses (see 2.1). Figure 2-3 shows the
schematic structure.
Compared to cables, busbars are particularly suitable for use with sharp bends due to their
low height. Busbars can be twisted as well as bent. The twisting and bending machine is
performed by a special bending machine. More details on twisting and bending capabilities
can be taken from Figure 2-3.

V5.0 / 06.08.2019 IS 2120-0004 8 / 28

 Product Data Sheet
Busbar FM 11009-007
© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-

2.3 Bending Geometry

For process-related reasons, bending radii are limited to the values displayed in the chart
below. Minimum distances between the bends must be maintained for structural integrity, as
well for process-related reasons.

Long edge Short edge

sible to any third parties!

25mm² : R1= 13mm 25mm² : R2= 3mm

32mm² : R1= 20mm 32mm² : R2= 3mm
35mm² : R1= 13mm 35mm² : R2= 4mm
50mm² : R1= 15mm 50mm² : R2= 4mm
70mm² : R1= 18mm 70mm² : R2= 4mm
90mm² : R1= 20mm 90mm² : R2= 4mm

Figure 2-4 Bending radii

V5.0 / 06.08.2019 IS 2120-0004 9 / 28

 Product Data Sheet
Busbar FM 11009-007

Busbars can be twisted as well as bent. More Details on twisting can be taken from
© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-

Figure 2-5.

Figure 2-5 Minimum distances for twisting

sible to any third parties!

2.4 Stripping & Welding

The busbars are first stripped by a laser in the welding points. For process-related reasons,
stripping lenghts must be a min. of 12mm. Again, as shown in Figure 2-6, minimum distances
from the next bend must be observed.

Cmin
25mm² 10
32mm² 10
35mm² 10
50mm² 10
70mm² 10
90mm² 10
Figure 2-6 Minimum distances for stripping

V5.0 / 06.08.2019 IS 2120-0004 10 / 28

 Product Data Sheet
Busbar FM 11009-007

2.5 Deratingcurve
© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-

Following charts show the max. permissible current load capacity for individual busbar cross
sections, under which the max. permissable temperature of the busbar of 105°C (short term
125°C) will be reached at a given ambient temperature.
The dotted-line represents the base-graph for the calculated current. The continuous-line rep-
resents a corrected-graph with current multiplied by a 0.8 correction-factor.
This corrected-graph is the desired Deratingcurve, showing the current load capacity per ref-
erence norm for the individual component.
sible to any third parties!

25mm² Cu - insulated

Figure 2-7 Deratingcurve 25mm² - Copper busbar

V5.0 / 06.08.2019 IS 2120-0004 11 / 28

 Product Data Sheet
Busbar FM 11009-007

32mm² Cu - insulated
© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-
sible to any third parties!

Figure 2-8 Deratingcurve 32mm²-Copper busbar

35mm² Cu - insulated

Figure 2-9 Deratingcurve 35mm² - Copper busbar

V5.0 / 06.08.2019 IS 2120-0004 12 / 28

 Product Data Sheet
Busbar FM 11009-007

50mm² Cu - insulated
© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-
sible to any third parties!

Figure 2-10 Deratingcurve 50mm² - Copper busbar

70mm² Cu - insulated

Figure 2-11 Deratingcurve 70mm² - Copper busbar

V5.0 / 06.08.2019 IS 2120-0004 13 / 28

 Product Data Sheet
Busbar FM 11009-007

90mm² Cu - insulated
© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-
sible to any third parties!

Figure 2-12 Deratingcurve 90mm² - Copper busbar

50mm² Al - insulated

Figure 2-13 Deratingcurve 50mm² - Aluminium busbar

V5.0 / 06.08.2019 IS 2120-0004 14 / 28

 Product Data Sheet
Busbar FM 11009-007

70mm² Al - insulated
© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-
sible to any third parties!

Figure 2-14 Deratingcurve 70mm² - Aluminium busbar

90mm² Al - insulated

Figure 2-15 Deratingcurve 90mm²- Aluminium busbar

V5.0 / 06.08.2019 IS 2120-0004 15 / 28

 Product Data Sheet
Busbar FM 11009-007

3 Flex Area
© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-

Flex connections are flexible conductors that are inserted between the busbars to compen-
sate for tolerances and prevent vibration damage. They are then welded to the busbars on
both sides and the welds are covered with caps. The cables can be designed as flat or round
copper strand conductors with silicone jacket. The schematic structure of a flex area of this
kind is illustrated in Figure 3-1.
sible to any third parties!

Figure 3-1 Flex area with flat cable

Flexible laminated copper connectors are another way of flexibly designing busbars and
thus ensuring tolerance compensation.
These connectors can also be coated with the desired coating on the contact surface.

Figure 3-2 Flexible laminated copper connector

V5.0 / 06.08.2019 IS 2120-0004 16 / 28

 Product Data Sheet
Busbar FM 11009-007

4 Fastening Parts
© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-

Fastening elements serve to fasten the busbar to the contact. For Copper busbars, this is
either done using punched or forged mounting plates of tinned copper that are welded to the
ends of the busbars in any outlet direction, or simply punching holes into the busbar (Figure
4-1). The busbar can be screwed to the contact using a bore in these mounting elements. The
corresponding screws are delivered pre-installed and captive by use of polyamide caps when
using the mounting plates. In a perforated busbar, the screws are installed by the customer.
For fastening/connecting aluminum busbars, a copper terminal with nickel plating must be
connected on the busbar, using ultrasonic welding technology.
sible to any third parties!

Figure 4-1 Forged (left) and punched (middle) mounting plate, perforated busbar (right)

V5.0 / 06.08.2019 IS 2120-0004 17 / 28

 Product Data Sheet
Busbar FM 11009-007

5 Attachments
© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-

5.1 Attachment Clip

The attachment clips fasten the bar in addition to the mounting elements. Figure 5-1 shows
this kind of clip.
sible to any third parties!

Figure 5-1 Attachment clips

V5.0 / 06.08.2019 IS 2120-0004 18 / 28

 Product Data Sheet
Busbar FM 11009-007

5.2 Spacers
© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-

In place of the usual foam material, spacers (Figure 5-2) are mounted on the bar and fixed
with adhesive tape to hold it in position and prevent vibration damage. These spacers come
in both single sided and double sided in order to find the perfect solution. They act as shock
absorbers and can be forced in between internal components in order to keep the busbar
snug and secure.
sible to any third parties!

Figure 5-2 Spacers

5.3 Weld-on elements

In order to be able to attach, e.g., sensors to the conductor, contacts called weld-on elements
are welded directly to the conductor. These elements can be coated in corrosion-resistant
metals for protection. One example for such a weld-on element is shown in Figure 5-3.

Figure 5-3 weld-on element for measure assistance

V5.0 / 06.08.2019 IS 2120-0004 19 / 28

 Product Data Sheet
Busbar FM 11009-007

5.4 Caps
© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-

The self-extinguishing (DIN EN 60695-11-10 V0) polyamide caps (Figure 5-4) are used as con-
tact protection over welding points. The caps installed over the mounting plates (Figure 5-4,
top) also protect the screw from being lost in transport and permit safe mounting through
the access hole. All conductor components are shielded according to IP2-Protective Class
for accessibility using a 12.5 mm standardized-finger.
sible to any third parties!

Figure 5-4 Polyamide caps

V5.0 / 06.08.2019 IS 2120-0004 20 / 28

 Product Data Sheet
Busbar FM 11009-007

6 Customer validation
© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-

The validation tests are carried out according to ISO 6722-1 (edition: 15.10.2011), DIN EN ISO
14270, DIN EN ISO 14273. This consists of the following tests. The individual test description
can be found on the following pages.

Result
Test Procedure Rigid
Flex Area
Busbar

Measurement of the 30-mi- No penetration after 4h salt water bath

OK OK
nute tensile strength (8.5.2) (3% NaCl), 30 min 1 kV AC, 5 min 5 kV AC

Measurement of the 1-minute No penetration after 10 min salt water

OK OK
tensile strength (8.5.3) bath (3% NaCl), 1 min 1 kV AC
sible to any third parties!

Strength of Insulation: to pres- No puncture after pressure test (2.9 N), 4h

OK OK
sure (8.6.3) at 180° and 10s bath in cold water

Thermal resistance during No penetration after wrapping around a

bending (8.6.4) 20mm mandrel six times at 155° for 1h
OK OK
cooled down to room temp. and 1 min
5kV AC

Thermal overload (8.6.5) No breakdown after 6h at 180°C, 16h at

OK OK
room temp. then bend and stress test.

Short term aging(240h) No breakdown after 240h at 125°C, 16h at

OK OK
(8.6.6) room temp. bend and stress test

Low-Temperature impact re- No breakdown after 16h at -15°C, impact

OK OK
sistance test (-15 °C) (8.6.9) and stress test

V5.0 / 06.08.2019 IS 2120-0004 21 / 28

 Product Data Sheet
Busbar FM 11009-007
© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-

Delivery terms per VW 75210- No knots, cracks, blisters or inclusions al-

OK OK
2 (6.4.1) lowed on the insulation coating

Delivery terms per VW 75210- No current leakage for busbar at 10s, 8 kV

OK
2 (6.4.2)

Abrasion resistance of insula- Min. 1500 abrasion cycles OK, over 80000 OK, over 1750
tion (8.3.2) strokes strokes

Strength of insulation: to The pattern remains constant OK, notched OK, notch force
notches (8.3.6) force of 500 N of 500 N

Derating Curve Derating Curve See test description

Peel force of welding accord- Peel force greater than 0.6kN at OK, Rail adapter: min 4,75kN,
ing to DIN EN ISO 14270 25mm/min peel off speed Flex tape adapter: min 0,98kN,
Rail flex tape: min 0,78kN
sible to any third parties!

Shear strenght of welding ac- Shear strength greater than 2kN at OK, Rail adapter: min 7,18kN,
cording to DIN EN ISO 14273 25mm/min pull of speed Flex tape adapter: min 4,8kN,
Rail flex tape: min 4,6kN

Flame Propagation Classification: self-extinguishing (V0)

UL 94 V0 UL 94 V0
Resistance TL 1011

Flame Propagation Classification: SE/NBR

SE/NBR SE/NBR
Resistance TL 1010

V5.0 / 06.08.2019 IS 2120-0004 22 / 28

 Product Data Sheet
Busbar FM 11009-007

30 Minutes Voltage Leakage Test (8.5.2)

© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-

Test speciments are conditioned for 4h in a salt water bath (3% NaCl). Then a voltage of 1 kV
AC is applied for 30 minutes. The voltage is then increased to 5kV (500V/s) for 5 minutes. No
breakdown may occur during the voltage tests. The schematic of the test apparatus can be
taken from Figure 6-1.

1 Voltage Provider
2 non- conducting container
3 Electrode
4 Test Specimen
5 Salt water bath
sible to any third parties!

Figure 6-1 Example of the 30 minute stress test apparatus

1 Minute Voltage Leakage Test (8.5.3)

Test specimens are stored for 10 minutes in a salt water bath (3% NaCl). The a voltage of
1kV AC is applied for 1 minute. No breakdown may occur.

Pressure Test at High Temperature (8.6.3)

The busbar is clamped in the test apparatus and loaded with a force of 2.90 N (see Figure
6-2). It is then stored under pressure for 4h at 100°C ± 2°C, after it is dipped in cold water for
10 seconds and then the voltage leakage tests is performed for 1 minute. Cosmetic defects
are permissible.

Figure 6-2 Pressure Test at High Temperature

V5.0 / 06.08.2019 IS 2120-0004 23 / 28

 Product Data Sheet
Busbar FM 11009-007

Thermal Testing while Bent (8.6.4)

© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-

Test specimens are wrapped six times around a 20mm diameter mandrel (according to ISO
6722-1, item 5.10.3.2) and fastened so that it does not unwrap. Test specimens are then con-
ditioned for 1h at 155°C. Then they are cooled to room temperature. The voltage test is then
carried out to as validation. No degradation or leakage may occur.

Figure 6-3 Busbar post-testing (unwrapped)

sible to any third parties!

Thermal Overload (8.6.5)

Test specimens stored at 150°C ± 3°C for 6h. Then they are stored at room temperature for
16h. The bend test is then carried out on the specimens and then are subjected to a voltage
leakage test for 1min.

Figure 6-4 Test Specimens for Thermal Overload

V5.0 / 06.08.2019 IS 2120-0004 24 / 28

 Product Data Sheet
Busbar FM 11009-007

Short-term Aging (240 h) (8.6.6)

© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-

Test specimens are stored at a temperature of 125°C ± 3°C for 240h, then are stored at a
minimum of 16h at room temperature and subjected to a bend test around a stationary man-
drel. The bend test is carried out at -25°C ± 2°C. Lastly they are tested for breakdown through
the voltage leakage test for 1 minute.

Low Temperature Impact Test (-15 °C) (8.6.9)

Test specimens are conditioned at -15°C ± 2°C for 16h. After conditioning they undergo an
impact test (see Figure 6-5). In this case, a weight falls from 100mm onto the steel piece,
under which the test specimen is located. Following the impact test, specimen is visually
inspected for insulation damage, then they are tested for breakdown through the voltage
sible to any third parties!

leakage test.

Figure 6-5 Low Temperature Impact Test Apparatus

Delivery Terms per VW 75210-2 (6.4.1)

No knots, cracks, blisters or inclusions allowed on the insulation coating.

V5.0 / 06.08.2019 IS 2120-0004 25 / 28

 Product Data Sheet
Busbar FM 11009-007

Delivery Terms per VW 75210-2 (6.4.2)

© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-

Insulation Coating of test samples is examined for flaws and subsequently tested for HV at
8 kV for 10 sec. No current leakage allowed

Abrasion Resistance of Insulation (8.3.2)

Test specimens are clamped into the abrasion device and tested at needle thickness of
0.45mm and a load of 7N. The test specimens must survive a minimum of 1,500 cycles.

Strength of Insulation (8.3.6)

Test specimens are clamped into the notched impact apparatus and a steel wire, 0.45mm in
diameter is pressed into the insulation material at a constant speed of 2 mm/min. The notch
force should be selected in a rational manner. In our experiments this was about 500N.
sible to any third parties!

Derating Curve Welding

A derating curve is created for the welding points on the busbar. Based on this curve, the
maximum permissible power loss can be found at the corresponding ambient temperature.
The corresponding curves can be seen in the following figures.

Peel Force oft he Welding according to DIN EN ISO 14270

The peek force oft he welding is determined according to DIN EN ISO 14270. The peel force
must at least 0,6kN at a peel off speed of 25mm/min.

Shear Strength oft he Weld according to DIN EN ISO 14273

The shear strength oft he weld is determined according to DIN EN ISO 14273. The shear
strength must be greater than 2kN at a pulling speed of 25mm/min.

Flame propagation according to TL 1011

The burning behaviour oft he flat conductor as well as the flexible conductor is determined.
The classification is V0 (self-extinguishing).

V5.0 / 06.08.2019 IS 2120-0004 26 / 28

 Product Data Sheet
Busbar FM 11009-007

Flame propagation according to TL 1010

© Fehler! Verweisquelle konnte nicht gefunden werden. Intercable GmbH. This document must not be copied or otherwise reproduced and must not be made acces-

The burning behaviour of the flat conductor and flexible conductor is determined. The classi-
fication is SE/NBR (self-extinguishing/not flammable).
sible to any third parties!

V5.0 / 06.08.2019 IS 2120-0004 27 / 28

INTERCABLE GmbH
Rienzfeldstrasse, 21
I-39031 Bruneck
Tel.: +39 0474 571 700
Fax: +39 0474 555 511
[email protected]
www.intercable.com © FM 11009-007 Intercable GmbH