1 Bimetal Technology

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Copper Contact Busway

SBGMar 2011Rev 6.2

- New Copper Solution


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Schneider Electric 2- SBG Exp CCB rev6.2 - Mar 2011

General Introduction


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Schneider Electric 3- SBG Export May 2010

Background of Aluminum

Unlike Oil and Copper (limited resource), Aluminum is the most abundant

(8%) metallic element, the 3rd most abundant of all elements (after oxygen

and silicon)

Aluminum is a good thermal and electrical

conductor, by weight better than copper(65% of conductivity by volume, 50% by weight)

Price of aluminum more stable than

copper- 100% increase over past 5

years, compared with 300% increase ofcopper!


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Problems of traditional aluminum busway (1)

Aluminum oxide (alumina or aloxite) forms when the metal exposed to

air, responsible for metallic aluminums resistance to weathering.

Therefore an electrical insulator(overheat).

Fretting corrosion happens at contact between PIU jaw and busbar(Fretting corrosion refers to corrosion damage at the asperities of contact

surfaces. This damage occurs under load and in the presence of repeated

relative surface motion, as often induced by vibration).


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Problems of traditional aluminum busway (2)

Fretting corrosion results from:

Contact between busbar and PIU jaw under load

Vibration (50Hz)

Repeated relative motion

Deformation on surface (hardness aluminum


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Our solution: Copper Contact (laminated

bimetal)

Silver plated bimetal plate cladding on

aluminum conductor at all connection contacts,

through high current and high pressure

Outer contact surface of the connection plate is

silver-plated copper, the inside surface is

Aluminum

All of busway connection zone are silver to

silver contact Copper placed only at where it is required at

contacts

Fretting corrosion does not happen as

hardness of copper is much higher thanaluminum

>


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Copper Contact Busway Offers

Medium Power (100A-800A) : Canalis KSA

High Power (800A-5000A): I-LINE II BFC

Canalis KSA (100A - 800A) Canalis KT/KHF more than 20 yearsI-LINE BFC (800A - 5000A) - new

More than 30 years application experience in Europe

26 millions meters installed worldwide

9 millions of energized joint packs

9 millions of energized plug-in units

Laminated Bimetal Technology introduced to High Power I-LINE II

series from Medium Power Canalis series

20 yearsMore than

30 years



Advantages

of




A safer, more reliable and economical solution

Safety and Reliability thanks tothe laminated bimetal technology, copper

contact solution removes all doubts and

uncertainties of past experience onapplication of aluminum for power

distribution

Durability service life of coppercontact busway is longer than aluminum

busway, and matches that of copper

busway

Economical copper contact buswayretains many features of copper busway,

yet far more economical and price stablethan copper busway

Aluminum Copper Contact Copper

safety and reliability level (IEC range)


service life level (IEC range)


price level (IEC range)



Green and Environmental Friendly

Reduce pollution pollution during plating process

reduced by 95%. Silver plating applied at only

contact areas instead of entire length of conductor.

RoHS compliant - eliminate the use of hazardous

substances and reduce the pollution*RoHS (Restriction of Hazardous Substances) directive restricts the

use of some hazardous materials (like Lead, Mercury, Cadmium andHexavalent chromium etc), firstly implemented in EU in 2006, and

similar directives are introduced in Asia.

The insulation material is halogen free and no toxic

emission in case of fire (DuPont Mylar)

Product at end of service life can be recycled

insulation easily separated from busbar

Bimetal clads removable from busbar

RoHS

Compliant

Green


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Energy Efficiency

Achieved Green Leaf Energy Efficiency

mark by Intertek, an equivalent level of

Energy Star / LEED.

Schneider Electric is conservative on

optimisation of cross section, which is

designed in such a way that noadditional cooling (e.g. cooling fins)

required on housing. Busway serving

the purpose of electrical distribution

Resistance and power consumption is

lower than the industrial average.


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Lower contact resistance

Silver- silver contact reduces

the contact resistance

The thermal imaging test

shows the temperature of the

connection plate is far lower

than the temperature of cablewhen running at full load

4.5%38.31Ni-Cu alloy

15%11.49Pure tin

61.8%2.901100 aluminum

100%1.722# pure copper

105%1.642# pure silver

Conductivi ty (IACS)Resistancem


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All features and benefitsof

I-Line and Canalisretained!!!


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SEISMIC COMPLIANCE

Schneider Busway System passed the seismic tests andcomplies with Zone-4, most severe, seismic requirements


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Seismic compliance

Full range ofstandard products of I-Line and Canalis

tested and certified to UBC zone 4, more severe,

condition

Tests carried out in EERTC (Earthquake Engineering

Research & Test Centre), witnessed and results agreed by

seismic experts ofShimizu Corporation Japan

Both mechanical (bending and twisting) and dynamic

tests (simulation of several historical earthquakes

including Kobe Japan 1995, Ojiya Japan 2004, ElCentro USA 1940, Building Construction

Wave Japan) performed and passed

Learning points achieved on recommendation of

supports consult factory for further info


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Full 14 type tests

in

IEC60439-1/2 ed.3.1 2005


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14 type tests in IEC 60439-2 ed.3.1: 2005

Note:

1) Edition 3.1 2005, 8.2.9 requires the glow-wire test at a temperature of 960C instead of 850C in Edition 3.0 2000

2) Edition 3.1 2005, 8.2.4 has more clear regulation that the resistance phase to PE measured after the short circuit

withstand test shall not exceed by more than 10% the value before test. Ed.3.0 ask to compare the resistance

before and after the test as indication in the remark.

3) 8.2.11 is not applicable


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3 fire-related type tests (IEC60439-1/2)

8.2.9 - Verif ication of the resistance ofinsulating materials to abnormal heat and

fire

Purpose and importance of this test To verify the insulating material of busway will not

burn or cause the burning when affected by

abnormal heat or by fire with the degree of 9600C

(the insulating material need to retain current-

carrying parts) or 6500C(other than former material).

Test arrangement

Use glow-wire to approach the sample, the

duration is 30 seconds. There shall be no obvious

and continuous flame or the flame shall extinguish

within 30 seconds when moving away the glow-wire.


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8.2.14 - Verif ication of resistance to flame-propagation

Purpose and importance of this test

To verify the resistance to flame propagation. Thefire resistant busway helps to prevent the flame

propagation and fire spread, save time for people

to run away from the fire

Test arrangement

Three standard busbar trunking units of the same

type are placed at regular intervals on a vertical

ladder into a fire test rig; every busbar trunking

shall present a different side orientation to the

burner flame impact. After burning has ceased, the

busbar trunking enclosures should be wiped clean.

All soot is to be ignored if, when wiped off, theoriginal surface is undamaged. If it does not ignite

or the maximum extent of the charred portion

(external or internal) of the busbar trunking has not

reached a height exceeding 2.5m above the

bottom edge of the burner, the system is deemed

has having passed the test.


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8.2.15 - Verif ication of fire resistance inbuilding penetrations

Purpose and importance of this test

Verify the fire resistance in building penetration. The

fire resistant busway can resist the smoke spread andpenetration; prevent the further spread of fire, save time

for people to run away from the fire. Suitable for the

busway designed to prevent the spread of fire with

specified time (60min, 120min, 180min, 240min)

Test is performed according to ISO834

Test arrangement

A representative busbar trunking fire-proof unit sample

shall be mounted as used in building practice on a test

floor, made of concrete. A fire seal shall be used to fillthe void around the busbar trunking enclosure passing

through the hole of the test floor. When performing the

test, a set of thermocouples shall be located on the

unexposed side of the sample to record the surface

temperatures of the busbar trunking enclosure

Required no smoke & temperature rise on unexposedsurface couldnt exceed 180K (Maximum) and 140K

(Average)


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KEMA KEUR

andASTA Diamond (1)

listed

(1) ASTA Diamond license being approved by ASTA


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KEMA KEUR and ASTA Diamond

Full range of I-Line and Canalis carries KEMA KEUR and

ASTA Diamond safety marks

A product carrying the marks is ensured by KEMA / ASTAthat it is safe and is produced identical to those originally

tested. Product and production location undersurveillance

of KEMA / ASTA

Critical for busway than other electrical product as semi-

standard, variety of lengths

General KEMA or ASTA type test is a one-time test on asingle specimen of sample. KEMA or ASTA is not responsible

for the conformity of the production with the specimen tested.

No safety marks

Full type tests in accordance with latest (2005) IEC version


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Mylar Insulation


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Mylar insulation

Mylar, sourced from USA/Europe, is a registered brand of Dupont, so

popular and widely used that it is regarded as one category of

insulation material (Coca-Cola = Coke)

Over 40+ years of installation of I-Line and Canalis still in use. Quality

and performance guaranteed by BOTH Schneider Electric and Dupont

Properties and performance controlled by Dupont, not played around at

busbar factory

Environmentally friendly, detachable and recyclable after service life

Halogen free and self-extinguished. IEC60439-1/2, 8.2.9 is a dedicated

test Verification of the resistance of insulating materials to abnormalheat and fire


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Epoxy insulation (1)

Epoxy is not a brand but a type of material - insulation

is the most critical material for sandwich busway (c.f.

engine for aircraft)

1 layer. pin hole is common with epoxy technology,

covered by PVC/PET tapes

Not recommended by IEC60439-2:"7.4.2.1 Protection by insulation of l ive parts

. NOTE Examples are electrical components embedded in insulation,

cables. Paints, varnishes, lacquers and similar products alone are generally

not considered to provide an adequate insulation for protection against

electric shock in normal service. For sandwich type busway, there is no air between the conductors, meaning epoxy or mylar are used as a

primary insulation. Since Epoxy belongs to the family mentioned in the "NOTE" of IEC60439, IEC

recommends not to use this

Schneider Electric uses a lot of epoxy for a lot of electrical equipment, but only as a secondary insulation

(primary insulation can be air between conductors)

Non recyclable, non environmentally friendly


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Epoxy insulation (2)

Special service condition (on specification of a world-leading, epoxy-

pioneered busway manufacturer in USA)


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Complete Schneider Electric Solution

from

transformer to sub main distribution,

fully coordinated using ourACB and MCCB


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Complete Schneider Electric Solution

Trihal transformer

I-Line-Trihal transformer tap

RM6 + T200I

Remote control modular

cubicles

Prisma

Blokset

Okken NSX Circuit Breaker

Busway Plug-in unit

equipped with

Power Meter


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Major Project References

of


M th 30 li ti i


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More than 30 years application experience

worldwide

The Molecular fusion technology is applied on the busway of

which amp rating more than 250A

In Europe, 90% high power busway utilize Molecular fusion

technology.


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Nord Villepinte Convention center

Project Name: Nord Villepinte Convention center

Location : North Paris

Area: 210,000m2

General information: one of the biggest exhibition

centers in Europe. Schneider copper contact

busway have been installed and operated for

more than 25 years.

Completion date: 1982 December

Scheme: double fishbone

Maximum capacity: 3200A

Single run: 183 meter


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Moscow Ostankino Tower

Project Name: Moscow Ostankino tower

Location : Moscow

General information: tallest TV tower in

Europe, the biggest swing is more than 20meters. In the year 2000, Aug, a serious

fire accident occurred because of the cable

overload. From that day on, they all use

Schneider new copper contact busway.Completion date: 2002, September

Scheme: double main trunking

Maximum capacity: 1600A Total length: 540 meter (270m x 2)

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