MNS Low Voltage Switchgear System Guide
Main Busbars The MNS main busbar system is arranged in the rear of the switchgear. This assures a maximum distance between
How to connect the small busbars of the high-voltage switchgear
Small busbars in high-voltage switchgear should be connected using properly prepared surfaces and secure mechanical joints such as bolted, clamped, or riveted connections to ensure low resistance, mechanical stability, and safe operation.
Material Preparation
Before connecting busbars, it is essential to prepare the contact surfaces according to the material:
- Copper busbars: Polish the surfaces with fine sandpaper to remove oxidation and achieve a mirror finish, then apply a power compound grease compliant with EN 50165 to improve conductivity and prevent corrosion .
- Aluminum busbars: Apply an aluminum-specific anti-oxidation agent and use copper-aluminum transition joints if connecting to copper to prevent electrochemical corrosion .
- Ensure all surfaces are clean, dry, and free of dust or debris to maintain low contact resistance .
Jointing Methods
Several methods are commonly used to connect small busbars:
- Bolted Joints: Overlap the busbars, drill or punch holes, and secure with stainless steel bolts and flat washers to distribute pressure evenly. Proper torque is critical to maintain electrical and mechanical integrity .
- Clamped Joints: Use external clamps around overlapping busbars to create uniform contact pressure without drilling holes. This method reduces current path distortion and is suitable for high-current applications .
- Riveted Joints: Insert rivets through pre-drilled holes to secure the busbars. Rivets cannot loosen like bolts, but controlling contact pressure is more challenging .
- Welding or Brazing: Provides a continuous conduction path and high mechanical strength, but requires skilled execution and is less flexible for maintenance .
- Plug-and-Socket or Crimped Connections: Useful for detachable or modular connections, often with insulating sleeves to protect conductors .
Installation and Safety Considerations
- Tightening: All fasteners must be torqued to manufacturer specifications to avoid overheating and ensure reliable current flow .
- Insulation: Use heat-shrink tubing or insulating barriers where necessary to prevent short circuits, especially in aluminum-copper transitions .
- Regular Inspection: Periodically check for signs of wear, corrosion, or heating effects, and clean busbars to maintain optimal conductivity .
- Spacing and Support: Maintain proper spacing and mechanical support to handle operational and short-circuit currents safely .
Summary
Connecting small busbars in high-voltage switchgear requires careful surface preparation, selection of appropriate jointing methods, and adherence to torque and insulation standards. Bolted, clamped, and riveted joints are the most common, while welding or plug-and-socket connections are used in specialized cases. Proper installation ensures low resistance, mechanical stability, and safe, reliable operation of the switchgear system .
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