Electrical PowerDistribution S OLUTIONS B US Eldre | FerrazShawmut B AR | R-Theta

SOLUTIONS GUIDE ELDRE IS NOW MERSEN

ELDRE IS NOW MERSEN A REPUTATION FOR QUALITY

Eldre is now part of the Mersen family. Mersen is known Mersen’s reputation for outstanding technical expertise, product worldwide for providing expertise to customers for safety and quality, and engineered safety is the result of over a century reliability of electrical power. With the addition of Eldre to the of design and manufacturing knowledge, coupled with state-of- Mersen family, Mersen adds laminated bus bar to its extensive WKHDUWHTXLSPHQWLQWKUHH,62UHJLVWHUHGIDFLOLWLHV(DFK portfolio of products, creating a powerful bundled product facility manufactures single and multilayer bus bars, as well as offering for the protection of power electronics. fully integrated solutions in which the laminated bus bar also serves as a platform for a multitude of discreet components: WHAT IS LAMINATED BUS BAR? ‡ In Europe, our 5,000 m2 plant in Angers is a center of Laminated bus bar is an engineered component consisting of excellence for laminated bus bar solutions layers of fabricated copper separated by thin dielectric materials, ‡ ,Q1RUWK$PHULFDRXUIW2 plant in Rochester, New ODPLQDWHG LQWR D XQL¿HG VWUXFWXUH 6L]HV DQG DSSOLFDWLRQV York is a vertically integrated center of excellence for all UDQJHIURPVXUIDFHPRXQWHGEXVEDUVWKHVL]HRID¿QJHUWLSWR SRZHUGLVWULEXWLRQVROXWLRQVSOXV$6&UHJLVWHUHG multilayer bus bars that exceed 20 feet in length. Laminated bus bar solutions are routinely used for low volumes up through tens ‡ In Asia, a brand-new 6,500 m2IDFLOLW\LQ6KDQJKDL&KLQD of thousands per week. offers full manufacturing capability of all power and bus bar solutions WHY CHOOSE LAMINATED BUS BAR? 2XU FRPPLWPHQW WR TXDOLW\ LV FOHDUO\ HYLGHQW IURP WKH YHU\ Bus bars reduce system costs, improve reliability, increase beginning of the design process, right through to the production capacitance, and eliminate wiring errors. They also lower RI WKH ODVW SDUW 2XU 4XDOLW\ 6\VWHP LV GHVLJQHG ZLWK GHIHFW inductance and lower impedance. Plus, the physical structure SUHYHQWLRQ LQ PLQG DQG LV FHUWL¿HG WR $6 2XU VWDII RI of bus bars offers unique features in mechanical design. For professional engineers and experienced designers develops the example, complete power distribution subsystems can also act tooling and manufacturing methods, procedures, and process as structural members of a total system. Multilayer bus bars SDUDPHWHUVWRPHHWRXUFXVWRPHUV¶VSHFL¿FDWLRQV offer a structural integrity that wiring methods just can’t match. With over sixty years of experience in designing laminated bus bars and complete in-house manufacturing capability, we KDYHWKHÀH[LELOLW\DQGH[SHUWLVHWRUHVSRQGWRRXUFXVWRPHUV¶ requirements through: ‡ quality control and quality assurance ‡ engineering and design ‡ chemical milling ‡ electroplating ‡ assembly ‡ epoxy encapsulation ‡ tool and die design and build ‡ metal fabrication ‡ metal joining ‡ die cutting ‡ laminating ‡ electrostatic powder coating

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TURN TO MERSEN FOR CUSTOMIZED ELECTRICAL PROTECTION SOLUTIONS FOR POWER ELECTRONICS

&RPELQH 0HUVHQ VTXDUH ERG\ VHPLFRQGXFWRU IXVHV ZLWK DQG SURGXFW H[SHUWLVH 0HUVHQ LV DEOH WR PD[LPL]H V\VWHP Mersen’s thermal protection and laminated bus bar offerings for performance, lower total costs, and reduce time to market. DQRSWLPL]HGV\VWHPVROXWLRQWRVXSSRUW\RXUSRZHUHOHFWURQLFV 2XUGHGLFDWHGSRZHUHOHFWURQLFVWHDPLVDYDLODEOHWRFXVWRPL]H designs. As a design partner with extensive application a solution for you.

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Bus Bar 3 PEACE OF MIND...

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SUPERIOR QUALITY FROM DESIGN THROUGH MANUFACTURE

)URP WKH ¿UVW GHVLJQ FRQVXOWDWLRQ WKURXJK GRFNWRVWRFN ‡ Precision manufacturing of dielectric components shipments, Mersen provides customers with innovative power is crucial in laminated bus bar production. To ensure distribution solutions. You’re always assured that we’ve omitted quality, we maintain calibrated humidity and temperature nothing in our quest for customer satisfaction. Let us offer you controlled conditions to store our insulation. Precision the same peace of mind that thousands of other companies have steel rule dies are used for cutting the insulation, ensuring enjoyed for more than 60 years. Here are just a few reasons: XQLIRUPLW\RIVL]HWRSURGXFHTXDOLW\EXVEDUV ‡ State-of-the-art metal fabrication is a key component ‡ Properly selected insulation is the key factor to a WRSURGXFLQJTXDOLW\SURGXFW2XUVWDWHRIWKHDUWPHWDO EXVEDU¶VHOHFWULFDOLQWHJULW\:HXWLOL]HDZLGHYDULHW\ IDEULFDWLRQLVPDLQWDLQHGLQKRXVHDQGLQFOXGHV&1& of dielectric materials, including Nomex, Tedlar, Mylar, fabricators, photo-chemical machining, production punch .DSWRQ(SR[\*ODVV*32*DWH[DQG3KHQROLFV SUHVVHVUDQJLQJXSWRWRQV&1&SUHVVEUDNHVDQG UHDGLO\DYDLODEOHWRPHHWYLUWXDOO\DQ\VSHFL¿FDWLRQ various edge conditioning processes. We offer a wide In addition to traditional sheet lamination systems, we range of metal joining processes including ultrasonic maintain our own electrostatic powder coating department ZHOGLQJLQGXFWLRQEUD]LQJWRUFKEUD]LQJDQGVROGHULQJ WKDWSURGXFHVDTXDOLW\HSR[\¿QLVKZLWKKLJKGLHOHFWULF ‡ Plating±2XUFRPSOHWHLQKRXVHSODWLQJGHSDUWPHQW protection for bus bars with geometric forms, or those FDQSURGXFHDOPRVWDQ\¿QLVKWRPHHW\RXUQHHGV2XU used in harsh environments. ¿QLVKLQJLQFOXGHVWLQWLQOHDGQLFNHOFRSSHUVLOYHUDQG ‡ Assembly and Lamination is controlled using gold. Plating under tight, laboratory-controlled conditions, VRSKLVWLFDWHGODPLQDWLQJV\VWHPVVSHFL¿FDOO\GHVLJQHG we monitor and control plating thickness to required and manufactured for each bus bar. Hardware and VSHFL¿FDWLRQVWRPHHWDOOFXVWRPHUUHTXLUHPHQWV&DUHIXO interconnection devices can be added before or after data monitoring, in-process controls, and x-ray testing the laminating and plating process. FRPELQHWRHQVXUHDTXDOLW\¿QLVK

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Bus Bar 5 POWER ELECTRONICS

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Thin copper conductors, separated by insulation material of only thousandths of an inch, provides the ultimate in low inductance for IGBT-based motor GULYHV,QFRUSRUDWLQJHOHFWURO\WLFFDSDFLWRUVLQWRWKHVDPHVWUXFWXUHVLPSOL¿HV packaging and reduces the effects of transient overshoots. Note the addition RI6QXEEHU&DSDFLWRUVDQG5HVLVWRUVEXLOWLQWRWKHODPLQDWHGEXVEDU

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6L[HOHFWURO\WLFFDSDFLWRUVDUHHDVLO\FRQQHFWHGWRWKLVHGJHVHDOHG two-layer laminated bus bar providing a low inductance power path for a low horsepower, variable speed motor drive. Note the use of a bonded insulator strip along the length of the bus bar to provide additional “creepage” protection between the plus and minus terminals.

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:LWKWKHLQWURGXFWLRQRIWKH,*%7LQWKHHDUO\V a new era of design sophistication began. The higher switching speed of today’s IGBT demands a low inductance power path which is uniquely delivered by the Mersen laminated bus bar.

Mersen’s innovative Power Electronic designs provide WKHXOWLPDWHLQORZLQGXFWDQFH'&SRZHUZKLFKLVWKH “life blood,” securing the best suppression of parasitic transients and safe operation for long life. The Mersen ODPLQDWHGEXVEDULVWKHNH\FRPSRQHQWRIWKH'&SRZHU +,*+&855(17,19(57(5 FLUFXLWHQDEOLQJWKH,*%7(OHFWURO\WLF&DSDFLWRUFLUFXLW to provide perfect power and trouble-free service. A laminated bus bar assembly consisting of three power layers and one signal OD\HUZLWKDWRWDORIFRQGXFWRUVSURYLGLQJDYHU\ORZLQGXFWDQFHSRZHUSDWK and complete gate drive circuitry all designed for a wave-solder assembly Engage Mersen’s design team on your next project SURFHVV7KLVEXVEDULVXVHGLQDV\VWHPSRZHUHGE\026)(7V DQGVHH¿UVWKDQGRXULQJHQXLW\DWZRUN ,WLQFOXGHV(OHFWURO\WLF&DSDFLWRUVKHDWVLQNVDQG029V

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High-current circuit board design using laminated technology for IGBTs and support components. Includes gold plating, quick connect mounting. This laminated bus bar is an enhanced design of a typical IGBT bus bar. Manufactured to be easily serviced, the design uses gold high FXUUHQWVRFNHWVZKLFKDUHVROGHUHGLQWRWKH'&OD\HUV7KHGHVLJQDOVR DFFRPPRGDWHVUHVLVWRUVDQG029VVROGHUHGULJKWLQWRWKHDVVHPEO\ &RPSOHWHO\HGJH¿OOHGSHULPHWHUWKHEXVEDUDOVRKDVLQVXODWHG mounting holes.

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Laminated bus bars provide a low inductance connection for capacitors. The assembly was designed for an automated production process and the DVVHPEO\LVWKH'&FDSDFLWRUEDQNXVHGLQFRQMXQFWLRQZLWKKLJKFXUUHQW high-speed switching applications. Positive and negative layers are formed and laminated without outside insulation. This design includes two rows of capacitors soldered into position.

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High-frequency applications present a unique thermal challenge requiring the DGGLWLRQRIZDWHUFRROLQJIRUHI¿FLHQWRSHUDWLRQ:KHQWKHUPDOFRQVLGHUDWLRQV exceed conventional means of heat dissipation, one option is to add water- FRROLQJWRWKHV\VWHP7KLVGHVLJQFRQWDLQV¿YHFRROLQJOLQHVVROGHUHG directly onto the epoxy powder coated conductors to maintain a constant WHPSHUDWXUH'XHWRWKHKLJKIUHTXHQF\RIWKH$&YROWDJH³VNLQHIIHFW´SOD\V a big role in the heat created from the bus and without this additional cooling, the bus would surely overheat.

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Bus Bar 7 ALTERNATIVE ENERGY

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'HVLJQHGZLWKDXWRPRWLYHUHOLDELOLW\LQPLQGWKLVWZROD\HUODPLQDWHGEXVEDU joins parallel rows of batteries together in a hybrid vehicle application.

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Multilayer, laminated bus bar used in a Photovoltaic Inverter application. 'LRGHV,*%7VDQG(OHFWURO\WLF&DSDFLWRUVDUHDOOHDVLO\LQWHUFRQQHFWHGLQRQH compact power distribution structure.

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As the depletion of fossil fuels drives our attention towards alternate energy sources to power our daily lives, Mersen’s laminated bus bars can be found in new, but familiar territory.

:KHWKHULW¶VLQ6RODU:LQG3RZHURU)XHO&HOOVWKH FUHDWLRQRI'&HQHUJ\IHHGVGLUHFWO\WKURXJK0HUVHQ¶V low inductance laminated bus bars into an IGBT and FDSDFLWRUFLUFXLWGHOLYHULQJWKHVDIHDQGHI¿FLHQWSRZHU our customers demand.

0$6675$16,7 Mersen’s quality-engineered laminated bus bars use state-of-the-art materials and manufacturing techniques This rugged two-layer, four-conductor bus bar is production built for a WKDWPLQLPL]HZHLJKWDQGPD[LPL]HVLPSOLFLW\ Hybrid Transit Inverter application. The perimeter is a laminated sealed-edge construction. It shows the system simplicity of combining capacitors and IGBTs into a single bus bar system.

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Bus Bar 9 TRANSPORTATION

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Fuel cells and hybrid electric vehicles require rugged, reliable power distribution. Heavy duty construction with epoxy powder coating as a GLHOHFWULFDOORZVWKLVODPLQDWHGEXVEDUGHVLJQWRSHUIRUPWRVSHFL¿FDWLRQV in harsh environments.

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Modern traction drives combine high current and high voltage in highly FRQ¿QHGVSDFHV0HUVHQ¶VGHVLJQH[SHULHQFHXWLOL]HVLQGLYLGXDOO\ODPLQDWHG conductors, glass insulation spacers, and unique copper bushing “vias” to DFKLHYHDQHI¿FLHQWFRQFHQWUDWHGSDFNDJHZLWKDPLQLPXPRIVSHFLDOWRROV

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Whether it’s carrying the high current necessary to power heavy equipment, rail, and subway cars—or UHGXFLQJZHLJKWDQGHQKDQFLQJSDFNDJLQJHI¿FLHQF\IRU the latest aircraft and hybrid vehicles—Mersen laminated bus bars bring unique advantages to the transportation industry that are not available with traditional wiring or single conductor bars. The electrical performance of Mersen-engineered laminated bus bar is a key component to success throughout the transportation industry.

A properly engineered laminated bus bar provides the /2&2027,9( lowest overall system inductance and the most balanced and distributed capacitance, making it the perfect match for The laminated bus bar shown here represents a single-phase leg for a the high demands of the transportation equipment industry. ODUJHWKUHHSKDVHLQYHUWHUSRZHULQJPRGHUQ$&ORFRPRWLYHV/RQJWHUP durability and continuous operation in hostile environments demand high Mersen laminated bus bars help transportation equipment quality and consistency. The laminated bus bar has molded-sealed edges manufacturers achieve their reliability goals, thus lowering and fully insulated mounting holes, built and tested to meet customer partial warranty costs and enhancing customer satisfaction. discharge requirements.

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8QLTXHO\GHVLJQHGWZROD\HUFRQGXFWRU3&%VW\OHEXVEDUVDYHVYDOXDEOH board space while delivering low-impedance power to power-semiconductors LQDXWRPRWLYHVRXQGV\VWHPV$OOFRQGXFWRUVDUHPDGHRIFRSSHUSODWHG for solderability and the entire assembly is formed at a right angle.

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Planar power technology is enhanced through laminating with thin dielectric materials which yields a sealed, rugged structure. This design is formed into a ³8´VKDSHDQGLVHOHFWULFDOO\WHVWHGXQGHUZDWHUWRDVVXUHSHUIRUPDQFH

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Individually laminated, this two-conductor bus bar connects electrolytic FDSDFLWRUVDQG,*%7VLQDVPDOOOLJKWZHLJKWSDFNDJHIRUDQ(9,QYHUWHU

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+LJKKRUVHSRZHUWUDFWLRQGULYHVEHQH¿WIURPWKHORZLQGXFWDQFHSRZHUSDWK made possible by Mersen laminated bus bars. Laminated bus bars are the HVVHQWLDOFRPSRQHQWWKDWWLHV,*%7VDQGFDSDFLWRUVWRJHWKHU%\PLQLPL]LQJ V\VWHPLQGXFWDQFHWUDQVLHQWRYHUVKRRWVDUHUHGXFHGZKLFKJUHDWO\VLPSOL¿HV the need for complex snubber circuitry. Laminated bus bar designs for motor drives can contain a number of modular bus bars, linked together, to connect all of the system components into one complete system.

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Bus Bar 11 DEFENSE & AEROSPACE

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This complex, nine layer, low inductance laminated bus bar is engineered WRSHUIRUPDWYHU\KLJKDOWLWXGHVLQDFRQ¿QHGDUHD,WLQWHUFRQQHFWVFXVWRP SRZHUPRGXOHVWKURXJKEUD]HGEXVKLQJVDQGFOLQFKW\SHKDUGZDUH 7KHKLJKWHPSHUDWXUH.DSWRQLQVXODWLRQLVHQWLUHO\HSR[\HGJH¿OOHG around each individual layer.

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8QFRPSURPLVLQJSHUIRUPDQFHDQGUHOLDELOLW\DUHDPXVWIRU defense and aerospace systems. That is why laminated bus bars designed by Mersen are commonplace in a wide range of defense applications, including missile guidance equipment, phase-array radar systems, sonar and radar tracking stations, airborne equipment, tanks, submarines, and numerous space programs. Mersen’s laminated bus bars offer other advantages for defense use, too. Their superior electrical characteristics help defense systems DFKLHYHPD[LPXPHOHFWULFDOSHUIRUPDQFHDQGHI¿FLHQF\ Laminated bus bars are also known to provide the most 685)$&(02817)25'()(16(32:(5(/(&7521,&62817 )25 '(()(16()( 32:(5(/(&752 compact means of packaging, achieving the highest overall system performance where physical space is a premium. 8VHGLQWDQGHPRQHDVDKLJKWHPSKLJKFXUUHQWERDUGIRUVZLWFKLQJ And, because bus bars can be engineered to double as components and the other is densely populated with chip capacitors. The use of Kapton insulation allows full solderability for surface mount components. a structural support member, they contribute to system %RWKEXVEDUVDUHHSR[\HGJH¿OOHGDQGGHVLJQHGWRZLWKVWDQGH[WUHPHO\ strength and rigidity at the same time. If that’s not enough, demanding conditions of temperature and altitude. 0HUVHQ¶VODPLQDWHGEXVEDUVVLPSOLI\¿HOGVHUYLFHWRR which makes it easier to keep mission critical equipment /HQJWKDSSUR[LPDWHO\ HDFK _9ROWDJH9'&_&XUUHQW$_ up and running. &RQGXFWRUVDQG

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High-current power distribution is easily handled with this six layer, twenty- RQHFRQGXFWRUODPLQDWHGEXVEDU'HVLJQHGWRIXQFWLRQDVD³KLJKFXUUHQW backplane,” a bank of special connectors are soldered directly to the bus bar, and used to distribute power within a turret control system.

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A complex and unique laminated bus bar design provides high-power distribution over a backplane with solder tabs for output connectors and gold plated input connections. This application for a laminated bus bar provides power within a Missile Guidance system. The pluggable input connections on this laminated bus bar are gold plated to provide low resistance and high reliability between the bus bar and its subsystem. Forty pairs of outputs from the bus bar to the backplane are made by solder connections. The bus bar is HQWLUHO\HQFDSVXODWHGXVLQJHSR[\HGJH¿OOSURYLGHDFRPSOHWHKHUPHWLFVHDO

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Bus Bar 13 INDUSTRIAL

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Mounted inside a circuit breaker power tray, individual bus bars are nested LQDPDFKLQHG)5IUDPHWRSURYLGHRXWSXWFRQQHFWLRQV7KLVDVVHPEO\ assures proper safety separation as well as single component installation.

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The rough and rugged world of the industrial environment demands a constant and consistent supply of quality SURGXFWVGHOLYHUHGULJKWWRWKHSURGXFWLRQÀRRU

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'HVLJQHGIRUORZLQGXFWDQFH,*%7SKDVHEXVEDUWKURXJKGHJUHHIRUPHG input connections, including raised top contact surfaces to accommodate snubber capacitors. High-temperature insulation material easily handles the demanding thermal requirements.

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Bus Bar 15 COMPUTERS

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7KHVHEXVEDUVDUHVWDPSHGEUD]HGPDFKLQHGDQGFRORUHGFRGHGHSR[\ powder coating dielectric insulation for differing voltages. Power interconnects directly from the power supply with included hardware so you get everything in one rugged package.

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As data volume and broadband use continue to expand, performance demands increase for high-speed servers, blade servers, network backbone equipment, engineering work stations, and such data storage systems as disk arrays.

Mersen laminated bus bars help these computer equipment designers meet that challenge, offering uncompromising HOHFWULFDOSHUIRUPDQFHZKLOHPLQLPL]LQJ(0,5),DQG FURVVWDON7KHORZSUR¿OHRIDODPLQDWHGEXVEDUSURYLGHV computer equipment manufacturers with the ultimate SDFNDJHHI¿FLHQF\HDVHRIVHUYLFHDQGFRQVLVWHQWTXDOLW\ necessary to satisfy the most demanding customers.

$SURSHUO\HQJLQHHUHGSRZHUGLVWULEXWLRQSODQXWLOL]LQJ laminated bus bars can also include thermal management, with the bus bar acting as a heatsink. The bus bar’s IRUP¿WWLQJGHVLJQVFDQKHOSLQFUHDVHWKHDLUÀRZZLWKLQ a system where space is at a premium.

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Modern supercomputer systems operate at extremely low voltages and require a high concentration of current. This two-conductor bus bar assembly is constructed from machined, stamped, and soldered components that are insulated with a high-quality epoxy powder coating, then laminated together to provide a low inductance power path distributed across a large circuit board or backplane.

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Large parallel bars carry a high degree of current

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Bus Bar 17 COMPUTERS

'UDZHUW\SHFRQQHFWRUVZLWK integrated harness mates power and signal together

High-current power connectors are an integral part of the bus bar system, enabling easy installation of power supplies

Gold-plated, multilayer bus bars mate with crown-edge type connectors. This connector can be production assembled to bus EDUVXVLQJSUHVV¿WWHFKQRORJ\

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$QH[FHOOHQWFRPELQDWLRQRIYDOXH7KLVPXOWLOD\HUODPLQDWHGEXVEDU A second laminated bus bar plugs incorporates several different connectors for both power and signal, and LQWRSUHVV¿WSRZHUFRQQHFWRUV through careful engineering, a wire harness is used for signal distribution. 0HUVHQFDQHQJLQHHUIXOO\WHVWHGDQGVHULDOL]HGVROXWLRQVWRVROYH\RXU SRZHUGLVWULEXWLRQFKDOOHQJH

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High-current connectors fastened to bus bar

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Epoxy powder coating allows multiple conductors, formed to differing geometries, to be assembled into a single unit. Insulated and bonded together, this assembly carries power to the backplane without adding costly and complex layers to the backplane.

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Redundant power supplies plug into this laminated bus bar design and IHHGKLJKFXUUHQWSRZHULQWRWKHFRPSXWHUEDFNSODQH1RWHWKH¿YHJODVV )5 PRXQWLQJVXSSRUWVZKLFKDUHERQGHGWRWKHVWUXFWXUHWRFUHDWHD ULJLGLQVXODWHGPRXQWLQJV\VWHP1LQH³&URZQ&OLS´KLJKFXUUHQWFRQQHFWRUV distribute power from the power supply onto the backplane.

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Bus Bar 19 TELECOM

&(//8/$5%$6(67$7,21 32:(5',675,%87,21 An economical design that carries power from multiple power supplies RQWRWKHEDFNSODQHZLWKLQD%DVH6WDWLRQ&DELQHW,QGLYLGXDOO\ODPLQDWHG and assembled together reducing a complex wiring scheme to a simple component, saving both space and assembly time.

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7ZRFRQGXFWRUODPLQDWHGEXVEDUVGHVLJQHGWRGLVWULEXWH'&SRZHUIURP dual power supplies across the backplane of an internet router. The insulation system uses a molded-edge seal around the perimeter as a cost-effective means of providing the proper creepage distance between the two conductors ZKLOHSURWHFWLQJWKHLQGLYLGXDOFRQGXFWRUVIURPGXVWDQGFRQWDPLQDQWV'XHWR the low voltage of the system, Mersen engineers assure that the design has VXI¿FLHQWFURVVVHFWLRQDODUHDIRUDPLQLPDOYROWDJHGURS

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In the intensely competitive telecommunications market, PDQXIDFWXUHUVRIHTXLSPHQWIRU&HOOXODU%DVH6WDWLRQVDQG Internet Routers must offer their customers exceptional performance and dependability. With their consistent quality, excellent electrical characteristics, minimal EMI, RFI, and crosstalk, Mersen laminated bus bars provide WKHSHUIHFWVROXWLRQ

Mersen laminated bus bars offer telecommunications equipment manufacturers many other advantages too — including ease of assembly, superior thermal management, ,17(51(75287(5 UHGXFHGZHLJKWSDFNDJLQJHI¿FLHQF\DQGRYHUDOOFRVW effectiveness over alternative means of power distribution. 7KLVWZRFRQGXFWRUEXVEDUGLVWULEXWHV'&SRZHUZLWKLQDQLQWHUQHWURXWHU 7KHODPLQDWHGVWUXFWXUHXWLOL]HVWDEVZLWKRIIVHWIRUPVDQGFOLQFKKDUGZDUH WRPRXQWGLUHFWO\RQWRWKHPLGSODQHZKLOHDOORZLQJIRUSURSHUDLUÀRZ High-current pluggable connectors are mounted directly to the bus bar for interchangeable power supplies.

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8VKDSHGZLWKDQJOHGSRZHULQSXWWDEVIHHGLQJDURXQGDUDFNPRXQWHG frame. The unit also has plated, soldered bushings for bullet-style circuit breakers.

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When system requirements call for redundant power supplies, laminated bus EDUVDUHLGHDO7KLVWZROD\HUGHVLJQXWLOL]HVSUHVV¿WVRFNHWVIRUSRZHUVXSSO\ input and mates downstream with a custom power distribution network.

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6L[WHHQOD\HUODPLQDWHGEXVEDUGLVWULEXWHV9DQGUHWXUQDFURVVDEDFN plane in a rack system for a network routing application. Heavy-gauge clinch hardware and anti-rotation tabs accommodate cable connections. The entire DVVHPEO\LVKHUPHWLFDOO\VHDOHGXVLQJHSR[\HGJH¿OO

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Bus Bar 21 TELECOM 7(/(&2032:(5',675,%87,21 Part of a rack-mounted circuit breaker network, this three-conductor, single-layer laminated bus bar assembly is used to provide power connections to a group of circuit breakers. Power connections are made at each end and three banks of Faston tabs provide A, B, and Ground connections for twenty circuit breakers.

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PEM hardware for power input connection

Molded barriers for connector isolation

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Faston tabs provide quick-connect power to circuit breakers

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$WZRFRQGXFWRUEXVEDUURXWLQJ¿OWHUV'&SRZHUWKURXJKULQJOXJVDQG clinch hardware, terminating in multiple power connectors mounted in a 8UDFNPRXQWHGSRZHUGUDZHU

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Three-phase shielded power is fed from a single power supply, extending KRUL]RQWDOO\DORQJDEDFNSODQH(OHYHQVHWVRIJROGSODWHGSLQVHQJLQHHUHG to pass directly through the backplane, ensure high reliability and low contact resistance connections to individual boards.

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7KUHHSRZHUVXSSOLHVIHHGWKLV'&EXVEDUDVVHPEO\WKURXJKDUHSHDWLQJ series of blade-style pluggable output “tabs” along its length. The long, narrow design makes short jump connections clean and easy for board PRXQWHGSOXJJDEOHFRQQHFWRUV7KHPDQXIDFWXUHUEHQH¿WVIURPWKHHI¿FLHQW ORZSUR¿OHGHVLJQDQGFOHDQGLVWULEXWHGFDSDFLWDQFHWKDWDUHWKHQDWXUDO results of laminated bus bars.

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5HGXQGDQW3RZHU6XSSOLHVSOXJGLUHFWO\LQWRWKLVIRXUOD\HUVL[FRQGXFWRU laminated bus bar through high-current power connectors and feed three VHSDUDWHYROWDJHVLQWRWKLVEDVHVWDWLRQDSSOLFDWLRQ6\VWHPRXWSXWVDUHIHG through special silver-plated pins, installed as an integral part of the bus bar.

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Heavy-duty power clips installed for mating with power supplies

Power pins are SUHVV¿WDQGVROGHUHG

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Bus Bar 23 VALUE ADDED

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Multilayer bus bars offer a structural integrity that wiring PHWKRGVMXVWFDQ¶WPDWFK0HUVHQ¶V9DOXH$GGHGEXVEDU designs incorporate a variety of components built right in. 3'$81,7:,7+%86%$5 (DFKRQHLVVDIHW\WHVWHGDQGFHUWL¿HGDOOGHVLJQHGWR help simplify your life at the system assembly level.

&RPSDFW Every day Mersen’s innovation delivers complete multi- design means 0XFKLPSURYHGDLUÀRZ component bus bar and power distribution assemblies RQO\8KHLJKW around the world to our dedicated family of customers. 6LJQL¿FDQWO\UHGXFHG assembly time

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All wires replaced by multilayer laminated bus bar

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Multilayer bus bar construction

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Main circuit breaker

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Plug-type output LQWHUFRQQHFWVLPSOL¿HV system installation and eliminates connection errors

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Integral wire feeds and connectors help eliminate wiring errors

Elcon Rapid-Lock connectors

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Bus Bar 29 LAMINATED BUS BAR DESIGN GUIDE

CONDUCTORS

&RQGXFWRU PDWHULDO VHOHFWLRQ LV FULWLFDO LQ PHHWLQJ HOHFWULFDO SHUIRUPDQFH DQG PHFKDQLFDO ULJLGLW\ UHTXLUHPHQWV &RPPRQ materials used are copper, aluminum, and a variety of copper alloys. The material chosen, the mechanical constraints, and the HOHFWULFDOSHUIRUPDQFHIRUWKHVSHFL¿FDSSOLFDWLRQGHWHUPLQHWKH FRQGXFWRU¶V PLQLPXP PHFKDQLFDO GLPHQVLRQV VHH &RQGXFWRU 6L]HLQWKH(OHFWULFDO'HVLJQVHFWLRQ  Thermal considerations may require system ventilation to remove excess heat from the bus bar. In this case, bus bar FRQ¿JXUDWLRQ PLJKW EH ORZ LQ SUR¿OH WKHUHE\ FKDQJLQJ WKH RULHQWDWLRQRIWKHEXVVWUXFWXUHDQGWKHDLUÀRZ%XVEDUVPD\ also serve to remove heat from components by performing as a heat sink. The selection of tabs or terminations may determine conductor thickness if there’s a need to accept studs, nuts, tabs or threaded inserts. Minimum mechanical requirements for the connection VW\OHFKRVHQPXVWEHFRQVLGHUHGIRURYHUDOOHI¿FLHQF\DQGFRVW effectiveness.

GROUNDS

7KH JURXQG UHWXUQ FRQGXFWRU VKRXOG EH HTXDO LQ VL]H DQG circular mil area to its corresponding voltage conductor. A few advantages of a separate ground return are:  GRXEOHWKHHIIHFWLYHFDSDFLWDQFH 2. JUHDWHUDUHDIRUFRROLQJWRPLQLPL]HWKHYROWDJHGURSGXH WRWHPSHUDWXUHULVH

The physical structure of bus bars offers unique features in  GUDVWLFDOO\UHGXFHGLQWHUFRXSOLQJHIIHFWVDQG mechanical design. For example, complete power distribution  the opportunity for advantageous shielding between levels, subsystems can also act as structural members of a total system. obtained by the use of interleaved grounds. The proper design of bus bars depends on an application’s mechanical and electrical requirements. This section includes basic formulas and data to aid design engineers in specifying bus MOUNTING EDUVIRUSRZHUGLVWULEXWLRQV\VWHPV2QFHDQRXWOLQHRIDEXVEDU KDVEHHQHVWDEOLVKHGVSHFL¿FGHVLJQDQGPDQXIDFWXULQJ 7RPRXQWDEXVEDUWRDQDVVHPEO\VWUXFWXUHKDUGZDUH VWXGV FRQVLGHUDWLRQVZLOODIIHFWWKHFRVW 6HH&RVW&RQVLGHUDWLRQV  KROHV HWF  FDQ EH PDQXIDFWXUHG LQWR WKH FRQGXFWRUV $Q alternative ground plane may be added as support for the bus We’ve provided basic design criteria to help you specify bus bars bar assembly and to provide a platform for mounting hardware. for your application. The information required to specify a bus EDULQFOXGHVFRQGXFWRUPDWHULDOQXPEHURIFRQGXFWRUV LQFOXGLQJ JURXQG GLPHQVLRQV OHQJWKZLGWKDQGWKLFNQHVV LQWHUFRQQHFWLRQ VFKHPHVPRXQWLQJFRQ¿JXUDWLRQ LIUHTXLUHG W\SHRI¿QLVKDQG choice of insulation material.

30 ep.mersen.com FINISH The equivalent circuit illustrates the associated inductance / FDSDFLWDQFH & DQGUHVLVWDQFH 5 ZKLFKDUHPRVWRIWHQ Mersen offers in-house conductor plating in tin, tin/lead, nickel, uniformly distributed along the bus bar. We discuss the basic silver, or gold. Plating is a major consideration in designing a relationships between physical dimensions and electrical bus bar because it is the point of contact for all bus bar electrical parameters in the following analysis. connections. The plating can provide advantageous electrical properties, decreasing the voltage drop. When gold is used, it is JHQHUDOO\RQO\SODWHGRQWHUPLQDWLRQVXUIDFHVWRPLQLPL]HFRVW

INSULATION

Bus bars use many different types of adhesive-coated insulation Figure 1. Figure 2. materials to permit structure layers to be laminated together. 3K\VLFDO5HSUHVHQWDWLRQ (OHFWULFDO(TXLYDOHQW 7KHUH DUH DGGHG EHQH¿WV IURP DQ HOHFWULFDO SHUVSHFWLYH Insulation provides an inside and outside barrier to its installed CONDUCTOR SIZE environment. Insulations can increase the capacitance and &DOFXODWLQJFRQGXFWRUVL]HLVYHU\LPSRUWDQWWRWKHHOHFWULFDODQG ORZHUWKHLQGXFWDQFHDQGLPSHGDQFH&RPPRQO\XVHGLQVXODWLRQ mechanical properties of a bus bar. Electrical current-carrying materials are Nomex®, Tedlar®, Mylar®, Kapton®8OWHP®, Mylar/ requirements determine the minimum width and thickness of 7HGODU 7HGODU0\ODU7HGODU 9DOR[®, epoxy-glass, heat shrink the conductors. Mechanical considerations include rigidity, tubing, and epoxy powder coating. There are many different mounting holes, connections, and other subsystem elements. WKLFNQHVVHV RI WKHVH LQVXODWLRQ PDWHULDOV DYDLODEOH &RQWDFW D The width of the conductor should be at least three times the 0HUVHQHQJLQHHUIRUPRUHLQIRUPDWLRQ6SHFLDOLQVXODWLRQVDUH thickness of the conductor. available upon request. Additions of tabs and mounting holes change the cross-sectional area of the conductor, creating potential hot spots on the bus COST CONSIDERATIONS bar. The maximum current for each tab or termination must be considered to avoid hot spots. Prices of bus bar assemblies vary depending upon quantity &URVVVHFWLRQDO DUHD DQG WKH OHQJWK GHWHUPLQH EXV EDU ordered. In addition, individual dimensional characteristics, FRQGXFWRUVL]H&URVVVHFWLRQDODUHD $ LVHTXDOWRFRQGXFWRU materials, manufacturing techniques, the interconnection WKLFNQHVV W PXOWLSOLHGE\FRQGXFWRUZLGWK Z  VFKHPH SODWLQJ ¿QLVK LQVXODWLRQ DQG KDUGZDUH UHTXLUHPHQWV affect overall cost. A  W Z LQFKHV2 Mersen engineers are available to assist in developing the most HI¿FLHQW DQG FRVWHIIHFWLYH GHVLJQ WR SURYLGH VROXWLRQV WR DQ\ $ YDOXH RI DSSUR[LPDWHO\  FLUFXODU PLOV SHU DPSHUH LV D power distribution problem. The earlier we are involved in your WUDGLWLRQDOEDVLVIRUGHVLJQRIVLQJOHFRQGXFWRUV6LQFHEXVEDUV design process, the more cost effective your solution is likely are not round, circular mils must be converted to mils squared WR EH (DUO\ LQYROYHPHQW HQDEOHV XV WR RSWLPL]H ERWK HDVH RI VLPSO\PXOWLSO\WKHFLUFXODUPLOVYDOXHE\  manufacturing and turnaround time. We recommend that you The following formula determines the minimum cross-sectional contact a new-product development engineer before you start DUHD RI D FRQGXFWRU 7KLV DUHD VKRXOG EH LQFUHDVHG E\ ¿YH designing your laminated bus bar power distribution system. percent for each additional conductor laminated into the bus VWUXFWXUH7KLVH[WUD¿YHSHUFHQWLVDVDIHW\IDFWRUFRPSHQVDWLQJ ELECTRICAL DESIGN for the compounding heat gain within the conductors. This equation calculates the minimum cross-sectional area Important characteristics of laminated bus bars are resistance, QHFHVVDU\IRUFXUUHQWÀRZ series inductance, and capacitance. As performance parameters of electronic equipment and components become more A  I  > N @ *-6 LQFKHV2 stringent, these characteristics take on even more importance. In determining the impedance of a power distribution system, A = cross-sectional area of the conductor in inches2 WKHVHFKDUDFWHULVWLFVDUHVLJQL¿FDQWLQVROYLQJWZRRIWKHPRVW , 0D['&FXUUHQWLQDPSHUHV important problems for designers—resistance and noise. It is important, therefore, to understand the electrical characteristics N = Number of conductors in the bus assembly of the laminated bus bar. 7RFDOFXODWHWKHFURVVVHFWLRQDODUHDRIDQ$&FXUUHQWVRXUFH )LJXUHVKRZVDEDVLFWZRFRQGXFWRUODPLQDWHGEXVEDUDQG \RXPXVWWDNHIUHTXHQF\LQWRFRQVLGHUDWLRQ VHHWKHVHFWLRQRQ Figure 2 shows its equivalent circuit. The bus bar is composed 6NLQ(IIHFW  of two parallel conducting plates separated by a dielectric.

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Bus Bar 31 1RWH7KLVIRUPXODKDVDEUHDNGRZQSRLQWDWDSSUR[LPDWHO\ INDUCTANCE amps of current. For calculations involving larger currents, we Maintaining a low inductance results in a low characteristic suggest you contact a Mersen engineer. In addition, you can impedance and greater noise attenuation. When minimum ¿QG DPSDFLW\ FKDUWV DQG FRPSDUDWLYH JUDSKV DW WKH &RSSHU inductance is a design objective, consider these tips: 'HYHORSPHQW$VVRFLDWLRQ¶VZHEVLWHZZZFRSSHURUJ  0LQLPL]HWKHGLHOHFWULFWKLFNQHVV 2. 0D[LPL]HWKHFRQGXFWRUZLGWK CAPACITANCE  Increase the frequency. &DSDFLWDQFHRIWKHEXVDUUDQJHPHQWGHSHQGVXSRQWKHGLHOHFWULF PDWHULDO DQG SK\VLFDO GLPHQVLRQV RI WKH V\VWHP &DSDFLWDQFH varies only slightly with frequency change, depending on the There are two types of inductance to be determined: internal stability of the dielectric constant. This variation is negligible and LQGXFWDQFHZKLFKLVDUHVXOWRIÀX[OLQNDJHVZLWKLQDFRQGXFWRU therefore is omitted in this analysis: and external inductance, which is determined by the orientation of the two current-carrying conductors.  K Z C = l picofarads 'LVWULEXWLRQRIFXUUHQWWKURXJKRXWDFRQGXFWRUDWKLJKIUHTXHQFLHV  G  LV FRQFHQWUDWHG QHDU WKH VXUIDFHV FDOOHG WKH ³VNLQ HIIHFW´  7KHLQWHUQDOÀX[LVUHGXFHGDQGLWLVXVXDOO\VXI¿FLHQWWRFRQVLGHU Increased capacitance results in a decreasing characteristic only the external inductance. At low frequencies, however, the impedance. Low impedance means greater effective signal internal inductance may become an appreciable part of the total suppression and noise elimination. It is therefore desirable to inductance. The formula for calculating the internal inductance develop maximum capacitance between conductor levels. This at a low frequency is extremely lengthy and thus omitted in may be achieved by: this analysis.  keeping the dielectric as thin as possible, consistent with good manufacturing and design practices The formula for external inductance is: 2. using dielectrics having a high relative permittivity NIDFWRU L =  G l nanohenrys Z 

SKIN EFFECT +LJK)UHTXHQF\,QGXFWDQFH W!SD

Because of skin effect phenomena, inductance and resistance L =  GSD l nanohenrys are dependent on frequency. At high frequency, currents tend to t Z  ÀRZRQO\RQWKHVXUIDFHRIWKHFRQGXFWRU7KHUHIRUHWKHGHSWK of penetration of the electromagnetic energy determines the RESISTANCE effective conducting volume. 7RFDOFXODWHWKH'&FRQGXFWRUUHVLVWDQFHWKHIROORZLQJIRUPXOD DSSOLHV 5HVLVWDQFHDWƒ&  The skin depth is given by: ȡ l   5 = ohms SD = inches DC Z t ¥› I M ȡ -6 5 = *  l ohms )RU&RSSHU DC Z t 

2.6 SD = inches 7RGHWHUPLQH'&FRQGXFWRUUHVLVWDQFHDWWHPSHUDWXUHVDERYH I ¥ ƒ&XVHWKLVIRUPXOD

As frequency increases, inductance decreases to a limiting Į 7HPSFRHI¿FLHQWRIUHVLVWLYLW\RIFRSSHUDWƒ&LV YDOXH ZKHUHDV WKH UHVLVWDQFH LQFUHDVHV LQGH¿QLWHO\ DV WKH 5 = 5  T -T RKPV IUHTXHQF\DSSURDFKHVLQ¿QLW\ 2 2 

52 = Resistance at elevated temp

R2 5HVLVWDQFHDWHOHYDWHGWHPSHUDWXUH 72

5 5HVLVWDQFHDWƒ& 7

32 ep.mersen.com For high frequencies the skin depth is taken into consideration. 7DEOHRI'H¿QLWLRQV 7KHIRUPXODIRU$&UHVLVWDQFHLV )RU W!6' A &URVVVHFWLRQDODUHDRIDFRQGXFWRULQLQFKHV2

5 = 2 l ȡ ohms C &DSDFLWDQFHLQSLFRIDUDGV AC SD Z ˜ Thickness of dielectric in inches $&UHVLVWDQFHDWƒ& ȡ Resistivity of the conductor in ohms/inch -6 5 = 2 l * ohms AC SD Z  I )UHTXHQF\LQKHUW]

I &XUUHQWLQDPSV

VOLTAGE DROP K 'LHOHFWULFFRQVWDQW As current travels across a conductor, it loses voltage. This Length of conductor in inches is caused by the resistivity of the conductor. The losses are l UHIHUUHG WR DV YROWDJH GURS 8VH WKLV IRUPXOD WR FDOFXODWH WKH L Inductance in nano henrys voltage drop across the conductors:

Lt Total inductance at high frequency VD  5 I Permeability of nonmagnetic M 5 = ȡ l ohms PDWHULDOV *KHQU\VLQFK  Z t  R Resistance in ohms  ȡ I l  VD = 9ROWV 6' 6NLQGHSWKLQLQFKHV Z t  t Thickness of the conductor in inches

IMPEDANCE o T 7HPSHUDWXUHDWSRLQWLQ&

In the design of laminated bus bars, you should consider o T2 7HPSHUDWXUHDWSRLQWLQ& maintaining the impedance at the lowest possible level. This ZLOOUHGXFHWKHWUDQVPLVVLRQRIDOOIRUPVRI(0, HOHFWURPDJQHWLF w Width of conductor in inches LQWHUIHUHQFH WRWKHORDG 9 9ROWDJHGURSLQYROWV Increasing capacitance and reducing inductance are the d determining factors in eliminating noise. › 3L  The formula for calculating characteristic impedance is: Į Temperature coeffecient of resistivity Z = ¥L/C ohms ] Impedence

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Bus Bar 33 RESISTANCE, INDUCTANCE, AND CAPACITANCE COMPARISONS

TWISTED PAIR MERSEN BUS BARS

$:*ZLUH VROLG ²ORQJ 0HUVHQEXVEDU²ORQJ[ZLGH[WKLFN ,QVXODWLRQWKLFNQHVV DSSUR[   ,QVXODWLRQWKLFNQHVV $0521Œ² &RQGXFWRUDUHD LQ2 &RQGXFWRUDUHD LQ2 5'& FDOFXODWHG  RKPV 5'& FDOFXODWHG  RKPV

Freq (Hz) RAC (ohms) / ȝKHQU\V C (pfds) Freq (Hz) RAC (ohms) / ȝKHQU\V C (pfds)

 0.006  50.0   0.0200 

6    6  0.0060 

       

$:*ZLUH VWUDQGHG ²ORQJ 0HUVHQEXVEDU²ORQJ[ZLGH[WKLFN ,QVXODWLRQWKLFNQHVV DSSUR[   ,QVXODWLRQWKLFNQHVV $0521² &RQGXFWRU$UHD LQ2 &RQGXFWRU$UHD LQ2 5'& FDOFXODWHG  RKPV 5'& FDOFXODWHG  RKPV

Freq (Hz) RAC (ohms) / ȝKHQU\V C (pfds) Freq (Hz) RAC (ohms) / ȝKHQU\V C (pfds)

   52.5    

6    6   

   52.0    

34 ep.mersen.com TYPICAL CONVERSION CHARACTERISTICS

Current DC Resistance Wire Size Carrying RAC (ohms) Cir Mils Sq Inches Thick (in.) Width (in.) of a 2-Conductor Gauge Capacity Bus (milliohm/ft) (amps)

22   .0005 .005   

   .0020 .005   

    .005   5.05

       2.00

       

       .500

0      252.00 .200

00       

INSULATION AMRON 5:6HULHVLVDOVRDFRPSRVLWH¿OPPDGHXSRI$PURQ  DQG$PURQ  7KHVH ¿OPV DUH XVHG DV LQWHUQDO LQVXODWLRQ 0HUVHQ XWLOL]HV PDQ\ LQVXODWLRQ V\VWHPV WR PHHW GLIIHUHQW and are recommended for high dielectric strength applications applications. These systems combine the dielectric materials 7HGODU0\ODU7HGODU  detailed in the table on the next page. By combining different materials with selective edge-conditioning techniques, our AMRON 6: 6HULHV  DUH SRO\HWK\OHQH WHUHSKWKDODWH 3(7  insulating systems are designed to exceed any and all of your ¿OPV3(7DUHSRO\HVWHU¿OPVZKLFKRIIHUDQH[FHOOHQWEDODQFH electrical, mechanical, and environmental requirements. RIHOHFWULFDOFKHPLFDOWKHUPDODQGSK\VLFDOSURSHUWLHV 7UDGH name: Mylar®  $PURQŒGLHOHFWULFSURGXFWVZHUHVSHFL¿FDOO\GHYHORSHGIRU use in the manufacture of bus bars. Many of the products AMRON 7:6HULHVLVDFRPSRVLWHLQVXODWRUPDGHXSRI$PURQ are coated with a B-stage resin that is reactivated during the 2 and Amron 6. This composite combines the mechanical DVVHPEO\ SURFHVV 0RVW RI RXU LQVXODWLQJ V\VWHPV DUH 8/ toughness of Nomex with the electrical properties of Mylar 5HFRJQL]HG 5HIHUHQFH ZZZXOFRP IRU D PDWHULDO OLVWLQJ 1RPH[0\ODU1RPH[  )LOH1R( AMRON 8: 6HULHV  DUH ODPLQDWHG VKHHWV FRQVWUXFWHG IURP AMRON 1:6HULHVDUHSRO\YLQ\OÀXRULGH 39) ¿OPV39) FRQWLQXRXV¿ODPHQW W\SH JODVV IDEULF ZLWK D ÀDPHUHWDUGDQW ¿OPV DUH FKHPLFDO DQG VROYHQWUHVLVWDQW GHPRQVWUDWH epoxy resin binder. Good fabrication, high dielectric, and excellent molding characteristics, and have both a high physical strengths make this material suitable for many GLHOHFWULF FRQVWDQW .IDFWRU  DV ZHOO DV D KLJK GLHOHFWULF HOHFWULFDODSSOLFDWLRQV 1(0$*UDGH)5  VWUHQJWK 7UDGHQDPH7HGODU®  AMRON 9: 6HULHV  DUH HSR[\ SRZGHU FRDWLQJV 7KHVH AMRON 2: 6HULHV  DUH DURPDWLF SRO\DPLGH SRO\PHU FRDWLQJV H[KLELW H[FHSWLRQDO GXUDELOLW\ $PURQ  VKRXOG EH papers. Mechanical toughness, thermal stability, and used where conventional insulation, due to part geometry, is VROYHQW UHVLVWDQFH DUH VRPH RI LWV FKDUDFWHULVWLFV 7UDGH not practical. name: Nomex® 

AMRON 3: 6HULHV  DUH SRO\LPLGH ¿OPV 7KHVH ¿OPV DUH Note: The insulations listed above are standard materials UHFRPPHQGHG IRU KLJK WHPSHUDWXUH DSSOLFDWLRQV 7UDGH used in the manufacture of our bus bars. Many other dielectric name: Kapton®  PDWHULDOV DPRQJ WKHP 9DOR[® 8OWHP®, and PEN, can be AMRON 4:6HULHVLVDFRPSRVLWH¿OPPDGHXSRI$PURQ LQFRUSRUDWHGLQWR\RXUGHVLJQWRPHHWVSHFL¿FUHTXLUHPHQWV  DQG $PURQ  8VHG H[FOXVLYHO\ DV RXWVLGH LQVXODWLRQ Be sure to consult with a Mersen application engineer in WKHVH ¿OPV SURYLGH DQ H[FHOOHQW VFXIIUHVLVWDQW FRDWLQJ VHOHFWLQJ LQVXODWLRQ DV YDOXHV PD\ ÀXFWXDWH DIWHU LQVXODWLRQ 0\ODU7HGODU  has been applied.

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Bus Bar 35 BUS BAR INSULATION TECHNIQUES

*/$66('*(),//(' (32;<('*(),//(' &216758&7,21 &216758&7,21

Edge insulation: Epoxy Epoxy Glass Typical HGJH¿OO

Internal Insulation &RQGXFWRU/D\HU &RQGXFWRU/D\HUV &RSSHURU$OXPLQXP Insulator Layers External Insulation

6LPSOHFRQVWUXFWLRQ /DPLQDWHG36$WDSH or Ty-Wrap assembly Radiused edges of copper Multiple colors available

(32;<32:'(5&2$7,1*

23(1/$0,1$7('&216758&7,21 02/'('6($/('&216758&7,21

36 ep.mersen.com STANDARDS 7KHVHOLVWVGHWDLOWKHVSHFL¿FDWLRQVWKDWRXUVWDQGDUGFRQGXFWRUPDWHULDOLQVXODWLRQDQGSODWLQJSURFHVVHVPHHW,QFRUSRUDWLQJWKHVH VWDQGDUGVLQWR\RXURZQVSHFL¿FDWLRQV QRWHV ZLOOKHOSUHGXFHPDQXIDFWXULQJFRVWVDQGUHGXFHF\FOHWLPHV

Conductor Material Plating

&'$ &RSSHU $670%% Tin $670%

&'$ Brass $670% Nickel 441$06

Phosphate Electroless &'$ $670% 0,/& %URQ]H Nickel Beryllium 6XOIDPDWH &'$ $670%% 0,/3 &X Nickel

&'$ &RSSHU$OOR\ $670% Gold $670%

$OOR\ Nickel/Iron $670) 6LOYHU 446

Alloy + $670% &RSSHU $06 Aluminum Tin-Lead $063$670%  Tin-Lead Insulation 0,6  $PURQ Tedlar®39) /3 $QRGL]H 0,/$ Amron 2 Nomex® 0,/, &KURPDWH 0,/& $PURQ Kapton® 0,/3 Passivate 443 Amron 6 Mylar®/PET 0,/,

$PURQ )5 0,/,

Epoxy $PURQ Powder $670' &RDWLQJ

$PURQ 8OWHP®

$PURQ 9DOR[®

Epoxy Edge Black or 0,/, Fill White

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Bus Bar 37 GLOSSARY OF TERMS

Capacitance Impedance Measured in farads, it is the opposition to voltage changes in an alternating = 0HDVXUHGLQRKPVLWLVWKHWRWDORSSRVLWLRQWRWKHÀRZRIFXUUHQW FXUUHQWFLUFXLWFDXVLQJYROWDJHWRODJEHKLQGFXUUHQWH[KLELWHGE\WZR offered by a circuit. Impedance consists of the vector sum of resistance conductors separated by an insulator. and reactance.

Capacitor Insulation Resistance A passive electronic component that stores energy in the form of The resistance offered, usually measured in megaohms, by an insulating DQHOHFWURVWDWLF¿HOG,QLWVVLPSOHVWIRUPDFDSDFLWRUFRQVLVWVRIWZR PDWHULDOWRWKHÀRZRIFXUUHQWUHVXOWLQJIURPDQLPSUHVVHG'&YROWDJH conducting plates separated by an insulating material called the dielectric. The capacitance is directly proportional to the surface areas of the plates, Insulators and is inversely proportional to the separation between the plates. 0DWHULDOVZKLFKSUHYHQWWKHÀRZRIHOHFWULFLW\1RQFRQGXFWLYHPDWHULDOVXVHG &DSDFLWDQFHDOVRGHSHQGVRQWKHGLHOHFWULFFRQVWDQWRIWKHPDWHULDO to separate electric circuits. separating the plates. Inverter Choke An electric or electronic device for producing alternating current from An inductor designed to present a high impedance to alternating current. direct current.

Clearance Partial Discharge 7KHFOHDUDQFHLVGH¿QHGDVVKRUWHVWGLVWDQFHWKURXJKWKHDLUEHWZHHQWZR $W\SHRIORFDOL]HGGLVFKDUJHUHVXOWLQJIURPWUDQVLHQWJDVHRXVLRQL]DWLRQLQDQ conductive elements. insulation system when the voltage stress exceeds a critical value.

Common Collector Connection Resistance 6DPHDVJURXQGHGFROOHFWRUFRQQHFWLRQ$OVRFDOOHGWKHHPLWWHUIROORZHU RDQGPHDVXUHGLQRKPV2SSRVLWLRQWRFXUUHQWÀRZDQGGLVVLSDWLRQRIHQHUJ\ A mode of operation for a transistor in which the collector is common to in the form of heat. both the input and the output circuits and is usually connected to one of the power rails. Self-inductance The property of a conductor that produces an induced voltage in itself Common Emitter Connection with changing current. The term inductance alone means self-inductance. 6DPHDVJURXQGHGHPLWWHUFRQQHFWLRQ$PRGHRIRSHUDWLRQIRUDWUDQVLVWRULQ When a varying current in one conductor induces a voltage in a neighboring which the emitter is common to the input and output circuits. The base is the conductor, the effect is called mutual inductance. input terminal and the collector is the output terminal. Shield Conductivity 3DUWLWLRQRUHQFORVXUHDURXQGFRPSRQHQWVLQDFLUFXLWWRPLQLPL]HWKHHIIHFWV How easily something allows electric current to pass through it. If a substance RIVWUD\PDJQHWLFDQGUDGLRIUHTXHQF\¿HOGV LVDJRRGFRQGXFWRURUKLJKO\FRQGXFWLYH IRUH[DPSOHFRSSHURUEUDVV LWZLOO allow electrons to pass freely through it, offering only minor resistance. Shunt A low-value precision resistor used to monitor current. Corona $OXPLQRXVGLVFKDUJHGXHWRLRQL]DWLRQRIWKHDLUVXUURXQGLQJDFRQGXFWRU Snubber caused by a voltage gradient exceeding a certain critical value. $UHVLVWRUFDSDFLWRU 5& QHWZRUNXVHGWRUHGXFHWKHUDWHRIULVHRIYROWDJHLQ switching applications. Corona Extinction Voltage (CEV) 7KHKLJKHVWYROWDJHDWZKLFKDFRQWLQXRXVFRURQDRIVSHFL¿HGSXOVH Voltage Drop amplitude no longer occurs, as the applied voltage is gradually decreased &RQGXFWRUVFDUU\LQJFXUUHQWDOZD\VKDYHLQKHUHQWUHVLVWDQFHRULPSHGDQFH from above the corona inception value. WRWKHFXUUHQWÀRZ9ROWDJHGURSLVWKHDPRXQWRIYROWDJHORVVWKDWRFFXUV through all or part of the circuit due to impedance. Corona Inception Voltage (CIV) 7KHORZHVWYROWDJHDWZKLFKDFRQWLQXRXVFRURQDRIVSHFL¿HGSXOVHDPSOLWXGH occurs as the applied voltage is gradually increased. THREE-LAYER BUS BAR WITH INDEPENDENT Creepage Distance The shortest distance separating two conductors as measured along a FASTON TABS AT surface touching both conductors. LONG END Dielectric 1RQFRQGXFWLQJPDWHULDOXVHGWRLVRODWHDQGRULQVXODWHHQHUJL]HG electrical components. PRESS-FIT BUSHINGS Dielectric Constant (K) The property of the dielectric material that determines how much electric WITH CROWN BAND HQHUJ\FDQEHVWRUHGLQDFDSDFLWRURIDSDUWLFXODUVL]HE\DYDOXHRI INSERTS applied voltage.

Dielectric Strength The maximum voltage an insulating material can withstand without breaking down. FLEXIBLE TABS FOR LOW EMI, RFI Acronyms for various types of electrical interference: electromagnetic PROFILE AREAS interference and radio-frequency interference.

Hi-Pot Test (High Potential Test) $WHVWSHUIRUPHGE\DSSO\LQJDKLJKYROWDJHIRUDVSHFL¿HGWLPHWRWZR isolated points in a device to determine the adequacy of insulating material.

38 ep.mersen.com FASTON TABS FROM BOLT ON TABS INSIDE THE BUS BAR, CONFINED WITHIN THE SAVES SPACE BUS BAR, SAVES SPACE AND MATERIAL

PANEL HARDWARE CLINCH HARDWARE FOR RING LUGS

SQUARE PINS FOR FASTON TABS EXTENDING SOLDER CONNECTIONS BEYOND THE BUS BAR OR WIRE WRAP OR WITHIN

MOLDER HARDWARE, FASTON TABS ALONG THE IDEAL FOR THIN EDGE WITH FORMS FOR MATERIALS AND HIGH EASY ACCESS TORQUE APPLICATIONS

MULTILAYER AND MULTI- FLANGE TAB CONDUCTOR TABS FOR CONSTRUCTION WITH PCB POWER CLINCH HARDWARE

RING LUG TERMINATIONS SOLDER PIN CONNECTION USING CLINCH STUD WITH THERMAL RELIEF HARDWARE IN FORMED TABS

SOLDER PINS FOR CONNECTORS IN PLASTIC PCB CONNECTION WITH HOUSING, SOLDERED INTO THERMAL RELIEF HOLES EACH CONDUCTOR IN BUS BAR

CLINCH STUD FLEX CIRCUIT HARDWARE IN SIDE TAB INTEGRATED INTO BUS INTERCONNECT (NOTE BAR FOR FLEXIBLE OFFSET FORM IN TAB) INTERCONNECTION

HIGH CURRENT POWER THREE-LAYER BUS BAR RECEPTACLE WITH UTILIZING EMBOSSED CROWN-BAND INSERTS “DIMPLES” FOR COPLANAR INTERCONNECTION

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Bus Bar 39 Main production sites

Industrial or commercial branch

A WORLD LEADER in safety & reliability for electrical power

A GLOBAL PLAYER

A global expert in materials FOLHQWV¶VSHFL¿FQHHGVWR and solutions for extreme HQDEOHWKHPWRRSWLPL]H environments as well as in their manufacturing process the safety and reliability in sectors such as energy, of electrical equipment, transportation, electronics, Mersen designs innovative chemical, pharmaceutical,

solutions to address its and process industries. BR-BUS BAR-001 | 02.13 5000 ImageNow © Mersen 2013

MERSEN Rochester MERSEN France MERSEN Shanghai -HIIHUVRQ5RDG UXHGX'pU\ 1R$6KX6KDQ5RDG 5RFKHVWHU1< 6W6\OYDLQG¶$QMRX 6RQJMLDQJ 86$ France 6KDQJKDL 7 7   7 ) )  

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