SOLUTIONS SOLUTIONS GUIDE BUS BAR Electrical Power Distribution Eldre | Ferraz Shawmut | R-Theta ELDRE IS NOW MERSEN ELDRE IS NOW MERSEN A REPUTATION FOR QUALITY Eldre is now part of the Mersen family. Mersen is known worldwide for providing expertise to customers for safety and reliability of electrical power. With the addition of Eldre to the Mersen family, Mersen adds laminated bus bar to its extensive portfolio of products, creating a powerful bundled product offering for the protection of power electronics. Mersen’s reputation for outstanding technical expertise, product quality, and engineered safety is the result of over a century of design and manufacturing knowledge, coupled with state-ofWKHDUWHTXLSPHQWLQWKUHH,62UHJLVWHUHGIDFLOLWLHV(DFK facility manufactures single and multilayer bus bars, as well as 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? Laminated bus bar is an engineered component consisting of layers of fabricated copper separated by thin dielectric materials, ODPLQDWHG LQWR D XQL¿HG VWUXFWXUH 6L]HV DQG DSSOLFDWLRQV UDQJHIURPVXUIDFHPRXQWHGEXVEDUVWKHVL]HRID¿QJHUWLSWR multilayer bus bars that exceed 20 feet in length. Laminated bus bar solutions are routinely used for low volumes up through tens of thousands per week. WHY CHOOSE LAMINATED BUS BAR? Bus bars reduce system costs, improve reliability, increase capacitance, and eliminate wiring errors. They also lower inductance and lower impedance. Plus, the physical structure of bus bars offers unique features in mechanical design. For example, complete power distribution subsystems can also act as structural members of a total system. Multilayer bus bars offer a structural integrity that wiring methods just can’t match. 2 ep.mersen.com In Europe, our 5,000 m2 plant in Angers is a center of excellence for laminated bus bar solutions ,Q1RUWK$PHULFDRXUIW2 plant in Rochester, New York is a vertically integrated center of excellence for all SRZHUGLVWULEXWLRQVROXWLRQVSOXV$6&UHJLVWHUHG In Asia, a brand-new 6,500 m2IDFLOLW\LQ6KDQJKDL&KLQD offers full manufacturing capability of all power and bus bar solutions 2XU FRPPLWPHQW WR TXDOLW\ LV FOHDUO\ HYLGHQW IURP WKH YHU\ beginning of the design process, right through to the production RI WKH ODVW SDUW 2XU 4XDOLW\ 6\VWHP LV GHVLJQHG ZLWK GHIHFW SUHYHQWLRQ LQ PLQG DQG LV FHUWL¿HG WR $6 2XU VWDII RI professional engineers and experienced designers develops the tooling and manufacturing methods, procedures, and process SDUDPHWHUVWRPHHWRXUFXVWRPHUV¶VSHFL¿FDWLRQV With over sixty years of experience in designing laminated bus bars and complete in-house manufacturing capability, we KDYH WKH ÀH[LELOLW\ DQG H[SHUWLVH WR UHVSRQG WR RXU FXVWRPHUV¶ 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 POWER ELECTRONICS BUNDLING SOLUTIONS TURN TO MERSEN FOR CUSTOMIZED ELECTRICAL PROTECTION SOLUTIONS FOR POWER ELECTRONICS &RPELQH 0HUVHQ VTXDUH ERG\ VHPLFRQGXFWRU IXVHV ZLWK Mersen’s thermal protection and laminated bus bar offerings for DQRSWLPL]HGV\VWHPVROXWLRQWRVXSSRUW\RXUSRZHUHOHFWURQLFV designs. As a design partner with extensive application DQG SURGXFW H[SHUWLVH 0HUVHQ LV DEOH WR PD[LPL]H V\VWHP performance, lower total costs, and reduce time to market. 2XUGHGLFDWHGSRZHUHOHFWURQLFVWHDPLVDYDLODEOHWRFXVWRPL]H a solution for you. Laminated bus bar 6TXDUHERG\ semiconductor fuses Heat sink (;3/2'('9,(: For Power Electronics solution inquiries, contact pesupport.nby@mersen.com .FSTFOtBus Bar 3 PEACE OF MIND... «LQWKHFRQ¿GHQFHDQGFRPIRUWIURPRYHURQH KXQGUHG\HDUVRIVXFFHVVDQGWHFKQLFDOLQQRYDWLRQ Q «EHFDXVHHDFKGHVLJQLVDXQLTXHVROXWLRQ EDVHGRQPLOOLRQVRIPDQKRXUVRIH[SHULHQFH «LQDZRUNLQJUHODWLRQVKLSZLWKYHUWLFDOO\LQWHJUDWHG IDFWRULHVUHFRJQL]HGZRUOGZLGHIRUH[FHOOHQFH «IURPDTXDOLW\GULYHQSURGXFWLRQEDVHGDSSURDFKWR WR PDQXIDFWXULQJ SUPERIOR QUALITY FROM DESIGN THROUGH MANUFACTURE )URP WKH ¿UVW GHVLJQ FRQVXOWDWLRQ WKURXJK GRFNWRVWRFN shipments, Mersen provides customers with innovative power distribution solutions. You’re always assured that we’ve omitted nothing in our quest for customer satisfaction. Let us offer you the same peace of mind that thousands of other companies have enjoyed for more than 60 years. Here are just a few reasons: Precision manufacturing of dielectric components is crucial in laminated bus bar production. To ensure quality, we maintain calibrated humidity and temperature controlled conditions to store our insulation. Precision steel rule dies are used for cutting the insulation, ensuring XQLIRUPLW\RIVL]HWRSURGXFHTXDOLW\EXVEDUV State-of-the-art metal fabrication is a key component WRSURGXFLQJTXDOLW\SURGXFW2XUVWDWHRIWKHDUWPHWDO IDEULFDWLRQLVPDLQWDLQHGLQKRXVHDQGLQFOXGHV&1& fabricators, photo-chemical machining, production punch SUHVVHVUDQJLQJXSWRWRQV&1&SUHVVEUDNHVDQG various edge conditioning processes. We offer a wide range of metal joining processes including ultrasonic ZHOGLQJLQGXFWLRQEUD]LQJWRUFKEUD]LQJDQGVROGHULQJ Plating±2XUFRPSOHWHLQKRXVHSODWLQJGHSDUWPHQW FDQSURGXFHDOPRVWDQ\¿QLVKWRPHHW\RXUQHHGV2XU ¿QLVKLQJLQFOXGHVWLQWLQOHDGQLFNHOFRSSHUVLOYHUDQG gold. Plating under tight, laboratory-controlled conditions, we monitor and control plating thickness to required VSHFL¿FDWLRQVWRPHHWDOOFXVWRPHUUHTXLUHPHQWV&DUHIXO data monitoring, in-process controls, and x-ray testing FRPELQHWRHQVXUHDTXDOLW\¿QLVK Properly selected insulation is the key factor to a EXVEDU¶VHOHFWULFDOLQWHJULW\:HXWLOL]HDZLGHYDULHW\ of dielectric materials, including Nomex, Tedlar, Mylar, .DSWRQ(SR[\*ODVV*32*DWH[DQG3KHQROLFV UHDGLO\DYDLODEOHWRPHHWYLUWXDOO\DQ\VSHFL¿FDWLRQ In addition to traditional sheet lamination systems, we maintain our own electrostatic powder coating department WKDWSURGXFHVDTXDOLW\HSR[\¿QLVKZLWKKLJKGLHOHFWULF protection for bus bars with geometric forms, or those used in harsh environments. Assembly and Lamination is controlled using VRSKLVWLFDWHGODPLQDWLQJV\VWHPVVSHFL¿FDOO\GHVLJQHG and manufactured for each bus bar. Hardware and interconnection devices can be added before or after the laminating and plating process. 4 ep.mersen.com :+$7,6$/$0,1$7('%86%$5" pg 2 32:(5(/(&7521,&6 pg 6 $/7(51$7,9((1(5*< pg 8 75$163257$7,21 pg 10 '()(16($(5263$&( pg 12 ,1'8675,$/ pg 14 &20387(56 pg 16 7(/(&20 pg 20 9$/8($''(' pg 24 /$0,1$7('%86%$5'(6,*1*8,'( pg 30 .FSTFOtBus Bar 5 POWER ELECTRONICS 02725'5,9(%86%$5 Thin copper conductors, separated by insulation material of only thousandths of an inch, provides the ultimate in low inductance for IGBT-based motor GULYHV,QFRUSRUDWLQJHOHFWURO\WLFFDSDFLWRUVLQWRWKHVDPHVWUXFWXUHVLPSOL¿HV packaging and reduces the effects of transient overshoots. Note the addition RI6QXEEHU&DSDFLWRUVDQG5HVLVWRUVEXLOWLQWRWKHODPLQDWHGEXVEDU 6L]H[_7KLFNQHVV_9ROWDJH9'&_&XUUHQW$ &$3$&,725%86%$5)2502725'5,9( 6L[HOHFWURO\WLFFDSDFLWRUVDUHHDVLO\FRQQHFWHGWRWKLVHGJHVHDOHG two-layer laminated bus bar providing a low inductance power path for a low horsepower, variable speed motor drive. Note the use of a bonded insulator strip along the length of the bus bar to provide additional “creepage” protection between the plus and minus terminals. 6L]H[_7KLFNQHVV_9ROWDJH9'&_&XUUHQW$ :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 FLUFXLWHQDEOLQJWKH,*%7(OHFWURO\WLF&DSDFLWRUFLUFXLW to provide perfect power and trouble-free service. Engage Mersen’s design team on your next project DQGVHH¿UVWKDQGRXULQJHQXLW\DWZRUN +,*+&855(17,19(57(5 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 SURFHVV7KLVEXVEDULVXVHGLQDV\VWHPSRZHUHGE\026)(7V ,WLQFOXGHV(OHFWURO\WLF&DSDFLWRUVKHDWVLQNVDQG029V 6L]H[_&RQGXFWRUVJDWHFLUFXLW_9ROWDJH9'&_ &XUUHQW$SHDN 6 ep.mersen.com 63$&(&5$)732:(5,19(57(5 High-current circuit board design using laminated technology for IGBTs and support components. Includes gold plating, quick connect mounting. This laminated bus bar is an enhanced design of a typical IGBT bus bar. Manufactured to be easily serviced, the design uses gold high FXUUHQWVRFNHWVZKLFKDUHVROGHUHGLQWRWKH'&OD\HUV7KHGHVLJQDOVR DFFRPPRGDWHVUHVLVWRUVDQG029VVROGHUHGULJKWLQWRWKHDVVHPEO\ &RPSOHWHO\HGJH¿OOHGSHULPHWHUWKHEXVEDUDOVRKDVLQVXODWHG mounting holes. 6L]H[_7KLFNQHVV_9ROWDJH9_&XUUHQW$ 02817,1*6758&785()25&$3$&,725%$1. Laminated bus bars provide a low inductance connection for capacitors. The assembly was designed for an automated production process and the DVVHPEO\LVWKH'&FDSDFLWRUEDQNXVHGLQFRQMXQFWLRQZLWKKLJKFXUUHQW high-speed switching applications. Positive and negative layers are formed and laminated without outside insulation. This design includes two rows of capacitors soldered into position. /HQJWK_:LGWK_9ROWDJH9_&XUUHQW$ +,*+)5(48(1&<:(/',1* &RQQHFWLQJDFRPSOH[QHWZRUNLQFOXGLQJ3RZHU,*%7V'LRGHV5HVLVWRUV DQG)LOP&DSDFLWRUVWKLVPXOWLOD\HUHSR[\HGJH¿OOHGEXVEDUSURYLGHVD FRPSDFWORZLQGXFWDQFHVROXWLRQ7KLUW\WZREXVKLQJVDUHEUD]HGLQWRSRVLWLRQ and maintain tightly controlled coplanar mounting surfaces on both top and bottom. Alternating the plus and minus layers throughout the assembly counters the skin effect of high frequencies. 6L]H[_9ROWDJH9'&_&XUUHQW$_7KLFNQHVV[ +,*+)5(48(1&<,19(57(5 High-frequency applications present a unique thermal challenge requiring the DGGLWLRQRIZDWHUFRROLQJIRUHI¿FLHQWRSHUDWLRQ:KHQWKHUPDOFRQVLGHUDWLRQV exceed conventional means of heat dissipation, one option is to add waterFRROLQJWRWKHV\VWHP7KLVGHVLJQFRQWDLQV¿YHFRROLQJOLQHVVROGHUHG directly onto the epoxy powder coated conductors to maintain a constant WHPSHUDWXUH'XHWRWKHKLJKIUHTXHQF\RIWKH$&YROWDJH³VNLQHIIHFW´SOD\V a big role in the heat created from the bus and without this additional cooling, the bus would surely overheat. 6L]H[_7KLFNQHVVDQG_9ROWDJH9_&XUUHQW$ .FSTFOtBus Bar 7 ALTERNATIVE ENERGY +<%5,'9(+,&/(6 'HVLJQHGZLWKDXWRPRWLYHUHOLDELOLW\LQPLQGWKLVWZROD\HUODPLQDWHGEXVEDU joins parallel rows of batteries together in a hybrid vehicle application. 6L]H[_7KLFNQHVV_9ROWDJH9'&_&XUUHQW$ 62/$532:(5 Multilayer, laminated bus bar used in a Photovoltaic Inverter application. 'LRGHV,*%7VDQG(OHFWURO\WLF&DSDFLWRUVDUHDOOHDVLO\LQWHUFRQQHFWHGLQRQH compact power distribution structure. 6L]H[_9ROWDJH9'&_&XUUHQW$_&RQGXFWRUV 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. Mersen’s quality-engineered laminated bus bars use state-of-the-art materials and manufacturing techniques WKDWPLQLPL]HZHLJKWDQGPD[LPL]HVLPSOLFLW\ 0$6675$16,7 This rugged two-layer, four-conductor bus bar is production built for a Hybrid Transit Inverter application. The perimeter is a laminated sealed-edge construction. It shows the system simplicity of combining capacitors and IGBTs into a single bus bar system. 6L]H[_7KLFNQHVV_9ROWDJH9_&XUUHQW$SHUOD\HU 8 ep.mersen.com :,1'0,//,19(57(5 7KLVODPLQDWHGEXVEDUGHVLJQGHPRQVWUDWHVH[FHOOHQWSDFNDJLQJHI¿FLHQF\ %\GHVLJQLQJDOOHOHFWULFDOFRQQHFWLRQSRLQWVIRUWKH,*%7V&DSDFLWRUV,2 and monitoring devices in one clean bus bar, overall system reliability is improved and optimal electrical performance is assured. 6L]H[_7KLFNQHVVDQG_9ROWDJH9_&XUUHQW$ 38%/,&75$163257$7,21 2QHRIWKHKDOOPDUNVIRU$OWHUQDWH(QHUJ\DSSOLFDWLRQVLVSDFNDJLQJ FRPSRQHQWVLQWLJKWFRQ¿QHV7KLVODPLQDWHGEXVEDUSDFNVQLQHHOHFWURO\WLF capacitors in a tight package in between two rows of IGBTs. This arrangement LVDQDWXUDO¿WIRUODPLQDWHGEXVEDUWHFKQRORJ\ 6L]H[[_&RQGXFWRUVHDFK_9ROWDJH9'&_ &XUUHQW$ .FSTFOtBus Bar 9 TRANSPORTATION $/7(51$7()8(/6<67(06 Fuel cells and hybrid electric vehicles require rugged, reliable power distribution. Heavy duty construction with epoxy powder coating as a GLHOHFWULFDOORZVWKLVODPLQDWHGEXVEDUGHVLJQWRSHUIRUPWRVSHFL¿FDWLRQV in harsh environments. 6L]H[_9ROWDJH9'&_&XUUHQW$_&RQGXFWRUV 75$&7,21'5,9( Modern traction drives combine high current and high voltage in highly FRQ¿QHGVSDFHV0HUVHQ¶VGHVLJQH[SHULHQFHXWLOL]HVLQGLYLGXDOO\ODPLQDWHG conductors, glass insulation spacers, and unique copper bushing “vias” to DFKLHYHDQHI¿FLHQWFRQFHQWUDWHGSDFNDJHZLWKDPLQLPXPRIVSHFLDOWRROV 6L]H[_&RQGXFWRUV_9ROWDJH9'&_&XUUHQW$ 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 lowest overall system inductance and the most balanced and distributed capacitance, making it the perfect match for the high demands of the transportation equipment industry. Mersen laminated bus bars help transportation equipment manufacturers achieve their reliability goals, thus lowering warranty costs and enhancing customer satisfaction. /2&2027,9( The laminated bus bar shown here represents a single-phase leg for a ODUJHWKUHHSKDVHLQYHUWHUSRZHULQJPRGHUQ$&ORFRPRWLYHV/RQJWHUP durability and continuous operation in hostile environments demand high quality and consistency. The laminated bus bar has molded-sealed edges and fully insulated mounting holes, built and tested to meet customer partial discharge requirements. 6L]H[_7KLFNQHVV_9ROWDJH9_&XUUHQW$ 10 ep.mersen.com (/(&75,&9(+,&/(32:(5',675,%87,21 :KHQSRZHUKDVWREHURXWHGWKURXJKWLJKWFRQ¿QHVWKDWWZLVWDQGWXUQ 0HUVHQ¶VHSR[\SRZGHUFRDWLQJSURYLGHVGLHOHFWULFSURWHFWLRQ7KLV two-conductor laminated assembly includes bonded ceramic chokes, nylon UHLQIRUFHGPRXQWLQJKROHVDQGÀRDWLQJFOLQFKKDUGZDUHIRUHDV\LQVWDOODWLRQ DQGRSWLPL]HGHOHFWULFDOSHUIRUPDQFHLQDQDXWRPRWLYHHQYLURQPHQW 6L]H[_&RQGXFWRUV_9ROWDJH9'&_&XUUHQW$ +,*+(1'$8',23&%%86%$5 8QLTXHO\GHVLJQHGWZROD\HUFRQGXFWRU3&%VW\OHEXVEDUVDYHVYDOXDEOH board space while delivering low-impedance power to power-semiconductors LQDXWRPRWLYHVRXQGV\VWHPV$OOFRQGXFWRUVDUHPDGHRIFRSSHUSODWHG for solderability and the entire assembly is formed at a right angle. /HQJWK_:LGWK_9ROWDJH9_&XUUHQW$WR$ (/(&75,&9(+,&/(&+$5*(3257 Planar power technology is enhanced through laminating with thin dielectric materials which yields a sealed, rugged structure. This design is formed into a ³8´VKDSHDQGLVHOHFWULFDOO\WHVWHGXQGHUZDWHUWRDVVXUHSHUIRUPDQFH 6L]HVTXDUH_7KLFNQHVV_9ROWDJH9'&_&XUUHQW$ (/(&75,&9(+,&/(32:(5(/(&7521,&6 Individually laminated, this two-conductor bus bar connects electrolytic FDSDFLWRUVDQG,*%7VLQDVPDOOOLJKWZHLJKWSDFNDJHIRUDQ(9,QYHUWHU 6L]H[_&RQGXFWRUV_9ROWDJH9'&_&XUUHQW$ /2&2027,9(75$&7,21'5,9( +LJKKRUVHSRZHUWUDFWLRQGULYHVEHQH¿WIURPWKHORZLQGXFWDQFHSRZHUSDWK made possible by Mersen laminated bus bars. Laminated bus bars are the HVVHQWLDOFRPSRQHQWWKDWWLHV,*%7VDQGFDSDFLWRUVWRJHWKHU%\PLQLPL]LQJ V\VWHPLQGXFWDQFHWUDQVLHQWRYHUVKRRWVDUHUHGXFHGZKLFKJUHDWO\VLPSOL¿HV the need for complex snubber circuitry. Laminated bus bar designs for motor drives can contain a number of modular bus bars, linked together, to connect all of the system components into one complete system. /HQJWK_:LGWK_9ROWDJH9'&_&XUUHQW$ .FSTFOtBus Bar 11 DEFENSE & AEROSPACE +,*+&855(17%2$5'/(9(/ &855 55(17%2$5'/( /(9 (9(/ 'HQVHSDFNDJLQJLVDKDOOPDUNRIODPLQDWHGEXVEDUVDVVKRZQLQWKLV H SDFNDJLQJ LV D KDOOPDUN RI OD DPLQDWHG EXV EDUV DV VKRZQ LQ WKLV OD\HUHGJH¿OOHGGHVLJQZLWK.DSWRQLQVXODWLRQWRZLWKVWDQGKLJK temperatures from soldering. Made for a special defense application, the design distributes power through wide tabs inserted and soldered into a backplane. Power inputs are located at one end for easy connection with a cable assembly. 6L]H[_&RQGXFWRUV´SHUOD\HU_9ROWDJH9'&_ &XUUHQW$SHUFRQGXFWRU $(5263$&(32:(5',675,%87,21 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. 6L]H[_7KLFNQHVVSHUOD\HU_9ROWDJH9'&_ &XUUHQW$ 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 compact means of packaging, achieving the highest overall system performance where physical space is a premium. And, because bus bars can be engineered to double as a structural support member, they contribute to system strength and rigidity at the same time. If that’s not enough, 0HUVHQ¶VODPLQDWHGEXVEDUVVLPSOLI\¿HOGVHUYLFHWRR which makes it easier to keep mission critical equipment up and running. 12 ep.mersen.com 685)$&(02817)25'()(16(32:(5(/(&7521,&6 2817 )2 )25 5 '()(16( ()( 32:(5 (/(&752 8VHGLQWDQGHPRQHDVDKLJKWHPSKLJKFXUUHQWERDUGIRUVZLWFKLQJ components and the other is densely populated with chip capacitors. The use of Kapton insulation allows full solderability for surface mount components. %RWKEXVEDUVDUHHSR[\HGJH¿OOHGDQGGHVLJQHGWRZLWKVWDQGH[WUHPHO\ demanding conditions of temperature and altitude. /HQJWKDSSUR[LPDWHO\HDFK_9ROWDJH9'&_&XUUHQW$_ &RQGXFWRUVDQG 5$'$532:(5',675,%87,21 'LVWULEXWLQJWKUHH$&DQGVL['&YROWDJHVDQGFXUUHQWVRYHUDORQJGLVWDQFH SUHVHQWVFKDOOHQJHVLQDVVHPEO\WLPHDYRLGLQJZLULQJHUURUVDQGHI¿FLHQW XVHRIDYDLODEOHVSDFH7KLVOD\HUODPLQDWHGDQGHSR[\HGJH¿OOHGEXVEDU system delivers power and reliability over a long distance in a tight package. Through the use of special “joiner bus bars,” the system is “daisy chained” WRGLVWDQFHVH[FHHGLQJWZHQW\IHHWLQOHQJWK /HQJWK_9ROWDJH9$&9'&_&XUUHQW$_ &RQGXFWRUV /21* =RRPHG; &RORUVLONVFUHHQODEHOVIRUHDV\YLVXDOLGHQWL¿FDWLRQ /$0,1$7('32:(5%$&.3/$1( High-current power distribution is easily handled with this six layer, twentyRQHFRQGXFWRUODPLQDWHGEXVEDU'HVLJQHGWRIXQFWLRQDVD³KLJKFXUUHQW backplane,” a bank of special connectors are soldered directly to the bus bar, and used to distribute power within a turret control system. 6L]H[_&RQGXFWRUV_9ROWDJH9'&_&XUUHQW$ 0,66,/(*8,'$1&(6<67(0 A complex and unique laminated bus bar design provides high-power distribution over a backplane with solder tabs for output connectors and gold plated input connections. This application for a laminated bus bar provides power within a Missile Guidance system. The pluggable input connections on this laminated bus bar are gold plated to provide low resistance and high reliability between the bus bar and its subsystem. Forty pairs of outputs from the bus bar to the backplane are made by solder connections. The bus bar is HQWLUHO\HQFDSVXODWHGXVLQJHSR[\HGJH¿OOSURYLGHDFRPSOHWHKHUPHWLFVHDO 6L]H[´_&RQGXFWRUV´_9ROWDJH9_&XUUHQW$ .FSTFOtBus Bar 13 INDUSTRIAL 5$&.0281732:(5',675,%87,21 Mounted inside a circuit breaker power tray, individual bus bars are nested LQDPDFKLQHG)5IUDPHWRSURYLGHRXWSXWFRQQHFWLRQV7KLVDVVHPEO\ assures proper safety separation as well as single component installation. 6L]H[_9ROWDJH9_&XUUHQW$_&RQGXFWRUV 0(',&$/,0$*,1* 7KLVVSDFHVDYLQJGHVLJQLQFRUSRUDWHV¿YHFRQGXFWRUVLQWZROD\HUVZLWK clinch hardware at each end. Its laminated, edge-sealed construction is formed to stay out of the way within a tightly packaged medical testing device. 6L]H/[:[+_9ROWDJHV999_&XUUHQW$_ &RQGXFWRUV The rough and rugged world of the industrial environment demands a constant and consistent supply of quality SURGXFWVGHOLYHUHGULJKWWRWKHSURGXFWLRQÀRRU Mersen’s industrial bus bar design solutions extend RYHUKDOIDFHQWXU\GHOLYHULQJWKHXOWLPDWHLQRSWLPL]HG laminated bus bars to countless manufacturers of motor drives, fork lift trucks, welding machines, power generators, LQGXVWULDOWHVWLQJPDFKLQHVDQGPXFKPRUH0HUVHQ¶V ODPLQDWHGEXVEDUGHVLJQVSURYLGHDSSOLFDWLRQVSHFL¿F characteristics, achieving a consistent level of performance that cannot be matched through wires, cables, or simple EDUVRIFRSSHU 02725$50$785(%86%$5 This six-conductor circular bus bar is comprised of three 2-conductor ODPLQDWHGVXEDVVHPEOLHVERQGHGWRJHWKHU7KHXQL¿HGVWUXFWXUHSURYLGHVD clean transition from power entry to motor windings. Glass mounting supports are bonded to the structure creating a rigid installation. 6L]HGLDPHWHU_&RQGXFWRU_9ROWDJH9_ &XUUHQW$SHUOD\HU 14 ep.mersen.com )25./,)7758&.%86%$5 6L[FRQGXFWRUODPLQDWHGEXVEDUDVVHPEO\FRPELQHV'&DQG$&EXVEDUV DVZHOODVDIXVHFRQQHFWLRQDOOLQRQHFRPSDFWSDFNDJH7KHV\VWHPLV GHVLJQHGWR¿WSHUIHFWO\LQDOLPLWHGVSDFHDQGSURYLGHVSRZHUWRDYDULDEOH speed motor in a rugged industrial environment. 6L]H[_&XUUHQW$_9ROWDJH9_&RQGXFWRUV &203$&7,*%7%86%$5 7KLVXQLTXHODPLQDWHG,*%7EXVEDUGHOLYHUVORZLQGXFWDQFH'&SRZHUZLWKLQ DFRQ¿QHGDUHD7KHGHVLJQDOVRLQFOXGHVVL[VHSDUDWHEXVEDUVDUUDQJHGDV $&RXWSXWZLWKLQOLQHGLRGHFRQQHFWLRQV 6L]H[_&RQGXFWRUV_9ROWDJH9'&9$&_ &XUUHQW$'&$$& ,1'8675,$/,19(57(5%86%$5 'HVLJQHGIRUORZLQGXFWDQFH,*%7SKDVHEXVEDUWKURXJKGHJUHHIRUPHG input connections, including raised top contact surfaces to accommodate snubber capacitors. High-temperature insulation material easily handles the demanding thermal requirements. 6L]H[_9ROWDJH9'&_&XUUHQW$_&RQGXFWRUV )5(48(1&<,19(57(5%86%$5 $QH[FHOOHQWOD\RXWFRQWDLQLQJWZRODUJH'&EXVEDUVDORQJZLWKWKHWKUHH $&RXWSXWEXVEDUVODPLQDWHGGLUHFWO\RQWRSPDNLQJDFRPSOHWHODPLQDWHG SRZHUGLVWULEXWLRQV\VWHPDOOXQGHUDVLQJOHSDUWQXPEHU1RWHWKHLQFOXVLRQ RI)DVWRQWDEVIRUFXUUHQWVHQVLQJDQGSUHVV¿WVWXGVIRUEDODQFLQJUHVLVWRUV 6L]H[_&XUUHQW$_9ROWDJH9'&_ &RQGXFWRUVDQG 9$5,$%/()548(1&<'5,9( 7KLVVLPSOH\HWFRPSOH[GHVLJQLQFRUSRUDWHV'&DQG$&EXVEDUV SOXVDFFRPPRGDWLRQVIRUWKUHHFXUUHQWVHQVRUVDWWKH$&RXWSXWSRLQWV DOOEXLOWLQWRDÀH[LEOHJHRPHWULFSDFNDJHGHVLJQHGWR¿WLQWRDWLJKW FRQ¿QHGRSHUDWLQJDUHD 6L]H[_&XUUHQW$_9ROWDJH9'&_ &RQGXFWRUVDQG .FSTFOtBus Bar 15 COMPUTERS 3&%723&% 7ZREXVEDUH[DPSOHVIRU'&SRZHUFRQQHFWLRQVEHWZHHQFLUFXLWERDUGV These assemblies use an edge sealed construction and employ a special insulating washer that allows compression of the two conductors onto the board while insulating the fastener from the live conductor. 6L]H[_7KLFNQHVV[_9ROWDJH9_&XUUHQW$ ,1)250$7,216725$*(6<67(06 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. 6L]H[_9ROWDJH9'&_&XUUHQW$ 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. 16 ep.mersen.com 683(5&20387(5%86%$5 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. 6L]H[_9ROWDJH9'&_&XUUHQW$ Large parallel bars carry a high degree of current A pair of thinner, laminated conductors connect to the heavyduty bus bars to create DXQL¿HGODPLQDWHGEXV bar structure 6HFWLRQZLWKWKLQQHU conductors is formed to make connection points 32:(5%$&.3/$1( 'LVWULEXWLQJSRZHUWRHLJKWEODGHVLQDODUJHVHUYHULVHDVLO\DFFRPSOLVKHG with this two-conductor laminated bus bar complete with blind mate power FRQQHFWRUV6KRUWFDEOHDVVHPEOLHVDUHEXLOWLQWRWKHEXVEDUIRUV\VWHP monitoring. Formed tabs at bottom accommodate in-line fuse connections. 6L]H[_9ROWDJH9'&_&XUUHQW$_&RQGXFWRUV .FSTFOtBus 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\ +,*+(1'6(59(5 A second laminated bus bar plugs LQWRSUHVV¿WSRZHUFRQQHFWRUV $QH[FHOOHQWFRPELQDWLRQRIYDOXH7KLVPXOWLOD\HUODPLQDWHGEXVEDU incorporates several different connectors for both power and signal, and through careful engineering, a wire harness is used for signal distribution. 0HUVHQFDQHQJLQHHUIXOO\WHVWHGDQGVHULDOL]HGVROXWLRQVWRVROYH\RXU SRZHUGLVWULEXWLRQFKDOOHQJH 6L]H[[_9ROWDJH9_&XUUHQW$ 3UHVV¿WSRZHUFRQQHFWRUVLQVWDOOHGGLUHFWO\LQWREXVEDUFRQGXFWRUV Note three conductors tightly laminated through form High-current connectors fastened to bus bar 18 ep.mersen.com &20387(5%$&.3/$1(32:(5',675,%87,21 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. /HQJWK_7KLFNQHVV_9ROWDJH9'&DQG9'&_&XUUHQW$ &20387(5%$&.3/$1( Redundant power supplies plug into this laminated bus bar design and IHHGKLJKFXUUHQWSRZHULQWRWKHFRPSXWHUEDFNSODQH1RWHWKH¿YHJODVV )5PRXQWLQJVXSSRUWVZKLFKDUHERQGHGWRWKHVWUXFWXUHWRFUHDWHD ULJLGLQVXODWHGPRXQWLQJV\VWHP1LQH³&URZQ&OLS´KLJKFXUUHQWFRQQHFWRUV distribute power from the power supply onto the backplane. 6L]H[_7KLFNQHVVSHUOD\HU_9ROWDJH9_ &XUUHQW$SHUOD\HU 32:(5',675,%87,21)25237,&$/6<67(06 3RZHUGLVWULEXWLRQEXVEDUXVHGLQ2SWLFDO1HWZRUN6\VWHP7KLVHI¿FLHQW DQGFRPSDFWEXVEDULVGHVLJQHGWRSURYLGH9SRZHURQWRDEDFNSODQH from its power supply, through circuit protection, common and differential PRGHLQGXFWRUV¿OPFDSDFLWRUVDQGUHVLVWRUVDOOZLWKRXWWKHQHHGIRUD VHSDUDWH3&%IRUWKHVROGHUHGFRQQHFWLRQVRIWKHUHVLVWRUVDQGFDSDFLWRUV 6L]H;_9ROWDJH9'&_&XUUHQW$_&RQGXFWRUV Power connector points Plug-type circuit breaker Film capacitors &HUDPLFFKRNHV Resistor and 029QHWZRUN .FSTFOtBus 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. 6L]H[[_9ROWDJH9'&_&RQGXFWRUWKLFNQHVV_ &XUUHQW$ 5287(5%$&.3/$1(',675,%87,21 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 6L]H[_9ROWDJH9'&_&XUUHQW$_&RQGXFWRUV 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, UHGXFHGZHLJKWSDFNDJLQJHI¿FLHQF\DQGRYHUDOOFRVW effectiveness over alternative means of power distribution. ,17(51(75287(5 7KLVWZRFRQGXFWRUEXVEDUGLVWULEXWHV'&SRZHUZLWKLQDQLQWHUQHWURXWHU 7KHODPLQDWHGVWUXFWXUHXWLOL]HVWDEVZLWKRIIVHWIRUPVDQGFOLQFKKDUGZDUH WRPRXQWGLUHFWO\RQWRWKHPLGSODQHZKLOHDOORZLQJIRUSURSHUDLUÀRZ High-current pluggable connectors are mounted directly to the bus bar for interchangeable power supplies. /HQJWK_:LGWK_9ROWDJH99_&XUUHQW$ 20 ep.mersen.com ,17(51(7%86%$56<67(0 8VKDSHGZLWKDQJOHGSRZHULQSXWWDEVIHHGLQJDURXQGDUDFNPRXQWHG frame. The unit also has plated, soldered bushings for bullet-style circuit breakers. 6L]H[[_9ROWDJH9_&XUUHQW$_&RQGXFWRUV 5('81'$1732:(5,1387 When system requirements call for redundant power supplies, laminated bus EDUVDUHLGHDO7KLVWZROD\HUGHVLJQXWLOL]HVSUHVV¿WVRFNHWVIRUSRZHUVXSSO\ input and mates downstream with a custom power distribution network. 6L]H[_9ROWDJH9'&_&XUUHQW$_&RQGXFWRUV %$&.3/$1(32:(5',675,%87,21 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 6L]H[_&RQGXFWRUV_&XUUHQW$SHUOD\HU_ 9ROWDJH9'& 7(/(&20081,&$7,216%2$5'/(9(/ 32:(5',675,%87,21 When board space is at a premium, laminated bus bars provide the perfect VSDFHVDYLQJVROXWLRQ7KHEXVEDULVGHVLJQHGWREHVROGHUHGLQWRD3&%DQG includes an integrated connector, which allows for interchangeability of either WKHSRZHUVXSSO\RU3&% 6L]H[_&RQGXFWRUV_&XUUHQW$_9ROWDJH9'& &,5&8,7%5($.(5%86%$5 7KLVVHYHQFRQGXFWRUQLFNHOSODWHGDVVHPEO\UHFHLYHV¿OWHUHGLQSXWSRZHU routed through pluggable breakers and directed to output terminals within a UDFNPRXQWHGV\VWHP6XFKFRPSDFWURXWLQJRIIHUVLPSURYHGSDFNDJLQJDQG LPSURYHGDLUÀRZ²ERWKNH\EHQH¿WVRIODPLQDWHGEXVEDUV 6L]H[_9ROWDJH9'&_&XUUHQW$_&RQGXFWRUV .FSTFOtBus 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. 6L]H[[_9ROWDJH9'&_&XUUHQW$_&RQGXFWRUV PEM hardware for power input connection Molded barriers for connector isolation 8KHLJKWIRUUDFN mount system Faston tabs provide quick-connect power to circuit breakers ),/7(5('32:(5,1387%86%$5 $WZRFRQGXFWRUEXVEDUURXWLQJ¿OWHUV'&SRZHUWKURXJKULQJOXJVDQG clinch hardware, terminating in multiple power connectors mounted in a 8UDFNPRXQWHGSRZHUGUDZHU 6L]H[_9ROWDJH9'&_&XUUHQW$_&RQGXFWRUV %$&.3/$1(32:(5',675,%87,21 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. 6L]H[_9ROWDJH9_&XUUHQW$_&RQGXFWRUV 22 ep.mersen.com ,17(51(75287(5%$&.3/$1(%86%$5 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. 6L]H[[_7KLFNQHVVDQG_9ROWDJH99_ &XUUHQW$ 7(/(&2032:(5',675,%87,21 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. 6L]H[_9ROWDJH9'&_&XUUHQW$_&RQGXFWRUV Heavy-duty power clips installed for mating with power supplies Power pins are SUHVV¿WDQGVROGHUHG Four-layer, HGJH¿OOHG bus bar .FSTFOtBus Bar 23 VALUE ADDED 3'$81,7%()25(%86%$5 8GUDZHUKHLJKWOEZHLJKW Two large contactors Two large capacitors 'R]HQVRIFOXWWHUHG ZLUHV SRRUDLUÀRZ Multilayer bus bars offer a structural integrity that wiring PHWKRGVMXVWFDQ¶WPDWFK0HUVHQ¶V9DOXH$GGHGEXVEDU designs incorporate a variety of components built right in. (DFKRQHLVVDIHW\WHVWHGDQGFHUWL¿HGDOOGHVLJQHGWR help simplify your life at the system assembly level. Every day Mersen’s innovation delivers complete multicomponent bus bar and power distribution assemblies around the world to our dedicated family of customers. 3'$81,7:,7+%86%$5 &RPSDFW design means RQO\8KHLJKW 0XFKLPSURYHGDLUÀRZ 6LJQL¿FDQWO\UHGXFHG assembly time 2QH³8´KHLJKWVPDOOHU All wires replaced by multilayer laminated bus bar “Plug-in” circuit breakers OLJKWHU assembly weight 24 ep.mersen.com 3'$$66(0%/<5((1*,1((5('86,1*%86%$57(&+12/2*< Multilayer bus bar construction &LUFXLWEUHDNHUVSOXJ directly into bus bar 3'$%86%$5 2QO\RQHFDSDFLWRUQHHGHG due to capacitance in the bus bar 6LQJOH,*%7UHSODFHVWZR contactors 5($59,(: &XWDZD\VKRZLQJWKHXVHRI bushings as “vias” to make connections within the laminated bus bar. .FSTFOtBus Bar 25 VALUE ADDED 3'$$66(0%/<$+,7,167$*(/,*+7,1*6<67(06 OD\HUODPLQDWHGEXVEDU makes easy connections to FLUFXLWEUHDNHUV Easy connection with contactors Faston connections inside SURWHFWLYH)5JODVV The design concept for this project was to create a rugged, lightweight power distribution system for a production OLJKWLQJDSSOLFDWLRQ'XHWRWKHSUHGLFWDEOHSHUIRUPDQFH characteristics of the solid copper conductors used in ODPLQDWHGEXVEDUVLQVWHDGRIWKHEXONDQGXQFHUWDLQW\RI ZLUHVWKHFUHDWLYLW\RIWKHGHVLJQWHDPZDVWDSSHG7RWDO success was achieved through compact packaging, light ZHLJKWDQGVLPSOL¿HGDVVHPEO\ 26 ep.mersen.com (0,¿OWHUV Main circuit breaker FRQGXFWRUODPLQDWHG output bus bar Plug-type output LQWHUFRQQHFWVLPSOL¿HV system installation and eliminates connection errors 6DIHW\VKLHOGSURYLGHV protection around high current areas FLUFXLWEUHDNHUV Electrolytic capcitors enhance system safety *URXQG ,QSXW 3/$7)250)25&,5&8,7%5($.(5&21),*85$7,216 &UHDWHGDVDWRWDOSRZHUGLVWULEXWLRQVFKHPH0HUVHQHQJLQHHUVZRUNHGZLWKWKHFOLHQWWRFUHDWHDEXVEDUVWUXFWXUHWKDWDFFHSWVLQSXWSRZHUDQG JURXQGGLYLGHVWKHSRZHUWKURXJKFLUFXLWEUHDNHUVDQGURXWHVWKHYDULRXVFXUUHQWVWRPRGXODURXWSXWFRQQHFWLRQV0HUVHQODPLQDWHGEXVEDUVFDQ EHHQJLQHHUHGWREHPDGHZLWKDQLQ¿QLWHQXPEHURIFRQQHFWRUVIXVHVFDSDFLWRUVUHVLVWRUQHWZRUNV¿OWHUVVXUJHSURWHFWRUVDQGFLUFXLWEUHDNHUV 2XUFRPSOHWHYDOXHDGGHGDVVHPEOLHVDUHVXSSOLHGIXOO\WHVWHGDQGUHDG\IRULQVWDOODWLRQ0DQXIDFWXULQJEHQH¿WVE\UHGXFHGDVVHPEO\DQGWHVWWLPH SXUFKDVLQJEHQH¿WVE\NHHSLQJWUDFNRIIHZHULWHPVUHGXFLQJLQYHQWRU\ /HQJWK_:LGWK_9ROWDJH9_&XUUHQW$ .FSTFOtBus Bar 27 VALUE ADDED 32:(56,*1$/',675,%87,21 $VHULHVRIVPDOOSRZHUVXSSOLHVSDUDOOHOWRSURYLGHV\VWHPSRZHULQD UDFNDSSOLFDWLRQ,QSXWFRQQHFWRUVDUHSUHVV¿WLQWRERWKWKHEXVEDUDQG 3&%VIRUV\VWHPVLPSOLFLW\$WWDFKHGWRWKLVEXVEDU¶VULJKWVLGHLVLWVPDWH DORQJYHUWLFDOEXVEDUZLWKSOXJJDEOHRXWSXWFRQQHFWRUVIRUV\VWHP distribution. Along the top section, signal output reports system intelligence to monitor each power supply’s performance. 6L]H[[_9ROWDJH9'&_&XUUHQW$_&RQGXFWRUV 5$&.028173'$32:(56,*1$/ Plug-type circuit breakers Integral wire feeds and connectors help eliminate wiring errors Elcon Rapid-Lock connectors $VVHPEO\¿WVLQWR8 high rack drawer 28 ep.mersen.com High-current power FRQQHFWRUVZLWK¿OWHUV Electrolytic capacitors Four-layer bus bar 'XDOYROWDJHVZLWFKHV 'DWDSRUWVIRU communication 6L[IURQWPRXQWHG circuit breakers Power and data connections 5$&.02817('32:(5',675,%87,21$66(0%/< Mersen engineers work closely with customers to design complete rack PRXQWHGSRZHUGLVWULEXWLRQDVVHPEOLHV7KLV3'$FRQWDLQVD-VKDSHG IRXUOD\HUODPLQDWHGEXVEDUWKUHHLQSXW¿OWHUVVL[FLUFXLWEUHDNHUVVHQVH PRQLWRULQJDQGGXDOYROWDJHVZLWFKHV7HVWHGVHULDOL]HGDQGFRPSOHWHO\ ODEHOHGHDFK3'$LVUHDG\IRUV\VWHPLQVWDOODWLRQE\WKHFXVWRPHU 6L]H[8_9ROWDJH99VZLWFKDEOH_&XUUHQW$ .FSTFOtBus 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 RULHQWDWLRQ RI WKH EXV VWUXFWXUH DQG WKH DLUÀRZ %XV EDUV PD\ 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. The physical structure of bus bars offers unique features in mechanical design. For example, complete power distribution subsystems can also act as structural members of a total system. 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 EDUVIRUSRZHUGLVWULEXWLRQV\VWHPV2QFHDQRXWOLQHRIDEXVEDU KDVEHHQHVWDEOLVKHGVSHFL¿FGHVLJQDQGPDQXIDFWXULQJ FRQVLGHUDWLRQVZLOODIIHFWWKHFRVW6HH&RVW&RQVLGHUDWLRQV We’ve provided basic design criteria to help you specify bus bars for your application. The information required to specify a bus EDULQFOXGHVFRQGXFWRUPDWHULDOQXPEHURIFRQGXFWRUVLQFOXGLQJ JURXQGGLPHQVLRQVOHQJWKZLGWKDQGWKLFNQHVVLQWHUFRQQHFWLRQ VFKHPHVPRXQWLQJFRQ¿JXUDWLRQLIUHTXLUHGW\SHRI¿QLVKDQG choice of insulation material. 30 ep.mersen.com JUHDWHUDUHDIRUFRROLQJWRPLQLPL]HWKHYROWDJHGURSGXH WRWHPSHUDWXUHULVH GUDVWLFDOO\UHGXFHGLQWHUFRXSOLQJHIIHFWVDQG the opportunity for advantageous shielding between levels, obtained by the use of interleaved grounds. MOUNTING 7RPRXQWDEXVEDUWRDQDVVHPEO\VWUXFWXUHKDUGZDUHVWXGV KROHV HWF FDQ EH PDQXIDFWXUHG LQWR WKH FRQGXFWRUV $Q alternative ground plane may be added as support for the bus bar assembly and to provide a platform for mounting hardware. FINISH Mersen offers in-house conductor plating in tin, tin/lead, nickel, silver, or gold. Plating is a major consideration in designing a bus bar because it is the point of contact for all bus bar electrical connections. The plating can provide advantageous electrical properties, decreasing the voltage drop. When gold is used, it is JHQHUDOO\RQO\SODWHGRQWHUPLQDWLRQVXUIDFHVWRPLQLPL]HFRVW The equivalent circuit illustrates the associated inductance /FDSDFLWDQFH&DQGUHVLVWDQFH5ZKLFKDUHPRVWRIWHQ uniformly distributed along the bus bar. We discuss the basic relationships between physical dimensions and electrical parameters in the following analysis. INSULATION Bus bars use many different types of adhesive-coated insulation materials to permit structure layers to be laminated together. 7KHUH DUH DGGHG EHQH¿WV IURP DQ HOHFWULFDO SHUVSHFWLYH Insulation provides an inside and outside barrier to its installed environment. Insulations can increase the capacitance and ORZHUWKHLQGXFWDQFHDQGLPSHGDQFH&RPPRQO\XVHGLQVXODWLRQ materials are Nomex®, Tedlar®, Mylar®, Kapton®8OWHP®, Mylar/ 7HGODU 7HGODU0\ODU7HGODU 9DOR[®, epoxy-glass, heat shrink tubing, and epoxy powder coating. There are many different WKLFNQHVVHV RI WKHVH LQVXODWLRQ PDWHULDOV DYDLODEOH &RQWDFW D 0HUVHQ HQJLQHHU IRU PRUH LQIRUPDWLRQ 6SHFLDO LQVXODWLRQV DUH available upon request. COST CONSIDERATIONS Prices of bus bar assemblies vary depending upon quantity ordered. In addition, individual dimensional characteristics, materials, manufacturing techniques, the interconnection VFKHPH SODWLQJ ¿QLVK LQVXODWLRQ DQG KDUGZDUH UHTXLUHPHQWV affect overall cost. Mersen engineers are available to assist in developing the most HI¿FLHQW DQG FRVWHIIHFWLYH GHVLJQ WR SURYLGH VROXWLRQV WR DQ\ power distribution problem. The earlier we are involved in your design process, the more cost effective your solution is likely WR EH (DUO\ LQYROYHPHQW HQDEOHV XV WR RSWLPL]H ERWK HDVH RI manufacturing and turnaround time. We recommend that you contact a new-product development engineer before you start designing your laminated bus bar power distribution system. ELECTRICAL DESIGN Important characteristics of laminated bus bars are resistance, series inductance, and capacitance. As performance parameters of electronic equipment and components become more stringent, these characteristics take on even more importance. In determining the impedance of a power distribution system, WKHVH FKDUDFWHULVWLFV DUH VLJQL¿FDQW LQ VROYLQJ WZR RI WKH PRVW important problems for designers—resistance and noise. It is important, therefore, to understand the electrical characteristics of the laminated bus bar. )LJXUH VKRZV D EDVLF WZRFRQGXFWRU ODPLQDWHG EXV EDU DQG Figure 2 shows its equivalent circuit. The bus bar is composed of two parallel conducting plates separated by a dielectric. Figure 1. Figure 2. 3K\VLFDO5HSUHVHQWDWLRQ (OHFWULFDO(TXLYDOHQW CONDUCTOR SIZE &DOFXODWLQJFRQGXFWRUVL]HLVYHU\LPSRUWDQWWRWKHHOHFWULFDODQG mechanical properties of a bus bar. Electrical current-carrying requirements determine the minimum width and thickness of the conductors. Mechanical considerations include rigidity, mounting holes, connections, and other subsystem elements. The width of the conductor should be at least three times the thickness of the conductor. Additions of tabs and mounting holes change the cross-sectional area of the conductor, creating potential hot spots on the bus bar. The maximum current for each tab or termination must be considered to avoid hot spots. &URVVVHFWLRQDO DUHD DQG WKH OHQJWK GHWHUPLQH EXV EDU FRQGXFWRUVL]H&URVVVHFWLRQDODUHD$LVHTXDOWRFRQGXFWRU WKLFNQHVVWPXOWLSOLHGE\FRQGXFWRUZLGWKZ A WZLQFKHV2 $ YDOXH RI DSSUR[LPDWHO\ FLUFXODU PLOV SHU DPSHUH LV D WUDGLWLRQDOEDVLVIRUGHVLJQRIVLQJOHFRQGXFWRUV6LQFHEXVEDUV are not round, circular mils must be converted to mils squared VLPSO\PXOWLSO\WKHFLUFXODUPLOVYDOXHE\ The following formula determines the minimum cross-sectional DUHD RI D FRQGXFWRU 7KLV DUHD VKRXOG EH LQFUHDVHG E\ ¿YH percent for each additional conductor laminated into the bus VWUXFWXUH7KLVH[WUD¿YHSHUFHQWLVDVDIHW\IDFWRUFRPSHQVDWLQJ for the compounding heat gain within the conductors. This equation calculates the minimum cross-sectional area QHFHVVDU\IRUFXUUHQWÀRZ A I>N@*-6LQFKHV2 A = cross-sectional area of the conductor in inches2 , 0D['&FXUUHQWLQDPSHUHV N = Number of conductors in the bus assembly 7RFDOFXODWHWKHFURVVVHFWLRQDODUHDRIDQ$&FXUUHQWVRXUFH \RXPXVWWDNHIUHTXHQF\LQWRFRQVLGHUDWLRQVHHWKHVHFWLRQRQ 6NLQ(IIHFW .FSTFOtBus Bar 31 1RWH7KLVIRUPXODKDVDEUHDNGRZQSRLQWDWDSSUR[LPDWHO\ amps of current. For calculations involving larger currents, we suggest you contact a Mersen engineer. In addition, you can ¿QG DPSDFLW\ FKDUWV DQG FRPSDUDWLYH JUDSKV DW WKH &RSSHU 'HYHORSPHQW$VVRFLDWLRQ¶VZHEVLWHZZZFRSSHURUJ INDUCTANCE Maintaining a low inductance results in a low characteristic impedance and greater noise attenuation. When minimum inductance is a design objective, consider these tips: 0LQLPL]HWKHGLHOHFWULFWKLFNQHVV CAPACITANCE &DSDFLWDQFHRIWKHEXVDUUDQJHPHQWGHSHQGVXSRQWKHGLHOHFWULF PDWHULDO DQG SK\VLFDO GLPHQVLRQV RI WKH V\VWHP &DSDFLWDQFH varies only slightly with frequency change, depending on the stability of the dielectric constant. This variation is negligible and therefore is omitted in this analysis: C = KZl picofarads G Increased capacitance results in a decreasing characteristic impedance. Low impedance means greater effective signal suppression and noise elimination. It is therefore desirable to develop maximum capacitance between conductor levels. This may be achieved by: keeping the dielectric as thin as possible, consistent with good manufacturing and design practices 2. using dielectrics having a high relative permittivity NIDFWRU SKIN EFFECT Because of skin effect phenomena, inductance and resistance are dependent on frequency. At high frequency, currents tend to ÀRZRQO\RQWKHVXUIDFHRIWKHFRQGXFWRU7KHUHIRUHWKHGHSWK of penetration of the electromagnetic energy determines the effective conducting volume. The skin depth is given by: SD = inches ¥IMȡ 2. 0D[LPL]HWKHFRQGXFWRUZLGWK Increase the frequency. There are two types of inductance to be determined: internal LQGXFWDQFHZKLFKLVDUHVXOWRIÀX[OLQNDJHVZLWKLQDFRQGXFWRU and external inductance, which is determined by the orientation of the two current-carrying conductors. 'LVWULEXWLRQRIFXUUHQWWKURXJKRXWDFRQGXFWRUDWKLJKIUHTXHQFLHV LV FRQFHQWUDWHG QHDU WKH VXUIDFHV FDOOHG WKH ³VNLQ HIIHFW´ 7KHLQWHUQDOÀX[LVUHGXFHGDQGLWLVXVXDOO\VXI¿FLHQWWRFRQVLGHU only the external inductance. At low frequencies, however, the internal inductance may become an appreciable part of the total inductance. The formula for calculating the internal inductance at a low frequency is extremely lengthy and thus omitted in this analysis. The formula for external inductance is: L = Glnanohenrys Z +LJK)UHTXHQF\,QGXFWDQFHW!SD Lt = GSDlnanohenrys Z RESISTANCE 7RFDOFXODWHWKH'&FRQGXFWRUUHVLVWDQFHWKHIROORZLQJIRUPXOD DSSOLHV5HVLVWDQFHDW& 5DC = ȡlohms Zt 5DC = * lohms Zt -6 )RU&RSSHU SD = 2.6 inches ¥I As frequency increases, inductance decreases to a limiting YDOXH ZKHUHDV WKH UHVLVWDQFH LQFUHDVHV LQGH¿QLWHO\ DV WKH IUHTXHQF\DSSURDFKHVLQ¿QLW\ 7R GHWHUPLQH '& FRQGXFWRU UHVLVWDQFH DW WHPSHUDWXUHV DERYH &XVHWKLVIRUPXOD Į 7HPSFRHI¿FLHQWRIUHVLVWLYLW\RIFRSSHUDW&LV 52 = 5T2-TRKPV 52 = Resistance at elevated temp R2 5HVLVWDQFHDWHOHYDWHGWHPSHUDWXUH72 5 5HVLVWDQFHDW&7 32 ep.mersen.com For high frequencies the skin depth is taken into consideration. 7KHIRUPXODIRU$&UHVLVWDQFHLV )RUW!6' 7DEOHRI'H¿QLWLRQV A &URVVVHFWLRQDODUHDRIDFRQGXFWRULQLQFKHV2 C &DSDFLWDQFHLQSLFRIDUDGV Thickness of dielectric in inches ȡ Resistivity of the conductor in ohms/inch I )UHTXHQF\LQKHUW] I &XUUHQWLQDPSV K 'LHOHFWULFFRQVWDQW l Length of conductor in inches L Inductance in nano henrys Lt Total inductance at high frequency M Permeability of nonmagnetic PDWHULDOV *KHQU\VLQFK R Resistance in ohms 6' 6NLQGHSWKLQLQFKHV t Thickness of the conductor in inches IMPEDANCE T 7HPSHUDWXUHDWSRLQWLQ&o In the design of laminated bus bars, you should consider maintaining the impedance at the lowest possible level. This ZLOOUHGXFHWKHWUDQVPLVVLRQRIDOOIRUPVRI(0,HOHFWURPDJQHWLF LQWHUIHUHQFHWRWKHORDG T2 7HPSHUDWXUHDWSRLQWLQ&o w Width of conductor in inches 9d 9ROWDJHGURSLQYROWV 3L Į Temperature coeffecient of resistivity ] Impedence 5AC = 2lȡ ohms SDZ $&UHVLVWDQFHDW& -6 5AC = 2l* ohms SDZ VOLTAGE DROP As current travels across a conductor, it loses voltage. This is caused by the resistivity of the conductor. The losses are UHIHUUHG WR DV YROWDJH GURS 8VH WKLV IRUPXOD WR FDOFXODWH WKH voltage drop across the conductors: VD 5I 5 = ȡlohms Zt VD = ȡIl9ROWV Zt Increasing capacitance and reducing inductance are the determining factors in eliminating noise. The formula for calculating characteristic impedance is: Z = ¥L/C ohms .FSTFOtBus Bar 33 RESISTANCE, INDUCTANCE, AND CAPACITANCE COMPARISONS TWISTED PAIR MERSEN BUS BARS $:*ZLUHVROLG²ORQJ 0HUVHQEXVEDU²ORQJ[ZLGH[WKLFN ,QVXODWLRQWKLFNQHVVDSSUR[ ,QVXODWLRQWKLFNQHVV $0521² &RQGXFWRUDUHD LQ &RQGXFWRUDUHD LQ2 2 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 $:*ZLUHVWUDQGHG²ORQJ 0HUVHQEXVEDU²ORQJ[ZLGH[WKLFN ,QVXODWLRQWKLFNQHVVDSSUR[ ,QVXODWLRQWKLFNQHVV $0521² &RQGXFWRU$UHD LQ &RQGXFWRU$UHD LQ2 2 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 Width (in.) Current Carrying Capacity (amps) DC Resistance of a 2-Conductor Bus (milliohm/ft) .005 .0020 .005 .005 5.05 2.00 .500 0 252.00 .200 00 Wire Size Gauge RAC (ohms) Cir Mils Sq Inches Thick (in.) 22 .0005 INSULATION 0HUVHQ XWLOL]HV PDQ\ LQVXODWLRQ V\VWHPV WR PHHW GLIIHUHQW applications. These systems combine the dielectric materials detailed in the table on the next page. By combining different materials with selective edge-conditioning techniques, our insulating systems are designed to exceed any and all of your electrical, mechanical, and environmental requirements. $PURQGLHOHFWULFSURGXFWVZHUHVSHFL¿FDOO\GHYHORSHGIRU use in the manufacture of bus bars. Many of the products are coated with a B-stage resin that is reactivated during the DVVHPEO\ SURFHVV 0RVW RI RXU LQVXODWLQJ V\VWHPV DUH 8/ 5HFRJQL]HG 5HIHUHQFH ZZZXOFRP IRU D PDWHULDO OLVWLQJ )LOH1R( AMRON 1:6HULHVDUHSRO\YLQ\OÀXRULGH39)¿OPV39) ¿OPV DUH FKHPLFDO DQG VROYHQWUHVLVWDQW GHPRQVWUDWH excellent molding characteristics, and have both a high GLHOHFWULF FRQVWDQW .IDFWRU DV ZHOO DV D KLJK GLHOHFWULF VWUHQJWK7UDGHQDPH7HGODU® AMRON 2: 6HULHV DUH DURPDWLF SRO\DPLGH SRO\PHU papers. Mechanical toughness, thermal stability, and VROYHQW UHVLVWDQFH DUH VRPH RI LWV FKDUDFWHULVWLFV 7UDGH name: Nomex® AMRON 3: 6HULHV DUH SRO\LPLGH ¿OPV 7KHVH ¿OPV DUH UHFRPPHQGHG IRU KLJK WHPSHUDWXUH DSSOLFDWLRQV 7UDGH name: Kapton® AMRON 4:6HULHVLVDFRPSRVLWH¿OPPDGHXSRI$PURQ DQG $PURQ 8VHG H[FOXVLYHO\ DV RXWVLGH LQVXODWLRQ WKHVH ¿OPV SURYLGH DQ H[FHOOHQW VFXIIUHVLVWDQW FRDWLQJ 0\ODU7HGODU AMRON 5:6HULHVLVDOVRDFRPSRVLWH¿OPPDGHXSRI$PURQ DQG$PURQ 7KHVH ¿OPV DUH XVHG DV LQWHUQDO LQVXODWLRQ and are recommended for high dielectric strength applications 7HGODU0\ODU7HGODU AMRON 6: 6HULHV DUH SRO\HWK\OHQH WHUHSKWKDODWH 3(7 ¿OPV3(7DUHSRO\HVWHU¿OPVZKLFKRIIHUDQH[FHOOHQWEDODQFH RIHOHFWULFDOFKHPLFDOWKHUPDODQGSK\VLFDOSURSHUWLHV7UDGH name: Mylar® AMRON 7:6HULHVLVDFRPSRVLWHLQVXODWRUPDGHXSRI$PURQ 2 and Amron 6. This composite combines the mechanical toughness of Nomex with the electrical properties of Mylar 1RPH[0\ODU1RPH[ AMRON 8: 6HULHV DUH ODPLQDWHG VKHHWV FRQVWUXFWHG IURP FRQWLQXRXV¿ODPHQW W\SH JODVV IDEULF ZLWK D ÀDPHUHWDUGDQW epoxy resin binder. Good fabrication, high dielectric, and physical strengths make this material suitable for many HOHFWULFDODSSOLFDWLRQV1(0$*UDGH)5 AMRON 9: 6HULHV DUH HSR[\ SRZGHU FRDWLQJV 7KHVH FRDWLQJV H[KLELW H[FHSWLRQDO GXUDELOLW\ $PURQ VKRXOG EH used where conventional insulation, due to part geometry, is not practical. Note: The insulations listed above are standard materials used in the manufacture of our bus bars. Many other dielectric PDWHULDOV DPRQJ WKHP 9DOR[® 8OWHP®, and PEN, can be LQFRUSRUDWHGLQWR\RXUGHVLJQWRPHHWVSHFL¿FUHTXLUHPHQWV Be sure to consult with a Mersen application engineer in VHOHFWLQJ LQVXODWLRQ DV YDOXHV PD\ ÀXFWXDWH DIWHU LQVXODWLRQ has been applied. .FSTFOtBus Bar 35 BUS BAR INSULATION TECHNIQUES (32;<('*(),//(' &216758&7,21 */$66('*(),//(' &216758&7,21 Edge insulation: Epoxy Glass Typical Epoxy HGJH¿OO Internal Insulation &RQGXFWRU/D\HUV &RSSHURU$OXPLQXP &RQGXFWRU/D\HU 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$7('&216758&7,21 36 ep.mersen.com 02/'('6($/('&216758&7,21 STANDARDS 7KHVHOLVWVGHWDLOWKHVSHFL¿FDWLRQVWKDWRXUVWDQGDUGFRQGXFWRUPDWHULDOLQVXODWLRQDQGSODWLQJSURFHVVHVPHHW,QFRUSRUDWLQJWKHVH VWDQGDUGVLQWR\RXURZQVSHFL¿FDWLRQVQRWHVZLOOKHOSUHGXFHPDQXIDFWXULQJFRVWVDQGUHGXFHF\FOHWLPHV Conductor Material Plating &'$ &RSSHU $670%% Tin $670% &'$ Brass $670% Nickel 441$06 &'$ Phosphate %URQ]H $670% Electroless Nickel 0,/& &'$ Beryllium &X $670%% 6XOIDPDWH Nickel 0,/3 &'$ &RSSHU$OOR\ $670% Gold $670% $OOR\ Nickel/Iron $670) 6LOYHU 446 + Alloy Aluminum $670% &RSSHU $06 Tin-Lead $063$670% Tin-Lead 0,6 $QRGL]H 0,/$ &KURPDWH 0,/& Passivate 443 Insulation $PURQ Tedlar®39) /3 Amron 2 Nomex® 0,/, $PURQ Kapton® 0,/3 Amron 6 Mylar /PET 0,/, $PURQ )5 0,/, $PURQ Epoxy Powder &RDWLQJ $670' $PURQ 8OWHP® $PURQ 9DOR[® Epoxy Edge Fill Black or White ® 0,/, .FSTFOtBus Bar 37 GLOSSARY OF TERMS Capacitance Measured in farads, it is the opposition to voltage changes in an alternating FXUUHQWFLUFXLWFDXVLQJYROWDJHWRODJEHKLQGFXUUHQWH[KLELWHGE\WZR conductors separated by an insulator. Impedance =0HDVXUHGLQRKPVLWLVWKHWRWDORSSRVLWLRQWRWKHÀRZRIFXUUHQW offered by a circuit. Impedance consists of the vector sum of resistance and reactance. Capacitor A passive electronic component that stores energy in the form of DQHOHFWURVWDWLF¿HOG,QLWVVLPSOHVWIRUPDFDSDFLWRUFRQVLVWVRIWZR conducting plates separated by an insulating material called the dielectric. The capacitance is directly proportional to the surface areas of the plates, and is inversely proportional to the separation between the plates. &DSDFLWDQFHDOVRGHSHQGVRQWKHGLHOHFWULFFRQVWDQWRIWKHPDWHULDO separating the plates. Insulation Resistance The resistance offered, usually measured in megaohms, by an insulating PDWHULDOWRWKHÀRZRIFXUUHQWUHVXOWLQJIURPDQLPSUHVVHG'&YROWDJH Insulators 0DWHULDOVZKLFKSUHYHQWWKHÀRZRIHOHFWULFLW\1RQFRQGXFWLYHPDWHULDOVXVHG to separate electric circuits. Choke An inductor designed to present a high impedance to alternating current. Inverter An electric or electronic device for producing alternating current from direct current. Clearance 7KHFOHDUDQFHLVGH¿QHGDVVKRUWHVWGLVWDQFHWKURXJKWKHDLUEHWZHHQWZR conductive elements. Partial Discharge $W\SHRIORFDOL]HGGLVFKDUJHUHVXOWLQJIURPWUDQVLHQWJDVHRXVLRQL]DWLRQLQDQ insulation system when the voltage stress exceeds a critical value. Common Collector Connection 6DPHDVJURXQGHGFROOHFWRUFRQQHFWLRQ$OVRFDOOHGWKHHPLWWHUIROORZHU A mode of operation for a transistor in which the collector is common to both the input and the output circuits and is usually connected to one of the power rails. Resistance RDQGPHDVXUHGLQRKPV2SSRVLWLRQWRFXUUHQWÀRZDQGGLVVLSDWLRQRIHQHUJ\ in the form of heat. Common Emitter Connection 6DPHDVJURXQGHGHPLWWHUFRQQHFWLRQ$PRGHRIRSHUDWLRQIRUDWUDQVLVWRULQ which the emitter is common to the input and output circuits. The base is the input terminal and the collector is the output terminal. Conductivity How easily something allows electric current to pass through it. If a substance LVDJRRGFRQGXFWRURUKLJKO\FRQGXFWLYHIRUH[DPSOHFRSSHURUEUDVVLWZLOO allow electrons to pass freely through it, offering only minor resistance. Corona $OXPLQRXVGLVFKDUJHGXHWRLRQL]DWLRQRIWKHDLUVXUURXQGLQJDFRQGXFWRU caused by a voltage gradient exceeding a certain critical value. Corona Extinction Voltage (CEV) 7KHKLJKHVWYROWDJHDWZKLFKDFRQWLQXRXVFRURQDRIVSHFL¿HGSXOVH amplitude no longer occurs, as the applied voltage is gradually decreased from above the corona inception value. Corona Inception Voltage (CIV) 7KHORZHVWYROWDJHDWZKLFKDFRQWLQXRXVFRURQDRIVSHFL¿HGSXOVHDPSOLWXGH occurs as the applied voltage is gradually increased. Creepage Distance The shortest distance separating two conductors as measured along a surface touching both conductors. Self-inductance The property of a conductor that produces an induced voltage in itself with changing current. The term inductance alone means self-inductance. When a varying current in one conductor induces a voltage in a neighboring conductor, the effect is called mutual inductance. Shield 3DUWLWLRQRUHQFORVXUHDURXQGFRPSRQHQWVLQDFLUFXLWWRPLQLPL]HWKHHIIHFWV RIVWUD\PDJQHWLFDQGUDGLRIUHTXHQF\¿HOGV Shunt A low-value precision resistor used to monitor current. Snubber $UHVLVWRUFDSDFLWRU5&QHWZRUNXVHGWRUHGXFHWKHUDWHRIULVHRIYROWDJHLQ switching applications. Voltage Drop &RQGXFWRUVFDUU\LQJFXUUHQWDOZD\VKDYHLQKHUHQWUHVLVWDQFHRULPSHGDQFH WRWKHFXUUHQWÀRZ9ROWDJHGURSLVWKHDPRXQWRIYROWDJHORVVWKDWRFFXUV through all or part of the circuit due to impedance. THREE-LAYER BUS BAR WITH INDEPENDENT FASTON TABS AT LONG END Dielectric 1RQFRQGXFWLQJPDWHULDOXVHGWRLVRODWHDQGRULQVXODWHHQHUJL]HG electrical components. Dielectric Constant (K) The property of the dielectric material that determines how much electric HQHUJ\FDQEHVWRUHGLQDFDSDFLWRURIDSDUWLFXODUVL]HE\DYDOXHRI applied voltage. PRESS-FIT BUSHINGS WITH CROWN BAND INSERTS Dielectric Strength The maximum voltage an insulating material can withstand without breaking down. EMI, RFI Acronyms for various types of electrical interference: electromagnetic interference and radio-frequency interference. Hi-Pot Test (High Potential Test) $WHVWSHUIRUPHGE\DSSO\LQJDKLJKYROWDJHIRUDVSHFL¿HGWLPHWRWZR isolated points in a device to determine the adequacy of insulating material. 38 ep.mersen.com FLEXIBLE TABS FOR LOW PROFILE AREAS FASTON TABS FROM BOLT ON TABS INSIDE THE BUS BAR, CONFINED WITHIN THE SAVES SPACE BUS BAR, SAVES SPACE AND MATERIAL PANEL HARDWARE CLINCH HARDWARE FOR RING LUGS SQUARE PINS FOR FASTON TABS EXTENDING SOLDER CONNECTIONS BEYOND THE BUS BAR OR WIRE WRAP OR WITHIN MOLDER HARDWARE, FASTON TABS ALONG THE IDEAL FOR THIN EDGE WITH FORMS FOR MATERIALS AND HIGH EASY ACCESS TORQUE APPLICATIONS MULTILAYER AND MULTI- FLANGE TAB CONDUCTOR TABS FOR CONSTRUCTION WITH PCB POWER CLINCH HARDWARE RING LUG TERMINATIONS SOLDER PIN CONNECTION USING CLINCH STUD WITH THERMAL RELIEF HARDWARE IN FORMED TABS SOLDER PINS FOR CONNECTORS IN PLASTIC PCB CONNECTION WITH HOUSING, SOLDERED INTO THERMAL RELIEF HOLES EACH CONDUCTOR IN BUS BAR CLINCH STUD FLEX CIRCUIT HARDWARE IN SIDE TAB INTEGRATED INTO BUS INTERCONNECT (NOTE BAR FOR FLEXIBLE OFFSET FORM IN TAB) INTERCONNECTION HIGH CURRENT POWER THREE-LAYER BUS BAR RECEPTACLE WITH UTILIZING EMBOSSED CROWN-BAND INSERTS “DIMPLES” FOR COPLANAR INTERCONNECTION .FSTFOtBus Bar 39 Main production sites Industrial or commercial branch A WORLD LEADER A GLOBAL PLAYER A global expert in materials and solutions for extreme environments as well as in the safety and reliability of electrical equipment, Mersen designs innovative solutions to address its MERSEN Rochester -HIIHUVRQ5RDG 5RFKHVWHU1< 86$ 7 ) FOLHQWV¶VSHFL¿FQHHGVWR HQDEOHWKHPWRRSWLPL]H their manufacturing process in sectors such as energy, transportation, electronics, chemical, pharmaceutical, and process industries. MERSEN France UXHGX'pU\ 6W6\OYDLQG¶$QMRX France 7 ) ep.mersen.com | busbar.com MERSEN Shanghai 1R$6KX6KDQ5RDG 6RQJMLDQJ 6KDQJKDL 7 BR-BUS BAR-001 | 02.13 | 5000 | ImageNow | © Mersen 2013 in safety & reliability for electrical power