Choosing the Right Aluminium Busbar: Key Factors to Consider

 Aluminum busbars are widely used in electrical power distribution systems and are similar to copper busbars in terms of their function and application. The specification of aluminum busbars depends on several factors such as maximum current, voltage drop, ambient temperature, and available space.

The following are some general specifications for aluminum busbars:

1. Material: Aluminum busbars are typically made of high-purity aluminum alloys with a minimum purity of 99.7%.

2. Cross-sectional area: The cross-sectional area of the busbar is determined by the maximum current that the busbar will carry. The current rating of the busbar is proportional to the cross-sectional area of the conductor.

3. Thickness: The thickness of the busbar is determined by the mechanical strength required to support the weight of the busbar and to withstand the electromagnetic forces that arise from high currents.

4. Shape: Aluminum busbars come in a variety of shapes including rectangular, square, round, and custom shapes. The shape of the busbar can affect its current-carrying capacity and voltage drop.

5. Surface finish: The surface finish of the busbar can impact its electrical conductivity and resistance to corrosion. Common surface finishes include bare aluminum, tin-plated aluminum, and anodized aluminum.

6. Insulation: In some applications, aluminum busbars may need to be insulated to prevent electrical arcing and to protect personnel from electrical shock. Insulation can be achieved using a variety of materials such as PVC, epoxy, or silicone.

7. Mounting method: The mounting method for aluminum busbars can vary depending on the specific application. Common mounting methods include bolt-on and clamp-on.

It is important to note that the specification of an aluminum busbar should be done by a qualified electrical engineer or designer who has expertise in the specific application and operating conditions. The specifications should comply with the relevant standards and codes for electrical equipment and installation. Additionally, aluminum busbars have a lower electrical conductivity compared to copper busbars, which means they may need to be larger in size to accommodate the same current rating as copper busbars.

Aluminum busbars are available in various sizes and configurations to accommodate different electrical power distribution systems. The selection of an aluminum busbar depends on several factors such as the maximum current, voltage drop, ambient temperature, and available space. Here is a general aluminum busbar selection chart that can be used as a reference:

Busbar Size (mm)	Current Rating (A)	Voltage Drop (mV/A/m)
25 x 3	95	7.8
25 x 6	180	3.9
25 x 10	300	2.3
40 x 6	270	2.5
40 x 10	450	1.5
40 x 20	810	0.8
50 x 6	350	2
50 x 10	600	1.3
50 x 20	1050	0.7
60 x 10	750	1.1
60 x 20	1300	0.6
80 x 10	1000	0.8
80 x 20	1700	0.5
100 x 10	1250	0.6
100 x 20	2200	0.4