Application Guide: ISM Bus Arrangement

Industrial group TAVRIDA ELECTRIC Application Guide PAGE No 1
Application Guide
ISM Bus Arrangement
Abbreviations
CB circuit breaker
ISM indoor switching module
MOCB minimum oil circuit breaker
OCB oil circuit breaker
TEL Tavrida Electric
VCB vacuum circuit breaker
WU withdrawable units
Approved by Signature Date

Franchise Dep. Manager V. Gorelov
Chief engineer P.Voronezsky
VCB Dep. Manager A. Gusev
Project Leader Approved by Alexey Chaly Date Date of revision Total Pages 25
Alexey Chaly
General information 3
1.The dimensions of the bus arrangement conditioned by rated current 4
2. The dimensions of the bus arrangement conditioned by the electrical strength of the insulation 4
2.1 Selection of the support insulation 4
2.2 Selection of air insulating distances 5
3.Electrodynamic stability of the bus arrangement 7

3.1 Definitions 7
3.2 Calculation of electrodynamic forces 7
3.3 Interaction of parallel conductors of finite length 9
3.4 Interaction of perpendicular conductors 9
3.5 Electrodynamic stability of conductive parts and fixing components 10
3.6 The mechanical strength test of the bars 13
3.7 Calculation of the bending stress 13
3.8 The test for mechanical short-circuit strength of support insulators 14
3.9 The mechanical resonance test of the bars 15
4. The peculiarities of the busbars connections to the high voltage ISM 16
Appendix A 20
1. Parallel Conductors 20
2. Perpendicular Conductors in a Plane 21
3. Perpendicular Conductors Not in the Same Plane 22
Appendix В 24
References 25
General information
A system of bare conductors fixed on the insulators and used for electric energy distribution
within switchgear cabinet is called buses (or bus arrangement).
The bus arrangement of TEL-type ISM is provided usually by tightly interconnected busbars, i.e.
so called tight bus arrangement is used. Copper, aluminium, or alloys of the latter are used as a
material for the busbars.
To provide fail-safe operation of the electrical equipment it is necessary to fulfil the requirements
as for busbars material, dimensions, and disposition. These requirements are listed in the given
application guide.
The first clause covers the questions concerning continuous rated currents. In the second
clause we deal with electrical strength of the insulation, where the main principles of support
insulation design and the busbars disposition to the earthed parts of the switchgear cabinet are
formulated.
The calculation of the electrodynamic stresses when short-circuit currents is given in the third
clause. The examples illustrate the theoretical results. The basic formulae are shown.
In the forth clause the process of the busbars interconnection to the high voltage ISM is
observed. For the design is rather sophisticated it is extremely important to take into account the
given requirements and recomendations.
1.The dimensions of the bus arrangement conditioned by rated current
The busbars material and sections should be selected according to continuous allowed current
of the load so that with maximum continuous current of the load of the circuit, the busbars are
intended for, their temperature rise does not exceed the normal value. Here the following condition
must be observed:
Iall>Imax.
Where:
- Iall is continuous allowed current of the busbar at maximum continuous temperature rise ϑall and
ambient temperature ϑ0 (see the Table1);
- Imax is maximum continuous current of the busbar is selected for (accounting permissible
continuous overload of the circuit).
Continuous allowed currents of the busbars (in amperes) are defined according to continuous
allowed temperature rise of the busbars and ambient temperature.
Continuous allowed temperature rise of the busbars in present days is taken to be equal +70°C,
for with higher temperature rise reinforced oxidation of the busbar contacts is observed. This causes
considerable increase of the contact resistance. The ambient temperature is taken to be equal +25°C.
The definite continuous currents of painted copper and aluminium busbars of different sections are
shown in table 1.
Continuous currents on painted rectangle copper and aluminium busbars with allowed
temperature rise + 70ºC and ambient temperature +25ºC.
Table 1.
Busbar Busbar Continuous allowed currents, А*
dimension section
1 bar 2 bars 3 bars
, mm mm2
copper aluminium copper aluminium copper aluminium
1 2 3 4 5 6 7 8
15х3 45 210 165 - - - -
20х3 60 275 215 - - - -
25х3 75 340 265 - - - -
30х3 90 405 305 - - - -
30х4 120 475 365 - - - -
40х4 160 625 480 - - - -
40х5 200 700 540 - - - -
50х5 250 860 665 - - - -
50х6 300 955 740 - - - -
60х6 360 1125 870 1740 1350 2240 1720
60х8 480 1320 1025 2160 1680 2790 2180
60х10 600 1475 1155 2560 2010 3300 2650
80х6 480 1480 1150 2110 1630 2720 2100
80х8 640 1690 1320 2620 2040 3370 2620
80х10 800 1900 1480 3100 2410 3990 3100
100х6 600 1810 1425 2470 1935 3170 2500
100х8 800 2080 1625 3060 2390 3930 3050
100х10 1000 2310 1820 3610 2860 4650 3640
120х8 960 2400 1900 3400 2650 4340 3380
120х10 1200 2650 2070 4100 3200 5200 4100
• It corresponds to horizontal positioning of the busbars whose body is arranged vertically. When
horizontal positioning of the busbars whose body is arranged horizontally, continuous allowed current
should be reduced by 5% for the bars up to 60 mm of width, including, and by 8% for the bars wider.
2. The dimensions of the bus arrangement conditioned by the electrical strength of the
insulation.
2.1 Selection of the support insulation.
Fail-safe operation of ISM insulating designs under continuous operating voltage is achieved by
the choice of corresponding creepage distance. We may consider the creepage distance being the
minimum surface distance of the insulated part between the metal parts of different potentials without
account of subcircuits passing through the layers of reinforcing material. The creepage distance sum
of sequentially connected parts is considered to be the creepage distance of build-up insulating
system or the insulator.
The minimum creepage distance of electrical installations depending on the pollution level must
correspond to Table II IEC 815. It is shown in Table 2.
Minimum nominal spesific creepage distance according to pollution level

Table 2.
Minimum nominal specific creepage distance lf,
Pollution level
(mm/kV)
I – Light 1,6
II- Medium 2,0
III- Heavy 2,5
IV – Very heavy 3,1
2.2 Selection of air insulating distances.
During the bus arrangement of ISM its safe electrical insulation must be provided:
- the insulation between ISM live parts and earthed parts;
- the insulation between the parts of different potentials of the same pole when open main
contacts;
- the insulation between the parts of neighboring poles being under voltage with any position of
ISM main circuits.
To attain the level of electrical insulation of ISM it is necessary to provide the following:
- air gaps;
- dimensions of the insulating parts that define the creepage distance;
- dimensions of the insulating parts, that provide their internal electrical strength.
Applying TEL-type ISM for the switchgear, the minimum insulating and creepage distances are
to be selected according to IEC 71-1 and IEC 815, or to national standards. The minimum nominal
creepage distance of the insulator between phase and earth is determined, according to the pollution
level of the site. The following relation may be observed:
lt = lf x Ur x kD
Where:
lf - is the minimum specific creepage distance (see Table II IEC 815);
Ur - is highest system voltage phase-to-phase for equipment (see Table 1a IEC 694);
kD - is the correction factor due to diameter (see Sub-clause 5.3 IEC 815).
If insulators are to be used between phases (phase-spacers for instance), the creepage
distance should be multiplied by √3 (for a three-phase system).
During retrofit procedure of out-of-date stationary OCB ( MOCB) and OCB (MOCB) installed on
withdrawable units for TEL-type ISM new bus arrangement is provided under condition of
electroinsulating distances of former external insulation. In case when it is impossible for some
reasons (for example, when applying the ISM with pole-to-pole distance of 210 mm for the
substitution of OCB with pole-to-pole distance of 230 mm) constructive measures are to be taken to
provide required insulating level. For instance, the busbars of extreme poles are rotated at an angle to
the axis of the current terminals of the ISM. In this case the additional insulating parts (see Figure 1)
or pole-to-pole insulating barriers are used.
Figure 1. Application of additional insulation when the bus arrangement of TEL-type ISM for
retrofit project of WU K-302 У1 with MOCB AK 10/800/20.
ISM support insulation
Additional insulation
Busbar
Sometimes in the process of ISM adaptation to the switchgear or to withdrawable units it is

impossible to arrange the module such a way that to stay in the clearances of retrofitted OCB and to
save position of the busbars. This leads to the reduction of “phase-to-earth” distances. Above
methods are used to solve this problem. (see Figure 2)
Figure 2. Application of the additional insulating barrier when the bus arrangement of TEL-
type ISM for retrofit project of WU K3-02 У1 with the MOCB AK 10/800/20.
Busbar
Insulating barrier
WU metal parts
ISM within switchgear and WU must withstand test voltages according to IEC 694.
- one minute power–frequency voltage tests (comply with p. 6.2.6.1 IEC 694);
- lightening impulse voltages tests(comply with p.6.2.6.2 IEC 694);
- partial discharge tests (p.6.2.9 IEC 694);
and also the requirements:

- to the creepage distance of external insulation (p.5.14 IEC 694);
- to the pollution level of the insulation;
- to the insulation of secondary circuits (p.6.2.10 IEC 694);
As an example, we may consider test rated voltages of range from 7 to 24 kV in accordance

with Table 1a IEC 694 (see Table 3)
Rated insulation levels for rated voltages of range I, series I.

Table 3.
Rated Rated short – duration power Rated lightening impulse withstand
voltage Ur, kV frequency withstand voltage Ud, voltage Up,
(r.m.s. value) kV (r.m.s. value) kV (peak value)
Common Across the Across the

Common value
value isolating distance isolating distance
(1) (2) (3) (4) (5)
40 46
7,2 20 23
60 70
60 70
12 28 32
75 85
75 85
17,5 38 45
95 110
95 110
24 50 60
125 145
3.Electrodynamic stability of the bus arrangement.
3.1 Definitions
Components of different dimensions and configurations form main circuits of switchgear. These
components are support insulators, bars, disconnects, and ect. In general the components are
arranged in different planes and at an angle to each other.
The current flowing through the circuit induces mechanical forces that tend to deform this circuit.
Besides, when current flows by two or more neighboring circuits, there are mechanical forces, that
make each circuit act upon the other (if the circuits are combined by a common magnetic flux). The
mechanical forces initiated between the components of one circuit or between neighboring circuits at
the time of current flowing are termed electrodynamic forces.
The value of the forces depends on different factors, mostly on the magnitude of the current. If
rated current, the electrodynamic forces are low and safe. But when short-circuit currents flow, the
electrodynamic forces may stimulate irreversible deformation or switchgear failure. Therefore, the
mechanical strength of the circuits and their supports must correspond to the value of the
electrodynamic forces.
The capacity of the equipment to withstand the electrodynamic forces when short-circuit
currents without being damaged, is termed electrodynamic stability.
In this unit examples of calculation of the electrodynamic forces and corresponding
recommendations for the switchgear design are considered.
3.2 Calculation of electrodynamic forces
In general the value of electrodynamic forces depends on the length, configuration, maximum
current, and disposition of the components that form the circuit; also it depends on the magnetism of
the medium enclosing the circuit. Further the conductors are supposed to be in the medium with
constant permeability that does not depend on the value of magnetic-field intensity (air and solid
insulants).
A common equation for calculation of electrodynamic force between separate parts
(conductors) of a circuit of any configuration is:
F = 1.02 ⋅ 10 −8 i1i2 ks (1)

where:
l1 l2
dl1 dl 2 sin α ⋅ sin β
ks = ∫ ∫ (2)
0 0 r2
- ks is the circuit factor that characterizes geometrical
dimensions of the conductors, their disposition and configuration;
- l1 and l2 are the length of the conductors;
- i1, i2 are the currents flow by the conductors;
- β is the angle between direction of the current i1 in dl1 element and the
induction vector direction formed by the conductor l1;
- α is the angle between direction of the current i2 in dl2 element and
radius vector r between dl2 and dl1 elements. (geometry is shown in
fig.3).
Figure 3
Vector direction of the electrodynamic force is defined under the following conditions:
А) if the conductors arranged in one plane the electrodynamic force acts in the same plane;
B) when the same direction of the current flowing through parallel conductors they (the conductors)
are attracted ; if the direction is reversed –they are repelled;
C) at nonparallel straight line conductors their axes are to be prolonged virtually up to their
intersection. If, in the formed angle, the current overflows from one conductor to the other through the
vertex of the angle, the electrodynamic forces tend to expand the angle formed by the conductors
axes, and the conductors tend to repel. If the currents in the sides of the angle are directed towards
one another, i.e. converge or diverge from the vertex, the electrodynamic forces tend to diminish the
angle, and the conductors are pulled together (fig. 4).
Figure 4
The expression (1) is simplified for the most important cases, namely:
- In case of interaction between two parallel conductors of finite length;

- In case of interaction between two subcircuits bent at right angle (one conductor is virtual
prolongation of the other);
- In case of perpendicular conductors interaction (if one conductor is not the virtual prolongation
of the other).
3.3 Interaction of parallel conductors of finite length
This case frequently occurs during switchgear calculations.

Let us consider, that the conductors are arranged in a distance a from each other and have the
length l. So the electrodynamic force is (see Appendix A)
F = 1.02 ⋅10 −8 (i1i2 )k s (3)

where the circuit factor is:
2l  a 2 a
ks =  1+ ( ) −  (4)
a  l l
This formula is true, if a ≥ P, where Р is the perimeter of the conductor section.
For example, for the rectangular bars a ≥ 2 (b+h), where b and h are the width and the
thickness of the bars cross-section accordingly.
Otherwise for more precise calculations in formula (3) it is necessary to take into account the
form factor as a multiplier, that is not difficult to calculate by diagrams shown in [1].
Thus,
2l  a 2 a
F = k ф ⋅1.02 ⋅10 −8 (i1i2 )  1+ ( ) − 
a l l
The form factor kf is shown in table 2 ( see Appendix B). It is clear that kf=1 is a good
approximation (deviation of calculations not more 10%) and not critical for calculations, as gives
majorization.
If two-phase short-circuit current the force of interaction between parallel conductors is:
F(2)=1.02⋅10-8i2(2) kskf (5)
If three-phase short-circuit current the medial phase is in the most complicated conditions. The
force of the phase is:
F(3)=1.02⋅10-8(31/2/2)⋅i2(3)⋅kskf. (6)
where:
the phase-shift for currents of three-phase neighboring conductors is corrected by the factor
(31/2/2). However, if to take into account, that in case of three-phase short-circuit, the current i (3) =
(2/31/2) i (2), and F (3) /F (2) =2/31/2=1.15. Thus, the calculation of switchgear for electrodynamic stability
should be executed for the electrodynamic forces, whose values are by 15 % above the values
obtained by formula (5).
It is important to note, that in the works specialized in calculations for electrodynamic forces
the following equation is given:
F=2.04⋅10-8(i1i2) l/a. (7)
i.e. the circuit factor ks=(2l/a) (see [1,2]). This expression can be used during the electrodynamic
stability test of electrical equipment. But it would be helpful to know that the expression is more
applicable for long conductors (for example, busbars,). When l≅a, the values we obtain from the
expression (7) exceed the values obtained from formulae (3,4) by 60%.
3.4 Interaction of perpendicular conductors
If the conductor, the current i flows through is bent at right angle, but the cross-section of
horizontal and vertical subcircuits is different (for example vertical subcircuit is a flat bar, horizontal is
a round bar), the electrodynamic force one subcircuit acts upon the other is calculated by the formula
(see Appendix A):
F = 1.02 ⋅10 −8 ⋅ i 2 ⋅ k s (8)

 ( B + B 2 + r 2 )(r + A2 + r 2 ) 
k s = ln  2 1 1
 (9)
 (r1 + r1 + r2 )( B + A + B 2 ) 
2 2 2
r1 and r2 are the radius of the round conductor or half a thickness of rectangular bar h/2 of the
horizontal and vertical subcircuits respectively ;
A and B are the length of the horizontal and vertical subcircuits.
If r1=r2 (the conductor of one section is bent at right angle) the circuit factor is reduced to:
 ( B + B 2 + r 2 )(r + A2 + r 2 ) 
k s = ln   (10)
 r (1 + 2 )( B + A2 + B 2 ) 
In switchgear designs perpendicular arrangement of the conductors not in the same plane frequently
occurs. Thus, as shown in Appendix A, the electrodynamic force, one conductor acts upon the other
as follows:
F = 1.02 ⋅10 −8 ⋅ i1i2 ⋅ k s (11)

 ( B + r 2 + a 2 + B 2 )(r + r 2 + a 2 + A2 ) 
k s = ln  2 1 1
 (12)
 ( B + A + a + B )(r1 + r12 + r22 + a 2 ) 
2 2 2
where:
a is the shortest distance between the conductors;
r1 and r2 are the radius of the round conductor or half a thickness of rectangular bar h/2;
A and B are the length of the vertical and horizontal conductors.
It is clear that when a → 0 last expression takes the form of the circuit factor for the case 1.2.1.
And if r1=r2 the expression reduces to:
 ( B + r 2 + a 2 + B 2 )(r + r 2 + a 2 + A2 ) 
k s = ln   (13)
 ( B + A2 + a 2 + B 2 )(r + 2r 2 + a 2 ) 
These results will be used for calculation of the bars mechanical strength and switchgear
designs, also for selection of the bars fixing components
3.5 Electrodynamic stability of conductive parts and fixing components
First of all we shall clarify, what dimensions of TEL-type switching devices are basic from the
point of view of calculations for electrodynamic stability. Thus, pole distances (the distance between
the terminals of the circuit breaker neighboring phases) and the distance between the terminals
(between high voltage terminals of one pole) we can consider being the basic dimensions. In Table 4
these values are introduced for CB delivered at the world and CIS market. To obtain full particulars
the basic CB parameters are introduced in the same table in the form of A-B/C, where A is the rated
voltage (кV), B is the rated breaking current, кA, and C is the rated current, А.
Table 4
VCB Pole distance, Distance Notes
parameters mm between the
terminals,mm
1 2 3 4
CIS market
10-20/1000 200, 250 170
10-31.5/1600 200, 250 280 The distance between
the axes of round terminals
(the third column)
The world market
12-20/1000 150, 210 170
24-16/800 210, 275 170
12-31.5/1600 150, 170, 210 205, 255 The distance between
(the third column)
24-25/1600 210, 275 305, 310 The distance between
(the third column)
It is clear that the range of pole distances has the following values: 150, 170, 200, 210, 250 and
275 mm, thus CB with the pole distance of 250 and 275 are applied, as a rule, in fixed-type
switchgear. The range of distances between terminals is 170, 205, 255, 280 and 310 mm.
Parameters of the bus arrangement of the switching devices are also important for
electrodynamic stability.
The bus arrangement of CB is executed, as a rule, with a help of rectangular or (rare) round
bars. The sectional plane depends on different factors: engineering factors (rated continuous current
and mechanical strength of the design) and economical factors (the range of products of neighboring
bars producers to the switchgear building company and standardization of consumed bars).
Dependence of the bars cross-section on the rated current is determined according to DIN 43670, the
mechanical strength is obtained according to the calculations and to the results of pilot samples test
at the time of the design. These factors to be described circumstantially.
In Table 5 parameters of the rectangular bars are shown. These copper and aluminium bars are
used when the bus arrangement of the circuit breakers installed on withdrawable units and in the
fixed-type switchgear. First are the values put into practice, in brackets – the values recommended by
DIN 43670 are indicated.
Table 5
Rated current, А Copper Aluminium
Withdrawable units
630 40х5 (40х5) 80х10 (50х6)
800 50х6 (50х6) 80х10 (60х8)
1000 80х10 (60х6) 80х10 (60х10)
1250 80х10 (60х10) inapplicable(80х10)
Fixed-type switchgear
630 40х5 (40х5) 60х6 (50х6)
800 50х6 (50х6) 60х6 (60х8)
1000 60х6 (60х6) 80х10 (60х10)
1. Example of calculation.
We calculate electrodynamic forces F (3) initiated during interaction of the bars connected to the terminals
of TEL-type switching modules. Let us consider that the bars are parallel and their length is equal 0.3m. The
calculation will be done for the current magnitudes of electrodynamic stability. These values are used when
electrical equipment test, namely: 41, 51, 63, 80 kV for CB of 16, 20, 25, 31.5 kV accordingly. We shall comply
with formulae (3,4) and (7).
The results of calculation are tabulated. The values of electrodynamic forces are expressed in N. The
values calculated by formula (7) are shown in brackets.
Table 6
Switching Pole distances
module
parameters (In.
о/In)
150 170 200 210
16/800 inapplicable 400 (684) inapplicable 289 (554)
20/1000 742 (1201) inapplicable 482 (900) 446 (857)
25/800 inapplicable inapplicable 736 (1374) 681 (1309)
31.5/1600 inapplicable inapplicable 1186 (2216) 1100 (2111)
The above shows that the absolute value of the electrodynamic force is 2955N≈3x103N.
Note: the calculations will be done by formula (7).
Consider the components of the bars fixing.

Support and bushing insulator are applied for the bars fixing in the switchgear and for the bars
insulation from the earth and from the other parts of the installation under different potential.
When retrofit procedure of the working equipment or development of the VCB installation
projects on withdrawable units we often have to deal with support insulators of cylindrical or a taper
body with a ribbed surface, made of polymeric materials or porcelain.
Basic parameter of the support insulator of definite value when switchgear calculations for
electrodynamic stability is the breaking force under bending. This force characterizes the force
applied on the insulator cap and perpendicularly directed to the axis. But complete or partial fracture
of the insulator may occur.
The parameters of support insulators of indoor installation are shown below in Tables 7 and 8.
Parameters of ИО-type support insulators produced by Bobrovsk insulator-making plant

Table 7
Parameter Norm
ИО 4-80 ИО 8-80 ИО 8-125
(56;130) (76, 130) (85, 210)
Rated operating voltage, кV 10 10 20
The maximum operating voltage, кV 12 12 24y
One minute test voltage of power 42 42 50
frequency, кV, rms
Test voltage of full lightening impulse 80 80 125

кV, peak
Breaking force under bending, kN 4.0 8.0 8.0
Weight, kg 0.5±0.05 0.9±0.09 0.85±0.09
Voltage of partial discharge, кV 7.6 7.6 15.2
Note: the first parameter in brackets is the external diameter of the insulator, the second parameter is the
thickness.
Parameters of ETB-type support insulators of NYIR-MIX-TRADE Company production

(Hungary).
Table 8
Parameter Value
Rated voltage, кV 24
One minute test voltage of power frequency, 50
кV, rms
Test voltage of full lightening impulse кV, peak 125
Working temperature, °С 90
Breaking force under bending, N 8000
Weight, kg 1.5
The analysis of support insulators parameters of other producers shows, that the breaking force
under bending is in the limits from 3.75 kN up to 16 kN for support insulators, range 10kV and from 4
up to 10kN, range 24kV.
3.6 The mechanical strength test of the bars
The bars chosen by continuous allowed current of the load should be tested for the mechanical
strength when short-circuit currents.
For this purpose:
1.1. The maximum force F (3) that acts upon the bar of medial phase when three-phase short
circuit
is obtained by the formula shown in p.3.2, 3.3.
1.2. The maximum bending moment is calculated by the following formula:
M=F (3) l/8 (14),

where l is the distance between the bar supports.
Let us calculate the maximum bending moment for the buses of the switching module exemplified in Unit
2. Consider that the parallel bars of the length 0.3 by the one end are fixed to the terminal of the switching
module and by the other - to the support insulator.
Table 9
Switching Pole distance from the table
module
parameters(In. о/In)
150 170 200 210
16/800 inapplicable 15 (26) 11 (21)
20/1000 28 (45) inapplicabe 18 (33.7) 16.8 (32)
25/800 inapplicable inapplicabe 27.6 (51.5) 25.5 (49.1)
31.5/1600 inapplicable inapplicable 44.5 (83) 41.3 (79.2)
3.7 Calculation of the bending stress of the bar.
σcal =M/W (15),

Where:
W is the moment of the bar resistance relating to the axis, perpendicular to the force direction.
When the rectangular bars are arranged on support insulators flat-wise W=bh2/6, for solid
round conductors W=πd3/32≈0.1d3.
Let us give the bending stress values of rectangular bars, copper and aluminium. We shall use examples
of calculation (1,2). Consider the bars are fixed on the support insulator flat-wise.
Copper bars
Table 10
Switching module Pole distance from the table
parameters(In.
о/In)
150 170 200 210

16/800 (50х6) inapplicable 6⋅10 (1.04⋅107)
6
inapplicable 4.4⋅10 (8.4⋅106)
6
20/1000 (60х6) 7.78⋅106 (1.25⋅107) inapplicabe 5⋅106 4.67⋅106 (8.89⋅106)

(
9.36⋅106)
25/800 (50х6) inapplicable inapplicabe 1.104⋅107 1.02⋅107 (1.96⋅107)
(2.06⋅107)
31.5/1600 inapplicable inapplicable 4.17⋅106 (7.78⋅106) 3.87⋅106 (7.43⋅106)
(80х10)
It is clear that maximum value of the bending stress for copper bars is σcal =2.06x107N/m2
Aluminium bars
Table 11
Switching module Pole distance from the table
parameters(In.
о/In)
150 170 200 210
16/800 (60х8) inapplicable 3.13⋅106 inapplicable 2.29⋅106
(5.42⋅106) (4.38⋅106)
20/1000 (60х10) 4.67⋅106 (7.5⋅106) inapplicable 3⋅106 (5.62⋅106) 2.8⋅106 (5.33⋅106)
25/800 (60х8) inapplicable inapplicable 5.75⋅106 5.313⋅106
(1.07⋅107) (1.02⋅107)
31.5/1600 inapplicable inapplicable 2.67⋅106 2.48⋅106
(100х10) (4.98⋅106) (4.75⋅106)
Maximum value of the bending stress for aluminium bars is σcal =1.07⋅107 N/m2.
The value of σcal must meet the following condition:
σall ≥ σcal (16)

Where:
σall–is allowed bending stress of the bar material. This value depends on the bar material. For
example, for aluminium E-Al F10 σall =7.0⋅107 N/m2, aluminum, for copper E-Cu σall=2.5⋅108 N/m2.
The properties of the other materials applied for production of conductive bars are listed in table
1 (see Appendix B).
Consider table 7. It is clear that for copper bars maximum σcal=2.06⋅107 N/m2<σcal =1.37⋅108 N/m2. For
alminium σcal=1.07⋅107 N/m2<σall=6.86⋅107 N/m2.
3.8 The test for mechanical short-circuit strength of support insulators.
The forces in bars at the time of short-circuit currents are transmitted to the insulators, that
correspond to the force value (and allowed force on the insulator should calculate not more than 60 %
of breaking load), i.e.
Fcal ≤ 0.6 ⋅ Fall (17)
Where:
F cal is maximum calculated load on the insulator when three-phase short-circuit current peak;
Fall is the allowed breaking force under bending. The safety factor is 0.6.
It is important to note, that the electrodynamic force acting upon each insulator, is expressed by
the formula Fcal =ψ F(3), where F(3) is the maximum electrodynamic force acting upon the medial bar at
three-phase short-circuit current; factor ψ characterizes the load on the insulator and depends on the
insulator type. For the most frequent cases factor ψ is introduced in table 12.
Table 12
Multiplier
The number of spans and the ways of their fixing. Factor ψ of characteristic
frequency, γ
Fixed both ends on the support insulators.(A А: 0.5 1.57
and B) В: 0.5
One end fixed on the support insulator (A), А: 0.625 2.45
and the other – on the bushing insulator(B) В: 0.375
Fixed both ends on the bushing insulators (A А: 0.5 3.56
Single- and B) В: 0.5
span bars fixing
Multiple Two spans. Support insulators (A,B,A) А: 0.375 2.45
spans for equal В: 1.25
distances
between supports
More than 3 spans A-marginal; B- А: 0.4 3.56

intermediate В: 1.1
It is clear from the table that for switching module with rated breaking current of 31.5kA (it corresponds to
the current of electrodynamic stability 80 kA) the maximum value of electrodynamic forces is F(3)=3⋅103N . It
is achieved when phase-to-phase distance is 150mm. Let us take this value as the basic to check if support
insulators of Russian production could be installed.
We may consider the bars fixing to the terminal of switching module as the fixing in the bushing insulator.
Here the factor ψ=0.625. Thus,
Fcal =ψ F(3)=1.88⋅103Н<0.6 Fcal =4.8⋅103Н,
where:
Fcal =8⋅103N (see table 4), and ИО 8-80-type support insulator is applicable with more than double safety
margin.
Application of ИО 4-80-type insulator whose Fcal=4⋅103N is also possible. However, the safe margin
relating to the limit 0.6 Fcal calculates only 22%. Additional test for the bars mechanical resonance is required.
3.9 The mechanical resonance test of the bars
The conductive bar fixed on both ends is the elastic system, which has its own (free) oscillations
of particular frequency and is subjected to harmonic alternating forces depending on the power
frequency of the current. If the natural frequency is close to the current frequency, there is an
excitation and sway of the bars, that makes the bending stress twofold or threefold. If the natural
frequency coincides with the second harmonic (100Hz), there is mechanical resonance and the
bending stress increases fivefold compare with the stress under static effect of the short-circuit
current. Therefore the mechanical resonance test of the bars should be carried out to be sure, that the
natural frequency of the bars is out of dangerous area, that is 30-160 Hz with the current frequency of
50Hz.
Natural frequency of the bars is calculated by the formula:
γ EW
fr = (18)
l2 m'
Where:
l is the distance between the supports;
g is characteristic frequency factor (see table10), depending on the way of the bars fixing to the
insulators;
E –the modulus of elongation (Young's modulus');
W – axial planar moment of inertia;
m ′ - mass per unit length;

For aluminium E = 6.5⋅1010 N/m2, m′ = 2.74⋅s⋅103, for copper E = 11⋅1010 N/m2, E = 11⋅1010
N/m2, m′ = 8.93⋅s⋅103,
where s is a cross- section area.
In case of rectangular bars s=bh, W=b3h/12 and this formula may be introduced in the
following form:
For aluminium bars
b
f ra = 5.02 ⋅105 (19)
l2
b
For copper bars f rc = 3.62 ⋅105 2 (20)
l
This frequency should exceed the limits of 30-160 Hz. Sometimes it is impossible to change
support insulators disposition geometry or to change the bars parameters that have an influence on
the frequency fr. In this case the factor of mechanical resonance Kr and the maximum calculated
stress in the bar should be multiplied by this factor. Thus the number of the maximum stress in bars
material takes the form:
σall ≥ Kr⋅σcal (21)
And the maximum calculated force on the support insulator:

Fcal = K r ⋅ψ ⋅ F(3) ≤ 0.6 ⋅ Fall (22)
The nomogram for calculation o Kr f is shown in fig.5
Let us calculate the frequency of natural
oscillation of copper or aluminium bar. Consider the
length of the bar is 0.3m; the bar is fixed on the
switching module terminal with its one end, with the
other bar is fixed on the support insulator. The bar is
round; the bar diameter is 40mm. Thus, the moment of
inertia W≈0.1d4. Characteristic frequency factor
γ=2.45, and the natural frequency of copper bar fr
=1.36кHz, that differs from the range 30-160Hz. During
the calculations it is not necessary to take into account
the mechanical resonance factor Kr
Figure 5
4. The peculiarities of the busbars connections to the high voltage ISM.
For ISM with the rated current up to 1000A (see Figure 6) the contact terminals of TEL-type ISM
constructively form:
-upper- faced cylindrical copper nickel plated contact with a special grooving made on its
contact surface with a central stud M10, full nut, disk spring washer and plane washer for the buses
fixing.
lower – copper, nickel plated busbar 40x10 with two plane holes ∅ 10,5 for the buses fixing by
means of M10 bolts.
And for the modules with rated current above 1000 A up to 1600A. (see Figure 7):
upper and lower - faced cylindrical, nickel plated copper contact with the central threaded hole
M16 for the buses fixing.
Figure 6. ISM/TEL Inom≤ 1000 A Figure 7. ISM/TEL Inom≥ 1200 A contact

contact terminals terminals
Fail-safe operation of ISM within switchgear depends on different factors, including treatment
quality of the contact surfaces.
Before treatment the contact surface of the busbar is cleared with petrol from dust and
preservative grease. In this process oxide film is removed from copper and aluminium busbars. There
should not be any cavities or unevenness on the contact surface. It is to be flat and regular. But polish
and lapping are not required for they do not improve the contact. The treatment of the contact surface
is carried out with simple abrasive tool: bench machine, manually operated drill with fixedwire wheel,
flap wheel or abrasive sheet, ect.
The metal dust obtained in the treatment process should be removed with clean dry cloth, and
then the surface is covered with a thin coat of grease, for example, technical vaseline. The contact
surfaces of aluminium busbars should be finished under thin coat of grease. Then contaminated
grease is removed and substituted with the clean one.
An application required and the type of anticorrosive coat of the busbar contact surface depends
on the rated current of the busbars, contact temperature, the contact material and switchgear
operational conditions (indoor or outdoor installation, ambient conditions).
If the contact terminal width of ISM is less than the width of the conductive busbar an
intermediate busbar is in use. It has the contact terminal width in the point of connection with the
contact and the busbar width in the point of connection with the busbar. Or the conductive busbar is
cut accordingly (see Figure 8).
Figure 8. The conductive busbar cut to width of the contact terminal of TEL-type ISM.
Contact terminal of ISM
Conductive busbar
The busbar connection to the contact terminals of the ISM is made such a way that the busbars
could join the contact terminals without tension in the points of connection. A bending force created by
the buses should not result in the deflection from the natural (observed before the buses) position of
the pole more than by 1 mm.
The measurements of the distances between arbitrarily chosen point in the top part of the pole
to the bases (of metal construction of the switchgear or WU cabinet) in two mutually perpendicular
directions are to be provided.
Attention! TEL-type ISM is sensitive to additional bending and torsion forces exerted
perpendicularly to the pole axis. They appear in the result of wrong bus arrangement. Non-
compliance with the requirement could cause sudden decrease of holding force of the
“magnetic latch” and the result will be the ISM failure.
For the same reason when the buses design the value of the normal forces to the pole axis and
applied to the ISM contact terminals should be limited to the recommended values. These forces
appear at the time of typical operations during exploitation of the switchgear (WU draw in or draw
out).
Figure 9. Allowed loads on the contact terminals of TEL-type ISM.
In case of expecting loads on the contact terminals exceeding, it is important to provide the bus
arrangement through additional support insulators for the contact terminals unloading. (see the buses
variant Figure 9 ).
The busbars connection to the contact terminals of the module is provided by means of bolts
and nuts using plane and disc spring washers.
All the components should have anticorrosive coat (cadmium plating, nitriding, zinc plating).
Bolted contacts are to correspond to the following requirements:
- to provide good mounting maintenance and inspection facilities;
- to create necessary contact pressure (under nut, and washers) that doesn’t cause the yield of
the busbars material under the normal conditions;
- to provide the good shake-proof facilities of the contact;
- to provide the contact environmental stability;
The types of bolt connections (the number and bolt diameter, contact cross-section) are
selected or tested in accordance with national or international standards.
In Table 3 (comply with IEC 694) the maximum allowed temperature rise for different conductive
and insulated parts of the switchgear are shown. The temperature rise of the contact connection with
the external conductor of copper, aluminium or its alloys is to be under +95°C in the installations with
rated voltage above 1000V. If tin, nickel-plated or silver-plated contact surface, the given temperature
rises by 10°C.
The the busbars fixing parts for the current above 600A must not create close magnetic circuit
around the buses; for this reason one of the plates or all coupling bolts on the one side of the busbar
are made of non-magnetic material (bronze, aluminium or its alloys).
The busbar connection to the ISM contact terminals should be executed considering the linear
thermal expansion compensation. So the fixing holes in the busbar are made by 1-2mm bigger the
bolt diameter.
For the tightening of the busbars connection to the contact terminals of the ISM the usage of
dynamometric wrench. Is recomended.
- the torque moment for the ISM with rated current up to 1000 A – 30 N⋅m;
- for the modules with rated current above 1000 A up to 1600 A – 70 N⋅m.
After bolt tightening, displaced grease is removed from the contact surface.
Appendix A
1. Parallel Conductors.
To begin this review section, the simplest, and the most well known case, consisting of two
parallel conductors in a distance a from each other, where each conductor is carrying a current, and
where both are flowing in the same direction has been chosen. Assuming, as it is shown in figure A1,
two parallel conductors with the length A and B, carrying the currents i1 and i2 accordingly.
Let us calculate the electrodynamic force the
left conductor acts upon the right conductor.
Thus, taking a small portion dl2 of the left
conductor and dl1 of the left conductor. The
distance between dl2 and dl1 is:
r = (l 2 − l1 ) 2 + a 2 ,
therefore:
a
sin α =
(l 2 − l1 ) 2 + a 2
Since the conductors are arranged in the

same plane, and the vectors of magnetic intensity
induced by the current i2 are perpendicular to the
axis of the other conductor, sinβ =1.
Figure A1
Accordingly:
AB
dl1 dl 2
F = 1,02 ⋅ 10 −8 i1i2 a ⋅ ∫ ∫ 3
0 0
[(l 2 − l1 ) + a ]
2 2 2
The integral is:

A B
dl 2
T = ∫ dl1 ∫ 3
.
0 0
[(l 2 − l1 ) + a ]
2 2 2
After the change of l2-l1=x we have:

A B −l1
1 dx
a 2 ∫0 ∫
T= dl1 3
, whence
−l1
( x2 + a2 ) 2
A 
1  ( B − l1 )dl1 A
l1 dl1 
T = 2 ∫ 1
+ ∫ 1 ,
a 0 
 [( B − l1 ) + a ] (l1 + a )
2 2 2 0 2 2 2

or, after the calculations we obtain:
T=
1
a2
{B 2
+ a 2 − ( B − A) 2 + a 2 + A 2 + a 2 − a . }
Thus:
F = 1,01⋅10 −8 i1i 2
1
a
{B 2
+ a 2 + ( B − A) 2 + a 2 + A 2 + a 2 − a . } (1.А)
If A=B=l:
2l  a
2
a 
−8
F = 1,02 ⋅10 i1i 2  1 +   −  (2.А)
a  l l

2. Perpendicular Conductors in a Plane.
Let us consider that the conductor the

current i flows through is bent at right angle
(see figure A2). In general the cross-section of
the horizontal and vertical subcircuit may be
different. We assume that the radius of the
horizontal and vertical subcircuit cross-section
is r1 and r2 relatively. If we are talking about
rectangular bars, r1 and r2 is half a thickness of
the cross-section of the horizontal and vertical
subcircuits.
The distance between dl1 and dl2 is:
l12 + l12 ,
Accordingly:
l1
sin α =
l12 + l 22 ,
Figure A2
Besides, sin β =1, because the conductors are arranged in the same plane.
Substituting the values in formula (1), we obtain:
A B
l1 dl1 dl 2
∫∫
−8
F = 1,02 ⋅ 10 (i ) 2
3
r1 r2
(l + l )
1
2 2
2
2
Here the integration is executed from r. This helps to single out the peculiarity of the integrand
when l1-l2=0 (it actually means that the current overflows from one subcircuit to the other by the
course of finite radius).
The integral in the last expression is easy to calculate:
A B
l1 dl1  ( B + B 2 + r 1 )(r + A 2 + r 2 ) 
∫ dl 2 ∫
2 1 1
3
= ln  .
 r
 1 ( r + r 2
+ r 2
)( B + A 2
+ B 2
) 
r1 r2
(l1 + l1 )
2 2 2 1 2
Thus:
 B + B 2 + r 2 )(r + A 2 + r 2 ) 
−8 2 1 1
F = 1,02 ⋅ 10 i2 ln  . (3.A)
 (r1 + r12 + r22 )( B + A 2 + B 2 ) 
3. Perpendicular Conductors Not

in the Same Plane.
This particular case is

represented in figure A3.
We assume that the length of
the horizontal and vertical conductor
is A and B respectively; l1 and l2 are
the distances to dl1 and dl2 elements
(the variables of the integration) in
the chosen coordinate system. For
the conductors are not in the same
plane the angle β between the
r
direction of the induction vector B
at dl1 is not equal 90°.
Let us calculate this angle.
The direction of the induction
r
vector B is defined by the rule of
right-handed screw.
Figure A3
The shortest distance from the axis of the vertical conductor to dl1 element is:
l12 + a 2 ,
the distance between dl1 и dl2 is:

l12 + l 22 + a 2 ,
thus:
l1
sin β = ,
a 2 + l12
a 2 + l12
sin α = ,
l12 + l 22 + a 2
where α is the angle between the vertical conductor and radius-vector from dl1 to dl2.
After substitution of the derived expressions in formula (1) we obtain:
AB
l1 dl1 dl 2
F = 1,02 ⋅ 10 (i1i2 ) ∫ ∫
−8
3
,
r1 r2
(l + l + a )
1
2 2
2
2 2
where the integral is:
A B A A
dl 2 l1 dl1 l1 dl1
T = ∫ l1 dl1 ∫ 3
= B∫ 1
− r2 ∫ 1
=
r1 r2
(l + l + a )
1
2 2
2
2 2 r1
(l + a )(l + B + a )
1
2 2
1
2 2 2 2 r1
(l + a )(l + r + a )
1
2 2
1
2 2 2 2
 ( B + a 2 + B 2 + r 2 )( r + A 2 + a 2 + r 2 ) 
= ln  2 1 1
.
 ( B + A + a + B )( r1 + r1 + r2 + a 2 ) 
2 2 2 2 2
Thus:
 
−8  ( B + r22 + a 2 + B 2 )(r1 + A 2 + a 2 + r12 ) 
F = 1,02 ⋅ 10 (i1i2 ) ln . (4.А)
 
 B + A + a + B )(r1 + r1 + r2 + a ) 
2 2 2 2 2 2
It is clear that at a→0 the expression (4.A) takes the form of (3.A) derived before for the
conductor bent at right angle.
Appendix В
The typical parameters of the bars material.

Таble 1
Material Yield end during the Young's module, Yield end under
tension, N/mm2 N/mm2 bending, N/mm2,
min/max
Copper
E-Cu F 20 200 11⋅104 120
E-Cu F 25 250 11⋅104 200/290
E-Cu F 30 300 11⋅104 250.360
E-Cu F 37 370 11⋅104 330/400
Aluminium
E-Al F 6,5/7 65-70 6.5⋅104 25/80
E-Al F8 80 6.5⋅104 50/100
E-Al F 10 100 6.5⋅104 70/120
E-Al F 13 130 6.5⋅104 90/160
Al F 10 100 6.5⋅104 70
Molybdenum-aluminium alloys
E-Al Mg Si 0.5 F17 170 7⋅104 450/650
E-Al Mg Si 0.5 F22 220 7⋅104 650/900
The form factor for different cross-sections and disposition of the bars.
Тable 2.
The bars The distances between the bars axes, mm
cross-section
130 150 170 200 210 250 275
Aluminium
40х4 1 1 1 1 1 1 1
60х6 0.92 0.95 0.96 1 1 1 1
80х10 - 0.9 0.93 0.95 0.96 0.98 1
Copper
30х4 1 1 1 1 1 1 1
40х5 1 1 1 1 1 1 1
50х6 0.95 0.97 1 1 1 1 1
60х6 0.92 0.95 0.96 1 1 1 1
60х10 0.93 0.95 0.96 1 1 1 1
80х10 - 0.9 0.93 0.95 0.96 0.98 1
References
1. Switchgear Manual. ABB, 9th edition. – ABB Calor Emag, Schaltanlagen AG, Mannheim,
Federal Republic of Germany, 1993.
2. High Voltage Circuit Breakers. Design and Applications. Ruben D. Garzon. Marcel Dekker,
INC. The USA, 1996.
3. L.N. Baptidanov, V.I. Tarasov. Electrical equipment of electrical stations and substations.
Moscow, 1952.
4. Y.N. Novicov. Theory and calculation of switching devices. Leningrad, 1970.

Application Guide: ISM Bus Arrangement

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Industrial group TAVRIDA ELECTRIC Application Guide PAGE No 1

Approved by Signature Date

1.The dimensions of the bus arrangement conditioned by rated current 4

3.Electrodynamic stability of the bus arrangement 7

4. The peculiarities of the busbars connections to the high voltage ISM 16

1.The dimensions of the bus arrangement conditioned by rated current

2.1 Selection of the support insulation.

Minimum nominal spesific creepage distance according to pollution level

II- Medium 2,0

III- Heavy 2,5

IV – Very heavy 3,1

2.2 Selection of air insulating distances.

ISM support insulation

Sometimes in the process of ISM adaptation to the switchgear or to withdrawable units it is

and also the requirements:

As an example, we may consider test rated voltages of range from 7 to 24 kV in accordance

Rated insulation levels for rated voltages of range I, series I.

Common Across the Across the

3.Electrodynamic stability of the bus arrangement.

3.2 Calculation of electrodynamic forces

F = 1.02 ⋅ 10 −8 i1i2 ks (1)

- In case of interaction between two parallel conductors of finite length;

3.3 Interaction of parallel conductors of finite length

This case frequently occurs during switchgear calculations.

F = 1.02 ⋅10 −8 (i1i2 )k s (3)

F(2)=1.02⋅10-8i2(2) kskf (5)

F=2.04⋅10-8(i1i2) l/a. (7)

3.4 Interaction of perpendicular conductors

F = 1.02 ⋅10 −8 ⋅ i 2 ⋅ k s (8)

where the circuit factor is:

F = 1.02 ⋅10 −8 ⋅ i1i2 ⋅ k s (11)

3.5 Electrodynamic stability of conductive parts and fixing components

Consider the components of the bars fixing.

Parameters of ИО-type support insulators produced by Bobrovsk insulator-making plant

Test voltage of full lightening impulse 80 80 125

Parameters of ETB-type support insulators of NYIR-MIX-TRADE Company production

3.6 The mechanical strength test of the bars

M=F (3) l/8 (14),

3.7 Calculation of the bending stress of the bar.

σcal =M/W (15),

150 170 200 210

20/1000 (60х6) 7.78⋅106 (1.25⋅107) inapplicabe 5⋅106 4.67⋅106 (8.89⋅106)

The value of σcal must meet the following condition:

σall ≥ σcal (16)

3.8 The test for mechanical short-circuit strength of support insulators.

More than 3 spans A-marginal; B- А: 0.4 3.56

Fcal =ψ F(3)=1.88⋅103Н<0.6 Fcal =4.8⋅103Н,

3.9 The mechanical resonance test of the bars

m ′ - mass per unit length;

And the maximum calculated force on the support insulator:

4. The peculiarities of the busbars connections to the high voltage ISM.

Figure 6. ISM/TEL Inom≤ 1000 A Figure 7. ISM/TEL Inom≥ 1200 A contact

Contact terminal of ISM

Figure 9. Allowed loads on the contact terminals of TEL-type ISM.

Since the conductors are arranged in the

The integral is:

After the change of l2-l1=x we have:

Let us consider that the conductor the

The integral in the last expression is easy to calculate:

3. Perpendicular Conductors Not

This particular case is

the distance between dl1 и dl2 is:

where the integral is: