The power supply with busbars in switchgears is a comparatively old and time-tested technology. One could therefore assume that there are few innovations to be expected in this field. Rittal says that its RiLine60 busbar system shows that this is not the case and that, using this system, users in the switchgear construction sector can save time and costs.
Busbar support with automatic cross-section adaptation
For flat copper bars there is a busbar support with integrated cross-section adaptation to fit different dimensions ranging from 15 x 5 to 30 x 10 mm. No additional parts are necessary (Figure 1). A slide accommodates the height adjustment for 5 mm bars and an integrated locating block automatically adapts to widths from 15 mm to 30 mm.
The patented copper bars in what is referred to as PLS format (Figure 2) can also be quickly and easily installed. This is made possible by a new locking system. Flat copper bars and bars of the PLS type can be flexibly used for applications with up to 1600 A capacity. The system has been type-tested to DIN EN 60439-1 and guarantees high stability, such as for short circuit resistance. In the course of the type testing, DIN EN 60439-1 compliance was likewise certified with respect to insulation properties, creepage and clearance distances and IP2x protection rating.
Along with the rail and end covers, the base tray offers all-round hazard protection, whereby the cover sections can be individually cut and snapped onto the base tray, and the end covers are attached directly to the busbar supports.
Connection adapter with IP2x protection rating
The connection adapter for the system is available in six sizes to cover currents ranging from 63 A to 1600 A. All adapters are available with feed-through function. The connection adapters have box terminals with a single-screw mechanism for cross-sections of up to 300 mm². The variants for laminated flat copper can handle currents up to 800 A or 1600 A. The covers for the connection adapters have a locking mechanism for which the locking position is clearly displayed via a slider and these covers provide for an IP2x protection rating.
Two mounting options for component adapter
There are two options to choose from when mounting component adapters for the busbar system; these are referred to as OneMove and One-Turn adapters. The OneMove adapter is attached to the rails using standard snap-on technology. The rails are pushed from above onto the rails and the profile of the base tray (Figure 3). The steel-reinforced clamping feet are suited for 5 mm as well as 10 mm bar thicknesses.
OneTurn adapters are hinged into the upper base tray section, which has to be additionally reinforced by an aluminium bar. The component adapter is then swung and snapped into the busbar system (Figure 4). The advantage of this variant is that less force is necessary while still maintaining good contact, due to the low leverage quotient needed for installation.
Both variants are available in widths of 45 mm and 55 mm, and there are 10 mm wide cable connectors which can be lined up sideways for auxiliary switches. This system makes it possible to create any module arrangement using a connector pin.
Three connection techniques for component adapters
Users also have various options to choose from for component connections. The simplest and classic type is standard mounted connection cables that are offered in standard sizes of AWG12, AWG10 and AWG6. There is also a new connection option using flexible tension spring clamps that can save time during mounting. For this, there are also two variants for conductors with a 6 mm² cross section for currents up to 32 A and for conductors with a 16 mm² cross-section for currents up to 65 A. Three main lines and eight auxiliary lines can be connected via one jack and one outgoing connector block.
With the basic version, the equipment is assembled directly on the component adapter. As an alternative to this solution, it is still possible to use support frames that permit servicing by separating the component and support frame from the component adapter (Figure 5). Thus, downtime can be considerably reduced when switching out components. Even if the device has been separated from the support frame, the component adapter covers the busbars to protect them from contact, making it possible to switch out components while operational (hot-swap).
Power circuit breakers are attached using what are referred to as CB adapters, which are suitable for all commercially available versions up to 630 A. The new sliding block concept (Figure 6) is used for this installation. The sliding block is mounted on the switchgear, the pre-assembled component slid into the appropriate guide channel, and then secured with a plug-in end stop. Box terminals are used for connecting models with capacities of up to 250 A while for versions up to 630 A, the connection is created using a solid threaded bolt. The contact tracks are completely imbedded in the adapter housing, which ensures high protection and short circuit resistance.
All plastic parts of the busbar system are halogen-free and guarantee fire protection that complies to UL 94-V0.
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