Tubular Busbar Clamps in Alum Alloy

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TUBULAR BUSBAR CLAMPS IN ALUMINIUM ALLOY
INTRODUCTION
The aluminium alloy tubular bus current carrying clamps depicted in this section are manufactured in certified aluminium
alloys, namely aluminium alloy grade LM-6 as a standard, alternatively in aluminium alloy LM-25 heat treated to a T6
temper where a clamp is required to comply with a higher strength rating.
Tubular Busbar
Standard South African busbar tubes are supplied in either the alloys 6101-A and/or 6261-TF which are both suitable
for electrical purposes. The 6261-TF alloy has better mechanical properties, but somewhat poorer electrical properties
than the 6101-A. However, for application of HV yards, where long spans are essential, the 6261-TF alloy with superior
mechanical properties is preferred. All imported Aluminium Alloy Tubular Busbar are in the grade 6101-BT6.
Alloy Type
6101-A
6261-TF
6101-BT6
Max Yield Strength

MPa
170
240
160
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Electrical Resistivety
at 20C in mm/m
0.03133
0.037
0.0333
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Max. Length which

can be supplied
10
1,400
1,860
0.6
19
0.9
2.8
6.8
14.1
26.1
1,560
2,070
0.6
0.9
2.9
7.0
14.4
26.8
45.6
3.77
1,690
2,240
0.6
0.9
3.0
7.1
14.8
27.5
46.8
1,810
4.89
1,920
2,550
0.6
1.0
3.1
7.5
15.5
28.8
49.1
10
2,199
5.94
2,110
2,790
0.6
1.0
3.2
7.9
16.4
30.3
51.8
1,206
3.26
1,690
2,240
0.7
0.6
1.8
4.3
8.9
16.4
28.0
1,492
4.03
1,880
2,490
0.7
1.8
4.3
9.1
16.7
28.5
1,772
4.78
2,040
2,710
0.7
1.8
4.4
9.2
17.1
29.1
46.6
2,312
6.24
2,320
3,070
0.7
1.9
4.6
9.6
17.8
30.3
48.75
73.9
10
2,827
7.63
2,540
3,360
0.7
2.0
4.8
9.9
18.4
31.4
50.3
76.7
1,458
3.94
1,950
2,580
0.7
1.2
2.9
6.1
11.3
19.2
30.8
1,806
4.88
2,170
2,880
0.7
1.2
3.0
6.2
11.4
19.5
31.2
2,149
5.80
2,370
3,140
0.7
1.2
3.0
6.3
11.6
19.8
31.7
48.3
2,815
7.60
2,700
3,580
0.7
1.3
3.1
6.5
12.0
20.4
32.7
49.9
73.1
10
3,456
9.33
2,960
3,920
0.7
1.3
3.2
6.7
12.4
21.1
33.9
51.6
75.6
12
4,072
10.99
3,130
4,150
0.7
1.4
3.3
6.9
12.8
21.8
35.0
53.3
78.0
4
6
1,835
2,714
4.95
7.33
2,900
3,500
1.0
1.0
3,569
9.64
4,000
1.0
1,960
5.29
2,520
3,330
1.0
1.6
3.3
6.2
10.6
16.9
25.9
37.8
2,435
6.57
2,790
3,700
1.0
1.6
3.4
6.3
10.7
17.2
26.2
38.3
54.3
2,903
7.84
3,060
4,050
1.0
1.7
3.4
6.4
10.9
17.4
26.5
38.3
55.0
3,365
9.08
3,270
4,330
1.0
1.7
3.5
6.4
11.0
17.6
26.8
39.3
55.6
3,820
10.31
3,490
4,630
1.0
1.7
3.5
6.5
11.1
17.8
27.2
39.8
56.4
57.8
Weight
Cross Section
mm
Wall Thickness
85C
A
Outer Diameter
Tolerance in outer
diameter incl. deviation
from roundness
Standard Tubular Busbar
mm
mm
mm
kg/m
Permanent
Electrical Load
Busbar Temp.
80
100
120
150
160
200
250
65C
A
955
2.58
1,178
3.18
1,395
25
25
Maximum sag (cm) due to own weight, 2 supports,

(for 3 supports multiply listed values by 0.415)
Support spacing (m)
0.4
25
12
14
16
18
20
22
24
26
28
30
45.6
47.6
1.9
1.9
2
25
0.2
0.7
10
4,712
12.72
3,830
5,070
1.0
1.7
3.6
6.7
11.4
18.3
27.9
40.8
12
5,579
15.06
4,060
5,380
1.0
1.8
3.7
6.9
11.7
18.7
28.5
41.8
59.2
2,463
6.65
3,030
4,010
1.2
1.0
2.1
3.8
6.7
10.8
16.4
24.0
34.0
3,063
8.27
3,410
4,520
1.2
0.4
1.0
2.1
4.0
6.8
10.9
16.5
24.2
34.3
3,657
9.87
3,720
4,920
1.2
0.4
1.0
2.2
4.0
6.8
11
16.7
24.5
34.6
47.7
63.8
4,825
13.0
4,270
5,660
1.2
0.4
1.1
2.2
4.1
7.0
11.2
17.0
24.9
35.3
48.6
65.4
86.1
10
5,969
16.1
4,680
6,200
1.2
0.4
1.1
2.3
4.2
7.2
11.4
17.4
25.4
36.0
49.6
66.8
88.0
12
7,087
19.1
4,990
6,610
1.2
5.0
1.1
2.3
4.3
7.3
11.6
17.7
25.9
36.7
50.6
68.0
89.6
3,848
10.4
4,140
5,490
1.5
25
0.3
0.7
1.4
2.5
4.3
6.9
10.5
15.4
21.8
30.0
40.3
53.1
4,599
12.4
4,520
5,990
1.5
25
1.4
2.5
4.3
6.9
10.6
15.5
21.9
30.1
40.5
53.4
25
0.1
0.1
0.4
47.3
6,082
16.4
5,190
6,870
1.5
25
1.4
2.6
4.4
10.7
15.7
22.2
30.6
41.2
54.3
10
7,540
20.4
5,700
7,560
1.5
25
1.4
2.6
4.5
7.2
10.9
16.0
22.7
31.2
42.0
55.4
12
8,972
24.2
6,100
8,080
1.5
25
1.4
2.7
4.5
7.3
11.1
16.2
23.0
31.6
42.5
56.1
14
10,380
28.0
6,420
8,500
1.5
23
1.5
2.7
4.6
7.4
11.3
16.5
23.3
32.1
43.2
57.0
16
11,762
31.8
6,640
8,800
1.5
19
1.5
2.8
4.7
7.5
11.5
16.8
23.8
32.7
44.0
58.0
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INSTALLATION PROCEDURE
When installing full or half expansion inter-connector clamps, care must be taken for the allowance of the thermal
expansion of the relevant basbar tube, be it aluminium or copper. An estimate of the expansion of various tubes due to
thermal expansion at various temperature changes is given in the tables below:
1.
Calculation of Thermal Expansion in Aluminium Tubes in mm

Length
of Tube
in
Meters
Temperature Difference T. in C

10
20
30
40
50
60
70
80
90
100
2.5
0.6
1.2
1.8
2.4
3.0
3.6
4.2
4.8
5.4
6.0
5.0
1.2
2.4
3.6
3.0
6.0
7.2
8.4
9.6
10.8
12.0
10
2.4
4.8
7.2
9.6
12.0
14.4
16.8
19.2
21.6
24.0
20
4.8
9.6
14.4
19.2
24.0
28.8
33.6
38.4
43.2
48.0
30
7.2
14.4
21.6
28.8
36.0
43.2
50.4
57.6
64.8
72.0
40
9.6
19.2
28.8
38.4
48.0
57.6
67.2
76.8
86.4
96.0
50
12.0
24.0
36.0
48.0
60.0
72.0
84.0
96.0
108.0
120.0
Temperature Co-efficient of Linear expansion (temp. range -20 + 200C

Aluminium: 23 x 10-6 (0,000023 per centigrade degree)
Example of the Calculation of Thermal Busbar Expansion:

Aluminium basbar tube, length
Temperature difference
Assembly temperature
10m
t=
=
t=
=
Max. Op. Temperature Min. Op. Temperature

(+80C) (-20C)
100C
+20C
For complete expansion length refer to table = 24.0mm.

Temperature difference between the final temperature (+80C) and the assembly temperature (+20C) is therefore
60C. Referring to the above table, the corresponding expansion difference will be 14,4mm. The clamp must
therefore be mounted in such a way that a shift of at least 14,4mm in the direction of the clamp centre is
guaranteed. A shift in the opposite direction in accordance with the temperature difference of (+20C) assembly
temperature and (+20C) being the lowest final temperature - 40C. Referring to the above tables, this value is
given as 9.6mm.
2.
Short Circuit Forces on Clamps
Notes:
Tube
Size
Current
Rating
Phase *
Spacing
Short
Circuit
mm
80 x 8
100 x 8
120 x 8
150 x 8
200 x 8
250 x 8
Amp
2 300
2 800
3 300
4 000
5 200
6 300
m
2.3
2.3
2.3
4.5
4.5
4.5
kA
16
25
25
50
50
50
* Indicates the phase spacing at which maximum short circuit forces occurs.
Transverse Short
Circuit Forces on Clamps
and Post Insulators
kN
4
6
6
16
16
20
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Clamps are designed to have a factor of safety of 2:1 with respect to the specified load. Unless the min. mechanical load
is specified, the standard strength LM-6 alloy clamp, is supplied.
3.
Busbar Tube Vibration Damping

Aluminium tubular busbars are subject to wind-generated vibration and oscillation. Because of the low self-damping
of tubular busbars very slight excitation forces will suffice to excite the tubes to vibrations amplitudes of the
order of the tube diameter, when there is a resilience of the excitation force with a natural frequency of the tube.
These high amplitudes produce additional dynamic stresses inside all structural parts and it is often necessary to
dampen this tube oscillation by the insertion of AAC conductor into the busbar. The increased self damping
provided by the insertion of damping conductor delays the onset of resilience build-up and this limits the maximum
amplitudes created by a given excitation force.
Recommended Damping Cables

As a rule it is normally sufficient to insert one conductor
into a tube, but in order to increase the safety and to
maintain maximum damping effect it is advisable to insert
two conductors into the tube (one at each end running for
2/3 of the tube length). The following table shows
recommended damping conductor sizes. A drain hole of
10mm diameter should be drilled at bottom centre point of
tubes to facilitate drainage of condensate moisture.
4.
Tube-
mm
Al-cable
mm
63
80
100
120
160
200
250
120
150
240
300
500
625
625
Nominal Linear Expansion of Tubular Busbars
Temperature
C
20
30
40
50
60
70
80
Expansion in mm/Per Meter

Aluminium
Copper
0.69
0.51
0.92
0.68
1.15
0.85
1.38
1.02
1.61
1.19
1.84
1.36
2.12
1.58
Permissible spacing
between supports
without damping cables
m (nominal values)
3.0
3.5
4.5
5.5
7.5
9.5
12.0

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TUBULAR BUSBAR CLAMPS IN ALUMINIUM ALLOY

Max Yield Strength

Copyright 2008 McWade Productions (Pty) Ltd

Max. Length which

Standard Tubular Busbar

Maximum sag (cm) due to own weight, 2 supports,

Support spacing (m)

Copyright 2008 McWade Productions (Pty) Ltd

Copyright 2008 McWade Productions (Pty) Ltd

Calculation of Thermal Expansion in Aluminium Tubes in mm

Temperature Difference T. in C

Temperature Co-efficient of Linear expansion (temp. range -20 + 200C

Example of the Calculation of Thermal Busbar Expansion:

Max. Op. Temperature Min. Op. Temperature

For complete expansion length refer to table = 24.0mm.

Short Circuit Forces on Clamps

Copyright 2008 McWade Productions (Pty) Ltd

Busbar Tube Vibration Damping

Recommended Damping Cables

Nominal Linear Expansion of Tubular Busbars

Expansion in mm/Per Meter

Copyright 2008 McWade Productions (Pty) Ltd

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