Technical Paper
Rel. 3/2004 Rev. 5/2009
What is Flexibar? Flexibar consists of pure electrolytic copper laminates that slide smoothly within a protective PVC jacket. The individual laminates allow the Flexibar to be shaped, twisted and bent to fit a wide range of panel layouts. The Flexibar Advantage
Figure 1
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•
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Space Advantage o Flexibar requires less installation space than cable. o A single piece of Flexibar can replace multiple runs of cable, which would connect to a single lug. o Protective PVC jacket allows the Flexibar to be mounted in tight areas where rigid busbar could not be used. Time Advantage o Flexibar eliminates to need for lugs which reduces installation time and cost. o Flexibar can replace rigid busbar designs eliminating the time spent engineering and fabricating rigid busbar. o Flexibar is easer to bend and shape than large cables, so installation is quicker. Operating Advantage o Greater surface area is utilized when making connections with Flexibar, so the connection points are at a lower operating temperature. o Ring terminals are no longer needed, simply punch or drill through the exposed end of the Flexibar to bolt to rigid bus or electrical components. Aesthetic Advantage o Flexibar increases design flexibility. o Flexibar neatly organizes hard to make connections.
Applications •
Low voltage power distribution and control connections o Busbar Systems o Motor Control Centers o Drive Systems o Switchboards o Transformers o Panelboards o Control Panels o Power Supplies o Electrical Machinery o UPS Systems
Rittal Corporation 1 Rittal Place Urbana, Ohio 43078 Phone: 1-800-477-4000 Email: [email protected] Website: www.rittal-corp.com
Page 1 of 4
Rel. 3/2004 Rev. 5/2009
Technical Specifications • • •
Agency Approvals o UL Recognized o CSA Certified Conductor o Bare or tinned electrolytic copper 2 o Resistivity 0.01758 Ω mm /m Insulator o Black, polyvinyl chloride o Temperature range: -30 to 105° C dry o UL recognized for 600 volts, CSA recognized for 1000 volts o Moisture resistant o Flame retardant VW-1 o Ultra violet retardant o Self-extinguishing per UL 94 VO o Tensile strength Unaged – 2620 LBF/IN Aged – 2820 LBF/IN o Elongation Unaged – 260% Aged – 200% o Manufacturing tested at 30,000 volts o Part number and dimensions are printed on the insulator
Selection
Length mm N 6 6 4 6 10 5 5 10 5 10 5 10 5 10 10
A mm B mm 9 0.8 13 0.5 15.5 0.8 15.5 0.8 15.5 0.8 20 1 24 1 24 1 32 1 32 1 40 1 40 1 50 1 50 1 63 1
2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000
Rated Ampacity Temp. Rise of 1) 50°C 250 200 300 350 450 400 450 800 550 1000 800 1200 900 1400 1600
30°C 220 150 210 290 350 300 370 600 470 800 600 950 700 1000 1240
10°C 120 110 140 170 190 180 230 340 280 460 340 500 400 600 715
Part No. Bare Copper SV
Part No. Tin Plated Copper SV
3565000 3566000 3567000 3568000 3569000 3570000 3571000 3572000 3573000 3574000 3575000 3576000 3577000 3578000 3579000
3565902 3566902 3567902 3568902 3569902 3570903* 3571903* 3572903* 3573903* 3574903* 3575903* 3576903* 3577903* 3578903* 3579903*
1)
Rittal Corporation 1 Rittal Place Urbana, Ohio 43078 Phone: 1-800-477-4000 Email: [email protected] Website: www.rittal-corp.com
The conductor tem perature of the lam inated copper busbar is derived from the sum total of the am bient tem peraure and the tem perature increase. * Length of Flexibar is 3000 mm
Page 2 of 4
Rel. 3/2004 Rev. 5/2009
Comparison Table 1
Figure 2
Ampacity 250 200 300 350 450 400 450 800 550 1000 800 1200 900 1400 1600
Part No. Bare Tinned Configuration 3565000 3565902 6x9x0.8 3566000 3566902 6x13x0.5 3567000 3567902 4x15.5x0.8 3568000 3568902 6x15.5x0.8 3569000 3569902 10x15.5x0.8 3570000 3570903* 5x20x1 3571000 3571903* 5x24x1 3572000 3572903* 10x24x1 3573000 3573903* 5x32x1 3574000 3574903* 10x32x1 3575000 3575903* 5x40x1 3576000 3576903* 10x40x1 3577000 3577903* 5x50x1 3578000 3578903* 10x50x1 3579000 3579903* 10x63x1
Flexibar Substitute For These Comparable Cable Sizes 1 x 3/0 or 2 x #3 AWG 1 x 3/0 or 2 x #3 AWG 1 x 4/0 or 2 x #2 AWG 1 x 300 kcmil or 2 x 1/0 or 3 x #3 AWG 1 x 600 kcmil or 2 x 3/0 or 3 x #1 AWG 1 x 400 kcmil or 2 x 2/0 or 3 x #2 AWG 1 x 600 kcmil or 2 x 3/0 or 3 x #1 AWG 1 x 2000 kcmil or 2 x 350 kcmil or 3 x 3/0 AWG 1 x 900 kcmil or 2 x 250 kcmil or 3 x 2/0 AWG 2 x500 or 3 x 250 kcmil or 4 x 4/0 AWG 1 x 1500 or 2 x 350 kcmil or 3 x 3/0 AWG 2 x 700 or 3 x 300 kcmil 2 x 500 kcmil or 3 x 4/0 AWG 2 x 900 or 3 x 400 or 4 x 350 kcmil 2 x 1400 or 3 x 600 or 4 x500 kcmil
* Length of Flexibar is 3000 mm
Electrical Connections • •
Flexibar Surface conditions – The surface of the Flexibar should be flat but not polished. Clean the surface of the Flexibar so that it is free of oxide and grease. Connection overlap (Figure 2) – The recommended overlap (H) should be at least 5 times the thickness (t) of all of the laminates. See Table 3 Table 2 Ampacity 250 200 300 350 450 400 450 800 550 1000 800 1200 900 1400 1600
Part No. Bare Tinned 3565000 3565902 3566000 3566902 3567000 3567902 3568000 3568902 3569000 3569902 3570000 3570903* 3571000 3571903* 3572000 3572903* 3573000 3573903* 3574000 3574903* 3575000 3575903* 3576000 3576903* 3577000 3577903* 3578000 3578903* 3579000 3579903*
Configuration 6x9x0.8 6x13x0.5 4x15.5x0.8 6x15.5x0.8 10x15.5x0.8 5x20x1 5x24x1 10x24x1 5x32x1 10x32x1 5x40x1 10x40x1 5x50x1 10x50x1 10x63x1
Min. Overlap 25 25 25 25 40 25 25 50 25 50 25 50 25 50 50
Bolt Number Size 1 clamp 1 clamp 1 clamp 1 clamp 1 clamp 1 5/16-16 1 1/16-14 2 1/16-14 1 1/16-14 2 1/16-14 1 1/2-13 2 1/2-13 2 1/16-14 2 1/2-13 3 1/2-13
* Length of Flexibar is 3000 mm
Rittal Corporation 1 Rittal Place Urbana, Ohio 43078 Phone: 1-800-477-4000 Email: [email protected] Website: www.rittal-corp.com
Page 3 of 4
Rel. 3/2004 Rev. 5/2009
•
Clamping torque values (Figure 3) – Using an SAE Grade 5 bolt, and contact washers:
Figure 3 Figure 3 Additional Recommended Fabricating Procedures •
•
•
Hole Diameters & Slots - The edge-of-hole to edge-of-part minimum distance is 0.188” or 1.5 times the total laminate thickness. o Tip: When drilling through the Flexibar, clamp the laminates together so that they do not ride up the drill bit. Bending Radii – The bend radius should be greater than or equal to ½” or the radius should equal 0.125” x the number of laminates. o Tip: Since the copper laminates will slide freely within the insulating jacket, follow the below procedure when shaping a piece of Flexibar. Strip the insulating jacket on one end of the Flexibar Clamp the copper laminates and drill the bolt hole(s) in the exposed end of the Flexibar (only drill holes in one end of the part) Insert a temporary “holding” bolt into the hole, that has been drilled, then form the Flexibar into the desired shape. Cut the Flexibar at the unexposed end to the desired length then strip that same end to reveal the copper laminates. Clamp the laminates together and drill the required bolt-holes. Twisting – When twisting Flexibar along its length, it is recommended that the part is not twisted greater than 90 degrees. The length allowance for a 90-degree twist should be at least three times the width of the Flexibar (including the insulating jacket).
The “Flexible” solution… This reliable alternative to cable or rigid bus will allow more “flexibility” in panel designs as well as save space and build-up time.
Rittal Corporation 1 Rittal Place Urbana, Ohio 43078 Phone: 1-800-477-4000 Email: [email protected] Website: www.rittal-corp.com
Page 4 of 4
What is Flexibar? Flexibar consists of pure electrolytic copper laminates that slide smoothly within a protective PVC jacket. The individual laminates allow the Flexibar to be shaped, twisted and bent to fit a wide range of panel layouts. The Flexibar Advantage
Figure 1
•
•
•
•
Space Advantage o Flexibar requires less installation space than cable. o A single piece of Flexibar can replace multiple runs of cable, which would connect to a single lug. o Protective PVC jacket allows the Flexibar to be mounted in tight areas where rigid busbar could not be used. Time Advantage o Flexibar eliminates to need for lugs which reduces installation time and cost. o Flexibar can replace rigid busbar designs eliminating the time spent engineering and fabricating rigid busbar. o Flexibar is easer to bend and shape than large cables, so installation is quicker. Operating Advantage o Greater surface area is utilized when making connections with Flexibar, so the connection points are at a lower operating temperature. o Ring terminals are no longer needed, simply punch or drill through the exposed end of the Flexibar to bolt to rigid bus or electrical components. Aesthetic Advantage o Flexibar increases design flexibility. o Flexibar neatly organizes hard to make connections.
Applications •
Low voltage power distribution and control connections o Busbar Systems o Motor Control Centers o Drive Systems o Switchboards o Transformers o Panelboards o Control Panels o Power Supplies o Electrical Machinery o UPS Systems
Rittal Corporation 1 Rittal Place Urbana, Ohio 43078 Phone: 1-800-477-4000 Email: [email protected] Website: www.rittal-corp.com
Page 1 of 4
Rel. 3/2004 Rev. 5/2009
Technical Specifications • • •
Agency Approvals o UL Recognized o CSA Certified Conductor o Bare or tinned electrolytic copper 2 o Resistivity 0.01758 Ω mm /m Insulator o Black, polyvinyl chloride o Temperature range: -30 to 105° C dry o UL recognized for 600 volts, CSA recognized for 1000 volts o Moisture resistant o Flame retardant VW-1 o Ultra violet retardant o Self-extinguishing per UL 94 VO o Tensile strength Unaged – 2620 LBF/IN Aged – 2820 LBF/IN o Elongation Unaged – 260% Aged – 200% o Manufacturing tested at 30,000 volts o Part number and dimensions are printed on the insulator
Selection
Length mm N 6 6 4 6 10 5 5 10 5 10 5 10 5 10 10
A mm B mm 9 0.8 13 0.5 15.5 0.8 15.5 0.8 15.5 0.8 20 1 24 1 24 1 32 1 32 1 40 1 40 1 50 1 50 1 63 1
2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000
Rated Ampacity Temp. Rise of 1) 50°C 250 200 300 350 450 400 450 800 550 1000 800 1200 900 1400 1600
30°C 220 150 210 290 350 300 370 600 470 800 600 950 700 1000 1240
10°C 120 110 140 170 190 180 230 340 280 460 340 500 400 600 715
Part No. Bare Copper SV
Part No. Tin Plated Copper SV
3565000 3566000 3567000 3568000 3569000 3570000 3571000 3572000 3573000 3574000 3575000 3576000 3577000 3578000 3579000
3565902 3566902 3567902 3568902 3569902 3570903* 3571903* 3572903* 3573903* 3574903* 3575903* 3576903* 3577903* 3578903* 3579903*
1)
Rittal Corporation 1 Rittal Place Urbana, Ohio 43078 Phone: 1-800-477-4000 Email: [email protected] Website: www.rittal-corp.com
The conductor tem perature of the lam inated copper busbar is derived from the sum total of the am bient tem peraure and the tem perature increase. * Length of Flexibar is 3000 mm
Page 2 of 4
Rel. 3/2004 Rev. 5/2009
Comparison Table 1
Figure 2
Ampacity 250 200 300 350 450 400 450 800 550 1000 800 1200 900 1400 1600
Part No. Bare Tinned Configuration 3565000 3565902 6x9x0.8 3566000 3566902 6x13x0.5 3567000 3567902 4x15.5x0.8 3568000 3568902 6x15.5x0.8 3569000 3569902 10x15.5x0.8 3570000 3570903* 5x20x1 3571000 3571903* 5x24x1 3572000 3572903* 10x24x1 3573000 3573903* 5x32x1 3574000 3574903* 10x32x1 3575000 3575903* 5x40x1 3576000 3576903* 10x40x1 3577000 3577903* 5x50x1 3578000 3578903* 10x50x1 3579000 3579903* 10x63x1
Flexibar Substitute For These Comparable Cable Sizes 1 x 3/0 or 2 x #3 AWG 1 x 3/0 or 2 x #3 AWG 1 x 4/0 or 2 x #2 AWG 1 x 300 kcmil or 2 x 1/0 or 3 x #3 AWG 1 x 600 kcmil or 2 x 3/0 or 3 x #1 AWG 1 x 400 kcmil or 2 x 2/0 or 3 x #2 AWG 1 x 600 kcmil or 2 x 3/0 or 3 x #1 AWG 1 x 2000 kcmil or 2 x 350 kcmil or 3 x 3/0 AWG 1 x 900 kcmil or 2 x 250 kcmil or 3 x 2/0 AWG 2 x500 or 3 x 250 kcmil or 4 x 4/0 AWG 1 x 1500 or 2 x 350 kcmil or 3 x 3/0 AWG 2 x 700 or 3 x 300 kcmil 2 x 500 kcmil or 3 x 4/0 AWG 2 x 900 or 3 x 400 or 4 x 350 kcmil 2 x 1400 or 3 x 600 or 4 x500 kcmil
* Length of Flexibar is 3000 mm
Electrical Connections • •
Flexibar Surface conditions – The surface of the Flexibar should be flat but not polished. Clean the surface of the Flexibar so that it is free of oxide and grease. Connection overlap (Figure 2) – The recommended overlap (H) should be at least 5 times the thickness (t) of all of the laminates. See Table 3 Table 2 Ampacity 250 200 300 350 450 400 450 800 550 1000 800 1200 900 1400 1600
Part No. Bare Tinned 3565000 3565902 3566000 3566902 3567000 3567902 3568000 3568902 3569000 3569902 3570000 3570903* 3571000 3571903* 3572000 3572903* 3573000 3573903* 3574000 3574903* 3575000 3575903* 3576000 3576903* 3577000 3577903* 3578000 3578903* 3579000 3579903*
Configuration 6x9x0.8 6x13x0.5 4x15.5x0.8 6x15.5x0.8 10x15.5x0.8 5x20x1 5x24x1 10x24x1 5x32x1 10x32x1 5x40x1 10x40x1 5x50x1 10x50x1 10x63x1
Min. Overlap 25 25 25 25 40 25 25 50 25 50 25 50 25 50 50
Bolt Number Size 1 clamp 1 clamp 1 clamp 1 clamp 1 clamp 1 5/16-16 1 1/16-14 2 1/16-14 1 1/16-14 2 1/16-14 1 1/2-13 2 1/2-13 2 1/16-14 2 1/2-13 3 1/2-13
* Length of Flexibar is 3000 mm
Rittal Corporation 1 Rittal Place Urbana, Ohio 43078 Phone: 1-800-477-4000 Email: [email protected] Website: www.rittal-corp.com
Page 3 of 4
Rel. 3/2004 Rev. 5/2009
•
Clamping torque values (Figure 3) – Using an SAE Grade 5 bolt, and contact washers:
Figure 3 Figure 3 Additional Recommended Fabricating Procedures •
•
•
Hole Diameters & Slots - The edge-of-hole to edge-of-part minimum distance is 0.188” or 1.5 times the total laminate thickness. o Tip: When drilling through the Flexibar, clamp the laminates together so that they do not ride up the drill bit. Bending Radii – The bend radius should be greater than or equal to ½” or the radius should equal 0.125” x the number of laminates. o Tip: Since the copper laminates will slide freely within the insulating jacket, follow the below procedure when shaping a piece of Flexibar. Strip the insulating jacket on one end of the Flexibar Clamp the copper laminates and drill the bolt hole(s) in the exposed end of the Flexibar (only drill holes in one end of the part) Insert a temporary “holding” bolt into the hole, that has been drilled, then form the Flexibar into the desired shape. Cut the Flexibar at the unexposed end to the desired length then strip that same end to reveal the copper laminates. Clamp the laminates together and drill the required bolt-holes. Twisting – When twisting Flexibar along its length, it is recommended that the part is not twisted greater than 90 degrees. The length allowance for a 90-degree twist should be at least three times the width of the Flexibar (including the insulating jacket).
The “Flexible” solution… This reliable alternative to cable or rigid bus will allow more “flexibility” in panel designs as well as save space and build-up time.
Rittal Corporation 1 Rittal Place Urbana, Ohio 43078 Phone: 1-800-477-4000 Email: [email protected] Website: www.rittal-corp.com
Page 4 of 4
