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FLEXIBLE CONDUCTORS Flexible ConduCtors overview

Spec-01138 D

EQUIPMENT PROTECTIONSUBJECT TO CHANGE WITHOUT NOTICEPOWER AND GROUNDING CONNECTIVITY1

SPEC-01138

763.422.2211

763.422.2600

POWER AND GROUNDING CONNECTIVITY

FLEXIBLE CONDUCTORS

FLEXIBLE CONDUCTORS OVERVIEW

FLEXIBLE CONDUCTORS PRODUCT OVERVIEW

Product Range

Insulated flexible busbar

(ERIFLEX FLEXIBAR)

Insulated braided conductor

(IBS, IBSB & IBSBR)

Power shunt

(PBC, PBCR & PPS)

Earth ground copper braids

(MBJ & BJ)

Earth ground stainless steel

braids (CPI)

Flat and round copper braids

in coils

Tubular copper braids in coils

Typical Uses

• Heavy-duty power interconnection

• Overcome vibration/alignment

problems

• Circuit breaker, generator and

prefabricated power network

conductor

• Expansion joints

• Variable terminating positions

• Machine connections

• Movable connection from massive

busbar system

• Alternative to large & multiple cables

• Alternative to rigid busbar

• Interconnects for low voltage power

distribution units

• IBSB specially designed for industrial

circuit breaker connection

• Overcome vibration/alignment problems

• Battery connections

• Earth ground connections

• Transformer or generator to busbar

connection

• Overcome vibration/alignment problems

• Power interconnection

• Switchgear & control equipment

• Power distribution

• Transportation

• Power, earthing/grounding and

equipotential connections

• Electrical bonding enclosure door

• EMI effect reduction application

• Switchgear & control equipment

• Rail transportation

• Electrical equipment

manufacturers

• Power generation (wind, solar)

• Data center

• Switchgear & control equipment

• Transport

• Electrical equipment

manufacturers

• Power generation

• Machinery manufacturer

• Interconnects for low voltage

power distribution units

• IBSB specially designed for

industrial circuit breaker

connection

• Overcome vibration/alignment

problems

• Battery connections

• Earth ground connections

• Earthing/grounding and equipotential

connections

• Superior abrasion, corrosion, chemical,

and UV resistance for outdoor

applications

• Expansion joints

• Connections for lightning protection

systems

• Transportation

• Food and beverage industry

• Power generation (wind, solar)

• Chemical and oil industry

• Automotive

• Defense & aerospace

• Civil construction

• Urban projects

• Earth/ground connections

• Power interconnection

• Lightning protection

• Flexible links

• Overcome vibration/alignment problems

• Defense & aerospace

• Rail transportation

• Automotive

• Electronics

• General electrical sector

• Civil construction

• Screening of cables from

electromagnetic, electrostatic and RF

interference

• Mechanical support

• Protection against abrasion and

corrosion

• EMC & EMH applications

• Defense & aerospace

• Transportation

• Electronics & communication

• Cable harness & assembly

makers

• Component distributors

Typical Market

Summary of content (32 pages)

PAGE 1
Flexible Conductors Flexible Conductors Overview POWER AND GROUNDING CONNECTIVITY FLEXIBLE CONDUCTORS FLEXIBLE CONDUCTORS OVERVIEW SPEC-01138 D63.422.2211 7 763.422.
PAGE 2
Flexible Conductors Flexible Conductors Overview ERIFLEX ERIFLEX FLEXIBAR INSULATED FLEXIBLE BUSBAR FEATURES SPECIFICATIONS • • • • • • • • • • • • • • • • • • • ERIFLEX FLEXIBAR is formed with multiple layers of thin electrolytic copper, available in plain or tin plated ERIFLEX FLEXIBAR connections are made by punching directly through the laminates.
PAGE 3
Flexible Conductors ERIFLEX FLEXIBAR Busbars and Accessories ERIFLEX FLEXIBAR BUSBAR SELECTION AND TECHNICAL CHARACTERISTICS ERIFLEX FLEXIBAR BUSBARS AND ACCESSORIES SPECIFICATIONS Temperature rise of conductor = T2 - T1 = ΔT (K) Ex: For a current of 630A, with: T1 = 40ºC - T2 = 90ºC 1) ∆T = 90 - 40 = 50K 2) In the 50ºK column, find the closest current value to 630A. ERIFLEX FLEXIBAR 5x32x1 - 552650 160 mm2 - 640A.
PAGE 4
Flexible Conductors ERIFLEX FLEXIBAR Busbars and Accessories Typical Application Current Rating ERIFLEX FLEXIBAR Composition ΔT 20° C (A) ΔT 45° C (A) ΔT 60° C (A) ΔT 30° C (A) “NEC “NEC “NEC ΔT 35° C (A) ΔT 40° C (A) ΔT 50° C (A) ΔT 65° C (A) ΔT 70° C (A) 310-16 310-16 310-16 75° C” 90° C” 60° C” 3 9 0.8 101 126 138 148 158 167 185 193 3 13 0.5 102 128 139 150 160 169 187 195 125 A 2 15.5 0.8 121 152 166 178 190 201 222 232 6 13 0.5 150 188 205 221 235 249 275 287 6 9 0.
PAGE 5
Flexible Conductors ERIFLEX FLEXIBAR Busbars and Accessories ERIFLEX FLEXIBAR, TINNED COPPER SPECIFICATIONS INDUSTRY STANDARDS Certification Details: UL 67, UL 758 CSA C22.2 No. 0 and 210 Complies With: IEC 60439.1, IEC 61439.1, IEC 61439.
PAGE 6
Flexible Conductors ERIFLEX FLEXIBAR Busbars and Accessories Typical Application Current Rating: 125 A Catalog Number L (Ft.) .T 30 K (A) .T 45 K (A) .T 60 K (A) N (in.) A (in.) B (in.) Cross Section (kcmil) 2 Bar Current Coefficient 3 Bar Current Coefficient Qty. FLEX2MTC3X9X08 6.56 126 158 185 3 0.354 0.031 42.63 1.72 2.25 1 FLEX2MTC3X13 6.56 128 160 187 3 0.512 0.02 38.48 1.72 2.25 1 FLEX2MTC2X155 6.56 152 190 222 2 0.61 0.031 48.94 1.72 2.
PAGE 7
Flexible Conductors ERIFLEX FLEXIBAR Busbars and Accessories Typical Application Current Rating: 800 A Catalog Number L (Ft.) .T 30 K (A) .T 45 K (A) .T 60 K (A) N (in.) A (in.) B (in.) Cross Section (kcmil) 2 Bar Current Coefficient 3 Bar Current Coefficient Qty. FLEX3MTC4X50X1 9.84 651 813 950 4 1.969 0.039 394.7 1.72 2.25 1 FLEX3MTC8X32X1 9.84 657 821 959 8 1.26 0.039 505.22 1.72 2.25 1 FLEX3MTC6X40X1 9.84 669 835 976 6 1.575 0.039 473.65 1.72 2.
PAGE 8
Flexible Conductors ERIFLEX FLEXIBAR Busbars and Accessories ERIFLEX ERIFLEX FLEXIBAR END COVER • • • • • • Conductor Width (in.) 0.79 0.94 1.26 Catalog Number ENDCOV20 ENDCOV24 ENDCOV32 Qty. Unit Weight (lb.) 0.42 0.48 0.
PAGE 9
Flexible Conductors ERIFLEX FLEXIBAR Busbars and Accessories FS SPACER CLAMP, SNAP CLOSE SPECIFICATIONS • • Material: Polyamide Working Temperature: -40 to 266 °F + +6 / INDUSTRY STANDARDS UL Recognized Flammability Rating: UL 94HB FEATURES • • • • • • • Provides support for ERIFLEX FLEXIBAR and insulated braided conductors without damaging the insulation Ensures correct spacing for optimum cooling Supports up to four conductors in parallel Easy to install Halogen free Recommended distance betwe
PAGE 10
Flexible Conductors ERIFLEX FLEXIBAR Busbars and Accessories RFS REINFORCED ERIFLEX FLEXIBAR SUPPORT % & 76 + +6 $ ' : • • • • • Supports up to eight conductors in parallel Ensures correct spacing for optimum cooling Easy to install Spacers are halogen free RoHS compliant Catalog Number Conductor Width (in.) D (in.) H (in.) W (in.) HS (in.) TS A (in.) B (in.) C (in.) Unit Weight (lb.) Qty. RFS4063 1.57 – 2.48 1.57 8.26 6.89 0.35 M8 5.9 4.72 3.54 0.
PAGE 11
Flexible Conductors Insulated Braided Conductors INSULATED BRAIDED CONDUCTORS (IBS, IBSB AND IBSBR) INSULATED BRAIDED CONDUCTORS SPECIFICATIONS Temperature rise of conductor = T2 - T1 = ΔT (K) Ex.: For a current of 630A, with: T1 = 40 C (104 F) - T2 = 90 C (194 F) 1) ΔT = 90 - 40 = 50K 2) In the 50 K column, find the closest current value to 630A. K = Kelvin degree (temperature calculated, but not measurable.
PAGE 12
Flexible Conductors Insulated Braided Conductors Assembly Instructions Screw “Contact” Washer Flat Washer IBS/IBSB/IBSBR Flat Washer “Contact” Washer Copper bar Screw Nut “Contact” Washer Flat Washer IBS/IBSB/IBSBR Flat Washer “Contact” Washer Copper bar Nut EQUIPMENT PROTECTION Spec-01138 D PH 763.422.2211 • FAX 763.422.2600 • pentairprotect.
PAGE 13
Flexible Conductors Insulated Braided Conductors IBSB/IBSBR INSULATED BRAIDED CONDUCTOR FOR CIRCUIT BREAKERS IBSB/IBSBR is compatible with all major brand molded case circuit breakers. Contact your Pentair representative to determine the correct size for your application.
PAGE 14
Flexible Conductors Insulated Braided Conductors Typical Application Current Rating: 300 A – Finish: Tinned Catalog Number Cross Section (kcmil) Conductor Width (in.) Conductor Thickness (in.) L (in.) A (in.) B (in.) C (in.) D (in.) HS1 (in.) HS2 (in.) Qty. IBSB70230 138.15 0.79 0.17 9.06 0.35 0.43 1.06 0.43 0.33 0.41 10 IBSB70330 138.15 0.79 0.17 12.99 0.35 0.43 1.06 0.43 0.33 0.41 10 IBSB70430 138.15 0.79 0.17 16.93 0.35 0.43 1.06 0.43 0.33 0.
PAGE 15
Flexible Conductors Insulated Braided Conductors Typical Application Current Rating: 630 A – Finish: Bare Catalog Number Cross Section (kcmil) Conductor Width (in.) Conductor Thickness (in.) L (in.) A (in.) B (in.) C (in.) D (in.) HS1 (in.) HS2 (in.) Qty. IBSBR240330 473.65 1.26 0.36 12.99 0.47 0.55 1.54 0.73 0.41 0.49 2 IBSBR240430 473.65 1.26 0.36 16.93 0.47 0.55 1.54 0.73 0.41 0.49 2 IBSBR240530 473.65 1.26 0.36 20.87 0.47 0.55 1.54 0.73 0.41 0.
PAGE 16
Flexible Conductors Insulated Braided Conductors IBS FLAT INSULATED BRAIDED CONDUCTOR FEATURES • • • • • • • • Suitable for all main electrical devices Resistant to vibration, improving reliability and performance Improves assembly flexibility and aesthetics Quick and easy installation No additional cutting, stripping, crimping and punching needed Integral palm without lugs or terminals reduces material and assembly weight Small wire diameter provides maximum flexibility RoHS compliant SPECIFICATIONS •
PAGE 17
Flexible Conductors Insulated Braided Conductors Maximum Ampacity Ratings Cross Section (mm²/kcmil) ÄT 30° C (A) ÄT 40° C (A) ÄT 45° C (A) ÄT 50° C (A) ÄT 55° C (A) ÄT 60° C (A) ÄT 70° C (A) 2 Bar Current Coefficient 3 Bar Current Coefficient 25/49.34 137 158 167 177 185 193 209 1.6 2 50/98.68 213 246 260 274 288 301 325 1.
PAGE 18
Flexible Conductors Insulated Braided Conductors Typical Application Current Rating: 400 A Catalog Number Cross Section Conductor Width (in.) Conductor Thickness (in.) Length L (in.) A (in.) Diameter Ø (in.) Hole Size HS (in.) Qty. IBS12033010 236.82 kcmil 0.94 0.39 12.99 0.47 1.06 0.41 2 IBS12043010 236.82 kcmil 0.94 0.39 16.93 0.47 1.06 0.41 2 IBS12053010 236.82 kcmil 0.94 0.39 20.87 0.47 1.06 0.41 2 IBS12063010 236.82 kcmil 0.94 0.39 24.80 0.47 1.06 0.
PAGE 19
Flexible Conductors Earth Ground Braids MBJ GROUNDING AND BONDING BRAID, TINNED COPPER EARTH GROUND BRAIDS FEATURES • • • • • • • • • • INDUSTRY STANDARDS UL Listed UL467 SPECIFICATIONS Complies With: IEC 60439.1, IEC 61439.1 • Complete range of earth/ground flexible connections from 6 100 mm² (11.84 - 197.35 kcmil) cross section and from 100 - 500 mm (3.937” - 19.
PAGE 20
Flexible Conductors Earth Ground Braids Catalog Number Intensity Thickness T (in.) Cross Section Length L (in.) Hole Size HS (in.) A (in.) B (in.) Unit Weight (lb.) Qty. MBJ3010010 180 A 0.079 59.20 kcmil 3.937 0.413 0.866 1.102 0.070 10 MBJ3015010 180 A 0.079 59.20 kcmil 5.906 0.413 0.866 1.102 0.103 10 MBJ3020010 180 A 0.079 59.20 kcmil 7.874 0.413 0.866 1.102 0.136 10 MBJ3025010 180 A 0.079 59.20 kcmil 9.843 0.413 0.866 1.102 0.
PAGE 21
Flexible Conductors Earth Ground Braids CPI GROUNDING AND BONDING BRAID, STAINLESS STEEL FEATURES • • • • • • • • • • • • INDUSTRY STANDARDS UL Listed, File No. 467 SPECIFICATIONS Complies With: IEC 60439.1, IEC 61439.1 • APPLICATION High-quality CPI stainless steel grounding and bonding braids can be installed in extremely corrosive environments, like offshore applications or coastal applications.
PAGE 22
Flexible Conductors Earth Ground Braids Catalog Number Cross Section Length L (in.) Hole Size HS (in.) A (in.) B (in.) C (in.) D (in.) Unit Weight (lb.) Qty. CPI70110012 138.15 kcmil 43.307 0.512 1.181 1.181 0.591 0.228 1.464 10 CPI7015012 138.15 kcmil 5.906 0.512 1.181 1.181 0.591 0.228 0.306 10 CPI7020012 138.15 kcmil 7.874 0.512 1.181 1.181 0.591 0.228 0.368 10 CPI7025012 138.15 kcmil 9.843 0.512 1.181 1.181 0.591 0.228 0.428 10 CPI7030012 138.
PAGE 23
Flexible Conductors Power Shunts PBC BRAIDED POWER SHUNT POWER SHUNTS / % & $ FEATURES Ideal for transformer-busduct link Undrilled palms can be customize by power press to fit customer specific designs Extra flexible power connection and good resistance to vibration • • • SPECIFICATIONS Wire Diameter: 0.006 (in.) Material: Copper • • FINISH Finish: Tinned • Catalog Number Cross Section .T 30 K .T 50 K Length L (in.) A (in.) B (in.) C (in.) 2 Bar Current Coefficient Qty.
PAGE 24
Flexible Conductors Flat Braids FLAT BRAIDS FTCB FLAT BRAID IN COIL, TINNED COPPER INDUSTRY STANDARDS UL Recognized SPECIFICATIONS • Material: Copper FINISH • Finish: Tinned Wire Diameter: 0.006 (in.) Catalog Number Nominal Current Cross Section Number of Wires Length (ft.) Thickness (in.) Width (in.) Unit Weight (lb.) Qty. FTCB153 30 A 5.92 kcmil 168 82 0.04 0.2 0.07 1 FTCB155 45 A 9.87 kcmil 288 82 0.04 0.3 0.11 1 FTCB158 65 A 15.78 kcmil 456 82 0.06 0.3 0.
PAGE 25
Flexible Conductors Flat Braids FRCB FLAT BRAID IN COIL, PLAIN COPPER FEATURES • • Braids in coil are mainly used for power distribution or earthing applications Non-magnetic material SPECIFICATIONS • Catalog Number Nominal Current Cross Section Number of Wires Wire Diameter (in.) Material: Copper Length (ft.) Thickness (in.) Width (in.) Unit Weight (lb.) Qty. FRCB153 30 A 5.92 kcmil 168 0.006 82 0.04 0.2 0.07 1 FRCB155 45 A 9.87 kcmil 288 0.006 82 0.04 0.3 0.
PAGE 26
Flexible Conductors Flat Braids FTCBI INSULATED FLAT BRAID IN COIL, TINNED COPPER FEATURES • • • Braids in coil are mainly used for power distribution or earthing applications Non-magnetic material Tinned finish provides a theft-deterrent appearance SPECIFICATIONS • Material: Copper, Polyvinylchloride FINISH • Finish: Tinned Catalog Number Nominal Current Cross Section Number of Wires Wire Diameter (in.) Length (in.) Thickness (in.) Width (in.) Unit Weight (lb.) Qty. FTCBI16 120 A 31.
PAGE 27
Flexible Conductors Round Braids ROUND BRAIDS RTCB ROUND BRAID IN COIL, TINNED COPPER INDUSTRY STANDARDS UL Recognized SPECIFICATIONS • Material: Copper FINISH • Catalog Number Nominal Current Cross Section Number of Wires Finish: Tinned Wire Diameter (in.) Length (ft.) Diameter (in.) Unit Weight (lb.) Qty. RTCB156 45 A 11.84 kcmil 352 0.006 82 0.157 0.13 1 RTCB158 65 A 15.78 kcmil 464 0.006 82 0.177 0.18 1 RTCB1510 75 A 19.74 kcmil 560 0.006 82 0.197 0.
PAGE 28
Flexible Conductors Round Braids RRCBI INSULATED ROUND BRAID IN COIL, PLAIN COPPER SPECIFICATIONS • Catalog Number Nominal Current Cross Section Number of Wires Material: Copper, Polyvinylchloride Wire Diameter (in.) Length (ft.) Diameter (in.) Unit Weight (lb.) Qty. RRCBI1510 75 A 19.74 kcmil 560 0.006 82 0.276 0.22 1 RRCBI1516 120 A 31.57 kcmil 900 0.006 82 0.315 0.35 1 Insulation Thickness (in.) Insulation Voltage Temperature Flammability Rating 0.
PAGE 29
Flexible Conductors Round Braids TTCE TUBULAR BRAID IN COIL, TINNED COPPER APPLICATION The primary use of tubular braid is to provide sensitive cables with an EMC/EMI screen to shield them against electromagnetic, electrostatic and radio frequency interference. Optimum screening performance is obtained using copper wire braid that can also be used for earth continuity purposes.
PAGE 30
Flexible Conductors Make Your Own Braided Connections CREATING BRAIDED CONNECTIONS MAKE YOUR OWN BRAIDED CONNECTIONS BD CRIMP AND DRILL TOOL • • • For crimping and drilling of braid terminals Use with FRCB Flat Braid in Coil, Plain Copper and FTCB Flat Braid in Coil, Tinned Copper Includes guide and drill bit Catalog Number Cross Section Drill Bit Diameter (mm) Screw Diameter Unit Weight (lb.) Qty. BD16 31.57 kcmil 6.5 M6 1.44 1 BD168 31.57 kcmil 8.5 M8 1.44 1 BD25 49.30 kcmil 11.
PAGE 31
Flexible Conductors Make Your Own Braided Connections PB LUG FOR FLAT BRAIDS SPECIFICATIONS • Material: Copper FINISH • Finish: Tinned 7 FEATURES • • • : Crimp to FTCB or FRCB braids to create custom flexible connections Crimped and drilled using BD Crimp and Drill Tool or Crimping Tool for Hydraulic Work Center RoHS compliant / Catalog Number Cross Section Width W (in.) Length L (in.) Thickness T (in.) Unit Weight (lb.) Qty. PALM16 31.57 kcmil 0.63 0.59 0.04 0.
PAGE 32
Flexible Conductors Make Your Own Braided Connections Notes EQUIPMENT PROTECTION Spec-01138 D PH 763.422.2211 • FAX 763.422.2600 • pentairprotect.