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CCA BUSBAR

Description:

Suzhou Huatong CCA busbar is the new composite material used for substituting the traditional copper busbar(Electrical Bus Bar, Aluminum Bus Bar, Electrical Busbars, Copper Buss Bar). Owning almost equal electronic conductivity and excellent tensile strength, CCA busbar offers economic and weight-saving choice.

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Detailed Information for HT Copper Clad Aluminum busbar which will save more Electrical Bus Bar, Aluminum Bus Bar, Electrical Busbars, Copper Buss Bar and other cost without reduction for quality and ampacity. Come to see more information for wholesale and other...

Technical Parameters

Model Description

Main Raw Materials

Copper: Standard Cathode Copper (Cu), copper content ≥ 99.95%
Aluminum: High Pure Aluminum (Al), aluminum content ≥ 99.85%

Technical parameters

Parameters of CCA busbar TLMY
Copper, Aluminum Volume Ratio 20:80
Copper, Aluminum Weight Ratio 45:55
Density(g/cm3) 3.94
DC Resistivity(Ωmm2/m) ≤0.02488
Tensile Strength(N/mm2) ≥110
Elongation Rate(%) ≥7
Interface Strength(mpa) >40

Bending Diameter

Nominal Size (a)
Bending Diameter (mm)
Nominal Size (a)
Bending Diameter (mm)
a≤3
a≤4
a≤5
12
16
20
a≤6
a≤8
a≤10
a≤12
24
32
40
48

Production Introduction

Production Brief Introduction

Suzhou Huatong CCA busbar is the new composite material used for substituting the traditional copper busbar. Owning almost equal electronic conductivity and excellent tensile strength, CCA busbar offers economic and weight-saving choice. Suzhou Huatong applies advanced solid-liquid machining processing technique, casts the aluminum liquid into the copper pipe then shapes under the pressure in the heating-cycle process, making the copper layer combining with aluminum layer firmly and permanently. Also, with its good flexibility and extensibility, the copper clad aluminum busbar is easy to shear, drill and bend. It is widely used in the electronic power equipment such as busway and high-low voltage switch cabinet and other different application environments.

The Characteristics of the Copper Clad Aluminum Bus Bar:

1. Excellent Electronic Conductivity: The volume proportion between copper and aluminum is 20:80, achieving 90% AC current-carrying capability of pure copper busbar.
2. Good Mechanical Property: with excellent tensile strength, flexibility and extensibility.
3. Low Weight: the density is only about 45% of pure copper so under the same volume, the cost will be greatly reduced.
4. Advanced Machining Processing Technique: Solid-Liquid machining processing technique to bond copper and aluminum permanently and firmly.
5. Good Extensity and Productivity: under special heat treatment, the product owns good plasticity and is well used in the process of bend, drill and shear.
6. Best Choice: Save copper material, low production cost and environment friendly.

Cross-Section Selection Reference

Current
Rating
(A)
Busduct
Current
Rating
(A)
Low-Voltage Switch Cabinet
Low-Voltage
High-Voltage
Horizontal Busbar
Breaker Main Circuit Vertical Busbar
Drawer Cabinet
Vertical Busbar
Intensive Type
Air Type
IP40
IP30
IP40
IP30
400
4×50
4×50

630


6×60
6×50

630
6×50
6×50

800

6×60
6×80
6×60

800
6×60
6×60
8×60
1000
6×100
6×80
6×60×2
6×100
6×100
1000
6×100
6×100
8×100
1250
6×120
6×100
6×80×2
6×120
6×120
1250
6×120
6×140
10×100
1600
10×100
8×100
8×80×2
10×100
6×140
1600
6×160
6×180
10×140
2000
10×80×2
10×100
10×80×2
8×80×2

2000
6×200
6×125×2
8×100×2
2500
10×100×2
10×125
10×80×3
10×80×2

2500
8×200
6×140×2
10×100×2
3150
10×100×3
10×100×2
10×100×3
10×100×2

3150
6×160×2
6×180×2
10×140×2
4000
10×120×3
10×120×2
10×100×4
10×100×3

4000
8×160×2

10×200×2
5000
10×120×4
10×120×3
10×100×6
10×120×4

5000
8×200×2

12×200×2
6300

10×120×4
10×100×8
10×100×6

6300
10×200×2

10×200×3






7200
12×200×2

10×200×4






Table of Current Carrying Capacity

Current Carrying Capacity under 35℃ environmental temperature and at different temperature rise

Product
Specification
Weight per
Meter (KG)
Current Carrying Capacity at Different
Temperature Rise
Product
Specification
Weight per
Meter (KG)
Current Carrying Capacity at Different
Temperature Rise
50K
60K
70K
50K
60K
70K
3×40
0.465
395
438
477
6×120
2.808
1580
1750
1906
4×40
0.617
514
569
620
8×120
3.730
1778
1969
2145
5×40
0.767
594
658
717
10×120
4.646
2018
2235
2435
6×40
0.915
665
736
820
12×120
5.575
2240
2481
2702
4×50
0.932
609
674
735
6×140
3.279
1708
1892
2061
5×50
0.964
721
799
870
8×140
4.359
1990
2203
2400
6×50
1.152
815
902
982
10×140
5.432
2258
2500
2725
8×50
1.522
949
1051
1145
12×140
6.518
2509
2779
3027
4×60
0.932
757
839
913
6×160
3.752
1980
2193
2390
5×60
1.160
856
948
1033
8×160
4.988
2238
2478
2700
6×60
1.388
883
978
1066
10×160
6.216
2545
2818
3070
8×60
1.837
1013
1123
1223
12×160
7.459
2827
3130
3410
10×60
2.280
1135
1257
1369
6×180
4.225
2093
2318
2525
4×80
1.247
909
1007
1097
8×180
5.620
2407
2666
2904
5×80
1.555
1010
1119
1219
10×180
7.007
2675
2962
3226
6×80
1.860
1175
1263
1376
12×180
8.389
2942
3258
3549
8×80
2.468
1339
1483
1530
6×200
4.698
2162
2395
2608
10×80
3.068
1410
1562
1702
8×200
6.250
2486
2754
3000
5×100
1.949
1195
1323
1442
10×200
7.796
2760
3056
3329
6×100
2.334
1344
1488
1621
12×200
9.335
3063
3393
3696
8×100
3.098
1523
1687
1838





10×100
3.856
1734
1920
2092





12×100
4.606
1922
2128
2319





Features of Huatong CCA BusBar

1. High interface strength
Huatong CCA busbar is solid-liquid combination of copper and aluminum. It is high temperature aluminum solution instantly melts inwall of copper pipe and diffuse copper and aluminum. These two procedures form the compound layer. The compound layer is thick, so the interface strength is high. When cut, pierced and bent, copper and aluminum could not delaminate and could bear the stress produces by heating expand and cooling contract in major range temperature difference. 2. Copper layer cross-section occupies 20% of entire section, which achieves highest performance price ratio
If copper layer is too thin, in order to achieve the required current-carrying capacity, big cross-section needs to be selected and this is not economic. If copper layer is too thick, the cost may rise sharply and it is difficult to process. When copper layer cross-section occupies 20% of entire section, electric conductivity and mechanical capacity could meet the demands of electronic control equipments and power distribution equipments. According to computer finite element analysis, this could achieve highest performance price ratio. 3. High electrical conductivity, completely replace Copper Buss Bar
Current-carrying capacity reaches 86% of T2(ETP) copper busbar. We could select one standard size bigger than copper buss bar when using cross-sections, and this does not influence the structures of electronic control equipments and power distribution equipments. We do not need to redesign and it is convenient to change. If the copper layer is thin, then the electrical conductivity is low. We need to select much bigger cross-sections than copper buss bar. Therefore, this influences the entire product structure and we need to redesign. This may bring troubles when selecting. 4. High hardness, meet dynamic stability demand
Copper clad Aluminum Bus Bar needs to meet dynamic stability demand in short circuit when using in electronic control equipments and power distribution equipments. Huatong CCA Busbar does not need to anneal after continuous rolling, truing and polishing and form directly. The hardness is high and could completely meet dynamic stability demand. 5. Interface strength constantly reinforces in use
Huatong CCA Busbar interface strength constantly reinforces in use, because the stress eliminates gradually and the strength of copper and aluminum diffusion increase gradually. 6. Interface could not cause electro corrosion
When solid and liquid combines, there is no factor which could lead to electrolyte between copper and aluminum, so the interface could not cause electro corrosion. Protest well the head faces to avoid moisture after cutting and piercing and then the interface could not cause electro corrosion too.

Six Advantages of Selecting Huatong CCA Busbar

In order to integrate the comprehensive utilization of national non-ferrous, Ministry of Industry and Information Technology of the People's Republic of China has listed copper clad Aluminum Bus Bar as one of the key products in "12th Five-Year" new materials development plan. High-performance copper clad aluminum bus bar produced by Suzhou Huatong conforms to the industrial policy of national new materials development and meets the selection requirements of complete equipments manufactures and will definitely substitute Copper Buss Bar. There are following six advantages of selecting Huatong CCA busbar(Electrical Bus Bar, Electrical Busbars, Copper Buss Bar):
1. Suzhou Huatong Compound Materials Co., Ltd is No.1 manufacturer on Copper & Aluminum compound material as industrial base around the world. The annual production capability on copper clad aluminum bus bar is 300000 tons, and we could produce more than 100 dimensions meeting the market request.
Suzhou Huatong was constructed in 2009, investing over USD 4 million as total capital and occupies 666666 square meters. The annual production capability on Copper & Aluminum compound material is 500000 tons. Among them, the initial capital is over USD 1.7 million and occupies 213333 square meters and the annual production capability on Copper & Aluminum compound material could reach 300000 tons. In September 2011,Suzhou Huatong fully put into production with automated production line and programmed control. We have developed more than 100 dimensions and we could produce according to the customers' specific request to meet the selection request of all enterprises.
2. Huatong copper clad Aluminum Bus Bar has passed the inspection of authoritative inspection organization and the identification of the industry, and obtained CECC certificate.
Suzhou Huatong's copper clad Aluminum Bus Bar passed the inspections from three authorized institutions including "National Center of Analysis and Testing for Non-ferrous Metals & Electronic Materials", "Machinery Industry Quality Supervision and Test Center for Electrical and Special Wire & Cable" and "China National Center for Quality Supervision and Test of Electrical Control and Distribution on Equipment (CCDT)". On 18 Dec 2007, Suzhou Huatong's copper clad Aluminum Bus Bar passed the identification of China Nonferrous Metals Industry Association. They evaluated the process engineering as "leading domestic level and international advanced level". On 16 Jun 2008, Suzhou Huatong's copper clad Aluminum Bus Bar passed the identification of China Electrical Equipment Industry Association. They evaluated the technical level as "this is the first time to use copper clad Aluminum Bus Bar as current-carrying conductor in low-voltage switchgears around the world and is international leading level". Suzhou Huatong's copper clad Aluminum Bus Bar gained CECC certificate which is the passport to foreign trade and market access. And Suzhou Huatong is the only enterprise which gained such CECC Certificate around China. National joint designed GCK2 low-voltage switchgear and C□LJ new type energy-saving busduct nominate Huatong copper clad Aluminum Bus Bar as current-carrying conductor. The product quality has reliable guarantee.
3. Suzhou Huatong drafts standard of machinery industry and attends to draft standard of power industry, who is the leader in copper & aluminum compound material industry.
China Electrical Equipment Industry Association issued CEEIA B220-2010 "Copper aluminum compound bus bars for electrical purposes" in March, 2010 which was drafted by Suzhou Huatong. According to the plan of Ministry of Industry and Information Technology of the People's Republic of China, Suzhou Huatong and Shanghai Electric Cable Research Institute drafted standard of machinery industry of "Copper clad Aluminum Bus Bar for electrical purposes" (also call copper & aluminum compound busbar) together. According to the plan of National Energy Bureau, Suzou Huatong attended to draft standard of power industry DL/T247-2012 "Copper clad Aluminum Bus Bar for equipments of transmission and commutation" (also call copper & aluminum compound busbar), which will be formally carried out on June 1st, 2012. Copper & aluminum compound busbar will be selected and used according to this standard.
4. When copper layer occupies 20% of entire volume, electric conductivity, mechanical capacity and process ability could meet the demands of complete sets of electrical equipments, which were verified by more than 200 projects over three years, without any risk.
According to computer finite element analysis, when copper layer cross-section occupies 20%, copper clad Aluminum Bus Bar could achieve highest performance price ratio and electric conductivity and mechanical capacity could meet the demands of electronic control equipments and power distribution equipments. 20% proportion is specified in both standards of machinery industry and power industry. If copper layer is too thin, conductor cross-section needs to be enlarged and the cabinet structure has to be changed, which are not economic. Huatong copper clad Aluminum Bus Bar has been used in more than 200 key projects such as Changchun FAW, Beijing Phoenix City etc. since 2008, which were reliable and running well, without any risk.
5. Huatong copper clad Aluminum Bus Bar adopts solid-liquid combination technique with high copper-aluminum interface strength, which could meet the processing request and could bear the stress produced by heating expansion and cooling contract in major range temperature difference and could use for long.
Huatong copper & aluminum compound busbar adopts the processing technique of "Solid-liquid Combination and Continuous Casting Direct Rolling", metallurgical bonding achieved. The high-temperature aluminum solution instantly melts inwall of copper pipe and diffuses copper and aluminum. These two procedures form the compound layer. The thickness of compound layer is more than 10μm, so the interface strength is high. The stress produced by heating expansion and cooling contract by 200℃ temperature difference could not destroy the interface combination after tests, but the interface combination strengthens because the interface stress eliminates and the diffusion enhances. In Shanghai Electric Cable Research Institute, 1000 times thermal cycling tests were done on Huatong copper & aluminum compound busbar. The temperature rise and resistivity proportion all met the requirements which fully proved that Huatong copper & aluminum compound busbar is reliable and could bear the thermal fatigue test.
6. Huatong copper clad Aluminum Bus Bar saves the copper with aluminum, which reduces the materials cost of electrical equipment enterprises and improves its market competitiveness. This product is light, easy to install and could further reduce the costs.
The density of Huatong copper clad Aluminum Bus Bar is 3.94g/cm³ and its current-carrying capacity reaches 86% of T2(ETP) copper busbar. In order to achieve the same current-carrying capacity requirement as copper busbar, one standard size bigger than copper busbars has to be selected. Compared with copper busbar, copper clad Aluminum Bus Bar could save more than 40% material costs of downstream enterprises and improve their market competitiveness with higher profit margins. It is easy to install, which could save both time and cost, further reducing the costs.
Suzhou Huatong established 39 branches in China and international department. We could meet the customer's demand in time and achieve a seamless connection with customers. Suzhou Huatong practices the marketing strategy of "unified retail price and unified sales model". Suzhou Huatong fully services the customers with high qualified products, satisfactory service and professional skills.
Suzhou Huatong wishes to cooperate with all enterprises and contribute our part to "Save Copper Resources, Benefit World & Environment"!
Note:
1. The current carrying capacity in this table is the data calculated under different environment according to JB /T10181-2000 and based on the measured data made by Shanghai Electric Cable Research Institute.(Copper layer section occupies 20% of entire section )
2. The data in this table is the AC current carrying capacity of busduct placed vertically and free of coating layers.
3. When the busbar is placed horizontally with the width ≤63mm, the data in the table shall be multiplied by 0.95; and when the width is >63mm, then multiply it by 0.92.
4. For DC current carrying capacity,When width is ≤50mm, same as AC current carrying capacity; when width is >50mm, DC current carrying capacity is 5-8% higher than AC current carrying capacity. The more is the width, the higher is the current carrying capacity.
5. For busbar with surface coated, the current carrying capacity is 5% higher when clad.
6. Data in this table is tested indoor. Outdoor factors such as wind velocity are not considered.

Features of New Type Energy-saving Busduct

1. With the cooling aluminum casing, it owns a beautiful appearance and has a stronger corrosion resistance by anodic oxidation, maintaining long term aesthetic appearance.
2. It uses CCA busbar as the conductor with high current carrying capability and has bigger cross-section size than standard size. According to the type test result, the temperature-rising is lower than the original copper busbar. What is more, the busduct applies non-magnetic aluminum shell which will not produce eddy current and hysteresis losses, and thus the overall carrying capacity has also been improved.
3. Low impedance, low pressure drop, low loss, safe and reliable operation.
The result to reduce the copper cross-section only increases the resistance, pressure drop and energy consumption, which not only cause potential security issue but also increase electricity charges. Moreover, manufacturers(CCA Busbar, Electrical Bus Bar, Electrical Busbars, Copper Buss Bar) have to take great risks. Applying the CCA busbar as conductor can achieve lower cost, low impedance, low pressure drop and low power consumption.
4. Apply the latest IOT technology to achieve intelligent monitoring to detect the connection temperature at lower cost, and the alarm signal can be sent to duty room to ensure the busduct's security operation.
5. It greatly improves the production efficiency due to the aluminum alloy shell, jumping the complicated procedure on bending, rolling, etc. The use of shell-free screw assembly will not only satisfy in the appearance, improve the protection level but also reduce the assembly time and increase the production efficiency.
6. Greatly reduce the cost on investment, and improve the market competitiveness. Also, increase the manufacturer's profit to achieve best return on investment.
7. There is strict investigation & inspection from the suppliers of raw material and insulating parts to ensure the quality, and to achieve low price by mass production.
8. Lower cost than ordinary copper cables; safer and easier to install than cable.
9. Compared to the copper busduct, this new type energy-saving busduct has the outstanding advantage on installment, particularly, one high location and big size on buscudt.
10.The revolutionary product can be applied on the wind power industry, which has a rapid development. The CCA busduct fully satisfies the requirement of wind power in the light weight, corrosion resistance, low temperature rising and anti-shock performance.

The Advantages of Producing New Type Energy-saving Busduct

Chinese policy of "Twelfth Five" economic development blueprint indicates the goal of establishing a resource-saving and environment-friendly society. Based on that, the new type energy-saving busduct launched by backbone organizations of electrical power distribution industry toward the policy direction will become the market mainstream. Basically speaking, there are six advantages of producing new type energy-saving busduct:

1. The new type energy-saving busduct as creative new product and the national industrial support item can apply as the energy-saving product of "Hi-tech Enterprise" with benefits in financing and long-term development.
The new type energy-saving busduct applies CCA busbar as current-carrying conductor, and selects the relative cross-section according to the standard of "IFC287-3-2". It significantly reduces the self-energy consumption of busway and can be applied as "Hi-tech Enterprise" energy-saving product which can obtain the state funds as key project. Also, it makes a positive contribution towards corporate financing, expanding the production and industrial expansion

2. The new type energy-saving busduct as the outcome of joint design can share national resource in the promotion process, owning huge market effects.
The new type energy-saving busduct launched by more than 50 backbone organizations including China Electrical Equipment Industrial Association and Tianjin Institution of Electric-Drive Design, Suzhou Huatong and Beijing Huabei Greatwall, can become the market mainstream by sharing the outcome of market promotion and advertisement. Meanwhile, if some manufacturers do not have pre-conditions for large scale production, Beijing Huabei Great Wall Corporation promises to support them with joint production at low price.

3. The new type energy-saving busduct with best return on investment and short production time cycle is the biggest opportunity for industry restructuring and product upgrade.
For a new product, generally speaking, millions of investment is required including multiple moulds to re-design such as shell and insulation part. According to the guidance policy to integrate resource, save cost and provide support, Suzhou Huatong unifies to develop the series of moulds, reduces the purchase cost by centralized way and estimates the proper inventory to improve the efficiency to meet the market demand. Therefore, the manufacturers can achieve zero inventory, greatly reduce the cost of investment and push the new product toward market in the shortest time, which create the potential market opportunity for multiple manufacturers.

4. There are three series of new type energy-saving busduct (intensive, air-based and wind-type) and total 23 specifications to fully meet the market demand.
The series of new type energy-saving busduct, including intensive, air-based and wind power type, achieve the international level in the areas of both design and parameters. Intensive busway ranges from 400A to 7200A with 13 specifications, while the maximum rated current is up to 7200A. Compared to the traditional busway, the major breakthrough is to increase to 6300A and 7200A from current levels. The air-based busway ranges from 400A to 2000A with 7 specifications while the wind power busway designs 5 specifications, ranging from 630A to 1600A. All products have passed the pattern test. These products can fully satisfy the market demand, and particularly, there is potential market opportunity in the wind power industry.

5. New type energy-saving busduct applies CCA busbar as current carrying conductor to reduce the cost and improve the market competitiveness.

The conductor part in the busway occupies up to 70% cost, and the main material is either copper or aluminum. If the copper which has the advantages of oxidation-resistance in the surface and low contact electrical resistance is used as the conductor, the cost is very high and the price trend is still increasing. Although the aluminum is much cheaper and weight-saving, it will cause the security issues due to its oxidation in the surface. The CCA busbar, which integrates the advantages of both copper and aluminum, while avoiding the weakness, will reduce at least 40% cost and ensure security level in the condition of meeting the GB7251.2 parameters requirement. This is the best choice for busway manufacturers to reduce the cost and enhance market competitiveness.

6. The new type energy-saving busduct uses aluminum alloy shell and screw-free assembly to improve production efficiency and reduce production cost.
New type energy-saving busduct applies aluminum alloy shell so the manufacturing can achieve easy installment by only placing the material and drilling to finish the whole assembly which save half workload compared with the traditional way. The choice of aluminum alloy shell is not only better in appearance, corrosion resistance, light weight, good performance on heat dissipation, no eddy current, current-carrying capability but also cost-saving and with high security level.
As No.1 CCA busbar manufacturer and industrial base, Suzhou Huatong provides all conductive materials used in pattern test of joint design. Beijing Huabei Great wall busway Co., Ltd, which provides busways in Beijing water cube and other 8 Olympic projects, is the famous enterprise focusing on the R&D on busway. It also provides all sample equipments for pattern test. In order to achieve big scale production, Suzhou Huatong and Beijing Huabei Great Wall jointly design the all component parts for new type energy-saving busduct, achieving unified development, unified purchase, unified distribution, unified way of technology transfer, providing technical system training and assisting the busway manufacturers in the areas of both sample and application of CCC certification.
In order to push the market promotion and rapid application of CCA Busbar, Suzhou Huatong will comprehensively cooperate with the majority of busway manufactures to achieve the mission of saving the copper resource and benefiting the world and environment.

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