Steps for busbar sizing calculator:

1. For copper busbar: Iccc = 1.2*busbar width*bus bar thickness.
2. For silver steel busbar: Iccc = 1.6*busbar width*bus bar thickness.
3. For aluminum busbar: Iccc = 0.8*busbar width*bus bar thickness.
4. For iron busbar: Iccc = 0.6*busbar width*bus bar thickness.
5. For galvanized steel busbar:

To  allow increased tolerances for the thickness of the powder to be applied. Allow for the largest reasonable bend radius. This will help the powder flow more smoothly without build-up or thinning.

Design Considerations

Storm Power Components specializes in applying insulation at extreme thicknesses, up to 100 mil or more.

Epoxy powder insulation is significantly denser than other spray-on applications, and unlike the powder coating often used for aesthetic purposes, the total application thickness is typically greater than 10 mils.

This capability allows for medium and high voltage applications up to 35,000 volts, allowing for drastic changes in the design of your medium and high voltage switchgear. Moreover, the versatility of the process and insulation allows it to be used in areas that are not normally considered.

OEMs utilizing this insulation technology can produce more competitive products – achieving a leg up on their competition. When designing a busbar to be epoxy powder-coated or evaluating a manufacturer, make sure to:

1. When possible utilize full round edge bar profiles:

The contoured edge of this profile allows for better adhesion of the epoxy powder as it “wraps” the edge of the busbar.

2. Avoid small cut-outs or holes in the conductor:

Small profile cut-outs or holes are difficult to edge condition and could create weak areas prone to premature failure.

3. Carefully consider design dimensions and labels:

Always dimension designs to the substrate, not the powder surface. Carefully consider masking location tolerances.

Extremely tight tolerances on masking locations are difficult and expensive to achieve. Consider allowing masking tolerances of +/- .0625.

4. Expertise applying extraordinary thicknesses:

Choose a provider who can perform a variety of thicknesses.

If the provider isn’t an expert in the process, you may end up with

• Non-conforming components,
• Holes excessively filled,
• Poor edge conditions, and
• Premature failures.

Epoxy powder insulation allows for drastic changes in the design of your medium- and high voltage switchgear OEMs using epoxy powder insulation can produce more competitive products – achieving a leg up on their competition

5. Multi-process capability:

Can the manufacturer execute both fluidized bed and electrostatic spray methods? Does the manufacturer control the full process, from cutting, bending, and punching, to electroplating, and finally, insulating? This helps ensure clean execution of all steps in the process and a better finished product with the shortest possible lead times.