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Busbar Coating Materials

Epoxy coating powder for low and medium voltage busbar and switchgear applications.

For AIS and GIS substations up to 38kV

Epoxy Coating Powders for Busbar Coating, Switchgear Equipment and High Voltage Fuses

Busbars, material types and the need for busbar insulation

Busbars are metal bars that conducts a substantial current of electricity within a switchboard, distribution board, substation, battery bank or other electrical apparatus. Busbars are most commonly made of copper, aluminum or brass. The biggest disadvantages of copper over aluminum or brass are density and relative cost. For a given current and temperature rise, an aluminium conductor would be lighter and cheaper, even though its cross-section would be larger. Despite this and many attempts to replace it, copper still remains the predominant material choice for busbars.

Busbars are typically split into three families:

Low & medium voltage busbars are coated with an epoxy coating powder to provide electrical insulation and to reduce air spacing between busbars. This allows for safer, more efficient designs of switchgear equipment. CAPLINQ has partnered with SolEpoxy Inc., to develop, market and distribute epoxy coating powders for power distribution. SolEpoxy epoxy coating powders for busbars reduce the minimum busbar spacing requirement and are equally well suited for aluminum and copper busbars.

SolEpoxy provides Industry Proven Epoxy Coating Powders for Busbars and other High Voltage Applications

For many years SolEpoxy has supplied a range of epoxy coating powders developed for medium voltage (600V – 38,000V) bus bar and switch gear applications. SolEpoxy is one of the few epoxy coating powder manufacturers with "switch panel-rated" material, meaning that their epoxy coating powders are qualified for use in Power Distribution Switch Boards. Given the critical nature of the application, the time and costs involved to pass UL-certification, major Power Management Companies reply on SolEpoxy and their family of UL-listed epoxy coating powders. All the products offered by SolEpoxy for busbar applications are UL-listed.

SolEpoxy offer epoxy coating powders that are specifically tailored for busbars, switchgear equipment, high voltage applications and other power distribution applications. Key material properties of SolEpoxy's epoxy coating powders are:

  • Powders that build to 5mm thickness for medium voltage
  • Flexible powders for compact, low voltage distribution
  • Smooth, uniform thickness for easy close-stack assembly
  • Superior adhesion to copper or aluminum busbar
  • Rapid build-rate improves cycles time and productivity
  • Productivity and technical support
  • Fine grinds to make-up particle size distribution
  • Fluidizing aid to ensure uniform coverage
  • Fluid Bed analysis to optimize quality, productivity & bed life
  • Economical formulations enable flexible, one-powder, low & medium voltage manufacturing solutions

SolEpoxy Epoxy Coating Powder Selector Guide for Low- and Medium-Voltage Busbars

The table below is designed to highlight the best product offerings for each unique application.

Epoxy Coating Powders for Busbars and Switchgear Equipment
General Specific Application SolEpoxy® Epoxy Coating Powder
DK15-0907 Red orDK15-0606 Tan DK19 Red DK15-0463 Black DK52 Gray
Top of Page
Power Distribution Electrical Housings, Bus Bars and Switchgear Bus Bars Low Voltage (up to 600V)
Bus Bars Medium Voltage (up to 38kV)11 Needs >2.8mm thick non-sag build
Switch Gear
High Voltage Fuses
Unique Feature The "One Powder Solution" for LV & MV Busbars Incredible Bed Life Stability & Outdoor Applications Highest Productivity & Fastest Build Rate Extremely Flexible & High Dielectric Strength
Product Properties
Highest service temperatures (High RTI rating) 130°C 105°C 130°C 105°C
Most stable fluidized bedlife
Best moisture and humidity resistance
Highest "non-sag" thickness in powder building >4mm (150mil) >5mm (200mil)
Highest powder build rate ~150 micron/sec ~175 micron/sec
Highest dielectric insulation properties 46 kv/mm 41 kv/mm 44 kv/mm 55 kv/mm
Highest arc resistance 135 secons 168 seconds 130 seconds 55 kv/mm
Extremely Flexible
UL94 Listing and Recognition UL94 V-0 UL94 V-0 UL94 V-0 UL94 V-0
Used on production parts for > 15 years
Powder colour █ Red and█ Tan █ Red █ Black █ Gray
RoHS Compliant
REACH Compliant
Application Method
Fluidized Bed ■■■■ ■■■■ ■■■■ ■■■■
Electrostatic Spray Gun □□□□ □□□□ ■■■■FG Version ■■□□

View our presentation on epoxy coating powders for busbar coating

Busbar Epoxy Coating Powder Presentation Transcript

Slide 1

SolEpoxy DK15-Series Epoxy Coating Powder for Low & Medium Voltage Busbars, Switchgear & Power Distribution. Footer: Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com

Slide 2

Epoxy Coating Powders for Power Distribution Busbars, switchgear, high voltage fuses. One of the few American coating powder suppliers with “switch panel – rated” material, SolEpoxy supports many of the world’s top electrical equipment manufacturers.

Key Application Requirements:

  • Powders that build to 5mm thickness for medium voltage
  • Flexible powders for compact, low voltage distribution
  • Smooth, uniform thickness for easy close-stack assembly
  • Superior adhesion to copper or aluminum busbar
  • Rapid build-rate improves cycles time and productivity
  • Productivity and technical support including
  • Fine grinds to make-up particle size distribution
  • Fluidizing aid to ensure uniform coverage
  • Fluid Bed analysis to optimize quality, productivity & bed life
  • Economical formulations enable flexible, one-powder, low & medium voltage manufacturing solutions

Busbars are coated to provide insulation SolEpoxy Coating Powders Busbars are copper or aluminium bars that conducts a substantial current of electricity within a switchboard, distribution board, substation, battery bank or other electrical apparatus.

Epoxy Coating PowerApplication Method 3 Electrostatic Coating … industry standard for busbar coatings, with beds using as much as 3,000kg at a time. Also used in passive electronics. … Electrostatic spraying can adhere to a wide area from a single spray direction. Porous Membrane Air Supply Original Level before Fluidizing Preheat part to 175°C (350°F) Lower part into powder air for 3-5 seconds Spray Booth Conveyor Ground Object Small Particle Atomization DK50-1000 Black Automotive Housings, Yokes & Thin Film Applications Fluidized Bed Video Link:goo.gl/J77saQ Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com BusbarMaterials Copper vs. Aluminum 4 Property Copper Aluminum Minimum Busbar Spacing, mm* *Without Epoxy Coating 50 100 Maximum Current per Busbar, A 4500 3220 Melting Point, °C 1083 660 Tensile Strength, N/mm2 225 55 Density, g/cc 8.91 2.7 Relative Cost $$$$ $ The only disadvantages of copper are density and relative cost. For a given current and temperature rise, an aluminium conductor would be lighter and cheaper, even though its cross-section would be larger. Despite this and many attempts to replace it, copper still remains the predominant material choice for busbars. SolEpoxy epoxy coating powders for busbars reduce the minimum busbar spacing requirement and are equally well suited for aluminum and copper busbars. Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com BusbarInsulation Why do we need it and how can we do it? … a tried and proven method first used by companies starting to coat busbars 5 Low & medium voltage busbars are coated to provide electrical insulation and to reduce air spacing between busbars. This can be done in two ways. Plastic (Mylar (PET), Kapton, Nomex) Sheathing is used to cover busbars Using Plastic Sheathing … used by companies that can understand the production and performance benefits. Use Insulating Epoxy Coating Powder Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com Busbars:EpoxyCoatingvs.PlasticSheathing Epoxy Coating Powder is better because… Plastic costs ~$9.00/ft ($30/m) Epoxy costs ~$3.00/ft ($10/m) It costs less than plastic per linear foot/meter Epoxy has higher operating temperature Epoxy can be used on Odd Shaped Parts … making it very versatile Plastic up to 200°F (93°C) Epoxy up to 350°F (180°C) 6 Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com Busbars:EpoxyCoatingvs.PlasticSheathing Property Epoxy Shrinktube Plastic Operating Temperature 180°C + (>350°F) 100°C (200°F) UL Class B (130°C) Yes No Solvent Resistance Excellent Good Dielectric Strength, V/mil ~ 1,000 ~ 600 Corona/Electrical Properties Excellent Low For Low Voltages (600V) Yes Yes High Voltages (up to 38 kV) Yes No Outdoor Use Yes Yes Weatherability Excellent Excellent Cost per Meter (per linear foot) ~ $10/m (~$3/ft) ~ $30/m (~$9/ft) Chemical Resistance Excellent Good Additionally, plastic usually does not react in the flexibilizers (ethylene glycol for example) and that comes out with heat over time. This in turn embrittles the plastic and it cracks (think about vinyl dashboards in cars in the 1960’s.) Summary of Advantages 7 Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com ArcResistance ASTM-D495 Test range Mean time of arc resistance (in Sec) Assigned PLC 420 and longer 0 360 through 419 1 300 through 359 2 240 through 299 3 180 through 239 4 120 through 179 5 60 through 119 6 Less than 60 7 The number of seconds that a material resists the formation of a surface-conducting path when subjected to an intermittently occurring arc of high voltage, low current characteristics. The results of testing the nominal 3mm thickness are considered representative of the material's performance in any thickness. Arc-resistant switchgear protects operating & maintenance personnel from dangerous arcing faults by redirecting or channeling the arc energy out the top of the switchgear. 8 Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com Price EpoxyCoatingPowdersforBusbarsandFuses Relative product positioning Performance High Voltage Fuses/ Low Functional Coating Provides a minimum dielectric strength as well as physical protection in a very thin layer. Axial fuses up to 250V. Requires RTI of 105°C Technology Gap? Class H? Thermally Conductive? Higher Voltage? DK15-0463 (RTI 130°C) Medium Voltage Busbar and Switchgear Medium Voltage (600V – 38,000V) Power Applications. RTI between 130°C of 155°C. Epoxy Coating Color Epoxy Coating Color DK15-2000E* *Sold as DK52 Gray DK15-0907 Red DK15-0606 Tan DK50-1000* *Sold as DK50 Black Low Voltage Busbar & Switchgear Busbar and Switchgear applications up to 600V RTI between 105°C to 130°C. 9 DK19 Red (RTI 105°C) Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com EpoxyCoatingPowdersforPowerApplications 10 Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com DK15-0463 Black Great Humidity Resistance for Outdoor Applications DK19 Red Higher Powder Thickness Build-up Fewer Process Dips Satin Black Matte Finish – RTI of 105°C Industry Standard Medium Voltage (600V – 38,000V) Power Applications Fine-Grind Version PowerDistributionEpoxyPowderPortfolio DK50-1000 Black* *Formerly DK50 DK19 Red FG Fine Grind for Better Beds DK15-0463FG Black Fine Grind Version for better beds Highly Flexible Coating Powder Still Meets RTI value of 105°C DK15-2000E Grey* Leaded Fuses and Applications Requiring Toughness and Flexibility *Formerly DK52 Grey DK15-0907 Red The “One Powder” solution for voltage bus RTI Capable at 150°C For Low & Medium Voltage Busbars Long Gel Version DK19 Red LG Long Gel Time Version for Improved Flow Out and Reduced Pinholes 11 & DK15-0606 Tan low and medium bars. SolEpoxy DK15-0907 Red & DK15-0606 Tan The “One Powder Solution” Epoxy Coating Powder for Low and Medium Voltage Busbars (up to 38kV) Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com ProductAdvantagesDK15-0907Red/DK15-0606Tan Thick, Uniform Coating Applies a thick, uniform coating in excess of 5mm – key to the insulation of medium voltage bus bars Productivity Support Provides productivity support and bed-life extenders 13 Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com Copper & Aluminum Great adhesion to copper and aluminum busbar applications Smooth Finish Smooth finish – no sagging – especially important for medium voltage coating applications ProductAdvantagesDK15-0907Red/DK15-0606Tan 14 DK15-0907 on Copper & Aluminum Bars DK15-0606 Tan on Aluminum Bars Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com ProductAdvantageDK15-0907Red&DK15-0606Tan 0 2 4 6 8 High Build Rate Higher productivity yields, by building faster with fewer dips Higher Arc Resistance Better protection for operating and maintenance personnel from dangerous arcing faults. Build Rate @ 180°C, in mils/sec 0 20 40 60 80 100 120 140 160 180 DK15-0463 DK15-0907 DK19 Arc Resistance in seconds & DK15-0606 Tan 15 Build Rate @ 180°C, in micron/sec 200 150 100 50 0 Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com PerformanceAdvantageSolEpoxyDK15-0907 Productivity Fine grinds and fluidizing agents to extend bed life and productivity One Powder Solution DK15-0907 Red & DK15-0606 Tan are both “one-powder solution” that works on both low voltage and medium voltage busbars 0 10000 20000 30000 40000 Voltage Low Voltage (up to 600V) Medium Voltage (up to 38,000V) 16 Niche Application SolEpoxy Products Flexible, Electrostatically sprayable, thin film,epoxy coating powder for motor housings or high voltage fuses Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com SolEpoxyDK19Red Application Use and Performance Advantage 18 Applies a thick, uniform coating in excess of 5mm – key to the insulation of medium voltage bus bars Nothing beats DK19 for thick, non-sag builds High Build Rate High Arc Resistance More than 160 secs means better protection for operating and maintenance personnel from dangerous arcing faults. DK19 Red has the fastest build rate of 7mil/s @ 180°C. This translates into fewer dips and higher production yield. 0 2 4 6 8 DK15-0463 DK15-0907 DK19 0 20 40 60 80 100 120 140 160 180 DK15-0463 DK15-0907 DK19 & DK15-0606 Tan & DK15-0606 Tan Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com PerformanceAdvantageofSolEpoxyDK15-2000E* *Formerly DK52 Gray 19 DK15-2000E is UL-listed with a V-0 flammability and RTI rating of 105°C UL Listed Moisture Resistant High Dielectric Strength Has the highest dielectric strength of all our epoxy coating powders DK15-2000E Gray has excellent moisture resistance, and the best hydrolytic stability of all our products. 0 200 400 600 800 1000 1200 1400 DK19 DK15-0907 DK15-2000E Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com NicheApplicationsofSolEpoxyDK15-2000E* *Formerly DK52 Gray 20 Highly flexible providing maximum design efficiency of low voltage busbar designs Flexible Low-Voltage Busbar Coating Copper lightning arrestors Coat High Voltage Leaded Axial Fuses Along with a 105°C RTI rating, it is still flexible enough to coat both the fuse & the axial leads The ribs in the epic are a silicone boot that goes over the metal oxide varistors. Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com DK50-1000 Blackthinlayerapplication 21 Thin Layer Application Can be applied as thin as 2-mil using Electrostatic Spray Application DK50-1000 Black can be applied by applied using Electrostatic Spray. Electrostatic spraying can adhere to a wide area from a single spray direction, so there is no need to spray from many different directions. Motor Housings and thin-film applications

Compare Busbar Epoxy Coating Powders

Epoxy Coating Powders vary widely in their composition and application. Epoxy Coating Powders can be used for coil windings, toroids and powder cores, capacitors, resistors and varistors, busbars and switchgears or other applications that require electrical insulation. Use our Epoxy Coating Powder selector tool to help you choose the right epoxy coating powder for your application.

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