Functional epoxy coating powders for busbar, switchgear and power distribution

SolEpoxy DK15-SeriesEpoxy Coating Powder for Low & Medium Voltage Busbars, Switchgear & Power Distribution

Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com2

Epoxy Coating Powders for Power DistributionBusbars, 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 voltageFlexible powders for compact, low voltage distributionSmooth, uniform thickness for easy close-stack assemblySuperior adhesion to copper or aluminum busbarRapid build-rate improves cycles time and productivityProductivity and technical support including

Fine grinds to make-up particle size distributionFluidizing aid to ensure uniform coverageFluid 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 PowdersBusbars 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 Power Application Method

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 BlackAutomotive Housings, Yokes & Thin Film

Applications

Fluidized BedVideo Link:goo.gl/J77saQ

http://goo.gl/J77saQ


Busbar MaterialsCopper vs. Aluminum

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.


Busbar InsulationWhy do we need it and how can we do it?

… a tried and proven method first used by companies starting to coat busbars

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


Busbars: Epoxy Coating vs. Plastic SheathingEpoxy 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 versatilePlastic up to 200°F (93°C)Epoxy up to 350°F (180°C)

Epoxy Insulating Coating Powders • Durable Dielectric Molding Compounds • Optoelectronic Compounds solepoxy.com

Busbars: Epoxy Coating vs. Plastic Sheathing

Property Epoxy Shrinktube PlasticOperating Temperature 180°C + (>350°F) 100°C (200°F)UL Class B (130°C) Yes NoSolvent Resistance Excellent GoodDielectric Strength, V/mil ~ 1,000 ~ 600Corona/Electrical Properties Excellent LowFor Low Voltages (600V) Yes YesHigh Voltages (up to 38 kV) Yes NoOutdoor Use Yes YesWeatherability Excellent ExcellentCost 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


Arc Resistance

ASTM-D495 Test rangeMean 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.


Price

Epoxy Coating Powders for Busbars and FusesRelative product positioning

Performance

High Voltage Fuses/ Low Functional CoatingProvides 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 SwitchgearMedium 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 RedDK15-0606 Tan

DK50-1000**Sold as DK50 Black

Low Voltage Busbar & SwitchgearBusbar and Switchgear applications up to 600V

RTI between 105°C to 130°C.

DK19 Red(RTI 105°C)


Epoxy Coating Powders for Power Applications


DK15-0463 BlackGreat Humidity Resistance for

Outdoor Applications

DK19 RedHigher Powder Thickness Build-up

Fewer Process Dips

Satin Black Matte Finish – RTI of 105°C

Industry StandardMedium Voltage (600V – 38,000V) Power Applications Fine-Grind Version

Power Distribution Epoxy Powder Portfolio

DK50-1000 Black**Formerly DK50

DK19 Red FGFine Grind for Better Beds

DK15-0463FG BlackFine Grind Version for better beds

Highly Flexible Coating PowderStill 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°CFor Low & Medium Voltage Busbars

Long Gel Version

DK19 Red LGLong Gel Time Version for Improved

Flow Out and Reduced Pinholes

& DK15-0606 Tan low and medium bars.

SolEpoxy DK15-0907 Red & DK15-0606 TanThe “One Powder Solution” Epoxy Coating Powder for Low and Medium Voltage Busbars (up to 38kV)


Product Advantages DK15-0907 Red / DK15-0606 Tan

Thick, Uniform CoatingApplies a thick, uniform coating in excess of

5mm – key to the insulation of medium voltage bus bars

Productivity SupportProvides productivity support and bed-life

extenders


Copper & AluminumGreat adhesion to copper and aluminum

busbar applications

Smooth FinishSmooth finish – no sagging – especially important

for medium voltage coating applications

Product Advantages DK15-0907 Red / DK15-0606 Tan

DK15-0907 onCopper & Aluminum Bars

DK15-0606 Tan on Aluminum Bars


Product Advantage DK15-0907 Red & DK15-0606 Tan

Com-petitor

DK15-0463

DK15-0907

0

2

4

6

8

High Build RateHigher productivity yields, by building

faster with fewer dips

Higher Arc ResistanceBetter protection for operating and maintenance

personnel from dangerous arcing faults.

Build Rate @ 180°C, in mils/sec

DK15-0463 DK15-0907 DK190

20406080

100120

140160180

Arc Resistance in seconds

& DK15-0606 Tan& DK15-0606 Ta

n

Build Rate @ 180°C, in micron/sec

200

150

100

50

0


Performance Advantage SolEpoxy DK15-0907

ProductivityFine grinds and fluidizing agents to extend

bed life and productivity

One Powder SolutionDK15-0907 Red & DK15-0606 Tan are both

“one-powder solution” that works on both low voltage and medium voltage busbars

0

10000

20000

30000

40000

Volta

geLow Voltage(up to 600V)

Medium Voltage(up to 38,000V)

Niche Application SolEpoxy ProductsFlexible, Electrostatically sprayable, thin film,epoxy coating powder for motor housings or high voltage fuses


SolEpoxy DK19 RedApplication Use and Performance Advantage

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.

DK15-0463 DK15-0907 DK190

2

4

6

8

DK15-0463 DK15-0907 DK190

20

40

60

80

100

120

140

160

180

& DK15-0606 Tan & DK15-0606 Tan


Performance Advantage of SolEpoxy DK15-2000E**Formerly DK52 Gray

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.

DK19 DK15-0907 DK15-2000E0

200

400

600

800

1000

1200

1400


Niche Applications of SolEpoxy DK15-2000E**Formerly DK52 Gray

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.


DK50-1000 Black thin layer application

Thin Layer ApplicationCan 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

Date post:	19-Nov-2014
Category:	Technology
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