Customized Transformer Copper Busbar by China Suppliers - High-Quality Factory Direct Solutions
The Description for Transformer Copper Busbar
Transformer copper busbars (also known as copper busbars) are the core conductive components for collecting and distributing current at the high and low voltage sides of a power transformer.
They are used for the safe transmission and distribution of large currents. Compared to cables, they have significant advantages such as high current carrying capacity, good heat dissipation, high mechanical strength, reliable connections, and low long-term operating losses.
They are widely applicable to oil-immersed, dry-type, box-type transformers, as well as distribution cabinets in power distribution rooms.
Technical Specification for Transformer Copper Busbar
| Specific (W × T mm) | Cross-sectional Area (mm²) | Current Capacity (A) | Matching Transformer Capacity |
|---|---|---|---|
| 50×5 | 250 | 750 | 315–630 kVA（Low-voltage side） |
| 60×6 | 360 | 990 | 630–1250 kVA |
| 80×8 | 640 | 1480 | 1250–2000 kVA |
| 100×10 | 1000 | 2000 | 2000–3150 kVA |
| (Dual) 125×8 | 2000 | 3400 | 3150–5000 kVA（Low Voltage High Current） |
Customization Options for Transformer Copper Busbar
Non-standard dimensions (width 10–120 mm, thickness 3–12 mm), length (3/6m standard, zero-cut / custom length)
Special processing: bending, drilling, slotting, T-type welding, silver plating / nickel plating
Insulation treatment: segmented bushing, overall spraying
Product Advantages
Low-loss energy-saving: High-purity T2 copper, with excellent conductivity, reduces transformer temperature rise and power loss
Stable structure: Flat structure dissipates heat quickly, resistant to electric force and vibration, flat connection surface, low and stable contact resistance
Compliance and safety: Full batch material testing, in line with national standards, factory provides material report and size inspection sheet
One-stop customization: Supports drawing processing, shortens on-site installation cycle
Selection Suggestions
Based on the rated current of the transformer, the recommended current density is 2.5–3.5 A/mm² (for natural cooling), and a 10%–20% overload margin should be reserved.
The width/thickness ratio should be controlled within 10 to avoid the influence of the current skin effect.
For outdoor or humid environments, tin plating or insulation coating treatment is preferred.
For high current, parallel connection of double copper bars can be adopted.
Application Scenarios for Copper Busbar
Oil-immersed power transformers — High and low voltage lead-out terminals
Dry-type transformers — Low-voltage busbars, busbars within cabinets
Internal connections of box-type substations (American style / European style)
Distribution rooms — Main busbars of distribution cabinets, capacitor cabinets
Package & Shipment
Frequently Asked Questions (FAQ)
What is a transformer copper busbar and what is its main function?
A transformer copper busbar is a core conductive component used to collect and distribute current at the high and low voltage sides of a power transformer. Its main function is the safe transmission and distribution of large currents, offering advantages such as high current carrying capacity, excellent heat dissipation, high mechanical strength, and low operating losses compared to conventional cables.
What copper material is used, and does it meet international standards?
Our transformer copper busbars are made from high-purity T2 copper, which provides excellent electrical conductivity and helps reduce transformer temperature rise and power loss. All products undergo full batch material testing and comply with national standards. Each shipment comes with a material report and dimensional inspection sheet.
What customization options are available for copper busbars?
We support a wide range of customization options including non-standard dimensions (width 10–120 mm, thickness 3–12 mm), custom lengths (standard 3m/6m or zero-cut to any length), special processing such as bending, drilling, slotting, T-type welding, silver plating, and nickel plating, as well as insulation treatments including segmented bushing and overall spraying.
How do I select the right copper busbar size for my transformer?
Selection should be based on the rated current of the transformer. The recommended current density is 2.5–3.5 A/mm² for natural cooling conditions, and a 10%–20% overload margin should be reserved. The width-to-thickness ratio should be kept within 10 to minimize the skin effect. For high-current applications, a parallel double copper bar configuration is recommended.
Which types of transformers and equipment are these copper busbars compatible with?
Our copper busbars are compatible with a wide range of equipment including oil-immersed power transformers, dry-type transformers, box-type substations (both American and European styles), as well as distribution cabinets and capacitor cabinets in power distribution rooms.
What surface treatment is recommended for outdoor or humid environments?
For installations in outdoor or humid environments, tin plating or insulation coating treatment is strongly recommended. These surface treatments provide enhanced corrosion resistance and long-term protection, ensuring reliable performance and extended service life under challenging environmental conditions.