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Busbar Repair
(A Revolution)

IFM is not only capable of blueprint-driven builds, but developing new processes. One of our customers specializes in induction heating equipment. The copper cooling tubes (which are conventionally soldered on) have a nasty habit of coming loose; causing not only a loss of cooling but sometimes dangerous electrical arcing. This is an extreme problem on a bus that carries 10,000 to 100,000 amps.

IFM has developed a proprietary process (patent pending) for effectively TIG welding the .049" wall copper tubes to the .250" thick copper of the bus, with copper fill instead of solder. The solders typically used in applications such as this have an average tensile strength around 15,000 psi as well as fairly low density. The copper filler used in our process, however, has an average tensile strength of about 90,000 psi. This 12 step process is available with tube replacement (refurbishing), and results in:

Over 100% more contact between the cooling tubes and the bus (see figures 1 and 2 below) -- improved thermally conductive area = more efficient use of coolant and better cooling.
The strength of a welded copper joint holding the tubes to the bus -- no more downtime due to costly reattachments = better value, less maintenance.
Approximately one pound of copper added to the bus per five feet of cooling tube -- a significant increase in mass, through which heat dissipates naturally = better cooling.
Better cooling = less resistance = LESS ELECTRICITY USED.
Our pricing on this process is comparable to soldering, and our work is covered by a Lifetime Warranty!
 
 

(FAQ) Frequently Asked Questions
on our busbar welding process.


Pre-cleaning photo of a welded bus

Our 12 step refurbishing process with tube replacement

1. All markings and locating points on the busbar are noted for later replacement.
2.

The busbar is sandblasted to remove insulative varnish and corrosion.
3. New cooling tubes are fabricated from grade K (hard) copper tubing with a rated burst pressure of 904 psi at 200 deg. Fahrenheit. All joints are TIG welded.
4. Each circuit of new tube is completed and air pressure tested to 150 psi before installation.
5. The old cooling tubes are heated and removed. Residual solder is removed and the busbar is prepared for welding.
6. Thorough inspection of the busbar for notable bends and deformations, which are corrected.
7. Each cooling tube is clamped and TIG welded to the busbar using our proprietary process.
8. Cooling tubes are flushed, water flow tested and water pressure tested..
9. Cooling tubes receive a second air pressure test to 150 psi.
10. The busbar is sandblasted again to prepare for coating.
11. Electrical connections are cleaned, polished and taped off.
12. The busbar is coated with red insulative varnish meeting Class F requirements, dielectric strength 2,100 VPM and all original markings are replaced.
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16680 Industrial, Roseville, MI 48066
Phone: (586) 776-8311 Fax: (586) 776-8331

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