POWERING WORLDWIDE

DC RAIL NETWORKS
AWARD WINNING MAGNETIC ACTUATOR TECHNOLOGY
AT THE HEART OF GLOBAL RAILWAYS

Key benefits

Low cost Proven Customised Award winning

of ownership design solutions magnetic actuator
technology

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 Description

PowerBond™ DC Switchgear is new range of DC switchgear

products intended for transit applications. Line (Track Feeder)
Switchgear includes a Busbar Selector which permits the
contact line to be connected to a positive or a negative busbar
via the circuit breaker.

The contact line can therefore be bonded to a safe potential using the same
switchgear panel as is normally used to energise it. All current making and breaking
is performed by the Circuit Breaker.

All maintainable elements are included on the withdrawable circuit breaker truck,
including the motorised busbar selector and the current/voltage transducers.

Figure Busbar Circuit Description

Selector Breaker
A Positive Closed PowerBond™ is providing power to the contact line. The unit acts as
a Line (Track Feeder) Circuit Breaker, with all protection
(e.g. Impedance, Undervoltage & Direct Acting) operational
B Positive Open PowerBond™ is not supplying power to the contact line but is ready
to do so. The Busbar Selector may be moved to the Negative position.
C Negative Open PowerBond™ is not bonding the contact line to negative but is ready to
do so. The Busbar Selector may be moved to the Positive position.
Optional track alive CB closing inhibit available
D Negative Closed PowerBond™ is connecting the contact line to the system negative and
is acting as an NSCD. Feeder protection, including the Direct Acting Trip,
is disabled in this position.

1. Alternatively, this busbar may be connected to Earth.

02
Features
PowerBond™ includes the below features:

1. Intended for 750V dc and 1500V traction power systems,

both overhead line and conductor (3rd and 4th) rail.

2. The High-Speed DC Circuit Breaker is based on the BRUSH Switchgear

‘NDC’ circuit breaker, which has many thousands of units in service
worldwide.

3. The Circuit Breaker features a Patented Design Magnetic Actuator

mechanism which offers reduced maintenance and improved
performance against other operating mechanism types.

4. Line (Track Feeder) and Rectifier Circuit Breakers are fitted

with a Uni-directional Direct Acting Trip.

5. All current making and breaking is carried out by the circuit breaker;
the busbar selector is an off-load device which is electrically interlocked
with the circuit breaker.

6. Protection, including the Direct Acting Trip mechanism, is disabled when

the Negative Busbar is selected.

7. The panel design is suitable for rear and bottom entry with optional
front cabling access. Versions for top entry main cables are also available.

8. Interlocking between the Circuit Breaker Truck and the panel prevents
access to live parts. Electrical interlocking eliminates the need for
external Interlock or Inhibit boxes.

9. Transducers (with the associated transducer fuses) are mounted

on the withdrawable truck, for the safety of maintenance, test and
commissioning teams.

10. Fully customisable control and protection scheme, which is compatible with
a wide range of protection relays including the BRUSH Switchgear Mitre+.

Circuit Breaker Configurations

The following circuit breaker configurations will be available:

Type Busbar Selector Fitted? Direct Acting Trip Fitted?

4kA Line (Feeder) Yes Yes (4-16kA standard)
6kA Rectifier No Yes (3kA standard)
8kA Rectifier No Yes (4kA standard)
6kA Interconnector No Optional
8kA Interconnector No Optional

2. 8000A Rectifier circuit breakers will be available in the future

3. 8000A Interconnector circuit breakers will be available in the future

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 Ratings

Ratings to EN 50123-1/2/6 and IEC 61992-1/2/6 Symbol 900 V Version 1800 V Version

Nominal Voltage Un 750V 1500V

Rated voltage UNe 900V 1800V

Rated insulation voltage UNm 1800V 3000V

Rated impulse withstand voltage UNi 18kV 18kV

Power Frequency Withstand Ua 6.9kA / 8.3kV 6.9kA / 8.3kV

Overvoltage OV 4 3

Pollution degree PD 4 4

Rated Auxiliary Voltage 48V, 50V, 110V or 125V dc

Circuit Breaker Rated Service Current INe 4000A (L) 4000A (L)
6000A (R) 6000A (R)
8000A (R; I)

Busbar Selector Rated Service Current INe 4000A (+ve) 4000A (+ve)
500A (-ve) 500A (-ve)

Positive Busbar Rated Service Current INe 6000A or 8000A

Negative Busbar rated Service Current INe 500A

Rated Short Circuit Current INss 125kA / 180kAp 100kA / 142kAp

Rated Short Time Withstand (Circuit Breaker) INcw 63kA / 90kAp for 250ms

Rated Short Time Withstand (Positive Busbar) INcw 125kA / 180kAp for 250ms

Rated Short Time Withstand (Negative Busbar) INcw 70kA / 100kAp for 250ms

Rated Short Time Withstand (Earth Bar) INcwe 10kA / 14.2kAp for 1s

Rated Track Time Constant Nc 100ms 63ms

Duty – Line (Feeder) Breakers f, e, d, l – duty cycle 1

Duty – Rectifier Breakers r, s, lr

Duty – Interconnectors ff, fr, lr

Critical current 50A Bi-Directional

Service life 40 years

Mechanical endurance – Circuit Breaker 20 000

Mechanical endurance – Busbar Selector 10 000

4. 1800V versions will be available in the future. Data subject to confirmation following type testing.

04
 D
Dimensions

Dimensions (per panel) as

shown on diagram to the right:
450mm Wide; 1520 Deep; 2139 High.

Key: A
A Circuit Breaker Compartment
B Busbar Compartment (Positive)

C Cable Compartment

D Low Voltage Compartment

E Vent (allow 600mm free space above vent)

F Busbar Compartment (Negative)

Front Elevation

Left-Hand Side Elevation

B F

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 Key Substation Design Requirements
• Space required in front of switchboard to allow CB Truck withdrawal: 1200mm

• Space required to the rear of the switchboard to allow rear access for cabling: 600mm

• Space required to the rear of the switchboard when cable access is via the front of the panel
(bottom or rear main cables only): 100mm (with frame leakage) or 50mm (no frame leakage)

• Space required to the left of the switchgear: 600mm (to allow doors to open)

• Space required to the right of the switchgear: 100mm

• The finished floor for the switchgear should be ±3mm over a common datum line over any
2500mm length. The floor should be flat and level for 1200mm in front of the switchboard.

Weights

Type Panel Weight (less breaker) Breaker Weight

4kA Line (Feeder) 360kg 295kg
6kA Rectifier 390kg 290kg
8kA Rectifier 400kg (TBC) 300kg (TBC)
6kA Interconnector 390kg (TBC) 290kg (TBC)
8kA Interconnector 400kg (TBC) 300kg (TBC)
Frame Leakage 300kg N/A

Frame Leakage Panel

Optional switchboard frame leakage panel (with the same dimensions as a circuit breaker panel). This may
be provided with or without cable boxes for the Positive and Negative cables.

Optional wall-mounted frame leakage panel (details on request).

Frame leakage insulated flooring thickness: 3mm (installed on top of finished floor level).

Heat Losses

Type 100% Load, Continuous Typical Load

4kA Line (Feeder) 650W 350W
6kA Rectifier 750W 600W
8kA Rectifier To be confirmed To be confirmed
8kA Interconnector To be confirmed To be confirmed

5. Actual heat losses are subject to substation loading and should be calculated for each substation to ensure the correct design of ventilation systems
or cooling plant.

06
Auxiliary Power
Switching Loads for 48V dc version:

Operation Current and duration @ 48V dc

Circuit Breaker Close 80A peak, 250ms nominal
Circuit Breaker Open (Reset) 25A peak, 200ms nominal
Capacitor Charge (following a trip command) <6A, 6 seconds nominal
Busbar Selector Position Change Running: 3.5A, 3.5 seconds nominal
Peak, while connecting: 8A, <0.5 second nominal

Standing loads (Estimated) @ 48V dc: Line (Feeder) – 1.0A; Rectifier – 0.5A; Interconnector – 0.5A; Frame
Leakage – 0.25A. Standing loads subject to control and protection scheme and will vary.

Anti-condensation heaters (optional): 70W @ 110V or 230V ac.

Cable Entry Options

Main Cable Entry options:

• Rear
• Bottom
• Top (requires the addition of an 450mm deep
adaptor chamber to the rear).

Up to 4 x 1000 mm2 cables can be accommodated

in a Line (Feeder). Up to 8 x 1000mm2 cables can
be accommodated in a Rectifier or Interconnector
panel. Details of quantities for other cable sizes
available on request.

100mm clearances or enhanced insulation is pro-

vided on the outgoing feeder panel circuit only.

Control cable entry from the top/rear of the Low

Voltage Compartment.

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 BRUSH
Switchgear Division: Unit 3, Blackwood Business Park,
Newport Road, Blackwood, South Wales NP12 2XH United Kingdom

T: +44 (0) 1495 223 001

E: [email protected]

September 2022

08 brush.eu