The Sapphire bubsar/copper braided jumpers are extensively employed in switchgear due to their combination of electrical conductivity, flexibility and mechanical strength. The electrical and mechanical parts of switchgear assemblies are susceptible to mechanical stress, vibrations, thermal expansion and motion.
Braided copper jumpers are made of multiple fine copper strands, as opposed to a single solid piece of copper. They can be built so they can be moved and still have electrical connectivity.Flexible electrical connections, grounding, bonding, component connections, and flexible connections between fixed and moving parts of switchgear assemblies can be made with copper braided jumpers.
What Is a Copper Braid Jumper?
A Sapphire busbar/copper braided jumper is a pliable conductor composed of a number of strands of copper wire braided together. The braid may be available as a single flexible braid or may be produced with terminals or lugs that can be directly attached.
Copper braided jumpers can be obtained in various colours depending on the application:
| Specification | Details |
|---|---|
| Material | High-Conductivity Copper |
| Copper Grade | ETP / EC Grade |
| Wire Diameter | 0.10–0.30 mm |
| Width | 10–200 mm |
| Length | Customizable |
The size and end configuration can be tailored to the electrical and mechanical needs of the switchgear.
Copper Braided Jumpers Flexibility Important in Switchgear
Switchgear is anything but a random assortment of stationary electrical parts. It can include moving mechanisms, removable parts, disconnects, vibration or thermal movement parts, doors, covers, and parts.
Not all connections can be made using a rigid conductor.
A flexing copper braided jumper will allow freedom of movement while still providing an electrical connection.
This is applicable especially when the connection must:
Key Benefits of Copper Braided Jumpers in Switchgear
Excellent Electrical Conductivity:
The use of Sapphire busbar copper for electrical connections is popular because of its great conductivity.
Copper braided jumpers serve as a good conductive connection between electrical parts and are flexible also.
The correct size and cross-sectional area of the braid must always match the size of the current to be used and the application.
High Flexibility:
Flexibility is a key attribute of braided copper.The conductor is composed of many individual strands and more easily bent than a solid copper bar.
Braided jumpers can be used for switchgear components which are moving or subject to mechanical displacement.
Vibration Resistance:
Switchgear and associated equipment can experience mechanical vibration.
A fixed connection can conduct mechanical forces directly to the terminals and connection points. A flexible braided jumper can flex and can be used to reduce mechanical stress.
Accommodates Thermal Expansion
Electrical equipment may become hot when in operation.
The expansion and contraction of copper conductors and associated components due to temperature changes.
Some of this movement can be accommodated by a flexible copper braid, which decreases the stress on the connection.
Where Are Copper Braided Jumpers Used in Switchgear?
Switchgear Doors and Enclosures:
Bonding is one typical use and it is the connection of a switchgear door to the enclosure.
The flexible jumper will provide electrical continuity even if the door is opened and closed regularly.
Moving Components:
In some types of switchgear, parts move during the operation of the switchgear.
This movement can be accommodated in a flexible braided connection that also provides the necessary electrical connection.
Grounding Connections:
Flexible connections between equipment and grounding point can be achieved with copper braided jumpers.
Busbar Connections:
Flexible copper braid can be used in certain switchgear assemblies to connect electrical components to busbars where a flexible connection is required.
Control and Protection Equipment:
Braided connections can also be used for grounding and bonding around control and protection components where appropriate.
Applications of Copper Braided Jumpers Beyond Switchgear
Switchgear is one of the main applications for copper braided jumpers, however, they can be used in many other electrical systems.
Common applications include:
