NEXUS Flexible Braided Conductor

NEXUS flexible braided copper conductors provide the flexible link between rigid busbars and equipment that moves, expands or vibrates. Each conductor is made to order, so the braid, the terminal geometry and the overall length are matched to the connection rather than the connection being designed around a stock part.

Product Range:

• Braided copper conductors — custom made, in flat rolled or standard braided form.
• Copper tapes — woven and braided laminated tapes.
• Round stranded copper flexibles for higher-movement connections.

Material and Finish: E-Cu (electrolytic copper) supplied plain or tinned. Individual dimensions can be varied slightly during the rolling process; non-standard dimensions may require design modification. Supplied in carton boxes or wooden cases.

Sizing:

• Assemblies: cross-sectional area from 38 to 3,500 mm², covering a current rating range of 200 to 10,000 A.
• Selection table: the catalogue current-rating table runs from 0.10 mm² (approx. 5 A) up to 1,200 mm² (approx. 2,150 A) — for example 25 mm² at approximately 150 A, 120 mm² at 420 A, 300 mm² at 780 A and 800 mm² at 1,500 A.

End Finishing: NEXUS presses and finishes the braid ends so the conductor bolts directly to its terminals, keeping electrical contact resistance at the connection point as low as possible. Terminal lugs can be supplied in copper or tinned copper, in single-hole or multi-hole patterns to suit the equipment.

Why a braided connection: a flexible braid absorbs thermal expansion, mechanical vibration and slight misalignment between fixed and moving conductors — stresses that would otherwise transfer into the busbar joint and the equipment terminals.

Typical Applications:

• Switchboards and switchgear: flexible links between busbars, breakers and incoming or outgoing sections.
• Power transformers: connections that must tolerate thermal movement and vibration.
• Power generator sets: alternator terminal connections subject to engine vibration.
• Earthing straps: bonding of enclosures, frames and equipment to earth.
• Power electronics: power semiconductors, thyristors, relays and battery connectors.
• Protection devices: current-operated earth-leakage circuit-breakers.