Medium powerbar busbar range

Medium Power BarBusbar Range160A - 800A

Medium Power Distribution Made Easy

www.e-i-eng.com

Powerbar Services » Complete co-ordination of Busbar project requirements – technical submittal.

» Site measures & Busbar survey.

» Autocad Co-ordinated drawings produced.

» Volt-Drop & Temp raise calculations.

» Delivery from approval 12-14 weeks.

» Site training & Busbar instillation.

» Special make up pieces in 2 weeks.

» Site testing & training.

» Thermal imaging surveys

TYPICAL INSTALLATION

Overview 4-8

Technical Data - Copper 10

Technical Data - Aluminium 11

Construction and Housing Details 12

Integral Earth and Isolated Earth Bar 13

Fire Barrier System 14

Fittings 15

Distribution Busbar 16

Tap Off Units 16-18

Flatwise Elbows 19

Edgewise Elbows 20

Flange Connection 21

Flange Cut-Out and Connection Details 23

Offset Sections 24

Combination Elbows 25

Flatwise T- Section 26

Edgewise T-Section 27

Flatwise Cross 28

Joint Packs 29

Edgewise / Flat Installation 30

Spring Hanger 31

End Feed Units 32

Centre Feed Units 33

End Cap 34

Expansion Units 35

Special Sections 36

Quick Reference Guide 38

Tabl

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4 Website: www.e-i-eng.com Tel: +44 (0)28 71 353030 Email: [email protected]

OverviewPowerBar MPB Busbar trunking is manufactured

using state of the art automation techniques and

the continuous innovation which results from our

intensive R&D program is reflected in our product

development.

MPB Busbar Trunking is a positive cost effective

alternative to cable for electrical distribution

particularly for high current applications.

Due to the familiarity of traditional cabling to

designers and installers it is easy to overlook the

limitations of cable installations and the benefits of

busbar trunking.

Electrical power cabling is difficult to handle,

difficult to install, takes up a lot of space particularly

at bends, and can be very disruptive within existing

sites. The performance of cable is limited by the

insulation materials utilized and by the size of

conductor CSA that can be sensibly installed and

terminated. The frequent need for multiple parallel

conductors used for volt drop and current carrying

capacities also adds to the problems.

Cable Installations initially require containment

systems such as tray, ladder, rack, trunking or conduit

to be installed on a dropper/unistrut support system.

The containment needs to be fixed in place and then

the cable installation can begin. The second process

of cable installations can be undertaken when this

is complete. Cables require to, be fixed, cleated,

dressed, labeled, glanded, terminated and tested

before being completed. Every single connection/

termination has to be completed by hand and

tested. The time for each of these processes quickly

adds up which adds significant costs, quality and

duration to a project. These are fundamentally

important concerns where cost, quality and program

improvements are paramount considerations.

The MPB Busbar is simply installed in sections on

unistrut systems and then tested.

Major changes and extensions to existing

installations can be very disruptive, particularly as the

electrical supply to parts of the system will have to be

isolated while work is being completed.

Such considerations are increasingly important as

the dynamic nature of business today leads to the

need for frequent re-fit of premises to exacting tenant

requirements.

PowerBar MPB busbar trunking systems offer

significant advantages over existing technologies and

over cable installations as our systems have been

designed from the outset with installation applications

in mind. A full range of products, a flexible approach

to manufacture and the ability to deliver custom

built bespoke adaptations for site specific conditions

make MPB the premier busbar trunking product on

the market.

MPB is a product comprising fixed conductors

housed within a non-ferrous aluminium casing with

provision at regular, customer defined distances

along its length, for fitting tap-off units.Typical Riser Installation


Overview

Tap-off units are devices that plug into the trunking

and provide terminals for the connection of lighting

and power distribution boards, power outlets, section

boards or other electrical loads.

Tap-off units provide a huge benefit in being able

to be added, repositioned or removed as necessary

without installing additional cabling back to the main

switchboard.

All tap off units are designed with safety of the end

user as a priority. The units have an interlock feature.

The lid of the unit is interlocked to the protection

device and so the lid can only be opened when the

device is de-energized.

Cable Installations are inflexible. Changes such

as relocation of circuits, repartition of office space

or adding additional circuits to accommodate

alterations in internal layouts can be inconvenient,

costly and take a long time to complete.

This obviously makes the restructuring of electrical

services simple and cost effective providing the

flexibility expected by modern businesses

MPB Busbar Trunking Installations are de-centralised

distribution centres offering local connections rather

than traditional centralized cabled installations

which are designed around central distribution load

centres such as switchboards, section boards or

distribution boards. These central units contain all the

necessary busbar, circuit breakers and protective

devices for the installation as it was designed initially.

There is generally little or no flexibility to ‘future proof’

these panels. Any additions to these units will require

shutdowns and cabling from this central position to

any new or modified loads regardless of location.

With a de-centralised MPB Busbar Trunking

installation, the protection devices are within the

tap-off unit and can therefore be installed close

to the equipment which it is supplying, minimizing

disruptions, cost and time. Protective devices located

adjacent to the load also assist greatly in fault finding

and maintenance.

Choose Busbar over CableThere are numerous advantages of MPB busbar

over cable installations.

MPB Busbar is aluminium cased busbar trunking

and is much less susceptible to damage than cable

on cable trays. Maintenance costs are reduced

along with the risk of damage caused by electrical

faults.

The design criteria for MPB busbar is similar, but

quicker and easier than the design criteria for the

equivalent cable installation. As standard the Current

rating (Ith) of the trunking must be greater than that of

the protective device which, in turn, must be greater

than the maximum load current.

MPB Busbar Trunking is much less affected

by grouping factors and ambient temperature

considerations than that of cable. In fact since MPB

Busbar Trunking is a modular product with pre-installed

conductors, grouping factors may be ignored,

removing a time consuming iteration of the design

process and the inevitable increase in conductor

sizes that usually results.

Performance under temperature demonstrates

clearly the superior performance of MPB Busbar

trunking. This performance differential increases with

the ambient temperature and at an ambient of

50degC, this difference can rise to a 30% difference

in performance in favour of MPB Busbar Trunking.

Due to the construction of MPB Busbar Trunking

voltage drop performance is always superior to

cable. A lower value of phase and neutral voltage

6300A Package Sub Station

5Website: www.e-i-eng.com Tel: +44 (0)28 71 353030 Email: [email protected]

SectionOverview

drop is a significant design factor that usually results

in increased cable conductor sizes and associated

costs. MPB Busbar Trunking simplifies the designer’s

work by allowing necessary longer runs to be used,

while remaining within the maximum allowable

voltage drop limits assigned in the design and

detailed within the BS7671 wiring regulations.

MPB Busbar Trunking also provides a low

impedance earth path which again is significantly

lower than an equivalent cable based installation.

This low impedance earth path results in earth fault

values that ensure disconnection times are adequate

regardless of fuse or circuit breakers being used.

Low impedance earth values also ensure reduced

step and touch voltages to exposed metalwork in

the event of earth faults, thus reducing secondary

implications of major fault conditions.

Selection of protective device is an easy process.

MPB Busbar Trunking can be provided with protection

devices from a range of manufacturers to ensure that

detailed co-ordination of devices can be achieved.

This co-ordination data is usually provided by

circuit breaker manufacturers but is limited to their

range of devices only. The availability of such tables

removes the need for designers to carry out detailed

calculations comparing energy let through and fault

withstand performance. With MPB Busbar Trunking

we will provide the protective devices that facilitate

this co-ordination exercise and provide the designer

with a fully co-ordinated solution, easy to design

system that provides the optimum in enhanced

discrimination and safe disconnections with minimum

client disruption.

MPB Busbar Trunking is provided with optional

certified 2 hour fire rating for fire wall penetration by

casting a compound into the trunking . these have

been tested to ISO930 and IEC439-28.1.15 and

ensure meeting the fire safety requirements of the

Building Regulations much easier with MPB Busbar

Trunking instead of traditional cabling.

There is a perception that busbar has a higher unit

cost per meter. Whilst this is likely to be the case at

face value when the installation costs and labour

costs are considered busbar installations will save

time and money. On a detailed comparison recently

completed savings of nearly 30% were realized.

When the factors noted above that generally add

cost to design such as volt drop and CPC sizing

are taken into account, then busbar advantages

become even more obvious.

Earlier completion of installations and projects

frees staff to move on to further revenue generating

projects, buildings can be occupied or rented by

new tenants more quickly thus generating more

rental income.

PowerBar offer full comprehensive support from our

highly qualified Engineering teams, who are involved

at every stage of your project from tendering, through

design, to installation and commissioning. We have

full technical support and a continuous improvement

approach through R&D

With such undoubted product quality, technical

advantages, cost saving, product support,

excellent service MPB Busbar Trunking is the

obvious choice


Overview


Section

Summary » PowerBar leaves more space for additional services.

Cables are bulky and difficult to handle,

» Cable installations are inflexible and changes can be

inconvenient and costly.

» Cable install time is much longer and quickly incurs

significant impacts on cost and completion time.

» PowerBar is ideal to replace multiple cable runs.

» Busbar reduces installation time.

» On Busbar repositioning of distribution points is made

easy.

» Busbar is far less susceptible to damage than cable,

thus maintenance costs are reduced.

» The process of selecting and sizing PowerBar trunking is

even quicker and easier than that of cable.

» PowerBar’s two hour excellent fire performance,

makes meeting the safety requirements of the building

regulations, easier with Busbar than cable.

» PowerBar has lower volt-drop than equivalent cable

arrangements.

» PowerBar it aesthetically pleasing in areas of high

visibility.

» PowerBar backup their products with comprehensive

support, which embraces every stage of the project,

from tendering through design, to installation and

commissioning and after sales services such as

maintenance, spares, additional Tap-Off units and

thermal imaging to mention a few.

» The flexibility of tap offs gives the benefit of future

expansion.

» PowerBar lends itself well to offsite construction in

prelabelled pods ready for delivery to site.

» PowerBar is suited to phased installations which is an

option you don’t have with cable.

MPB Features » Copper or Aluminium conductor’s mill finish

» Joint Pack is factory fitted on one end of each busbar

section, this saves time during installation on site.

» Up to 5 No configurable tap-off Points per 3m length.

» All Tap-off have mechanical/electrical interlocks with a

“Earth First, Break Last” safety feature.

» Tap Off connection is made directly on to the busbar

conductor.

» Automatic automated assembly improves quality,

reduces production time.

» Fire barriers.

» Integrated case earth.

Overview

Multiple Tap Off Slots


Low Voltage Busbar PowerBar’s “Medium” PowerBar (MPB) range

is a 690 volt, totally encased, non-ventilated, air

insulated construction available with either copper

or aluminium conductors. The copper option is

available from 160A to 800A, the aluminium options

are available from 160A to 630A. The MPB range is

available with a standard Ingress Protection rating of

IP54. MPB can be used either feeder or distribution

application or a combination of both. There is no

need for any special splice connections and the 2

types are fully interchangeable provided they are

the same current, configuration and voltage rating.

The short circuit withstand ratings for the distribution

busbar is equal to the feeder busbar.

StandardsThe MPB range is fully ASTA Tested Certified and is

CE approved. It is manufactured in a BS EN ISO 9001:

2000 and BS EN ISO18001 & PAS 99 certified facility.

It is designed and manufactured in accordance with

IEC60439-1 and IEC60439-2.

Configuration Phases Neutral Earth

TP 100% 0% Case

TP/N 100% 100% Case

TP/E 100% 0% 100%

TP/NE 100% 100% 100%

TP/DN 100% 200% Case

Note: Case, refers to the Aluminium casing being utilised as a 100% housing ground.

Type Tests » Verification of temperature rise limits.

» Verification of the dielectric properties.

» Verification of the short circuit withstand strength.

» Verification of the effectiveness of the protective circuit.

» Verification of Clearance & creepage distances.

» Verification of mechanical operation.

» Verification of the degree of protection.

» Verification of the electrical characteristics.

» Verification of structural strength.

» Verification of crushing resistance.

» Verification of resistance to abnormal heat.

» Verification of resistance to flame propagation.

» Verification of the fire barrier in building penetration.

ASTA CertsPowerBar Ltd has done extensive testing at ASTA and

KEMA accredited laboratories to ensure the product

we supply meets the international requirements.

Overview

An Integrated Approach

…and our people

We value our customers

Technical DataTechnical Data Table – Copper

RATING 160A 250A 400A 630A 800A

Rating Current (Amps) 160A 250A 400A 630A 800A

Rating Insulation Voltage 690V 690V 690V 690V 690V

SHORT CIRCUIT STRENGTH

Rated Fused S/C current @ 400VAC 80kA 80kA 80kA 80kA 80kA

Fuse Size (A) 160A 250A 400A 630A 800A

RATING SHORT TIME WITHSTAND CURRENT (Icw)

1 second (kA) 9.48kA 9.48kA 16kA 25kA 30kA

Peak Value (kA) 16kA 16kA 32kA 52.25kA 63kA

CONDUCTORS C.S.A (mm2) COPPER (PHASE)

Bar Dimensions 20mm*5mm 20mm*5mm 35mm*5mm 55mm*5mm 75mm*5mm

Cross Sectional Area 100mm² 100mm² 175mm² 275mm² 375mm²

CONDUCTORS C.S.A (mm2) COPPER (NEUTRAL/INTEGRAL CLEAN EARTH)

Bar Dimensions 20mm*5mm 20mm*5mm 35mm*5mm 55mm*5mm 75mm*5mm


PROTECTIVE EARTH C.S.A(mm2) ALUMINIUM HOUSING


WEIGHT

Weight of trunking (4 bar system) kg/mtr 8.5kg 8.5kg 12kg 17kg 22kg

RESISTANCE (m /m)

0.172 0.172 0.102 0.065 0.048

REACTANCE (m /m)

0.126 0.126 0.093 0.075 0.056

IMPEDANCE (m /m)

0.218 0.218 0.138 0.100 0.073

VOLT DROP LINE TO LINE (V/m) at given Power Factor

Volt drop line to line P.F 0.8 0.094 0.094 0.095 0.106 0.099





Technical Data

Technical DataTechnical Data Table – Aluminium

RATING 160A 250A 400A 630A

Rating Current (Amps) 160A 250A 400A 630A

Rating Insulation Voltage 690V 690V 690V 690V

SHORT CIRCUIT STRENGTH

Rated Fused S/C current @ 400VAC 80kA 80kA 80kA 80kA

Fuse Size (A) 160A 250A 400A 630A

RATING SHORT TIME WITHSTAND CURRENT (Icw)

1 second (kA) 9.48kA 9.48kA 16kA 25kA

Peak Value (kA) 16kA 16kA 32kA 52.25kA

CONDUCTORS C.S.A (mm2) ALUMINIUM (PHASE)

Bar Dimensions 20mm*5mm 35mm*5mm 55mm*5mm 75mm*5mm

Cross Sectional Area 100mm² 175mm² 275m² 375mm²

CONDUCTORS C.S.A (mm2) ALUMINIUM (NEUTRAL/INTEGRAL CLEAN EARTH)

Bar Dimensions 20mm*5mm 40mm*5mm 55mm*5mm 75mm*5mm

Cross Sectional Area 100mm² 200mm² 300m² 375mm²

PROTECTIVE EARTH C.S.A (mm2) ALUMINIUM HOUSING

Cross Sectional Area 1102mm² 1177mm² 1276mm² 1376mm²

WEIGHT

Weight of trunking (4 bar system) kg/mtr 6.6kg 7kg 9.65kg 11.88kg

RESISTANCE (m /m)

0.160 0.140 0.093 0.075

REACTANCE (m /m)

0.093 0.090 0.067 0.066

IMPEDANCE (m /m)

0.218 0.138 0.100 0.073

VOLT DROP (V/m)

Volt drop line to line P.F 0.8 0.051 0.072 0.080 0.102





SectionTechnical Data


Section

Construction Details (Conductor/Insulation System)

Medium PowerBar conductors are fabricated from

either High Density 99.99% conductivity copper,

or 55% conductivity aluminium. The CSA of the

conductors varies depending on the rating of the

system. The conductors have fully rounded edges

and this makes for a smooth and easy connection

between the busbar and the Joint Pack. The

conductors are insulated by means of a clear air

gap between each phase. The gap is maintained

by mounting the conductors in a special moulding

which is a durable, high strength, polycarbonate

material rated as a Class B 130°C insulator. The

moulding also ensures a clear air gap is maintained

between the conductors and the external busbar

earth casing. With applicable creepage and

clearance to IEC60439.

Distribution busbar applications connect directly

onto the conductor at the contact location points of

the Tap Off Box Slot outlet.

Housing DetailsThe PowerBar MPB range is constructed with

a lightweight and rugged extruded aluminium

assembly. The aluminium extrusions are arranged

without the need for welding or seams. The final

assembly is riveted together along its length providing

a fully encased tamper proof design.

The aluminium housing provides an excellent

ground path through the busbar system. The cross

sectional area of the aluminium housing of the

busbar assembly is significantly larger that the C.S.A

of the individual conductors.

The all-aluminium housing as a non ferrous metal,

provides excellent heat dissipation properties. It is

unaffected by reduction in reactance and magnetic

flux leakage, as compared to steel housing. The

aluminium housing resists rust and other elements.

The integrity and strength of the housing assures

specifiers and users with a safe and durable

installation over the spectrum of industrial and

commercial applications.

Section

Construction Detail

Construction Detail


Construction Details

160A - 1102

250A 160A 1102

400A 250A 1177

630A 400A 1276

800A 630A 1376

Integral Earth (Case)The aluminium extrusion assembly is utilised to

provide an earth path along the length of the busbar

system. The system earth continuity is maintained

through each joint by the earth joint covers. The

aluminium joint covers are furnished with earth

contact surfaces on the inside, when installed the

contact surfaces are bolted directly to the earth of

the busbar outer casing. The result is a 100% earth

path that assures earth continuity with very low

impedance characteristics.

PowerBar have successfully conducted short circuit

testing through the case of the MPB busbar system

for each current rating verifying the earth fault path of

our busbar trunking ratings

Isolated Earth Bar (50% or 100% Copper or Aluminium)

In this optional arrangement the earth conductor

is an internal conductor within the busbar assembly.

It is fully isolated from the Aluminium casing and the

other internal conductors. The continuity is maintained

through the joint pack. This option is available to

meet the ever-growing need for an isolated earth

in systems with heavy microprocessor, based loads

or large computer based installations where Earth

isolation is essential.

Section

Busbar Rating (Amps)Protective Earth C.S.A

(in mm²)Copper Aluminium

Housing Detail (Case Earth) Isolated Earth Arrangement


SectionSystem Earth


Section

Fire Barrier SystemPowerBar busbar systems offer a fully certified fire

wall penetration barrier. This fire barrier has a 2 hour

rating of the fire resistance material used inside the

housing of the Busbar.

Key considerations for utilising fire barriers are:

» 1. Life Safety.

» 2. Prevention of the passage of smoke or flame from

one enclosed space to another.

Remember:

» 1. Aluminium Melts @ 660°C (933K)

» 2. Copper Melts @ 1084°C (1,357K)

» 3. Average fire temperature @ 1,200°C (1,473K)

The fire barrier is manufactured using a fire

retardant compound which is “cast” within the

housing of the busbar system so that it creates an

integral barrier which encapsulates the conductors.

PowerBar Fire Barriers are Tested to ISO830 and IEC

439-28.1.15

Section

Fire Barrier


Fire Barrier System


FittingsWhen PowerBar is used for a distribution installation,

it will provide a space saving versus the equivalent

cable. This use of standard accessory fittings and the

ability to provide bespoke solutions in an optimum

time means PowerBar can solve most arduous

installation problems

We design and build all of the fittings in house and

there are solutions to meet every applications needs.

These are detailed on the following pages: feeder

sections, distribution sections, flanges, elbows, offsets,

tees, tap off units, power take off sections, transformer

connections, reducers, adapter cubicles, expansion

joints, cross joints, end feed units and centre feed

units.

Feeder BusbarStraight sections of Feeder busbar can be supplied

in any length, from a minimum of 600mm to a

maximum of 4000mm.

The table below illustrates the different types of

build arrangement used depending on the rating of

busbar required for the application.

Speisesammelschienen

MPB Busbar

Busbar Rating (Amps) Bar Per

PhaseCopper Aluminium

Phase Bar Size (mm) Construction Type

Depth Width

Busbar Size (mm) Phase Configuration

Depth Width

160A - 20mm 5mm 1 Single 67.5mm 168mm ALL

250A 160A 20mm 5mm 1 Single 67.5mm 168mm ALL

400A 250A 35mm 5mm 1 Single 82mm 168mm ALL




SectionFeeder Busbar


Section

Distribution BusbarStraight sections of Distribution busbar can be

supplied in any length, from a minimum of 600mm to

a maximum of 4000mm.

160 - Single

250 160 Single

400 250 Single

630 400 Single

800 630 Single

Tap Off SlotThe tap off slot outlet and cover are made from

a durable, high strength, polycarbonate material

rated as Class B, 130ºC insulator. The tap off slot

cover is designed to prevent access to the contacts

behind the cover and prevent the entry of dirt, dust or

moisture.

The cover can be removed by using a flat head

screw driver to rotate the cover lock. The tap off slot

is IP2X(finger safety) in accordance with IEC60439

standards, with the cover removed. With the tap

off module installed or the cover fitted the rating is

IP54. A cover is required over unused tap off slots to

maintain the ingress protection (IP) level to IP54. When

fitting a tap off unit the cover has to be removed.

The Tap off box cover is used to ensure protection

of the contact surfaces from dirt, dust or moisture.

Tap Off Units (plug in type)All PowerBar tap off units are designed with the

safety of the installer and user as the key criteria. The

following features are standard for both fused and

circuit breaker type plug-in units.

Extended Earth Contact Bracket

The PowerBar tap off unit has an extended Earth

Contact Bracket which ensures the Earth ground

is always the first point to connect with the busbar

system during installation and the last point to

disconnect during the removal of a tap off unit.

Shutter Actuator

The Earth contact is designed to make positive

contact with the busbar earth ground before the

phase or neutral contacts engage the busbar.

The unit is also fitted with an extended shutter

actuator which ensures the tap off unit cannot be

inserted upside down (180 degrees out of rotation),

as the design of the shutter actuator will prevent this.

This ensures correct phasing of conductors.

Verteilerschienen

Busbar Rating (Amps)Construction Type

Copper Aluminium

Tap Off Slot (Cover removed)

Tap Off Slot (Cover fitted)


Distribution Busbar/Tap Off Units

Tap Off Slot


Clamping Mechanism

To ensure the tap off unit is seated correctly on the

busbar, the clamping mechanism will draw the unit

tight onto the busbar housing as the installer tightens

the mounting bracket assembly at the rear.

The PowerBar tap off units have an interlock which

prevents the tap off door from being opened while

the tap off unit is in the ON position and to prevent

the accidental closing of the device while the door is

open.

As a counter measure to the effects of thermal

expansion and vibration, the tap off unit is secured to

the busbar housing with high tensile strength, lockable

hardware.

Special Tap-Off UnitsPowerBar LTD take a flexible customer focused

approach to our manufacture custom engineered

and custom built tap off arrangements are the norm

not the exception.

Special Features Are:

» Metering option for landlord electrical tariff purpose.

» BMS Monitoring of breaker status.

» BMS monitoring of metering systems.

» Automatic remote open/close features.

» Load shedding features.

» Integral sockets.

» Integral distribution boards.

» Cable spreader boxes.

Tap Off Units (plug in type)

Section

Typical Tap Off Box

3D CAD-Design Service Available


SectionTap Off Units


Section

Tap Off UnitThe standard Tap-Off box usually has bottom and

side removable gland plates for cable access, but

other variations are available and are dependent on

the client’s needs and requirements for the ease of

cable access.

Please contact the PowerBar engineering

department for further information.

Abgangskästen

Tap Off Box

Circ

uit B

rea

ker (

MC

CB)

-

Tap

Off

Units

Maximum Amps

Maximum Volts (AC)

Tap Off Slots Box Type X Y ZApprox.

Weight (kg)

100A 600V 1 V4 400mm 256mm 147mm 10

160A 600V 1 V4 400mm 256mm 147mm 10

200A 600V 1 V4 400mm 256mm 147mm 10

250A 600V 1 V1 500mm 340mm 250mm 20

315A 600V 1 V1 500mm 340mm 250mm 20

400A 600V 2 MPB-V1-D 500mm 340mm 250mm 23

630A 600V 2 MPB-V1-D 500mm 340mm 250mm 23

NOTE: The list above is based on typical situation, other factors need to be considered when deciding on what type of box to use, such as, location of box, cable size, additional accessories, etc.

Fuse

ab

le &

Sw

itche

d

Tap

Off

Units

(SW

/FS)

100A 600V 1 V4 400mm 256mm 147mm 10

160A 600V 1 V4 400mm 256mm 147mm 10

200A 600V 1 V4 400mm 256mm 147mm 10

250A 600V 1 V1 500mm 340mm 250mm 20

315A 600V 1 V1 500mm 340mm 250mm 20

400A 600V 2 MPB-V1-D 500mm 340mm 250mm 23

630A 600V 2 MPB-V1-D 500mm 340mm 250mm 23

NOTE: The list above is based on typical situation, other factors need to be considered when deciding on what type of box to use, such as, location of box, cable size, additional accessories, etc.

Our Tap Off box range is a “plug-in” type up to 630A. Above 630A the Tap Off Units range change to

“In-line”, these units are fixed in position. Please contact the PowerBar engineering department for

further information.


Tap Off Unit

Maximum Amps

Maximum Volts (AC)

Tap Off Slots Box Type X Y ZApprox.

Weight (kg)


Flatwise ElbowsFlatwise elbows are used to make changes in the direction of the busbar system. There are two main types:

Flatwise Up and Flatwise Down. These can be used to turn the busbar route up or down if the busbar is running

on its edge, or to turn the busbar route left or right when the busbar is running on its flat. The tables below can be

used as a guide for sizing Elbows.

As PowerBar manufactures these in-house, we can produce elbows up to 179°. Please contact PowerBar

Engineering department for further information.

Flache Winkelstücke

Flatwise Elbow 90˚ Flatwise Elbow 0-179˚

FLAT

WIS

E EL

BOW

(U

p o

r Do

wn)

Cu Al X Y X Y X Y

160A - 195mm 205mm 350mm 350mm 1000mm 1000mm

250A 160A 195mm 205mm 350mm 350mm 1000mm 1000mm

400A 250A 203mm 210mm 350mm 350mm 1000mm 1000mm

630A 400A 214mm 225mm 350mm 350mm 1000mm 1000mm

800A 630A 225mm 241mm 350mm 350mm 1000mm 1000mm

Rating (Amps) Minimum Leg Size Standard Leg Size Maximum Leg Size


SectionFlatwise Elbows


Section

Edgewise ElbowsEdgewise elbows are used mainly to make changes in the directions of the busbar system; there are two main

types, Edgewise left and Edgewise right. These can be used to turn the busbar route up or down if the busbar is

running on its flat, or to turn the busbar route left or right when the busbar is running on its edge. The tables below

can be used as a guide for sizing Elbows.

As PowerBar manufactures these in-house, we can produce elbows from 1° to 179°. Please contact PowerBar

Engineering department for further information.

Winkelstücke hochkant

Edgewise Elbow 90˚ Edgewise Elbow 0-179˚

EDG

EWIS

E EL

BOW

(L

eft

or R

ight

)

Cu Al X Y X Y X Y

160A - 246mm 246mm 350mm 350mm 1000mm 1000mm

250A 160A 246mm 246mm 350mm 350mm 1000mm 1000mm

400A 250A 246mm 246mm 350mm 350mm 1000mm 1000mm

630A 400A 246mm 246mm 350mm 350mm 1000mm 1000mm

800A 630A 246mm 246mm 350mm 350mm 1000mm 1000mm

Rating (Amps) Minimum Leg Size Standard Leg Size Maximum Leg Size


Edgewise Elbows


Flange ConnectionsFlanges provide a direct connection to low

voltage switchgear, switchboards, transformer

enclosures and other apparatus. Cut out details,

dimensions and drilling plans are provided with the

customer drawings and it is the responsibility of the

switchgear manufacturer to provide the opening, drill

connections in the switchgear, provide and terminate

the connecting hardware. PowerBar can provide

coordination of phasing ect with other equipment.

On receipt of detailed equipment, standard flanges

can be offset to the left or right of the section as

required

A flange combination elbow is a combination of

a standard elbow and a standard flange. Flange

combination elbows are typically used when the

minimum leg lengths for either the standard elbow or

the standard flange cannot be maintained, a typical

example would be when the busbar must run close

to the top of the switchboard, whilst avoiding other

services or when there is reduced head-height above

the switchgear. The gap between the busbar and the top of the

panel can be reduced down to as little as 50mm, if

necessary.

Anschlussstücke

Standard Panel Flange

(Ext

ern

al S

tum

p S

ize

) Cu

160A - 200mm 1000mm

250A 160A 200mm 1000mm

400A 250A 200mm 1000mm

630A 400A 200mm 1000mm

800A 630A 200mm 1000mm

Rating (Amps)

AlMinimum Maximum

Clearance Detail


SectionFlange Connections


SectionKombinations-Flanschverbindungen

Maximum FlatwiseMinimum FlatwiseRating (Amps)

160A - 195mm 86.5mm 1000mm 405mm

250A 160A 195mm 86.5mm 1000mm 405mm

400A 250A 203mm 94mm 1000mm 410mm

630A 400A 214mm 104mm 1000mm 425mm

800A 630A 225mm 114mm 1000mm 441mm

FLA

NG

E EL

BOW

S (F

latw

ise

)

Cu Al Y Z Y Z

Panel Flange Combination Flatwise Elbow Panel Flange Combination Edgewise Elbow


160A - 246mm 134mm 1000mm 455mm

250A 160A 246mm 134mm 1000mm 455mm

400A 250A 246mm 134mm 1000mm 455mm

630A 400A 246mm 134mm 1000mm 455mm

800A 630A 246mm 134mm 1000mm 455mmFLA

NG

E EL

BOW

S (E

dg

ew

ise

)

Cu Al Y Z Y Z


Combination Flange Connections


Standard Panel Flange Cut Outs and Connection Details

Plan für standardmäßige Flanschaussparungen

Panel Flange Plate cut-out detail for PowerBar MPB Range. (160A – 800A)


SectionFlange Cut Out and Connection Details


Section

Offset Sections (Flatwise & Edgewise)An offset is used to avoid obstacles such as pipes steel columns, etc… and to conform to the structure of the

building. It is basically two elbows fabricated into a single piece for use where space prohibits the use of two

standard elbows. There are again four types: Flatwise Offset Up and Down, Edgewise Offset Right and Left.

Versetzte Richtungsänderungen

Edgewise Offset Flatwise Offset


160A - 195mm 50mm 1000mm 600mm

250A 160A 195mm 50mm 1000mm 600mm

400A 250A 203mm 50mm 1000mm 585mm

630A 400A 214mm 50mm 1000mm 565mm

800A 630A 225mm 50mm 1000mm 545mm

FLAT

WIS

E O

FFSE

T (U

p &

Do

wn)

Cu Al Y Z Y Z

Maximum EdgewiseMinimum EdgewiseRating (Amps)

160A - 246mm 80mm 1000mm 600mm

250A 160A 246mm 80mm 1000mm 600mm

400A 250A 246mm 80mm 1000mm 600mm

630A 400A 246mm 80mm 1000mm 600mm

800A 630A 246mm 80mm 1000mm 600mm

EDG

EWIS

E O

FFSE

T (L

eft

& R

ight

)

Cu Al Y Z Y Z


Offset Sections


Combination ElbowsThese are used where space is at a premium and where the busbar must conform to the building’s structure

and change direction, utilizing a small amount of space. They have been developed by combining the two

different types of elbow, Flatwise and Edgewise, together into one piece.

The tables below show the typical sizes for copper and aluminium combination elbows per rating (Amps)

Kombinationswinkel

CO

MBI

NAT

ION

ELB

OW

S (F

latw

ise

/Ed

ge

wis

e &

Ed

ge

wis

e/F

latw

ise

)

Cu

Rating (Amps)

Al

Minimum Combination Elbow

Z X Y

160A - 246mm 168mm 195mm

250A 160A 246mm 168mm 195mm

400A 250A 246mm 175mm 203mm

630A 400A 246mm 185mm 214mm

800A 630A 246mm 195mm 225mm

CO

MBI

NAT

ION

ELB

OW

S (F

latw

ise

/Ed

ge

wis

e &

Ed

ge

wis

e/F

latw

ise

)

Cu

Rating (Amps)

Al

Maximum Combination Elbow

Z X Y

160A - 1000mm 600mm 1000mm

250A 160A 1000mm 600mm 1000mm

400A 250A 1000mm 585mm 1000mm

630A 400A 1000mm 565mm 1000mm

800A 630A 1000mm 545mm 1000mm Combination Elbow


SectionCombination Elbows


Section

Flatwise T-sectionFlatwise Tees are used to split one Busbar run into two separate runs. This can be very helpful in utilizing a small

amount of space and supplying two different parts of the building with power. T sections have been developed

by combining a feeder length and a Flatwise elbow together into one piece.

T-Section sizes are dependent on some factors: the size depends on the rating of the busbar, and also on how

many phases are needed. Please contact the PowerBar engineering department for further information.

Flache T-Kästen

Flatwise T-section


Flatwise T-section


Edgewise T-sectionEdgewise Tees are used to split one run into two separate runs. This can be very helpful in utilizing a small

amount of space and supplying two different parts of the building with power. T sections have been developed

by combining a feeder length and an Edgewise elbow together into one piece.

T-Section sizes are dependent on some factors: the box size depends on the rating of the busbar, and also on

how many phases are needed. Please contact the PowerBar engineering department for further information.

Hochkant-T-Kästen

Edgewise T-section


SectionEdgewise T-section


Section

Flatwise CrossFlatwise Crosses are used to split one run in to three. This can be very useful in utilizing a small amount of

space and distribute power to multiple parts of a building. Crosses have been developed by combining two

Flatwise elbows together into one piece.

Cross Section sizes are dependent on some factors: the size depends on the rating of the busbar, and also on

how many phases are needed. Please contact the PowerBar engineering department for further information.

Flache Kreuzstücke

Flatwise Cross Section


Flatwise Cross


Joint PacksThe PowerBar joint Pack is a compression joint

design, which utilises a joint tightening design to

distribute the pressure evenly over the joint pack.

There is one 5mm fish plate conductor for each

phase, which have a bevelled edge to allow for

easier installation. When fully torqued the fish plates

will sandwich the busbar conductor.

Above is the torque detail for the Joint Pack.

The bolts should be firstly tightened evenly to

remove the slack in the joint pack. Following this

the correct torque of 10Nm should be applied in a

sequential manner 1 followed by 2 followed by 3

followed by 4.

Klemmblöcke

Joint Fitted on Busbar

Joint Detail

Joint Detail


SectionJoint Packs


Section

Busbar can either be installed to run on its “Flat” or

on its “Edge”, the decision of how to run the busbar is

governed by a number of factors:

» Busbar Route

» Type of Installation

» Available Space

» Size of Busbar

The modular design of the PowerBar Busbar System

is such that it lends itself readily to either type of

installation.

Edge Installation

This is the preferred method of installation for MPB

busbar systems, it is also the main method used to

install distribution busbar in building risers, as the rising

busbar needs to run with the “Neutral” on the left

hand side as you look at the front face of the busbar,

this is to ensure the tap off face of the busbar is

exposed to accept the tap off units.

Flat Installation

When required the MPB busbar system can be

installed on its flat. Additional steel supports (unistrut)

must be utilised to achieve this.

Befestigungen

Bar Installed on Flat

Bar Installed on Edge

Edge Installation Detail


Fixings


Spring HangerSpring Hangers are used to support vertical

busbar runs. There are used to support the weight

of the busbar system on each floor and they also

compensate for minimal building movement

and thermal expansion. The maximum distance

between spring hangers may not exceed 5m. The

recommended installation method is pictured. The

standard spring bracket is designed to suit our busbar

system. Please contact our engineering department

for details.

Specification Details » Spring - Max. load 50kg each

(6 x spring = 50 x 6 = 300kg)

- O/D – 17.5mm

- I/D – 11.0mm

- Wire dis. – 3.66mm

- Free Length – 77.0

- Max. deflection 11mm (4.55kg/mm)

Befestigungen


SectionFixings

Spring Hanger Installation

Vertical Spring Bracket Assembly

Vertical Spring Bracket Assembly

Section

End Feed UnitsCable End Feed units are used on the ends of

busbar risers which are cable fed. They can be on the

top of the busbar, feeding down through the building,

or they can be located on the bottom of the busbar

riser, feeding up through the building. The size of

the cable end feed unit depends on a number of

factors:

» Rating of Busbar

» Size of Cable

» Number of Cables

» Is Protect Device OR Isolator Required?

The table below can be used as a size guide

to determine the cable end feed unit to suit your

installation.

The units can be specially manufactured to suit

your requirements, a typical requirement would be

a gland plate on the side to allow side entry cables.

Please contact the PowerBar engineering department

for further information.

Cu

160A - 500mm 500mm 182mm

250A 160A 500mm 500mm 182mm

400A 250A 500mm 500mm 182mm

630A 400A 500mm 500mm 182mm

800A 630A 730mm 500mm 182mm

Rating (Amps)

Al

Typical Cable End Feed Sizes

X Y Z

NOTE: The list above is based on typical situation; other factors need to be considered when deciding on which type of box to use, such as, location of box, cable size, Protection Devices (fault rating) additional accessories etc

Cable End Feed Unit


End Feed Units

CABLE ENTRY THROUGH THEBOTTOM OF BOX


Centre Feed UnitsCable Centre Feed units are used on the centre

of busbar risers which are cable fed. They are used

to allow the busbar to feed from a central location,

feed both up and down through the busbar system.

The size of the cable Centre feed unit depends on a

number of factors:

» Rating of Busbar

» Size of Cable

» Number of Cables

» Is a Protection Device OR an Isolator Required?

The table below can be used as a size guide to

determine the cable Centre feed unit to suit your

installation.

The units can be specially manufactured to suit

your requirements. Please contact the PowerBar

engineering department for further information.

Cu

160A - 500mm 500mm 182mm

250A 160A 500mm 500mm 182mm

400A 250A 500mm 500mm 182mm

630A 400A 500mm 500mm 182mm

800A 630A 730mm 500mm 182mm

Rating (Amp)

Al

Typical Cable Centre Feed Sizes

X Y Z

NOTE: The list above is based on typical situation; other factors need to be considered when deciding on witch type of box to use, such as, location of box, cable size, Protection Devices (fault rating) additional accessories etc.

Cable Centre Feed Unit


Centre Feed Units

End CapEnd caps are used to safely cap off the end of a busbar run, typically a rising busbar might be capped off at

the top of the run and the end of the final section of busbar. The End Cap units are factory fitted but they can

be easily removed on site to allow for extension of a busbar system, etc.

If the busbar run is bottom fed the End Cap would be located at the top end of the busbar, if the system is top

fed then the End Cap would be located at the bottom, In the case of a centre fed system then two End Caps

must be used one at the top and one at the bottom.

End Cap


End Cap

Expansion UnitsExpansion Units are fittings which are used to accommodate for expansion and contraction of a busbar

system and for building movement. Expansion units are typically installed in the centre of long busbar runs, and

might also be used at the beginning of riser runs to minimize the stress on the lower section of the busbar run.

Another common use would be where a busbar crosses an expansion joint of a building.

Expansion Units are recommended when a straight busbar run exceeds 60m. Expansion units allow for a

40mm movement along the length of the busbar run.

Please contact the PowerBar engineering department for further information.

Expansion Units


SectionExpansion Units


We manufacture a Variety of more specialist fittings

and components depending on the requirements

of the system, ranging from Step up/down Reducers,

Phase Rotation units, In-line disconnect Cubicles,

In-line Tap Off Units, custom built busbar connection

Units, etc… Some are detailed below. Please contact

the PowerBar engineering department for further

information.

Step Up / Down Reducers

Busbar Reducers are used to step up or down

between different busbar ratings where a reduction

in the busbar size or rating may be required. A typical

example might be reducing a 800A busbar run into a

250A system.

Phase Rotation Units

Phase Rotation Units have a number of uses, they

can be used to rotate the Phasing of a busbar system

through 180° (L1 N L2 E L3 to L3 E L2 N L1), these units

can also be used to “transverse” the busbar Phases

to suit the system it is being connected into, (L1 N L2 E

L3 To L3 E L2 N L1)

Special Sections

Phase Rotation Unit


Section

PowerBar Ltd can produce a wide range of “special” sections of busbar to suit a wide Variety of applications

and unusual issues that may arise.

For any special requirements please contact the PowerBar engineering department for further information.

Special Sections

Special Offset Busbar Section


Quick Reference Guide Critical Dimensions

Busbar Passing through a wall, ceiling or floor:

» Centreline of a joint to the wall, ceiling or floor. Min =

190mm.

» Joints cannot be positioned inside a wall, ceiling or

floor; joints must be accessible for maintenance.

Feeder Busbar Clearances:

» from the top of the busbar to a ceiling/floor/wall or

other busbar. Min = 50mm.

» From the side of the busbar to a ceiling/floor/wall or

other busbar. Min = 50mm

Distribution Busbar Clearances:

» Clearance must be given to provide for access and

operation of the Tap off Unit.

» Otherwise, clearances for the feeder busbar apply.

Feeder Busbar Length:

» Minimum Length = 600mm

» Maximum Length = 4000mm

Distribution Busbar Length:

» Minimum Length = 600mm.

» Maximum Length = 4000mm

Flatwise Elbow Section:

» Minimum leg length = varies depending on the busbar

rating and conductor material.

» Maximum leg length = 1000mm.

Edgewise Elbow Section:

» Minimum leg length = 246mm

» Maximum leg length = 1000mm.

Combination and Offset Elbows:

» Minimum leg length = varies depending on the busbar


» Maximum leg length = varies depending on the busbar


Critical Details

» Busbar drawings must have all relevant dimensions.

» Centreline dimensions are expected (please note any

dimensions that are not centreline dimensions)

» Walls and floor must be located and shown (wall/floor

thickness must be given).

» T he front of all switchboards must be given and provide

the phasing for any existing boards.

» Transformer connection requires full details.

» When using rising busbar please note the phase

orientation of the distribution sections.

Quick Reference Guide

E&I Engineering Ireland Ltd/Powerbar LimitedBallyderowen Burnfoot Lifford Co. Donegal Ireland

T: +44(0) 28 71353030 +353 (0)74 9368719

F: +44(0) 28 71354100 +353(0)74 9368106

W: www.e-i-eng.comE: [email protected] pr

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y du

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Documents

Medium powerbar busbar range