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Transcript of 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
e of
con
tent
s
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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
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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
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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
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Overview
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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
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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
Cross Sectional Area 100mm² 100mm² 175mm² 275mm² 375mm²
PROTECTIVE EARTH C.S.A(mm2) ALUMINIUM HOUSING
Cross Sectional Area 1102mm² 1102mm² 1177mm² 1276mm² 1376mm²
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
Volt drop line to line P.F 0.9 0.093 0.093 0.092 0.100 0.093
Volt drop line to line P.F 0.95 0.090 0.090 0.087 0.093 0.087
Volt drop line to line P.F 1.0 0.084 0.084 0.081 0.087 0.081
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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
Volt drop line to line P.F 0.9 0.051 0.072 0.078 0.100
Volt drop line to line P.F 0.95 0.050 0.070 0.076 0.096
Volt drop line to line P.F 1.0 0.044 0.061 0.065 0.081
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SectionTechnical Data
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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
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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
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SectionSystem Earth
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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
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Fire Barrier System
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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
630A 400A 55mm 5mm 1 Single 102.5mm 168mm ALL
800A 630A 75mm 5mm 1 Single 122.5mm 168mm ALL
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SectionFeeder Busbar
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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)
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Distribution Busbar/Tap Off Units
Tap Off Slot
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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
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SectionTap Off Units
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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.
18 Website: www.e-i-eng.com Tel: +44 (0)28 71 353030 Email: [email protected]
Tap Off Unit
Maximum Amps
Maximum Volts (AC)
Tap Off Slots Box Type X Y ZApprox.
Weight (kg)
19 Website: www.e-i-eng.com Tel: +44 (0)28 71 353030 Email: [email protected]
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
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SectionFlatwise Elbows
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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
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Edgewise Elbows
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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
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SectionFlange Connections
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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
Maximum FlatwiseMinimum FlatwiseRating (Amps)
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
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Combination Flange Connections
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Standard Panel Flange Cut Outs and Connection Details
Plan für standardmäßige Flanschaussparungen
Panel Flange Plate cut-out detail for PowerBar MPB Range. (160A – 800A)
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SectionFlange Cut Out and Connection Details
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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
Maximum FlatwiseMinimum FlatwiseRating (Amps)
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
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Offset Sections
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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
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SectionCombination Elbows
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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
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Flatwise T-section
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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
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SectionEdgewise T-section
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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
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Flatwise Cross
29 Website: www.e-i-eng.com Tel: +44 (0)28 71 353030 Email: [email protected]
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
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SectionJoint Packs
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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
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Fixings
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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
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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
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End Feed Units
CABLE ENTRY THROUGH THEBOTTOM OF BOX
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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
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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
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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
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SectionExpansion Units
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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
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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
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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
rating and conductor material.
» Maximum leg length = varies depending on the busbar
rating and conductor material.
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
oduc
ed b
y du
rgan
med
ia.ie