Medium powerbar busbar range

Medium Power Bar Busbar Range 160A - 800A Medium Power Distribution Made Easy

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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

Table of contents

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 Tap Off Units

16 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

Overview

Overview

terminated. The frequent need for multiple parallel

PowerBar MPB Busbar trunking is manufactured

conductors used for volt drop and current carrying

using state of the art automation techniques and

capacities also adds to the problems.

the continuous innovation which results from our intensive R&D program is reflected in our product

Cable Installations initially require containment

development.

systems such as tray, ladder, rack, trunking or conduit to be installed on a dropper/unistrut support system.

MPB Busbar Trunking is a positive cost effective

The containment needs to be fixed in place and then

alternative to cable for electrical distribution

the cable installation can begin. The second process

particularly for high current applications.

of cable installations can be undertaken when this is complete. Cables require to, be fixed, cleated,

Due to the familiarity of traditional cabling to

dressed, labeled, glanded, terminated and tested

designers and installers it is easy to overlook the

before being completed. Every single connection/

limitations of cable installations and the benefits of

termination has to be completed by hand and

busbar trunking.

tested. The time for each of these processes quickly adds up which adds significant costs, quality and

Electrical power cabling is difficult to handle,

duration to a project. These are fundamentally

difficult to install, takes up a lot of space particularly

important concerns where cost, quality and program

at bends, and can be very disruptive within existing

improvements are paramount considerations.

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

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

Typical Riser Installation

4

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along its length, for fitting tap-off units.

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Overview Section

Tap-off units are devices that plug into the trunking

these panels. Any additions to these units will require

and provide terminals for the connection of lighting

shutdowns and cabling from this central position to

and power distribution boards, power outlets, section

any new or modified loads regardless of location.

boards or other electrical loads.

With a de-centralised MPB Busbar Trunking Tap-off units provide a huge benefit in being able

installation, the protection devices are within the

to be added, repositioned or removed as necessary

tap-off unit and can therefore be installed close

without installing additional cabling back to the main

to the equipment which it is supplying, minimizing

switchboard.

disruptions, cost and time. Protective devices located adjacent to the load also assist greatly in fault finding

All tap off units are designed with safety of the end

and maintenance.

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

Choose Busbar over Cable There are numerous advantages of MPB busbar over cable installations.

device is de-energized.

Cable Installations are inflexible. Changes such

MPB Busbar is aluminium cased busbar trunking

as relocation of circuits, repartition of office space

and is much less susceptible to damage than cable

or adding additional circuits to accommodate

on cable trays. Maintenance costs are reduced

alterations in internal layouts can be inconvenient,

along with the risk of damage caused by electrical

costly and take a long time to complete.

faults.

This obviously makes the restructuring of electrical

The design criteria for MPB busbar is similar, but

services simple and cost effective providing the

quicker and easier than the design criteria for the

flexibility expected by modern businesses

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.

6300A Package Sub Station

Performance under temperature demonstrates MPB Busbar Trunking Installations are de-centralised

clearly the superior performance of MPB Busbar

distribution centres offering local connections rather

trunking. This performance differential increases with

than traditional centralized cabled installations

the ambient temperature and at an ambient of

which are designed around central distribution load

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

centres such as switchboards, section boards or

in performance in favour of MPB Busbar Trunking.

distribution boards. These central units contain all the necessary busbar, circuit breakers and protective

Due to the construction of MPB Busbar Trunking

devices for the installation as it was designed initially.

voltage drop performance is always superior to

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

cable. A lower value of phase and neutral voltage

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Overview

drop is a significant design factor that usually results

There is a perception that busbar has a higher unit

in increased cable conductor sizes and associated

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

costs. MPB Busbar Trunking simplifies the designer’s

face value when the installation costs and labour

work by allowing necessary longer runs to be used,

costs are considered busbar installations will save

while remaining within the maximum allowable

time and money. On a detailed comparison recently

voltage drop limits assigned in the design and

completed savings of nearly 30% were realized.

detailed within the BS7671 wiring regulations.

When the factors noted above that generally add MPB Busbar Trunking also provides a low

cost to design such as volt drop and CPC sizing

impedance earth path which again is significantly

are taken into account, then busbar advantages

lower than an equivalent cable based installation.

become even more obvious.

This low impedance earth path results in earth fault

Earlier completion of installations and projects

values that ensure disconnection times are adequate

frees staff to move on to further revenue generating

regardless of fuse or circuit breakers being used.

projects, buildings can be occupied or rented by new tenants more quickly thus generating more

Low impedance earth values also ensure reduced

rental income.

step and touch voltages to exposed metalwork in the event of earth faults, thus reducing secondary

PowerBar offer full comprehensive support from our

implications of major fault conditions.

highly qualified Engineering teams, who are involved at every stage of your project from tendering, through

Selection of protective device is an easy process.

design, to installation and commissioning. We have

MPB Busbar Trunking can be provided with protection

full technical support and a continuous improvement

devices from a range of manufacturers to ensure that

approach through R&D

detailed co-ordination of devices can be achieved.

With such undoubted product quality, technical This co-ordination data is usually provided by

advantages, cost saving, product support,

circuit breaker manufacturers but is limited to their

excellent service MPB Busbar Trunking is the

range of devices only. The availability of such tables

obvious choice

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.

6

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Overview Section

Summary

MPB Features

»»

PowerBar leaves more space for additional services.

»»

Copper or Aluminium conductor’s mill finish

Cables are bulky and difficult to handle,

»»

Joint Pack is factory fitted on one end of each busbar

»» »»

Cable installations are inflexible and changes can be

section, this saves time during installation on site.

inconvenient and costly.

»»

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

Cable install time is much longer and quickly incurs

»»

All Tap-off have mechanical/electrical interlocks with a

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

“Earth First, Break Last” safety feature. »»

conductor. »»

easy. »» »»

Tap Off connection is made directly on to the busbar Automatic automated assembly improves quality, reduces production time.

Busbar is far less susceptible to damage than cable,

»»

Fire barriers.

thus maintenance costs are reduced.

»»

Integrated case earth.

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.

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Multiple Tap Off Slots

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7

Overview

Low Voltage Busbar

Type Tests

PowerBar’s “Medium” PowerBar (MPB) range

»»

Verification of temperature rise limits.

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

»»

Verification of the dielectric properties.

insulated construction available with either copper

»»

Verification of the short circuit withstand strength.

or aluminium conductors. The copper option is

»»

Verification of the effectiveness of the protective circuit.

available from 160A to 800A, the aluminium options

»»

Verification of Clearance & creepage distances.

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

»»

Verification of mechanical operation.

available with a standard Ingress Protection rating of

»»

Verification of the degree of protection.

IP54. MPB can be used either feeder or distribution

»»

Verification of the electrical characteristics.

application or a combination of both. There is no

»»

Verification of structural strength.

need for any special splice connections and the 2

»»

Verification of crushing resistance.

types are fully interchangeable provided they are

»»

Verification of resistance to abnormal heat.

the same current, configuration and voltage rating.

»»

Verification of resistance to flame propagation.

The short circuit withstand ratings for the distribution

»»

Verification of the fire barrier in building penetration.

busbar is equal to the feeder busbar.

ASTA Certs

Standards

PowerBar Ltd has done extensive testing at ASTA and

The MPB range is fully ASTA Tested Certified and is

KEMA accredited laboratories to ensure the product

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

we supply meets the international requirements.

2000 and BS EN ISO18001 & PAS 99 certified facility.

It is designed and manufactured in accordance with IEC60439-1 and IEC60439-2.

Configuration Phases TP 100%

0%

Neutral

Earth

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.

8

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An Integrated Approach

We value our customers

…and our people

Technical Data

Technical Data Technical 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 Cross Sectional Area

20mm*5mm 20mm*5mm 35mm*5mm 55mm*5mm 75mm*5mm 100mm²

100mm²

175mm²

275mm²

375mm²

CONDUCTORS C.S.A (mm2) COPPER (NEUTRAL/INTEGRAL CLEAN EARTH) Bar Dimensions Cross Sectional Area

20mm*5mm 20mm*5mm 35mm*5mm 55mm*5mm 75mm*5mm 100mm²

100mm²

PROTECTIVE EARTH C.S.A(mm2) ALUMINIUM HOUSING Cross Sectional Area

1102mm²

WEIGHT

1102mm²

Weight of trunking (4 bar system) kg/mtr

RESISTANCE (m /m)

8.5kg

8.5kg

1177mm²

12kg

275mm²

375mm²

1276mm²

1376mm²

17kg

22kg

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

10

175mm²

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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TechnicalSection Data

Technical Data Technical 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 Cross Sectional Area

20mm*5mm 35mm*5mm 55mm*5mm 75mm*5mm 100mm²

175mm²

275m²

375mm²

CONDUCTORS C.S.A (mm2) ALUMINIUM (NEUTRAL/INTEGRAL CLEAN EARTH) Bar Dimensions Cross Sectional Area

20mm*5mm 40mm*5mm 55mm*5mm 75mm*5mm 100mm²

200mm²

PROTECTIVE EARTH C.S.A (mm2) ALUMINIUM HOUSING Cross Sectional Area

WEIGHT Weight of trunking (4 bar system) kg/mtr

RESISTANCE (m /m)

REACTANCE (m /m)

IMPEDANCE (m /m)

VOLT DROP (V/m)

1102mm²

6.6kg

1177mm²

7kg

300m²

375mm²

1276mm²

1376mm²

9.65kg

11.88kg

0.160 0.140 0.093 0.075

0.093 0.090 0.067 0.066

0.218 0.138 0.100 0.073

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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Construction Details

Construction Details (Conductor/Insulation System) Medium PowerBar conductors are fabricated from

Section Section

Housing Details The PowerBar MPB range is constructed with a lightweight and rugged extruded aluminium

either High Density 99.99% conductivity copper,

assembly. The aluminium extrusions are arranged

or 55% conductivity aluminium. The CSA of the

without the need for welding or seams. The final

conductors varies depending on the rating of the

assembly is riveted together along its length providing

system. The conductors have fully rounded edges

a fully encased tamper proof design.

and this makes for a smooth and easy connection between the busbar and the Joint Pack. The

The aluminium housing provides an excellent

conductors are insulated by means of a clear air

ground path through the busbar system. The cross

gap between each phase. The gap is maintained

sectional area of the aluminium housing of the

by mounting the conductors in a special moulding

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

which is a durable, high strength, polycarbonate

of the individual conductors.

material rated as a Class B 130째C insulator. The moulding also ensures a clear air gap is maintained

The all-aluminium housing as a non ferrous metal,

between the conductors and the external busbar

provides excellent heat dissipation properties. It is

earth casing. With applicable creepage and

unaffected by reduction in reactance and magnetic

clearance to IEC60439.

flux leakage, as compared to steel housing. The aluminium housing resists rust and other elements.

Distribution busbar applications connect directly onto the conductor at the contact location points of

The integrity and strength of the housing assures

the Tap Off Box Slot outlet.

specifiers and users with a safe and durable installation over the spectrum of industrial and commercial applications.

Construction Detail

Construction Detail

12

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Section

SystemSection Earth

Integral Earth (Case) The aluminium extrusion assembly is utilised to provide an earth path along the length of the busbar

Isolated Earth Bar (50% or 100% Copper or Aluminium) In this optional arrangement the earth conductor

system. The system earth continuity is maintained

is an internal conductor within the busbar assembly.

through each joint by the earth joint covers. The

It is fully isolated from the Aluminium casing and the

aluminium joint covers are furnished with earth

other internal conductors. The continuity is maintained

contact surfaces on the inside, when installed the

through the joint pack. This option is available to

contact surfaces are bolted directly to the earth of

meet the ever-growing need for an isolated earth

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

in systems with heavy microprocessor, based loads

path that assures earth continuity with very low

or large computer based installations where Earth

impedance characteristics.

isolation is essential.

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

Busbar Rating (Amps) Copper

Aluminium

Protective Earth C.S.A (in mm²)

160A

-

1102

250A

160A

1102

400A

250A

1177

630A

400A

1276

800A

630A

1376

Housing Detail (Case Earth)

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13

Fire Barrier System

Section Section

Fire Barrier System PowerBar 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

14

Fire Barrier

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Speisesammelschienen

Feeder Busbar Section

Fittings When 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 Busbar Straight sections of Feeder busbar can be supplied in any length, from a minimum of 600mm to a MPB Busbar

maximum of 4000mm.

The table below illustrates the different types of build arrangement used depending on the rating of busbar required for the application.

15

Busbar Rating (Amps)

Phase Bar Size (mm)

Copper

Depth

Width

Aluminium

Bar Construction Per Type Phase

Busbar Size (mm) Depth

Phase Configuration

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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Distribution Busbar/Tap Off Units

Distribution Busbar

Verteilerschienen Section

Tap Off Units (plug in type)

Straight sections of Distribution busbar can be

All PowerBar tap off units are designed with the

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

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

a maximum of 4000mm.

following features are standard for both fused and circuit breaker type plug-in units.

Busbar Rating (Amps) Copper

Aluminium

Construction Type

Extended Earth Contact Bracket

160

-

Single

250

160

Single

Contact Bracket which ensures the Earth ground

400

250

Single

is always the first point to connect with the busbar

630

400

Single

system during installation and the last point to

800

630

Single

disconnect during the removal of a tap off unit.

Tap Off Slot The tap off slot outlet and cover are made from

The PowerBar tap off unit has an extended Earth

Shutter Actuator The Earth contact is designed to make positive

a durable, high strength, polycarbonate material

contact with the busbar earth ground before the

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

phase or neutral contacts engage the busbar.

cover is designed to prevent access to the contacts behind the cover and prevent the entry of dirt, dust or moisture.

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),

The cover can be removed by using a flat head screw driver to rotate the cover lock. The tap off slot

as the design of the shutter actuator will prevent this.

This ensures correct phasing of conductors.

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 Slot (Cover removed)

Tap Off Slot

Tap Off Slot (Cover fitted)

16

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Section

Clamping Mechanism

Tap Off Section Units

Tap Off Units (plug in type)

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 Units PowerBar LTD take a flexible customer focused approach to our manufacture custom engineered and custom built tap off arrangements are the norm not the exception.

Typical Tap Off Box

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.

3D CAD-Design Service Available

17

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Tap Off Unit

Abgangskästen Section

Tap Off Unit The 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.

Circuit Breaker (MCCB) - Tap Off Units

Tap Off Box

Maximum Amps

Maximum Volts (AC)

Tap Off Slots

Box Type

X

Y

Z

Approx.

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

Fuseable & Switched Tap Off Units (SW/FS)

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.

Maximum Amps

Maximum Volts (AC)

Tap Off Slots

Box Type

X

Y

Z

Approx.

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.

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.

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Flache Winkelstücke

Flatwise Elbows Section

Flatwise Elbows Flatwise 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.

Flatwise Elbow 90˚

Flatwise Elbow 0-179˚

Rating (Amps)

FLATWISE ELBOW (Up or Down)

Cu

19

160A

Al

-

Minimum Leg Size X

Y

Standard Leg Size X

Y

Maximum Leg Size X

Y

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

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Edgewise Elbows

Winkelstücke hochkant Section

Edgewise Elbows Edgewise 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.

Edgewise Elbow 90˚

Edgewise Elbow 0-179˚

Rating (Amps)

EDGEWISE ELBOW (Left or Right)

Cu

20

160A

Al

-

Minimum Leg Size X

Y

Standard Leg Size X

Y

Maximum Leg Size X

Y

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

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Anschlussst端cke

Flange Connections Section

Flange Connections 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.

(External Stump Size)

Flanges provide a direct connection to low

Rating (Amps)

On receipt of detailed equipment, standard flanges

Cu

Al

Minimum Maximum

160A

-

200mm 1000mm

250A

160A

200mm 1000mm

400A

250A

200mm 1000mm

630A

400A

200mm 1000mm

800A

630A

200mm 1000mm

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

Clearance Detail

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.

Standard Panel Flange

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Combination Flange Connections Kombinations-Flanschverbindungen Section

FLANGE ELBOWS (Edgewise)

FLANGE ELBOWS (Flatwise)

Panel Flange Combination Flatwise Elbow

22

Rating (Amps) Cu

Al

Panel Flange Combination Edgewise Elbow

Minimum Flatwise Y

Z

Maximum Flatwise Y

Z

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

Rating (Amps) Cu

160A

Al

-

Minimum Flatwise Y

Z

Maximum Flatwise Y

Z

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 455mm

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Plan für standardmäßige Flanschaussparungen Flange Cut Out and Connection Details Section

Standard Panel Flange Cut Outs and Connection Details

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

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Offset Sections

Versetzte Richtungsänderungen 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.

Edgewise Offset

Flatwise Offset

Rating (Amps)

FLATWISE OFFSET (Up & Down)

Cu

Al

Z

Y

Z

-

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

Cu

EDGEWISE OFFSET (Left & Right)

Y

Maximum Flatwise

160A

Rating (Amps)

24

Minimum Flatwise

Al

Minimum Edgewise Y

Z

Maximum Edgewise Y

Z

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

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Kombinationswinkel

Combination Elbows Section

Combination Elbows These 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.

COMBINATION ELBOWS

(Flatwise/Edgewise & Edgewise/Flatwise)

COMBINATION ELBOWS

(Flatwise/Edgewise & Edgewise/Flatwise)

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

25

Rating (Amps)

Cu

160A

Al

-

Minimum Combination Elbow

Z

X

Y

246mm 168mm 195mm

250A

160A 246mm 168mm 195mm

400A

250A 246mm 175mm 203mm

630A

400A 246mm 185mm 214mm

800A

630A 246mm 195mm 225mm

Rating (Amps)

Cu

Al

160A

-

Maximum Combination Elbow

Z

X

Y

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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Flatwise T-section

Flache T-K채sten Section

Flatwise T-section Flatwise 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.

Flatwise T-section

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Hochkant-T-K채sten

Edgewise T-section Section

Edgewise T-section Edgewise 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.

Edgewise T-section

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Flatwise Cross

Flache Kreuzst端cke Section

Flatwise Cross Flatwise 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.

Flatwise Cross Section

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28

Klemmblรถcke

JointSection Packs

Joint Packs The 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.

Joint Detail

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

Joint Detail

sequential manner 1 followed by 2 followed by 3 followed by 4.

Joint Fitted on Busbar

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Fixings

Befestigungen 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.

Bar Installed on Edge

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.

Edge Installation Detail

Bar Installed on Flat

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30

Befestigungen

Fixings Section

Spring Hanger Spring 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.

Vertical Spring Bracket Assembly

Specification Details »»

Spring - M ax. load 50kg each (6 x spring = 50 x 6 = 300kg)

Spring Hanger Installation

- O/D – 17.5mm - I/D – 11.0mm - Wire dis. – 3.66mm - Free Length – 77.0 - Max. deflection 11mm (4.55kg/mm)

Vertical Spring Bracket Assembly

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31

End Feed Units

Section

End Feed Units

The units can be specially manufactured to suit

Cable End Feed units are used on the ends of

your requirements, a typical requirement would be

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

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

top of the busbar, feeding down through the building,

Please contact the PowerBar engineering department

or they can be located on the bottom of the busbar

for further information.

riser, feeding up through the building. The size of the cable end feed unit depends on a number of CABLE ENTRY THROUGH THE BOTTOM OF BOX

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.

Cable End Feed Unit

Rating (Amps)

Cu

160A

Al

-

Typical Cable End Feed Sizes

X

Y

Z

500mm 500mm 182mm

250A

160A 500mm 500mm 182mm

400A

250A 500mm 500mm 182mm

630A

400A 500mm 500mm 182mm

800A

630A 730mm 500mm 182mm

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

32

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Centre Feed Units

Centre Feed Units

The units can be specially manufactured to suit

Cable Centre Feed units are used on the centre

your requirements. Please contact the PowerBar

of busbar risers which are cable fed. They are used

engineering department for further information.

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.

Typical Cable Centre Feed Sizes

Rating (Amp) Cu

160A

Al

-

X

Y

Z

Cable Centre Feed Unit

500mm 500mm 182mm

250A

160A 500mm 500mm 182mm

400A

250A 500mm 500mm 182mm

630A

400A 500mm 500mm 182mm

800A

630A 730mm 500mm 182mm

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.

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33

End Cap

End Cap End 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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Expansion Section Units

Expansion Units Expansion 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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Special Sections

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 Phase Rotation Unit

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)

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Special Sections 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 Offset Busbar Section

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37

Quick Reference Guide

Quick Reference Guide Critical Dimensions

Edgewise Elbow Section:

Busbar Passing through a wall, ceiling or floor:

»»

Minimum leg length = 246mm

»»

»»

Maximum leg length = 1000mm.

Centreline of a joint to the wall, ceiling or floor. Min = 190mm.

»»

Joints cannot be positioned inside a wall, ceiling or

Combination and Offset Elbows:

floor; joints must be accessible for maintenance.

»»

Minimum leg length = varies depending on the busbar rating and conductor material.

Feeder Busbar Clearances: »»

»»

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

Maximum leg length = varies depending on the busbar rating and conductor material.

other busbar. Min = 50mm. »»

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

Critical Details

other busbar. Min = 50mm

»»

Busbar drawings must have all relevant dimensions.

»»

Centreline dimensions are expected (please note any

Distribution Busbar Clearances: »»

dimensions that are not centreline dimensions)

Clearance must be given to provide for access and

»»

operation of the Tap off Unit. »»

Walls and floor must be located and shown (wall/floor thickness must be given).

Otherwise, clearances for the feeder busbar apply.

»»

T he front of all switchboards must be given and provide the phasing for any existing boards.

Feeder Busbar Length:

»»

Transformer connection requires full details.

»»

Minimum Length = 600mm

»»

When using rising busbar please note the phase

»»

Maximum Length = 4000mm

orientation of the distribution sections.

Distribution Busbar Length: »»

Minimum Length = 600mm.

»»

Maximum Length = 4000mm

Flatwise Elbow Section: »»

Minimum leg length = varies depending on the busbar rating and conductor material.

»»

38

Maximum leg length = 1000mm.

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