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The busbar system is used to transfer electrical energy to a vertical or horizontal point along the route within the facility, starting from a point such as a transformer, generator or panel, or to distribute energy to the loads within the facility by taking energy from the current receiving points utilizing tap off boxes.Busbar systems are widely used in high-rise buildings, factories, workshops, assembly lines, warehouses, stations, hotels, airports, petrochemical plants, data centers and supermarkets, etc. that require medium and low voltage current distribution.
Busbar General Information
A Short History of Busbar Trunking Systems
The Busbar Trunking System was first introduced in America during the 1930s to meet the requirements of the construction industry, with the advent of skyscrapers and the development of production technologies in factories.
European countries and Japan started using this system in the early 1950s, however during the 1970s EAE Elektrik A.Ş. started its own production and the use of busbar trunking systems in Turkey began.
EAE E-Line Busbar
With their modular configuration, EAE E-Line Busbar with its modular configuration, EAE E-Line Busbar energy distribution systems meet all the power requirements in modern corporations and buildings. Alterations in layouts, addition of machinery, and supply of power at various points can be accomplished without disrupting the operational ability of the facility.
Power is distributed via isolated bars within a sheet metal or aluminium casing and is efficiently distributed using tap-off boxes which can be plugged in and out safely from tap-off boxes along the length of the busbar without interrupting the power supply to supplementary equipment, supplied by the same busbar.
E-Line KX Busbar & Busbar Systems
E-Line Busbars, which has international test certificates, can be expanded, replaced, moved or reused whenever necessary. It is very easy, economical and safe to extract take power using tap off boxes placed anywhere along the route.
Types of Busbars According to the Current Intake Point
Busbar systems are divided into two according to the current intake points.
What is a bolt-on busbar?
Bolt-on Busbar System: Busbar systems that allows the distribution of electrical current via current supply tap off boxes junctures positioned in the busbar system.
Bolt-on: Used where current needs to be supplied from junctures positioned in busbar system and direct supply is executed.
What is a plug-in busbar?
Plug-in Busbar System: Busbar trunking systems that allows the receiving of electrical current via current supply tap off boxes on current supply (Plug-in point) windows on the casing of the busbar system.
Plug-in: Used where current is to be supplied from junctures positioned in busbar systems and plug-in window. (Only straight modules)
Types of Busbars According to Structure
Busbar systems are divided into two as air insulated and compact (sandwich type) according to their structure.
What is Air Insulated Busbar?
The most distinct specification of the air insulated Busbar system is that there is a certain gap between the conductors and the Busbar system functions in a closed metal body in an insulated environment provided with air.
The conductors (Aluminum or Copper) are not connected to each other as in the compact Busbar system.
If the conductors used in the Busbar system are in the range of 25A to 63A; conductors are placed in an insulated sheath (such as E-Line KY-S, E-Line DL/SL, E-Line KAM/KAP).
If the conductors used in the Busbar system are 100A amperes and above; it is placed on post insulators at certain intervals (such as E-Line MK, E-Line KO-II). These systems are generally produced in a multiple tap-off distribution Busbar structures.
What is Compact (Sandwich Type) Busbar?
These are the compact (Sandwich Type) Busbar systems, which are the latest stage in which robotic technology is used in its production.
The main specification of the compact Busbar system is that after the conductors (Aluminum or Copper) are wrapped with insulation materials (primarily B class polyester film, which is coated with an epoxy or polypropylene insulating material and temperature resistant), they are placed in the metal body in the form of sandwiches without any air gap.
With the compact structure, the dimensions are minimized as much as possible according to the capacity of the energy carried. Since the distance between the conductors is minimized, the inductive reactance is reduced and accordingly the voltage drop is reduced.
Thanks to the housing that acts as cooling, heat transfer is supplied in the most ideal way. Sandwich Type Busbar systems are produced from 400A and above.
Busbar Current Carrying Capacities
Busbar MV: Provides transfer and distribution of electrical current between 950A and 5700A (Medium Voltage Busbar: Protection with metal over cast resin). Conductors are manufactured from aluminum or electrolytic copper as per customer request.
Busbar KX: Provides transfer and distribution of electrical current between 400A and 6300A (By means of tin-plated aluminum busbar or copper busbar conductors.)
Busbar CR (Cast Resin Busbar): Provides transfer and distribution of electrical current between 630A and 6300A (By means of aluminum busbar or copper busbar conductors.)
Busbar KO-II: Provides transfer and distribution of electrical current between 160A and 800A (By means of aluminum busbar or copper busbar conductors.)
Busbar MK: Provides transfer and distribution of energy in the current levels between 100A and 225A (By means of aluminum busbar or copper busbar conductors.)
Busbar CCR (IP68 Aluminium housing Cast Resin Busbar): Provides transfer and distribution of energy in the current levels between 600A-6300A.
Busbar KD: Provides transfer and distribution of energy in the current levels between 160A-800A.
Busbar Tap-Off Boxes Specifications
Tap-Off Boxes are used to draw power from the Busbar Trunking To supply the Rack Cabinets with the required energy and monitor the consumption. EAE offers a wide range of Tap-Off Boxes constructed out of sheet metal and plastic.
| Maximum Voltage | 600V UL, 1000V IEC |
| Ampere Ranges | Plastic tap-off box: from 16A to 80A. Sheet metal tap-off box: from 125A to 1000A. up to 80A for MKP Data / up to 125A for KOP Data. |
| Housing | Aluminum, sheet metal or plastic material |
| Certificate | All EAE Busbar tap-off boxes are IEC certified. |
| IP Protection Class | IP55 when tap-off box cover is closed / IP2X when it is open |
Busbar Tap-Off Specifications for Data Center
| Ampere Ranges | Plastic tap-off box: from 16A to 80A. Sheet metal tap-off box: up to 1000A. Aluminum tap-off box: up to 80A for MKP Data / up to 125A for KOP Data. |
Frequently Asked Questions About Busbar Systems
The busbar system is a system that consists of straight lengths, supply elements, turning elements, panel and transformer modules, T-connectors, reduction and expansion transition modules.
Maintenance of the busbar system should be externally inspected annually. Busbar maintenance should never be done under electrical load. It should be ensured at every stage that all electrical connections are disconnected. Since energizing a busbar system that has been contaminated by water or moisture will damage the system and the employees. Precautions must be taken; tests must be carried out and possible causes must be eliminated. IEC 61439-6 standards, safety-related specifications in the country should be followed and implemented by all operating services. Since cleaning and other materials containing hydrocarbons that can be used during maintenance may have harmful effects on plastic materials, EAE must be contacted before use. EAE Busbar Systems operate silently under normal operating conditions. There may be a very slight buzz in some installations. This sound is impermissible; It may occur due to the fact that the joint points, metal parts are not assembled according to the user manuals. The system must be overhauled by turning off the energy and the problem must be eliminated. Any dripping or moisture that may appear on the busbar modules should be eradicated from the environment without delay and the cause should be eliminated.
Busbar systems are extremely easy to install thanks to their modular design. However, like all electrical systems, it is recommended that the installation be carried out by qualified personnel who are experts in their field and have received the necessary occupational health and safety training. Pre-assembly, assembly steps and what to do post assembly are explained in the manuals of the relevant products. Before commencing the assembly without reading the instructions or assembly manual.
E-Line MK Busbar Installation
E-Line KX and KO-II Vertical Busbar Installation
E-Line KY-S Lighting Busbar Installation
Busbar systems have non-flammability and halogen-free features. (Busbar systems are tested, certified and manufactured according to IEC 60331-1 and BS 6387 standards) KX series superior designed compact busbar systems from EAE have the ability to operate under 830°C heat for 3 hours.
Busbar Tap-off Box provides the energy which powers machines, equipment or switchboards.
Busbar trunking is an energy transmission and distribution system produced using copper or aluminium conductor options that make power distribution simpler and more flexible.
The busbar may be more expensive than a harness, however it lasts longer and does not need to be replaced regularly. EAE busbar systems(E-Line CR, E-Line CCR and E- Line MV) can suitably withstand outdoor weather conditions, making them the perfect solution for electrical substations or switchyards.
The price of the busbar per meter varies according to the conductor type (copper or aluminium) that is used in the busbar system for e.g , the number of conductor bars used, types of coating and whether the busbar body is painted or unpainted. You can obtain information from EAE customer service for the current EAE Busbar price per meter.
In the busbar assembly, the support system is selected according to the following factors, dimensions, weights and arrangements (ceiling, wall, floor) of the busbar duct system it will support. In addition, the environmental conditions where the busbar system will be used and the existing facilities structure also play an important role in the selection of the support system. For example, if the ambient weather conditions where the busbar ducts will be used are extremely hot or cold, the support system should be designed using highly corrosion resistant coated materials .In addition, the support system should be mounted safely and securely, taking into account the busbar location and weight.
It is a busbar module that allows easy rotation of the busbar at 100-160-225 ampere levels, and also provides expansion on the busbar due to heat. The module has taken its name because it is in the form of a bellow and flexible structure when viewed from the exterior. Articulated Busbar is also referred to as Flexible Return Module and Dilation(Expansion) Module.
When to use a Flexible Return Module (Articulated Busbar)?
It is used in the parts that need to be rotated in the busbar line at 100-160-225 ampere levels..
What are the Types of Dilatation Module (Articulated Busbar)?
There are two types according to the moduls operand:- Vertical Rotation: It is used in situations where the busbar line needs to turn upwards or downwards.
- Horizontal Rotation: It is used in situations where the busbar line needs to turn clockwise or anti clockwise.
Longevity
EAE E-Line Busbar systems have structural features that do not require specific maintenance. Each component of the system is modular and can be installed and uninstalled effortlessly. The entire system can be moved with ease between locations.
Modern Look
In addition to their functionality, E-Line Busbar systems give a modern look to business corporations.
Flexibility and Economy
Through their modular structure and superior design features, E-Line Busbar systems provide uncomplicated, economical, quick and state-of-the-art solutions for the repositioning of machinery and similar equipment in business corporations. All modifications and additions can be be accomplished effortlessly without interrupting the daily operation of the facility.