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Powerbar HPB CAST RESIN

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www.powerbar-busbar.com Powerbar HPB CAST RESIN

CONTENTS

Introduction

Standards

Busbar Dimensions

Chemial Resistance

Straight Lengths

Elbows

Offsets & Combination Elbows

Flanges

Flanges

FlangesSpecials

Joint Pack Installation

Typical Installation

Typical Installation

Technical Data (Copper)

Technical Data (Copper)

Technical Data (Aluminium)

Technical Data (Aluminium)

Quick Reference Guide

Other Catalogues

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www.powerbar-busbar.com

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Powerbar is a patented range of Busbar trunking that is utilised within

building and industrial applications to deliver power to Electrical Loads.

It is an alternative to traditional cabling and provides numerous

advantages to the I nstaller and Client including savings on space, time and cost.

There are also electrical savings due to reduced losses, reduced voltage drop and

flexibility to reposition load centres, using tap-off points.

Powerbar Overview

The Powerbar range of products is built with patented processes that make it the most reliableproduct of its type, providing peace of mind for your installation. This, together with unrivalledproduct support, means that the Powerbar range of products will provide the optimum solutionto your distribution requirements.

Powerbar services the UK and European markets from our manufacturing plant in Donegal, Irelandand the Middle East from our plant in Ras Al Khaimah, U.A.E. We pride ourselves on meeting ourclients deadlines and ensuring a quick turnaround on final make-up pieces.

From concept to commissioning we provide complete in-house engineering. Site surveys 3D - CAD Drawings Project Management Thermal Imaging

Thanks to our highly skilled team, we are experts at providing the client with exactly what theyrequire and are well experienced in producing bespoke parts to meet the clients unique demand.

Cast Resin

Powerbars Cast Resin(CRB) range i s a 1000 Volt, maintenance free, IP68 rated busbarsystem for outdoor, hazardous, or life safety applications.

The conductor is available in aluminium or copper, totally encapsulated in a fire retardant, selfextinguishing, and homogenous polymer concrete guaranteeing high resistance to fire, water,moisture, mechanical loads, chemicals and extreme temperature conditions (-40C to 60C).

The range is available from 800A to 6300A available with multiple six bar congurations to suitproject requirements, including Neutral, Double Neutral, and Earth.

INTRODUCTION

Standards

The Cast Resin range is fully ASTA Tested Certified and is CE approved. It is manufactured in aCertified Management Systemenvironment where Quality BS EN ISO 9001:2008, Safety OHSAS18001:2007 and Environmental ISO 14001 standards are applied to all aspects of the manufacturingand installationprocesses. It is manufactured in accordance with IEC61439-1 and IEC61439-6.

Type Tests

8.2.1 verification of Temperature Rise Limits.8.2.2 verification ofthe Dielectric Properties.8.2.3 verication ofthe Short Circuit Withstand Strength.8.2.4 verification ofthe Effectiveness of the Protective Circuit.8.2.5 verification ofClearance & Creepage Distances.8.2.6 verification ofMechanical Operation.8.2.7 verication oftheDegree of Protection.8.2.9 verication of theElectrical Characteristics .8.2.10 verification of Structural Strength.8.2.12 verification of Crushing Resistance.8.2.13 verication ofResistance to Abnormal Heat.8.2.14 verification ofResistance to Flame Propagation.

8.2.15 verification ofthe Fire Barrier in Building Penetration.

ASTA Certificates

Powerbar completed extensive testing at ASTA and KEMA accredited laboratories to ensure theproduct we supply meets the international requirements.

UL Classified

Powerbar completed extensive testing at UL accredited laboratories to ensure the product we supplymeets UL requirements in accordance to IEC60439-2.

Ingress ProtectionThe product has been rated at IP68 in accordance with IEC 60529.

Impact Resistance Test

The product has been rated at IK10 in accordance with IEC 62262.

Seismic Compliance

The product has a Qualication Level High in accordance to IEE Standard 693-2005.

Fire Resistance

The product has been rated at F 180 in accordance with IEC 60331-1 and meets ISO 834 standards.

Damp Heat

The product is in accordance with IEC60068-2-78 (Damp Heat Steady State) and IEC 60068-2-3 (DampHeat Cyclic).

Explosive Atmosphere (ATEX)The product has the following ATEX markings in accordance with IEC60079-0:2009 andIEC60079-18:2009:

All certificates available on request

OHSAS 18001:2007

OHS 533652

ISO 9001:2008

FM 12680

ISO 14001:2004

No: EMS 566536

STANDARDS

II 2 G Ex e IIC T5

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Powerbar HPB CAST RESINwww.powerbar-busbar.com

0403

CHEMICAL RESISTANCEBUSBAR DIMENSIONS

Key: SS- Single Stack DS- Double Stack

Chemicals Directly After Contact After 24 hours More Than 48 hours

Boric Acid 1 1 1

Hydrochloric Acid 10% 1 3 3

Sulfuric Acid 10% 1 1 1

Citric Acid 1 3 3

Lactic Acid 5% 1 3 3

Formic Acid 10% 3 3 3

Nitric Acid 10% 1 3 3

Acetic Acid 10% 3 3 3

Ethanol 1 1 1

Acetone 1 2 2

Calcium Chloride 1 1 1

Fuel (Diesel) 1 1 1

Ester 1 3 3

Ether 1 2 2

Formalin 37% 3 3 3

Glycerol 1 3 3

Ammonia 10% 1 1 1

Ammonia 30% 1 3 3

Sodium Hydroxide 10% 1 1 1

Sodium Hydroxide 50% 1 3 3

Lubricant 1 1 1

Engine Oil 1 1 1

Pentane 1 1 1

Toluene 1 3 3

Chlorinated Hydrocarbons 3 3 3

Javel Water 1 1 1

Copper Rating (A) Construction Type Busbar Height (H) (mm)

800 SS 100

1000 SS 130

1250 SS 105

1400 SS 120

1600 SS 145

2000 SS 175

2500 SS 210

3200 DS 310

4000 DS 360

5000 DS 460

6300 DS 560

Key:1 - Cast Resin is Resistant to Chemical2 - Chemical Evaporated Quickly from Cast Resin3 - Cast Resin is Affected by Chemical

Busbar Heights

Busbar Widths

Aluminium Rating (A) Construction Type Busbar Height (H) (mm)

1000 SS 110

1250 SS 130

1400 SS 150

1600 SS 180

2000 SS 230

2500 DS 300

3200 DS 380

4000 DS 540

5000 DS 620

Configuration Phases Neutral Earth

TP 100% 0% 0%

TP/N 100% 100% 0%

TP/E 100% 0% 100% or 50%

TP/NE 100% 100% 100% or 50%

TP/DN 100% 200% 0%

Note: If no earth bar is specified, earthing is to be provided by installation contractor.

3 Pole System

80mm

H

5 Pole System

120mm

H

6 Pole System

140mm

H

4 Pole System

100mm

H


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ELBOWSSTRAIGHT LENGTHS

Feeder Length

Feeder lengths can be supplied at any lengthbetween a minimum of 500mm and a maximumof 4000mm.

Feeder lengths account for the bulkof a busbar run.

SS LengthMin = 500mm - Max = 4000mmDS Length

Min = 500mm - Max = 4000mm

Minimum Busbar Length (mm)1500mm up to 2 tap off points

Maximum Busbar Length (mm)4000mm up to 6 tap off points

There are two types of tap off unit housingsavailable:

Option A:Glass matt for standard IP68.

Option B:

Stainless Steel housing for IP68, flame retardant& extreme environmental conditions.

Key Features of Tap-Off Box:

High impact strength Resistance to adverse climate condition Resistant to UV Radiation Flame Retardant Frame sizes: 250A plug-in frame (MCCB Trip unit 32A-250A) 630A plug-in frame (MCCB Trip unit 315A-630A) 800A plug-in frame (MCCB Trip unit 800A) 1600A plug-in frame (ACB Trip unit 1000A-1600A) IP68 Side or bottom IP68 cable entry.

Distribution Length

Distribution lengths are like feeder lengths butwith tap off slots. Tap off slots allow tap off unitsto be plugged into the busbar run.

Key features of Plug-in type MCCB (Internal):

Unambiguous remote signalling of the circuit breaker positions, On/Off/Tripped, wired with auxiliary contacts Option to lock plug-in device with padlocks

to prevent insertion of the circuit breaker Visible conductive disconnection of the

main circuit Easy to exchange the circuit breaker in case

of failure, simply plug-in / plug-out theMCCB

Flatwise Elbows

Flatwise elbows are typically used to make 90changes in the direction of the busbar system.There are two kinds, flatwise up and flatwisedown. These can be used to turn the busbarroute up or down if it is running on its edge, orto turn the busbar left and right if it is runningon its flat.

SS LengthMin = 300mm - Max = 1000mm

DS Length

Min = 500mm - Max = 1000mm

Total Max Length = 2000mm

Edgewise ElbowsFlatwise Elbows

Edgewise Elbows

Edgewise elbows are typically used to make 90changes in the direction of the busbar system.There are two kinds, edgewise right andedgewise left. These can be used to turn thebusbar route up or down if it is running on itsflat, or to turn the busbar left and right if it isrunning on its edge.

SS LengthMin = 300mm - Max = 1000mm

DS Length

Min = 300mm - Max = 1000mm



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FLANGESOFFSETS & COMBINATION ELBOWS

Offset Sections (Flat & Edge)

An Offset is used to avoid obstacles such aspipes or steel columns and to conform to thestructure of the building. It is basically twoelbows fabricated into one single piece. Thereare four types of offset section; flatwise offsetup and down, and edgewise offset left and right.

Length per LegMin = 350mm - Max = 500mmMax Offset = 600mm

Combination Elbows

Combination elbows are used to conform to thebuilding structure and to utilise a small amountof space to change direction, by combiningboth flatwise and edgewise elbows.

Length per Leg

Min = 350mm - Max = 500mm

Edgewise Offset

Edgewise Flatwise Offset

Flatwise Offset

Flatwise Edgewise Offset

Combination Possibilities

Flatwise Offset UpFlatwise Offset DownEdgewise Offset RightEdgewise Offset Left

Combination Possibilities

Edgewise Right/Flatwise UpEdgewise Right/Flatwise DownEdgewise Left/Flatwise UpEdgewise Left/Flatwise DownFlatwise UP/Edgewise LeftFlatwise Up/Edgewise RightFlatwise Down/Edgewise LeftFlatwise Down/Edgewise Right

Flange Connections

Flange connections provide a directconnection to Low VoltageSwitchgear, Transformer Enclosures,and other electrical equipment.

Panel Flange T2L- Min = 500mm - Max = 1000mm





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FLANGESFLANGES









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JOINT PACK INSTALLATIONSPECIALS

Flatwise Tee

Spring Hanger Installation

Flatwise Tee

Flatwise tees are used to split one busbar runinto two runs going in different directions. Thiscan be very useful in utilizing a small amountof space and supplying two different parts of abuilding with power. They are combination of afeeder length and a flatwise elbow.

Joint Pack

The PowerBar Joint pack is a compression jointdesign, which utilizes a specially designedBelleville washer to distribute the pressureevenly over the joint pack.Joint packs are used to connect all othercomponents in a busbar system, from feederlengths to flatwise tees.

SS Length per Leg

Straight edge - Min = 300mm - Max = 1500mwm

DS Length per Leg

Short edge - Min = 300mm - Max = 1000mm


Special Sections

We manufacture a variety of more specialized units and components depending on the requirements of the system. These range from End FeedUnits, Centre Feed Units, Expasions Units, Edgewise Tees, Flatwise Cross, Step Up/Step Down Reducers, Phase Rotation Units, In-line DisconnectCubicles, In-line Tap Off Units and custom built busbar connection units.

Powerbar can produce a wide range of special sections of busbar to suit a wide variety of applications and unusual issues that may arise.

Please contact PowerBar regarding any special requirements as we take pride in our ability to produce bespoke parts to meet ourclients needs.

Spring Hanger

Spring hangers are used to support verticalbusbar runs on each floor and they alsocompensate for building movement andthermal expansion.

The maximum distance between the springhangers may not exceed 3m.

For multistack arrangement please contact ourengineering department for details. (See backcover for contact information).

Joint Pack

Edge Installation Flat Installation Installation Cross-section

Edge Installation

This is the preferred method of installation forthe smaller rating busbar system, it is also themain method used to install distribution busbarin building risers as the rising busbar needs tobe in the correct orientation in order to ensurethe tap off face of the busbar is exposed toaccept the tap off units

Flat Installation

This tends to be the preferred method ofinstallation for multistack systems which aremuch taller when positioned on their edge.When coordinated throughout the building onits flat any busbar rating only has a height of140mm irrespective of rating.


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TECHNICAL DATA (COPPER)TECHNICAL DATA (COPPER)

Technical Data - Copper

Rating 800A 1000A 1250A 1400A 1600A

Rating Current (Amps)(lth) 800 1000 1250 1400 1600

Rating Insulation Voltage (V) 1000V 1000V 1000V 1000V 1000V

Rating Short TimeWithstand Current (lcw)

1Second (KA) 40 40 50 65 65

Peak Value (KA) 88 88 105 143 143

Conductor C.S.A. (mm) Copper (Phase)

Cross Sectional Area 240mm 328mm2 450mm 540mm 690mm

Conductor C.S.A. (mm) Copper (Neutral)


Conductor C.S.A. (mm) Copper(Integral Clean Earth 100% & 50%)

C ro ss Se ct io na l A re a ( 10 0% E ar th ) 2 40 mm 328mm2 450mm 540mm 690mm

Cross Sectional Area (50% Earth) 120mm 210mm 225mm 270mm 345mm

Height

Height of the trunking (mm) 100mm 130mm 105mm 120mm 145mm

Weight

Weight of the trunking (4 bar system) kg/m 30.9 42.9 37.5 43.6 53.6

Resistance

Resistance (m/m) at 20C 0.048 0.052 0.040 0.033 0.026


Reactance

Reactance (m/m) at 50Hz 0.051 0.047 0.045 0.040 0.033

Impedance

Impedance (m/m) at 80C 0.079 0.080 0.067 0.057 0.046

Voltage Drop per metre atFull Load 50Hz

Voltage drop, pf = 0.7 (V/m) at 80C 0.155 0.136 0.145 0.138 0.127

V ol ta ge d ro p, p f = 0 .8 ( V/ m) a t 8 0 C 0 .1 56 0.138 0.145 0.137 0.125








TechnicalData- Copper

Rating 2000A 2500A 3200A 4000A 5000A 6600A

Rating Current (Amps)(lth) 2000 2500 3200 4000 5000 6600

Rating Insulation Voltage (v) 1000 1000 1000 1000 1000 1000

Rating short timewithstand current(lcw)

1 Second (KA) 65 65 100 100 100 120

Peak Value (KA) 143 143 220 220 220 280

Conductor C.S.A.(mm) Copper (Phase)

Cross sectional Area 870mm 1080mm 1500mm 1800mm 2400mm 3000mm

Conductors C.S.A.(mm) Copper(Neutral)

Cross Sectional Area 870mm 1080mm 1500mm 1800mm 2400mm 3000mm

Conductor C.S.A.(mm) Copper(Integral Clean Earth 100% & 50%)

Cross Sectional Area (100% Earth) 870mm 1080mm 1500mm 1800mm 2400mm 3000mm

Cross Sectional Area (50% Earth) 435mm 540mm 750mm 900mm 1200mm 1500mm

Height

Height of the trunking (mm) 175 210 310 360 460 560

Weight

Weightofthetrunking(4barsystem)kg/m 65.7 79.7 115.3 135.4 175.6 215.8

Resistance

Resistance (m/m) at 20C 0.020 0.016 0.012 0.010 0.007 0.006

Resistance (m/m) at 80C 0.025 0.020 0.015 0.012 0.009 0.007

Reactance

Reactance (m/m) at 50Hz 0.027 0.021 0.016 0.014 0.011 0.009

Impedance

Impedance (m/m) at 80C 0.037 0.029 0.022 0.018 0.014 0.011


Voltagedrop, pf= 0.7 (V/m) at 80C 0.128 0.126 0.120 0.127 0.122 0.125

Voltage drop, pf= 0.8 (V/m) at 80C 0.126 0.125 0.118 0.125 0.119 0.121




Volt drop, pf= 0.7 (V/m) at 80C 0.142 0.140 0.133 0.141 0.136 0.139





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TECHNICAL DATA (ALUMINIUM)TECHNICAL DATA (ALUMINIUM)

Technical Data - Aluminium

Rating 1000A 1250A 1400A 1600A 2000A

Rating Current (Amps)(lth) 1000 1250 1400 1600 2000

Rating Insulation Voltage (V) 1000V 1000V 1000V 1000V 1000V

Rating Short TimeWithstand Current (lcw)

1Second (KA) 25 36 36 50 50

Peak Value (KA) 52 78 78 105 105

Conductor C.S.A. (mm)Aluminium (Phase)


Conductor C.S.A. (mm)Aluminium (Neutral)


Conductor C.S.A. (mm) Aluminium(Integral Clean Earth 100% & 50%)

Cross Sectional Area (100% Earth) 480mm 600mm2 720mm 900mm 1200mm

C ro ss S ec ti on al A re a ( 50 % E ar th ) 2 40 mm 300mm 360mm 450mm 600mm

Height

Height of the trunking (mm) 110mm 130mm 150mm 180mm 230mm

Weight

Weight of the trunking (4 bar system)kg/m

27.6 32.6 37.7 45.2 57

Resistance



Reactance

Reactance (m/m)at 50Hz 0.044 0.037 0.032 0.026 0.021

Impedance

Impedance (m/m) at 80C 0.093 0.075 0.063 0.051 0.03


V ol ta ge d ro p, p f = 0 .7 (V /m ) a t 8 0 C 0 .1 53 0.156 0.148 0.136 0.130






Vo lt ag e d ro p, p f = 0. 8 ( V/ m) a t 8 0 C 0 .1 68 0.171 0.161 0.149 0.143



Technical Data - Aluminium

Rating 2500A 3200A 4000A 5000A

Rating Current (Amps)(lth) 2500 3200 4000 5000

Rating Insulation Voltage (V) 1000V 1000V 1000V 1000V

Rating Short Time Withstand Current(lcw)

1Second (KA) 80 80 100 100

Peak Value (KA) 176 176 221 221

Conductor C.S.A. (mm) Aluminium(Phase)

Cross Sectional Area 1440mm 1920mm 2880mm 3360mm

Conductor C.S.A. (mm) Aluminium(Neutral)

Cross Sectional Area 1440mm 1920mm 2880mm 3360mm

Conductor C.S.A. (mm) Aluminium(Integral Clean Earth 100% & 50%)

Cr os s S ec ti on al Area (1 00 % E ar th) 1 44 0mm 1920mm 2880mm 3360mm

Cross Sectional Area (50% Earth) 720mm 960mm 1440mm 1680mm

Height

Height of the trunking (mm) 300mm 380mm 540mm 620mm

Weight

Weight of the trunking (4 bar system)kg/m

75.3 95.5 135.8 156

Resistance

Resistance (m/m) at 20C 0.013 0.01 0.006 0.005

Resistance (m/m) at 80C 0.027 0.021 0.014 0.012

Reactance

Reactance (m/m) at 50Hz 0.017 0.013 0.009 0.008

Impedance

Impedance (m/m) at 80C 0.032 0.025 0.017 0.014


Voltage drop, pf = 0.7 (V/m) at 80C 0.135 0.132 0.113 0.121










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QUICK REFERENCE GUIDE

Critical Dimensions

Busbar passing through a wall, ceiling or floor:

Centre-line of a joint to the wall, ceiling or oor minimum - 190mm.

Joints cannot be positioned inside a wall, ceiling or oor joints must be accessible

for maintenance.

Feeder Busbar Clearances:

From the top of the busbar to a wall, ceiling, floor or another busbar minimum - 200mm. This is to allow for joint pouring.

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 - 500mm

Maximum length - 4000mm

Distribution Busbar Length:

Minimum length - 500mm

Maximum length - 4000mm

Flatwise Elbow Section:

Minimum leg length 300mm for Single Stack

500mm for Double Stack

Maximum leg length 1000mm

Edgewise Elbow Section:

Minimum leg length 300mm

Maximum leg length 1000mm

Critical Details

Busbar drawing must have all relevantdimensions.

Centre-line dimensions are expected(please note any dimensions that are notcentre-line dimensions).

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

The front of all switchboards must be given and the phasing for any existing boards must be provided.

Transformer connections require full details.

When using rising busbar please note the phase orientation of the distribution sections.

Horizontal distribution busbar run on its Flat should always be oriented with the Neutral phase to the top face.

Service Conditions:

Ambient Temp : -15C to +50C

Relative Humidity: 95% or below

Temperature Rise Stability:

Temperature Rise limits are within +55C orless on the external busduct surface asspecied in IEC 60439-1 & 2

TECHNICAL DATA (ALUMINUIM)


OTHER CATALOGUES

HPB Copper Edition

HPB Copper IEC Edition

Tap Off Units


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website: www powerbar-busbar comwebsite: www powerbar-busbar com

PowerBar Limited has a policy of continuous development and therefore has the r ight to supply a product whichmay differ in detail from those shown in this publication.

POWERBAR LTD

BallyderowenBurnfootLiffordCo. DonegalIreland

Tel: +44 (0) 28 71353030

+353 (0) 74 9368719

Fax: +44 (0) 28 71354100

+353 (0)74 9368106

Email:[email protected]

POWERBAR GULF LLC

N16/N17Al Ghail Industrial ParkRas Al KhaimahPO Box 31921UAE

Tel: +971 (0)72 216100

Fax:+971 (0)72 216107

Email: [email protected]

UK OFFICE

E & I Engineering2/8 Victoria AvenueLondonEC2M 4NSUK

Tel: +44 (0) 20 32061650

Email:[email protected]

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