MPB

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
Overview 4-8
Table of contents
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
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 The MPB Busbar is simply installed in sections on
conductor CSA that can be sensibly installed and 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 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 Choose Busbar over Cable
device and so the lid can only be opened when the There are numerous advantages of MPB busbar
device is de-energized. over cable installations.
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 designers 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.

Overview
Section
Summary MPB Features

PowerBar leaves more space for additional services. Copper or Aluminium conductors 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. Earth First, Break Last safety feature.
PowerBar is ideal to replace multiple cable runs. Tap Off connection is made directly on to the busbar
Busbar reduces installation time. conductor.
On Busbar repositioning of distribution points is made Automatic automated assembly improves quality,
easy. 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.
PowerBars 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
Multiple Tap Off Slots
option you dont have with cable.

Overview
Low Voltage Busbar Type Tests

PowerBars 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 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.

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 20mm*5mm 20mm*5mm 35mm*5mm 55mm*5mm 75mm*5mm
Cross Sectional Area 100mm 100mm 175mm 275mm 375mm
CONDUCTORS C.S.A (mm2) COPPER (NEUTRAL/INTEGRAL CLEAN EARTH)

Bar Dimensions 20mm*5mm 20mm*5mm 35mm*5mm 55mm*5mm 75mm*5mm
PROTECTIVE EARTH C.S.A(mm2) ALUMINIUM HOUSING

WEIGHT
Weight of trunking (4 bar system) kg/mtr 8.5kg 8.5kg 12kg 17kg 22kg
RESISTANCE (m /m)
0.172 0.172 0.102 0.065 0.048
REACTANCE (m /m)
0.126 0.126 0.093 0.075 0.056
IMPEDANCE (m /m)
0.218 0.218 0.138 0.100 0.073
VOLT DROP LINE TO LINE (V/m) at given Power Factor

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

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 20mm*5mm 35mm*5mm 55mm*5mm 75mm*5mm
Cross Sectional Area 100mm 175mm 275m 375mm
CONDUCTORS C.S.A (mm2) ALUMINIUM (NEUTRAL/INTEGRAL CLEAN EARTH)

Bar Dimensions 20mm*5mm 40mm*5mm 55mm*5mm 75mm*5mm
Cross Sectional Area 100mm 200mm 300m 375mm
PROTECTIVE EARTH C.S.A (mm2) ALUMINIUM HOUSING

Cross Sectional Area 1102mm 1177mm 1276mm 1376mm
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

Construction Details Section
Section
Construction Details Housing Details

(Conductor/Insulation System) The PowerBar MPB range is constructed with
Medium PowerBar conductors are fabricated from 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 130C 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
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Section SystemSection
Earth
Integral Earth (Case) Isolated Earth Bar

The aluminium extrusion assembly is utilised to (50% or 100% Copper or Aluminium)
provide an earth path along the length of the busbar 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)

Protective Earth C.S.A
Copper Aluminium (in mm)
160A - 1102
250A 160A 1102
400A 250A 1177
630A 400A 1276
800A 630A 1376
Housing Detail (Case Earth) Isolated Earth Arrangement

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 @ 660C (933K)
2. Copper Melts @ 1084C (1,357K)
3. Average fire temperature @ 1,200C (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

Fire Barrier
439-28.1.15
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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.
Busbar Rating (Amps) Phase Bar Size (mm) Bar Busbar Size (mm)
Construction Phase
Per
Type Configuration
Phase
Copper Aluminium Depth Width 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
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Distribution Busbar/Tap Off Units Verteilerschienen
Section
Distribution Busbar 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)
Construction Type
Copper Aluminium Extended Earth Contact Bracket
160 - Single The PowerBar tap off unit has an extended Earth
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 Shutter Actuator

The tap off slot outlet and cover are made from 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, 130C 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 The unit is also fitted with an extended shutter
moisture. 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 as the design of the shutter actuator will prevent this.
screw driver to rotate the cover lock. The tap off slot 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)
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Section Tap Off Units
Section
Clamping Mechanism 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
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Tap Off Unit Abgangsksten
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 clients needs and requirements for the ease of
cable access.
Please contact the PowerBar engineering

department for further information.
Tap Off Box
Maximum Maximum Approx.

Tap Off Slots Box Type X Y Z
Circuit Breaker (MCCB)
Amps Volts (AC) Weight (kg)

- Tap Off Units
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.
Maximum Maximum Approx.

Tap Off Slots Box Type X Y Z
Amps Volts (AC) Weight (kg)
Fuseable & Switched
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.
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Flache Winkelstcke 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) Minimum Leg Size Standard Leg Size Maximum Leg Size
Cu Al X Y X Y X Y
160A - 195mm 205mm 350mm 350mm 1000mm 1000mm

FLATWISE ELBOW
(Up or Down)
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 Winkelstcke 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) Minimum Leg Size Standard Leg Size Maximum Leg Size
Cu Al X Y X Y X Y
EDGEWISE ELBOW
160A - 246mm 246mm 350mm 350mm 1000mm 1000mm

(Left or Right)
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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Anschlussstcke Flange Connections
Section
Flange Connections Rating (Amps)

Minimum Maximum
Flanges provide a direct connection to low Cu Al
(External Stump Size)

voltage switchgear, switchboards, transformer 160A - 200mm 1000mm
enclosures and other apparatus. Cut out details,
dimensions and drilling plans are provided with the 250A 160A 200mm 1000mm
customer drawings and it is the responsibility of the
switchgear manufacturer to provide the opening, drill 400A 250A 200mm 1000mm
connections in the switchgear, provide and terminate
the connecting hardware. PowerBar can provide 630A 400A 200mm 1000mm
coordination of phasing ect with other equipment.
On receipt of detailed equipment, standard flanges 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
Clearance Detail
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.
Standard Panel Flange
Website:Tel:
Combination Flange Connections
Kombinations-Flanschverbindungen
Section
Panel Flange Combination Flatwise Elbow Panel Flange Combination Edgewise Elbow
Rating (Amps) Minimum Flatwise Maximum Flatwise

FLANGE ELBOWS (Flatwise)
Cu Al Y Z 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

FLANGE ELBOWS (Edgewise)
Cu Al Y Z Y Z
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 455mm
Website:Tel:
Plan fr standardmige 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)
Website:Tel:
Offset Sections Versetzte Richtungsnderungen
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

Cu Al Y Z Y Z
160A - 195mm 50mm 1000mm 600mm

FLATWISE OFFSET
(Up & Down)
250A 160A 195mm 50mm 1000mm 600mm
400A 250A 203mm 50mm 1000mm 585mm
630A 400A 214mm 50mm 1000mm 565mm
800A 630A 225mm 50mm 1000mm 545mm
Rating (Amps) Minimum Edgewise Maximum Edgewise

Cu Al Y Z Y Z
EDGEWISE OFFSET
160A - 246mm 80mm 1000mm 600mm

(Left & Right)
250A 160A 246mm 80mm 1000mm 600mm
400A 250A 246mm 80mm 1000mm 600mm
630A 400A 246mm 80mm 1000mm 600mm
800A 630A 246mm 80mm 1000mm 600mm
Website:Tel:
Kombinationswinkel Combination Elbows
Section
Combination Elbows
These are used where space is at a premium and where the busbar must conform to the buildings 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)
Rating (Amps) Minimum Combination Elbow

(Flatwise/Edgewise & Edgewise/Flatwise)
Cu Al Z X Y
COMBINATION ELBOWS
160A - 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) Maximum Combination Elbow

(Flatwise/Edgewise & Edgewise/Flatwise)
Cu Al Z X Y
COMBINATION ELBOWS
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
Website:Tel:
Flatwise T-section Flache T-Ksten
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-Ksten 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 Kreuzstcke
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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Klemmblcke 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
Joint Detail
the correct torque of 10Nm should be applied in a
sequential manner 1 followed by 2 followed by 3
followed by 4.
Joint Fitted on Busbar
Website:Tel:
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
Website:Tel:
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
Website:Tel:
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
factors: BOTTOM OF BOX
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) Typical Cable End Feed Sizes
Cu Al X Y Z
160A - 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

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
Rating (Amp)
Centre Feed Sizes
Cu Al X Y Z Cable Centre Feed Unit
160A - 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.
Website:Tel:
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

Expansion Units
Section
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

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)

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

Quick Reference Guide
Quick Reference Guide

Critical Dimensions Edgewise Elbow Section:
Busbar Passing through a wall, ceiling or floor: Minimum leg length = 246mm
Centreline of a joint to the wall, ceiling or floor. Min = Maximum leg length = 1000mm.
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: Maximum leg length = varies depending on the busbar
from the top of the busbar to a ceiling/floor/wall or 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 Walls and floor must be located and shown (wall/floor
operation of the Tap off Unit. thickness must be given).
Otherwise, clearances for the feeder busbar apply. The 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.
Maximum leg length = 1000mm.

E&I Engineering Ireland Ltd/
Powerbar Limited
Ballyderowen
Burnfoot
Lifford
Co. Donegal
Ireland
produced by durganmedia.ie
T: +44(0) 28 71353030
+353 (0)74 9368719
F: +44(0) 28 71354100
+353(0)74 9368106
W: www.e-i-eng.com
E: info@e-i-eng.com

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Medium Power Bar

Overview terminated. The frequent need for multiple parallel

Major changes and extensions to existing

Such considerations are increasingly important as

PowerBar MPB busbar trunking systems offer

MPB is a product comprising fixed conductors

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MPB Busbar Trunking is much less affected

Performance under temperature demonstrates

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MPB Busbar Trunking is provided with optional

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Summary MPB Features

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Low Voltage Busbar Type Tests

Configuration Phases Neutral Earth

TP/N 100% 100% Case

TP/E 100% 0% 100%

TP/NE 100% 100% 100%

TP/DN 100% 200% Case

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and our people

SHORT CIRCUIT STRENGTH

RATING SHORT TIME WITHSTAND CURRENT (Icw)

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

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

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

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

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SHORT CIRCUIT STRENGTH

RATING SHORT TIME WITHSTAND CURRENT (Icw)

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

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

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

VOLT DROP (V/m)

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Construction Details Housing Details

Integral Earth (Case) Isolated Earth Bar

PowerBar have successfully conducted short circuit

Busbar Rating (Amps)

Housing Detail (Case Earth) Isolated Earth Arrangement

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Fire Barrier System

Key considerations for utilising fire barriers are:

The fire barrier is manufactured using a fire

PowerBar Fire Barriers are Tested to ISO830 and IEC

We design and build all of the fittings in house and

The table below illustrates the different types of

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

Distribution Busbar Tap Off Units (plug in type)

Tap Off Slot Shutter Actuator

The Tap off box cover is used to ensure protection

Tap Off Slot (Cover removed)

Tap Off Slot

Tap Off Slot (Cover fitted)

Clamping Mechanism Tap Off Units (plug in type)

The PowerBar tap off units have an interlock which

As a counter measure to the effects of thermal

Special Tap-Off Units

Special Features Are:

3D CAD-Design Service Available

Tap Off Unit

Please contact the PowerBar engineering