Efficient Data Center Busbar Systems for Reliable Power Distribution

Busbar trunking systems are vital for safe, scalable and efficient power distribution in modern data centers. With high capacity, flexibility and reliability, customized busbar architectures provide long-term value over traditional cabling solutions.

GRL offers expertly engineered busbar systems purpose-built for your specific data center requirements. Contact our specialists today to discuss how to optimize your power infrastructure using GRL busbar systems.

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Introduction

Busbar trunking systems provide centralized, dedicated power distribution in data centers to efficiently deliver large currents from the utility source to racks and equipment. Busbars offer superior safety, capacity and flexibility compared to traditional cabling.

Consisting of bare or insulated conductors mounted to supports within enclosures, busbar systems enable easy tap-offs to server racks and reconfiguration as data center capacity expands. Custom busbar layouts optimize power flow, redundancy and monitoring.

With ever-increasing compute densities in modern data centers, busbars offer a safe, maintainable solution for meeting high current capacity and availability needs. Read on to learn how data centers leverage busbar technology for scalable, resilient power infrastructure.

Benefits of Using Busbars

Busbar trunking offers significant advantages for data center power distribution:

High Current Capacity

Busbars are sized for 1000 to 6000 amps capacity, far exceeding cables. This caters to increasing rack densities and future growth in a compact footprint.

Low Losses

The lower impedance of busbar conductors minimizes I2R heating losses, ensuring energy efficient power delivery to IT loads.

Ease of Modification

Tap-off points can be conveniently added anywhere along busbar length to extend power to new racks or zones.

Flexible Architecture

Layouts can integrate redundancy and multiple power sources through busbar risers, loops and interconnections.

Safety and Protection

Insulation, isolation, proper clearances and IP rating reduces risks from faults and accidents. Integrated monitoring allows rapid detection.

For scalable, efficient and safe power distribution, busbar systems are ideal for modern data centers.

Design Considerations

Key aspects to consider when planning busbar systems in data centers:

Electrical Load Evaluation

Analyze present load and expected growth, server power densities, redundancy levels and duty cycle to arrive at capacity requirements.

Layout Planning

Determine optimal routing to rack bays considering cable lengths, phasing, redundancy loops and physical installation constraints.

Busbar Sizing

Select busbar ampacity for phase and neutral conductors based on load currents and deratings, considering harmonics and future expansion.

Standard Compliance

Design busbar layouts, separation and protections as per NFPA 70, BS 7671 and other data center standards.

Accessibility and Cooling

Ensure adequate access space for maintenance and adequate airflow for busbar cooling. Coordinate ceiling layout for busbar enclosures.

Careful planning ensures an optimized and standards-compliant busbar system design.

Installation Guidelines

Proper installation of busbar trunking is essential for safe, reliable data center power distribution:

Structural Provisions

Ensure surfaces can support busbar weights. Provide independent stable supports every meter or less along busbar lengths.

Connections and Terminations

Use compatible terminals for busbar joints and tap-offs. Tighten to specified torques. Insulate exposed sections suitably.

Earthing Requirements

Bond busbar enclosure properly using designated earthing points. Provide adequate local supplementary bonding.

Protection and Isolation

Install IP2X rated busbar enclosure sections. Use phase barriers and covers at joints.

Inspection and Testing

Inspect busbars visually for defects, clearances and isolation. Test insulation resistance and continuity prior to energization.

With meticulous installation and testing, busbar systems will operate safely and to their rated capacity.

Maintenance Aspects

To keep busbar systems running reliably over decades:

Cleaning

Vacuum or wipe dust and debris from busbars and enclosures regularly following safety procedures.

Inspection

Check for signs of overheating, corrosion, cracks, flashovers and insulation damage during preventive maintenance.

Relocation or Extension

Disconnect power and isolate sections properly when shifting or adding new tap-off boxes.

Repairs

Repair or replace damaged busbar sections after isolating the faulty area. Remove corrosion and reapply insulating coat.

Testing

Test insulation resistance annually. Check torque of bolted connections and thermograph joints.

Proactive maintenance minimizes faults and extends the safe operating life of data center busbars.

Safety and Risk Management

Busbar hazards in data centers require mitigations:

Insulation and Isolation

Use insulated busbars or install shrouding. Partition high and low voltage sections. Earth exposed metal properly.

Warning Signs

Post safety signs indicating high voltage near isolation points and tap-off boxes.

Access Restrictions

Prevent unqualified access into busbar sections through locks, barriers and monitoring.

Fire Prevention

Monitor temperature and load. Ensure adequate busbar ventilation. Detect faults rapidly.

Backup Connections

Provide alternate cabling links between critical PDUs and racks to use if busbar segment needs isolation.

With prudent design, procedures and access control, busbar operation can be made safe.

Customization for Data Centers

Busbars offer ample flexibility to tailor the system to data center requirements:

Enclosures and Accessories

Select IP rated enclosures. Install barriers, covers and doors at tap points. Provide pull offs, switches and indicators.

Tap-offs and Drops

Position tap boxes and busbar droppers to feed specific rack lines based on load density.

Adapters and Redundancy Links

Use adapters to interface busbar sections. Add removable links between busbars for redundancy.

Sizing and Layout

Optimize conductor sizing zones to balance capacity and flexibility. Model options through analysis and prototyping.

The busbar trunking system can be adapted to achieve an efficient, scalable data center architecture.

Latest Innovations

Advances in busbar technology provide opportunities to further improve data center performance:

High Ampacity Conductors

New alloys like copper-silver and encapsulated aluminum increase current density while limiting temperature rise.

Compact Busway

Busbars with reduced footprint save space over conventional designs while carrying equal loads.

Intelligent Monitoring

IoT enabled busbars allow remote monitoring of current, voltage, faults and temperature.

Hybrid Systems

Combined busbar-cable systems use bus trunks for high capacity, cables for flexible final drops.

By leveraging such innovations, data center busbar systems can stay cutting-edge.

GRL Busbar System Solutions

GRL provides custom engineered busbar systems to meet specialized data center requirements:

High Quality Manufacturing

Our busbars are constructed from high conductivity copper and insulated with Class F composite coatings for electrical integrity.

Stringent Testing

100% production testing ensures busbars meet dielectric strength, temperature rise and short circuit withstand standards.

Expert Technical Support

Our engineering team helps design optimal busbar layouts for your data center using modeling tools and past project experience.

Custom Designs

We tailor busbar systems from ampacity to form factor based on your load projections, redundancy needs and physical constraints.

Global Installations

GRL has delivered busbar solutions for data centers across regions in conjunction with major electrical contractors.

Trust GRL busbars to distribute data center power reliably and efficiently.

GRL-busbar system

Frequently Asked Questions

  1. What is a busbar system in data centers?

Busbar systems consist of bare or insulated conductive bars mounted within protective enclosures to distribute power from utility source to server racks in data centers.

  1. Why are busbars used in data centers?

Compared to cables, busbars offer higher capacity, lower losses, ease of taps, flexibility, safety and reliability – vital attributes for data centers.

  1. What are the benefits of busbar systems in data centers?

Key benefits include high current capacity, flexibility for growth, efficient power delivery, simple installation, isolation and redundancy for reliability.

  1. What standards apply to data center busbars?

Busbars have to comply with NFPA 70, BS 7671 and IEC 61439 standards for layout, electrical spacing, insulation, earthing and isolation.

  1. How does busbar design affect data center reliability?

Busbar redundancy loops, multiple feeds, compartmentalization and robust connections are vital for ensuring availability during faults.

  1. How to select the right busbar for a data center?

Consider present load, growth projections, voltage, phasing, physical constraints and redundancy requirements when selecting busbar ratings and layout.

  1. What busbar current ratings are used in data centers?

Busbar current ratings range from 1000A to 6000A typically, depending on data center size. High density facilities require 4000-6000A capacity.

  1. What’s the difference between busbar and cabling in data centers?

Busbars offer higher capacity, lower losses, better flexibility for taps, enhanced safety and reliability compared to cables.

  1. How to install and terminate busbars in data centers?

Busbars require firm supports, matched expansion joints, torque-tightened taps, insulation of exposed sections and earthing as per standards.

  1. How does busbar layout impact cooling in data centers?

Adequate overhead space for ventilation and preventing obstructions to air flow are considerations for busbar routing layouts.

  1. What insulation is used for data center busbars?

Class F composite epoxy or polyester powder coatings are typically used for insulating data center busbars due to their electrical integrity.

  1. How are busbar systems maintained and tested?

Regular inspection, cleaning, thermography checks, insulation testing and torque verification of connections ensures proper busbar maintenance.

  1. What safety measures apply to data center busbars?

Warning signs, access restrictions, insulation, isolation, fire detection/suppression and redundancy are vital busbar safety aspects.

  1. How are busbars earthed in data centers?

Busbar enclosures include multiple earthing points that must be connected to the data center earth grid as per safety guidelines.

  1. What types of busbar enclosures are used in data centers?

Modular aluminum or steel NEMA rated enclosures with adequate ingress protection suit busbar installation and maintenance in data centers.

  1. How are busbars connected to PDUs in data centers?

Large lug-type cable terminations or busbar-to-busbar joints using high current rated flexible connections interface busbars to PDUs.

  1. What busbar accessories are needed in data centers?

Shrouds, covers, fire barriers, doors, interchange links, indicators, metering and monitoring devices are typical busbar accessories.

  1. How are busbars customized for data centers?

Enclosure sizes, conductor ratings, tap-off locations, redundancy links and monitoring can be customized based on data center requirements.

  1. How can busbars improve data center energy efficiency?

The lower losses from busbar trunking compared to cables reduces overall data center energy consumption and improves efficiency.

  1. What busbar innovations are shaping data centers?

Busbar advancements like high conductivity composites, remote monitoring, compact busway, hybrid systems and high current ratings benefit modern data centers.

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