The Leading Electrical Brand in China
The Leading Electrical Brand in China
Busbar trunking, also known as busway, provides an efficient and safe means of distributing power in commercial, industrial and infrastructure settings. This comprehensive guide covers busbar trunking system design, specification, installation and maintenance best practices.
Facility electrical engineers, contractors and maintenance teams will find the information helpful for incorporating busbar trunking into new construction or retrofit projects. Contact GRL for more infomation or ask for a free sample.
Busbar trunking consists of prefabricated busbar conductors enclosed in a protective housing. The system distributes power to downstream equipment via tap-off units or plug-in connections.
Key components of a busbar trunking system include:
Busbar trunking offers significant benefits versus traditional cabling:
With ampacity from 100A to 5000A, busbar trunking serves numerous applications such as:
Busbar trunking provides unique advantages that make it an attractive choice for many projects:
Safety – The totally enclosed housing isolates and shields live busbars, preventing contact. Properly designed systems are finger-safe.
Reliability – The rugged enclosed construction protects conductors from environmental contaminants. This reduces failures.
Efficiency – Low impedance busbars minimize voltage drop compared to cables. This improves power quality.
Adaptability – Layouts can be adjusted by adding and reconfiguring components. Additional loads are easily accommodated.
Serviceability – Individual sections can be isolated for safe maintenance access without extensive downtime.
Space Savings – Compact busbar trunking frees up space for other equipment compared to bundles of cables.
Damage Resistance – The sturdy housing resists impacts from carts and other hazards common in industrial settings.
With rising labor costs and crammed electrical spaces, busbar trunking offers valuable advantages over traditional cabling distribution.
Busbar trunking is available in a wide range of capacities, voltages and configurations:
Ampacities – Offerings range from 100A to 5000A. Common sizes are 225A, 400A, 630A, 800A, 1000A, 1250A, 1600A, 2000A and 2500A.
Voltages – 600V and 690V are standard with higher ratings possible. Many systems are dual-rated.
IP Ratings – IP ratings from IP41 to IP55 provide ingress protection for indoor and outdoor uses.
Configurations – Vertical or horizontal mounting orientations. Indoor, outdoor, sandwich, non-ventilated, stainless, hazardous location and fire-rated designs.
Materials – Copper and aluminum busbars. Steel, stainless or aluminum housings.
Standards – UL-845, IEC, BS, DIN and other certifications available.
Consult manufacturers early when specifying to match busbar trunking capacities and configurations to your needs.
Proper system design is key to realizing the benefits of busbar trunking:
Straight Sections – Backbone runs use straight sections joined by splice plates or flexible connections. Standard lengths are 2 to 5 meters.
Elbows – 90 and 45 degree elbows route the busway around obstacles. Inner radius options prevent overheating.
Tees – Tee sections create branch circuit runs or tie paralleling busways together.
Expansion Joints – These compensate for thermal expansion and building movement to avoid stresses.
End Feeds – End feed units transition to cable connections for power supply. Various styles suit different scenarios.
Tap Boxes – Tap boxes create plug-in or bolted connections along the busway length to serve equipment.
Hangers – Hanger components securely mount busway to the structural ceiling or walls along its route.
Physics-based modeling and simulations help optimize layouts and thermal performance. Access points for future equipment can be integrated into the initial design.
Proper installation of busbar trunking prevents hazards and ensures electrical integrity:
Busbar trunking must be securely mounted using hangers spaced per manufacturer guidelines. Seismic bracing suits earthquake-prone regions.
Adjoining sections utilize splice plates, flexible connectors or flanged joints. Gaps, alignment and hardware torque specifications must be followed during assembly.
Tap boxes bolt to busway sections or plug in for tool-less connections. Mounting surface preparation and gasket seating are vital for waterproofing.
The housing requires solid ground bonding back to the supply panel. Ground lugs or eyelets are joined using proper wire gauges and tightened securely.
Electrical PPE including arc flash suits, voltage-rated gloves and insulated tools are mandatory for any busbar trunking work.
Follow all installation instructions exactly to result in a code-compliant and electrically sound system.
Preventative maintenance ensures maximum busbar trunking lifespan and reliability:
Visual Inspections – Arrange periodic inspections checking for damage, leaks, overheating signs or insulation degradation. Scan joints closely.
Thermal Scans – Use IR thermography to map temperatures along the busway and identify any hot spots needing service.
Bolt Torque Checks – Verify connection hardware remains properly tightened over time. Loose bolts increase resistance.
Cleaning – Remove accumulated dust using a vacuum. Avoid pressure washing or harsh chemicals.
Lubrication – Apply manufacturer-approved lubricants to door hinges, locks and moving joints if specified.
Leak Repairs – Seal any housing leaks immediately to prevent moisture ingress and corrosion.
With reliable busbar trunking and conscientious maintenance, lifespans exceeding 20 years are readily achievable.
When procuring busbar trunking, consider these best practices:
Experienced Partner – Select an established manufacturer who specializes in busway. Avoid assemblers who import generic housing and busbars.
Design Assistance – Work with suppliers early to optimize layouts, connections and components tailored for your facility.
Customization – Seek flexible partners able to modify standard products to meet unique requirements.
UL-Listing – Confirm busbar trunking carries UL-845 listing or equivalent certifications for safety and performance testing.
Quality Validation – Review manufacturing quality control procedures and factory testing data when evaluating suppliers.
Local Support – A vendor with representatives nearby improves responsiveness during and after installation.
Choosing the right busbar trunking experts as partners ensures your project’s success.
Busbar trunking offers compelling advantages for electrical distribution. To best leverage it on your next project:
Busbar trunking delivers safety, reliability, efficiency and adaptability – making it the right choice for modern electrical infrastructure.
Busbar trunking, also called busway, uses enclosed prefabricated busbars to distribute power. It offers safety, flexibility and ease of connections versus traditional cabling.
Major types are sandwich busbar trunking which is totally enclosed, and air-insulated designs with ventilation. Other variations include indoor, outdoor, non-segregated, and fire-rated busbar trunking.
Offerings range from 100A to 5000A. Voltages span 600V to 690V+, with many dual-rated for flexibility. IP ratings from IP41 to IP55 provide ingress protection.
Configurations include horizontal, vertical, L-shaped and U-shaped layouts using straight runs, elbows and tee sections. Expansion joints, end feeds and tap boxes complete systems.
Calculate expected load with safety factor. Consult manufacturer sizing charts and rating tables to select a busbar trunking ampacity meeting capacity needs within max temperature rise.
Common accessories include elbows, expansion joints, end feeds, tap boxes, splice plates, hangers, seismic braces, firestop sleeves, disconnect switches, circuit breakers, and waterproof connection kits.
Applications include commercial buildings, data centers, solar farms, manufacturing plants, infrastructure, airports, hospitals, shopping malls, and any large facilities needing distribution capacity.
Sections bolt together through splice plates. Equipment connects via tap boxes. The system must be securely mounted using hangers and properly grounded. Safety gear is mandatory during installation.
Benefits include safety, smaller footprint, ease of modifications, quick installations, reduced voltage drop, protection from damage, and ability to easily handle added loads.
Busbar trunking and busway refer to the same enclosed electrical distribution system. Busway is an older term while busbar trunking is more common today.
Key standards include UL-845, IEC 61439, BS EN 61439, DIN EN 61439, AS/NZS 61439 and others. Quality busbar trunking is certified to applicable standards.
Yes, tap-off boxes of various types allow connecting power cables anywhere along busbar trunking lengths to supply equipment loads.
Standard busbar trunking lengths range from 2 to 5 meters. Shorter 500mm sections are also available. Runs can be extended indefinitely via expansion joints.
Waterproof connection kits include rubber collars, sealant tape and anti-corrosion gel to prevent moisture ingress where tap boxes interface with busbar trunking.
Busbar trunking is supported along its route using hangers bolted to the ceiling or structure. Lateral seismic braces anchor it safely in earthquake zones.
Safety gear like arc flash suits, insulated gloves and mats must be used. Hazard risk assessments and energized work permits are required. Proper grounding prevents shocks.
Routine inspections check for damage, overheating, leaks and loose connections. Thermal scans identify hot spots. Hardware torque is validated. Dust is removed.
Design factors include layout, straight lengths, elbows, tees, tap-offs, and accessories tailored for electrical loads and space. Advance modeling optimizes the system.
The housing must be continuously grounded back to the supply using proper ground lugs and wire gauges. This provides a return path for faults and prevents electric shock.
Key steps are assembling straight and elbow sections, mounting using hangers, making tap-off connections, waterproofing joints, grounding, and performing safety checks before energizing.
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