Expert Guide to Planning and Installing Copper Busbar Systems

Copper busbar systems provide a robust and efficient means of distributing power in industrial facilities, commercial buildings, utilities and more. This guide covers specifying, designing, manufacturing, installing and maintaining copper busbars for optimal performance.

Engineers, contractors and technicians will find best practices for incorporating copper busbar systems into electrical projects from start to finish. Contact us if you have any questions or need free samples. GRL can provide you with high quality products and perfect solutions.

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Introduction

Copper busbar systems consist of thick, prefabricated copper conductors mounted on insulators that function as the main power distribution backbone.

Copper offers excellent qualities for busbar material:

  • High conductivity minimizes power losses
  • Ductility allows shaping into various busbar profiles
  • Corrosion resistance ensures longevity
  • High-temperature operation without annealing
  • Proven performance record over decades

Benefits of using copper busbar systems include:

  • Less space needed than cables
  • Lower voltage drop than cables
  • Quick, easy installation
  • Improved cooling and heat dissipation
  • Short-circuit withstand strength
  • Expandability and modularity

Copper busbar systems are commonly found in:

  • Switchgear and motor control centers
  • Data centers and telecom facilities
  • UPS and battery rooms
  • Process automation systems
  • Solar and wind power installations

With current ratings from under 100A to over 5000A, copper busbars efficiently serve most power distribution needs.

GRL-Copper Busbar Systems

Copper Busbar Specifications

Proper material specifications and sizing ensures the copper busbar system meets your electrical loads and duty cycle.

Busbar Sizes

Common commercial busbar sizes (width x thickness) include:

  • 12 x 3 mm
  • 20 x 3 mm
  • 20 x 5 mm
  • 30 x 3 mm
  • 30 x 5 mm
  • 40 x 3 mm
  • 40 x 5 mm
  • 50 x 5 mm

Larger bars exceeding 100 x 10 mm accommodate higher capacities. Custom shapes and sizes can be produced as needed.

Current Ratings

Maximum current ratings vary by busbar size and acceptable temperature rise:

  • 20 x 3 mm = 150A
  • 20 x 5 mm = 250A
  • 30 x 3 mm = 225A
  • 30 x 5 mm = 350A
  • 40 x 5 mm = 500A
  • 50 x 5 mm = 700A

Rule of thumb is approximately 1A per mm width. Proper ventilation is required to achieve these ratings.

Applicable Standards

Copper busbars are designed to comply with standards like IEC, DIN, JIS, BS and UL. Quality systems adhere to ISO 9001.

Material Certification

Reputable busbar manufacturers certify copper purity and material composition. Common grades are C10100 or C10200 with 99.99%+ copper content.

Busbar System Sizing

Consult manufacturer reference charts for standard busbar sizes and current ratings. For large projects, perform load calculations to determine busbar capacity needed factoring in safety margins.

Copper Busbar System Design

Proper system design tailors the busbar arrangement, equipment connections and accessories to your facility’s needs:

Busbar Arrangement

Busbars run horizontally or vertically depending on space constraints. Access points facilitate equipment connections. Expansion joints enable extending systems.

Typical busbar arrangements include:

  • Main distribution backbones
  • Branch runouts
  • Multilevel distribution zones
  • Ring systems for redundancy

CAD tools model electrical behavior and heating to optimize busbar routing.

Equipment Connections

Busbars interface with switchgear, transformers, panels, drives and other equipment through:

  • Bolted connections
  • Tap-box power tappings
  • Vertical quick-disconnect risers
  • Low-voltage circuit breaker connections

Interface points are designed for fast installation using standard hardware.

Busbar Joints

Adjacent busbar sections connect via lap joints or flexible connections using copper braid or cabling. This allows disassembly for maintenance. Insulated covers or epoxy potting seal joints.

Busbar Accessories

Accessories like insulation, markers, warning signs, end caps, covers, braces and hangers complete the system design.

Work with experienced busbar manufacturers early in the design process to develop an optimal system meeting your needs.

Manufacturing Quality Copper Busbars

Use a specialized busbar company to fabricate your copper busbar system. Seek these capabilities:

In-House Manufacturing

Avoid importing bare busbar shape blanks. Choose a company with in-house capabilities including:

  • CNC machining from copper stock
  • Automated bending and milling
  • Precision welding and brazing
  • Passivation and cleaning

This ensures quality workmanship under one roof.

Testing and Certification

Reputable manufacturers test busbar systems including:

  • Dimensional checks
  • High-pot electrical testing
  • Certifications to UL, IEC and other standards
  • Material certification to C10100/C10200 grade
  • Quality systems conforming to ISO 9001

Review test reports and quality documents when comparing suppliers.

Customization Expertise

Experienced manufacturers can provide:

  • Custom busbar sizes and shapes
  • Application-specific designs to order
  • Mixed materials like copper-aluminum
  • Specialized accessories

Choose a highly responsive partner able to adapt the system to your needs.

Installing Copper Busbar Systems

Proper installation technique ensures a safe, reliable and electrically robust busbar system:

Mounting – Busbars must be securely mounted on insulated standoff supports spaced per guidelines.

Gaps – Maintain required minimum spacing between busbar phases and ground based on voltage.

Connections – Follow all hardware torque specifications when joining components. Avoid overtightening.

Insulation – Insulate busbar joints using approved tapes, boots or epoxy potting.

Grounding – Properly ground the housing and components back to the supply panel.

Safety – Electrical PPE and precautions are mandatory when working on busbar systems.

Careful workmanship during installation prevents hazards and reduces faults over the system lifespan.

Copper Busbar Maintenance

Preventative maintenance ensures maximum performance and lifespan for copper busbars:

Inspections – Visually inspect busbars annually for damage, leaks, loose hardware or signs of overheating.

Scans – Use IR thermography to identify any hot spots needing service.

Cleaning – Clean dust and debris from busbar surfaces and enclosures. Avoid pressure washing.

Hardware – Confirm all busbar hardware remains torqued to specifications.

Testing – Perform insulation resistance, continuity and dielectric testing during maintenance outages.

Repairs – Promptly repair any damaged insulation or defective components.

Proactive maintenance minimizes faults and extends copper busbar lifespans beyond 20 years.

Working With Copper Busbar Suppliers

When procuring copper busbars, look for these capabilities in suppliers:

Experience – Select an established company focused on busbar manufacturing versus a generic assembler.

Design Support – Work with the supplier’s engineers early to optimize the system layout and design.

Customization – Seek flexible partners able to modify standard busbars to meet unique needs.

UL-Listing – Verify the busbar system carries UL-845 or equivalent international testing certifications.

Quality – Review factory quality control and testing documentation for assurance.

Responsiveness – Choose companies with representatives nearby that can provide timely support.

Picking the right copper busbar partner ensures a successful project.

Leveraging Copper Busbars Efficiently

To maximize benefits for your next project:

  • Engage experienced busbar experts early in design
  • Take advantage of modular scalability and flexibility
  • Follow proper installation and safety procedures
  • Implement a copper busbar preventative maintenance program
  • Verify testing and certifications when evaluating suppliers
  • Model electrical loads and thermal performance to right-size the system
  • Accommodate future capacity growth through system design

Copper busbars deliver space savings, reliability, efficiency and safety – making them a top choice for modern electrical projects.

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Frequently Asked Questions

What is a copper busbar system?

Copper busbar systems use thick, prefabricated copper conductors to distribute power in an industrial facility or building. Busbars are mounted on insulated supports and connected to equipment.

What are the benefits of copper busbars?

Benefits include high conductivity, smaller footprint versus cables, modular/flexible design, quick installation, heat dissipation, short-circuit strength and proven reliability.

What sizes of copper busbar are available?

Common sizes range from 12 x 3 mm to over 100 x 10 mm. Widths from 20 to 50 mm are typical. Thicknesses range from 3 to 10 mm. Busbars can also be custom shaped.

What are the current ratings for copper busbars?

Rule of thumb is approximately 1 amp per mm width. A 30 x 3 mm busbar can carry around 225A. Actual rating depends on temperature rise and cooling.

How do you determine busbar size needed?

Calculate total current load with safety margin, check manufacturer reference tables for standard ratings, and select appropriate busbar size to stay within max temperature rise.

What busbar joints are used in copper busbar systems?

Common movable joints are lap joints, flexible braided connections and cabling. These allow disassembly for maintenance. Insulated covers or epoxy potting seal and protect joints.

How do you select a copper busbar manufacturer?

Choose a specialized manufacturer with in-house design, CNC machining, testing capabilities and proven expertise engineering busbar systems.

What are the steps in designing a copper busbar system?

Key design steps involve determining layout, equipment connections, joints, accessories and clearances based on electrical requirements, site space and codes.

How should you install copper busbars?

Busbars must be securely wall-mounted, maintaining proper spacings per NEC. Sections join via bolted connections. Electrical safety gear and practices are mandatory during installation.

What standards apply to copper busbar systems?

They are designed to meet IEC, DIN, JIS, BS, UL and other standards. Quality systems comply with ISO 9001. Copper purity complies with grade C10100/C10200 standards.

Can copper busbars be installed outdoors?

Yes, outdoor installations require weatherproof housings or enclosures. The copper holds up well in outdoor environments due to corrosion resistance. Proper clearances are maintained.

How do you connect equipment to copper busbars?

Equipment connections are made via drilling holes in busbars and bolting on lugs, using tap boxes to create threaded studs, or fastening to equipment bus stubs.

How are copper busbars terminated?

Busbar ends are terminated with caps that bolt on. Some terminations incorporate mounting holes for easy installation. Phase barriers separate terminations.

How close can copper busbars be spaced?

Clearance between busbars and ground depends on voltage but 15-25mm between phases and 15mm between bus and ground are typical spacings per NEC.

How are copper busbars supported and braced?

Busbars are supported along their length on insulated standoffs or mounting channels. Vertical supports brace against short circuit forces. Equipment connections add stability.

How do you joint adjacent copper busbar sections?

Sections are joined via lap joints, flexible connectors or cabling. Mating surfaces are cleaned and compound applied before tightening hardware. Joints are insulated.

Can you tap power from a copper busbar run?

Yes, tap boxes with studs allow connecting power cables at any point along a busbar’s length. Some busbars incorporate tap holes for the same purpose.

What safety rules apply for copper busbar installations?

NEC spacing rules must be followed. Joints are fully insulated. Warning labels are applied. Only qualified electricians handle installation. Gear for arc flash protection is mandatory.

How long do copper busbars last?

With quality manufacturing and proper maintenance, copper busbar lifespans easily exceed 20 years. Some systems serve reliably for over 30 years before upgrades are warranted.

How are joints insulated in a copper busbar system?

Joints use heat shrink tubing, taping or molded insulating covers for protection and isolation. Epoxy potting seals out moisture on joints in harsh environments.

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