Legrand Busbar Power Distribution Systems Guide in 2023

Legrand busbar distribution systems offer high capacity, integrated routing to simplify deploying significant electrical power in modern buildings and processes. Models like Canalis and ICTA provide configurable distribution with plug-in and wall-mounted options to suit various applications.

Legrand busbar enables faster installation along with flexibility to handle evolving layouts over time. Robust construction and minimal maintenance requirements ensure lasting value over decades of reliable service. Legrand brings engineering innovation to manufacturing top-tier busbar trunking systems that solve complex power challenges. Contact us for more infomation if you have any questions.

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Introduction

Busbar power distribution offers an alternative to traditional cabling for applications requiring high capacity circuit management. Legrand manufactures reliable, high-performing busbar trunking systems that provide modular plug-in power distribution suitable for a wide variety of facilities.

This guide covers Legrand’s popular busbar offerings, technical ratings, installation considerations, maintenance recommendations, and usage advantages. Legrand’s busbar systems allow cost-effective, customizable electrical distribution and easy upgrades as needs change.

Advantages of Legrand Busbar

Legrand busbar delivers key benefits:

High Current Capacity

  • Copper and aluminum trunking rated up to 6300A.
  • Accommodates more load than cables.
  • Reduces voltage drop over long runs.

Compact Distribution

  • Neat, integrated power routing compared to bulky cables and conduit.
  • Saves space vertically and horizontally.

Fast Installation

  • Avoids labor-intensive cable pulls.
  • Adjustable straight lengths speed layout.
  • Plug-in connections accelerate commissioning.

Flexible Layouts

  • Adjustable lengths and tap-off boxes suit varied floorplans.
  • Straight sections and elbows create optimal runs.

Simple Connections

  • Plug-in tap-off boxes simplify power connections.
  • No junction boxes or splicing required.

Legrand busbar allows high capacity distribution with reduced installation costs that can fluctuate as building needs change.

Legrand Busbar Types

Legrand manufactures busbar trunking systems in multiple configurations:

ICTA Plug-In Busbar

  • Features plug-in tap-off boxes for simple connections.
  • 3 phase and 4 pole options up to 6300A.
  • Easily relocate taps by shifting plugs.

Canalis Wall-Mounted Busbar

  • Distributes power horizontally along walls.
  • More cost-effective than overhead systems for shorter runs.
  • Feeder and plug-in tap-off options.

Overhead Distribution

  • Suspended overhead to free up floorspace.
  • Connects production equipment via vertical drops.
  • Integrates with ceiling-mounted switchgear.

Legrand busbar designs accommodate diverse facility layouts and power requirements.

Technical Details

Legrand busbar provides:

Conductors

  • 99.9% pure copper or aluminum trunking.
  • Optional silver, tin, or nickel plating.

Ampacities

  • Up to 6300A at 415V with high purity copper.
  • 100A to 4000A+ models.

Voltage Ratings

  • 600V and 1000V maximum designs.
  • Insulation for up to 1kV.

Standards

  • UL 857 certified and CE marked.
  • RoHS compliant, non-toxic materials.

Enclosures

  • Indoor ventilated NEMA 1 metal housings.
  • Outdoor epoxy-coated NEMA 3R watertight construction.

Legrand’s robust busbar provides configurable power distribution to suit diverse demands.

Installation

Careful Legrand busbar installation includes:

Layout Planning

  • Map proposed runs to optimize segmentation.
  • Ensure convenient accessibility to planned tap locations.
  • Specify direction changes and lengths to suit.

Hanging and Mounting

  • Use factory-provided hangers to suspend overhead systems securely.
  • Anchor wall-mounted busbar firmly using support brackets.
  • Maintain recommended clearances and strain relief.

Connecting Loads

  • Use proper cable lugs and torque levels at tap-off boxes.
  • Use twist-on plug connectors for plug-in busbar.

Switchgear Integration

  • Connect busbar to main LV distribution panels.
  • Link busbar to integrated branch circuit breakers.

Proper mechanical and electrical installation best practices maximize safety, electrical performance and lifespan.

Maintenance Tips

Reliable Legrand busbar operation requires minimal maintenance:

Inspections

  • Check housings and connections for damage, cracks, or overheating.
  • Verify covers and doors seal properly without gaps.
  • Confirm busbars remain straight without bending or joint separation.

Testing

  • Use IR scanning on joints and terminations while energized to check for hot spots indicating loose connections.
  • Perform insulation resistance tests. Compare to baseline values.
  • Verify low resistance across full length.

Cleaning

  • Vacuum or wipe dust and dirt from equipment exteriors and interiors.
  • Clean and re-torque any corroded parts like lugs or contacts.

Safety

  • De-energize prior to any internal servicing. Use proper PPE for voltage.
  • Address any identified deficiencies immediately before small issues escalate.

Routine inspection and maintenance sustains peak performance over decades of service.

What is Legrand busbar trunking?

Legrand busbar trunking consists of prefabricated copper and aluminum conductor bars housed in protective enclosures for distributing power. It offers a more integrated, higher-capacity alternative to traditional cabling for commercial and industrial applications up to 6000A. Benefits include:

  • Compact distribution pathways
  • Adjustable segments and tap-off points
  • Easy integration with switchgear
  • Simplified installation
  • Relocate connections by shifting plugs
  • Overhead, wall-mounted and plug-in types

Legrand manufactures robust, well-engineered busbar systems that provide configurable power distribution able to meet diverse electrical demands.

How does a Legrand busbar system work?

A Legrand busbar distribution system operates by:

  • Feeding high capacity incoming power into the busbar from distribution equipment.
  • Conducting electricity through the length of the busbar via protected copper bars.
  • Tapping power off at multiple points utilizing bolt-on or plug-in tap boxes.
  • Shielding current-carrying elements within sturdy enclosed metal housing.
  • Allowing quick connections to equipment by plugging into receptacles along busbar’s length.
  • Offering an alternative to individual conduit and wires for distribution.

Legrand busbar simplifies routing electrical power directly from gear to loads in customizable configurations.

What are the advantages of Legrand busbar?

Compared to traditional cabling, Legrand busbar advantages include:

  • Higher capacity distribution in a small footprint
  • Lower impedance losses over long runs
  • Integrated power routing via bus trunking
  • Adjustable layouts to suit varied spaces
  • Fast installation by eliminating cable pulls
  • Easy reconfiguration using plug-in connections
  • Simplified maintenance without masses of wires
  • Organized runs free up usable space both vertically and horizontally
  • Potential cost savings for large installations

Legrand busbar provides flexible, high-performing power distribution suitable for diverse modern facilities.

What types of busbar does Legrand offer?

Legrand manufactures several busbar trunking types:

ICTA – Features plug-in tap-off boxes for simple connections at points along busbar lengths.

Canalis – Wall-mounted busbar distributes power horizontally and connects with panelboards.

Overhead – Distributes power from overhead, hanging down to supply equipment. Saves floor space.

All provide similar capacities and advantages. The optimal type depends on facility layout, location of loads, and ease of installation access.

Can you plug into Legrand busbar?

Yes, Legrand busbar systems provide plug-in tap-off boxes that allow convenient connections by simply plugging quick connectors into receptacles along the busbar length.

Benefits of plug-in connections include:

  • No hardwiring required to tap power from busbar.
  • Adjustable tap locations to suit equipment.
  • Easy to relocate or add taps as facility evolves.
  • Plug-in units available up to 400A.
  • Quick installation accelerates commissioning.

Legrand’s plug-in busbar models maximize distribution flexibility compared to permanently wired systems.

How do you install Legrand busbar systems?

Properly installing Legrand busbar involves several steps:

  • Layout planning to optimize lengths and position tap boxes conveniently
  • Hanging overhead systems securely from ceilings or structural supports
  • Anchoring wall-mounted busbar firmly to wall at proper height
  • Using appropriate cable lugs and torques for terminations
  • Connecting busbar to originating power distribution equipment
  • Maintaining proper busbar alignment without bends
  • Testing insulation resistance and continuity prior to energization
  • Verifying grounding connections meet applicable standards

Following Legrand’s specifications ensures maximized safety, performance and lifespan.

What switchgear does Legrand busbar integrate with?

Legrand busbar systems connect with LV switchgear to distribute power:

  • Feeders can connect to main switchgear breaker outputs.
  • Integrated Legrand PowerPact or MasterPact circuit breakers distribute power.
  • Provides an alternative to masses of large feeder cables from gear rooms.
  • Legrand TXpert software aids integrated selections.

Close coordination of Legrand switchgear and busbar enables simplified yet robust power architectures within facilities tailored to demands.

What current ratings are available for Legrand busbar?

Legrand busbar trunking offers ampacities starting from 100A up to 6000A to suit both branch and main feeder distribution needs:

  • 100A, 160A, 250A, 400A, 630A, 800A, 1000A, 1250A, 1600A, 2000A, 2500A, 3150A, 4000A, 5000A, 6300A
  • 415V, 440V, 480V distribution voltages

Higher purity copper busbar allows the greatest ampacities. IPxxB insulation enables tapping power directly. Legrand can fulfill high capacity requirements.

Are Legrand busbars UL listed?

Yes, Legrand busbar trunking systems carry UL 857 certification and labeling in the United States. The UL 857 standard dictates requirements including construction, thermal performance, electrical spacing and short circuit testing.

UL listing provides assurance Legrand busbar systems have passed safety evaluations by an accredited laboratory. This includes fault withstand, dielectric voltage withstand, and temperature rise tests. The UL mark signifies safety and reliability.

Can Legrand busbar be used outdoors?

Yes, Legrand manufactures busbar trunking systems suitable for both outdoor and indoor installation:

Outdoor

  • Watertight NEMA 3R enclosures protect against rainfall and moisture ingress.
  • UV-resistant epoxy coating prevents corrosion.
  • Cycle tested for thermal expansion stresses.
  • Heating elements can be added for cold climates.

Indoor

  • Ventilated NEMA 1 metal housing for dry environments.
  • Rated for ambient temperatures up to +40C.
  • Also available with ingress protection up to IP54 rating for dusty areas.

Legrand offers busbar appropriately rated for all application environments.

How long do Legrand busbars last?

Properly installed Legrand busbar systems provide extremely long operational lifespans of 30-50 years or longer. Key reliability factors include:

  • Utilizing high purity copper conductor bars. Aluminum also available.
  • Avoiding bending or distortion of the busbar alignment.
  • Selecting housings sized to avoid exceeding temperature rise limits.
  • Keeping terminations and joints properly tightened.
  • Preventing exposure to moisture, fluids, chemicals.
  • Regular inspection and minor maintenance.

With Legrand’s well-engineered robust construction and appropriate maintenance, their busbar systems serve facilities with dependable power distribution for decades.

Does Legrand make aluminum busbar?

Yes, Legrand offers both copper and aluminum busbar trunking systems:

Copper

  • More expensive but provides optimal conductivity. Recommended for long runs.
  • Allows higher amp capacities especially under continuous loads.
  • Less prone to oxidation concerns and heating.

Aluminum

  • Lower cost material can reduce budget for large systems.
  • Sufficient conductivity for many applications.
  • Larger cross sections required than copper for equivalent ampacity.

Legrand can provide guidance on selecting either copper or aluminum busbar to optimize technical performance and project budgets.

How do you splice Legrand busbar?

Splicing Legrand busbar segments utilizes sleeve connections with bolted clamp joints:

  • Clean busbar ends and sleeve mating surfaces thoroughly before splicing.
  • Apply oxidation inhibiting compound on busbar ends.
  • Insert busbar ends fully into sleeve without gaps.
  • Tighten flange bolts incrementally in a star pattern to recommended torque levels.
  • Avoid bending busbars – Use elbow accessories if direction changes needed.
  • Check for high resistance across splice using micro-ohmmeter.

Properly mated busbar sleeve connections ensure minimal voltage drop and heating under load across critical joints.

What maintenance does Legrand busbar require?

Legrand busbar systems require minimal periodic maintenance:

  • Visual inspections – Check for damage, leaks, corrosion, debris accumulation.
  • Thermal inspections – Scan key joints using IR cameras under load to identify any hot spots from loose connections.
  • Continuity testing – Use micro-ohmmeters to measure resistance across joints and entire lengths.
  • Cleaning – Remove dust and dirt from housing exteriors and interiors. Re-torque connections.
  • Testing insulation resistance – Compare to baseline values to detect any deterioration.
  • Safety – De-energize busbar before any internal maintenance activities.

Following Legrand maintenance guidelines sustains safety and integrity over decades of service.

How is Legrand busbar sized?

Properly sizing Legrand busbar involves:

  • Summing the ampacity demands of all expected loads. Add capacity for future growth.
  • Choosing the minimum busbar amp rating exceeding the total current.
  • Considering the temperature rise based on the number of current carrying conductors and housing ventilation.
  • Calculating expected voltage drop across the full run length based on conductor resistivity.
  • Right-sizing and spacing tap-off boxes to properly distribute power.
  • Selecting integrated branch breakers sized to coordinate with busbar system.

Electrically sizing the busbar to handle the facility’s loads ensures power meets current and voltage needs at all points.

How much does Legrand busbar cost?

Legrand busbar trunking costs around:

  • $60 – $100 per foot installed for 250A – 400A copper plug-in busbar
  • $70 – $120 per foot installed for 630A – 1000A aluminum feeder busbar
  • $200 – $375 per foot installed for 4000A overhead copper distribution busbar

Variables like run length, accessories, ampacity, materials, installation labor impact exact cost. Contact Legrand for a specific quote tailored your project’s needs.

What are the alternatives to Legrand busbar?

Alternatives to Legrand busbar distribution include:

Conduit and Wiring

  • Requires pulling conductors through conduit – time and labor intensive.
  • Any changes mean rewiring – less flexible.

Cable Bus

  • Enclosed insulated power cables.
  • Limited plug-in tap-off ability.

Busduct

  • Enclosed ducts housing bundled conductors like busbar.
  • Primarily used for main feeder applications.

When flexible high capacity distribution is needed, Legrand busbar offers advantages over these traditional approaches.

How is Legrand busbar different from busduct?

While both enclosed duct systems, key differences between busbar and busduct include:

Busbar

  • Uses solid copper or aluminum bars – lower impedance.
  • Simpler, more compact construction.
  • Air alone often provides insulation.

Busduct

  • Houses insulated power cables rather than solid bars.
  • Bulkier duct-like mechanical design.
  • Insulation required between current carrying elements.
  • Often used for large primary feeder runs versus distribution.

Legrand busbar provides optimized branch circuit-style distribution within commercial and industrial facilities. Busduct is more common at higher voltages.

How do you specify a Legrand busbar system?

Specifying the optimal Legrand busbar system involves:

  • Determining the total load current and voltage requirements
  • Choosing appropriate conductor ampacity, typically aluminum or copper
  • Selecting suitable housings like ventilated, raintight or outdoor
  • Defining accessories needed like elbows, expansion joints, hangers
  • Identifying any integrated devices like circuit breaker tap-offs
  • Right sizing the number and locations of tap-off boxes
  • Providing electrical and mechanical layout requirements

Legrand can develop submittal-ready spec sheets customized for your specific project’s busbar trunking needs.

Can Legrand busbar connect to other brands?

Yes, Legrand busbar systems can interoperate with busbar from other manufacturers:

  • Standardized conductor bar sizing enables interfacing different brands.
  • Custom splicer sleeves join sections mechanically.
  • But electrical insulation needs special considerations where busbars mate.

Recommended approach:

  • Minimize use of mixed-brand busbar to limit interfaces.
  • Transition between brands inside grounded switchgear panels if possible.

When unavoidable, properly joining Legrand busbar to other manufacturers’ systems can expand architectural choices.

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