busbar trunking system

busbar trunking system

Get in touch!

Alice Webster
Business Development Manager

Colin Thatcher
Sales Manager

m. +44 (0) 7827 943368

t. +44 (0) 1539 797604
e. a.webster@ibar-emea.com

m. +44 (0) 7823 402814

t. +44 (0) 1539 797604
e. c.thatcher@ibar-emea.com

Rob Anderson
Business Development Manager

Dean Bradshaw
Sales Director

m. +44 (0) 7703 679511

t. +44 (0) 1539 797604
e. r.anderson@ibar-emea.com

m. +44 (0) 7884 311049

t. +44 (0) 1539 797604
e. d.bradshaw@ibar-emea.com

IBAR (EMEA) Ltd

Westmorland Business Park
Kendal
Cumbria
LA9 6NS
UK

ISO9001 - ISO14001
OHSAS 18001

t. +44 (0) 1539 797604

f. +44 (0) 1539 724384
e. sales@ibar-emea.com
www.ibar-emea.com
Registered in England No. 08695995

HXA

Product Catalogue

Resin Insulated Aluminium Conductors

High Power (800A - 5000A)

Contents

1 - Introduction

2
3

A truly end to end solution

Transformer Flange
Termination Cap

1 Introduction 3

Tap-off Box

2 Product Library 4-13

3 Technical Overview 15
Distribution Length

3.1 - 3.14

Technical Parts Detail

16-33

Transformer Housing

Expansion Unit
Panel Flange Flatwise

4 Applications Engineering 34

Edgewise Elbow

5 iControl Integration 34
6 Parts Numbering Guide 35

Offset
Joint Pack

Feeder Length

LV Switchboard

HXA is part of the IBAR HX range of

high power busbar trunking systems.
HXA utilises a sandwich arrangement
of individually insulated busbars
(using a specialist epoxy resin coating)
which are contained within a unique
two piece, IP55 rated, Aluminium
trunking / housing.
The HX range is also available with a
HDHC Copper (99.9%) BS EN 13601
conductor.
About IBAR
IBAR (EMEA) Ltd is part of the Mardix
Group of companies.
The IBAR range of power distribution
busbar trunking system products has
been developed to meet the growing
demands of the critical power industry.

Ref: IBAR-HXA-CAT
Published 05/06/14
Revision 1.0.0
Author: AB

Employing innovative designs to

improve performance and reduce costs
we have invested in the best available
technologies to ensure our finished
product is of the highest quality.
Our highly skilled engineering teams
and applications engineers can tailor
a solution to meet even the most
demanding requirements.
IBAR employs more than 45 years of
leading-edge experience incorporating
all the quality, reliability and
innovation for which our group is
renowned.

All IBAR product is manufactured

within the UK to the latest British
Standards (BS EN 61439-6).
From small scale to multi million
pound projects, we hope you will make
IBAR your first choice for busbar.

2 - Product Library

A solution for the most challenging buildings

2.1 Feeder Lengths

Feeder Busbar
There are many applications which require the ability to move
large amounts of power; the most common of which is the
transmission of power between transformers and low voltage
switchboards and then further sub-distribution.
IBARs HXC range provides a high-power transmission busbar
solution with busbar ratings ranging from 1000A up to
6300A. Each rating type can be supplied with between 3 and
6 conductive bars arranged in a sandwich type construction
and insulated with a specialist resin coating. Configurations
are available for 3-phase, 3-phase and neutral / protected
earth (for loads susceptible to harmonic distortion / leakage
currents) and optional double rated neutral.

Standard lengths:

4m
3m
2m
1m

Distribution Busbar
Busbar trunking systems are favoured greatly over traditional
fixed position cable installations due to the flexibility of the
available tap-off locations.

2.2 Distribution Lengths

The standard straight 3m lengths can be fitted with up to four

specially engineered tap-off points at standard or custom
locations.

Up to 4no
tap-off points
per 3m length

Each tap-off location features high-integrity weld-bonded

copper connection tabs. This high-quality, high-conductivity
connection means only a single tap-off location is required for
tap-offs of up to 630A.
Available Ratings Available Configurations *
800A
1000A
1250A
1400A
1600A

2000A
2500A
3200A
4000A
5000A

See the HX Range Tap-offs

Product Catalogue for
more information

TP
TP&N
TP&E
TP&N&E
TP&2N
TP&2N&E
* All feature Case Earth

Puzzled? Speak to our expert

applications engineers now!
t. +44 (0) 1539 797604
e. engineering@ibar-emea.com

2.3 Flatwise Elbow

2.4 Edgewise Elbow

2.5 Custom Elbow

2.6 Flatwise Offset

2.7 Combination Elbow / Offset

2.12 Expansion Unit

2.8 Transformer / Parallel Flange

2.9 Panel Flange

2.13 Joint Packs

2.10 Combination Panel Flange / Elbow

2.11 T Section

2.15 End Feeder Unit

2.16 Termination Cap

2.17 Centre Feeder

2.18 Edgewise Installation Brackets

2.19 Flatwise Installation Brackets

2.24 Final Connection Lengths

2.20 Vertical Hangars

2.22 Fire Barrier

No problems,
just solutions

Express lead times

typically < 1 week!

2.25 Tap-off Boxes

2.23 Transition Unit (Cast Resin to Internal)

See the HX Range Tap-offs

Product Catalogue for
more information

10

11

Joint pack

Specialist
epoxy
resin
insulation

Polyester
powder
coated
finish

Double
headed
shear
nut

Unique two piece

IP55 Aluminium
trunking case
6101A
Aluminium

See the HXC Range Product

Catalogue for Copper
Conductor Systems

12

3 - Technical Overview
Rated C urrent ln [A]

Rated operating voltage

Rated insulation voltage
Frequency
Degree of protection
Casing material
Conductor arrangement
Conductor profile
Conductor material
Conductor surface treatment
Conductor Insulation

800

1400

1600

2000

2500

3200

4000

5000

Straights are one of the most common parts of any trunking system.Custom
lengths can be manufactured to suit each application requirement within the
ranges below. Feeder type busbar is used for end to end transmission and
distribution type incorporates tapping outlets for connection of tap off units.
In most cases it is preferred that the application of the product leave
straights as the final site measure pieces to enable faster turnaround times
and greater flexibility.

1000

1250

1400

1600

2000

155 x 105
55 x 6
322
6.0
6.8
7.6
8.5

155 x 140
80 x 6
472
7.6
8.8
10.0
11.2

155 x 170
110 x 6
652
9.2
10.9
12.6
14.3

155 x 185
125 x 6
742
10.1
12.0
13.9
15.9

155 x 205
145 x 6
862
11.3
13.5
15.8
18.0

155 x 260
200 x 6
1192
14.5
17.6
20.8
23.9

800

1000

1250

1400

1600

2000

2500

3200

4000

5000

Icw [kA]rms

25

50

65

65

65

80

80

100

120

120

Ipk [kA]

55

110

143

143

143

176

176

220

264

264

Icw [kA]rms

15

30

39

39

39

48

48

60

72

72

Ipk [kA]

33

66

85.8

85.8

85.8

100.8

100.8

132

158.4

158.4

Icw [kA]rms

15

30

39

39

39

48

48

60

72

72

Icc [kA]

15

30

39

39

39

48

48

60

72

72

Ipk [kA]

33

66

85.8

85.8

85.8

100.8

100.8

132

158.4

158.4

W x H [mm]
W x D [mm]
CSA [mm2]
p [kg/m]
p [kg/m]
p [kg/m]
p [kg/m]

2500

3200

4000

Standard lengths (x): 4m, 3m, 2m, 1m

Minimum length (x): 0.5m Maximum length (x): 4m

5000

155 x 370 155 x 440 155 x 550 155 x 720

2 x 110 x 6 2 x 145 x 6 2 x 200 x 6 3 x 160 x 6
1725
2385
2857
1305
18.4
22.6
29.0
36.6
21.8
27.0
35.2
43.8
51.3
41.6
31.6
25.2
47.8
59.1
36.0
28.6

Construction Types (Single, Double and Triple)

Single - 800A - 2000A

Double - 2500A - 4000A

Triple - 5000A

busbar trunking system

HXC

Straight Lengths

1000
1000
50/60
55
Aluminium
Sandwich
Rect. Full radius corner
Electrical Grade 6101A
Plain (Tinned optional)
Epoxy UL94 (V0)
800

Fault Rating
Rated short-time current for
three-phase fault (1s)
Allowable peak current for
three-phase fault
Rated short-time current for
single-phase fault (1s)
Allowable peak current for
single-phase fault
Rated short-time protection
current (1s)
Rated conditional protection
current
Protection circuit peak rated
current

1250

Ue [V]
Ui [V]
f [Hz]
IP

Dimensions
Casing overall dimensions
Conductor dimensions
Conductor CSA
Weight (3 conductors)
Weight (4 conductors)
Weight (5 conductors)
Weight (6 conductors)

1000

3.1 - Straight Lengths

HXA

13

14

3.2 - Flatwise Elbows

3.3 - Edgewise Elbows

Flatwise Elbows

15

Edgewise Elbows
Flatwise elbows are used to make directional
changes to busbar runs usually at 90o to the
direction of travel.

Edgewise elbows are used to make directional

changes to busbar runs usually at 90o to the
direction of travel.

In addition to providing left and right elbows in

standard 90o it is possible to have custom angles
manufactured (please contact our applications
and engineering team for further information).

In addition to providing left and right elbows in

standard 90o it is possible to have custom angles
manufactured (please contact our applications
and engineering team for further information).

See the table below for further information on

sizes available.

See the table below for further information on

sizes available.

Typical Arrangement

Typical Arrangement

Minimum

Maximum

X &Y

X &Y

350
350
350
350
350
350
500
500
500
600

250
250
250
275
300
325
375
415
485
600

700
700
700
700
700
700
700
700
700
600

St and ard

Busbar Rat ing (Amps)

C o nst ruct io n
Type

800
1000
1250
1400
1600
2000
2500
3200
4000
5000

Single
Single
Single
Single
Single
Single
Double
Double
Double
Triple

350
350
350
350
350
350
500
500
500
600

St and ard

Busbar Rat ing (Amps)

C o nst ruct io n
Type

800
1000
1250
1400
1600
2000
2500
3200
4000
5000

Single
Single
Single
Single
Single
Single
Double
Double
Double
Triple

350
350
350
350
350
350
350
350
350
350

Minimum

Maximum

X &Y

X &Y

350
350
350
350
350
350
350
350
350
350

275
275
275
275
275
275
275
275
275
275

600
600
600
600
600
600
600
600
600
600

16

3.4 - Flatwise Offsets

3.5 - Edgewise Offsets

Flatwise Offsets

17

Edgewise Offsets
Offsets are commonly used to avoid small
obstructions and obstacles that the use of two
elbows would make inefficient.

Offsets are commonly used to avoid small

obstructions and obstacles that the use of two
elbows would make inefficient.

The four variants of offset are edgewise left &

right and flatwise left & right.

The four variants of offset are edgewise left &

right and flatwise left & right.

See table below for size options available.

See table below for size options available.

Typical Arrangement

Typical Arrangement

St and ard

Busbar Rat ing

(Amps)

C o nst ruct io n
Type

800
1000
1250
1400
1600
2000
2500
3200
4000
5000

Single
Single
Single
Single
Single
Single
Double
Double
Double
Triple

350
350
350
350
350
350
500
500
500
550

Minimum

Maximum

Minimum

Maximum

X &Y

X &Y

350
350
350
350
350
350
500
500
500
550

250
250
250
275
300
325
375
415
485
550

650
650
650
650
650
650
650
650
650
650

50
50
50
50
50
50
50
50
50
50

St and ard

Busbar Rat ing

(Amps)

C o nst ruct io n
Type

700
700
700
675
640
570
675
640
570
640

800
1000
1250
1400
1600
2000
2500
3200
4000
5000

Single
Single
Single
Single
Single
Single
Double
Double
Double
Triple

350
350
350
350
350
350
350
350
350
350

Minimum

Maximum

Minimum

Maximum

X &Y

X &Y

350
350
350
350
350
350
350
350
350
350

275
275
275
275
275
275
275
275
275
275

650
650
650
650
650
650
650
650
650
650

75
75
75
75
75
75
75
75
75
75

700
700
700
700
700
700
700
700
700
700

18

3.6 - Panel Flange

3.7 - Flange Elbow Flatwise

19

Flange Elbow Flatwise

Panel Flange

Panel flanges are the standard fittings used to make

connections to other items of LV equipment such as
switchboards and transformers etc.

Panel flanges are the standard fittings

used to make connections to other items
of LV equipment such as switchboards and
transformers etc.

Panel flanges with integrated 90o change of direction

allow for low headroom applications and are available
both in flatwise and edgewise formats.

Each rating of flange has set dimensions for the

cutout and fixing points that are supplied on
drawings with each unit.

Each rating of flange has set dimensions for the cut

out & fixing points identical to that of straight type
units the details of which are supplied on drawings
with each unit.

Phase rotation from other equipment to a

busbar system needs careful coordination
and all phase details must be highlighted and
approved at design stage.

Phase rotation from other equipment to a busbar

system needs careful coordination and all phase
details must be highlighted and approved at design
stage.

Panel flanges can also be manufactured

with integrated 90o change of direction to
accommodate low headroom applications.

Typical Arrangement

Typical Arrangement

Busbar Rat ing

(Amps)

C o nst ruct io n Type

800
1000
1250
1400
1600
2000
2500
3200
4000
5000

Single
Single
Single
Single
Single
Single
Double
Double
Double
Triple

St and ard

Minimum

Maximum

250
250
250
250
250
250
250
250
250
250

250
250
250
250
250
250
250
250
250
250

800
800
800
800
800
800
800
800
800
800

Minimum

Maximum

Busbar Rat ing (Amps)

C o nst ruct io n
Type

800
1000
1250
1400
1600
2000
2500
3200
4000
5000

Single
Single
Single
Single
Single
Single
Double
Double
Double
Triple

115
115
115
140
165
190
240
280
350
441.5

250
250
250
275
300
325
375
415
485
600

800
800
800
800
800
800
800
800
800
441.5

500
500
500
500
500
500
500
500
500
600

20

3.8 - Flange Elbow Edgewise

Flange Elbow Edgewise

3.9 - Flat Tee

21

Flat Tee
Panel flanges are the standard fittings used to make
connections to other items of LV equipment such as
switchboards and transformers etc.

Tee units are used to make branched busbar

runs. The tee units create a 90o branch to
accomodate multiple end supply points from a
single source and can, in certain applications, be
a more efficient way of creating a widespread
distribution backbone.

Panel flanges with integrated 90o change of direction

allow for low headroom applications and are available
both in flatwise and edgewise formats.

Tees are available in compact form in flatwise

construction.

Each rating of flange has set dimensions for the cut

out & fixing points identical to that of straight type
units the details of which are supplied on drawings
with each unit.
Phase rotation from other equipment to a busbar
system needs careful coordination and all phase
details must be highlighted and approved at design
stage.

Typical Arrangement

Typical Arrangement

Minimum

Maximum

Busbar Rat ing (Amps)

C o nst ruct io n
Type

800
1000
1250
1400
1600
2000
2500
3200
4000
5000

Single
Single
Single
Single
Single
Single
Double
Double
Double
Triple

140
140
140
140
140
140
140
140
140
140

275
275
275
275
275
275
275
275
275
275

800
800
800
800
800
800
800
800
800
800

500
500
500
500
500
500
500
500
500
500

Busbar Rat ing (Amps)

C o nst ruct io n Type

800
1000
1250
1400
1600
2000
2500
3200
4000
5000

Single
Single
Single
Single
Single
Single
Double
Double
Double
Triple

St and ard
X

1000
1000
1000
1000
1000
1000
1000
1000
1000
1250

375
375
375
375
375
375
550
550
550
675

22

3.10 - Fire Barriers

3.11 - End Feed

Fire Barrier

23

End Feed
Fire barrier units are manufactured as a complete assembly
on standard length sections (see table) using calcium
silicate based material that is classified as non-combustible
according to EN13501-1. The material is free from asbestos
and quartz and is extremely lightweight with excellent
insulating value, high mechanical strength and good heat
resistance. The boards are designed for maximum service
temperatures of up to 1050C.

End feed units are used to connect cables to feed a

busbar run. Typical use is in a building riser, either
at the top or bottom but they are also found feeding
horizontal systems.
Side and bottom glanding areas allow for the greatest
flexibility when it comes to cabling the unit.
The size of an end feed is generally governed by the
size, type and number of cables being connected, see
below for the standard sizes available.

Due to the jacket design they can be installed on any length

bar to accommodate applications that do not suit the use
of a standard length section. But these must be highlighted
during design phase to allow manufacture.

Special sizes and configurations can be designed to suit

particular applications, please contact our applications
engineering team for further details.

Fire penetration ratings of up to 240 minutes are available

(S240) according to ISO 834-1 on all ratings of IBAR.

Typical Arrangement

Typical Arrangement

F ire Barrier Dimensio ns

Typical Apert ure Size

Busbar Rat ing

(Amps)

C o nst ruct io n
Type

A (mm)

B (mm)

C (mm)

D (mm)

W (mm)

H (mm)

800
1000
1250
1400
1600
2000
2500
3200
4000
5000

Single
Single
Single
Single
Single
Single
Double
Double
Double
Triple

1200
1200
1200
1200
1200
1200
1200
1200
1200
1200

175
175
175
175
175
175
175
175
175
175

125
160
190
205
225
280
390
460
570
740

600
600
600
600
600
600
600
600
600
600

205
205
205
205
205
205
205
205
205
205

155
190
220
235
255
310
420
490
600
770

Busbar Rat ing (Amps)

800
1000
1250
1400
1600
2000
2500
3200
4000
5000

St and ard

St and ard

St and ard

600
600
600
600
600
600
600
600
600
600

600
600
600
600
600
600
800
800
800
800

350
350
350
350
350
350
650
650
650
800

24

3.12 - Centre Feed

3.13 - Hangars and Fixings

Hangars and Fixings

Centre Feed

Correct mounting of the busbar trunking run is a critical

element of ensuring a trouble free system. The IBAR HX
system has a range of mounting & clamping hardware
that is fully compatible with the widely available Unistrut
system.

Centre feed units are used to connect cables to feed

a busbar run. As its name suggests the centre feed
unit will be situated somewhere along the busbar run
feeding power to both branches that connect.
Centre feed units can be used to supply any busbar
configuration, building risers and horizontal systems.
Side and bottom glanding areas allow for the greatest
flexibility when it comes to cabling the unit.

Horizontal installations will make use of the universal

fixing clamp that is able to accommodate flatwise and
edgewise orientations and fixed clamps that are typically
used on long straight runs where expansion needs to be
controlled. Both of these clamps fit onto standard
41x41mm Unistrut as illustrated below.

The size of an end feed is generally governed by the

size, type & number of cables being connected, see
below for the standard sizes available.

Vertical riser installations make use of the fixed clamps

and proprietary spring brackets used to distribute load
evenly across the building structure and isolate the bar
from excessive vibration or building movement.

Special sizes and configurations can be designed

to suit particular applications, please contact our
applications engineering team for further details.

Typical Arrangement
Typical Arrangements

Busbar Rat ing (Amps)

800
1000
1250
1400
1600
2000
2500
3200
4000
5000

St and ard

St and ard

St and ard

600
600
600
600
600
600
600
600
600
600

600
600
600
600
600
600
800
800
800
800

350
350
350
350
350
350
650
650
650
800

25

26

4 - Applications Engineering

The success of a busbar installation starts from the very

moment that IBAR is specified, our team of driven and
dedicated sales and application engineers are pro-active in
making sure that you get what you want when you need it.

Approval
Ensure key project stakeholders approval of equipment
supply and busbar layout design prior to any non-standard
parts manufacture.

Our experienced team of in-house applications engineers are

on hand to make using IBAR a hassle free process utilising a
catalogue of standard and customisable parts they are able
to create bespoke solutions tailored to the most demanding
requirements.

Manufacture, delivery & installation

Production drawings issued and manufacturing slots booked
based on delivery & installation plan. Itemised parts delivered
to site fully labelled to match installation drawings.

Our teams work closely with other infrastructure and power

system providers to coordinate critical elements such as
phase orientation.

6 - Parts Numbering Guide

Site measures
Once available for inspection any final connection pieces are
confirmed, measured and manufactured. Delivery is then
prioritised to suit the installation.

HX

Part Variant Code

ST4 = Standard 4M
...
ST3 = Standard 3M

#
Bars

Conductor Type Code

A = Aluminium
C = Copper

16

4P

SF

ST3

Typical process:
Building survey
Procure available floor plans, 3D models and supplement with
site survey to confirm dimensions and assess obstructions.

IBAR Range Code

HX = High Power

Busbar layout drawings

Generate and layout accurate 3D busbar runs using 3D CAD
software to create BIM compliant models. Attention to
positioning of tap off units, phase orientation and efficient
installation.

Rating Code (A)

16 = 1600A
...
63 = 6300A

Coordinate with infrastructure and other suppliers

Liaison with third parties to confirm phase rotation and avoid
infrastructure clashes during install. Installation teams are
fully involved as part of the coordination process.

5 - iControl Cloud Integration

Every piece of IBAR is fitted with an iControl Cloud tag, this enables components to be referenced within a particular busbar
run together with arrangement drawings, commissioning reports and lifecycle servicing reports to be uploaded and retained
for the life of the asset.
Access to iControl Cloud is provided free of charge to IBAR customers for the first year from Practical Completion
(of the IBAR installation).
iControl Cloud can be extended to include any other asset, full details are available online at

TM
HXC-16-4P-PF-ST
Cloud
iContr
dd
Cluou
l ol
ntoro
l Clo e Tag
iCotr
-ST B01
Servic
/001/1
P-PF4/001
gg
21347-4
ice aTa
iConServ
Serial No.
HXC-16
ice T
A
T 1 B01
Serv
/00
-S
.
/14
F
1600
01
No
-P
rt
7/0 P
t [InA]
PaCurren
A
1
2134
-16-4
V 5 0 0 0 00000
1 B0
000111888
HXC690
4/00
AV
rial Noe. [Ue]
SeVoltag
01/1
0 0 0 00 0 0
1600
47/0
Hz 5 0 0
21350
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Part Type Code

SF = Straight Feeder
...
PF = Panel Flange

Part Type Codes

Part Variant Codes

Rating Codes

CF
Centre Feed
CM Combination
EC
End Cap
EF
End Feed
EX
Expansion
FB
Fire Barrier
JP
Joint Pack
LE
Elbow Edgewise
LF
Elbow Flatwise
NR
Neutral Rotation
PF
Panel Flange
PR
Phase Rotation
SD
Straight Distibution
SF
Straight Feeder
TF
Tee Flatwise
TX
Transformer Flange
ZE
Offset Edgewise
ZF
Offset Flatwise

060 60min Rating

120
120min Rating
240 240min Rating
CD
Custom Down
CL
Custom Left
CR
Custom Right
CU
Custom Up
CX Custom
LD
Left Downwards
LU
Left Upwards
RD
Right Downwards
RU
Right Upwards
SL
Standard 90 Left
SR
Standard 90 Right
ST
Straight
ST1
Standard 1m Straight
ST2
Standard 2m Straight
ST3
Standard 3m Straight
ST4
Standard 4m Straight

8 800A
10 1000A
12 1250A
14 1400A
16
1600A
20 2000A
25 2500A
32 3200A
40 4000A
50 5000A
63 6300A
# Bars / Poles
3 TP
4
TP&N / TP&E
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TP&2N / TP&N&E
6 TP&2N&E

27