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11/14/2016
Installation tips for prefabricated busbar systems and cables (on photo: Example of high power distribution; credit: Legrand)
Installation configuration
The term installation configuration, when applied to prefabricated busbar systems and cables power transport
and power distribution in the installation, essentially refers to the geometric requirements of the conductor routing that
will have to be taken into consideration.
Adaptability requirements may also be added to these considerations, particularly at the level of connection of usage
points which must have the required flexibility (for example frequent disconnections or changes).
1. Conductor rating
1. Cable trays or prefabricated busbar systems?
2. Dimension and size of the distribution system
3. Bend radius
4. Mechanical resistance
5. Specific installation requirements
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1. Conductor rating
To design a power transport system with prefabricated busbar systems or cables, it is necessary to have an overall
vision of the routing to be achieved, paying particular attention to changes of direction, obstructions (partitions, fire
breaks, doors, etc.) or obstacles (pillars, walls, etc.), which must be avoided without any interruption in the continuity
of the conductors.
With this approach, it is recommended that a site inspection be carried out before the project in order to evaluate
the routing problems. If this is not possible, a study will be made on the blueprint.
The choice of a cable tray or prefabricated busbar system must be compatible with the routing required, without
forgetting to check that the accessories necessary for changes of direction,to avoid obstacles, for alterations of level
and feedthroughs are actually available.
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Figure 1 Example of routing of prefabricated busbars and cable trays (on photo: Zucchini
busbars; credit: hermestrading.net)
Moreover, it is necessary to give consideration to the characteristics of the floor tiles or the walls (for example
reinforced concrete), the difficulty in securing supports, as well as the size and weight of the cable trays or
prefabricated busbar systems.
Go back to installation tips
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Figure 2 Routing of power cables (left) and prefabricated busbar systems (right)
These integrated systems, perfectly calculated from an electrical and electromagnetic point of view, allow the flow of
very high power and give very high levels of protection against specific stresses: IP, fire, electromagnetic radiation.
Integrating them into the infrastructure of the building requires preliminary consideration to ensure that optimum
solutions are selected. specific rules must be followed for installation and assembly.
Prefabricated busbar systems are generally classified as high power, medium power and
low power. They allow all types of power transport from the power source to the end usage point
(workstations, machines, lighting, etc.).
Cable trays and prefabricated busbar systems are two different systems, each with its own advantages. Of course,
their use can also depend on common practice. Naturally, the two systems are complementary and can be installed at
different levels, or for different usages at the same site.
The cross-section and number of cables to be installed can also be an important variable for consideration. The
greater the number of cables and the wider their cross-section, the closer together the supports must be. The
minimum bend radius must also be considered.
With a global approach to conductor routing, it is also necessary to consider the other services in the
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Figure 3 The configuration of the site, obstructions, the coexistence of different networks sometimes lead to complex routing
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and safe maintenance. With this in mind, the choice must take into consideration operations that could affect the
production costs or management of the system.
As the installation evolves, prefabricated busbar systems guarantee continuity of service by allowing
connections and disconnections with the power on. On the other hand, it can be less costly to install trunking or cable
trays in installations that do not require any particular modifications or maintenance.
The choice of a distribution system is not limited to a single solution. According to the complexity and size of the
building, the power used, the configuration of the location and the environmental conditions, prefabricated busbar
systems, trunking or cable trays can be jointly used.
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This equipment, which could potentially be fitted with protection or isolation devices, will be able to
power the starting points of the additional lines.
Figure 4 Cable solution: addition of a new distribution board to a junction box provided for this purpose
With the prefabricated busbar system solution, the busbars used as main lines are fitted with connection
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points. In this case, to power new lines, junction boxes simply have to be fitted directly onto the busbar. If required,
these junction boxes will be equipped with protection or isolation devices.
Similar precautions will be taken at terminal circuit level to ensure maximum flexibility, should there be changes in the
layout of workstations and/or an extension.
Figure 5 Prefabricated busbar system solution: addition of a new workstation by direct connection with the busbar system
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