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Recommended Low-Voltage Busbars

Specialty cable knowledge brief Published 23 May 2024

Prepared for preliminary research by the ZITHA SPECIALTY knowledge desk. Confirm fire performance, mechanical protection, loss budgets and installation requirements against current standards and product documentation.

Selecting low-voltage busbars requires balancing current capacity, thermal performance, short-circuit withstand, material choice, and IEC 61439 compliance.Key Considerations for Busbar Selection

1. Material Choice

  • Copper: High conductivity, smaller cross-section for the same current, better thermal performance, but more expensive.
  • Aluminum: Lighter and cheaper, but requires a larger cross-sectional area to carry the same current as copper and has slightly lower conductivity . 2. Current Rating and Cross-Section
  • Determine the continuous current (Ir) the busbar must carry without exceeding permissible temperature rise.
  • Use current density guidelines: typically 1.5–2.5 A/mm² for copper in enclosed environments. For example, a 300 A load at 2 A/mm² requires a 150 mm² cross-section .
  • Consider diversity factors for multiple circuits to avoid oversizing; e.g., a 2700 A total load with a 0.6 diversity factor results in a main busbar requirement of 1620 A . 3. Short-Circuit Withstand
  • Busbars must survive prospective short-circuit currents for a specified duration (usually 1–3 seconds).
  • Ensure mechanical strength and support spacing are adequate to handle peak forces during faults . 4. Thermal Performance
  • IEC 61439 defines temperature rise limits: typically 70°C above ambient for copper and 55°C for aluminum.
  • Consider ambient temperature, enclosure type, and mounting orientation (vertical or horizontal) as they affect cooling and heat dissipation . 5. Voltage Drop and Layout
  • Minimize voltage drop by optimizing busbar length, cross-section, and symmetry in multi-branch systems.
  • Hotspots often occur at studs and terminations, so ensure proper connection design . 6. Insulation and Spacing
  • Maintain adequate clearances and creepage distances according to voltage rating and environmental conditions.
  • Insulation coordination is critical for safety and reliability . 7. Corrosion and Environmental Protection
  • Apply anti-corrosion treatments if exposed to humid or corrosive environments.
  • Consider enclosure protection levels (IP rating) to prevent moisture ingress . 8. Future Expandability and Serviceability
  • Design busbars to allow easy expansion, maintenance, and protection coordination.
  • Document material, cross-section, short-circuit rating, insulation, and service conditions as part of compliance with IEC 61439 .
Practical Selection Workflow
  1. Define load current, peak currents, and diversity factor.
  2. Choose material (copper or aluminum) based on conductivity, cost, and weight.
  3. Calculate cross-sectional area using current density and thermal limits.
  4. Verify short-circuit withstand and mechanical support.
  5. Check voltage drop, spacing, and insulation requirements.
  6. Apply environmental and corrosion protection measures.
  7. Ensure IEC 61439 compliance and document all parameters for verification . By following these steps, engineers can select low-voltage busbars that are safe, efficient, and reliable, while accommodating future system expansion and maintenance needs.

Recommended Low-Voltage Busbars - ZITHA TECH SPECIALTY CABLES (Pty) Ltd [PDF]

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