Guide To Busbar Systems And IEC 61439 Standards
It continued a determination across the sector to harmonise the low voltage industry through the creation of one
Meaning of Low-voltage busbar specifications
Low-voltage busbars are designed for electrical systems up to 1000 V AC (1500 V DC), with specifications governed by IEC 61439 and related standards, covering current capacity, thermal limits, insulation, and fire safety.
Standards and Compliance
Low-voltage busbars are primarily governed by IEC 61439, which defines design verification, test requirements, and thermal performance for busbar assemblies in switchgear and control gear systems . In the UK and Europe, BS EN 61439-6 aligns with IEC 61439-6, providing additional guidance for busbar trunking systems, including fire-stop measures and safe installation practices . Compliance ensures proper electromagnetic compatibility, corrosion resistance, and degree of protection.
Voltage and Current Ratings
- Voltage rating: Up to 1000 V AC and 1500 V DC for low-voltage applications .
- Current rating: Determined by busbar cross-section, material (copper or aluminum), and system diversity factor. For example, a 22-circuit system with a total equipment requirement of 2700 A and a diversity factor of 0.6 would require a main busbar rated for 1620 A .
- Thermal limits: Maximum safe operating temperature is typically 140°C, which is 105 K above a 35°C ambient .
Materials and Construction
- Conductors: Copper or aluminum, often with high mechanical and electrical performance.
- Insulation: Low-voltage busbars may use epoxy-resin casting (B.I.M. mix) for moisture resistance, fire resistance, and self-extinguishing properties .
- Modular design: Prefabricated elements allow flexible assembly, with 2-sided compression contacts ensuring reliable electrical connections .
Busbar Trunking Systems
- Trunking systems provide modular, space-saving solutions for distribution in buildings and industrial facilities .
- Fire safety: Trunking units are designed to limit heat propagation and may include factory-fitted fire-stops .
- Digital planning: Tools like SIMARIS and BusbarCheck apps allow configuration, energy monitoring, and integration with BIM and IoT systems .
Installation and Safety
- Supports and covers: Finger-safe covers and busbar supports are used to prevent accidental contact .
- Junctions and extremities: Overcast with insulating material to maintain IP68 or IP67 protection and mechanical robustness .
- Maintenance: Regular inspection and adherence to manufacturer instructions are essential for safe operation .
Applications
Low-voltage busbars are widely used in:
- Power distribution boards and switchgear
- Industrial plants, refineries, and offshore installations
- High-rise building distribution systems
- Photovoltaic and renewable energy systems By following these specifications and standards, low-voltage busbars ensure safe, reliable, and efficient electrical distribution in a variety of applications.
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