5 Reasons Why Your Business Needs Busbar Systems？

While initial installation costs may be higher, the total cost of Rolinx busbars solutions is typically 20-30% lower over a 10-year period when considering:

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Busbar solutions feature modular designs that facilitate maintenance and system modifications. Furthermore, simplify electrical connections by reducing the number of required individual cables. For this reason, connection points can be accessed without disrupting the entire system, reducing mean time to repair (MTTR) by up to 60% compared to conventional wiring. The standardized connection interfaces also enable rapid system reconfiguration and expansion.

Therefore, these advantages make busbar solutions an essential component in modern electrical distribution systems, particularly in applications requiring high reliability, efficiency, and adaptability.

Laminated busbars from Rolinx are high-performance electrical conductivity solutions designed for efficient power transmission and distribution in complex electrical systems. These precision-engineered components represent a sophisticated approach to electrical interconnection and power management. Therefore, the laminated busbars are considered advanced power distribution technology.

Electrical power transmission technologies have undergone significant evolutionary transformations, with laminated busbars emerging as a sophisticated alternative to traditional busbar configurations. This comparison explores the critical distinctions between these two power distribution methodologies.

ROLINX Easy

Designed for low and medium-voltage applications with lower electrical performance requirements. ROLINX Easy laminated busbar solution is without outer insulation and closed mold technology, offering high short circuit resistance, optimized conductivity, and high currents above A.

• High short circuit resistance and low conductivity.
• A cost-effective alternative for stacked busbars.
• Manufactured in a controlled production process.
• The ease of use helps to reduce installation times.

ROLINX Performance

Designed for medium and high voltage applications and in combination with high currents over A. ROLINX Performance laminated busbar offers all material, lamination, and plating configurations with optimized inductance and design to control partial discharge.

• Provides optimized inductance.
• Designed for controlling partial discharge
• Shaped to fit high-voltage applications
• Proven technology

ROLINX Thermal

An evolution of ROLINX Performance offering increased working temperature up to 130°C.

• Developed to get more power from the existing system and design.
• Extended thermal characteristics: up to 130°C.
• Extended humidity rating.
• Designed to last.

ROLINX Hybrid

One piece solution combines power and signal lines. ROLINX Hybrid laminated busbar is for low-voltage applications like battery cell connection in Electrical Vehicles.

• One-piece solution for signal lines and power connection in battery modules.
• Reduces installation time.
• Eliminates wiring errors.
• Streamlines the supply chain.

ROLINX Power-Circuit

Designed as an alternative solution to traditional PCBs. It offers high voltage and current capacity with low inductance and compact 3D design.

• Compact 3D design.
• Fit for high-volume assembly processes.
• Good thermal management.
• Low inductance.

ROLINX Compact

Busbar uses epoxy powder coating as outer insulation instead of insulation films. It offers tight-fitting solutions when limited space is available.

• Optimized design fit for narrow space connection.
• High power density capabilities.
• High-temperature resistance.
• Easy to insulate very complex shapes.

ROLINX Flex

Flexible busbars are pure copper laminates within protective PVC insulation offering flexibility for customized solutions.

• Flexible configurations with/without rigid parts.
• Easy and quick bending.
• Ideal for parts with vibrations and/or thermal expansion.
• Space saving in compact designs.
• Design flexibility.

ROLINX Housing Solutions

Injection molded solutions in combination with busbars offer great flexibility for customized solutions.

• Integration of connectors or structural functions.
• Reduced weight.
• Space savings in compact designs no spacers required.
• Improves design flexibility with complex 3D shapes.
• Ideal for high-volume production.

ROLINX CapLink Solutions

Capacitors integrated on ROLINX Laminated Busbar Solutions offer a low inductance.

• Low ESL & ESR.
• High ripple current capabilities.
• High reliability.
• Long useful life.

ROLINX Busbars Engineering Services

Include a range of services to meet critical application needs regardless of size or complexity. Our services include current, heating, and inductance simulations, and standard and specific testing capabilities like static self-heating and accelerating aging tests.

• Increased reliability due to the optimized busbar layout.
• Reduced busbar architecture complexity.
• Minimized design risk and costs.
• Increased flexibility.
• Lower total cost of ownership.

Current

Typical range: 100A – A

Voltage

The busbars can operate at different DC voltage levels. Typical values for nominal, rated insulation, impulse withstand, high potential, and partial discharge voltages are listed below and are determined according to EN -1 chapter 4.2.3.1 Annex D table D.1 are the following:

• *Minimum nominal +20% depending on application (higher relative percentage for the railway power distribution systems)
• The high voltage test can be determined as per the formula: 2*Ui+2kV acc. IEC Annex B.3 during 1 minute.
• To determine partial discharge voltage see point Partial Discharge.

Clearance Distance

Clearance is the shortest distance in air between two conductive parts. Typical clearance values according to EN -1 chapter 5.2 table A.3 and overvoltage category 2 (OV2) are the following:

Overvoltage category OV2 definition: Circuits that are not directly connected to the contact line, and which are protected against over-voltages.

Creepage Distance

Creepage distance means the shortest distance along the surface of a solid insulating material between two conductive parts. Typical creepage values according to EN -1 chapter 6.2 table A.7 and insulation materials group 1 (CTI <600V 5mm / kV) and pollution degree 2 (PD2) are the following:

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• *Minimum nominal +20% depending on application (higher relative percentage for the railway power distribution systems)
• Pollution degree PD2 definition: Normally only non-conductive pollution occurs. Occasionally, however, a temporary conductivity caused by condensation is to be expected when the equipment is out of operation.

Partial Discharge

The partial discharge test helps to predict the future performance and reliability of the busbar. Typically partial discharge should be below <10pC according to IEC at defined voltage Vtest.

Test Cycle:

• 1min 1.5 Um / √2
• 30s Vtest 1.1 Um / √2
• Max 10pC @ last 5 s Vtest

Physical Dimensions and Tolerances

The table below lists the physical dimensions and standard tolerances for the busbars.

Bending

The bending information below gives general recommendations to minimize the stress in the material.

There are various features to terminate the busbar for system connection. The table below describes the most common methods and some factors to be considered when designing a busbar.

• Min: -50°C / Max: Extended +130°C
• Cooling system: Natural convection
• Relative humidity: Max: 55°C / 95% RH

The move to busbar power distribution systems was ignited in large part due to new regulations outlined by the International Electrotechnical Commission (IEC) about the importance of global standardization in the design and functionality of industrial power distribution. But in the handful of years since busbar emerged on the world stage, manufacturers have experienced a variety of key benefits in incorporating this more modular approach to power distribution, particularly in terms of reducing energy consumption and costs.

Here, we’ll look at a couple of key design features of busbar power that can help manufacturers create a more cost-effective, efficient power distribution architecture, and what makes Rittal’s busbar power solutions the ideal choice for manufacturers in almost any application.

Busbar power systems are quick and easy to scale

One of the more impactful ways that busbar power distribution systems can help reduce costs and increase efficiency is the ability to quickly and easily scale to meet production demands.

Traditional control panels are limited in the ability to increase wiring capacity, and they also lack configuration flexibility and versatility. What’s more, control panels that can be modified usually require drilling or tapping of an industrial enclosure, and this can require both specialized tooling and a significant time investment. Modular busbar systems can be configured and modified without the need for drilling, and this also accelerates the ability to scale power distribution based on demand or the footprint of your automation infrastructure.

Whereas legacy IEC systems are designed for specific uses, busbar’s simplified engineering makes it easier for designers to retrofit power distribution systems to fit a wide range of applications. 

This not only reduces the potential for downtime when scaling your automation infrastructure to meet production demands, but it also makes manufacturers better equipped to add new production lines based on market forces — for example, the flexibility of busbar power systems would streamline the process of adding a new production line.

Busbar power distribution prioritizes performance without sacrificing flexibility

Traditional industrial control panels rely on large power distribution blocks (PDBs) to provide electricity throughout an enclosure. Not only can these large PDBs be extremely cumbersome to install or customize given the amount of space they occupy, they also don’t offer the most efficient use of energy. What’s more, the large quantity of cables and wires used in traditionally wired panels takes up precious space inside the enclosure, making it difficult to troubleshoot issues or execute routine enclosure maintenance.

Busbar power panels are designed to replace the side line wiring and accessories of an industrial electrical panel. Busbar power panels replace power distribution blocks (PDBs)  and the large number of cables with a single conductor that carries the same amperage while freeing up space inside the enclosure.

Making the move to busbar power helps maximize uptime on the factory floor by reducing instances of electrical overload which are one of the primary causes of motor failures — in fact, about 30% of all motor failures are caused by overload conditions, and busbar is better equipped to respond and adapt to an electrical imbalance.

Not only does busbar optimize the performance of your automation systems, it also helps create a safer manufacturing environment for workers, and it also helps reduce the likelihood of accident arcing, an event that can be extremely hazardous and costly.

From a short circuit rating, busbar power systems offer a higher default short circuit current rating (SCCR), which further enhances a safer automation infrastructure by adding additional protection from electrical faults or arcing incidents. Plus, the configuration flexibility of busbar allows for the integration of extra supports to increase the SCCR based on application or required voltage.

Busbar power distribution panels are manufactured to a global operational and efficiency standard

Speed-to-market and the ability to accelerate the deployment of automation systems are key for manufacturers to be competitive in their market. The variable nature of traditionally wired panels and the lack of product standardization can make it difficult to ensure delivery and deployment in ways that reduce the possibility of downtime. Busbar power panels are manufactured using IEC standards and UL guidelines that establish a standardized design for a more simplified approach to power distribution. 

This simplified, standardized design also adheres to global safety and operational standards. Not only does this help manufacturers create more reliable, consistent power distribution workflows, it also helps manufacturers specify power distribution systems that can be easily integrated across a wide range of applications, creating more versatile power distribution solutions.

Rittal’s approach to modular busbar power panels can help you create automation systems based on speed, flexibility, and versatility. For example, RiLine Compact busbar systems utilizes a 3-pole, plug-and-lock connection at the front of the panel for easier, more efficient cable configuration. The RiLine Compact Busbar System offers a variety of mounting capabilities, including a top-mounting that allows for a more versatile use of space inside the enclosure and provides a complete touch-safe system.

But this is just the beginning of how busbar power can help manufacturers unlock more efficient, cost-effective power distribution.

If you want to learn more, please visit our website Busbar Systems.

Download our white paper to learn more about how busbar power systems can help you future-proof your industrial automation infrastructure.