More about Busbars

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Busbars are thick, heavy conductive metal components used for electrical applications, especially those pertaining to a single connection between multiple circuits or transfer of large currents. They are found in large power distribution units, such as electrical substations and switchboards, and can be insulated or uninsulated depending on the application. Similarly, they are either left exposed (open-air busbars) or contained, as is acceptable to the operation.

Copper busbars are regularly used for many applications, due to the superior conductivity of copper. The amount of current a busbar can carry is determined by its size and by the peak temperature of the operation; larger busbars can safely hold larger currents. Temperature ranges vary between materials, as well; aluminum, for example, is more sensitive to maximum temperatures than copper due to its rapid oxidation. Typically, busbars are installed as strips or tubes; these shapes both have relatively high surface areas, and therefore lose heat at a faster rate than other types, allowing for regular use without as much risk of overheating or associated dangers. Custom shapes are also produced, as busbar applications are specific to electrical system design and facility constraints.

Busbars are manufactured for uses ranging from circuit board level to large, high current systems. They may include stud and screw terminals, and one or two bars; dual bars are simply one block holding two busbars and therefore offering two poles. Busbars also feature mounting holes for installation purposes. Depending on the design, fabrication of busbars can entail a number of machining processes, including bending, cutting and punching. More sophisticated designs may require more advanced manufacturing processes, such as CNC machining.

When selecting busbars, be sure to check its amp rating, maximum temperature, size and VAC rating. It is equally important to determine whether you need to purchase a cover or enclosure for the busbar system.