Solid insulated busbar system

General Information

Especially for the transmission of higher current and in case of limited space, the solid busbar insulation system is an alternative to parallelconnected cables and metalenclosed busbar connections.

The following inherent benefits speak for the use of fully insulated busbars:


  • Compact design
  • Low space requirements
  • Small bending radii
  • 3-dimensional geometric shape is possible

Safety Benefits

  • Capacitive Grading system
  • Capable of withstanding high thermal and dynamic short circuit currents
  • Safe to touch
  • No short-circuits due to full insulation
  • Natural cooling due to effectual conductor design
  • High operational reliability due to factory routine test

Construction and Installation Work

  • Easy installation due to standardised installation and fixing parts
  • Minimum project work for the user

Production Length

The length and geometric shape is limited by the size of the equipment, local facilities and the means of transportation.

Multiple Busbar Connections

The length of the individual busbars is limited by the manufacturing process, transportation and installation conditions. For complex installations the busbars have to be connected. The connection is performed with flexible connectors between the busbars to allow thermal expansion and to compensate for tolerances during installation. These joints are fully insulated by connection sleeves, which cover the capacitive grading at the busbar ends.

Busbar Fixing

For installation of the busbar system a flexible mounting system is used. Adjustments can easily be done at site. The busbar fixing clamps include aluminium C-profiles, angles, T-screws and fixing clamps. The fixing elements are adjustable with respect to each other and adjustable in all directions therefore allowing compensation for building tolerances. The fixing clamps include fixed bearings and movable bearings allowing the busbar to move axially within the fixing clamps in case of thermal expansion. In the first instance, the capability of the equipment to withstand a short-circuit must be considered for the busbar fixing. Another criterion is the natural frequency of the busbar. The distance between fixing points must be chosen to avoid resonance with respect to the power frequency of the system and its harmonics. The distance between the fixing points of the busbar is individually calculated for each order.

A respective calculation tool is available which includes

  • Busbar diameter
  • Phase distance
  • Mass of the busbar
  • Bending strength

Fixing Clamps

The standard connection between busbars is a standardized flat terminal in accordance with the rated current.

There is a wide range of possibilities for connecting the system with the plant. For optimal connection a customized design can be realised.


A separate earthing connection dimensioned in accordance with the required short circuit current generally has to be installed parallel to the busbar system. Every single busbar, connection sleeve and metallic fixation material has to be earthed on this earthing connection. If a busbar or a connecting sleeve is not earthed correctly these elements will be destroyed after a certain amount of time.