hager Unibar H 800 A User guide

Busbar system
unibar H
System manual
800 A to 4000 A

Table of contents
2 Technical changes reserved
Table of contents
1About this manual 5
1.1 Warranty and Liability 5
1.2Copyright 5
1.3 Revision index 5
2Why a busbar system? 6
3Construction and characteristics 8
3.1 Characteristics of the busbar system 8
3.2 System components: Overview 9
3.3 Busbar elements: Design 11
3.3.1 Double body system (from 2500 A) 12
3.3.2 Dimensions according to rated current 12
3.4 Busbar elements: Features 13
3.4.1 Connection joint with joint block 13
3.4.2 Straight length busbar elements 15
3.4.3 Changes of direction 15
3.4.4 Feeder units 16
3.5 Tap-off units for plug-in (125 - 630 A) 17
3.6 Tap-off units for connection joints (250 - 1250 A) 18
4Product selection 20
4.1 Type key for busbar elements 20
4.2 Straight busbar elements 22
4.2.1 Straight busbar elements without plug-in 22
4.2.2 Straight busbar elements with plug-in 24
4.2.3 Fire Barrier 25
4.2.4 Expansion compensation unit 26
4.3 Change Directions 27
4.3.1 Elbow, horizontal 27
4.3.2 Knee, vertical 28
4.3.3 Double horizontal change direction (Z-element) 29
4.3.4 Double vertical change direction (Z-element) 30
4.3.5 Offset change direction (offset elbow/knee) 31
4.4 T-elements 32
4.4.1 T-element, horizontal 32
4.4.2 T-element, vertical 33
4.5 Connection elements 34
4.5.1 Transformer connection element 34
4.5.2 Terminal elements 35

Table of contents
Technical changes reserved 3
4.6 Drill holes for connecting flanges 38
4.6.1 Standard type 38
4.6.2 Other types 39
4.7 Cable feeder 41
4.7.1 Cable end feeder 41
4.7.2 Cable intermediate feeder 41
4.8 Tap-off units 42
4.8.1 Type key for tap-off units 42
4.8.2 Tap-off units for plug-in 43
4.8.3 Tap-off units for connection joints 45
4.9 Accessories 46
4.9.1 End flange 46
4.9.2 Fastening material 46
4.9.3 Joint block, standard (spare part) 47
4.9.4 Joint block for tap-off units 47
5Sketches of busbar elements 48
6Technical data 52
6.1 Conductors aluminium, 4 bars (N, L1, L2, L3), PE housing 52
6.2 Conductors aluminium, 5 bars (N, L1, L2, L3, PE2), PE housing 52
6.3 Conductors copper, 4 bars (N, L1, L2, L3), PE housing 54
6.4 Conductors copper, 5 bars (N, L1, L2, L3, PE2), PE housing 55
6.5 Calculating the voltage drop 56
6.6 Temperature derating 57
6.7 EMC values 57
6.8 Sprinkler test 58
6.9 Functional endurance 59
6.10 Connecting to unimes H energy distributor 61
7Installation, handling and maintenance 63
7.1 For your safety 63
7.1.1 Intended use 63
7.1.2 Requirements for authorised personnel 65
7.1.3 Observe the assembly instructions 66
7.2 Transport and storage 67
7.2.1 Lifting busbar elements 67
7.2.2 Storage 68
7.3 Assembling the unibar H system 69
7.3.1 Hangers 69
7.3.2 Mounting direction and installation position 70
7.3.3 Assembly principle for connection joints with protection type
IP55/IP65 72
7.3.4 Assembly principle for connection joints with protection type IP68 74
7.3.5 Cable feeds 76
7.3.6 Fire barrier 77
7.3.7 End flange 78

Table of contents
4 Technical changes reserved
7.3.8 Fitting tap-off units to plug-in (125 - 630 A) 79
7.3.9 Fitting tap-off units to connection joints (250 - 1250 A) 81
7.4 Operation, maintenance and enlargement 82
7.4.1 Maintenance 82
7.4.2 Enlargement 83
8Comments for specifications for tenders 84
9Formula characters and abbreviations in accordance with EN
61439-1/-6 86
10 Glossary 87
11 Index 91

About this manual
Technical changes reserved 5
1About this manual
This document is intended for planners, operators and users of the unibar H
busbar system. The system manual provides information about the efficient use
of the busbar system and also provides information
-on planning and dimensioning,
-of a general nature on handling and operation.
Related documents
-Follow the assembly instructions for the unibar H busbar system. The
assembly instructions provide detailed information on
-safe transport of the busbar elements,
-safe assembly and installation,
-safe operation,
-safe maintenance,
-the expansion of installed unibar H busbar trunking systems.
1.1 Warranty and Liability
These instructions do not extend the Sales and Delivery Conditions of Hager. No
new claims concerning the warranty and guarantee, which extend beyond the
Sales and Delivery Conditions, can be derived from this manual.
Liability note
Hager reserves the right to modify or supplement the product or the
documentation at any time without prior notice. Hager assumes no liability for
typographical errors and any damage which may arise from them.
1.2 Copyright
The content of this system manual is protected by copyright. Reprinting,
translations and copies of the system manual in any form, even in part, require
the written consent of the publisher.
Product names, company names, trademarks or registered trademarks are the
property of their respective owners and must be treated as such.
unibar is a registered word mark of Hager SE, Blieskastel.
1.3 Revision index
Document No.: 6LE005515A
System manual for unibar H busbar system, Version V1.0 10/2018

Why a busbar system?
6 Technical changes reserved
2Why a busbar system?
Energy distribution must not only be flexible and low priced, but also
space-saving, safe and with a long service life. unibar H busbar systems from
Hager are just that: efficient and reliable. With this system energy can be
transported and distributed precisely: from the transformer to the low voltage
switchgear and through the entire building.
Space-saving
As a result of its compact construction, the busbar system is very space-saving.
Particularly with changes of direction, there are no bend radii of any kind or
similar to be observed.
Safe
Safety for persons and buildings is ensured by tested short circuit values of up to
253 kA (Ipk) and very low fire loads. In particular, the tested firewalls are reliable
and safe.
Cable laying (left) versus unibar H (right)
-low space requirement of busbars
-neat, safe installation with tested firewalls with unibar H
The busbars conform to EN 61439-1 and EN61439-6.
Long, maintenance-free working life
With an average lifetime of over 25 years for an installed busbar, the investment
is well protected. Furthermore, the installed busbar trunking system is
maintenance-free. The clamping bolts at the connection joints can be checked at
a later time without having to disconnect the busbar run (Protection Type IP55 /
IP65).

Why a busbar system?
Technical changes reserved 7
Flexible
We comply with the customer’s specifications when creating the routing plan for
the busbar system. The route is adapted to local circumstances and can be
modified at any time. Modifications and expansions with unibar components are
possible at any time after the installation of the busbar trunking system. In this
way, all the requirements for the strand course can be met. Tap-off units up to
630 A can be plugged into the plug-in of straight busbar elements, even when
there is current on the busbar run.
Cost-effective
When considering costs, attention must be paid not only to the purchase price of
the material, but also to the assembly costs. An expansion will also contribute
considerably to the overall costs. The following graphics illustrate potential cost
savings from using busbars in contrast to laying cables. Incidentally, the graphics
do not take account of the additional savings due to the lower space
requirements of busbars:
Example of cost comparison for initial installation: due
to the lower assembly costs, savings are possible
when busbars are used
Example of cost comparison including 1st Expansion:
with the expansion, busbars offer the possibility of
significantly lower overall costs

Construction and characteristics
8 Technical changes reserved
3Construction and characteristics
3.1 Characteristics of the busbar system
-Compliance with the IEC 61439-1 and 61439-6 international standards, as
well as all European and national standards derived from them; CE-marking.
-Voltages up to 1000 V, frequency 50/60 Hz
-Protection type IP55 / IP65 or IP68 (cast resin system, only for energy
transport), also feasible combined within one busbar run
-The inner conductor of the busbar elements is made either from a tinned
aluminium alloy or from 99.9% pure ETP-copper conforming to EN 13601
-Housing made from 1.5 mm galvanised steel or an aluminium housing,
painted in RAL 7035 (special colours possible)
-Housing is used as PE protective conductor
-Heat is dissipated by the surface of the housing. The temperature rise of the
housing remains below 55 ° even at the rated current, irrespective of the
installation position and orientation
-Ambient temperature: min. -5 °C, max. 35 °C, 24-hour average 35 °C
-System components are free of silicones and halogens
Flexibility and expandability
-Horizontal and vertical mounting is possible, with no reduction in nominal
capability (with N conductor in bottom position for horizontal mounting and
flat installation position)
-Busbar elements available in various geometric shapes for changing direction
-Straight busbar elements available with or without plug-in in lengths up to
3 m
-Straight busbar elements available in selectable lengths 410 - 3000 mm
-Individual busbar elements can be removed without having to remove the
adjacent busbar elements (protection type IP55 / IP65).
-The joint block in the connection joints of the busbar elements enables
efficient assembly and later checking or tightening of the torque (protection
type IP55 / IP65).
-State-of-the-art single bolt clamps with torque indicated by the shear-off
bolt.
-Torque with the joint block in the connection joints of the busbar
elements: approx. 60 Nm
-Feeder units for transformers, terminals and cable feeders
Tap-off units for plug-in or connection joints
-Tap-off units can also be installed later by electrical specialists
-Tap-off units available with HRC fused switch disconnector, or with circuit
breakers (MCCB)
-Tap-off units up to 630 A for plug-in on straight busbar elements can be fitted
while voltage is applied (taking account of EN 50110 and national regulations)
-Tap-off units 250 A - 1250 A available for connection joints with a special
joint block

Construction and c haracteris ti cs
3.2 System components: O ver view
1
Terminal conn e c t ion
2
Straight length, with or without p lug - in
3
Bracket, vertical ( kn ee )
4
Bracket, hori zon t a l
5
T-pieces ( T - b oxes )
6
Double bracket, vertical / Z-knee ( Z - b ox )
7
Tap-off unit ( sym b oli c rep re s e n t a t ion )
- for plug-in (125 - 630 A, can be plugged in when voltage is applied
on busbar run)
- for connection joints (250 - 1250 A)
8
Fastening material ( sy mb oli c r e p re s e n t a t ion )
Technical changes reserved 9

Construction and characteristics
10 Technical changes reserved

Construction and characteristics
Technical changes reserved 11
3.3 Busbar elements: Design
For standard applications with 4 inner bars: the neutral conductor N has the
same cross-section as L1/L2/L3.
The protective earth PE corresponds to the housing.
If a larger cross-section is demanded for the PE, an additional inner bar (PE2) is
inserted. All internal conductors (N, L1, L2, L3 and PE2) have the same
cross-section.
The internal conductors consist of either aluminium or copper and are insulated
over their entire length. The insulation coating consists of an F-class polyester
tape.
-Aluminium conductors are coated over their entire length with zinc, copper
and tin.
-Copper conductors consist of 99.9% pure ETP copper conforming to EN
13601.

Construction and characteristics
12 Technical changes reserved
3.3.1 Double body system (from 2500 A)
Busbar elements with high rated currents In for 2500 A / 3200 A / 4000 A consist
of two parallel conductor bundles (Double body system, doubled conductor
system) In this case the conductors are installed together in two packs in one
housing.
-Aluminium conductors: Double body system for rated current Inof 2500 A,
3200 A and 4000 A
-Copper conductors: Double body system for rated current Inof 3200 A and
4000 A
The different conductors for the same phase are connected in parallel at each
connection joint (at least every 3 m for standard elements). Conductors for the
same phase thus undergo phase balancing at each connection joint to ensure
uniform current distribution. Special elements for phase compensation are not
necessary.
Installation efficiency, balanced load distribution
The solution with two parallel conductor packs in one housing has two major
advantages compared with other systems:
-Quick, simple installation (phases need only be combined once)
-Load distribution is balanced
3.3.2 Dimensions according to rated current
Rated current In
H for Al
H for Cu
800 A
85 mm
1000 A
95 mm
85 mm
1250 A
121 mm
85 mm
1600 A
160 mm
121 mm
2000 A
205 mm
150 mm
2500 A
286 mm D
185 mm
3200 A
376 mm D
248 mm D
4000 A
416 mm D
306 mm D
D = Double body system,
doubled conductor system

Construction and characteristics
Technical changes reserved 13
3.4 Busbar elements: Features
-4-pole (N, L1, L2, L3) and 5-pole (N, L1, L2, L3, PE2) available, each with PE
housing
-Neutral conductor has same cross-section as the phases (L1, L2, L3
conductors)
-System elements available as single conductor or double conductor (double
body system) according to rated current
-Protection type for standard housing: IP55
-Phases labelled at both ends of the busbar element
-Insulation materials are temperature resistant up to 155 °C
-Dielectric proof voltage of 3500 V
3.4.1 Connection joint with joint block
The connection joint between adjacent busbar elements is implemented with a
joint block. The joint block consists of
-the supplied joint block (with shear-off bolt),
-the supplied flanges for covering, for connecting the PE housings and for
additional mechanical stabilisation.
Connection joint with joint block for
protection type IP55
-Joint block for electrical and mechanical
connection of the inner conductors of
adjacent busbar elements
-Side flanges and screws
-Torque on clamp can be checked at a
later time; disconnection of busbar run is
not necessary for this
-Joint block can be changed at any time
(for a tap-off unit or other conversions /
expansions)
The connection joint with a joint block between unibar H busbar elements
ensures the following in a work process:
-the electrical and mechanical connection of all inner conductors in the
busbar, including the PE conductor
-with double body systems (doubled conductor systems), additionally the
parallel switching and phase balancing of the busbars
The interior of the joint block consists of silver-plated copper plates which have
been alternately layered with insulating material plates. The insulating material is
temperature-resistant up to 200 °C.

Construction and characteristics
14 Technical changes reserved
Single bolt clamp(s)
The joint block is fitted with single bolt clamp(s) to clamp and connect the
conductors of adjacent busbar elements. The joint block is provided with 1, 2, or
4 bolt clamps, depending on the rated current and number of internal conductors
in the busbars.
Illustration of principle of joint block with single bolt clamp: efficient assembly,
subsequent replacement possible (for protection type IP 55/65)
Efficient assembly with indication of torque
-The conductor rails of the adjacent busbar elements are fed from both sides
into the clamping block until the conductors are uniformly aligned.
-The single bolt clamp(s) on the joint block is then tightened with a torque
wrench until the double-headed bolt (on the outer part of the shear bolt)
shears off. This occurs at a torque of approx. 60 Nm.
Subsequent checking of the clamp while current is on the busbar run is possible
-The joint block in the connection joints of the busbar elements enables
efficient assembly. On connection joints with
protection type IP55 / IP65, the cap-sealed flange opening allows subsequent
checking or tightening of the torque.
-The torque on the joint block can be checked without having to disconnect
the busbar run.
With IP55 / IP65, the connecting block can be changed at a later date
-With a protection type IP55 / IP65 connection joint, the joint block can be
changed at a later date.
-Using accessories, it is possible in protection types IP55 and IP65 to use a
tap-off unit for connection joints (250 - 1250 A) at each connection joint
between straight busbar elements.
-Using accessories, it is possible in protection types IP55 and IP65 to
implement a cable intermediate feeder or other conversions/enlargements at
each connection joint between straight busbar elements.

Construction and characteristics
Technical changes reserved 15
Connection joints for protection type IP68
Connection joints in busbar elements with protection type IP68 (cast resin
system) are formed with essentially the similar joint block as for protection type
IP55.
-The torque for the clamping block in the connection joints for adjacent
busbar elements is approx. 60 Nm, at which point the outer part of the
shear-off bolt shears off.
The flanges are fitted with seals and for protection type IP68 provide openings for
filling the cast resin mixture.
-Later checking of the tightening torque of the single bolt clamp(s) (the clamp)
is not planned for here.
-Busbars with protection type IP68 are intended exclusively for energy
transport.
3.4.2 Straight length busbar elements
-Available with plug-in (IP 55) or
without plug-in (IP55 / IP65 or IP68 (cast resin system))
-Available without plug-in in standard lengths 1 m, 2 m , 3 m
-Available without plug-in in selectable lengths 410 to 3000 m
-With plug-in: Straight length busbar elements of protection type IP55 can
support up to 6 plug-in on each 3 m length (depending on the rated current,
see chapter Product selection)
-Plug-in on one side (3 plug-in)
-Plug-in on both sides, offset (4 plug-in, 2 plug-in each on each
137-mm side)
-Plug-in on both sides (6 plug-in, 3 plug-in each on each 137-mm side)
3.4.3 Changes of direction
Changes of direction are implemented with standardized system components.
Standardized system components are available with various rated currents (see
chapter Product selection):
-Elbows/knees: Horizontal elbows, vertical knees, Z-elements horizontal,
Z-elements vertical, offset elbows/knees
-T-elements(T-boxes): Horizontal T-elements, vertical T-elements
-Variants with different positions of the phases / N conductor
Flexible changes of direction and changes of direction implemented as cable
connections are not permissible.

Construction and characteristics
16 Technical changes reserved
3.4.4 Feeder units
-Standardized feed options for transformers, terminals and cable feeder are
available
-Terminal elements for different rated current, direction and conductor
configurations
-Type-tested terminal elements to Hager unimes H energy distribution system
(connection up to 4000 A)
Connection of unibar H to unimes H
Cable intermediate feeder
Cable intermediate feeder for connection joint between two adjacent straight
busbar elements.
-The cable intermediate feeder is used to feed busbar elements from a
connection joint.
-The two busbar elements are fed simultaneously via the cable intermediate
feeder. Independent supply of one side is not possible.
-Cable intermediate feeder can be used to reduce the voltage drop over long
busbar runs.
-The maximum current carried is 2000 A for aluminium- and 2500 A for copper
inner conductors in the busbars.

Construction and characteristics
Technical changes reserved 17
3.5 Tap-off units for plug-in (125 - 630 A)
-Tap-off units for plug-in are available for straight busbar elements with
plug-in in protection type IP55. They can be used on straight busbar
elements with plug-in of any rated current.
-Tap-off units for plug-in with currents up to 630 A can be installed while
operating (without disconnecting the busbar run). However, country-specific
regulations may prohibit connecting to live busbar runs.
-Tap-off units for plug-in are constructed to fit only one way.
-They are fitted with an interlock which prevents the units from being plugged
into or being removed from the straight busbar elements while the protection
device is switched on.
Connection compartment for tap-off units
Planning information: Tap-off units for 400 and 630 A plug-in have an extra large
connection compartment. Consequently they can only be fitted to straight busbar
elements with up to 2 plug-in per side.
Dimensions of straight busbar element with 2 plug-in per side
On straight busbar elements with three plug-in on one side, when fully extended
only tap-off units up to a maximum rated current of 250 A are possible.
Dimensions of straight busbar element with 3 tap-off units per side

Construction and characteristics
18 Technical changes reserved
Tap-off units with fused switch disconnector, or MCCB
-Tap-off units for plug-in are equipped with circuit breakers (MCCB) or HRC
fused switch disconnector.
-Empty tap-off units for self configuration are also available.
Tap-off units with HRC fused switch disconnectors are available for the following
fuses (delivery always without fuses):
HRC fuse
Rated current of tap-off unit
Size 00
125 A
Size 1
250 A
Size 2
400 A
Size 3
630 A
3.6 Tap-off units for connection joints (250 - 1250 A)
Tap-off units for connection joints are available for connection joints on straight
busbar elements with protection type IP55. They can be used at connection
joints on straight busbar elements of any rated current.
-Installing a tap-off unit requires the power to be disconnected from the
busbar run.
-A joint block for tap-off units (with a special joint block), available as an
accessory, is installed.
-Tap-off units for plug-in are equipped with circuit breakers (MCCB) or HRC
fused switch disconnectors.
Connection compartment for tap-off units
Planning information: Because of the dimensions, the installation of a tap-off unit
for connection joint may restrict the fitting of tap-off units on neighbouring
straight busbar elements with plug-in (for version of straight busbar elements
with plug-in offset on both sides).
Dimensions of tap-off unit for connection joints (on left in picture)

Construction and characteristics
Technical changes reserved 19
Notices

Product selection
20 Technical changes reserved
4Product selection
The order numbers for aluminium conductor material, 4 inner rails (N, L1, L2, L3),
PE housing (steel) are always given.
Variant order numbers will arise from the type key.
4.1 Type key for busbar elements
Examples:
-4 bars, straight length, 800 A, 2 m, aluminium conductors, IP55, RAL7035:
KEH33S80LMA
-4 bars, straight length, 1600 A, 2 m, aluminium conductors, IP55, RAL7035:
KEH36S80LMA
For further types please ask your hager partner.