Power distribution inside a control panel doesn’t get much attention until something goes wrong — a hot spot, a wiring error, a panel that takes twice as long to build as it should. That’s exactly why iAutomation partnered with Rittal North America for a live webinar breaking down one of the most overlooked upgrades in panel building: busbar power distribution.
Hosted by Chris Mable, System Consultant at Rittal North America, the session walked attendees through what busbar systems are, how they’ve evolved, and why more panel shops and OEMs are making the switch from traditional wire-based distribution.
Missed the live session? Watch the full webinar recording here.
From Wire to Busbar: A Quick Evolution
Power distribution inside an enclosure has come a long way — from basic wire, to flat and profile copper, to flexible/laminated copper, all the way up to modular multi-bar systems used in switchgear and substations. Busbar represents the modular next step in that evolution: a metallic conductor system (most commonly copper, sometimes aluminum) with interlocking bars, standardized taps, and standardized mounting for electrical components.
What Makes Up a Busbar System
Chris broke the system down into its core building blocks: end covers, base trays, cover sections, busbar supports, and — depending on the application — support panels and cross members for splitting busbar between enclosures. On top of that structure sits a family of functional device adapters (DIN, circuit breaker, fuse, connection, and current distribution adapters) that let engineers mount starters, breakers, and other components directly to the bar instead of hand-wiring each connection.
One detail worth calling out for anyone spec’ing a system: SCCR (Short Circuit Current Rating). Support spacing plays a direct role in achieving higher SCCR ratings — spacing supports at roughly 200mm apart, paired with a high current-limiting OCPD (like Class J or L fuses), can get a system to 65kA.
Why It Matters: The Benefits
The webinar grouped the benefits into three buckets:
- Design & Engineering — fewer components to spec, published SCCR and amperage ratings on tested products, and globally accepted certifications (UL, CSA, IEC).
- Assembly & Panel Building — flexible layouts where adapters can be repositioned or added as the system expands, fewer panel modifications, less wiring labor, and real space savings from eliminating line-side wiring, ducts, and large bend radii.
- Customer & End User — better contact hazard protection and clearer, easier-to-maintain components on the panel floor.
The numbers back it up. Compared to traditional wire-to-panel builds, moving to a modular busbar board can save up to 30% in engineering time (thanks to pre-tested, fully digital product data) and up to 75% in assembly time, since components mount without the wiring and expertise traditional builds require.
Traditional vs. Busbar, Side by Side
Chris also walked through a real application comparison. A traditional power distribution panel design needed two 1400x800x500mm enclosures, 15 circuit breakers, a main disconnect, and both main and branch power distribution blocks. The busbar version of that same application fit into a single enclosure — with over 50 linear feet of line-side wire, dozens of individually measured and terminated wire pieces, and multiple drilled/tapped mounting holes eliminated entirely.
How to Get Started
If you’re considering busbar for your next panel design, Chris outlined the questions to have answered before reaching out:
- What’s your enclosure space and floor/space constraints?
- What size is your main breaker (amperage)?
- What size and how many conductors are on your line-side feed?
- What’s your bill of materials for bus-mounted components?
- What SCCR is required?
- Does the system need to be UL Listed, and to what spec (508, 891, or other)?
From there, your iAutomation representative can connect you directly with a Rittal System Consultant for focused training, preliminary concepts and BOM development, and even CAD reference builds — getting ahead of the engineering phase before a single wire is cut.
Want to talk through a busbar application for your panels? Reach out to your iAutomation representative to get connected with a Rittal System Consultant, or watch the full webinar recording to see the complete breakdown.
