Custom manufacturing from drawings
Each busbar is designed and supplied for a specific project, questionnaire, or customer assembly drawing.
Key features
Two voltage classes
Clear product line separation: SHMGI for 1 kV and SHMGI-10 for 10 kV with reinforced insulation of 4±0.2 mm.
Extruded PVC insulation
A solid PVC layer applied by continuous extrusion ensures consistent thickness and high flexibility.
M1 copper 99.9%
Cu-ETP (M1) copper conductor with a minimum copper content of 99.9% guarantees minimal resistance and heating.
Application context
SHMGI are in demand where standard busbars or cable jumpers do not provide the required flexibility and precision. The products are used in panels, LV switchgear, and switchgear with rigid routes and limited space.
Typical market offering
- Mass-produced standard busbars from open catalog without reference to specific cabinet layout.
- Specialized manufacturers with precise parameters, but without separation of 1 kV and 10 kV product lines and complete design documentation.
METAENERGY solution
- Custom manufacturing from drawing and questionnaire—routing, holes, and lengths precisely match the assembly diagram.
- Two separate product lines SHMGI (1 kV) and SHMGI-10 (10 kV) with datasheet and design documentation for each type, including test parameters.
For LV switchgear and panel equipment manufacturers
Rigid internal routing and limited bending radius require flexible busbars that can be precisely fitted into the allocated space. SHMGI are manufactured precisely to the dimensions of the compartment or cabinet.
A multilayer stack of plates is loosely placed within the insulation: during bending, the plates shift without friction or mechanical stress. This simplifies assembly and prevents conductor damage.
For electrical installation and commissioning companies
Installation in limited space requires precise matching of lengths, holes, and bending radii. SHMGI are supplied with verified dimensions according to the agreed drawing, reducing the risk of rework on site.
Extruded PVC insulation is stable in thickness and withstands test voltage up to 42 kV (for SHMGI-10). This provides a safety margin during installation and operation.
Below are the SHMGI product lines and their key parameters, allowing you to select the appropriate configuration for a specific application.
Products
METAENERGY flexible insulated copper busbar range consists of two series, differing in voltage class, insulation thickness and acceptance testing. Common cross-sections and current ratings at different ΔT are shown in the table below; the full range is available in the "Current ratings and dimensions" section.
SHMGI
SHMGI — flexible copper busbar rated 1 kV
Stack of copper strips in black PVC insulation, insulation thickness 2±0.2 mm. Standard solution for low-voltage switchgear assemblies.
- Rated voltage 1 kV.
- Insulation: PVC, black, applied by continuous extrusion.
- Test voltage 2.2 kV, dielectric strength >20 kV/mm.
- Copper Cu-ETP (M1), 99.9%.
- Supplied per specification sheet or drawing: lengths, holes, tinning (optional) to suit project requirements.
Standard insulation thickness of 2±0.2 mm provides sufficient dielectric strength for networks up to 1 kV. When ordering, specify the complete length value (e.g., SHMGI 8×120×1 L290mm) and required hole configuration.
SHMGI-10
SHMGI-10 — flexible copper busbar for 10 kV
Reinforced terracotta PVC insulation 4±0.2 mm thick. Designed for medium-voltage 10 kV networks.
- Rated voltage 10 kV.
- Insulation: PVC, terracotta, extruded.
- Test voltage 42 kV, dielectric strength >20 kV/mm.
- Copper Cu-ETP (M1), 99.9%.
- Manufactured strictly according to drawings and specification sheet; all parameters are recorded in the passport and design documentation.
For 10 kV, insulation thickness accuracy and compliance with test voltages are critical. All values are per passport and design documentation; selecting the wrong product line leads to project non-compliance.
Common SHMGI Cross-Sections — Permissible Current at Different ΔT (per catalog)
| Designation | Cross-section, mm² | ΔT 70 °K, A | ΔT 60 °K, A | ΔT 50 °K, A | ΔT 40 °K, A | ΔT 30 °K, A |
|---|---|---|---|---|---|---|
| SHMGI 2×15.5×0.8 | 24.8 | 252 | 234 | 212 | 191 | 165 |
| SHMGI 3×24×1 | 72 | 490 | 453 | 413 | 370 | 320 |
| SHMGI 4×40×1 | 160 | 727 | 673 | 615 | 550 | 476 |
| SHMGI 5×50×1 | 250 | 1,100 | 1,016 | 930 | 830 | 718 |
| SHMGI 6×63×1 | 378 | 1,437 | 1,330 | 1,215 | 1,085 | 941 |
| SHMGI 8×100×1 | 800 | 2 147 | 1 990 | 1 815 | 1 625 | 1 405 |
| SHMGI 10×120×1 | 1200 | 2 755 | 2 550 | 2 330 | 2 070 | 1 792 |
| SHMGI 10×160×1 | 1600 | 4 115 | 3 810 | 3 480 | 3 115 | 2 695 |
Current rating and dimensions
SHMGI current rating depends on the temperature difference ΔT between the busbar and the air inside the enclosure. Below is the complete range from the METAENERGY product catalog and examples of SHMGI / SHMGI-10 dimensions.
Permissible current is given for the temperature difference ΔT between the busbar and the air inside the enclosure (T2 − T1) according to the general METAENERGY product catalog. Final cross-section and layout are confirmed by the panel design engineer.
SHMGI — current rating calculation at ΔT 70…30 °K (complete catalog range)
| Designation | Cross-section, mm² | ΔT 70 °K, A | ΔT 60 °K, A | ΔT 50 °K, A | ΔT 40 °K, A | ΔT 30 °K, A |
|---|---|---|---|---|---|---|
| SHMGI 3×9×0.8 | 21.6 | 158 | 147 | 134 | 120 | 104 |
| SHMGI 2×15.5×0.8 | 24.8 | 252 | 234 | 212 | 191 | 165 |
| SHMGI 2×20×1 | 40 | 326 | 300 | 275 | 246 | 214 |
| SHMGI 6×9×0.8 | 43.2 | 290 | 269 | 245 | 220 | 190 |
| SHMGI 2×24×1 | 48 | 450 | 416 | 380 | 340 | 295 |
| SHMGI 4×15.5×0.8 | 49.6 | 380 | 350 | 320 | 286 | 248 |
| SHMGI 3×20×1 | 60 | 428 | 395 | 360 | 323 | 280 |
| SHMGI 2×32×1 | 64 | 480 | 445 | 406 | 363 | 315 |
| SHMGI 9×9×0.8 | 64.8 | 314 | 291 | 265 | 237 | 206 |
| SHMGI 3×24×1 | 72 | 490 | 453 | 413 | 370 | 320 |
| SHMGI 6×15.5×0.8 | 74.4 | 476 | 440 | 402 | 360 | 318 |
| SHMGI 4×20×1 | 80 | 476 | 440 | 402 | 360 | 312 |
| SHMGI 2×40×1 | 80 | 538 | 500 | 455 | 406 | 352 |
| SHMGI 4×24×1 | 96 | 550 | 540 | 465 | 416 | 360 |
| SHMGI 3×32×1 | 96 | 570 | 525 | 480 | 430 | 372 |
| SHMGI 5×20×1 | 100 | 498 | 460 | 420 | 376 | 326 |
| SHMGI 6×20×1 | 120 | 546 | 506 | 462 | 413 | 358 |
| SHMGI 5×24×1 | 120 | 608 | 563 | 514 | 460 | 398 |
| SHMGI 3×40×1 | 120 | 617 | 570 | 522 | 466 | 405 |
| SHMGI 10×15.5×0.8 | 124 | 538 | 498 | 455 | 407 | 352 |
| SHMGI 4×32×1 | 128 | 648 | 600 | 548 | 490 | 425 |
| SHMGI 6×24×1 | 144 | 670 | 620 | 566 | 506 | 438 |
| SHMGI 3×50×1 | 150 | 700 | 650 | 592 | 530 | 460 |
| SHMGI 5×32×1 | 160 | 758 | 702 | 640 | 573 | 496 |
| SHMGI 4×40×1 | 160 | 727 | 673 | 615 | 550 | 476 |
| SHMGI 3×63×1 | 189 | 798 | 740 | 675 | 603 | 522 |
| SHMGI 8×24×1 | 192 | 802 | 743 | 678 | 606 | 525 |
| SHMGI 6×32×1 | 192 | 846 | 783 | 715 | 640 | 555 |
| SHMGI 10×20×1 | 200 | 762 | 706 | 645 | 576 | 500 |
| SHMGI 5×40×1 | 200 | 900 | 832 | 760 | 680 | 590 |
| SHMGI 4×50×1 | 200 | 860 | 795 | 727 | 650 | 563 |
| SHMGI 10×24×1 | 240 | 948 | 877 | 800 | 716 | 592 |
| SHMGI 6×40×1 | 240 | 1 018 | 943 | 860 | 770 | 667 |
| SHMGI 3×80×1 | 240 | 980 | 906 | 827 | 740 | 640 |
| SHMGI 5×50×1 | 250 | 1 100 | 1 016 | 930 | 830 | 718 |
| SHMGI 4×63×1 | 252 | 1 010 | 935 | 855 | 763 | 661 |
| SHMGI 8×32×1 | 256 | 1 018 | 943 | 860 | 770 | 667 |
| SHMGI 6×50×1 | 300 | 1 225 | 1 135 | 1 035 | 925 | 802 |
| SHMGI 5×63×1 | 315 | 1 220 | 1 125 | 1 030 | 920 | 797 |
| SHMGI 10×32×1 | 320 | 1 230 | 1 140 | 1 040 | 930 | 805 |
| SHMGI 8×40×1 | 320 | 1 230 | 1 140 | 1 040 | 930 | 805 |
| SHMGI 4×80×1 | 320 | 1 200 | 1 110 | 1 015 | 906 | 785 |
| SHMGI 6×63×1 | 378 | 1 437 | 1 330 | 1 215 | 1 085 | 941 |
| SHMGI 10×40×1 | 400 | 1 400 | 1 295 | 1 181 | 1 055 | 915 |
| SHMGI 8×50×1 | 400 | 1 393 | 1 290 | 1 175 | 1 050 | 912 |
| SHMGI 5×80×1 | 400 | 1 390 | 1 285 | 1 175 | 1 050 | 910 |
| SHMGI 4×100×1 | 400 | 1 446 | 1 340 | 1 225 | 1 093 | 947 |
| SHMGI 6×80×1 | 480 | 1 627 | 1 505 | 1 375 | 1 230 | 1 065 |
| SHMGI 10×50×1 | 500 | 1 650 | 1 525 | 1 395 | 1 245 | 1 080 |
| SHMGI 5×100×1 | 500 | 1 635 | 1 515 | 1 385 | 1 235 | 1 070 |
| SHMGI 8×63×1 | 504 | 1 650 | 1 525 | 1 395 | 1 245 | 1 080 |
| SHMGI 6×100×1 | 600 | 1 843 | 1 705 | 1 550 | 1 393 | 1 205 |
| SHMGI 10×63×1 | 630 | 1 895 | 1 755 | 1 600 | 1 435 | 1 240 |
| SHMGI 8×80×1 | 640 | 1 895 | 1 755 | 1 600 | 1 430 | 1 240 |
| SHMGI 10×80×1 | 800 | 2 100 | 1 945 | 1 775 | 1 585 | 1 375 |
| SHMGI 8×100×1 | 800 | 2 147 | 1 990 | 1 815 | 1 625 | 1 405 |
| SHMGI 8×120×1 | 960 | 2 530 | 2 340 | 2 135 | 1 905 | 1 650 |
| SHMGI 10×100×1 | 1000 | 2 350 | 2 170 | 1 985 | 1 775 | 1 535 |
| SHMGI 12×100×1 | 1200 | 2 500 | 2 315 | 2 115 | 1 890 | 1 636 |
| SHMGI 10×120×1 | 1200 | 2 755 | 2 550 | 2 330 | 2 070 | 1 792 |
| SHMGI 12×120×1 | 1440 | 2 869 | 2 654 | 2,427 | 2,159 | 1,868 |
| SHMGI 10×160×1 | 1600 | 4,115 | 3,810 | 3,480 | 3,115 | 2,695 |
Standard SHMGI / SHMGI-10 size examples (length 2000 mm)
| Designation | Cross-section, mm² | Number of plates | Plate width, mm | Plate thickness, mm |
|---|---|---|---|---|
| SHMGI / SHMGI-10 2×15.5×0.8 | 24.8 | 2 | 15.5 | 0,8 |
| SHMGI / SHMGI-10 3×24×1 | 72 | 3 | 24 | 1 |
| SHMGI / SHMGI-10 4×40×1 | 160 | 4 | 40 | 1 |
| SHMGI / SHMGI-10 5×50×1 | 250 | 5 | 50 | 1 |
| SHMGI / SHMGI-10 6×63×1 | 378 | 6 | 63 | 1 |
| SHMGI / SHMGI-10 8×100×1 | 800 | 8 | 100 | 1 |
| SHMGI / SHMGI-10 10×120×1 | 1200 | 10 | 120 | 1 |
Comparison of key parameters by product line
Parameters are provided according to specifications and design documentation. Exact values for each specific configuration are indicated in the product certificate.
| Parameter | SHMGI (1 kV) | SHMGI-10 (10 kV) |
|---|---|---|
| Rated operating voltage | 1 kV | 10 kV |
| Insulation material | PVC, black | PVC, terracotta |
| Insulation thickness | 2±0.2 mm | 4±0.2 mm |
| Test voltage | 2.2 kV | 42 kV |
| Dielectric strength | >20 kV/mm | >20 kV/mm |
| Conductor material | Copper Cu-ETP (M1), 99.9% | Copper Cu-ETP (M1), 99.9% |
| Standard length | 2000 mm (up to 6000 mm on request) | 2000 mm (up to 6000 mm on request) |
| Regulatory documentation | According to TU 3449-001 | According to MPRTS.6855.010 TU |
| Optional tinning | Galvanic Sn-Bi 6–12 µm (tin-bismuth) | Galvanic Sn-Bi 6–12 µm (tin-bismuth) |
Tested at voltages up to 42 kV
Every batch of SHMGI-10 undergoes acceptance testing at 42 kV, confirmed by passport and design documentation. Even in 1 kV configuration, insulation has a safety margin of >20 kV/mm.
Advantages
The combination of custom manufacturing, quality materials, and well-engineered design reduces installation risks and extends LV switchgear service life.
Extruded PVC insulation
A solid layer applied by continuous extrusion ensures uniform thickness along the entire length, high flexibility, and resistance to mechanical stress.
Multi-layer laminated plates without friction
Plates are loosely laid in insulation and not bonded together. During bending, they shift without internal stress, preventing conductor damage.
Custom-engineered for your project
Manufactured strictly to drawings or specification sheets: lengths, bending radii, hole diameters and positions match the enclosure or cell mounting layout.
Additional benefits for designers and assemblers
Drawing based on specification sheet
The design department prepares a drawing based on your specification sheet, eliminating errors and ensuring compliance with the actual layout.
Clear separation of 1 kV and 10 kV
Two independent product lines eliminate confusion with insulation and testing, each with its own certificate and documentation.
Easy installation and punching
Perforation or template drilling is recommended after bending. Video instructions are available on the manufacturer's website.
M1 copper 99.9%
High-purity copper ensures low contact resistance, minimal heating, and stable contact connections.
Tinning for special environments
Optional Sn-Bi electroplating increases corrosion resistance and facilitates switching in marine equipment, chemical and mining industries.
Position in METAENERGY product range
SHMGI solve the challenge of flexible insulated connections inside LV switchgear and switchgear assemblies. For other operating conditions, related product lines are available in the catalog.
Cross-section range
from 21.6 to 1600 mm²
Covers requirements from control circuits to main circuits of low-voltage and medium-voltage switchboards.
Number of plates
from 2 to 12
Flexible configuration allows precise selection of flexibility and current load for specific circuit breakers or busbars.
Voltage classes
1 kV and 10 kV
Two separate insulation designs eliminate errors during engineering, installation, and ordering.