Product / Flexibar
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nVent ERIFLEX Flexibar is a high-performance flexible busbar solution engineered for modern low-voltage power distribution systems. Built with multiple layers of electrolytic copper laminations inside a durable, self-extinguishing sleeve, Flexibar combines the flexibility of cable with the strength and efficiency of a traditional busbar.
It is ideal for compact panels, switchgear, power equipment and data centers where space optimization, high-current capacity and reliability are critical.
Design and Construction:
Flexibar is constructed using laminated, uninsulated or tinned copper strips encapsulated in premium insulation:
- Flexibar Advanced — Halogen-free TPE, 115°C rating
- Flexibar Standard — PVC insulation, 105°C rating
- Flexibar Summum — High-temperature silicone, 280°C rating
The grooved insulation design reduces contact with copper laminates, enabling easy bending, routing and compact installation layouts. Class II insulation ensures safe operation in close proximity to grounded metal parts.
Electrical Design & Performance:
The laminated construction minimizes skin effect and eddy current losses, enabling uniform current distribution and improved efficiency over cables and rigid busbars, especially under high frequency loads.
Skin Effect:
Skin effect is a phenomenon in alternating current (AC) where the current tends to flow closer to the outer surface of a conductor rather than uniformly throughout its cross-section. This occurs because the alternating magnetic field produced by the AC induces opposing eddy currents inside the conductor. These circulating currents restrict the flow of current toward the center.
As frequency increases, the effect becomes more significant, leading to:
- Higher current density at the surface
- Reduced effective cross-section of the conductor
- Higher electrical resistance and increased power losses
Eddy Currents:
Eddy currents are induced circulating currents that form within a conductor when it is exposed to a changing magnetic field, such as in AC power systems. These currents oppose the main current flow and create additional resistive losses within the conductor.
The impact of eddy currents becomes more pronounced with:
- Larger solid conductor cross-sections
- Higher operating frequencies
- Poor heat dissipation
This results in increased heating, reduced usable conductor area, and lower overall electrical efficiency.
Flexibar Advantage:
Flexibar overcomes the limitations of both skin effect and eddy currents typically seen in round conductors and solid busbars. Its laminated copper construction and rectangular geometry allow current to distribute more uniformly across the surface, reducing current concentration near the perimeter. Meanwhile, the multiple thin copper layers act as independent conductive paths, preventing the formation of large eddy currents and improving heat dissipation.
This unique design delivers:
- Lower electrical losses
- Higher current-carrying capacity
- Better thermal performance
- Improved efficiency in AC power applications
Flexibar therefore provides superior performance compared to traditional cables or rigid busbars of the same cross-section.
Flexibar supports direct drilling and punching for termination, reducing the need for lugs and enabling faster installation. Its self-supporting structure allows 3D routing and tight bends in space-constrained layouts.
Class II Insulation:
The Flexibar Advanced and Standard having Class II insulation certification, according IEC 61439-1 mainly due to:
- High dielectric strength (>20kV/mm)
- High mechanical resistance (IK 09)
- High temperature resistance (Glow wire test 960°C)
nVent ERIFLEX insulation material combines the following features:
• Low smoke, halogen-free, flame retardant
• High temperature resistant
• Tin-plated
This certification allows:
- Touching and fixing directly to metal parts permitted (no clearance distance needed).
- Max operating current: up to 100% of the conductor maximum rated temperature (80% without Class II)
Product Range and Features:
Flexibar is available in cross sections from 20 mm² to 1200 mm² and current ratings from 125 A to 2800 A per conductor. Up to three conductors can be paralleled for higher capacity.
Key Features:
- High flexibility for compact and complex routing
- Low inductance and reduced power losses
- UL 94 V-0 and IEC 60754 compliant insulation
- Suitable for harsh and corrosive environments
- Flame-retardant and halogen-free (Flexibar Advanced)
- Excellent thermal and mechanical performance
Fabrication and Forming Capabilities of Flexibar
One of the major advantages of nVent ERIFLEX Flexibar is its ease of fabrication and forming during panel assembly and installation. Flexibar can be processed using conventional tools without the need for welding, brazing, or specialized machining.
The following fabrication operations can be performed easily:
- Bending (tight bends, multi-axis angles)
- Folding
- Twisting
- Cutting
- Punching / drilling
- Stripping insulation
The example below illustrates typical forming operations that can be carried out on Flexibar:
This high formability eliminates the need for custom busbar bends or multiple cable runs, and helps reduce installation time, material cost, and space requirements
Quality Validated by Tests & Certifications:
nVent ERIFLEX Flexibar is tested and approved to meet some of the highest international safety and performance standards for electrical power distribution systems. The product is certified for use in panelboards, switchboards, and appliance wiring applications under UL and CSA standards.
Flexibar is recognized under:
- UL 67 & UL 891 for panelboards and switchboards
- CSA C22.2 No. 29 and C22.2 No. 244
- UL 758 Appliance Wiring Material (up to 1500V DC / 1000V AC)
- CSA C22.2 No. 210 (Appliance Wiring Material)
Flexibar Advanced is additionally certified according to:
- CSA C22.2 No. 210 (1000 VAC)
These certifications confirm compliance with the requirements for mechanical performance, fire resistance, durability, electrical safety, and operational reliability.
In order to be recognized, these products have to undergo a series of rigorous tests that will assess of their performance in a lab setting reproducing the working environment of a real panelboard or switchboard.
Comparison Chart
Why Choose Flexibar?
Compared to conventional solutions:
Versus Cable
- Up to 20% smaller footprint
- Higher ampacity per cross-section
- Eliminates lugs and reduces connection points
Versus Rigid Busbar
- Faster installation and routing
- No welding, bending or fabrication required
- Excellent for vibration-prone environments
nVent ERIFLEX Flexibar is a compact, reliable and advanced alternative to conventional busbars and cabling systems. With superior electrical and thermal characteristics, global certifications and unmatched installation flexibility, Flexibar ensures faster, cleaner and more efficient power distribution for modern electrical infrastructure.