ElexoBus – Flexible Copper Power Link System

ELEXOBUS is a ready-to-install high-current flexible power link system for LV and MV applications up to 3.3 kV , designed as a flexible busbar solution and an efficient alternative to rigid busbar and busduct connections.

It combines BizLink Silitherm SIF/POL silicone cable technology with Elexo proprietary low-resistance copper terminals, delivering a flexible, thermally optimized and easy-to-install solution for high-current electrical connections.

ELEXOBUS is specifically designed for transformer to switchgear connections, generator links, UPS systems and energy storage applications, where high current capacity, compact routing and installation simplicity are critical.

ELEXOBUS is designed as a flexible alternative to rigid copper busbar systems in demanding power distribution applications.

Key advantages

Flexible routing
Silicone insulated cable allows tight bending radii (3×D to 5×D), enabling installation in confined spaces such as substation cabinets, electrical rooms and retrofit installations.

High electrical efficiency
Elexo proprietary copper terminals ensure low contact resistance and optimized current distribution, maximizing conductivity across the connection.

Cooler electrical connections
Elexo terminals operate ≥10°C cooler than standard crimp lugs under equivalent load conditions, improving thermal stability and long-term reliability.

Thermal consistency across the connection
Both ends of the assembly are terminated with Elexo technology, preserving the thermal budget from transformer busbar to switchgear busbar.

Simple installation
ELEXOBUS installs in standard cable trays, cable ladders and conduits, using conventional glands and mounting hardware.
No dedicated installation system or proprietary accessories required.

High temperature cable technology
BizLink Silitherm silicone insulation supports continuous operating temperatures up to 180°C, providing superior thermal resilience compared to conventional PVC cables.

Copper busbar compatibility
Fully compatible with standard copper busbar systems used in European LV substations, ensuring easy integration into existing designs.

Typical applications

ELEXOBUS flexible power links are used in many electrical power distribution systems:

• Transformer → LV switchboard connections
• Generator → main distribution panel
• Switchboard → switchboard interconnections
• UPS → power distribution boards
• Battery energy storage systems
• Data centre power links
• Flexible busbar links for mission-critical power distribution

These applications require high current capacity combined with flexible routing, especially in retrofit or space-constrained installations.

Technology

ELEXOBUS combines two complementary technologies to deliver high-performance electrical connections.

Silicone flexible power cable by BizLink Silitherm
SIF/POL silicone cable provides:

• high flexibility even at large cross-sections (up to 630 mm²)
• excellent thermal resistance
• halogen-free construction
• reliable performance in industrial environments.

The cable is designed for 90°C conductor class operation (IEC), enabling optimized current density while maintaining compliance with standard electrical design practices.

Elexo proprietary copper power terminals
Each ELEXOBUS assembly is terminated at both ends with Elexo STT series copper terminals.

These terminals are engineered with:

• optimized contact surface geometry
• controlled crimping process
• minimized electrical contact resistance.

The result is improved thermal behaviour across the entire electrical connection, from transformer busbar to switchboard busbar.

Electrical performance concept

ELEXOBUS delivers optimized performance by combining two key factors:

Higher cable thermal capability
Silicone insulation provides enhanced thermal resistance, enabling stable operation at 90°C conductor class compared to typical 70°C PVC systems.

Lower termination temperature
Elexo terminals operate ≥10°C cooler than standard cable lugs, reducing thermal stress at connection points.

Combined effect:

• optimized conductor sizing
• improved thermal behaviour
• reduced system losses
• lighter and more compact installations
• easier cable routing

Parallel conductors

For higher current requirements, multiple ELEXOBUS cables per phase can be connected in parallel using Elexo multi-cable terminal plates.
The terminal geometry is designed to accommodate multiple cable heads while maintaining:

• optimal electrical performance
• uniform current distribution
• mechanical stability

ELEXOBUS is fully compatible with the Elexo Braided Power Conductors system, enabling scalable high-current solutions.

Call to action

Need help selecting the correct ELEXOBUS configuration?
Contact the Elexo technical team for:

• transformer connection sizing
• multi-cable assemblies
• project-specific electrical calculations