bus bar truncking design for sandwich

Corporate Mission

Mission & Quality policy

he Controls & Switchgear Co. Ltd

aims to be the world's leading

BUSDUCT / BUSTRUNKING manufacturer.

It will seek to be the industry benchmark

in terms of quality and reliability of product

and speed and efficiency of execution.

The Controls & Switchgear Co. Ltd

intends to achive this leadership status

by leveraging the combination of

world class product design,

manufacturing infrastructure, engineering

acumern and customer service.

T

2

We are committed to achieve excellence in design and Manufacturing of Busduct and Busbartrunking System through:

Upgrading Equipments & QA system as per latest Standards and Customers Requirements.

Quick readdressal of Customer Concern taking corrective and preventive actions.

Providing adequate resources including Infrastructure & Competent Personnel.

We are committed to review our Quality Management Systems to achieve continual improvements.

QUALITY POLICY

2

3

CONTR S &TCH E

PTD

OL SWI

G AR COM ANY L .

Manufacturing Plant at Hardwar

Manufacturing Unit

3

4

Manufacturing facilities

AMADA, CNC TURRET PUNCHING

AUTOMATIC BUSBAR CUTTING MACHINE

EPOXY POWDER COATING PLANT

BUSBAR SLEEVING MACHINE

INSULATION CUTTING MACHINE - lASER

5

Contents

Technical Parameters

Standard & Specifications

Bustrunking System 11

Main Components

A) Feeder Bustrunking, Plug-in Bustrunking 12

B) Uni-Block Busbar Joint 13

C) Horizontal elbow, Horizontal offset elbow 14

D) Vertical elbow, Vertical offset elbow, Vertical Tee Section 15

E) Certification & Approvals 16 - 17

F) Standard Flange End 18

G) Flange End Box, Rubber Bellow & Flexibles 19

h) Plug in Boxes 20

I) Spring & Rigid Hanger 21

Other Components 22

Complete Engineering Solution 23

Installation Instructions 24 - 27

Major installations 28 - 29

Major Export orders 30

Other Busbar Systems 31

6 - 9

10

6


Technical Data : SBC (Copper Sandwich Insulated Bus Trunking)

OVERALL DIMENSION & WEIGHT

PARAMETER UNIT SINGLE TIER TWO TIER

Product code SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC

50N1 70N1 100N1 125N1 150N1 175N1 200N1 230N1 125N2 150N2 175N2 200N2 230N2

Rated current (In) A 800 1000 1250 1500 1750 2000 2250 2500 3000 3600 4000 4500 5000

Busbar size (Copper) mm 6x50 6x70 6x100 6x125 6x150 6x175 6x200 6x230 6x125 6x150 6x175 6x200 6x2303 Phases & Neutral

No. of conductors per Nos. 1 1 1 1 1 1 1 1 2 2 2 2 2Phase / Neutral

Rated short time current kArms 45 50 65 65 75 75 100 100 120 120 120 180 180for 1 second (Icw)

Rated peak short kA 84 105 143 143 165 165 220 220 264 264 264 396 396time curent (Ipk)



50N1 70N1 100N1 125N1 150N1 175N1 200N1 230N1 125N2 150N2 175N2 200N2 230N2

Overall dimension of 147x H 95 115 145 170 195 220 245 275 340 390 440 490 550Busbar Trunking (mm)(without Internal Earthing)

Weight of Busbar Trunking Kg / m 22 28 35 42 48 54 60 67 84 96 108 120 134(without Internal Earthing)

Overall dimension of 150x H 95 115 145 170 195 220 245 275 340 390 440 490 550Busbar Trunking (mm) (with Internal Earthing)

Weight of Busbar Trunking Kg / m 25 31 39 47 53 60 67 74 94 106 120 134 148(with 50% Internal Earthing )

CURRENT RATING

H

H

7


Technical Data : SBC (Copper Sandwich Insulated Bus Trunking)

VOLTAGE DROP - 50 Hz

Composite Voltage Drop,

at full load concentrated

at the end.

These values will become

half if load is distributed

along the run.

mV/m/A

mV/m/A

mV/m/A

mV/m/A

· Voltage Drop Calculation Formulas

Dv =Ö3 I (RcosØ + SinØ)

where Dv : Line-to-Line voltage drop (v/m)

I : Load Current (A) CosØ: Load power factor

2 sinØ = Ö 1- cos ø R: AC resistance at load current (W/m) R=R x 95

· R : AC resistance at rated current(I )(W/m)95 0

(Shown in the table) oa : Temperature coefficient of conductor at 20 c

-3 -3 3.85 x 10 (copper), 4.00 x 10 (aluminum)I : Rated Current0

X : Reactance (shown in the table) (W)

21+a(55x(1/1 ) +20)0

1+75a

ELECTRICAL RESISTANCE / REACTANCE & IMPEDANCE - 50 Hz



50N1 70N1 100N1 125N1 150N1 175N1 200N1 230N1 125N2 150N2 175N2 200N2 230N2

Resistance m /m 0.0616 0.0431 0.0304 0.0243 0.0202 0.0173 0.0151 0.0131 0.0121 0.0101 0.0086 0.0076 0.00660@ +20 C (R )20

Resistance at thermal m /m 0.077 0.055 0.04 0.033 0.028 0.024 0.021 0.019 0.016 0.014 0.012 0.011 0.01conditions (R)

Reactance m /m 0.038 0.03 0.022 0.018 0.016 0.014 0.012 0.01 0.009 0.008 0.007 0.006 0.005@ 50Hz (X)

Impedance at thermal m /m 0.0859 0.0626 0.0457 0.0376 0.0322 0.0278 0.0242 0.0215 0.0184 0.0161 0.0139 0.0125 0.0112conditions (Z)


50N1 70N1 100N1 125N1 150N1 175N1 200N1 230N1 125N2 150N2 175N2 200N2 230N2

P. F. 0.7 0.1404 0.1038 0.0757 0.0623 0.0537 0.0464 0.0403 0.0354 0.0305 0.0269 0.0232 0.0208 0.0183

P. F. 0.8 0.1462 0.1074 0.0783 0.0644 0.0554 0.0478 0.0416 0.0367 0.0315 0.0277 0.0239 0.0215 0.0191

P. F. 0.9 0.1487 0.1084 0.0790 0.0650 0.0557 0.0480 0.0418 0.0372 0.0317 0.0279 0.0240 0.0217 0.0194

P.F.1.0 0.1334 0.0953 0.0693 0.0572 0.0485 0.0416 0.0364 0.0329 0.0277 0.0242 0.0208 0.0191 0.0173

PARAMETER UNIT TWO TIERSINGLE TIER

8


Technical Data : SBA (Aluminum Sandwich Insulated Bus Trunking)

ELECTRICAL RESISTANCE / REACTANCE & IMPEDANCE


Product code SBA SBA SBA SBA SBA SBA SBA SBA SBA SBA SBA

50N1 70N1 100N1 125N1 150N1 175N1 200N1 125N2 150N2 175N2 200N2

Resistance m /m 0.0993 0.0704 0.0490 0.0391 0.0325 0.0278 0.0243 0.0194 0.0162 0.0139 0.01220 @ +20 C (R )20

Resistance at thermal m /m 0.1250 0.0900 0.0640 0.0520 0.0440 0.0380 0.0340 0.0260 0.0220 0.0190 0.0170conditions (R)

Reactance m /m 0.0340 0.0260 0.0190 0.0150 0.0130 0.0110 0.0100 0.0070 0.0060 0.0060 0.0050@ 50Hz (X)

Impedance at thermal m /m 0.1295 0.0937 0.0668 0.0541 0.0459 0.0396 0.0354 0.0269 0.0228 0.0199 0.0177conditions (Z)



50N1 70N1 100N1 125N1 150N1 175N1 200N1 125N2 150N2 175N2 200N2

P. F. 0.7 0.1936 0.1413 0.1011 0.0816 0.0537 0.0597 0.0536 0.0402 0.0341 0.0305 0.0268

P. F. 0.8 0.2085 0.1517 0.1084 0.0876 0.0554 0.0641 0.0575 0.0433 0.0367 0.0326 0.0288

P. F. 0.9 0.2205 0.1599 0.1141 0.0924 0.0557 0.0675 0.0606 0.0458 0.0388 0.0342 0.0303

P.F.1.0 0.2165 0.1559 0.1108 0.0572 0.0901 0.0658 0.0589 0.0450 0.0381 0.0329 0.0294

VOLTAGE DROP

Composite Voltage Drop,

at full load concentrated

at the end.

These values will become

half if load is distributed

along the run.

mV/m/A

mV/m/A

mV/m/A

mV/m/A


9

Technical Data : SBA (Aluminum Sandwich Insulated Bus Trunking)

CURRENT RATING

OVERALL DIMENSION & WEIGHT



50N1 70N1 100N1 125N1 150N1 175N1 200N1 125N2 150N2 175N2 200N2

Overall dimension of 147x H 95 115 145 170 195 220 245 340 390 440 490Busbar Trunking (mm)(without Internal Earthing)

Weight of Busbar Trunking Kg/m 15 17 20 22.5 25 27.5 30 45 50 55 60(without Internal Earthing)

Overall dimension of 150x H 95 115 145 170 195 220 245 340 390 440 490Busbar Trunking (mm) (with Internal Earthing)

Weight of Busbar Trunking Kg/m 16 18 21.5 24 27 29.5 32 48 54 59 64(with50%Internal Earthing)



50N1 70N1 100N1 125N1 150N1 175N1 200N1 125N2 150N2 175N2 200N2

Rated current (In) A 500 630 800 1000 1250 1350 1600 2000 2500 2750 3200

Busbar size (Aluminium) mm 6x50 6x70 6x100 6x125 6x150 6x175 6x200 6x125 6x150 6x175 6x2003 Phases & Neutral

No. of conductors per Nos. 1 1 1 1 1 1 1 2 2 2 2Phase / Neutral

Rated short time current k Arms 30 40 50 65 75 75 85 100 120 120 150for 1 second (Icw)

Rated peak short kA 63 84 105 143 165 165 187 220 264 264 330time curent (Ipk)

H

H

10

Standard & Specifications

3P+N+PE3P+N+PE+External Earth3P+2N+PE3P+N+PE + Internal Earth

1. Compliance of standard IEC 60439 (1&2) & IS 8623 (1&2)

2. Independent certification authority ASTA- UK, KEMA - Holland, DAMSTRA - Nether Land, CPRI - India.

3. System 3Phase, full neutral

4. Current Ratinga) Copper Bustrunking SBC 800A ~ 5000Ab) Aluminium Bustrunking SBA 500A ~ 3200A

5. Rated operational voltage (Ue) 1000 Volt, AC

6. Rated insulation voltage (Ui) 1000 Volt, AC

7. Rated impulse withstand voltage(Uimp) 12 KV(1.2/50 s)

8. Rated frequency 50 Hz/60 Hz*

9 Enclosure material 1.6 mm (16 SWG GI)

10. Paint shade Epoxy polyster powder coated pebble grey shade(RAL-7032)

11. Busbar material (full round edge)a) Copper 99.9% pure ETP gradeb) Aluminium 99.5% pure 19501 grade

12. Busbar insulation Multi layer insulation of CLASS - ‘F’

13. Maximum temp rise As per IEC 60439(1&2) & IS 8623(1&2)

14. Degree of protection IP 54 for plug in typeIP 55 for feeder bustrunking (suitable with canopy for outdoor application)

15. Busbar configuration

* R X Z values for 60 Hz available on request

(Tested as per IEC 60529)

AN EDFL G E D XN BO

LAN ED ENDF G

L ..VSWI CH EAT G R

P G IN BOLU X

BPLUG IN OX

P G IN S TLU BU DUC

BLECA

LOSEND C URE

F ED IN OXE B

PLUG IN BOX

E CLOS END UR

E CLOS REND U

E CLOS REND U

PLUG INBOX

LU NP G IBOX

PLUG INBOX

EDGEWISEHANGER

I S LA DN U TE U D B S UCT

I S LAN U TED BUSDUCT

I S LATE U D CTN U D B S U

D OXFEE IN B

OXFEED IN B

H I TOR ZON ALLBE OW

HORIZONTALSOFF- ET

ERV TICALOWELB

Bustrunking System

General

Busbar Trunking System for electrical distribution is an alternative to cumbersome

conventional cable distribution system .

Decentralized distribution is the main highlight of this distribution system.

This system eliminates separate requirement of distribution & panel boards.

Loads can be fed from Plug-in Boxes unlike cables where each floor /machine is to be fed separately from the main switchboard.

Can be installed quickly with minimum technical expertise and have good asthetics.

Any section of bustrunking can be removed without distrurbing adjacent sections.

System is maintenance free and adds elegance to the surrounding.

Close proximity of busbars doesn’t allow mutual inductance between phases yeilding low reactance, low impedance, low voltage drop and low power loss.

Specially designed housing tightened at every 250 mm act as a heatsink to yeild improved thermal characteristic, high mechanical andshort circuit strength.

Due to elimination of air there is no rise of chimney effect, so no firebarriers are required.

Due to compactness system can be installed in lesser space.

Automatic polarity is maintained during installation.

System can be mounted edgewise OR flatewise, horizontally or vertically in any direction with all kinds of bends and tees etc.

Flexible and safe distribution system leads to easy and fast installation.

System is completely re-usable.

Salient Features

Rising Main Distribution

Horizontal Distribution

11

N

S

ED CLO

URE

RD

T

L

IGI VER

ICAE

HANGR

REDUCER

MEDIUMHANGER

HORIZONTAL

EOW

LB

VERTICALTEE

I CGEA

SWT

H

R

ABLE TRA

C

Y

DG

SE

EEW

I

HG

ANER

F

ED

LANG

NBOX

ED

H

O

ORIZNTAL

FOF

-SET

G

FLANE

ENDW

FLATIS

E

HG

ANER

H

N

ORIZOTAL

ETE

L

VERTICA

ELBOW

F

D

LANGE EN

T CSPRING VER I AL

ERHANG

EXPANSION J INO T

PLU I HO EG N L

PL UUG IN NIT

R I T CIG D VER I AL

H EANG R

BASE CH ANEL

FEED IN BOX

EN ANGTR D FL ED

D XEN BO

T SFRAN ORMER

Third Floor

Second Floor

First Floor

Basement

12

Main Components

Plug-in Bustrunking

Where branch loads are to be fed from the main line.

Vertical Rising mains to various floors with help of Plug - in Boxes.

Plug-in Points shown are indicative only.

Rating and Number of plug-in-points shall be as per the site requirement .

Feeder BustrunkingStraight length is used for the purpose of power transmission.

Transformer to Panel

Main Panel to Sub Panel

Generator to Panel

Panel to rising mains..

L

0

m

300 m

L - 3 Meter Standard Length

13

Main Components

UNI-BLOCK BUSBAR JOINT

Joint block is operatable by one / two HTS bolts.

Joint assembly can be removed / installed in installed condition.

Disc spring washer are used to uniformly distribute pressure.

Recommended torque for tightening is 7 Kgf-mtr.

Specially designed to accommodate thermal expansion of busbars and housing.

With single bolt (For busbar size upto 6x125mm)

With double bolt (For busbar size 6x150 to 6x230mm)

1. DMC Insulation

2. Conductor CU/AL

3. End Plates

4. Belleville Washers

5. HTS Bolt5

4

4

1

1

1

1

1

2

2

2

2

3

3

14

Standard Length & Min. Length A x B x C (mm)

600 x 600 x 600mm

Copper 800~2500A Aluminum 500~1750A

Copper 3000~5000AAluminum 2000~3200A

Current Rating

Standard Length & Min. Length A x B (mm)

300 x 300mm

Copper 800~2500A Aluminum 500~1750A


Current Rating

Horizontal Offset [Z] Elbow

Horizontal Elbow

A

B

A

B

C

Main Components

15

Main Components

Standard Length & Min. Length A x B (mm)

400 x 400 mm Copper 800~2500A Aluminum 500~1750A


Current Rating

500 x 500 mm

Standard Length & Min. Length A x B x C(mm)

400 x 400 x 400mm Copper 800~2500A Aluminum 500~1750A


Current Rating

500 x 500 x 500mm

Standard Length & Min. Length A x B x C(mm)

400 x 400 x 400mm Copper 800~2500A Aluminum 500~1750A


Current Rating

500 x 500 x 500mm

Vertical Offset [Z] Elbow

Vertical Tee Seciton

Vertical Elbow

B

A

C

B

A

C

B

A

Certification & Approvals

16 17

18

Main Components

Standard Flange End

01.

02.

03.

04.

05.

06.

07.

08.

09.

10.

11.

12.

13.

14.

15.

SBC/SBA 50N1

SBC/SBA 70N1

SBC/SBA 100N1

SBC/SBA 125N1

SBC/SBA 150N1

SBC/SBA 175N1

SBC/SBA 200N1

SBC 230N1

SBC/SBA 100N2

SBC/SBA 125N2

SBC/SBA 150N2

SBC/SBA 175N2

SBC/SBA 200N2

SBC 230N2

SBC/SBA 150N3

155

175

206

231

256

281

306

336

352

402

452

502

552

612

552

50

70

100

125

150

175

200

230

100

125

150

175

200

230

150

Fig. 1

Fig. 1

Fig. 1

Fig. 1

Fig. 1

Fig. 1

Fig. 1

Fig. 1

Fig. 2

Fig. 2

Fig. 2

Fig. 2

Fig. 2

Fig. 2

Fig. 3

Fig. 4

Fig. 4

Fig. 5

Fig. 5

Fig. 6

Fig. 6

Fig. 7

Fig. 7

Fig. 5

Fig. 5

Fig. 6

Fig. 6

Fig. 7

Fig. 7

Fig. 6

1

1

1

1

1

1

1

1

2

2

2

2

2

2

3

A

B

C

D

S.No Product CodeTerminal

DetailBusbar

Hole DetailNo.of

Basbar

DIMENSIONS

A W

Appliable StandradFlange End Box Bellow

Fig.1 (1 Tier)

Fig.4 Fig.5 Fig.6 Fig.7

Fig.2 (2 Tier) Fig.3 (3 Tier)

50

W

= =

=

=

=

=

150

150

150

60 60

60

60

60

60

690

690

60

60

60

60

60

60

16 16

30

0

30

03

002

00

15TYP

148 148

NN

L1L1

L2L2

L3L3

120 120 120150 150 150

15TYP

5TYP

A A

19

6

A

W

Æ14(Type)

W WW

5050 50 50

50

50

50 50

50

X X X

16

30

03

00

148

N L1 L2 L3

150 150 150

X XX

19

Rubber Bellow

01.

02.

03.

04.

BOX A

BOX B

BOX C

BOX D

500

500

700

700

250

350

620

800

250

250

350

350

120

120

150

150

540

540

740

740

4

4

5

5

3

3

5

5

180

180

185

185

145

195

165

210

290

390

660

840

50

100

150

150

SBC/SBA-50N1, 70N1, 100N1, 125N1

SBC/SBA-150N1, 175N1, 200N1, 230N1

SBC/SBA-100N2, 150N2, 175N2, 200N1, 230N2

SBC/SBA-150N3, 175N3, 200N3

S.NoFlangeEnd Box

Dimension (in mm)Application for

A B C D E F G H I J K (Recommended)

Flange End Box cum Termination Detail

Laminated Copper Flexible

N L3 L2 L1

50

50

50

X

PE

X’

NOT IN C&S SCOPE

SECTION XX’

C3

00

N L3

L2

L3

TOTAL NUMBER OF HOLE (F)X DISTANCE BETWEEN HOLE(G)

TOTA

L N

UM

BE

R O

F H

OLE

(H

)X D

ISTA

NC

E B

ET

WE

EN

HO

LE(I

)

20 A

D

J B+

80

D D

A+8020

2020 E

B

NOT IN C&S SCOPE

PANEL/TRANSFORMER/DISEL GENRATOR FLANGE

K

14(Typ)

TOTAL NUMBER OF HOLE (F)X DISTANCE BETWEEN HOLE(G)

TOTA

L N

UM

BE

R O

F H

OLE

(H

)X D

ISTA

NC

E B

ET

WE

EN

HO

LE(I

)

A+80

A 20

M.S. CHANNEL

20 20

20

B

CJ

B+

80

E

PLAN

copper Flexible code For Ordering

Holes to be drilled at siteas per requirement

Thickness (t)as per Rating

COPPER FLEXIBLE CODE FOR ORDERING CFX

t

50

50

25

50 25

L98

Switchgear side(Panel/D.G./TFR.)

Bustrunking Side

98

23

25

Lengh

L

Rating

Main Components

20

Main Components

Interlocking with bustrunking to ensure “Plug-in” and

“Plug-out” possible only in ‘OFF’ condition is

available as an optional

Live contacts silver plated are isolated / properly

shrouded.

4 Pole isolator upto 125A.

Earth contact of Plug-in boxes makes first & breaks last.

For cables entry, provision of gland plates on three sides.

Contacts of Plug-in are silver plated.

Sheet thickness 1.6 mm CRCA, Epoxy powder coated.

Plug-in Boxes - IP 54

With provision for door Interlocking & Interlocking with bus trunking (for MCCB and SFU)With Fuse HoldersB:200 Amps(DIN type)C:250 ~ 400 AmpsWith MCCB (2 / 3 / 4 poles)Type B : 200 Amps. (MCCB height < 170)Type C : 250 ~ 400 Amps. (MCCB height < 270)With SFU: (TPN / 4 Poles), C & S makeType C: 200A (BS type), : 250A (DIN), 315A (BS) & 400A (DIN)

With in-built IsolatorWith MCB : 32 & 63 AmpsWith Fuse holder : 32 & 63 Amps (BS type)With MCCB : upto 63 Amps 2 / 3 / 4 poles) (MCCB height < 130m)

Overall Dimensions (in mm) 4P - 280(L) X 135(W) X 117(H)5P - 280(L) X 160(W) X 117(H)

Type B, C & D

Type O

With in-built IsolatorWith provision for door Interlocking & Interlocking with bus trunking (for MCCB and SFU)With Fuse Holder : 100 & 125 Amps (DIN type)With MCCB : upto 125 Amps (2 / 3 / 4 poles)(MCCB height < 170m)With SFU : 32 ~ 125 Amps (TPN / 4 Poles) (C & S make, DIN or BS type)

Type A

Overall Dimensions (in mm) 4P - 370(L) X 135(W) X 115.5(H)5P - 370(L) X 160(W) X 115.5(H)

Overall Dimensions(in mm) Type B - 4P & 5P - 435(L) X 250(W) X 170(H) Type C - 4P & 5P - 600(L) X 340(W) X 230(H) Type D - 4P & 5P - 800(L) X 400(W) X 250(H)

21

Spring & Rigid Hanger

Fit the Rigid Hanger to the ‘U’ clamp already fitted to both side of

the lowest bustrunking in the ground floor.

Remove nut A from Rigid hanger assembly, and pass the M16 bolt

thru the holes in the ‘C’ channel already grouted on the floor/wall

Position the bustrunking height as per layout drawing by rotating

the nut B until bustrunking reaches desired level.

Lock nut A from lower end of bolt to the ‘C’ channel.

Installation - Rigid Hanger

Fit the Spring Hanger to the ‘U’ clamp already fitted to both side

of the bustrunking (Rising Mains)..

Remove nut A from Rigid hanger assembly, and pass the

M16 bolt thru the holes in the ‘C’ channel already grouted on the floor/wall

Due to bustrunking weight the spring will compress and creates a gap

between nut ‘C’ and L support. Tighten nut ‘C’ to eliminate the gap.

Adjust nut B on both sides of bustrunking until it reaches desired level

for fixing joint with lower bustrunking. Ensure that nut B is adjusted equally

on both sides to install bustrunking vertically straight.

Lock nut A from lower end of bolt to the ‘C’ channel.

Repeat steps for subsequent bustrunking.

Loosen nut C to allow enough gap for spring to expand

under thermal conditions after complete installation.

Installation - Spring Hanger

Enlarge view of U/L clamp

U clamp(Clamped tightened with bustrunking)

Plug-in Box

First Floor

2nd Floor

Vertical Spring Hanger

Vertical Spring Hanger

Spring Hanger

Vertical Rigid Hanger

(At lowest floor only)

Plug-in Point

Gr. Floor

Basement

To End Feed Unit / Panel

Flo

or Th

ickn

ess

Flo

or H

eig

ht

Vertical Rigid Hanger

ISMC 150x75Not in Scope of Supply)




L SUPPORT

N

N

L1

L1

22

Reducer

End Feed Box (Direct)

Sectional Isolator Unit

End Cover

Vertical Support

These are required to connect two dissimilar rating / type of bustrunking. Reducer may be designed with switching or isolating device.

To feed bustrunking through cables, Direct End Feed Unit (EFU) is available with sufficient space for direct connection through lugs and bolts. MCCB,

SFU, Isolators and Fuse Holders etc. can be fitted in End Feed Unit as per specific requirement. 375mm length of bustrunking is integrally fitted

(measured and charged with bustrunking) along with End Feed Unit as standard practice so that joint between End Feed Unit and bustrunking is

exactly same as of two normal bustrunking lengths.

Undrilled cable gland plate is provided for multiple cable feeding option. End Feed unit can be made LHS or RHS type as per site requirement.

These are required to Isolate the bustrunking run in between, for various reasons. Section Isolator Unit can be fitted with Load Break Switches / SFU’s

/ MCCB’s.

These are required to close the open end of Rising main / bustrunking at the end and it provides necessary IP level.

One set of Vertical Support is recommended per floor per rising main along with rigid or spring hanger (as applicable) when the floor height is more

than 3.5mtrs to avoid horizontal swing in bustrunking sections.

Other Components

400 A

630 A

Complete Engineering Solution

23

(Typical Horizontal Layout ) (Typical Rising Mains )

(Typical End termination)

TERACE FLOOR

END COVER

GROUND FLOOR

147

28

0 (

TY

P.)

62

05

90

59

05

90

75

07

50

75

07

50

75

07

50

75

07

50

75

07

50

75

07

50

40

30

40

30

40

30

12

80

110

03

00

03

00

03

00

03

00

01

30

01

28

01

30

0

RIGID HANGER

PLUG-IN BOX

Plug In Point (TYP.)

BEAM(TYP.)

FIRST FLOOR

SECOND FLOOR

THIRD FLOOR

SPRING HANGER

24

Installation Instructions

General Preparation

Unpacking

Storage

Protection From Contaminants

First check that the intended route for the bus trunking is clear of all obstructions

an that all apertures in walls and floors are of correct size and at correct location.

Apertures should generally leave 50mm around the Bustrunking enclosure. Please

refer layout and assembly drawings for any special features.

Determine fixed points of the installation (feed units, flanged end, elbows, tee

etc.) anthen decide support points.

Ensure there is sufficient horizontal and vertical clearance from the wall and

ceiling to provide easy access to joints, both for original installation and for any

future maintenance requirements.

The bus trunking should be located away from polluted atmosphere such as

corrosive fumes, furnace gases and chemicals etc.

Care must be taken while unpacking. Cutter, should be used to cut all steel straps

securing the package. Nail pullers should be used for unpacking wooden casings.

Carefully remove any support blocks or other fittings which may have been used

for shipping.

When Bustrunking is received, unpack temporarily to inspect its physical condition.

Also check and ensure that the consignment is complete and correct as per the

order. Restore the materials in original packing condition, if it is required to be

stored for longer period prior to installation.

It is recommended to remove the polythene sheet (covering the entire

Bustrunking) only after completion of installation, in order to protect the

Bustrunking from water, slurry & paint etc. during installation.

Never keep the Bustrunking in inclined / vertical condition. Stacking should be

firmly supported to prevent any slippage.

Always store the Bustrunking products in original packing to avoid any damage,

deformations and entry of any contaminants like dust, moisture and vermins.

Cover trunking with water proof sheets.

Bus trunking should be adequately protected from liquids, moisture and other

contaminants. Some common source of contaminants are :

Bus trunking must be protected from these contaminants during installation. Bus

trunkin is not weather resistant until completely installed with all covers & boxes

fitted & secured.

Ideally water bank of min. 125mm height should be installed around all floor

openings for riser bus trunking to prevent liquid spillages from entering in the

opening and running down the bus trunking.

Protect bus trunking with a temporary protective cover to prevent water from

falling on to the Bustrunking directly until the roof is repaired.

Protect bus trunking with a temporary protective cover to prevent water

falling onto the busbar until leaking pipes are repaired. Where pipes (especially

cold water pipes) pass directly above bus trunking, the busbar should be protected

from dripping condensate by insulating the pipe or permanently shielding the bus

trunking.

Moisture / Water dripping

Floor level liquids

Leaking Roof

Pipes

These guidelines are provided to reduce the risk of personal injury, equipment damage

during handling and also to facilitate movement of the bus trunking sections and

accessories at site.

Handle bus trunking with care to avoid damage to internal components and the enclosure.

While transporting, take care not to drop it or let it hit other object. A fork lift may offer a

more convenient method of handling and has the added advantage of permitting it to be

hoisted between levels. Ensure the load is stable and safely secured.

Platform lifts or elevators, either manually or power operated, can be used

advantageously in moving bus trunking equipments between elevations. Check that the

weight of personnel plus trunking is within the capacity of the lift / elevator.

While lifting vertical lengths, take care to use an adequate sling and slinging method so

that the equipment does not slip or fall.

If a crane is used to install bus trunking, use nylon straps and distribute the weight on

each lift. If cables are used, insert thick pieces of foam or corrugated cardboard between

them to prevent the bus trunking from being damaged. Do not place slings, cables or

chains around bus trunking ends since damage can easily occur.

If a fork lift or similar hoist is used, properly position the bus trunking on the fork to

distribute its weight. Careful approach is a must to avoid any damage to the metal

housing that would break busbar insulators and result in a failure.

Do not drag bus trunking across the floor or across other busbar sections.

While installing vertical section, it may be easier to lower the bus trunking from one floor

above where it will be installed. Vertical sections are often stored on the floor above their

final location to facilitate lowering them into position. Do not damage end of trunking

when raising from horizontal to vertical positions.

When the work is suspended during the installation, the ends of the connecting sections

should be protected against water and dust by keeping the trunking covered with

polythene.

When the work is suspended during the installation, the ends of the connecting sections

should be protected against water and dust by keeping the trunking covered with

polythene.

Never use busbars / conductors of Bustrunking for lifting sections.

Fix support with ceiling/wall/structure to accommodate bustrunking hangers before

proceeding with fixing of bustrunking.

Do not leave Bustrunking section unsupported at ends while next section is being fitted as

this could cause damage. Use supports/brackets to ensure trunking remains correctly

aligned at all times.

Level and plumb Bustrunking (align vertically and horizontally) before final tightening of

all joint hardware.

In case the “Insulation Resistance” is found abnormal after installation of complete route,

much time is spent to detect faulty parts. It is therefore recommended that the insulation

resistance checking be partially conducted by 500V megger even during the installation.

Handling / Hoisting

Hanging / Supporting

25


Two types of horizontal supports are available . Choose one depending upon

Edgewise installtion as shown in diagram. It is generally preferred to

install edgewise.

After hangers have been installed with tie rods (Not part of bustrunking supply),

bustrunking length may be joined starting from EFU / Flanged End.

To connect one length to the other please refer Figure-1

Horizontal support need to be tighten with hanger once the run is completed.

It is recommended to support Bustrunking at intervals of around 1.5 meters

(1.0mtr minimum & 2 meters maximum) depending upon following points:

Shape, strength, rigidness and distance of hangers from ceiling / wall.

Rating (Low/high) and numbers of plug-in boxes to be fitted between two brackets.

Ensure each element of Bustrunking run is supported by at least one bracket.

As far as possible avoid fixing of bracket at Bustrunking joint area and at plug-in point

window.

Minimum distance between two Bustrunking will increase if plug-in box/end fe ed

unit/reducer etc. is fitted in any of the straight run. 100mm clearance need to be

considered between two boxes / unit installed on parallel runs. Space required for

door opening should also be considered. 100mm min. clearance should be considered

in case of trunking running close to beam / columns / pillars

Spacing between two brackets

Horizontal installation

For Vertical Installation two types of hangers are provided :

Rigid hanger at lowest floor and spring hanger for all balance floors.

Following sizes of opening and clearances are recommended for comfortable

installation, operation and maintenance (however actual decision will always

depend upon the site condition).

Floor opening and minimum Clearances

Vertical Installation

Never fill floor opening with mortar / cement.

Minimum clearances between two trunking running parallel should be 100mm.

between plug-in-boxes /end feed units / reducers etc. Space required for door

opening should also be considered.

Floor opening should be completely covered /sealed.

FLOOR CUT - OUT

HORIZONTAL EDGE WISE

A

A

WALL

WALL

A= 200 Mini without EFU/Reducer etc.A= 550 Mini without EFU/Reducer etc.

A= 200 Mini without EFU/Reducer etc.A= 550 Mini without EFU/Reducer etc.

* Not in C&S scope

26

Joint assembly

1.Fix Bottom Joint Cover ensuring gap between enclosure of two section as 250 mm.( Figure1)

2. Loose Joint Hex nut(M12) & fit Uniblock Joint till it rests on Bottom joint cover. Do not attempt direct hammer force to fit joint.(figure 2)

3. Apply 7.0 Kgf-mtr. torque to tighten Joint Hex nut .(figure 3)

4.Fix both Side Joint Covers & then Top Joint Cover.(figure 4)

Figure. 4

Figure. 1

Figure. 3

Figure. 2

Installation instructions

27


Earthing

Inspection & Testing

Bond the internal / external earthing busbars of bustrunking to main earthing ofsystem with adequate busbars or cable links as per standards and electrical regulations.

For bustrunking with internal earth, continuity is maintained through joints. Andfor bustrunking with external earth continuity is maintained through external links. Plug-in-boxes have integral earth clip which makes automatic contact while plugging the box on to the bustrunking.

Inspection after installation

Before energizing check:(a) Whether the bus trunking is not damaged.

(b) Whether the connecting parts are fixed precisely.

(c) Whether the bolt connecting the equipment are securely fastened.

(d) Whether the hangers are supporting the bus trunking securely.

(e) Whether all the joint covers and tap off outlet covers of bus trunkingare closed.

(f) Whether all busbar joints are tightened to the recommended torque.

(g) Whether end covers are fitted to the end of all runs.

Thereafter INSULATION RESISTANCE of complete installation (Run wise) shall be checked after disconnecting all equipments either by opening theisolator switch or setting the breakers in ‘OFF’ position. The insulationresistance value can not be specified due to the difference of the length ofrun / route and the environmental condition, but if it is a driedatmosphere, normally it shows a value above 100Mega ohms (500Vmegger).

In case it is below 10Mega ohms it has to be checked as it is most likelythat there may exist some factors which are reducing the insulation. Megger value of bustrunking section individually can be carried out byisolating joint assembly to locate the fault.

Reason for low insulation value can be due to above mentioned (a) to (g) factors, presence of moisture /contaminants or breakage of jointinsulators Defective section may be put to hot blowing air for drying themoisture and improving megger value.

If the insulation value does not improve, contact the C&S.

Periodic checking

Summary

Even though the system is virtually maintenance free following checks are recommended (for guaranteeing safe usage of the bustrunking for a longtime) preferably once in a year.

Check to ensure there is no deformation, damage, dust etc. through out the whole length of the bus trunking and there is no dislocation,bending and other abnormality of the connecting covers, hangers anplug-in- boxes.

Environment where the bus trunking is used sometimes changes afterits installation. Check that the environment is not hazardous evenpartially due to water, moisture, high temperature, corrosive gas,immoderate vibration, dust etc.

Since the spring washers are employed in busbar joints, there shall beno problem of joint loosening. Therefore, periodical check is notnecessary if recommended torque is applied to the joint clampassembly during installation. However it is advisable to re-check thetightening after full loading of bustrunking for 24 hou

Check and ensure that total load is not exceeding the capacity of bustrunking. Especially, pay attention when the main line is branchedby elbows, tee’s or crosses.

Highly insulating, non-hygroscopic Insulation material are used forbusbars, hence IR value should not reduce at later stage. Still it isadvisable to check IR value by megger (500V) periodically.

Review all layout drawings and other technical details very carefully.

Check description and identification of each piece before installing it.

Follow the joint assembly instructions.

Check insulation resistance while fixing sections of bustrunking during installation.

Check for possible source of contaminants that may fall on the bus trunkingduring installation and take preventive actions.

(a) Check the external appearances

(b) Environmental check

(c) Check the joint connections

(d) Check the load condition

(e) Check the insulation resistance (IR)

28

Major Installations

Hotels

Multi Storey Buildings

Industries

Software Parks

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Four Season - Mumbai Inter Continental The Grand- Mumbai ITC hotel - Mumbai Le-Meridian Hotel - Pune / Bangalore Maya Inn - Chandigarh Sayaji Hotel - Indore Shangri-La Hotel - New Delhi

Gold Hill Sqaure - Bangalore Hiranandani Gardens - Mumbai IOCL - Mumbai / New Delhi MMTC - Mumbai ONGC Corporate Office - Mumbai Ranbaxy Corporate Office - Gurgaon Spenzer Plaza - Chennai State Trading Corporation-New Delhi S T Microelectronic - Noida TATA Memorial Centre

APC - Bangalore Atlas Copco - Pune Ashok Leyland - Chennai, Gurgaon Auto Max - Gurgaon Bajaj Auto - Pune/Aurangabad Delphi India - Noida Denso India Limited - Manesar Dhampur Sugar Mills - Dhampur Escorts Farmatrac - Faridabad Kirloskar Motors - Chennai Hero Honda - Dhauwera Hindustan Lever Limited - Assam Jindal Steel & Power - Raigarh Maruti Suzuki - Manesar Mercedes Benz - Pune New Holland - Greater Noida Subros - Noida Thai Summit - Pant Nagar Toyota Techno Park - Bangalore TVS Suzuki- Mysore

Adobe Software - Noida Cadence Design Systems - Noida Convergys technologies - Gurgaon CTS - Pune Dell Computer - Chandigarh G.E. Capital - Hyderabad HCL Technologies -Noida IBM - Noida IFlex - Bangalore Infosys - Banglore/Chandigarh/ Chennai/ Mysore Karbay - Hydrabad K. Raheja IT Park - Hydrabad Mahindra British Telecom - Pune Philips Software Centre - Bangalore RMZ Aerospace - Banglore Tata Consulting Services - Calcutta Wipro Technologies - Pune / Kolkatta / Chennai

29

Major Installations

Hospitals

Exhibition Halls

CPWD / PWD

Railways

Temple

Telecommunication

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medabad

Dr. Hedgavers Arogya Sansthan - Delhi

Govt. General Hospital - Chennai

Maulana Azad - New Delhi

Safdarjung Hospital - New Delhi

Sir. Ganga Ram Hospital - New Delhi

ITPO - Chennai

ITPO - New Delhi

M.P. Export facilitation Centre

Delhi Secretariat - New Delhi

Gene Bank (Pusa) - New Delhi

High Court - New Delhi

Parliament House - New Delhi

Parliament Library - New Delhi

Northern Railway - Lucknow

Rail Bhawan - Delhi

Swamy Narayan Temple - Mumbai

BSNL - New Delhi / Hyderabad

C-DOT - New Delhi

DOT - Mumbai

MTNL - Mumbai

Appolo Hospital - Ah

Artemis Hospital - Gurgaon

Batra Hospital - New Delhi

Escorts Heart Institute - New Delhi

G. P. Hospital - Mumbai

Jaideva Institute of Cardiology - Bangalore

Mayur Bhawan - New Delhi

Shastri Bhawan - New Delhi

Yojna Bhawan - New Delhi

Major Export Orders

1. KYCR Coil Industries - Bangladesh

2. Dafna Tower - Doha

3. Doha Tower - Doha

4. 81 flats at AI-Sadd - Doha

5. B+G+5 Flats - Doha

6. B+G+6 Flats - Doha

7. G+11 Building - Doha

8. Westbay 44 Tower - Doha

9. Shk Falak Twin Tower - Doha

10. Mellineium Tower - Doha

11. Mushreif Tower - Doha

12. Port Saeed - Dubai

13. Evershine Trading - Dubai

14. Baiji Power Plant - IRAQ

15. LDPE Project Bandar Imam - Iran

16. P.T. Indo - Bharat Rayon - Indonensia

17. Magadi Soda plant - Kenya

18. AL Nazzar Tower - Jordan / Kuwait

19. Al Mazaya Tower - Kuwait

20. Kuwait National Petroleum Corporation - Kuwait

21. Kirby Building System - Kuwait

22. Holiday Inn - Kuwait

23. P.T Prakasa Heavyndo - Malaysia

24. Cyber Tower, Ebene city - Mauritius

25. Rusail Power Project - Oman

26. Haima West Power station - Oman

27. Salalah Power Project -Oman

28. OMIFCO -Oman

29. E-Services - Manila, Philipines

30. P.S Bank - Philipines

31. Victoria Tower - Philipines

32. Alstom - South Africa

230

Mission & Quality policy

31

Air Insulated

Busbar Trunking System

(125 2000 Amps.)

Segregated Non-Segregated

Phase Busduct

(415 - 15.0KV, upto 5000 Amps.)

Isolated Phase Busducts

(11 - 24 kV up to 20,000 Amps.)

Lighting Trunking (32 - 63A)

bus bar truncking design for sandwich

Documents

busbar systems

automatic busbar

busbar size copper

vertical offset elbow

d vertical elbow

horizontal offset elbow

b uniblock busbar joint

manufacturing plant