1

Works at Kasna

Certifications & ApprovalsCertifications & Approvals

1. Standards, Specifications & Salient Features ....................................................... 5

2. Technical Parameters .................................................................................... 6-7

3. Main Components

A. Bus Trunking, Busbar Joint ............................................................... 8

B. Horizontal Elbow, Horizontal Offset, Horizontal Tee Section .............. 9

C. Vertical Elbow, Vertical Offset, Vertical Tee Section ............................ 10

D. Flanged End & Copper Flexibles ...................................................... 11

E. Plug-in Boxes ................................................................................... 12

F. Vertical Rigid Hanger & Vertical Spring Hanger ................................. 13

G. Horizontal Support & Other Components ......................................... 14

4. Installation Instructions .................................................................................. 15-19

5. Typical Installation ........................................................................................ 20

6. Other Busbar System ..................................................................................... 21

7. Major Installations ........................................................................................ 22-23

Contents

General

Busbar Trunking System is the modern factory built Electrical Distribution System designed not only as an alternative to cablesbut have many advantages over conventional cable distribution system and is fast becoming Industry/ building standard forfuture. Decentralized distribution is the main highlight of this distribution system i.e. each equipment / appliance used in theinstallation is protected immediately by a protective device & can be maintained individually without disturbing other distributionnetworks thus reducing downtime. This system also eliminates separate requirement of distribution & panel boards. Loadscan be fed from Plug-in Boxes unlike cables where each floor / machine is to be fed separately from the main switchboard.Furthermore, this system can be installed quickly with minimum technical expertise

Compact Low Impedance Sandwich Bus Trunking (SBC / SBA)

Insulated Sandwich Bus Trunking is prefabricated, pre tested system in standard length and shapes available in Copper andAluminum in ratings from 500A to 5000A suitable for system voltages up to 1000V. These can be used as rising mains andfor horizontal power distribution. It consists of three phases and neutral conductor with option of pre decided specificallylocated Plug-in points. The basic construction and assembly features of these systems make them different from othersystems. Busbars are insulated from each other by electrical insulating materials throughout it’s length except at joint andPlug-in points, and are tightly packed in enclosures (bolted at regular intervals).

Standards and Specification

Equipment is designed for low voltage power distributionas per IEC 60439(1&2) and IS 8623 (1 &2)

System is designed for rated operational and insulationvoltage - 1000VAC,

Rated impulse withstand voltage -12kV and rated frequencyof 50Hz.

SBC: Copper bustrunking (3ø, 4W) available from800A ~ 5000A and

SBA: Aluminium bustrunking is available from500A ~ 3600A (3ø, 4W).

Bustrunking enclosure is made of CRCA / G.I sheet of1.6mm (16 SWG) with epoxy polyster powder coating ofpebble grey shade (RAL-7032)

Fully round edge busbars in SBC type are made of 99.9%pure ETP grade Copper.

Fully round edge busbars in SBA type are made of 99.5%pure, 19501 grade aluminum.

Earthing: Internal earth of G.I / Copper of cross-sectionequal to 50% of phase (option-1) and External earth ofCu / Al of desired section can be provided, duly riveted /bolted along with bustrunking enclosure (Option-2).

As a standard practice, degree of protection is IP-54 forPlug-in type and IP-55 for feeder type bustrunking.

Individual busbars are covered with multi layers of F-classflexible insulation material.

System is designed for ambient temperatures of 40°Cwith temperature rise limits on bustrunking as perstandards.

Three plug-in outlets on front side of 3mtr section can beprovided as standard, (5nos. max on special request).

Salient Features

Compact Sandwich construction

Close proximity of busbars doesn’t allow mutual induc-tance between phases yeilding low reactance, low im-pedance, low voltage drop and low power loss.

Specially designed housing bolted at every 250mm actas a heat sink to yeild improved thermal characteristic,high mechanical and short circuit strength.

Due to compactness system can be installed in lesserspace.System is maintenance free and adds elegance to thesurrounding.

Due to elimination of air there is no rise of chimneyeffect, so no fire barriers are required.

Automatic polarity is maintained during installation.

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

Flexible and safe distribution system leads to easy andfast installation. System is completely re-usable.

Any section of bustrunking can be removed withoutdistrurbing adjacent sections.

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Technical Parameters

TTTTTechnical Data : SBC (Copper Sandwich Insulated Bus Technical Data : SBC (Copper Sandwich Insulated Bus Technical Data : SBC (Copper Sandwich Insulated Bus Technical Data : SBC (Copper Sandwich Insulated Bus Technical Data : SBC (Copper Sandwich Insulated Bus Trunking)runking)runking)runking)runking)

Compliance of standards IEC 60439 - Part 1 & 2 / IS:8623 - Part 1 & 2Rated operational voltage (Ue) 1000V AC

Rated insulation voltage (Ui) 1000V AC

Rated impulse withstand voltage Uimp 12kV(1.2 / 50µs)

Rated frequency 50 Hz

Insulation Busbars fully insulated with class F (155°C)material

Enclosure material CRCA / G. I. OF THICKNESS 1.6 mm (16 SWG)System 3Ø 4 wire, full neutral

Produc t codeP roduc t codeP roduc t codeP roduc t codeP roduc t code SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC50N1 70N1 100N1 125N1 150N1 175N1 200N1 230N1 125N2 150N2 175N2 200N2 230N2

Rated cu r ren t ( I n )Ra ted cu r ren t ( I n )Ra ted cu r ren t ( I n )Ra ted cu r ren t ( I n )Ra ted cu r ren t ( I n ) A 800 1000 1250 1500 1750 2000 2250 2500 3000 3600 4000 4500 5000

Busbar s i ze (Copper )Busbar s i ze (Copper )Busbar s i ze (Copper )Busbar s i ze (Copper )Busbar s i ze (Copper ) mm 6x50 6x70 6x100 6x125 6x150 6x175 6x200 6x230 6x125 6x150 6x175 6x200 6x2303 Phases & Neu t ra l3 Phases & Neu t ra l3 Phases & Neu t ra l3 Phases & Neu t ra l3 Phases & Neu t ra l

No. o f conduc to r s pe rNo. o f conduc to r s pe rNo. o f conduc to r s pe rNo. o f conduc to r s pe rNo. o f conduc to r s pe r Nos. 1 1 1 1 1 1 1 1 2 2 2 2 2Phase / Neu t ra lPhase / Neu t ra lPhase / Neu t ra lPhase / Neu t ra lPhase / Neu t ra l

Ra ted shor t t ime cu r ren tRa ted shor t t ime cu r ren tRa ted shor t t ime cu r ren tRa ted shor t t ime cu r ren tRa ted shor t t ime cu r ren t kArms 40 50 65 65 75 75 100 100 120 120 120 180 180for 1 second ( I cw )fo r 1 second ( I cw )fo r 1 second ( I cw )fo r 1 second ( I cw )fo r 1 second ( I cw )

Ra ted peak shor tRa ted peak shor tRa ted peak shor tRa ted peak shor tRa ted peak shor t kA 84 105 143 143 165 165 220 220 264 264 264 396 396t ime cu ren t ( Ipk )t ime cu ren t ( Ipk )t ime cu ren t ( Ipk )t ime cu ren t ( Ipk )t ime cu ren t ( Ipk )

R e s i s t a n c eR e s i s t a n c eR e s i s t a n c eR e s i s t a n c eR e s i s t a n c e mΩ/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 0.0066@ +20@ +20@ +20@ +20@ +2000000C (RC (RC (RC (RC (R2020202020 )))))

Res i s tance a t t he rma lRes i s tance a t t he rma lRes i s tance a t t he rma lRes i s tance a t t he rma lRes i s tance a t t he rma l mΩ/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 0.01cond i t ions (R )cond i t i ons (R )cond i t i ons (R )cond i t i ons (R )cond i t i ons (R )

R e a c t a n c eR e a c t a n c eR e a c t a n c eR e a c t a n c eR e a c t a n c e mΩ/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 )@ 50Hz (X )@ 50Hz (X )@ 50Hz (X )@ 50Hz (X )

Impedance a t t he rma lImpedance a t t he rma lImpedance a t t he rma lImpedance a t t he rma lImpedance a t t he rma l mΩ/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 0.0112cond i t i ons (Z )cond i t i ons (Z )cond i t i ons (Z )cond i t i ons (Z )cond i t i ons (Z )

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

Compos i t e VCompos i t e VCompos i t e VCompos i t e VCompos i t e Vo l tage Drop ,o l tage Drop ,o l tage Drop ,o l tage Drop ,o l tage Drop , mV/ m /A

at fu l l l oad concen t ra teda t fu l l l oad concen t ra teda t fu l l l oad concen t ra teda t fu l l l oad concen t ra teda t fu l l l oad concen t ra ted 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

at the end . These va luesa t the end . These va luesa t the end . These va luesa t the end . These va luesa t the end . These va lues mV/ m /A

wi l l become ha l f i f l oadwi l l become ha l f i f l oadwi l l become ha l f i f l oadwi l l become ha l f i f l oadwi l l become ha l f i f l oad 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

is d i s t r ibu ted a long thei s d i s t r ibu ted a long thei s d i s t r ibu ted a long thei s d i s t r ibu ted a long thei s d i s t r ibu ted a long the mV/ m /A

r u nr u nr u nr u nr u n 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

mV/ m /A

Overa l l d imens ion o fOvera l l d imens ion o fOvera l l d imens ion o fOvera l l d imens ion o fOvera l l d imens ion o f 147x H 95 115 145 170 195 220 245 275 340 390 440 490 550Busbar TBusbar TBusbar TBusbar TBusbar Trunk ingrunk ingrunk ingrunk ingrunk ing (mm)(w i thou t In te rna l Ear th ing )(w i thou t In te rna l Ear th ing )(w i thou t In te rna l Ear th ing )(w i thou t In te rna l Ear th ing )(w i thou t In te rna l Ear th ing )

WWWWWeigh t o f Busbar Te igh t o f Busbar Te igh t o f Busbar Te igh t o f Busbar Te igh t o f Busbar Trunk ingrunk ingrunk ingrunk ingrunk ing Kg / m 22 28 35 42 48 54 60 67 84 96 108 120 134(wi thou t In te rna l Ear th ing )(w i thou t In te rna l Ear th ing )(w i thou t In te rna l Ear th ing )(w i thou t In te rna l Ear th ing )(w i thou t In te rna l Ear th ing )

Overa l l d imens ion o fOvera l l d imens ion o fOvera l l d imens ion o fOvera l l d imens ion o fOvera l l d imens ion o f 150x H 95 115 145 170 195 220 245 275 340 390 440 490 550Busbar TBusbar TBusbar TBusbar TBusbar Trunk ingrunk ingrunk ingrunk ingrunk ing (mm)(w i th In te rna l Ea r th ing )(w i th In te rna l Ea r th ing )(w i th In te rna l Ea r th ing )(w i th In te rna l Ea r th ing )(w i th In te rna l Ea r th ing )

WWWWWeigh t o f Busbar Te igh t o f Busbar Te igh t o f Busbar Te igh t o f Busbar Te igh t o f Busbar Trunk ingrunk ingrunk ingrunk ingrunk ing Kg / m 25 31 39 47 53 60 67 74 94 106 120 134 148(wi th 50% In te rna l Ea r th ing )(w i th 50% In te rna l Ea r th ing )(w i th 50% In te rna l Ea r th ing )(w i th 50% In te rna l Ea r th ing )(w i th 50% In te rna l Ea r th ing )

PARAMETER UNIT 1-Tier 2 - Tier

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Technical Parameters

TTTTTechnical Data : SBA (Aluminum Sandwich Insulated Bus Technical Data : SBA (Aluminum Sandwich Insulated Bus Technical Data : SBA (Aluminum Sandwich Insulated Bus Technical Data : SBA (Aluminum Sandwich Insulated Bus Technical Data : SBA (Aluminum Sandwich Insulated Bus Trunking)runking)runking)runking)runking)Compliance of standards IEC 60439-Part 1 & 2 / IS:8623- Part 1 & 2Rated operational voltage (Ue) 1000V ACRated insulation voltage (Ui) 1000V ACRated impulse withstand voltage Uimp 12kV (1.2 / 50µs)Rated frequency 50 HzInsulation Busbars fully insulated with class F (155°C)materialEnclosure material CRCA / G. I. OF THICKNESS 1.6 mm (16 SWG)System 3Ø 4 wire, full neutral

Product codeProduct codeProduct codeProduct codeProduct code SBA SBA SBA SBA SBA SBA SBA SBA SBA SBA SBA SBA SBA50N1 70N1 100N1 125N1 150N1 175N1 200N1 230N1 125N2 150N2 175N2 200N2 230N2

Rated current (In)Rated current (In)Rated current (In)Rated current (In)Rated current (In) A 500 630 800 1000 1250 1350 1600 1750 2000 2500 2750 3000 3600

Busbar size (Aluminium)Busbar size (Aluminium)Busbar size (Aluminium)Busbar size (Aluminium)Busbar size (Aluminium) mm 6x50 6x70 6x100 6x125 6x150 6x175 6x200 6x230 6x125 6x150 6x175 6x200 6x2303 Phases & Neutral3 Phases & Neutral3 Phases & Neutral3 Phases & Neutral3 Phases & Neutral

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

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

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

ResistanceResistanceResistanceResistanceResistance mΩ/m 0.0993 0.0704 0.0490 0.0391 0.0325 0.0278 0.0243 0.0211 0.0194 0.0162 0.0139 0.0122 0.0106@ +20@ +20@ +20@ +20@ +200 0 0 0 0 C (R C (R C (R C (R C (R2020202020)))))

Resistance at thermalResistance at thermalResistance at thermalResistance at thermalResistance at thermal mΩ/m 0.1250 0.0900 0.0640 0.0520 0.0440 0.0380 0.0340 0.0300 0.0260 0.0220 0.0190 0.0170 0.0150conditions (R)conditions (R)conditions (R)conditions (R)conditions (R)

ReactanceReactanceReactanceReactanceReactance mΩ/m 0.0340 0.0260 0.0190 0.0150 0.0130 0.0110 0.0100 0.0080 0.0070 0.0060 0.0060 0.0050 0.0040@ 50Hz (X)@ 50Hz (X)@ 50Hz (X)@ 50Hz (X)@ 50Hz (X)

Impedance at thermalImpedance at thermalImpedance at thermalImpedance at thermalImpedance at thermal mΩ/m 0.1295 0.0937 0.0668 0.0541 0.0459 0.0396 0.0354 0.0310 0.0269 0.0228 0.0199 0.0177 0.0155conditions (Z)conditions (Z)conditions (Z)conditions (Z)conditions (Z)

P. F. 0.7 0.1936 0.1413 0.1011 0.0816 0.0694 0.0597 0.0536 0.0463 0.0402 0.0341 0.0305 0.0268 0.0231

Composite VComposite VComposite VComposite VComposite Voltage Drop atoltage Drop atoltage Drop atoltage Drop atoltage Drop at mV/m/A

full load concentrated at thefull load concentrated at thefull load concentrated at thefull load concentrated at thefull load concentrated at the P. F. 0.8 0.2085 0.1517 0.1084 0.0876 0.0745 0.0641 0.0575 0.0499 0.0433 0.0367 0.0326 0.0288 0.0249

end. These values willend. These values willend. These values willend. These values willend. These values will mV/m/A

become half if load isbecome half if load isbecome half if load isbecome half if load isbecome half if load is P. F. 0.9 0.2205 0.1599 0.1141 0.0924 0.0784 0.0675 0.0606 0.0528 0.0458 0.0388 0.0342 0.0303 0.0264

distributed along the rundistributed along the rundistributed along the rundistributed along the rundistributed along the run mV/m /A

P.F.1.0 0.2165 0.1559 0.1108 0.0901 0.0762 0.0658 0.0589 0.0520 0.0450 0.0381 0.0329 0.0294 0.0260

mV/m /A

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

WWWWWeight of Busbar Teight of Busbar Teight of Busbar Teight of Busbar Teight of Busbar Trunkingrunkingrunkingrunkingrunking Kg/m 15 17 20 22.5 25 27.5 30 33 45 50 55 60 66(without Internal Earthing)(without Internal Earthing)(without Internal Earthing)(without Internal Earthing)(without Internal Earthing)

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

WWWWWeight of Busbar Teight of Busbar Teight of Busbar Teight of Busbar Teight of Busbar Trunkingrunkingrunkingrunkingrunking Kg/m 16 18 21.5 24 27 29.5 32 35.5 48 54 59 64 71(with 50% Internal Earthing)(with 50% Internal Earthing)(with 50% Internal Earthing)(with 50% Internal Earthing)(with 50% Internal Earthing)

PARAMETER UNIT 1-Tier 2-Tier

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Main Components

BustrunkingSBC & SBA type Sandwich Busbar trunking system is available in 4 pole i.e. 3 phase, 4 wire system.

Internal Earth busbar of G.I/ Copper of cross-section equal to 50% of Phase busbar as optional can also be supplied.

Single / double external earthing of Cu / Al duly (rivetted / bolted) with bustrunking as another option.

Feeder BustrunkingStraight length is used for the purpose of power transmission. i.e. applications, from Transformer to Panel or Main Panel toSub Panel or Generator to Panel or panel to rising mains..

Plug-in BustrunkingApplications where branch loads are to be fed from the main line e.g. Vertical Rising mains to various floors with help ofPlug-in Boxes.Supply up to 400A can be fed from the Plug-in points.A standard 3 meter bustrunking generally comprises of 3 Plug-in Points as shown.Maximum of 5 Plug-in points can be provided on request.Fixed Tap-Off Points rated upto 800A can also be provided on request.

Busbar Joint (UNI-BLOCK JOINT)

Joint block is operatable by one / two HTS bolts.

Joint assembly can be removed / installed at any time in installed condition.

Disc spring washer are used in Uniblock joint to uniformly distribute pressure.

Recommended torque for tightening is 7 Kg-mtr.

These joints are specially designed to accommodate thermal expansion of busbars and housing.

Standard Straight Length (mm) Minimum Straight Length (mm)

3 0 0 03 0 0 03 0 0 03 0 0 03 0 0 0 5 0 05 0 05 0 05 0 05 0 0

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Single Bolt UNI-BLOCK JOINT(For busbar size upto 6x125mm)

Double Bolt UNI-BLOCK JOINT (For busbar size 6x150 to 6x230mm)

Horizontal Offset (Z) Elbows

Horizontal Tee Sections

Main Components

Horizontal Elbows

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

Copper 800~2500AAluminum 500~1750A

300 x 300mmCopper 3000~5000AAluminum 2000~3600A

Current Rating Standard Length &Min. Length A x BxC (mm)

Copper 800~2500AAluminum 500~1750A

300 x 300 x 300mmCopper 3000~5000AAluminum 2000~3600A

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Current Rating Standard Length &Min. Length A x BxC (mm)

Copper 800~2500AAluminum 500~1750A 600 x 600 x 600 mmCopper 3000~5000AAluminum 2000~3600A

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Vertical Offset (Z) Elbows

Vertical Tee Sections

Main Components

Vertical Elbows

Current RatingCurrent RatingCurrent RatingCurrent RatingCurrent Rating Standard Length &Standard Length &Standard Length &Standard Length &Standard Length &Min. Length A x B (mm)Min. Length A x B (mm)Min. Length A x B (mm)Min. Length A x B (mm)Min. Length A x B (mm)

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

Copper 3000~5000AAluminum 2000~3600A 500 x 500mm

Current RatingCurrent RatingCurrent RatingCurrent RatingCurrent Rating Standard Length &Standard Length &Standard Length &Standard Length &Standard Length &Min. Length AxBxC (mm)Min. Length AxBxC (mm)Min. Length AxBxC (mm)Min. Length AxBxC (mm)Min. Length AxBxC (mm)

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

Copper 3000~5000AAluminum 2000~3600A 500 x 400 x 500mm

Current RatingCurrent RatingCurrent RatingCurrent RatingCurrent Rating Standard Length &Standard Length &Standard Length &Standard Length &Standard Length &Min. Length AxBxC (mm)Min. Length AxBxC (mm)Min. Length AxBxC (mm)Min. Length AxBxC (mm)Min. Length AxBxC (mm)

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

Copper 3000~5000AAluminum 2000~3600A 500 x 500 x 500mm

Main Components

Flanged endThese are used for connecting bustrunking with flanges of panels, generating sets and transformers etc. for supply / feedingof power. These are available in standard length of 375mm. Other lengths can also be made as per request.

Copper FlexiblesThese are made of high conductivity laminated copper foils. These are mainly used for expansion joints OR for connectionof bustrunking with Panel / DG Sets /Transformers. (Thickness ‘t’ and number of flexibles will vary from rating to rating.)

Rating (Amps.) Rating (Amps) Fig. Dimension DimensionCu. Al. A B

800 500 a 50 -

1000 630 a 70 -

1250 800 b 100 25

1500 1000 b 125 37.5

1750 1250 c 150 25

2000 1350 c 175 37.5

2250 1600 d 200 25

2500 1750 d 230 40

3000 2000 e 125 37.5

3600 2500 f 150 25

4000 2750 f 175 37.5

4500 3000 g 200 25

5000 3600 g 230 40

Single Tier

Double Tier

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Main Components

TTTTTypeypeypeypeype A L x W x HA L x W x HA L x W x HA L x W x HA L x W x H 380 x 250 x 170

With in-built IsolatorWith provision for door Interlocking &Interlocking with bus trunking (for MCCBand SFU)

With Fuse Holder : 100 & 125 Amps (DINtype)

With MCCB : upto 125 Amps (2 / 3 / 4poles)

(MCCB height < 170m)

With SFU : 32 ~ 125 Amps (TPN / 4 Poles)(C & S make, DIN or BS type)

TTTTTypeypeypeypeype B, CB, CB, CB, CB, C &&&&& D D D D D L x W x H450 x 250 x 230 - “B”600 x 340 x 230 - “C”

With provision for door Interlocking &Interlocking with bus trunking (for MCCBand SFU)With Fuse Holders B : 200 Amps(DIN type) C : 250 ~ 400 Amps

With 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)Type D : 800A, Available on request

Plug-in Boxes

Plug-in boxes with MCCB / SFU’s / Fuse holders or loadbreak switches (32A-400A) can be provided with doorinterlocking.

Interlocking with bustrunking to ensure “Plug-in” and“Plug-out” possible only in ‘OFF’ condition is availableas an optional

All plug-in boxes are compatible with all ratings ofbustrunking.

Plug-in boxes can be easily mounted, ensuring 100%automatic polarity.

Live contacts are isolated / properly shrouded.

4 Pole isolator is provided in Plug-in boxes upto 125Afor extra safe connection on live bustrunking.

Safe, easy and quick plug-in / plug-out is possible onlive bustrunking. Earth contact of Plug-in boxes makesfirst & breaks last.

To connect cables each plug-in box has provision of glandplates on three sides.

Contacts of Plug-in are silver plated.

TYPE-O

TYPE-A

TYPE-B, C & D

TTTTTypeypeypeypeype O L x W x HO L x W x HO L x W x HO L x W x HO L x W x H 300 x 140 x 120

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

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Installation InstructionsFor Mounting Rigid Hanger1 Fit the Rigid Hanger to the ‘U’ clamp already fitted to both side of the lowest bustrunking in the ground floor.2 Remove nut A from Rigid hanger assembly, and pass the M16 bolt thru the holes in the ‘C’ channel already grouted

on the floor/wall3 Position the bustrunking height as per layout drawing by rotatingthe nut B until bustrunking reaches desired level.4 Lock nut A from lower end of bolt to the ‘C’ channel.

For Mounting Spring Hanger1 Fit the Spring Hanger to the ‘U’ clamp already fitted to both side of the bustrunking (Rising Mains)..2 Remove nut A from Rigid hanger assembly, and pass the M16 bolt thru the holes in the ‘C’ channel already grouted

on the floor/wall3 By virtue of bustrunking weight the spring will compress and creates a gap between nut ‘C’ and L support. Tighten nut

‘C’ by hand so as to eliminate the gap.4 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.5 Lock nut A from lower end of bolt to the ‘C’ channel.6 Repeat step #1,2,3,4,5 for subsequent bustrunking.7. Loosen nut C to allow enough gap for spring to expand under thermal conditions after complete installation.

Main Components

Vertical Rigid Hanger and Vertical Spring HangerThese are used to install the rising mains.One set of Rigid hanger per rising main must be installed at the start of the risingmains (i.e. At the lowest floor) to prevent expansion of bustrunking in downward direction. One set of Spring hanger perrising main per floor for rest of the floors need to be installed to absorb the bustrunking load and to allow vertical expansionof bustrunking in upward direction only. These can be fitted on ISMC 100x75 (or equivalent) channels mounted on floors /walls as shown below.

Vertical Rigid Hanger

Vertical Spring Hanger

Channel

Channel

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requirement. 375mm length of bustrunking is integrally fitted(measured and charged with bustrunking) along with EndFeed Unit as standard practice so that joint between EndFeed Unit and bustrunking is exactly same as of two normalbustrunking lengths. Undrilled cable gland plate is providedfor multiple cable feeding option. End Feed unit can bemade LHS or RHS type as per site requirement.

Flanged End Box (Adaptor Box)Flanged End Box (Adaptor Box)Flanged End Box (Adaptor Box)Flanged End Box (Adaptor Box)Flanged End Box (Adaptor Box)Flanged End Box is used to accomodate Flange End andconnect it to Panel or Transformer through flexibleconnections. It differes from End Feed Unit since it does nothave any integral bustrunking length.

Flanged End Box may be provided with necessary busbararrangement for phase matching of bustrunking withequipment and usually contains openings / window for busbaraccessibility.

Expansion UnitExpansion UnitExpansion UnitExpansion UnitExpansion UnitIt is usually recommended to be installed after at everyuninterupted run of 50 mtrs to accomodate for compositeexpansion of complete bustrunking run. Expansion duct isset by fixing bolts to prevent duct expansion during transitand installation. After complete installation remove the fixingbolts to allow thermal expansion of bustrunking at full load.

FFFFFixed Tixed Tixed Tixed Tixed Tapapapapap-----off Poff Poff Poff Poff Provision (500 rovision (500 rovision (500 rovision (500 rovision (500 ~ 800A)800A)800A)800A)800A)It is specially designed Tap-Off Point along with Tap-Off Boxarrangement provided on main bustrunking as per therequirement ready to use MCCB / SFU etc.

Other Components

ReducerReducerReducerReducerReducerThese are required to connect two dissimilar rating / typeof bustrunking. Reducer may be designed with switchingor isolating device.

Sectional Isolator UnitSectional Isolator UnitSectional Isolator UnitSectional Isolator UnitSectional Isolator UnitThese are required to Isolate the bustrunking run in between,for various reasons. Section Isolator Unit can be fitted withLoad Break Switches / SFU’s / MCCB’s.

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

VVVVVertical Supportertical Supportertical Supportertical Supportertical SupportOne set of Vertical Support is recommended per floor perrising main along with rigid or spring hanger (as applicable)when the floor height is more than 3.5mtrs to avoidhorizontal swing in bustrunking sections.

WWWWWall / Floor Flangeall / Floor Flangeall / Floor Flangeall / Floor Flangeall / Floor FlangeThese are plates designed to cover the cut-out made forpassing bustrunking through walls or floor. WALL / FLOORflanges are required to be fitted to the both sides of wall orfloor. When using the flange together with floor support incase of rising mains, place them between the floor andbase channel.

End Feed Box (Direct)End Feed Box (Direct)End Feed Box (Direct)End Feed Box (Direct)End Feed Box (Direct)To feed bustrunking through cables, Direct End Feed Unit(EFU) is available with sufficient space for direct connectionthrough lugs and bolts. MCCB, SFU, Isolators and FuseHolders etc. can be fitted in End Feed Unit as per specific

Horizontal SupportThese are recommended to be placed at every 1.5mtrs. (1.0mtr mini. & 2.0mtrs max.)

Edgewise Horizontal Support Flatwise Horizontal Support

Rating in Copper (Amps.) Rating in Aluminium (Amps) A (mm) B (mm)

800, 1000, 1250 500, 630, 800 240 300

1500, 1750, 2000, 2250, 2500 1000, 1250, 1350, 600, 1750 390 450

3000, 3600 2000, 2500 540 600

4000, 4500, 5000 2750, 3000 640 700

4.1 Mois ture / WMois ture / WMois ture / WMois ture / WMois ture / Water drippingater drippingater drippingater drippingater dripping

Bus trunking must be protected from thesecontaminants during installation. Bus trunking is notweather resistant until completely installed with allcovers & boxes fitted & secured.

4.2 Floor level liquidsFloor level liquidsFloor level liquidsFloor level liquidsFloor level liquids

Ideally water bank of min. 125mm height should beinstalled around all floor openings for riser bustrunking to prevent liquid spillages from entering inthe opening and running down the bus trunking.

4.3 Leaking RoofLeaking RoofLeaking RoofLeaking RoofLeaking Roof

Protect bus trunking with a temporary protective coverto prevent water from falling on to the Bustrunkingdirectly until the roof is repaired.

4.4 PipesPipesPipesPipesPipes

Protect bus trunking with a temporary protective coverto prevent water falling onto the busbar until leakingpipes are repaired. Where pipes (especially cold waterpipes) pass directly above bus trunking, the busbarshould be protected from dripping condensate byinsulating the pipe or permanently shielding the bustrunking.

4.5 SprinklersSprinklersSprinklersSprinklersSprinklers

Protect bus trunkin g from direct spray of sprinklers.

5.0 Handling / Hoisting

These guidelines are provided to reduce the risk ofpersonal injury, equipment damage during handlingand also to facilitate movement of the bus trunkingsections and accessories at site.

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

5.2 While transporting, take care not to drop it or let it hitother object.

5.3 A fork lift may offer a more convenient method ofhandling and has the added advantage of permittingit to be hoisted between levels. Ensure the load isstable and safely secured.

5.4 Platform lifts or elevators, either manually or poweroperated, can be used advantageously in moving bustrunking equipments between elevations. Check thatthe weight of personnel plus trunking is within thecapacity of the lift / elevator.

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Installation Instructions

1.0 General Preparation

1.1 First check that the intended route for the bus trunkingis clear of all obstructions and that all apertures inwalls and floors are of correct size and at correctlocation. Apertures should generally leave 50mmaround the Bustrunking enclosure. Please refer layoutand assembly drawings for any special features.

1.2 Determine fixed points of the installation (feed units,flanged end, elbows, tees etc.) and then decidesupport points.

1.3 Ensure there is sufficient horizontal and verticalclearance from the wall and ceiling to provide easyaccess to joints, both for original installation and forany future maintenance requirements.

1.4 The bus trunking should be located away from pollutedatmosphere such as corrosive fumes, furnace gasesand chemicals etc.

2.0 Unpacking

2.1 Care must be taken while unpacking. Cutter, shouldbe used to cut all steel straps securing the package.Nail pullers should be used for unpacking woodencasings.

2.2 Carefully remove any support blocks or other fittingswhich may have been used for shipping.

2.3 When Bustrunking is received, unpack temporarilyto inspect its physical condition. Also check and ensurethat the consignment is complete and correct as perthe order. Restore the materials in original packingcondition, if it is required to be stored for longer periodprior to installation.

2.4 It is recommended to remove the polythene sheet(covering the entire Bustrunking) only after completionof installation, in order to protect the Bustrunking fromwater, slurry & paint etc. during installation.

3.0 Storage

3.1 Never keep the Bustrunking in inclined / verticalcondition. Stacking should be firmly supported toprevent any slippage.

3.2 Always store the Bustrunking products in originalpacking to avoid any damage, deformations and entryof any contaminants like dust, moisture and vermins.Cover trunking with water proof sheets.

4.0 Protection From Contaminants

Bus trunking should be adequately protected fromliquids, moisture and other contaminants. Somecommon source of contaminants are :

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5.5 While lifting vertical lengths, take care to use an

adequate sling and slinging method so that theequipment does not slip or fall.

5.6 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 orchains around bus trunking ends since damage can

easily occur.

5.7 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 insulatorsand result in a failure.

5.8 Do not drag bus trunking across the floor or across

other busbar sections.

5.9 While installing vertical section, it may be easier tolower 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.

5.10 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.

5.11 Never use busbars / conductors of Bustrunking for

lifting sections.

6.0 Hanging / Supporting

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.

6.1 Horizontal installation

6.1.1 Two types of horizontal supports are available .

Choose one depending upon Edgewise / Flatwise

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 on page18.

Horizontal support need to be tighten with hanger

once the run is completed.

6.1.2 Spacing between two brackets

It is recommended to support Bustrunking at inter-

vals 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.

6.1.3 Minimum clearance from wall, ceiling, beams /

columns and between two trunking running parallel

RECOMMENDATION

HORIZONTAL EDGE WISE

6.2 Vertical Installation

6.2.1 For Vertical Installtion two types of hangers areprovided: Rigid hanger at lowest floor and springhanger for all balancefloors.

To connect one length to the other please refer

Figure -1 on page18.

6.2.2 Floor opening and minimum Clearances

Following sizes of opening and clearances arerecommended for comfortable installation,operation and maintenance (however actualdecision will always depend upon the sitecondition).

Installation Instructions

RISING MAINS

RECOMMENDATION

RECOMMENDATION

FLOOR CUT-OUT

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 over WATER BANK with cover plate to

prevent entry of contaminants as shown below:

Minimum distance between two Bustrunking willincrease if plug-in box/end fe ed unit/reducer etc. isfitted in any of the straight run. 100mm clearanceneed to be considered between two boxes / unitinstalled on parallel runs. Space required for dooropening should also be considered. 100mm min.clearance should be considered in case of trunkingrunning close to beam / columns / pillars

Joint point should not come inside the wall crossingand behind any restricted area like pillars, trussesetc. Joint line should be clear by atleast 200mm onboth sides

RECOMMENDATION

WATER BANK

RECOMMENDATION

HORIZONTAL FLAT WISE

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7.0 Joint Assembly

Before joining two bustrunking sections, ensure that the conductor surface and insulating materials arenot damaged. Also check they are free of dust otherwise clean them thoroughly. Following steps willmake joining much easier.

7.1 Join two sections by fixing Bottom Joint Cover with help of Flanged Bolts which will create a gap of30~36mm between busbars of two sections to facilitate insertion of joint assembly.

7.2 Loosen bolt ofUNIBLOCK Joint Assembly and fit on the busbars at joint area.

7.3 Apply torque of 7.0 Kg-Mtr. to the UNIBLOCK Joint assembly to ensure correct pressure and connections.

7.4 Place the Side Joint Covers on both sides and fix them with the help of hardwares.

7.5 Place the Top Joint Covers and fix it with hardwares.

8.0 Mounting of Plug-in-box

Lower rating Plug-in-box upto 125 Amps are available with inbuilt off load isolator. Following are themounting steps:

8.1 Open the plug-in cover at desired position on bus trunking.

8.2 Box should always be plugged in with cover in open condition (no load condition).

8.3 Place the box parallel on to the bus trunking with cover in open condition and push it till it aligncompletely

8.4 Close the cover of box. Loosen the clamps and fix it with the bus trunking enclosure.

8.5 Now Plug-in-box is ready to energized.

Higher rating plug-in-box should also be inserted, in no-load condition. Boxes with MCCB/SFU havesafety interlocking for this purpose i.e. plug-in is possible with door-open condition only. Place thebox parallel to bus trunking and push it hard till it aligns completely. Loosen the clamps and fix itwith the bus trunking enclosure. Plug-in Box can be energized after closing the door.

Figure - 1

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Installation Instructions

9.0 Earthing

9.1 Bond the internal / external earthing busbarsof bustrunking to main earthing of system withadequate busbars or cable links as per standardsand electrical regulations.

9.2 For bustrunking with internal earth, continuityis maintained through joints. And for bustrunkingwith external earth continuity is maintainedthrough external links.

9.3 Plug-in-boxes have integral earth clip whichmakes automatic contact while plugging thebox on to the bustrunking.

10.0 Inspection & Testing

10.1 Inspection after installation

Before energizing check:

(a) Whether the bus trunking is not damaged.

(b) Whether the connecting parts are fixedprecisely.

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

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

(e) Whether all the joint covers and tap offoutlet covers of bus trunking are closed.

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

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

Thereafter INSULATION RESISTANCE ofcomplete installation (Run wise) shall be checkedafter disconnecting all equipments either byopening the isolator switch or setting thebreakers in ‘OFF’ position. The insulationresistance value can not be specified due tothe difference of the length of run / route andthe environmental condition, but if it is a driedatmosphere, normally it shows a value above100MΩ (500V megger). In case it is below10MΩ it has to be checked as it is most likelythat there may exist some factors which arereducing the insulation. Megger value ofbustrunking section individually can be carriedout by isolating joint assembly to locate thefault. Reason for low insulation value can bedue to above mentioned (a) to (g) factors,presence of moisture / contaminants orbreakage of joint insulators . Defective sectionmay be put to hot blowing air for drying themoisture and improving megger value. If theinsulation value does not improve, contact themanufacturer.

10.2 PPPPPeriodic checkingeriodic checkingeriodic checkingeriodic checkingeriodic checking

Even though the system is virtually maintenancefree following checks are recommended (forguaranteeing safe usage of the bustrunking fora long time) preferably once in a year.

(a) Check the external appearances

Check to ensure there is no deformation,damage, dust etc. throughout the wholelength of the bus trunking and there isno dislocation, bending and otherabnormality of the connecting covers,hangers and plug-in- boxes.

(b) Environmental check

Environment where the bus trunking isused sometimes changes after itsinstallation. Check that the environmentis not hazardous even partially due towater, moisture, high temperature,corrosive gas, immoderate vibration, dustetc.

(c) Check the joint connections

Since the spring washers are employedin busbar joints, there shall be noproblem of joint loosening. Therefore,periodical check is not necessary ifrecommended torque is applied to thejoint clamp assembly during installation.However it is advisable to re-check thetightening after full loading of bustrunkingfor 24 hours.

(d) Check the load condition

Check and ensure that total load is notexceeding the capacity of bustrunking.Especially, pay attention when the mainline is branched by elbows, tee’s orcrosses.

(e) Check the insulation resistance (IR)

Highly insulating, non-hygroscopicInsulation material are used for busbars,hence IR value should not reduce at laterstage. Still it is advisable to check IRvalue by megger (500V) periodically.

11.0 Summary

11.1 Review all layout drawings and other technicaldetails very carefully.

11.2 Check description and identification of eachpiece before installing it.

11.3 Follow the joint assembly instructions.

11.4 Check insulation resistance while fixing sectionsof bustrunking during installation.

11.5 Check for possible source of contaminants thatmay fall on the bus trunking during installationand take preventive actions.

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Typical Installations

Switchgear to Switchgear

Rising Mains Transformer to SwitchgearHorizontal Distribution

Generator to Switchgear

Offset Connection Switchgear to Sub-Panel

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Air Insulated Busbar Trunking System(125 ~ 2000 Amps.)

Other Busbar System from C&S

Isolated Phase Busduct(11-24kV, upto 20,000 Amps.)

Segregated Non-SegregatedPhase Busduct

(415V - 15.0kV, upto 5000 Amps.)

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Hotels

Bharat Hotels - Mumbai

ITC hotel - Mumbai

Le-Meridian Hotel - Pune

Maya Inn - Chandigarh

Sayaji Hotels - Indore

Hotel Kanishka - New Delhi

Multi Storey Buildings

Spenzer Plaza - Chennai

Hiranandani Gardens - Mumbai

S T Microelectronic - Noida

MMTC - Mumbai

IOCL - Mumbai / New Delhi

ONGC - Mumbai

Gold Hill Sqaure - Bangalore

Industries

APC - Bangalore

Auto Max - Gurgaon

Atlas Copco - Pune

Bajaj Auto - Pune/Aurangabad

Delphi India - Noida

Denso India Limited - Manesar

TVS Suzuki- Mysore

Kirloskar Motors - Chennai

Mercedes Benz - Pune

Hero Honda - Dhauwera

Hindustan Lever Limited - Assam

Subros - Noida

Escorts Farmatrac - Faridabad

Toyota Techno Park - Bangalore

Banks

NABARD Bank - M umbai

Dena Bank - Mumbai

Union Bank of India - Mumbai

Software Parks

Adobe Software - Noida

Cadence Design Systems - Noida

Convergys technologies - Gurgaon

G.E. Capital - Hyderabad

IFlex - Bangalore

Mahindra British Telecom - Pune

Wipro Technologies - Pune / Kolkatta / Chennai

Philips Software Centre - Bangalore

Tata Consulting Services - Calcutta

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J.P TECHNO PARK, BANGALORE

ADOBE SOFTWARE PARK, NOIDA

CADENCE DESIGN SYSTEMS, NOIDA

Major Installations

Hospitals

Appolo Hospital - Ahmedabad

Escorts Heart Institute - New Delhi

Jaideva Institute of Cardiology - Bangalore

Batra Hospital - New Delhi

G. P. Hospital - Mumbai

Maulana Azad - New Delhi

Govt. General Hospital - Chennai

Safdarjung Hospital - New Delhi

Dr. Hedgavers Arogya Sansthan - Delhi

Sir. Ganga Ram Hospital - New Delhi

Exhibition Halls

ITPO - New Delhi

ITPO - Chennai

M.P. Export facilitation Centre

CPWD / PWD

Parliament House - New Delhi

Parliament Library - New Delhi

Yojna Bhawan - New Delhi

Delhi Secretariat - New Delhi

Shastri Bhawan - New Delhi

Mayur Bhawan - New Delhi

Gene Bank (Pusa) - New Delhi

High Court - New Delhi

Railways

Northern Railway - Lucknow

Rail Bhawan - Delhi

Temple

Swamy Narayan Temple - Mumbai

Telecommunication

C-DOT - New Delhi

BSNL - New Delhi / Hyderabad

MTNL - Mumbai

DOT - Mumbai

Export Project

Alstom - South Africa

Cyber Tower, Ebene City - Mauritius

Evershine Trading Co. -Dubai

P. T. Prakasa Heavyndo - Malaysia

PARLIAMENT LIBRARY, NEW DELHI

DELHI SECRETARIAT, NEW DELHI

HIRANANDANI GARDENS, MUMBAI

Major Installations

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