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Mission & Quality policy

Corporate Mission The 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.

QUALITY POLICY
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.

Manufacturing Unit

Manufacturing Plant at Hardwar

GEAR ITCH & SW OLS R T N CO

LTD. PANY COM

Manufacturing facilities

AMADA, CNC TURRET PUNCHING

AUTOMATIC BUSBAR CUTTING MACHINE

EPOXY POWDER COATING PLANT

BUSBAR SLEEVING MACHINE

INSULATION CUTTING MACHINE - lASER

Contents

Technical Parameters Standard & Specifications Bustrunking System

6-9 10 11

Main Components
A) Feeder Bustrunking, Plug-in Bustrunking B) Uni-Block Busbar Joint C) Horizontal elbow, Horizontal offset elbow D) Vertical elbow, Vertical offset elbow, Vertical Tee Section E) Certification & Approvals F) Standard Flange End G) Flange End Box, Rubber Bellow & Flexibles h) Plug in Boxes I) Spring & Rigid Hanger Other Components Complete Engineering Solution Installation Instructions Major installations Major Export orders Other Busbar Systems 12 13 14 15 16 - 17 18 19 20 21 22 23 24 - 27 28 - 29 30 31
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Technical Parameters

H H

Technical Data : SBC (Copper Sandwich Insulated Bus Trunking)


CURRENT RATING
PARAMETER Product code UNIT SBC SBC SBC SINGLE TIER SBC SBC SBC SBC SBC SBC SBC TWO TIER SBC SBC SBC

50N1 70N1 100N1 125N1 150N1 175N1 200N1 230N1 125N2 150N2 175N2 200N2 230N2 Rated current (In) Busbar size (Copper) 3 Phases & Neutral No. of conductors per Phase / Neutral Rated short time current for 1 second (Icw) Rated peak short time curent (Ipk) A mm Nos. kArms kA 800 1000 1250 1500 1750 2000 2250 2500 3000 3600 4000 4500 5000

6x50 6x70 6x100 6x125 6x150 6x175 6x200 6x230 6x125 6x150 1 45 84 1 50 105 1 65 143 1 65 143 1 75 165 1 75 165 1 100 220 1 100 220 2 120 264 2 120 264

6x175 6x200 6x230 2 120 264 2 180 396 2 180 396

OVERALL DIMENSION & WEIGHT


PARAMETER Product code UNIT SBC SBC SBC SINGLE TIER SBC SBC SBC SBC SBC SBC SBC TWO TIER SBC SBC SBC

50N1 70N1 100N1 125N1 150N1 175N1 200N1 230N1 125N2 150N2 175N2 200N2 230N2 Overall dimension of Busbar Trunking (without Internal Earthing) Weight of Busbar Trunking (without Internal Earthing) Overall dimension of Busbar Trunking (with Internal Earthing) 147x H (mm) 95 115 145 170 195 220 245 275 340 390 440 490 550

Kg / m 22 150x H (mm) 95

28 115

35 145

42 170

48 195

54 220

60 245

67 275

84 340

96 390

108 440

120 490

134 550

Weight of Busbar Trunking Kg / m 25 (with 50% Internal Earthing )

31

39

47

53

60

67

74

94

106

120

134

148

Technical Parameters
Voltage Drop Calculation Formulas D v = 3 I (Rcos + Sin) R95 : AC resistance at rated current(I0)(W /m) (Shown in the table) where D v : Line-to-Line voltage drop (v/m) a : Temperature coefficient of conductor at 20oc I : Load Current (A) -3 -3 3.85 x 10 (copper), 4.00 x 10 (aluminum) Cos: Load power factor 2 I0 : Rated Current sin = 1- cos R: AC resistance at load current (W /m) X : Reactance (shown in the table) (W ) 1+a (55x(1/1 ) +20) R=R x Technical Data : 1+75a SBC (Copper Sandwich Insulated Bus Trunking)
2 0 95

ELECTRICAL RESISTANCE / REACTANCE & IMPEDANCE - 50 Hz


PARAMETER Product code UNIT SBC 50N1 Resistance @ +200C (R20) Resistance at thermal conditions (R) Reactance @ 50Hz (X) Impedance at thermal conditions (Z) m /m m /m SBC 70N1 SBC SINGLE TIER SBC SBC SBC SBC SBC SBC SBC TWO TIER SBC SBC SBC

100N1 125N1 150N1 175N1 200N1 230N1

125N2 150N2

175N2 200N2 230N2

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 0.077 0.055 0.04 0.033 0.028 0.024 0.021 0.019 0.016 0.014 0.012 0.011 0.01

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

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 0.0112

VOLTAGE DROP - 50 Hz
PARAMETER Product code Composite Voltage Drop, UNIT SBC SBC SBC SINGLE TIER SBC SBC SBC SBC SBC SBC SBC TWO TIER SBC SBC SBC

50N1 70N1 100N1 125N1 150N1 175N1 200N1 230N1 125N2 150N2 175N2 200N2 230N2 mV/m/A at full load concentrated 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 at the end. These values will become mV/m/A half if load is distributed 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 along the run. mV/m/A 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 mV/m/A 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

Technical Parameters

Technical Data : SBA (Aluminum Sandwich Insulated Bus Trunking)


ELECTRICAL RESISTANCE / REACTANCE & IMPEDANCE
PARAMETER Product code UNIT SBA 50N1 Resistance @ +200 C (R20) Resistance at thermal conditions (R) m /m m /m SBA 70N1 SBA SINGLE TIER SBA SBA 150N1 SBA SBA SBA TWO TIER SBA 150N2 SBA 175N2 SBA 200N2 0.0122 0.0170

100N1 125N1

175N1 200N1 125N2 0.0278 0.0243 0.0194 0.0380 0.0340 0.0260

0.0993 0.0704 0.0490 0.0391 0.0325 0.1250 0.0900 0.0640 0.0520 0.0440

0.0162 0.0139 0.0220 0.0190

Reactance @ 50Hz (X) Impedance at thermal conditions (Z)

m /m

0.0340 0.0260 0.0190 0.0150 0.0130

0.0110 0.0100 0.0070

0.0060 0.0060

0.0050

m /m

0.1295 0.0937 0.0668 0.0541 0.0459

0.0396 0.0354 0.0269

0.0228 0.0199

0.0177

VOLTAGE DROP
PARAMETER Product code UNIT SBA 50N1 Composite Voltage Drop, at full load concentrated at the end. SBA SBA SINGLE TIER SBA SBA 150N1 SBA 175N1 SBA SBA TWO TIER SBA 150N2 SBA 175N2 SBA 200N2 0.0268

70N1 100N1 125N1

200N1 125N2

P. F. 0.7 0.1936 0.1413 0.1011 0.0816 0.0537 0.0597 0.0536 0.0402 0.0341 0.0305 mV/m/A

P. F. 0.8 0.2085 0.1517 0.1084 0.0876 0.0554 0.0641 0.0575 0.0433 0.0367 0.0326 These values will become mV/m/A half if load is distributed along the run. P. F. 0.9 0.2205 0.1599 0.1141 0.0924 0.0557 0.0675 0.0606 0.0458 0.0388 0.0342 mV/m/A

0.0288

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 mV/m/A

Technical Parameters

H H

Technical Data : SBA (Aluminum Sandwich Insulated Bus Trunking)


CURRENT RATING
PARAMETER Product code UNIT SBA 50N1 Rated current (In) Busbar size (Aluminium) 3 Phases & Neutral No. of conductors per Phase / Neutral Rated short time current for 1 second (Icw) Rated peak short time curent (Ipk) A mm Nos. k Arms 500 6x50 1 30 SBA SBA SINGLE TIER SBA SBA 150N1 1250 6x150 1 75 SBA SBA SBA TWO TIER SBA 150N2 2500 6x150 2 120 SBA 175N2 2750 6x175 2 120 SBA 200N2 3200 6x200 2 150

70N1 100N1 125N1 630 6x70 1 40 800 1000

175N1 200N1 125N2 1350 1600 2000

6x100 6x125 1 50 1 65

6x175 6x200 6x125 1 75 1 85 2 100

kA

63

84

105

143

165

165

187

220

264

264

330

OVERALL DIMENSION & WEIGHT


PARAMETER Product code UNIT SBA 50N1 Overall dimension of 147x H Busbar Trunking (mm) (without Internal Earthing) Weight of Busbar Trunking Kg/m (without Internal Earthing) Overall dimension of Busbar Trunking (with Internal Earthing) 150x H (mm) 95 SBA SBA SINGLE TIER SBA SBA 150N1 195 SBA SBA SBA TWO TIER SBA 150N2 390 SBA 175N2 440 SBA 200N2 490

70N1 100N1 125N1 115 145 170

175N1 200N1 125N2 220 245 340

15 95

17 115

20 145

22.5 170

25 195

27.5 220

30 245

45 340

50 390

55 440

60 490

Weight of Busbar Trunking Kg/m (with50%Internal Earthing)

16

18

21.5

24

27

29.5

32

48

54

59

64

Standard & Specifications

1. 2. 3. 4.

Compliance of standard Independent certification authority System


a) Copper Bustrunking b) Aluminium Bustrunking

IEC 60439 (1&2) & IS 8623 (1&2) ASTA- UK, KEMA - Holland, DAMSTRA - Nether Land, CPRI - India. 3Phase, full neutral
SBC 800A ~ 5000A SBA 500A ~ 3200A

Current Rating

5. 6. 7. 8. 9 10. 11.

Rated operational voltage (Ue) Rated insulation voltage (Ui) Rated impulse withstand voltage(Uimp) Rated frequency Enclosure material Paint shade
a) b)

1000 Volt, AC 1000 Volt, AC 12 KV(1.2/50 s) 50 Hz/60 Hz* 1.6 mm (16 SWG GI) Epoxy polyster powder coated pebble grey shade(RAL-7032)
99.9% pure ETP grade 99.5% pure 19501 grade

Busbar material (full round edge)


Copper Aluminium

12. 13. 14.

Busbar insulation Maximum temp rise


(Tested as per IEC 60529)

Multi layer insulation of CLASS - F As per IEC 60439(1&2) & IS 8623(1&2) IP 54 for plug in type IP 55 for feeder bustrunking (suitable with canopy for outdoor application) 3P+N+PE 3P+N+PE+External Earth 3P+2N+PE 3P+N+PE + Internal Earth

Degree of protection

15.

Busbar configuration

* R X Z values for 60 Hz available on request

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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.
Third Floor
EN D CL OS U

Rising Main Distribution

RE

SPRING VERTICAL HANGER


D EN

FL

GE AN

Second Floor

IC RT VE OW B EL

AL

Can be installed quickly with minimum technical expertise and have good asthetics. Any section of bustrunking can be removed without distrurbing adjacent sections.
RI G HA ID V ER NG TI ER CA

EXPANSION JOINT

System is maintenance free and adds elegance to the surrounding.

L TA ON RIZ HO E TE

E IS W D R AT EN FL NGE GE HA AN FL

First Floor
RE

PLUG IN HOLE

PLUG IN UNIT
DU

CE R

RIGID VERTICAL
L TA ON RIZ ET HO FF-S O

HANGER

Salient Features

ME DI HA U NG M ER

HO RI EL Z BO ON TA W L

BASE CHANEL

Close proximity of busbars doesnt 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 heat sink to yeild improved thermal characteristic, high mechanical and short circuit strength. Due to elimination of air there is no rise of chimney effect, so no fire barriers are required. Due to compactness system can be installed in lesser space. Automatic polarity is maintained during installation.
VERTICAL ELBOW

VE RT TE IC AL E

D GE AN OX FL B D EN

FEED IN BOX

E IS W R GE ED NGE HA

TR END FLANGED END BOX TRANSFORMER

Basement
E BL CA

AY TR

R EA HG ITC SW

Horizontal Distribution
INSULATED BUSDUCT INSULATED BUSDUCT

FLANGED END BOX

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.

HORIZONTAL ELBOW INSULATED BUSDUCT FEED IN BOX

EDGEWISE HANGER
HORIZONTAL OFF-SET

FEED IN BOX

FLANGED END

CABLE

L.V. SWITCHGEAR PLUG IN BOX

PLUG IN BUSDUCT

PLUG IN BOX FEED IN BOX


PLUG IN BOX

PLUG IN BOX

END CLOSURE

END CLOSURE
PLUG IN BOX

END CLOSURE
PLUG IN BOX

END CLOSURE

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Main Components
Feeder Bustrunking
Transformer to Panel Main Panel to Sub Panel Generator to Panel Panel to rising mains.. Straight length is used for the purpose of power transmission.

L
L - 3 Meter Standard Length

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 .

0m 0 30

12

Main Components

UNI-BLOCK BUSBAR JOINT

3 1 2 1 2 1 2 1 2 3 1

1. DMC Insulation 2. Conductor CU/AL 3. End Plates 4. Belleville Washers 5. HTS Bolt

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)
13

Main Components

Horizontal Elbow
A
B
Current Rating Copper 800~2500A Aluminum 500~1750A Copper 3000~5000A Aluminum 2000~3200A Standard Length & Min. Length A x B (mm) 300 x 300mm

Horizontal Offset [Z] Elbow


Current Rating Copper 800~2500A Aluminum 500~1750A Standard Length & Min. Length A x B x C (mm) 600 x 600 x 600mm

Copper 3000~5000A Aluminum 2000~3200A

B
C

14

Main Components
Vertical Elbow

Current Rating Copper 800~2500A Aluminum 500~1750A Copper 3000~5000A Aluminum 2000~3200A

Standard Length & Min. Length A x B (mm) 400 x 400 mm 500 x 500 mm

Vertical Offset [Z] Elbow


C

Current Rating Copper 800~2500A Aluminum 500~1750A Copper 3000~5000A Aluminum 2000~3200A

Standard Length & Min. Length A x B x C(mm) 400 x 400 x 400mm 500 x 500 x 500mm

Vertical Tee Seciton


C

Current Rating Copper 800~2500A Aluminum 500~1750A Copper 3000~5000A Aluminum 2000~3200A

Standard Length & Min. Length A x B x C(mm) 400 x 400 x 400mm 500 x 500 x 500mm

15

Certification & Approvals

16

17

Main Components Standard Flange End

14(Type)
50 50 50 50 50 W 50 50 50 W 50

50 W W

Fig.4

Fig.5

Fig.6

Fig.7

690 60 690 60 60

= 150=

60 60

= 150=

60 60

= 150 =

60 60

196

15TYP 60

5TYP 60

15TYP 60 148 148 148 16 16 300 300 300 X X X X 16 X X 200 300


120 120 120

150
N L1

150
L2

150
L3

300

150
N L1

150
L2

150
L3

L1

L2

L3

Fig.1 (1 Tier)

Fig.2 (2 Tier)

Fig.3 (3 Tier)

S.No 01. 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. 12. 13. 14. 15.

Product Code 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

DIMENSIONS A W 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

Terminal Detail 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

Busbar Hole Detail 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

No.of Basbar 1 1 1 1 1 1 1 1 2 2 2 2 2 2 3

Appliable Standrad Flange End Box Bellow

18

Main Components
Flange End Box cum Termination Detail
A+80 A

20
TOTAL NUMBER OF HOLE (H)X DISTANCE BETWEEN HOLE(I)

20

S.No
01.

Flange End Box BOX A BOX B BOX C BOX D

Dimension (in mm)

F 4 4 5 5

G 180 180 185 185

H 3 3 5 5

K (Recommended)

Application for SBC/SBA-50N1, 70N1, 100N1, 125N1 SBC/SBA-150N1, 175N1, 200N1, 230N1 SBC/SBA-100N2, 150N2, 175N2, 200N1, 230N2 SBC/SBA-150N3, 175N3, 200N3

500 250 250 120 540 500 350 250 120 540 700 620 350 150 740 700 800 350 150 740

145 290 50 195 390 100 165 660 150 210 840 150

B+80

02. 03.

20

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

20 SECTION XX

04.

300

PE

N L3 L2 L3

X C

X NOT IN C&S SCOPE

14(Typ) NOT IN C&S SCOPE

50 50 50

L3

L2

L1

K PANEL/TRANSFORMER/DISEL GENRATOR FLANGE

Rubber Bellow

Laminated Copper Flexible


23 50 25 Holes to be drilled at site as per requirement

25 25

50

98

98

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

Bustrunking Side

20
TOTAL NUMBER OF HOLE (H)X DISTANCE BETWEEN HOLE(I)

A+80 A

Thickness (t) as per Rating 20

B B+80

copper Flexible code For Ordering

50

COPPER FLEXIBLE CODE FOR ORDERING


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

CFX Rating

L Lengh

20 M.S. CHANNEL

PLAN

19

Main Components Plug-in Boxes - IP 54


Type O
Overall Dimensions (in mm) 4P - 280(L) X 135(W) X 117(H) 5P - 280(L) X 160(W) X 117(H) With in-built Isolator With MCB : 32 & 63 Amps With Fuse holder : 32 & 63 Amps (BS type) With MCCB : upto 63 Amps 2 / 3 / 4 poles) (MCCB height < 130m)

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) With in-built Isolator With 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 B, C & D
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) With provision for door Interlocking & Interlocking with bus trunking (for MCCB and SFU) With Fuse HoldersB: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 make Type C: 200A (BS type), : 250A (DIN), 315A (BS) & 400A (DIN)

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.

20

Spring & Rigid Hanger


Vertical Spring Hanger

2nd Floor

L1

Floor Height

ISMC 150x75 Not in Scope of Supply)

U clamp(Clamped tightened with bustrunking)


ISMC 150x75 Not in Scope of Supply)

Plug-in Box

Vertical Spring Hanger

Spring Hanger

First Floor

L SUPPORT
Plug-in Point Vertical Rigid Hanger (At lowest floor only)
ISMC 150x75 Not in Scope of Supply) ISMC 150x75 Not in Scope of Supply)

Enlarge view of U/L clamp

Gr. Floor

Vertical Rigid Hanger

Floor Thickness

L1

Installation - Spring 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.

Basement To End Feed Unit / Panel

Installation - 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.

21

Other Components

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

Reducer

400 A

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.

End Feed Box (Direct)

Sectional Isolator Unit

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

End Cover

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

Vertical Support

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.

22

Complete Engineering Solution

(Typical Horizontal Layout )

(Typical Rising Mains )


END COVER TERACE FLOOR 1300 147 1100 3000 PLUG-IN BOX RIGID HANGER GROUND FLOOR 1280 BEAM(TYP.) Plug In Point (TYP.) 750 4030 280 (TYP.) 620 750 750 3000 SPRING HANGER FIRST FLOOR 1280 590 750 750 750 3000 SECOND FLOOR 1300 3000 590 750 750 THIRD FLOOR 590 750 750 750

(Typical End termination)

4030

4030

750

23

Installation Instructions
General Preparation
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.

Handling / Hoisting

Unpacking

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 : Moisture / Water dripping 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. Floor level liquids 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. Leaking Roof Protect bus trunking with a temporary protective cover to prevent water from falling on to the Bustrunking directly until the roof is repaired. Pipes 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.

Storage

Protection From Contaminants

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.

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.

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Installation Instructions
Horizontal installation
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. Spacing between two brackets 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

Vertical Installation
For Vertical Installation two types of hangers are provided : Rigid hanger at lowest floor and spring hanger for all balance floors. Floor opening and minimum Clearances 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 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.

WALL

HORIZONTAL EDGE WISE

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

WALL

* Not in C&S scope

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

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Installation instructions

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

Figure. 1

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)

Figure. 2

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

Figure. 3

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

Figure. 4

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Installation Instructions

Earthing
Bond the internal / external earthing busbars of bustrunking to main earthing of system with adequate busbars or cable links as per standards and electrical regulations. For bustrunking with internal earth, continuity is maintained through joints. And for 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.

Periodic checking
Even though the system is virtually maintenance free following checks are recommended (for guaranteeing safe usage of the bustrunking for a long time) preferably once in a year. (a) Check the external appearances 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 an plug-in- boxes. (b) Environmental check Environment where the bus trunking is used sometimes changes after its installation. Check that the environment is not hazardous even partially due to water, moisture, high temperature, corrosive gas, immoderate vibration, dust etc. (c) Check the joint connections Since the spring washers are employed in busbar joints, there shall be no problem of joint loosening. Therefore, periodical check is not necessary if recommended torque is applied to the joint clamp assembly during installation. However it is advisable to re-check the tightening after full loading of bustrunking for 24 hou (d) Check the load condition Check and ensure that total load is not exceeding the capacity of bustrunking. Especially, pay attention when the main line is branched by elbows, tees or crosses. (e) Check the insulation resistance (IR) Highly insulating, non-hygroscopic Insulation material are used for busbars, hence IR value should not reduce at later stage. Still it is advisable 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 trunking during installation and take preventive actions.

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 trunking are 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 the isolator switch or setting the breakers in OFF position. The insulation resistance value can not be specified due to the difference of the length of run / route and the environmental condition, but if it is a dried atmosphere, normally it shows a value above 100Mega ohms (500V megger). In case it is below 10Mega ohms it has to be checked as it is most likely that there may exist some factors which are reducing the insulation. Megger value of bustrunking section individually can be carried out by isolating 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 joint insulators Defective section may be put to hot blowing air for drying the moisture and improving megger value. If the insulation value does not improve, contact the C&S.

Inspection & Testing

Summary

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Major Installations
Hotels
n n n n n n n

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

Multi Storey Buildings


n n n n n n n n n n

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

Industries
n n n n n n n n n n n n n n n n n n n n

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 n IFlex - Bangalore Infosys - Banglore/Chandigarh/ Chennai/ Mysore Karbay - Hydrabad n 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
n n n n n n n n n n n n n n n

Software Parks

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Major Installations
Hospitals
n

Appolo Hospital - Ahmedabad Artemis Hospital - Gurgaon n Batra Hospital - New Delhi n Dr. Hedgavers Arogya Sansthan - Delhi n Escorts Heart Institute - New Delhi n G. P. Hospital - Mumbai n Govt. General Hospital - Chennai n Jaideva Institute of Cardiology - Bangalore n Maulana Azad - New Delhi n Safdarjung Hospital - New Delhi n Sir. Ganga Ram Hospital - New Delhi n

Exhibition Halls
n n

ITPO - Chennai ITPO - New Delhi M.P. Export facilitation Centre n

CPWD / PWD
n n

Delhi Secretariat - New Delhi Gene Bank (Pusa) - New Delhi High Court - New Delhi n Parliament House - New Delhi n Parliament Library - New Delhi n Mayur Bhawan - New Delhi n Shastri Bhawan - New Delhi n Yojna Bhawan - New Delhi n

Railways
n n

Northern Railway - Lucknow Rail Bhawan - Delhi

Temple

Swamy Narayan Temple - Mumbai

Telecommunication
n

BSNL - New Delhi / Hyderabad C-DOT - New Delhi n DOT - Mumbai n MTNL - Mumbai n

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Major Export Orders


1. 2. 3. 4. 5. 6. 7. 8. 9. KYCR Coil Industries - Bangladesh Dafna Tower - Doha Doha Tower - Doha 81 flats at AI-Sadd - Doha B+G+5 Flats - Doha B+G+6 Flats - Doha G+11 Building - Doha Westbay 44 Tower - Doha 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
30 2

Mission & Quality policy

Isolated Phase Busducts


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

Segregated Non-Segregated Phase Busduct (415 - 15.0KV, upto 5000 Amps.)

Air Insulated Busbar Trunking System (125 2000 Amps.)

Lighting Trunking (32 - 63A)

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