TABLE OF CONTENTS ABOUT RTC-ELECTRO-M

ABOUT RTC-ELECTRO-M 3
RTC-ELECTRO-M is a manufacturer of electrical equipment. with
TKLN CAST-RESIN BUS DUCTS IP68 over 10 years of experience in engineering, production and installa-
Advantages 4 tion of cast-resin bus bar systems according to international industry
Application 4 standards.
General information 4
TKLN Cast-resin bus duct design 5
Тypes, basic technical parameters and dimensions 7 2006 – Foundation of the company
Designation system 8 Initially the company started operating as an official representative of
Standard elements 9 European electrical equipment manufacturers in the territory of Russia
Dimensions of contact flags in terminal elements 28 and CIS countries.
Special solutions 30
Mounting of TKLN bus ducts 31
Bus duct routing methods 33 2009 – Phase-insulated TPL bus bar production start-up
Connection of bus duct elements 34 In 2009, RTC-ELECTRO-M commissioned a factory to produce epoxy
resin phase-insulated TPL bus bars, primarily for medium voltage ap-
The methods for connecting bus ducts to equipment 35
plications. Main advantages of phase-insulated TPL bus bars are com-
Scope of supply 35
pact design, small bending radii and maintenance free operation..
Site photos 36

TMS TYPE BUS DUCT IN METAL ENCLOSURE
2 Advantages 37
Application 37
General information 37
TMS bus duct design 38
Тypes, basic technical parameters and dimensions 40
Designation system 41
Standard elements 42
Dimensions of contact flags in terminal elements 51
Special solutions 52
Mounting of TMS bus ducts 53
Bus duct routing methods 55
Connection of bus duct elements 55
The methods for connecting bus ducts to equipment 56
Scope of supply 56
Site photos 57
RATED CURRENT DERATING FACTORS 58
VOLTAGE DROP CALCULATION 58
2013 – Non-segregated cast-resin TKL bus bar
production start-up 3
TKL bus bars represent copper or aluminium conductors of rectangu-
lar shape covered with an special insulating compound consisting of
epoxy resin with fine-grained mineral fillers..
2015 – New factory opening
On October 28, a new production factory opened. The factory is
equipped with modern European equipment and allows combining
two unique epoxy resin insulation technologies in one manufacturing
platform..
2016/ 2017 – RTC-ELECTRO-M becoming part
of the Tefelen Group
In 2016 RTC-ELECTRO-M acquired a bus bar producer pbp Preissinger
GmbH in Germany together with Phoenix Mecano AG to form Tefelen
Preissinger GmbH. In 2017, RTC-ELECTRO-M set up a Tefelen LLC in
the USA together with the same partner Phoenix Mecano AG.

QUALITY MANAGEMENT. CERTIFICATION 59 2017 – Manufacturing of TMS bus ducts in metal enclosure
RTC-ELECTRO-M started production of bus ducts in metal enclosure
ANNEX
Project references 60
Questionnaire 61
 TKLN CAST-RESIN BUS DUCTS IP68 TKLN CAST-RESIN BUS DUCT DESIGN
TKLN bus duct consists of elements in various configuration. Bus duct element as per fig. 1 consists of parallel copper
or aluminium rectangular cross-section current-conducting buses enclosed in the special insulating material. The
ADVANTAGES casted insulation material (compound) consists of special resin and particles of fine-grained materials. The compound
possesses perfect dielectric properties, high mechanical strength and has a high fire, ultraviolet and chemical resistance.
ƒƒ High fire safety (2 hours of exposure to direct fire with shock at a temperature of at least 830 °C in accordance with The elements are manufactured in lengths not exceeding 6 m.
IEC 60331-12) At the installation site, connection joints between bus duct elements are casted by compound which provides the
ƒƒ Fire-resistance in building penetrations REI 360 in accordance with ISO 834-75 insulation continuity along the whole length of the route with the IP68 protection degree. Design of bus bar element
ƒƒ Protection degree IP68 in accordance with IEC 60529:2013 connection joints allows compensating the construction tolerances .
ƒƒ High mechanical strength of insulation IK10 in accordance with IEC 62262:2002 (impact energy of 50 J)
ƒƒ Suitable for high humidity areas
ƒƒ High resistance to chemical, ultraviolet and aggressive environments Maintenance-free
ƒƒ Compact dimensions and any turning angles
ƒƒ Minimal probability of short-circuiting
ƒƒ Installation without welding
ƒƒ Designed for operation at seismic loads of division 9 by EMS-98 scale at the elevations of up to 70 m

APPLICATION
4 5
POWER PLANTS
Auxiliary circuits, excitation circuits of synchronous generators, inter-section bridges
Fig. 1. TKLN cast-resin bus duct elements

SUBSTATIONS The bus duct elements as per fig. 2 are connected using a special set of connecting and insulating plates tightened with
LV side power supply, auxiliary circuits screws. After installation of the connection set and tightening the screw, the connection is casted with a similar compound
prepared at the installation site (for more detailed description of the element connection process see page 34 ).

INDUSTRIAL COMPANIES
Oil and gas, metallurgical, pulp and paper companies etc. : for connection to plant LV distribution
panels

CIVIL CONSTRUCTION FACILITIES

High-rise residential and office buildings, hospitals, shopping centres, etc. for distribution systems
comprising a feeder bus duct line, branch lines and tap-offboxes

GENERAL INFORMATION
TKLN cast-resin fire-safe bus ducts for the rated current up to 11,000 A are used for electrical connections in power
plants and substations, residential buildings, malls, petrochemical, oil&gas and industrial applications, and installed in
AC circuits with frequency of 50 and 60 Hz with rated voltage up to 1 kV, and direct current circuits with rated voltage Fig.2. Connection of TKLN cast-resin bus duct elements
up to 1.5 kV and rated current up to 22,800 A.
For connection with different electrical equipment, terminal elements are used. Terminal elements can be custom-made
according to the project requirements. The contact flags of the terminal elements have openings for bolted connection
Alternating current Direct current
of terminal elements with electrical equipment (for more detailed description of terminal elements see page 15-27).
Rated voltage Up to 1 kV Up to 1.5 kV
Rated current Up to 11,000 A Up to 22,800 А
 6
Fig.3. TKLN cast-resin bus duct terminal elements

the route assembly drawing developed for a particular project.

bus duct systems (operational check of bus ducts and its operating conditions).
Fig.4. TKLN cast-resin bus duct expansion element

Fig. 5. Connection of TKLN cast-resin bus duct to equipment

On customer request, bus duct connection joint elements can be tin plated, nickel plated or silver plated.

resin bus ducts are maintenance free. RTC-ELECTRO-M experts regularly visit the sites after installation to inspect the
RTC-ELECTRO-M provides services for installation supervision and installation of bus ducts at the customer’s site. Cast-
enclosures for bus duct connection with transformers and LV switchgears. The list of bus duct elements is defined in
Additional accessories include current and voltage transformers, branching devices for cable connection and protective
precise interval is determined based on the route design for a particular project (for ordering information see page 14).
stallation interval of expansion elements is 30 m for copper bus ducts with and 25 m for aluminium bus ducts. A more
For compensation of the bus duct thermal dilatations, special expansion elements are used (see fig. 4). The average in-

Тypes, basic technical parameters and dimensions of TKLN cast-resin bus ducts* Table 1
Resistance to short-
circuit,kA Resistance per 1 m of phase, μΩ Specific Weight per 1
Current Conductor BxH, Overall dimensions
power losses running meter
Rated Rated Electro Active Reactive conducting cross- mm2 BxH, mm
Designation per 1 m of (max.),kg
voltage, kV current, А dynamic, Thermal bus section per one
(1s) IT phase, W/m Number of conductors
R20 R95 X material phase, mm2
I dyn 5 4 3 5 4 3
TKLN-A-06-X-68 874 95 27 81 106 50 81 360 120х120 105x120 84x120 33 29 24
TKLN-A-08-X-68 1041 95 35 60 79 40 86 480 120х140 105x140 84x140 38 34 28
TKLN-A-10-X-68 1250 248 43 48 64 34 99 600 120х160 105x160 84x160 44 38 32
TKLN-A-15-X-68 1693 271 87 32 42 24 120 900 120х210 105x210 84x210 58 51 42
TKLN-A-20-X-68 2136 279 87 24 32 19 146 Al 1200 120х260 105x260 84x260 72 63 52
TKLN-A-25-X-68 2564 290 87 19 25 16 164 1500 120х310 105x310 84x310 86 75 62
TKLN-A-30-X-68 3000 381 173 17,3 22,8 14 205 1800 120x390 105x390 84x390 108 94 78
TKLN-A-40-X-68 4000 381 173 13,5 17,8 10,7 284 2400 120x490 105x490 84x490 136 119 98
TKLN-A-50-X-68 4700 381 173 11 14,5 8,7 320 3000 120x590 105x590 84x590 164 143 118
1
TKLN-M-06-X-68 1125 95 35 48 64 50 81 360 120х120 105x120 84x120 44 38 30
TKLN-M-08-X-68 1340 95 45 36 48 40 86 480 120х140 105x140 84x140 53 45 37
TKLN-M-10-X-68 1600 248 55 29 38 34 97 600 120х160 105x160 84x160 63 53 43
TKLN-M-15-X-68 2180 271 113 19 29 24 138 900 120х210 105x210 84x210 86 73 59
TKLN-M-20-X-68 2750 279 113 14 23 19 174 Cu 1200 120х260 105x260 84x260 110 93 74
TKLN-M-25-X-68 3300 290 113 12 19 16 207 1500 120х310 105x310 84x310 133 113 90
TKLN-M-30-X-68 4000 381 225 11,1 14 14 224 1800 120x390 105x390 84x390 164 139 112
TKLN-M-40-X-68 5100 381 225 8,6 10,7 10,7 286 2400 120x490 105x490 84x490 211 179 143
TKLN-M-50-X-68 6100 381 225 7 8,7 8,7 346 3000 120x590 105x590 84x590 258 218 174

* Upon the Customer’s requirement, bus ducts with other technical parameters may be manufactured.
7
 DESIGNATION SYSTEM STANDARD ELEMENTS
ST series straight element

А 15 5 1600

8 9
Designation example for ordering a standard 4m straight five-conductor TKLN element with aluminium conductors for
1600 А current - TKLN-A-15-5-68 / ST-S4-1600.
Same for the non-standard length element, e.g. 3500mm, – TKLN-A-15-5-68 / ST-X4-3500-1600.

PT series straight element with plug-in tap-off plug

874 1125 А 15 5 1600

1041 1340
1250 1600
1693 2180
2136
2564

Designation example for ordering a standard 3m straight five-conductor TKLN element with aluminium conductors for
1600 А current with two plug-in tap-off plugs – TKLN-A-15-5-68 / PT-S3-2-1600.
 FT series straight element with stationary tap-off plug LH series vertical L-bow element

А 15 5 1600 А 15 4 1600

Designation example for ordering a standard 3m straight five-conductor TKLN element with aluminium conductors for
1600 А current with two bolt-on tap-off plugs – TKLN-A-15-5-68 / PT-S3-2-1600.
10 Designation example for ordering a standard vertical L-bow four-conductor TKLN element with aluminium conductors for 11
1600 А current – TKLN-A-15-4-68 / LV-S-1600.
Same for the non-standard length L2 vertical L-bow element, e.g. 800mm, – TKLN-A-15-4-68 / LV-X1-800-1600.
LH series horizontal L-bow element

А 15 4 1600 ZH series Z-shaped horizontal element

А 15 4 1600

Designation example for ordering a standard horizontal L-bow four-conductor TKLN element with aluminium
conductors for 1600 А current - TKLN-A-15-4-68 / LH-S-1600.
Same for the non-standard length L2 horizontal L-bow element, e.g. 800mm – TKLN-A-15-4-68 / LH-X2-800-1600. Designation example for ordering a standard Z-shaped horizontal four-conductor TKLN element with the dimensions
L1=305mm, L2=600mm, L3=1095mm with aluminium conductors for 1600 А – TKLN-A-15-4-68 / ZH-S2-600-1600.
 ZV series Z-shaped vertical element TH series T-shaped horizontal element

А 15 4 1600 А 15 4 1600

12 Designation example for ordering a standard Z-shaped vertical four-conductor TKLN element with the dimensions L1=350mm,
L2=600mm, L3=1050mm with aluminium conductors for 1600А current– TKLN-A-15-4-68 / ZV-S2-600-1600.
Designation example for ordering a standard T-shaped horizontal four-conductor TKLN element with the dimensions
L1=305mm, L2=847.5mm, L3=847.5mm with aluminium conductors for 1600А current– TKLN-A-15-4-68 / TH-S2-1600. 13
Same for non-standard elements with the dimensions L1=305mm, L2=1000mm, L3=695mm – TKLN-A-15-4-68 / TH-X2-
1000-1600.

ZHV series combined element

TV series T-shaped vertical element
А 15 4 1600
А 15 4 1600

Designation example for ordering a standard combined four-conductor TKLN element with the dimensions L1=305mm, Designation example for ordering a standard T-shaped vertical four-conductor TKLN element with the dimensions
L2=1000mm, L3=695mm with aluminium conductors for 1600А current– TKLN-A-15-4-68 / ZHV-S2-1000-1600. L1=350mm, L2=825mm, L3=825mm with aluminium conductors for 1600А current– TKLN-A-15-4-68 / TV-S2-1600.
Same for non-standard elements with the dimensions L1=350mm, L2=1000mm, L3=650mm – TKLN-A-15-4-68 / TV-
X2-1000-1600.
 EX series expansion element TES series terminal element

А 15 4 1600 А 1600

Designation example for ordering a standard expansion four-conductor TKLN

element with aluminium conductors for 1600 А – TKLN-A-15-4-68 / EX-S-1600.

TP series transpositional element

Designation example for ordering a standard transpositional four-conductor

TKLN element with aluminium conductors for 1600 А current – TKLN-A-15-4-68
/ TP-S-(L1, L2, L3, L4 – L4, L3, L2, L1)-1600.

14 А 15 4 1600 15

Note: Dimensions B and H are given in table 1, page 7, the dimensions of contact flags are shown on page 28 and 29.
Designation example for ordering the standard terminal four-conductor element TKLN of TES-VPA series with aluminium
conductors and interphase distance of contact flags being X=210mm, Y=210mm for 1600А current – TKLN-A-15-4-68 /
TES-VPA-S-1600.
Same for the non-standard element with the interphase distance of contact flags being X=300mm, Y=250mm – TKLN-A-15-4-68
/ TES-VPA-X-300-250-1600.

TF series reduction element

А 15 4 1600

Code: S - (code of bus duct with lower rated current)

Designation example for ordering a standard reduction four-conductor TKLN
element with aluminium conductors with current reduction from 1600 А to 1000
A – TKLN-A-15-4-68 / TF-S-08-1600-1000.
 TES series terminal element TES series terminal element

А 1600 А 1600

16 17

Note: Dimensions B and H are given in table on page 7, the dimensions of contact flags are shown on page 28.
Designation example for ordering the standard terminal four-conductor element TKLN of TES-HPA series with aluminium
conductors and interphase distance of contact flags being X=165mm, Y=165m for 1600А current – TKLN-A-15-4-68 / TES-
HPA-S-1600.
Same for the non-standard element with the interphase distance of contact flags being X=300mm, Y=250mm – TKLN-A-15-4-68
/ TES-HPA-X-300-250-1600.

Note: Dimensions B and H are given in table on page 7, the dimensions of contact flags are shown on page 29.
Designation example for ordering the standard terminal four-conductor element TKLN of TES-VPE series with aluminium
conductors and interphase distance of contact flags being X=670mm, Y=290mm for 1600А current – TKLN-A-15-4-68 /
TES-VPE-S1-1600.
Same for the non-standard element with the interphase distance of contact flags being X=300mm, Y=250mm – TKLN-A-15-4-68
/ TES-VPE-X-300-250-1600.
 TES series terminal element TEH series terminal element

А 1600

18 19

Note: Dimensions B and H are given in table on page 7, the dimensions of contact flags are shown on page 28.
Designation example for ordering the standard terminal four-conductor element TKLN of TEH-HPA series with aluminium
conductors, the length of 1000 mm and interphase distance of contact flags being X=100 mm for 1600А current –
TKLN-A-15-4-68 / TEH-HPA-S1-1600.
Same for the non-standard element with the interphase distance of contact flags being X=300mm – TKLN-A-15-4-68 / TEH-
HPA-X-300-1600.
Note: Dimensions B and H are given in table on page 7, the dimensions of contact flags are shown on page 28 and 29.
Designation example for ordering the standard terminal four-conductor element TKLN of TES-HPE series with aluminium
conductors and interphase distance of contact flags being X=210mm, Y=210mm for 1600А current – TKLN-A-15-4-68 / TES-
HPE-S-1600.
Same for the non-standard element with the interphase distance of contact flags being X=300mm, Y=250mm – TKLN-A-15-4-68
/ TES-HPE-X-300-250-1600.
 TEH series terminal element TEH series terminal element

20 21

Note: Dimensions B and H are given in table on page 7, the dimensions of contact flags are shown on page 51.

Designation example for ordering the standard terminal four-conductor element TKLN of TEH-HPA series with aluminium
conductors, the length of 600 mm and interphase distance of contact pads being X=100 mm for 1600А current –
TKLN-A-15-4-68 / TEH-HPA-S2-1600.
Note: Dimensions B and H are given in table on page 7, the dimensions of contact flags are shown on page 29. Same for the non-standard element with the interphase distance of contact flags being X=300mm – TKLN-A-15-4-68 / TEH-
Designation example for ordering the standard terminal four-conductor element TKLN of TEH-HPA series with aluminium HPA-X2-300-1600.
conductors, the length of 1000 mm and interphase distance of contact flags being X=105 mm for 1600А current –
TKLN-A-15-4-68 / TEH-HPE-S1-1600.
Same for the non-standard element with the interphase distance of contact flags being X=300mm – TKLN-A-15-4-68 / TEH-
HPE-X-300-1600.
 TEH series terminal element TEH series terminal element

22 23

Note: Dimensions B and H are given in table on page 7, the dimensions of contact flags are shown on page 29.
Note: Dimensions B and H are given in table on page 7, the dimensions of contact flags are shown on page 28.
Designation example for ordering the standard terminal four-conductor element TKLN of TEH-HPPE series with
Designation example for ordering the standard terminal four-conductor element TKLN of TEH-HPPA series with
aluminium conductors, the length of 600 mm and interphase distance of contact flags being X=105 mm for 1600А current –
aluminium conductors, the length of 600 mm and interphase distance of contact flags being X=100 mm for 1600А
TKLN-A-15-4-68 / TEH-HPPE-S-1600.
current – TKLN-A-15-4-68 / TEH-HPPA-S-1600.
Same for the non-standard element with the interphase distance of contact flags being X=300mm – TKLN-A-15-4-68 / TEH-
Same for the non-standard element with the interphase distance of contact flags being X=300mm – TKLN-A-15-4-68 /
HPPE-X-300-1600.
TEH-HPPA-X-300-1600.
 TEH series terminal element
24
Note: Dimensions B and H are given in table on page 7, the dimensions of contact flags are shown on page 29.
Designation example for ordering the standard terminal four-conductor element TKLN of TEH-VPE series with aluminium
conductors, the length of 1000 mm and interphase distance of contact flags being X=120 mm for 1600А current –
TKLN-A-15-4-68 / TEH-VPE-S-1600.
Same for the non-standard element with the interphase distance of contact flags being X=300mm – TKLN-A-15-4-68 / TEH-
VPE-X-300-1600.
TEH series terminal element
25
Note: Dimensions B and H are given in table on page 7, the dimensions of contact flags are shown on page 29.
Designation example for ordering the standard terminal four-conductor element TKLN of TEH-VPA series with aluminium
conductors, the length of 1500mm and interphase distance of contact flags being X=105 mm for 1600А current –
TKLN-A-15-4-68 / TEH-VPA-S1-1600.
Same for the non-standard element with the interphase distance of contact flags being X=300mm – TKLN-A-15-4-68 / TEH-
VPA-X-300-1600.
 TEH series terminal element
26
Note: Dimensions B and H are given in table on page 7, the dimensions of contact flags are shown on page 29.
Designation example for ordering the standard terminal four-conductor element TKLN of TEH-VPPE series with aluminium
conductors, the length of 1500mm and interphase distance of contact flags being X=120 mm for 1600А current –
TKLN-A-15-4-68 / TEH-VPPE-S1-1600.
Same for the non-standard element with the interphase distance of contact flags being X=300mm – TKLN-A-15-4-68 / TEH-
VPPE-X-300-1600.
TEH series terminal element
27
Note: Dimensions B and H are given in table on page 7, the dimensions of contact flags are shown on page 29.
Designation example for ordering the standard terminal four-conductor element TKLN of TEH-VPPA series with aluminium
conductors, the length of 1000 mm and interphase distance of contact flags being X=105 mm for 1600А current –
TKLN-A-15-4-68 / TEH-VPPA-S1-1600.
Same for the non-standard element with the interphase distance of contact flags being X=300mm – TKLN-A-15-4-68 / TEH-
VPPA-X-300-1600.
 DIMENSIONS OF CONTACT FLAGS IN TERMINAL ELEMENTS
Series and code of terminal elements Series and code of terminal elements
TKLN: TEH-HPA-S TKLN: TES-VPA-S1 TEH-VPE-S
TEH-HPA-S1 TES-VPE-S TEH-VPE-S1
TEH-HPPA-S TES-VPE-S1 TEH-VPPE-S
TEH-HPPA-S1 TES-HPE-S1 TEH-VPPE-S1
TES-VPA-S TEH-HPE-S TEH-VPA-S
TES-HPA-S TEH-HPE-S1 TEH-VPA-S1
TES-HPA-S1 TEH-HPPE-S TEH-VPPA-S
TES-HPE-S TEH-HPPE-S1 TEH-VPPA-S1

BUS DUCT CODE BUS DUCT CODE

28 29
 SPECIAL SOLUTIONS MOUNTING OF TKLN BUS DUCTS
Building penetration set
Bus ducts shall be mounted on loadbearing building structures (supports, floor, walls, ceiling) according to engineering
Standard penetration BP-S Fire-safety penetration BP-F drawings using special steel or aluminium elements, seat angles, steel studs of various lengths and metalware supplied in set
(fire resistance REI360 by ISO 834-75) with the bus ducts.

Horizontal mounting
Bus duct support consists of steel elements, studs and metalware. For mounting on building structures, anchor bolts or
special clamps (for attachment to racks) are applied.
Two supports are used for mounting the every bus bar element.

Standard floor mounting of HSS

30 Fig. 6. Partitions 31
Standard opening dimensions B+100mm x H+100mm for a standard penetration and
B+150mm х H+150mm for a fire-safety penetration.

1 – Wall, 2 – Plate (aluminium for BP-S, stainless steel for BP-F), 3 – Anchor bolt,
4 – Firestop foam /Mineral wool, 5 – Fire protective board (Promatect H), 6 – Firestop sealant
Standard attachment to rack

TB series tap-off boxes

A tap-off box is used for power take-off directly from the bus duct to the consumer via the cable. Rated current: 16-1000А.
The device may be equipped with the automatic circuit breaker, disconnector, fuse or other equipment subject to the customer
requirement.
Protection level:
- for a plug-in power tap-off box (TB-P) IP 54
- for a stationary tap-off box (TB-B) up to IP68

Standard suspension (basic option)

 Standard suspension to roofing
BUS DUCT ROUTING METHODS
The minimal gaps provided for between the straight portion of a bus duct and a wall as well as a straight portion of the
bus duct and ceiling are shown on the following drawings.

Standard suspension to rack

Vertical routing
32 33

Horisontal routing

Vertical mounting
Spring supports are intended for mounting of vertical bus duct sections considering the thermal expansion compensation.
The support consists of the spring block and mounting sections for fixing the spring block to the structures at the facility.
Each element of the vertical section of the bus duct shall be mounted using spring supports.

Standard vertical spring suspension

Standard vertical spring stand

Standard vertical fixed suspension

 CONNECTION OF BUS DUCT ELEMENTS (JOINTS) THE METHODS FOR CONNECTING
The elements connected between each other by using connecting plates and by casting the insulating compound into BUS DUCTS TO EQUIPMENT
the special casting moulds in the following sequence:
- the adjacent elements are placed with ensuring the gap between their terminals within 25-35 mm; For connection of the bus ducts to the electrical equipment, terminal elements and flexibles of various designs are used.
- the plates are installed on contact flags of each element with observing the strict symmetry and fixed using the
fasteners ensuring the necessary torque of 75 Nm;
- casting moulds are installed;
- insulating compound is casted
- insulating compound is left for hardening (hardening develops in 4 hours at the air temperature of +25 0С, in 6 hours
at the air temperature of +15 0С and in 10 hours at the air temperature of +5 0С);
BF series Braided Flexible
- after the insulating compound hardening, the casting moulds are removed.

IF series Insulated Flexible

34 35

For protection of contact connections, in equipment connection points, protective enclosures may be used (protection
degree up to IP65).

Straight joint SCJ

SCOPE OF SUPPLY
The bus duct scope of supply includes:
ƒƒ Bus bar elements
ƒƒ A set of connecting plates for connection joints
ƒƒ Moulds for joints casting with the insulating compound
ƒƒ Chemical components for making the insulating compound
ƒƒ Flexibles for connecting the equipment
ƒƒ Bus duct mounting system for fixing to building structures and metalware
ƒƒ Grounding system for supports, plates, protective enclosures etc.

The set of supporting documents includes:

ƒƒ Certificates
Angle joint LCJ
ƒƒ Operation Manual
ƒƒ Installation Manual
ƒƒ Design documents
ƒƒ Packing List
ƒƒ Routine Test reports
ƒƒ Warranty Certificate
 SITE PHOTOS TMS TYPE BUS DUCT IN METAL ENCLOSURE

ADVANTAGES
ƒƒ Compact dimensions and any turning angles
ƒƒ Small weight of elements
ƒƒ High resistance to short-circuit currents
ƒƒ High mechanical strength
ƒƒ Low electrical losses
ƒƒ Effective natural cooling
ƒƒ Not requiring welding during bus duct installation
ƒƒ Designed for operation at seismic loads of division 9 by EMS-98 scale at the elevations of up to 70 m
ƒƒ Operation temperature of -45° to +60°С.

APPLICATION

POWER PLANTS
36 Auxiliary circuits, excitation circuits of synchronous generators, inter-section bridges 37

SUBSTATIONS
LV side power supply, auxiliary circuits

INDUSTRIAL COMPANIES
Oil and gas, metallurgical, pulp and paper companies etc. : for connection to plant LV distribution
panels

CIVIL CONSTRUCTION FACILITIES

High-rise residential and office buildings, hospitals, shopping centres, etc. for distribution systems
comprising a feeder bus duct line, branch lines and tap-offboxes

GENERAL INFORMATION
TMS bus bar trunking systems for rated current up to 11,000 A are used for electrical connections in power plants and
substations, residential buildings, malls and shopping centers, other industrial applications and installed in the three-
phase AC circuits with frequency of 50 and 60 Hz with rated voltage up to 1 kV, and direct current circuits with rated
voltage up to 1.5 kV and rated current up to 22,800 A.

Alternating current Direct current

Rated voltage Up to 1.2 kV Up to 1.5 kV
Rated current Up 11,000 A Up 22,800 А
 TMS BUS DUCT TRUNKING SYSTEM DESIGN
TMS bus duct consists of elements in various designs. Bus duct elements as per fig. 7, consists of parallel copper or
aluminium insulated buses of rectangular section enclosed in the extruded aluminium enclosure featuring the cooling
ribs. The absence of air gaps between buses favours the decrease of inductive resistance and improves heat dissipation
of the system. The bus duct elements are manufactured in length not exceeding 4 m.
All the current conductors of the TMS bus duct are insulated with mylar film. The insulation possesses high chemical
strength, is flame-retardant and has excellent electrical insulating properties and protects the conductor s against
contact with moisture and air. The design of bus bar element joints allows to compensate construction tolerances.

Fig.9. TMS bus duct terminal elements

For compensation of the bus duct thermal dilatations, special expansion elements are applied (see fig. 10). The average
installation interval is 40 m for copper bus ducts with and 35 m for aluminium bus ducts. A more precise interval is
determined based on the route design for a particular project (for ordering information see page 46).

Fig. 7. TMS bus duct trunking system elements

38 39
The elements are connected between each other according to fig.8 using a special set of connection and insulating
plates tightened between each other with bo lts (for the detailed description of the connection process see p. 33 ).

Fig.10. TMS bus duct trunking system expansion element

Additional accessories include current and voltage transformers, branching devices for cable connection and protective
enclosures for the bus duct connection with transformers and LV switchgears. The list of bus duct components is
defined in the route assembly drawing developed for a particular project.
On customer request, bus duct conductors can be tin plated, nickel plated or silver plated.

RTC-ELECTRO-M provides services for installation supervision and installation of bus ducts at the customer’s site. RTC-
ELECTRO-M experts regularly visit the sites after installation to inspect the bus duct systems (operational check of bus
ducts and itsoperating conditions).

Fig.8. Connection of TMS bus duct trunking system elements

For connection to different electrical equipment, terminal elements are used (see fig. 9) Terminal elements can be
produced in different designs depending on the project requirements. The contact flags of the terminal elements
have the openings for bolted connection of the terminal elements with the electrical equipment (for more detailed
description of terminal elements see page 48-50). For connecting of the bus duct elements between each other, no
openings in connection flags are required.
 40
Types, basic technical parameters and dimensions of TMS bus ducts* Table 2

940
1140
1370
1850
2340
2810
3300 226
4290 285
5170 362
1180
1450
1750
2380
3000
3620
4290 224
5610
6710 345

* Upon the Customer’s requirement, bus ducts with other technical parameters may be manufactured.

940
1140

5170
4290
3300
2810
2340
1850
1370
1180

6710
5610
4290
3620
3000
2380
1750
1450
DESIGNATION SYSTEM

41
 STANDARD ELEMENTS

ST series straight element LH series horizontal L-bow element

А 15 4 1600

42 Designation example for ordering a standard 4m straight five-conductor TMS element with aluminium conductors for 1600 Designation example for ordering a standard horizontal L-bow four- conductor TMS element with aluminium conductors for 43
А current - TMS-A-15-5-68 / ST-S4-1600. 1600 А – TMS-A-15-4-68 / LH-S-1600.
Same for the non-standard length element, e.g. 3500mm, – TMS-A-15-5-68 / ST-X4-3500-1600. Same for the non-standard length L2 horizontal L-bow element, e.g. 800mm, – TMS-A-15-4-68 / LH-X2-800-1600.

PT series straight element with plug-in tap-off plug

LV series vertical L-bow element

А 15 5 1600
А 15 4 1600

Designation example for ordering a standard 3m straight five- conductor TMS element with aluminium conductors for 1600 Designation example for ordering a standard vertical L-bow four- conductor TMS element with aluminium conductors for
А with two plug-in tap-off plugs – TMS-A-15-5-68 / PT-S3-2-1600. 1600 А current – TMS-A-15-4-68 / LV-S-1600.
Same for the non-standard length L2 vertical L-bow element, e.g. 800mm, – TMS-A-15-4-68 / LV-X1-800-1600.
 ZH series Z-shaped horizontal element ZHV series combined element

А 15 1600 А 15 1600

Designation example for ordering a standard Z-shaped horizontal four-conductor TMS element with the dimensions
L1=305mm, L2=600mm, L3=1095mm with aluminium conductors for 1600 А – TMS-A-15-4-68 / ZH-S2-600-1600. Designation example for ordering a standard combined four-conductor TMS element with the dimensions L1=305mm,
44 L2=1000mm, L3=695mm with aluminium conductors for 1600А current– TMS-A-15-4-68 / ZHV-S2-1000-1600. 45

ZV series Z-shaped vertical element TH series T-shaped horizontal element

А 15 1600
А 15 1600

Designation example for ordering a standard Z-shaped vertical four- conductor TMS element with the dimensions L1=350mm,
L2=600mm, L3=1050mm with aluminium conductors for 1600А current– TMS-A-15-4-68 / ZV-S2-600-1600.
Designation example for ordering a standard T-shaped horizontal four-conductor TMS element with the dimensions
L1=305mm, L2=847.5mm, L3=847.5mm with aluminium conductors for 1600А current– TMS-A-15-4-68 / TH-S2-1600.
Same for non-standard elements with the dimensions L1=305mm, L2=1000mm, L3=695mm – TMS-A-15-4-68 / TH-X2-
1000-1600.
 TV series T-shaped vertical element TP series transpositional element

А 15 1600 А 15 1600

455 772,5 455 455

505 747,5 505 505
555 722,5 555 555
Designation example for ordering a standard transpositional four-conductor TMS element with aluminium conductors for
1600 А current – TMS-A-15-4-68 / TP-S-(L1, L2, L3, L4 – L4, L3, L2, L1)-1600.
Designation example for ordering a standard T-shaped vertical four-conductor TMS element with the dimensions L1=350mm,
L2=825mm, L3=825mm with aluminium conductors for 1600А current– TMS-A-15-4-68 / TV-S2-1600.
46 47
Same for non-standard elements with the dimensions L1=350mm, L2=1000mm, L3=650mm – TMS-A-15-4-68 / TV-X2-
1000-1600.
TF series reduction element

А 15 1600
EX series expansion element

А 15 1600
Code: S - (code of bus duct with lower rated current)
Designation example for ordering a standard reduction four-conductor TMS
element with aluminium conductors with reduction from 1600 А to 1000 A –
TMS-A-15-4-68 / TF-S-08-1600-1000.

Designation example for ordering a standard expansion four-conductor TMS

element with aluminium conductors for 1600 А – TMS-A-15-4-68 / EX-S-1600.
 TES series terminal element TES series terminal element

А 1600 А 1600

Standart elem
ment
Bus duct code Component code
L1, mm X,Y
3 conductors 4 conductors 5 conductors mm
48 6 VPA-S 1000 1000 1000 120 49
8 VPA-S 1000 1000 1000 140
10 VPA-S 1000 1000 1000 160
15 VPA-S 1000 1000 1000 210
20 VPA-S 1500 1500 1500 260
25 VPA-S 1500 1500 2000 310
30 VPA-S 1500 2000 2000 365
40 VPA-S 2000 2000 2500 465
50 VPA-S 2000 2500 3000 565

Note: Dimensions of contact flags are shown on page 51.

Designation example for ordering the standard terminal four-conductor element TMS of TES-VPE series with aluminium
conductors and interphase distance of contact flags being X=670mm, Y=290mm for 1600А current – TMS-A-15-4-68 /
TES-HPA-S-1600.
Same for the non-standard element with the interphase distance of contact flags being X=300mm, Y=250mm – TMS-A-15-4-68
Note: Dimensions of contact flags are shown on page 51. / TES-HPA-X-300-250-1600.
Designation example for ordering the standard terminal four-conductor element TMS of TES-VPA series with aluminium
conductors and interphase distance of contact flags being X=210mm, Y=210mm for 1600А current – TMS-A-15-4-68 /
TES-VPA-S-1600.
Same for the non-standard element with the interphase distance of contact flags being X=300mm, Y=250mm – TMS-A-15-4-68
/ TES-VPA-X-300-250-1600.
 DIMENSIONS OF CONTACT FLAGS IN TERMINAL ELEMENTS
TEH series terminal element Series and code of terminal elements
TMS: TES-VPA-S TMS: TEH-HPA-S2
TES-HPA-S TEH-HPA-S3
А 15 1600
TES-HPA-S
TES-HPA-S

BUS DUCT CODE

50 51

Note: Dimension H is given in table 2 on page 40, contact flags dimensions are shown on page 51.
Designation example for ordering the standard terminal four-conductor element TMS of TEH-HPA series with aluminium
conductors, the length of 1000 mm and interphase distance of contact flags being X=100 mm for 1600А current –
TMS-A-15-4-68 / TEH-HPA-S1-1600.
Same for the non-standard element with the interphase distance of contact flags being X=300mm – TMS-A-15-4-68 / TEH-
HPA-X-300-1600.
 SPECIAL SOLUTIONS INSTALLATION OF TMS BUS DUCTS
Wall penetration ST series straight element

Standard penetration BP-S Fire-safety penetration BP-F Bus ducts shall be mounted on loadbearing building structures (supports, floor, walls, ceiling) according to a engineering
(fire resistance REI360 by ISO 834-75) drawings using special steel or aluminium elements, seat angles, steel studs of various lengths and metalware supplied in set
with the bus ducts.

Horizontal mounting
Bus duct support consists of steel elements, studs and metalware. For mounting on building structures, anchor bolts or
special clamps (for attachment to racks) are applied.
Two supports are used for mounting the bus bar element.

Standard floor mounting of HSS

52 Fig. 11. Partitions 53

Standard opening dimensions: B+100mm x H+100mm for a standard partition
and B+150mm х H+150mm for a fireproof partition.

1 – Wall, 2 – Plate (aluminium for BP-S, stainless steel for BP-F), 3 – Anchor bolt,
Standard attachment to rack
4 – Firestop foam /Mineral wool, 5 – Fire protective board (Promatect H), 6 – Firestop sealant

TB series tap-off boxes

A tap-off box is used for power take-off directly from the bus duct to the consumer via the cable. Rated current is 16-1000А.
The device may be equipped with the automatic circuit breaker, disconnector, fuse or other equipment subject to the customer
requirement.
Protection level: IP 54

Standard suspension (basic option)

 BUS DUCT ROUTING METHODS
Standard suspension to roofing The minimal gaps provided for between the straight portion of a bus duct and a wall as well as a straight portion of the bus
duct and ceiling are shown on the following drawings.

Standard suspension to rack

CONNECTION OF BUS DUCT ELEMENTS (JOINTS)

54
Vertical mounting
Spring supports are intended for mounting of vertical bus duct sections considering the thermal diletation compensation.
The support consists of the spring box and mounting sections for fixing the spring box to the structures at the facility.
Each element of the vertical section of the bus duct shall be mounted using spring supports.
The elements are connected between each other by using connecting plates and metalware in the following sequence: 55
- the adjacent elements are placed with ensuring the gap between their terminals within 25-35 mm;
- the lower connection cover is mounted
- the plates are installed on contact flags of each element with observing the strict symmetry and fixed using the fasteners
ensuring the necessary torque (the double-headed bolts are tightened until the break off of the second head);
- the upper connection cover is mounted.

Standard vertical spring suspension

Standard vertical spring stand

Standard vertical fixed suspension

Joint code: SSJ

 THE METHODS FOR CONNECTING SITE PHOTOS
BUS DUCTS TO EQUIPMENT
For connection of the bus ducts to the electrical equipment, terminal elements and flexibles of various designs are used.

BF series Braided Flexible

IF series Insulated Flexible

56 57
For protection of contact connections, in equipment connection points, protective enclosures may be used (protection
degree up to IP65).

SCOPE OF SUPPLY
The bus duct scope of supply includes:
ƒƒ Bus bar elements
ƒƒ A set of connecting plates for joints
ƒƒ Flexibles for connecting the equipment
ƒƒ Bus duct mounting system for fixing to building structures and metalware
ƒƒ Grounding system for supports, plates, protective enclosures etc.

The set of supporting documents includes:

ƒƒ Certificates
ƒƒ Operation Manual
ƒƒ Installation Manual
ƒƒ Design documents
ƒƒ Packing List
ƒƒ Routine Test reports
ƒƒ Warranty Certificate
 RATED CURRENT DERATING FACTORS QUALITY MANAGEMENT. CERTIFICATION
High quality of the bus ducts is ensured by careful incoming inspection of components, conductor materials (copper
and aluminium tubes and bars), insulating and other materials, as well as production quality management and and
routine testing of each bus duct component in the electrical HV laboratory.

RTC-ELECTRO-M implemented the Quality Management System in compliance with ISO 9001:2015 standard.

The bus ducts have passed testing in KEMA and DEKRA laboratories and obtained certificates of conformity to
the international standard of IEC 61439-6 (2012).

Calculation example:
Rated current of TKLN-A-20-X-68 bus duct when installed at the sea altitude of 2500 m with the maximum ambient
temperature 30 0С will be IН = Iном (table 1) x K1 x K2 = 2136 x 1.08 x 0.95 = 2191А
58 59

VOLTAGE DROP CALCULATION

 ANNEXES Questionnaire
ANNEX Project references
TKLN bus duct
Facility Location Application Year
Boiler room Russia Boiler room 2013

Kolyma HPP Russia HPP 2014

Nizhne-Bureyskaya HPP Russia HPP 2015

Sayano-Shushenskaya HPP Russia HPP 2015

Zelenchukskaya HPP-PSPP Russia HPP 2015

Kuybyshev Refinery Russia Oil Refinery 2016

Corrugating Plant Russia Factory 2017

SS Fontanka Russia SubStation 2017

Rostov CHP No. 2 Russia CHP 2017

UPG ZRU No. 1 Russia Gas Refinery 2017

Almaza City Center Egypt Mall 2017

Admiralty Shipyards Russia Factory 2017

Mini CHP Russia CHP plant 2018

60 Frequency converter Russia Industrial 2018
61
ZRU-2 Russia Substation 2018

Vympel Russia Industrial 2018

Smolensk Nuclear Power Plant Russia Nuclear Power Plant 2018

Garbage-sorting plant Russia Industrial 2018

Kola Nuclear Power Plant Russia Nuclear Power Plant 2018

Armenian Nuclear Power Plant Armenia Nuclear Power Plant 2018

Power Plant Brazil CHP plant 2018

Cherepovetz Iron and Steel Works Russia Iron and Steel Works 2019

SP Solar Infinity Egypt Substation 2019

TMS bus duct

Facility Location Application Year
Generating station 500 kW Russia Generating station 2018
«Electromashina» Factory Russia Factory 2018
KuybyshevAzot Russia Chemical industry 2018

* Leave empty if you prefer our technical specialist to make a selection

** In the absence of the information, the calculation will be made based on the route configuration: 1 turn per each 5 m of the
bus bar route
*** In the absence of the information, the calculation will be made based on configuration of the route with 2 terminal
components
**** Provide the additional information (e.g. The necessity to introduce the additional equipment)