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FURUTECBusduct System
An Efficient PowerDistribution System withJapanese Technology.
Furutec Electrical Sdn Bhd was incorporated in Penang, Malaysia in 1995 to manufacture under-licensed Furukawa Busduct System. It is officially a wholly-owned subsidiary of the EITA Group of Companies with state-of-the-art CNC and laser cutting manufacturing facilities in 2008.
Having benefitted from more than a decade-long of experience in producing under- licensed Furukawa busduct system, Furutec is noted for its relentless and uncompromising commitment on quality and excellence as the Japanese manufacturing practice and culture have been firmly embedded into Furutec busduct system. Continuing with the tradition of stringent Japanese technology and accumulated 10 years of experience in producing Furukawa busduct system, Furutec busduct system is today a proud Malaysian brand of precision and quality.
The commitment towards quality products and services has enabled us to achieve ISO 9001:2008 Quality Management System.
Furutec Busduct System is tested and certified by ASTA, INTERTEK and TÜV SÜD PSB in accordance to IEC 60439-2, IEC 60439-1, IEC 60529:2001, BS 6387:1994, JIS A1304 and other international standards. In 2009, Furutec busduct system has successfully obtained its full type test certificates from ASTA UK in accordance to IEC60439-1 & IEC60439-2.
Furthermore, with our well-equipped and state-of-the-art R&D laboratory, our products are verified for temperature rise-limit test for current up to 6000A according to the international standards, namely IEC 60439-1, IEC 60439-2 , JIS C8364 and so on. We continue to innovate in order to meet our customers’ expectation and trust towards our products.
Our products are successfully installed in various prestigious projects in Malaysia as well as South East Asia for the past decade. We take pride in further expanding our success to more countries through our regional partners.
ABOUT FURUTEC
FURUTEC HP-Busduct
Phase Isolator
Mylar Polyester Film
Electro-Galvanized (EG)Sheet Steel Housing withEpoxy Powder Coating
Leaf Spring
High Tensile Joint Bolt
Aluminium or Copper Conductor1
2
TRANSFORMER
3
4
5
6
1 Edgewise Elbow with Flange End2 Busduct Straight Feeder3 Combination Elbow4 Flatwise Offset5 Flatwise Elbow with Flange End6 Flexible Link7 Edgewise Offset8 Flange End Box9 End Cap10 Tap Box11 Reducer
12 Vertical Spring Hanger13 Tap Off Unit14 Vertical Hanger15 Flatwise Elbow16 Busduct Joint17 Tee Elbow18 Edgewise Elbow19 End Closure
7
CABLETRAY
8
9
10
1112
13
14
15
17
18
19
16
SWITCHBOARD
FLOOR SLAB
About Furutec IBusduct Design Layout II, IIIContent 01
Specification and Standards 02-05
Testing & Certification Verification of Temperature Rise Limit 06 Verification of Dieletric Properties 06 Verification of Short Circuit Strength 07 Verification of Effectiveness of the Protective Circuit 08 Verification of Clearance and Creepage Distances 08 Verification of Structural Strength 08 Verification of Crushing Resistance 08 Verification of Degree of Protection 09 Verification of the Resistance of Insulating Materials to Abnormal Heat and Fire 09 Verification of the Electrical Characteristics of the Busbar Trunking System 10-11 Fire Resistance Test 12
Physical DataHP-Busduct Copper & Aluminium Conductor Size 13 Flange End / Flange End Box 14-15 Flatwise Elbow / Edgewise Elbow 16 TEE Elbow 17 Flatwise Offset / Edgewise Offset 18 Combination Elbow 19 Elbow with Flange End / Flange End Box 20 End Cap / End Closure 21 Vertical Spring Hanger / Vertical Hanger 22-23 Edgewise / Flatwise Hanger 24 Expansion Unit 25 Reducer 26 Flexible Link 27 Tap-Off Unit 28-29
L-Duct Copper Conductor Size 30 Flange End / Flange End Box 31 Flatwise / Edgewise Elbow 32 End Closure 32 Vertical Spring Hanger / Vertical Hanger 33 Flatwise / Edgewise Hanger 34 Tap-Off Unit 34
Design Factors 35-37
Installation & Maintenance Procedure 38-44
Project Reference 45
CONTENTS | 01
CONTENT
Furutec busduct system is designed to meet the requirement of commercial, industrial and residential applications. It carries up to 6000A with reduced energy losses and heat.
Furutec busduct system is known for:
1) Low current density in its class2) Flexible and modular in design3) Occupying lesser space4) Fast installation and lower installation cost and easy maintenance5) Lower voltage drop and higher short-circuit ratings6) Good electro-magnetic shielding7) Fire resistance and non-flammable propagation8) Flexibility for future expansion9) Strong mechanical strength, high degree of protection and applicable for large span installation
Furutec busduct system is designed and manufactured in accordance to the following international standards:
IEC 60439-2 Particular Requirements for Busbar Trunking System (Busway)IEC 60439-1 Low Voltage Switchgear and Controlgear AssembliesJIS C 8364 Japanese Industrial Standards for BuswaysIEC 60529:2001 Degree of Ingress ProtectionBS 6387:1994 Performance Requirements for Cables required to Maintain Circuitry Integrity under Fire Conditions (Adoption)JIS A 1304 Method of Fire Resistance Test for Structural Parts of BuildingsBS 5486:Part 2NEMA BU1IEC60331 (Adoption)
The maximum operating voltage of Furutec busduct is 660V. The rated current of HP-Busduct is from 600A to 6000A and L-Duct from 200A to 400A for both copper and aluminium busduct system.
General
Design Standards
System Voltage & Rated Current
02 | SPECIFICATION & STANDARDS
SPECIFICATION & STANDARDS
Busduct Housing
The compact sandwich design of HP-busduct can be configured to 3-phase 3-wire (3P3W), 3-phase 4-wire (3P4W) or 3-phase 5-wire (3P5W with integral earth bar).
Due to the existence of non-linear loads in today’s modern buildings, harmonic current is an unavoidable effect thatoverheats the neutral conductor and deteriorate the performance of equipment. Furutec HP-Busduct offers an additional neutral conductor as an option to minimize the harmonic effects.
Copper and aluminium conductors are of the conductivity 99.98% and 61%, respectively. Both conductors meet allelectrical, thermal and mechanical properties and comply to the relevant international standards, such as JIS H3140, ASTM B187M, BS EN 13601, etc.
Each aluminium or copper conductor (except at joint parts) is wholly insulated with multi-layer polyester films. The polyester film meets the requirement of Class B(130oC). Class F and Class H are optional. The rated insulation voltage is up to 1000V at 50Hz or 60Hz of frequency. Each conductor is tin-plated (silver-plated as an option) to provide protection from corrosion and high conductivity at the contact surface.
Furutec busduct system is of the low impedance type and totally enclosed for protection against mechanical damage and dust accumulation. The busduct housing is made of Electro-Galvanized sheet steel with epoxy powder coating.
Conductors are fully enclosed with the busduct housing, which provides an excellent heat dissipation, thus improving the power transmission efficiency and reducing voltage drop. The construction of busduct housing is compact and robust in design to meet the rated short-circuit ratings.
System Configuration and Phase Sequence
Conductor and Insulation Material
3P3W
L1
L2
L3
3P4W
L1
L2
L3
N
3P5W
50%E
L1
L2
L3
N
3P4W 200% N
L1
L2
L3
200%N
3P5W 200% N
50%E
L1
L2
L3
200%N
SPECIFICATIONS & STANDARDS | 03
Joint System
HP-Busduct Joint Installation ( Indoor Type )
HP-Busduct Joint Installation ( Outdoor Type )
JOINT COVER
HIGH TENSILE
LEAF SPRING
LEAF SPRING
JOINT COVER
ELECTRO-GALVANISEDSTEEL SHEET HOUSING M12 BOLT
M12 NUT
M8 BOLT
JOINT COVER
HIGH TENSILE
LEAF SPRING
LEAF SPRING
JOINT COVER
M12 BOLT
M8 BOLT
M12 NUT
M6 NUTS
M6 SCREWS
OUTDOOR COVER
OUTDOOR COVER
ELECTRO-GALVANISEDSTEEL SHEET HOUSING
Furutec busduct joint features a “maintenance-free”double-bolt joint design. This double-bolt joint system ensures a sufficient electrical contact area and good mechanical strength. Its high tensile clamping bolts in duct-to-duct jointing do not penetrate through the conductors. A spring steel material named as leaf spring that is wider than the conductors, is used to ensure a constant pressure on conductor contact area. It is believed that this clamped joints generate less heat at busduct joint as compared to bolted joint system, which necessitate the drilling or punching of holes through the conductors with the bolt holes causingdistortion to the lines of current flow. This clamped joint with leaf springs also has a more even contact pressure than the one using bolt-through joint.
04 | SPECIFICATION & STANDARDS
Method of Mounting
Degree of Protection
Temperature Rise Limit
For horizontal busduct installation, the edgewise/flatwise hanger or flat hanging clamp shall be installed in every 1500mm interval.
Vertical busduct system shall be supported adequately with vertical spring hanger / vertical hanger at each floor. Intermediate supports shall be provided if floor height exceeds 5000mm.
Furutec busduct housing is designed and constructed to meet the requirement of indoor and outdoor installation. The degreeof protection of Furutec busduct housing is verified and tested in accordance to IEC 60529 by ASTA, TÜV SÜD PSB and SIRIM
Refer to page 9 for the definition of IP classification
The temperature rise at any points of the external metal surface of busduct housing will not exceed 55oC above ambienttemperature.
The temperature rise at any points of external insulated conductors will not exceed 70oC above ambient temperature whenoperating at rated load current.
Both parameters are in line with IEC60439-1 and IEC60439-2.
Furutec busduct system is able to operate at full rated current at a maximum ambient air temperature of 40oC without anyderating effects.
Indoor Installation
IP42, IP54
Long Period of Immersion
IP68
Outdoor Installation
IP55, IP65, IP66
SPECIFICATIONS & STANDARDS | 05
Furutec Busduct system has been tested and certified to IEC 60439-1and IEC 60439-2 certified by ASTA and TÜV SÜD PSB.
Verification of Temperature Rise Limit
The following pictures illustrate some temperature rise tests successfully carried out on Furutec busduct system.
Verification of Dielectric Properties
Furutec Busduct System is capable of carrying full rated current continuously in ambient condition of 95% relative humidity and maximum ambient temperature of 40oC. When busduct is installed in a higher ambient temperature, the busduct current ratings shall be derated according to the factors as illustrated in the table below.
It comprises two tests, namely dielectric test voltage and impulse voltage withstand test. They are applied to all live parts and interconnected exposed conductive parts of the busduct system.
For the impulse voltage withstand test, the busduct is tested with a test voltage of 7.4kVpk. The 1.2/50µs impulse voltage applied 3 times at the interval of 1s minimum.
For the dielectric test voltage, it is carried out after the type tests, such as temperature rise test, short circuit strength test, degree of protection test, structural strength test, crushing resistance test, etc in order to ensure that no electricity current leaking occurs.
Ambient Temperature oC
40
45
50
55
60
65
70
Derating Factor
1.00
0.95
0.90
0.85
0.80
0.74
0.67
PSB Singapore
06 | TESTING & CERTIFICATION
TESTING & CERTIFICATION
600A800A
1000A1200A1350A1500A1600A2000A2500A3200A3500A4000A4500A5000A6000A
Short-time Withstand Current(kA/3 Sec)
Short-time Withstand Current(kA/1 Sec)
Busduct Ratings(Ampere)
4050505050505060
100100100150150150150
243030303030303660606090909090
500
Ia250 k/div
HP660V4000A
Make break time: 1.05s
U=310V
Ia=185.2kAIb=190.0kAIc=180.0kAI2t=37.49 GA2s
250-
-250-
-500
kA
500
Ib250 k/div
250-
-250-
-500
kA
500
Ic250 k/div
250-
-250-
-500
kA
0131 ms/div s
0.131 0.262 0.393 0.524 0.655 0.786 0.917 1.048 1.179 1.31
Verification of Short-Circuit Strength
Short-circuit tests have been conducted on Furutec HP-Busduct system. The above left picture illustrates an example of a 4000A HP-Busduct tested with 180kA/sec short-circuit condition.
TESTING & CERTIFICATION | 07
Verification of the Effectiveness of the Protective Circuit
This test is conducted in 2 sessions. The first test is to verify effective connection between the exposed conductive parts of busduct and the protective circuit, where the resistance between the incoming protective conductor and the relevant exposed conductive part must not exceed 0.1 Ω. The second test is to verify the short-circuit strength of the protective circuit, where the single phase test between protective conductor and the nearest phase conductor. The value of the prospective short circuit current used is 60% of the value of the prospective short circuit current of the 3 phases short circuit withstand test of the busduct system.
Verification of Structural Strength
The verification of structural strength has been conducted on a horizontal installation of HP-Busduct. Mechanical loads are applied to both HP-Busduct feeder and joint section for the duration of five minutes.
Verification of Clearance and Creepage Distances
Creepage is the shortest path between two conductive parts (or between a conductive part and the bounding surface of theequipment) measured along the surface of the insulation. A proper and adequate creepage distance protects against tracking, a process that produces a partially conducting path of localized deterioration on the surface of an insulating material as a result of the electric discharges on or close to an insulation surface. Clearance is the shortest distance between two conductive parts (or between a conductive part and the bounding surface of the equipment) measured through air. Clearance distance helps prevent dielectric breakdown between electrodes caused by the ionization of air. The dielectric breakdown level is further influenced by relative humidity, temperature, and degree of pollution in the environment. For this verification test, the minimum distance for the creepage and clearance involves phase to phase & phase to earth of the busduct system.
Verification of Crushing Resistance
A HP-busduct straight feeder, which is supported horizontally on a flat surface, is tested and verified to withstand a crushing force of at least four times its linear mass (kg/m) for the duration of five minutes on minimum four different locations of the busduct.
08 | TESTING & CERTIFICATION
Verification of Degree of Protection
The enclosure of Furutec Busduct System is tested in accordance to IEC60529:2001 Classification of Degree of Protection. Furutec Busduct System is verified to comply with IP6X and IPX6 requirement.
The IP classification is categorized into 2 parts; The first digit denotes protection against ingress of solid objects and the second digit denotes protection against water.
Verification of the Resistance of Insulating Materials to Abnormal Heat and Fire
The glow wire test is used to simulate the effect of heat as it may arise in malfunctioning electrical equipment, such as with overloaded or glowing components. The glow wire test is conducted according to IEC 60695-2-10 and IEC 60695-2-11 on the insulating material taken from the Busduct. A test specimen is held for 30 seconds against the tip of the glow wire. The glow wire heated through electricity resistance with the temperature heated up to 960oC.
Protection against ingress of solid objects Protection against water
Protected against foreign objects greater than 1mm
Protected against foreign objects greater than 1mm
Dust protected
Dust protected
Dust tight
Dust tight
Dust tight
Dust tight
No protection
Drops of water falling at up to 15o from the vertical
Projected water from all directions (limited ingress permitted)
Jets of water(limited ingress permitted)
Jets of water(limited ingress permitted)
Heavy jets of water(limited ingress permitted)
Effects of immersion between 15cm and 1m
Long period of immersion under pressure
4 0
2
4
5
5
6
7
8
4
5
5
6
6
6
6
1mm
15O
1m
1mm
TESTING & CERTIFICATION | 09
Verification of the Electrical Characteristics of the Busbar Trunking System
Due to low impedance, the voltage drop of busduct system is low compared to conventional cable system. Therefore, busduct system is a more efficient power transmission media as compared to conventional cable system. The value of resistance, reactance and impedance of HP-Busduct at both 50Hz and 60Hz 3-Phase AC are illustrated in the tables below:
BusductRatings Resistance
R
600A800A1000A1200A1350A1500A1600A2000A2500A3000A3500A4000A4500A5000A
1.2570.8480.6410.5180.4360.3780.3600.2860.2180.1800.1430.1260.1200.095
ReactanceX
Frequency 50 Hz
0.3230.2350.1850.1520.1290.1130.1070.0840.0650.0540.0420.0380.0360.028
ImpedanceZ
1.2970.8790.6670.5400.4540.3940.3750.2980.2280.1880.1490.1310.1250.099
ResistanceR
1.3850.8510.6450.5230.4430.3860.3670.2930.2210.1840.1460.1290.1220.098
ReactanceX
Frequency 60 Hz
0.3870.2820.2220.1830.1550.1350.1280.1010.0780.0640.0510.0450.0430.034
ImpedanceZ
1.4380.8960.6820.5540.4690.4090.3890.3100.2350.1950.1550.1360.1300.103
Aluminium Conductor
BusductRatings
600A800A1000A1200A1350A1500A1600A2000A2500A3200A3500A4000A4500A5000A6000A
0.9740.7840.5300.4050.3310.3310.2820.2350.1660.1410.1230.1100.0940.0820.078
Frequency 50 Hz
0.3800.3230.2350.1850.1520.1520.1290.1070.0760.0650.0560.0510.0430.0380.036
1.0450.8480.5800.4450.3640.3640.3110.2590.1820.1550.1350.1210.1040.0910.086
0.9770.7890.5360.4120.3380.3380.2890.2410.1690.1440.1270.1130.0960.0840.080
Frequency 60 Hz
0.4560.3870.2820.2220.1830.1830.1550.1280.0910.0780.0680.0610.0520.0450.043
1.0780.8790.6060.4680.3840.3840.3280.2730.1920.1640.1430.1260.1090.0960.091
ResistanceR
ReactanceX
ImpedanceZ
ResistanceR
ReactanceX
ImpedanceZ
Copper Conductor
(Unit = 10 -4 Ω/m)
(Unit = 10 -4 Ω/m)
10 | TESTING & CERTIFICATION
Voltage Drop
Voltage Drop Calculation :
V = 3 . I (RcosØ + XsinØ)
R = R95 x1 + α( 55 x ( )2 + 20 )
1 + 75α
I
I0
V = Line-to-Line Voltage Drop (V/m)
I = Load Current (A)
I0 = Rated Current (A)
cosØ = Load Power Factor
sinØ =
R = AC resistance at load current (Ω/m)
R95 = AC resistance at rated current (Io) (Ω/m)
α = Temperature coefficient of conductor at 20 oC = 3.85 x 10 –3(Copper)/4.00 x 10 –3 (Aluminium)
X = Reactance (Ω/m)
1 - cos2 Ø
Where
BusductRatings
600A
800A
1000A
1200A
1350A
1500A
1600A
2000A
2500A
3000A
3500A
4000A
4500A
5000A
0.131
0.118
0.111
0.108
0.102
0.098
0.100
0.099
0.094
0.094
0.087
0.087
0.094
0.082
0.135
0.122
0.115
0.112
0.106
0.102
0.104
0.103
0.098
0.098
0.090
0.091
0.098
0.086
0.132
0.120
0.114
0.111
0.105
0.101
0.103
0.102
0.097
0.096
0.089
0.090
0.096
0.085
0.129
0.117
0.111
0.108
0.103
0.099
0.100
0.100
0.095
0.094
0.087
0.088
0.094
0.083
0.125
0.114
0.108
0.105
0.100
0.096
0.098
0.097
0.092
0.092
0.085
0.086
0.092
0.080
0.120
0.110
0.104
0.102
0.096
0.093
0.094
0.094
0.089
0.089
0.082
0.083
0.089
0.078
0.144
0.118
0.112
0.109
0.104
0.100
0.102
0.101
0.096
0.096
0.089
0.089
0.095
0.085
0.149
0.124
0.118
0.115
0.110
0.106
0.103
0.107
0.101
0.101
0.094
0.095
0.101
0.090
0.147
0.123
0.117
0.114
0.109
0.106
0.107
0.107
0.101
0.101
0.093
0.094
0.100
0.089
0.144
0.121
0.115
0.112
0.107
0.104
0.105
0.105
0.099
0.099
0.092
0.092
0.098
0.088
0.139
0.118
0.112
0.110
0.105
0.101
0.103
0.102
0.097
0.096
0.089
0.090
0.096
0.086
0.135
0.114
0.109
0.107
0.102
0.098
0.100
0.099
0.094
0.094
0.087
0.088
0.093
0.083
1.00 0.95 0.90 0.85 0.80 0.75 1.00 0.95 0.90 0.85 0.80 0.75
Power Factor cos φ at 50Hz Power Factor cos φ at 60Hz
Line-to-Line Voltage Drop for 3-phase Aluminium Busduct
( Unit = Volt/m )
BusductRatings
600A
800A
1000A
1200A
1350A
1500A
1600A
2000A
2500A
3200A
3500A
4000A
4500A
5000A
6000A
0.101
0.109
0.092
0.084
0.077
0.086
0.078
0.081
0.072
0.073
0.075
0.076
0.073
0.071
0.081
0.109
0.117
0.100
0.092
0.085
0.094
0.085
0.089
0.079
0.080
0.081
0.083
0.080
0.078
0.089
0.108
0.117
0.100
0.093
0.085
0.095
0.086
0.089
0.079
0.081
0.082
0.084
0.081
0.078
0.089
0.107
0.116
0.099
0.092
0.085
0.094
0.085
0.089
0.078
0.080
0.081
0.083
0.080
0.078
0.089
0.105
0.114
0.098
0.090
0.083
0.093
0.084
0.087
0.077
0.079
0.080
0.082
0.079
0.077
0.087
0.102
0.111
0.096
0.089
0.082
0.091
0.082
0.086
0.076
0.077
0.078
0.081
0.077
0.075
0.086
0.102
0.109
0.093
0.086
0.079
0.088
0.080
0.083
0.073
0.075
0.077
0.078
0.075
0.073
0.083
0.111
0.121
0.103
0.096
0.088
0.098
0.090
0.093
0.082
0.084
0.086
0.088
0.084
0.081
0.093
0.112
0.122
0.105
0.097
0.090
0.100
0.091
0.094
0.083
0.085
0.087
0.089
0.085
0.082
0.094
0.111
0.121
0.105
0.097
0.090
0.100
0.091
0.094
0.083
0.085
0.087
0.089
0.085
0.082
0.094
0.110
0.120
0.104
0.096
0.089
0.099
0.090
0.093
0.082
0.084
0.086
0.088
0.084
0.052
0.093
0.107
0.117
0.102
0.095
0.088
0.097
0.088
0.092
0.081
0.083
0.085
0.087
0.083
0.080
0.092
1.00 0.95 0.90 0.85 0.80 0.75 1.00 0.95 0.90 0.85 0.80 0.75
Power Factor cos φ at 50Hz Power Factor cos φ at 60Hz
Line-to-Line Voltage Drop for 3-phase Copper Busduct
( Unit = Volt/m )
TESTING & CERTIFICATION | 11
Fire Resistance Test
Conductor
Mica Tape
Polyester Film
Resistance to Fire AloneIEC 60331 : 3 hours at 750°CBS 6387 Category ‘C’ : 3 hours at 950°CJIS A 1304 : 30 mins at 840°C
Resistance to Fire with WaterBS 6387 Category ‘W’ : 15 mins at 650°C (with water spray 15 mins)
JIS A1304Fire resistance test has been conducted on Furutec busduct system with jointsection in an independant testing authority.Flame Temperature : 840°CTest Voltage : 660 VTest Duration : 30 minsTest Furnace : Large scale fire resistant furnace, where the busduct is heated up to 840°C from all directions.
BS 6387:1994 Category ‘C’
Resistance to fire alone test has been conducted on Furutec busduct feederand joint section in an independant testing authority.
Flame Temperature : 950 °C Test Voltage : 660VTest Duration : 3 hours
Furutec Fire Rated Busduct is designed for essential electrical services. It is tested to JIS A 1304, BS 6387 (Adoption)and IEC 60331 (Adoption)
Mylar Polyester Film
Fire-Rated Mica Tape
Conductor
12 | TESTING & CERTIFICATION
Copper & Aluminium Conductor Size
HP-BUSDUCT
BusductRatings
(Ampere)
ConductorPer Phase (mm)
Model No. A (mm)
3P3W3P4W
3P4W+E3P5W
3P3W 3P4W3P4W+E3P5W
3P3W
B (mm) Figure Total Weight (kg/m)
600A800A
1000A1200A1350A1500A1600A2000A2500A3200A3500A4000A4500A5000A6000A
HP600CHP800C
HP1000CHP1200CHP1350CHP1500CHP1600CHP2000CHP2500CHP3200CHP3500CHP4000CHP4500CHP5000CHP6000C
115125150175200200225260400450500600675750780
14.016.020.925.830.830.835.742.661.571.481.292.3
107.0121.8127.7
3P4W
16.218.725.031.337.637.643.952.775.387.9
100.4112.9131.8150.7158.2
3P5W3P4W+E
17.320.127.134.141.141.148.157.882.196.1
110.1123.2144.2165.1173.5
One - 6 x 40One - 6 x 50One - 6 x 75
One - 6 x 100One - 6 x 125One - 6 x 125One - 6 x 150One - 6 x 185Two - 6 x 125Two - 6 x 150Two - 6 x 175
Three - 6 x 125Three - 6 x 150Three - 6 x 175Three - 6 x 185
100 120
1
2
3
BusductRatings
(Ampere)
ConductorPer Phase (mm)
Model No. A (mm)
3P3W3P4W
3P4W+E3P5W
3P3W 3P4W3P4W+E3P5W
3P3W
B (mm) Figure Total Weight (kg/m)
600A800A
1000A1200A1350A1500A1600A2000A2500A3000A3500A4000A4500A5000A
HP600AHP800A
HP1000AHP1200AHP1350AHP1500AHP1600AHP2000AHP2500AHP3000AHP3500AHP4000AHP4500AHP5000A
125150175200225250260315450520630750780945
10.212.314.316.418.420.421.325.836.842.551.561.363.877.3
3P4W
11.113.516.018.420.923.324.329.741.848.759.570.073.089.2
3P5W3P4W+E
11.514.116.819.522.124.825.931.744.351.763.574.477.695.2
One - 6 x 50One - 6 x 75
One - 6 x 100One - 6 x 125One - 6 x 150One - 6 x 175One - 6 x 185One - 6 x 240Two - 6 x 150Two - 6 x 185Two - 6 x 240
Three - 6 x 175Three - 6 x 185Three - 6 x 240
100 120
1
2
3
Aluminium Conductor :
BB
B
A
A
A
3000mm
( Standard Straight Length )
3000mm
( Standard Straight Length )
MALE FEMALE
Copper Conductor :
Figure 1
Figure 2
Figure 3
600A - 2000A
2500A - 3500A
4000A - 6000A
PHYSICAL DATA | 13
PHYSICAL DATA
Flange End / Flange End Box
2500A~3500A Flange End
150
A-6
0
C
A
(A-3
0)/2
(A-3
0)/2
B-60
B
EE
C
F
8-Ø10 HOLES
OPE
NIN
G
OPENING
130130130
6
600A~2000A Flange End
C
150
BE
B-60
A
A-3
0
A-6
0
4-Ø10 HOLES
OPENING
OPE
NIN
G
100100100
6
600A~2000A Flange End Box
B
450 C
150
B
A
4-M8 BOLTS
REMOVABLE FRONTMETAL COVER
NON-FERROUS MATERIAL BOTTOMCOVER FOR CABLE TERMINATION
NON-FERROUS MATERIAL BOTTOM COVER FOR CABLE TERMINATION
6
100100100
450
A
2500A~3500A Flange End Box
CC
F
450
B
150
B
A
4-M8 BOLTS
130130130
6
450
A
REMOVABLE FRONTMETAL COVER
TOP
VIEW
TOP
VIEW
TOP
VIEW
TOP
VIEW
SID
E VI
EW
SID
E VI
EW
SID
E VI
EW
SID
E VI
EW
FRO
NT
VIEW
FRO
NT
VIEW
FRO
NT
VIEW
FRO
NT
VIEW
14 | PHYSICAL DATA
22
4020
DDD
22
4020
DD
4020
D
2222
12
4020
22
4020
DDD D
Fig. 4Fig. 3Fig. 2Fig. 1 Fig. 5
NON-FERROUS MATERIAL BOTTOM COVER FOR CABLE TERMINATION
REMOVABLE FRONTMETAL COVER
Busduct Ratings (Ampere) Dimensions (mm)
Aluminium
Figure A
B3P3W
3P4W3P4W+E3P5W
Copper
-
600
800
1000
1200
1350
1500
1600
2000
-
2500
-
3000
3500
-
-
4000
4500
5000
175
185
210
235
260
285
310
320
375
460
510
560
580
690
660
735
810
840
1005
1
1
2
2
3
3
4
4
5
3
3
4
4
5
3
3
4
4
5
350 450
410 540
600
800
1000
1200
1350,1500
1600
-
2000
-
2500
3200
3500
-
-
4000
4500
5000
6000
-
C
40
50
75
100
125
150
175
185
240
125
150
175
185
240
125
150
175
185
240
D
-
-
40
50
40
50
40
45
45
40
50
40
45
45
40
50
40
45
45
E
145
155
180
205
230
255
280
290
345
215
240
265
275
330
210
235
260
270
325
F
-
200
225
250
260
315
200
225
250
260
315
4000A~5000A Flange End
150
A-6
0
OPENING B-60
C C
10-Ø10 HOLES
OPE
NIN
G A
(A-3
0)/2
(A-3
0)/2
B
EEE
C
FF
130130130
6
4000A~5000A Flange End Box
C CC
F F
4-M8 BOLTS
450
B
150
A
B
450
A
130130130
6
TOP
VIEW
SID
E VI
EW
FRO
NT
VIEW
TOP
VIEW
SID
E VI
EW
FRO
NT
VIEW
PHYSICAL DATA | 15
Flatwise Elbow / Edgewise Elbow
Busduct Ratings (Ampere) Standard LengthsL1 x L2 (mm)
Minimum LengthsL1 x L2 (mm)
Aluminium Copper
600 to 6000 400 x 400 270 x 270
Note : Maximum length of edgewise elbow (L1 + L2) is 2500mm
Busduct Ratings (Ampere) Standard LengthsL1 x L2 (mm)
Minimum LengthsL1 x L2 (mm)
Aluminium Copper
-600800100012001350150016002000
-2500
-3000
-3500
-400045005000
60080010001200
1350,15001600
-2000
-250032003500
-4000
-450050006000
-
300 x 300305 x 305315 x 315330 x 330340 x 340355 x 355365 x 365370 x 370400 x 400440 x 440465 x 465490 x 490500 x 500540 x 540555 x 555580 x 580615 x 615630 x 630715 x 715
400 x 400
600 x 600
750 x 750
Note : Maximum length of flatwise elbow (L1 + L2) is 2500mm
L2
L1
L1
L2
Edgewise Elbow
Flatwise Elbow
16 | PHYSICAL DATA
TEE Elbow
Busduct Ratings (Ampere) Standard LengthsL1 x L2 x L3 (mm)
Minimum LengthsL1 x L2 x L3(mm)
Aluminium Copper
-600800
100012001350150016002000
-2500
-3000
-3500
-400045005000
600800
10001200
1350,15001600
-2000
-250032003500
-4000
-450050006000
-
235 x 235 x 235240 x 240 x 240250 x 250 x 250265 x 265 x 265275 x 275 x 275290 x 290 x 290300 x 300 x 300305 x 305 x 305335 x 335 x 335375 x 375 x 375400 x 400 x 400425 x 425 x 425435 x 435 x 435475 x 475 x 475490 x 490 x 490515 x 515 x 515550 x 550 x 550565 x 565 x 565650 x 650 x 650
400 x 400 x 400
600 x 600 x 600
750 x 750 x 750
Note : Maximum length of TEE elbow ( L1 + L2 + L3 ) is 2500mm
L1
L2
L3
PHYSICAL DATA | 17
Busduct Ratings (Ampere) Flatwise Offset Edgewise Offset
Standard LengthsL1 x L2 x L3 (mm)
Minimum LengthsL1 x L2 x L3 (mm)
Minimum LengthsL1 x L2 x L3(mm)
Standard LengthsL1 x L2 x L3 (mm)
Aluminium Copper
-600800100012001350150016002000
-2500
-3000
-3500
-400045005000
600800
10001200
1350,15001600
-2000
-250032003500
-4000
-450050006000
-
300 x 260 x 300305 x 270 x 305315 x 295 x 315330 x 320 x 330340 x 345 x 340355 x 370 x 355365 x 395 x 365370 x 405 x 370400 x 460 x 400440 x 345 x 440465 x 370 x 465490 x 395 x 490500 x 405 x 500540 x 345 x 540555 x 460 x 555580 x 370 x 580615 x 395 x 615630 x 405 x 630715 x 460 x 715
400 x 400 x 400 270 x 200 x 270
600 x 600 x 600
400 x 500 x 400
750 x 750 x 750
Note : Maximum length of offset elbow ( L1 + L2 + L3 ) is 2500mm
Flatwise Offset / Edgewise Offset
Flatwise Offset Edgewise Offset
L2
L1
L3
L2
L1
L3
18 | PHYSICAL DATA
Combination Elbow
Busduct Ratings (Ampere) Standard LengthsL1 x L2 x L3 (mm)
Minimum LengthsL1 x L2 x L3(mm)
Aluminium Copper
-600800
100012001350150016002000
-2500
-3000
-3500
-400045005000
600800
10001200
1350,15001600
-2000
-250032003500
-4000
-450050006000
-
300 x 235 x 270305 x 240 x 270315 x 250 x 270330 x 265 x 270340 x 275 x 270355 x 290 x 270365 x 300 x 270370 x 305 x 270400 x 335 x 270440 x 375 x 270465 x 400 x 270490 x 425 x 270500 x 435 x 270540 x 475 x 270555 x 490 x 270580 x 515 x 270615 x 550 x 270630 x 565 x 270715 x 650 x 270
400 x 400 x 400
600 x 600 x 600
750 x 750 x 750
Note : Maximum length of combination elbow ( L1 + L2 + L3 ) is 2500mm
L2
L1
L3
L2
L1
L3
PHYSICAL DATA | 19
Elbow with Flange End / Flange End Box
Busduct Ratings (Ampere)
Aluminium Copper
Standard Lengths (mm)
L1 L2 L3 L4 L1 L2 L3 L4
Minimum Lengths (mm)
600
800
1000
1200
1350, 1500
1600
-
2000
-
2500
3200
3500
-
4000
-
4500
5000
6000
-
-
600
800
1000
1200
1350
1500
1600
2000
-
2500
-
3000
-
3500
-
4000
4500
5000
300
305
315
330
340
355
365
370
400
440
465
490
500
540
555
580
615
630
715
185
190
200
215
225
240
250
255
285
325
350
375
385
425
440
465
500
515
600
400 400 275 275
400 400
600
600
750
L2
L1
450
AB
L4
L3
BA
450
Flatwise Elbow with Flange End boxEdgewise Elbow with Flange End box
Refer to page 14 and 15 for dimensions of A and B
20 | PHYSICAL DATA
End Cap / End Closure
End Closure End Cap
B A
35
165mm B
A
Busduct Ratings(Ampere)
A (mm) B (mm)Busduct Ratings(Ampere)
A (mm) B (mm)
600
800
1000
1200
1350
1500
1600
2000
2500
3200
3500
4000
4500
5000
6000
115
125
150
175
200
200
225
260
400
450
500
600
675
750
780
100 120
Copper Busduct
3P3W3P4W
3P4W+E3P5W
3P4W3P4W+E3P5W
3P3W3P4W
3P4W+E3P5W
3P3W
3P3W3P4W
3P4W+E3P5W
600
800
1000
1200
1350
1500
1600
2000
2500
3000
3500
4000
4500
5000
125
150
175
200
225
250
260
315
450
520
630
750
780
945
100 120
Aluminium Busduct
PHYSICAL DATA | 21
Vertical Spring Hanger / Vertical Hanger
For 600A to 1000A HP-Busduct For 1200A to 2000A HP-Busduct
For 2500A HP-Busduct
For 4000A to 6000A HP-Busduct
Vertical HangerVertical Hanger
Vertical hanger Vertical Spring Hanger
Vertical hanger Vertical Spring Hanger
Vertical Spring HangerVertical Hanger
For 3000A to 3500A HP-Busduct
60M10x30 BOLT
M12 STUDBOLT
50155
7550
Vertical Spring Hanger
170
75
275
50
M10x30 BOLT
SPRINGM12 STUDBOLT
60
5075
155 50
M12 STUDBOLT
M10x30 BOLT60
Vertical Spring Hanger
60
M12 STUDBOLT
SPRING
M10x30 BOLT
50
275
7517
0
170
75
275
50
M10x30 BOLT
SPRINGM12 STUDBOLT
60
60
5075
155 50
M12 STUDBOLT
M10x30 BOLT
60
M12 STUDBOLT
SPRING
50
275
7517
0
M10x30 BOLT
5075
155 50
M12 STUDBOLT
60
M10x30 BOLT
605050
7515
5
M10x30 BOLT
M12 STUDBOLT
60
7550
170
275
SPRINGM12 STUDBOLT
M10x30 BOLT
22 | PHYSICAL DATA
600A - 1000A
A
A +
60 A +
60
A +
60
A +
60
A +
60
120
246
180
1200A - 2000A
A
2500A 3000A - 3500A 4000A - 6000A
A
180
246
Vertical Spring Hanger
A
STUD BOLT M12
BOLT M10x30
75 75
275 26
0
5017
0
A + 60
60
180
246
60
7517
050
275 26
0
120
(BY CONTRACTORS)BASE CHANNEL
Vertical Hanger
75
BOLT M10x30
STUD BOLT M12
A
140
155 50
50
180
60
A + 60
246
60
7550
50
120
BOLT HOLES
BOLT HOLES
140
155
BASE CHANNEL(BY CONTRACTORS)
275 26
0
5017
0
60
180
246
246
180
60
140
155
7550
50
A
180
246
A
180
246
BOLT HOLES
BOLT HOLES
FIRE BARRIER( BY CONTRACTORS )
FIRE BARRIER( BY CONTRACTORS )
FIRE BARRIER( BY CONTRACTORS )
FIRE BARRIER( BY CONTRACTORS )
Refer to page 13 for the dimensions of A
PHYSICAL DATA | 23
Edgewise / Flatwise Hanger
Fig 1
Fig 2
Fig 3
Edgewise Hanger
Flatwise Hanger
EDGEWISE HANGER
Ø14 HOLESC
A
B
Ø14 HOLES
EDGEWISE HANGER
C
B
A
(BY CONTRACTORS)
ANGLE METAL BAR& HANGER ROD
(BY CONTRACTORS)
ANGLE METAL BAR& HANGER ROD
(BY CONTRACTORS)
ANGLE METAL BAR& HANGER ROD
Ø14 HOLES
EDGEWISE HANGER
2-M10 x 30 BOLT
2-M10 BOLT
2-M10 BOLT
C
B
A
BusductRatings
(Ampere) Fig3P3W
3P4W3P4W+E3P5W
3P3W3P4W
3P4W+E3P5W
3P3W3P4W
3P4W+E3P5W
A B
Dimensions (mm)
C
600800
10001200135015001600200025003000320035004000450050006000
140
112
1
2
3
160
132
220
240
220
280
300
280
Busduct Rating (Ampere) Dimensions (mm)
Aluminium Copper A B C
-600800100012001350150016002000
-2500
-3000
-3500
-400045005000
60080010001200
1350, 15001600
-2000
-250032003500
-4000
-450050006000
-
165175200225250275300310365450500550570650680725800830995
38487398123148173183238323373423443523553598673703868
225235260285310335360370425510560610630710740785860890
1055
2-M10x30 BOLT (BY CONTRACTORS)
C
A
B
ANGLE METAL BAR& HANGER ROD
Ø14 HOLES
24 | PHYSICAL DATA
Expansion Unit
Busduct Ratings (Ampere) A(mm)
Aluminium Copper
-600800
100012001350150016002000
-2500
-30003500
--
400045005000
60080010001200
1350,15001600
-2000
-250032003500
--
4000450050006000
-
115125150175200225250260315400450500520630600675750780945
500
A
450
The busduct system expands and contracts when the current loading varies and the ambient temperature changes.The expansion unit is the transition section compensating the thermal expansion and contraction.
PHYSICAL DATA | 25
Reducer is used to reduce busbar sizes to the final load. It provides users with more economic power transmission anddistribution method. The minimum length (L) is 600mm and the reduction from one busbar size to another does not exceed 50%
Reducer
L
L
L
L
L
L
26 | PHYSICAL DATA
Flexible Link
Busduct Ratings Fig
Dimension
T (mm)Type
600A
800A
1000A
1200A
1350A
1500A
1600A
1 F5013 x 1
F10013 x 1
F12014 x 1
2
3
13
13
14
Busduct Ratings Fig
Dimension
T (mm)Type
2000A2500A3000A3200A3500A4000A4500A5000A6000A
F15014 x 1
F15014 x 2
F12014 x 3
F15014 x 3
F15016 x 3
14.5
14.5
4
4
4
4
3
3 14
14
14.5
16
F12014 x 2
Dimension of Flexible Link according to busduct ratings
"T"
320
120
4040
8-Ø12 H OLES
2020
150
25
40 40 40
25
40 40 40
150
12-Ø12 HOLES
150
2020
4040
2525
3535 40 40
3535 40 40
150
8-Ø12 HOLES
4030
2020
4040
2525
30
100
4030 30
50
4-Ø12 HOLES
4040
2020
150
25
25 25
25
2525
FIG. 2 FIG. 3 FIG. 4FIG. 1
PHYSICAL DATA | 27
FLEXIBLE LINK
TRANSFORMER LV BOX(NOT THE SCOPE OF BUSDUCT MANUFACTURERS)
FLANGE END
BUSDUCT SYSTEM
Tap-Off Units
MCCB Rating L
100AF225AF400AF
340430550
W
230265310
H
200220250
Fig
112
Plug in box is mechanically interlocked with the busduct housing to prevent installation or removal while the MCCB is in ‘ON’ position. It is equipped with an operating handle to control the switching mechanism. The plug in box makes positive ground connection to the busduct housing before making contact to the phase conductors.
PLUG IN BOXMCCB
PLUG IN HOLE COVER
PLUG IN HOLE
L
W
H
100AF, 225AF & 400AF Tap-Off Unit & Plug In Hole (Plug In Type)
100AF & 225AF Plug In Box 400AF Plug In Box
Fig 2Fig 1
Open
Open
E L1 L2 L3 N E L1 L2 L3 N
L
160
HW W H70 70
160
L
Phase IsolatorTo segregate the tapping position of each phase of the conductors
E
REMOVABLE BOTTOM COVERFOR CABLE TERMINATION REMOVABLE BOTTOM COVER
FOR CABLE TERMINATION
E
E E
Refer to the installation procedures of tap-off units on page 41
NL3
L2L1 E
28 | PHYSICAL DATA
MCCB Rating W L H
600AF800AF
1000AF1200AF
908998
11081108
373373488488
200200290290
600AF, 800AF, 1000AF & 1200AF Tap Box and Tap Bar (Bolt On Type)
TAP BOX
TAP BAR
H
L
W4-M6 Screw
REMOVABLE BOTTOM COVERFOR CABLE TERMINATION
PHYSICAL DATA | 29
Copper & Aluminium Conductor Sizes
L-Duct
Busduct Ratings(Ampere)
Conductor per Phase(mm)A (mm) Weight (kg/m)
200A
300A
400A
56
71
96
3 x 20
3 x 35
3 x 60
7.5
9.5
12.5
Copper Conductor :
A
167
L1 L2 L3 N E
Conductors Phase Isolator
The air-insulated type of L-Duct can be configured as 3-phase 3-wire (3P3W), 3-phase 4-wire (3P4W with external earth bar) and 3-phase 5-wire (3P5W with integral earth bar).
Electro-Galvanized Sheet Steel Housing with Epoxy Powder Coating
30 | PHYSICAL DATA
L3L2
NE
L1
Flange End / Flange End Box
Busduct Rating(Ampere) Fig
A(mm)
200A300A400A
360360450
B(mm)
150165190
C(mm)
120120160
D(mm)
7070
100
E(mm)
203560
F(mm)
350350400
G(mm)
350350500
H(mm)
120135160
112
Copper Busduct System :
Flange End
Flange End Box20
Ø11 HOLE
4020
2-Ø11 HOLE
Figure 1 Figure 2
D
D
GF
H
NON-FERROUS MATERIAL BOTTOMCOVER FOR CABLE TERMINATION
REMOVABLE METALFRONT COVER
D
A
A-30
C
E D
L1 L2 L3 N
DD
A-60OPENING
4-Ø10 HOLES
OPE
NIN
G
B
B-30
B-60
L3L2
NE
L1
PHYSICAL DATA | 31
Flatwise / Edgewise Elbow
End Closure
Copper Busduct System
Busduct Ratings(Ampere)
A(mm)
200A300A400A
597499
155
A
170
Edgewise Elbow
L2L1
NL3
E
Flatwise Elbow
L3N
E
L1L2
32 | PHYSICAL DATA
Vertical Spring Hanger / Vertical Hanger
Copper Busduct System
Busduct Ratings(Ampere)
A(mm)
200A300A400A
567196
Vertical Hanger
Vertical Spring Hanger
BASE CHANNELFLAT HANGING CLAMP
STUD BOLT
(BY CONTRACTORS)
(M12x220)
FRONT VIEW
(BY CONTRACTORS)BASE CHANNEL
(M12x330)STUD BOLT
FLAT HANGING CLAMP
SPRING
FRONT VIEW
BOLT M10x30
STUD BOLT M12
A
C/W CLAMP
167
250
250
754020
140
145 50
50
30
BASE CHANNEL
FIRE BARRIER(BY CONTRACTORS)
FIRE BARRIER(BY CONTRACTORS)
(BY CONTRACTORS)
167
A
20 4017
075
265 26
0
250
167
C/W CLAMP
A
STUD BOLT M12
BOLT M10x30
30
(BY CONTRACTORS)BASE CHANNEL
A
167
50
250
PHYSICAL DATA | 33
Flatwise / Edgewise Hanger
Tap-Off Units
Busduct Ratings(Ampere) A (mm) B (mm) C (mm)
200300400
208223248
128143168
268283308
MCCB Rating W (mm) L (mm) H (mm)
100AF225AF
400500
195230
118118
Plug in box is mechanically interlocked with the busduct housing to prevent installation or removal while the MCCB is in ‘ON’ position. It is equipped with an operating handle to control the switching mechanism. The plug in box makes positive ground connection to the busduct housing before making contact to the phase conductors.
L1L2
N L3
E
L
W
H
HOLDER
172
C
B
A
Edgewise Hanger
208
288
348
(BY CONTRACTORS)
ANGLE METAL BAR& HANGER ROD
(BY CONTRACTORS)
ANGLE METAL BAR& HANGER ROD
FLATHANGINGCLAMP
167
Flatwise Hanger
L1 L2 L3 N
63W
E
L
H
70
Open
REMOVABLE BOTTOM COVERFOR CABLE TERMINATION
E
Refer to the installation procedures of tap-off units on page 41
34 | PHYSICAL DATA
1. Minimum Distance Between Parallel-Installed Busduct System.
1.1 Indoor Type (Edgewise Installation).
Busduct joints installed side by side. Busduct joints installed deviating from each other (Dimension “C” is above 190mm).
A A
JOINT POINT
B
190
JOINT POINT
(C)
B
Busduct Ratings(Ampere)
3P3W
Dimension “A” (mm)
150600 - 6000A
3P4W/3P5W
160
3P3W
85
3P4W/3P5W
95
Dimension “B” (mm)
1.2 Outdoor Type (Edgewise Installation).
Busduct joints installed side by side. Busduct joints installed deviating from each other (Dimension “C” is above 500mm).
Busduct Ratings(Ampere) 3P3W
Dimension “A” (mm)
170600-6000A
3P4W/3P5W
190
3P3W
130
3P4W/3P5W
150
Dimension “B” (mm)
A A
JOINT POINT
110
BB
500
JOINT POINT
(C)
110
60
JOINT POINT
DESIGN FACTORS | 35
DESIGN FACTORS
1.3 Indoor / Outdoor Type (Flatwise Installation).
Minimum clearance for busduct installed flatwise in parallel.
1.4 Plug-in Type Busduct Installation.
Minimum clearance for plug-in busduct installed in parallel.
2. Minimum Clearance between busduct and wall, floor, etc.
2.1 Ceiling and Wall. 2.2 Beam.
200
200
200
200
100 100
50190
JOINT POINT
50 50W W W
PLUG IN BOX
PLUG IN BUSDUCT
CEILING
WA
LL
WA
LL
CEILING CEILING
36 | DESIGN FACTORS
Busduct joints must not be installed in between the wall and floor. The busduct joints shall be at least 240mm from the ceiling surface. If vertical spring hanger is installed on the floor, the distance between busduct joint and base channel shall be at least 450mm. If vertical hanger is installed on the floor, the distance between busduct joint and base channel shall be at least 300mm. The height of base channel is recommended to be 75mm.
2.3 Distance between busduct joint and floor/ceiling surface for through floor installation (A) and ceiling installation (B)
2.3 Distance between busduct joint and wall surface for through wall installation
Indoor Type Busduct. Outdoor Type Busduct.
JOINT POINT
240
(INDOOR TYPE)
WALL WALL
JOINT POINT
240
JOINT POINT
240
(OUTDOOR TYPE)(INDOOR TYPE)
BASE CHANNEL
FLOOR SLAB FLOOR SLAB
(BY CONTRACTORS)
450
7524
0
(A)
(B)
JOINT POINT
300
7524
0
VERTICAL SPRING HANGER
VERTICAL HANGER
(A)
(B)
DESIGN FACTORS | 37
Common Practice
Installation Procedures
Storage and Preparation Prior to Installation
1. When the busduct arrives at project site, check the type and quantity of busduct feeders and accessories from delivery orders. Inspect for any physical damages caused during transportation and unloading.
2. Keep the busduct at dry place, away from water and moisture, preferably under the roof protected from rain. Cover the busduct with water-proof material if necessary.
3. Do not lay the busduct directly onto the ground or in an upright position. Always place pieces of wood under the busduct and stack up firmly.
4. For long period storage, ensure that the busduct is placed at a dry place free from condensation.
Installation Procedures
1. To prevent the joint of the busduct from being soiled, wrap both ends with water-proof material while unpacking.
2. Use sufficiently strong materials and equipment for transportation and lifting.
3. Insert thick pieces of rag or corrugated cardboard when hanging busduct with rope to prevent the busduct from being damaged or scratched. For busduct rated 2500A and above, pieces of strong wood should be used when rope is applied, in order to prevent the busduct housing from being deformed.
4. Before installing the busduct joint, examine the conductor contact surface or insulation materials for any damages. Besides, ensure that the joint areas are not soiled with dust, dirt and other foreign matter.
5. During the busduct joint installation, it is recommended to perform Megger test for every busduct feeder during installation works. In case of the megger value is found abnormal after installation of the whole busduct route, extra time will be required to determine the faulty busduct feeders.
6. Ensure that the ends of busduct are protected against water and dust if the installation halted during construction.
INSTALLATION & MAINTENANCE PROCEDURE
38 | INSTALLATION & MAINTENANCE PROCEDURE
1
4
5
2
4
6
3
5
7
Busduct Joint
HP-Busduct Joint Assembly
1. Determine the male and female sides of the busduct feeders to be connected.
2. Align the busducts feeders end to end.
3. Align the leaf springs so that the high tensile bolts can be fitted through the busduct housing.
4. Tighten the two bolts alternately to ensure even distribution of force is applied to the busduct joint. Tighten them until the leaf springs become almost flat and until the snap-pin-hole on the high tensile bolt is visible.
5. Insert the snap pins into the pin holes.
6. Cover the busduct joint section with joint covers on both sides.
7. The installation is complete.
INSTALLATION & MAINTENANCE PROCEDURE | 39
L-Duct Joint Assembly
1. Align two L-Duct busduct feeders by overlapping the conductors.
2. Fix busduct housing with side covers on both sides.
3. Connect each phase conductor with screws, nuts, plain washes and spring washes. Make sure that the screws are fully tightened.
4. Insert a phase isolator to the joint section.
5. Connect the external earth bars to the earth bars at the side of busduct housing.
6. Install the joint cover on both sides of busduct housing to complete the joint assembly.
L3N
L2L1
E
M6 SCREW
SIDE COVER
M8 BOLT
PHASE ISOLATOR
M5 SCREW
JOINT COVER
BELLEVILLE WASHER
SPRING WASHER
M8 NUT
EXTERNALEARTH BAR
JOINT COVER
M5 SCREW
40 | INSTALLATION & MAINTENANCE PROCEDURE
Tap Off Units (Plug In Type)
1. Check the drawings to identify the location of tap-off units to be installed.
2. Remove the cover of each plug-in hole.
3. Ensure that the MCCB handle is in ‘OFF’ position.
4. By using the earth jaw of the plug in box as guidance, insert the plug in clips into the plug in hole of the busduct.
5. Open the top cover of the plug in box. Fasten the duct-fixing screws in the box to firmly attach the plug in box to the busduct.
6. Terminate cables to the outgoing terminal of MCCB and insert internal barriers (perspex) to prevent accidental contact with the live parts at the terminals of MCCB.
7. Installation is complete.
1
3
5
2
4
5
2
4
5
7
Insert EarthJaw here
Plug inClips
Tap-off units shall make positive ground connection with busduct housing or earth conductors before making contact with the phase conductors.
Make sure that the MCCB is in ‘OFF’ position before carrying out any live installation works of tap-off unit to the plug in holes of busduct system.
INSTALLATION & MAINTENANCE PROCEDURE | 41
Vertical Spring Hanger / Vertical Hanger
1. Drill 4 nos bolt holes of Ø12mm on the housing of the busduct.
2. Install the vertical hanger and fix to the busduct tightly.
3. Connect the busduct in sequence and install the vertical spring hangers to each floor accordingly.
Refer to page 22 and 23 (HP-Busduct) and page 33 (L-Duct) for the details of dimension of vertical spring hanger and vertical hanger
Tap Box (Bolt On Type)
1. Remove the tap bar cover. If the busduct is 3P5W type, extra care is required in order not to damage the earth during removal of the cover.
2. Open the cover of the Tap Box and insert the tap bar through the opening of the tap box and fix the box to the tap bar flange by fastening the screws.
3. Fix the box to the busduct housing using flat hanging clamps provided by Furutec
4. Fix the top cover of the box.
5. Installation is complete.
Horizontal Hanger (Edgewise/Flatwise Hangers)
1. Prepare the angle metal support for busduct prior to the horizontal hanger installation.
2. Hang the hanger rods from the ceiling and attach the angle metals at the height of the busduct to be laid.
3. The horizontal hangers should be installed in every internal of at least 1500mm (1.5m) including the busduct elbows.
Refer to the details of Edgewise / Flatwise Hanger on page 24 (HP-Busduct) and page 34 (L-Duct)
42 | INSTALLATION & MAINTENANCE PROCEDURE
Inspection and Testing upon Completion of Busduct Installation
1. After the completion of busduct installation at project site, it is advisable to carry out a thorough inspection on the whole busduct route, followed by measurement of insulation resistance / Megger.
2. Before conducting the measurement of insulation resistance, all the equipment connected to busduct system should be disconnected and MCCB rotary handle of tap-off units should be in ‘OFF’ position.
3. The insulation resistance value cannot be specified due to different length of the busduct and environmental condition. But if it is installed in a dry atmosphere, the value of resistance should be approximately 100 MΩ (500V Megger). In case, the measurement is less than 10MΩ, thorough examination is required as there might be some external factors, which decrease the insulation strength and energizing of busduct system is not recommended.
4. The following inspection procedures should be carried out. Determine whether:-
4.1) The busduct feeders are physically damaged.
4.2) All the connecting parts are fixed precisely (e.g. flange end box, tap-off units, etc)
4.3) The bolts for connecting to the equipment are securely fastened.
4.4) The busduct joint are tightened in accordance to Furutec‘s requirement and recommendation.
4.5) The hangers support the busduct securely.
Maintenance
The following maintenance procedures and periodical inspection are recommended to ensure a safe operation of busductsystem for long terms.
1. Period of Inspection
1.1 An inspection on busduct once a year or once every two years is recommended. If busduct system is installed in unfavourable conditions such as, temperature and/or humidity is high, there is a lot of dust or in similar environment, the periodical inspection must be conducted.
1.2 In the event of the following unusual conditions, inspection must be carried out immediately in each case:
a.) After severe earthquake
b.) After being involved in a fire
c.) After being exposed to water
d.) After an electrical fault
2. Maintenance and Routine Inspection
2.1 Inspection on External Appearance
Check whether :-
There is any deformation, damage, dirt, etc throughout the whole length of busduct systems
There is any dislocation, bending and other abnormality of the connecting covers, hangers and plug-in appliances
INSTALLATION & MAINTENANCE PROCEDURE | 43
2.2 Environmental Inspection
The environment, where the busducts are installed, sometimes changes after the installation works. Check whether theenvironment has become hazardous due to water, moisture, high temperature, corrosive gas, immoderate vibration, dust, etc.
2.3 Inspection for Abnormal Heat
A high-tech Infra Red Thermography instrument is recommended to detect abnormal heat and measure the operatingtemperature of busduct system.
For the ease of maintenance, a thermal indicator can be placed onto the busduct housing. If the temperature rise of the busducthousing exceeds the limit, the colour of the indicator will change. e.g. from white to red colour.
2.4 Inspection on Connection Sections
Check whether :-
HP-Busduct is securely fastened with joint bolts and nuts and both sides of the busduct joint sections are held with a pair of leaf springs. Leaf springs are flat and the pin holes are inserted with snap pins Screws and nuts at the overlapping conductor of L-Duct joint sections are not loose due to thermal expansion and contraction
Busduct is supported by vertical spring hangers, vertical hangers, edgewise / flatwise horizontal hangers according to manufacturer’s requirement and recommendation. All the connecting parts, such as leaf springs, hangers, busduct joints, joint covers, etc are fixed precisely
2.5 Inspection on Load Condition
After the installation of plug-in busduct feeders, increase of electrical load is expected at the early stage. An inspection has tobe carried out to ensure that the total connected load does not exceed the rated current of the busduct before the load is increased.
2.6 Measurement of Insulation Resistance
Measure the insulation resistance between each conductor and between conductor and housing. When it is less than 5MΩ or far below the previous value, the possibility of existence of defect is very high. When the measurement is carried out, the electrical loads and connected equipment shall be disconnected.
2.7 Inspection on Rust or Peeling of Paint on Busduct Housing
If there are some peeled-off paint or rust on the busduct housing, cleaning work and touch-up painting are recommended.
44 | INSTALLATION & MAINTENANCE PROCEDURE
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Suria KLCC & Maxis Tower (Malaysia)
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Four Point Hotel - Sheraton (Malaysia)
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Supreme Court(Singapore)
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Fuji Electric(Malaysia)
Industrial Projects
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Bintang Fairlane Residences (Malaysia)
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Sunway Pyramid Mall(Malaysia)
PROJECT REFERENCE
PROJECT REFERENCE | 45
Sales & Marketing contact :
(member of EITA Group of companies)Plot 89, Lorong Perindustrian Bukit Minyak 11,Kawasan Perindustrian Bukit Minyak, MK 13, 14100 Seberang Perai Tengah, Penang, MalaysiaTel: +604-508 0228 Fax: +604-508 0227E-mail: [email protected]: www.furutec.com.my
FURUTEC Electrical Sdn. Bhd. (057207-W)
Lot 4, Block A, Jalan SS13/7Subang Jaya Industrial Estate47500 Subang JayaSelangor Darul Ehsan, MalaysiaTel: +603-5637 8363 Fax: +603-5635 0538Website: www.eita.com.my
* The information is subject to change without prior notice. Consult Furutec at the time of order.
FTAug10@2010. All rights reserved.