Works at Kasna - Alpha Magnetics
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Transcript of Works at Kasna - Alpha Magnetics
Works at Kasna
Certifications & ApprovalsCertifications & Approvals
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Contents
1. Standards, Specifications & Salient Features ....................................................... 5
2. Rising Main & Horizontal Trunking Installation .................................................... 6
3. Technical Parameters ..................................................................................... 7-8
4. Main Components .......................................................................................... 9
5. Physical Data ............................................................................................... 10-13
6. Other Components ......................................................................................... 14
7. Installation Instructions .................................................................................. 15-19
8. Other Busbar System ..................................................................................... 20
9. Typical Installations ....................................................................................... 21
10. Major Installations ........................................................................................ 22-23
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Busbar trunking system in compact design is the most efficient, safe and ideal system for electricity supply
to industrial installations and high rise structures, offering a wide current range from 125A to 2000A in
type CBC (Copper conductor) and 160A to 1250A in type CBA (Aluminium conductor) with possibil ity of
feeding loads upto 400A with standard plug-in boxes. The system has provision for 4 Plug-in outlets per
meter, which can be fitted quickly and provide total flexibil ity for any change in distr ibution layout at
a later stage. The system has been designed especially for installations and projects where power supply
has to be made available rapidly. These are most suitable for applications where exact location and
power consumption is not sure and possible changes in physical distr ibution of loads are envisaged.
Standards & SpecificationStandards & SpecificationStandards & SpecificationStandards & SpecificationStandards & SpecificationE q u i p m e n t i s d e s i g n e d f o r l o w v o l t a g epower distribution as per IEC 60439 (Part 1&2),IS 8623 (Part 1&2).
Bustrunking enclosure is made from cold rolled steelsheet 1.6mm (16 SWG) with epoxy polyester powdercoating of pebble grey shade (RAL 7032).
As a standard practice the degree of protection isIP-52 for all ratings. Equipment with IP54 protection canbe supplied at extra cost.
Busbars in CBC type are made of 99.9% pure copper,ETP grade, whereas in CBA type, Busbars are made of63401 WP grade aluminium alloy. Busbars are with fullround edges for easy insertion and removal of plug-in boxes.
Advantages of Compact DesignAdvantages of Compact DesignAdvantages of Compact DesignAdvantages of Compact DesignAdvantages of Compact Design
Compact size and easy installation
Unmatched reliability
Flexibility leading to reduced costs
Polarity errors are totally eliminated
Low impedance & hence low voltage drop
Improved thermal characteristics.
Provides distribution & protection through Plug-in-pointsLow cost, flexible & safe distribution systemeliminates the requirement of separate distributionLT panel.
Salient FSalient FSalient FSalient FSalient Features of Compact Teatures of Compact Teatures of Compact Teatures of Compact Teatures of Compact Trunkingrunkingrunkingrunkingrunking
Small, compact and rigid construction.
Automatic polarity maintained throughout thesystem during installation.
Pleasant Light Grey Powder coated finish on rustproof enclosure.
Inside the bus trunking, busbars are supported atever y 250 mm for r ig id and shockproofconstruction.
Busbars in enclosure are held tight, and cannoteasily slide even in vertical runs when used as risingmains.
Riveted construction adopted for tamper-proofsystem.
System can be mounted edgewise or flatwise,horizontally or vertically in any direction with allkinds of bends, tees and crosses.
Un-drilled busbars of two sections can be joinedtogether by Joint Clamp using HTS bolts.
Extra safe cable connection in plug-in-boxeswithout additional cable support.
Tap off points are fully shrouded to prevent anyaccidental contact. They are further closed bynondetachable plastic covers.
Plug in boxes can be easily mounted, ensuring100% automatic polarity. Earth contact makes firstand breaks last.
4 pole isolator is provided in plug-in-boxes upto125A for extra safe connection on live bus trunking.
All plug-in boxes are COMPATIBLE with all ratings ofbus trunking.
Two sections can be electrically isolated formaintenance and testing in installed conditionwithout dismantling or removal of any section.
Both sides of bus trunking can be used withprovision of 4 tap off outlets per meter. (2 no’s. oneach side)
Safe, easy and quick plug-in / plug-out possible onlive bus trunking.
Considerable saving in installation and operationalcost. SYSTEM IS MAINTENANCE FREE.
System is totally reusable, easy to dismantle,reinstall and extend. Each section can beindividual ly replaced or dismantled withoutdisturbing other sections.
Fire barrier provision with F & T rating for 2 hourscan be provided as per requirement for floor andwall crossings (Refer UL 1479).
Temperature rise on enclosure for all ratings is 25oCmax. for safety of operators
High dielectric strength and insulation levelmaintained even in hot and humid condition byuse of high impact, f lame retardant, non-hygroscopic insulators made of F-class material‘NORYL’
Plug-in boxes with MCCB and SFU can be providedwith door interlocking and interlocking with bustrunking to ensure “Plug-in” and “Plug-out” possibleonly in ‘OFF’ condition.
BusbarBusbarBusbarBusbarBusbar TTTTTrunkingrunkingrunkingrunkingrunking SystemSystemSystemSystemSystem
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Rising Main InstallationRising Main InstallationRising Main InstallationRising Main InstallationRising Main Installation
Horizontal Bus Trunking Instal lat ion
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PARAMETER UNIT
TRUNKING TYPE CBC CBC CBC CBC CBC CBC CBC CBC CBC CBC CBC CBC125 250 315 400 500 630 800 1000 1250 1500 1750 2000
Overall Dimensions mm 147 x 147 x 147 x 147 x 147 x 147 x 147 x 147 x 147 x 147 x 147 x 147 x60 60 75 75 95 95 115 135 190 230 230 270
Rated Current A 125 250 315 400 500 630 800 1000 1250 1500 1750 2000
Insulation Voltage V 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
Peak Short Circuit KA 7.5 30 40 52 73 84 105 105 105 105 143 143Current
RMS Short Circuit KA 5.0 15 20 25 35 40 50 50 50 50 65 65Current (1 Sec.)
Conductor Material Cu Cu Cu Cu Cu Cu Cu Cu Cu Cu Cu Cu
No. of Conductors 1 1 1 1 1 1 1 1 2 2 2 2per Phase / Neutral
Phase Cross Section mm2 28 90 120 180 240 300 420 540 600 720 840 1080
Neutral Cross Section mm2 28 90 120 180 180 180 300 420 360 600 600 840
PE Cross Section mm2 36 36 36 36 75 75 75 75 75 75 75 75Cu Conductor
PE Enclosure mm2 84 84 102 102 110 110 118 126 164 184 184 204(Cu equivalent)
Trunking Weight Kg/m 7.5 9.6 12.0 13.8 17.5 19.2 24.2 29.3 33.4 40.6 44.0 54.3
Degree of Protection IP 52 52 52 52 52 52 52 52 52 52 52 52(IEC 529)
Reactance at mΩ/m 0.155 0.122 0.110 0.092 0.079 0.069 0.057 0.050 0.033 0.030 0.027 0.02450Hz X
Resistance at mΩ/m 0.635 0.197 0.148 0.099 0.074 0.059 0.042 0.033 0.030 0.025 0.021 0.01620oC R
Impedance at mΩ/m 0.653 0.232 0.184 0.135 0.108 0.091 0.071 0.060 0.044 0.039 0.034 0.02920oC Z
Resistance at mΩ/m 0.818 0.254 0.191 0.127 0.095 0.076 0.055 0.042 0.038 0.032 0.027 0.021Thermal Condition
Impedance at mΩ/m 0.832 0.282 0.220 0.157 0.124 0.103 0.079 0.066 0.050 0.044 0.038 0.032Thermal Condition
mV/Am 1.183 0.0456 0.367 0.268 0.213 0.178 0.137 0.113 0.087 0.076 0.066 0.055
mV/Am 1.294 0.479 0.379 0.272 0.214 0.177 0.135 0.111 0.087 0.075 0.066 0.054
mV/Am 1.392 0.489 0.381 0.268 0.208 0.171 0.128 0.104 0.084 0.072 0.063 0.051
mV/Am 1.417 0.441 0.331 0.220 0.165 0.132 0.094 0.073 0.066 0.055 0.047 0.037
Inside of Enclosure Outside of Enclosure
Technical Data : CBC (Copper Bus Trunking)
Voltage drop L-Lfor COSφφφφφ withnominal loadconcentratedat the end
(3P+N)
TTTTTechnicalechnicalechnicalechnicalechnical PPPPParametersarametersarametersarametersarameters
at 0.7
at 0.8
at 0.9
at 1.0
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Technical Data : CBA (Aluminium Bus Trunking)
PARAMETER UNIT
TRUNKING TYPE CBA CBA CBA CBA CBA CBA CBA CBA160 250 400 500 630 800 1000 1250
Overall Dimensions mm 147 x 147 x 147 x 147 x 147 x 147 x 147 x 147 x60 75 95 115 135 190 230 270
Rated Current A 160 250 400 500 630 800 1000 1250
Insulation Voltage V 1000 1000 1000 1000 1000 1000 1000 1000
Peak Short Circuit KA 17 30 52 73 84 105 105 105Current
RMS Short Circuit KA 10 15 25 35 40 50 50 50Current (1 Sec.)
Conductor Material AL AL AL AL AL AL AL AL
No. of Conductors 1 1 1 1 1 2 2 2per Phase / Neutral
Phase Cross Section mm2 90 180 300 420 540 600 840 1080
Neutral Cross Section mm2 90 180 180 300 420 360 600 840
PE Enclosure mm2 84 102 110 118 126 164 184 204(Cu equivalent)
Trunking Weight Kg/m 7.2 9.6 11.60 13.50 15.50 18.90 23.20 27.40(3P + N)
Degree of Protection IP 52 52 52 52 52 52 52 52As per IEC 529
Reactance at mΩ/m 0.140 0.095 0.074 0.060 0.052 0.038 0.030 0.02550Hz X
Resistance at mΩ/m 0.348 0.174 0.104 0.075 0.058 0.052 0.037 0.02920oC R
Impedance at mΩ/m 0.375 0.198 0.128 0.096 0.078 0.065 0.048 0.03820oC Z
Resistance at mΩ/m 0.411 0.205 0.120 0.088 0.068 0.062 0.044 0.034Thermal Condition
Impedance at mΩ/m 0.434 0.226 0.144 0.107 0.086 0.072 0.053 0.042Thermal Condition
m V / A m 0.671 0.367 0.241 0.181 0.147 0.122 0.090 0.072
m V / A m 0.715 0.383 0.248 0.184 0.149 0.125 0.092 0.073
m V / A m 0.746 0.392 0.248 0.183 0.146 0.125 0.091 0.072
m V / A m 0.711 0.356 0.213 0.152 0.119 0.107 0.076 0.059
Voltage dropL-Lfor COSφφφφφ withnominal loadconcentratedat end
TTTTTechnicalechnicalechnicalechnicalechnical PPPPParametersarametersarametersarametersarameters
at 0.7
at 0.8
at 0.9
at 1.0
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B u s t r u n k i n gB u s t r u n k i n gB u s t r u n k i n gB u s t r u n k i n gB u s t r u n k i n g
Temperature rise on busbars at full load current over ambient of 40oC in case of copper Bustrunking
(CBC) is 55oC and in case of aluminium Bustrunking (CBA) is 45oC. As a Stamdard practiceCBC provides
system of 3P+N+PE and CBA provides system of 3P + N. Neutral section in both case is more than
1/2 of phase section. Neutral of full section can also be provided, if required by the distr ibution system.
Including enclosure equivalent as PE, both CBC & CBA meet earthing requirement as per standards.
Additional earthing can also be provided at extra cost. Busbars are insulated with sufficient clearances.
However if required, heat shrinkable PVC sleeves can be provided on Busbars at extra cost. Standard
section length of bus trunking is 3.0, however non-standard smaller length can also be supplied as per
site requirement. All sections can be easily coupled together by special insulated joint system with the
help of ordinar y tools.
Busbar Jo in tBusbar Jo in tBusbar Jo in tBusbar Jo in tBusbar Jo in tSingle bolt BUS CLAMP joint for each phase & neutralbusbar is provided in CBC 125~400 and CBA160~250. These can be easily slided over the busbarson either side after removing HTS Bolts for isolation orjoining of two sections. Recommended torque fortightening is 3.5 kg-mtr.
For higher ratings (i.e. CBC 500~2000 and CBA400~1250) UNIBLOCK joint is provided to join all fourbusbars (3P+N) together, with the help of SINGLE HTSBOLT. This joint after loosening can be taken out or fittedvery easily for isolation or joining of two sections.Recommended toque for tightening is T.0 Kg-mtr.
End CoverEnd CoverEnd CoverEnd CoverEnd Cover
These are designed to close the open ends of eachrun of bus trunking.
End Feed UnitTo energize bus trunking, end feed Unit (EFU) is availablewith sufficient space for direct connection through lugsand bolts (for enclosure size “Physical Data” to bereferred). MCCB, SFU, Isolators and Fuse holders etc.can also be fitted in end feed unit as per specificrequirement. 250mm length of bus trunking is integrallyfitted along with end feed unit as standard practice sothat joint between end feed unit and bus trunking isexactly same, as of two normal bus trunking. Un-drilledcable gland plate is provided for multiple cablefeeding option. A set of thrust pad forms an integral partof end feed unit to support busbars firmly and allowsexpansion in outward direction only. End feed unit canbe made LHS or RHS type as shown in Physical dataas per site needs. (to be mentioned while ordering)
Centre Feed UnitCentre Feed UnitCentre Feed UnitCentre Feed UnitCentre Feed UnitThese are similar to EFU but have the flexibility forpositioning between any two sections of bus trunking.Full rated current can be fed in bus trunkingsimultaneously on both sides of centre feed unit. 250mm bus trunking is integrally fitted with centre feed uniton both sides for joining purpose. Centre feed unit is
made in one standard type as shown in “Physical data”with cable entry from bottom. Polarity and site conditionneed to be examined for proper connection.
Flange EndThese are applicable for connections with panels,generating sets & transformers etc. for supply / feedingpurpose. For type and size, physical data can bereferred.
Elbow TElbow TElbow TElbow TElbow Tee & Crossee & Crossee & Crossee & Crossee & CrossThese are available to extend bus trunking main run inall possible direction. These are available in standardsizes as indicated in “Physical data”.
BracketsStandard brackets CBK-1 and CBK-2 are available tosuspend bus trunking horizontally in all possibledirections. For selection of bracket, physical data canbe referred. For vertical installation (Rising main)bracket, CBK-3 need to be used. Type and rating oftrunking need to be specified while ordering to supplysuitable size of fasteners.
Plug-in-BoxesStandard plug-in-boxes are available from 32A to400Amps with MCB/ MCCB / SFU / Fuse holders. All plug-in-boxes are compatible with all ratings of bus trunking.Detailed dimensions and feature are illustrated in“Physical data” Undrilled cable gland plates areprovided on three sides of Plug-in-boxes for cableconnections from either side. Polarity is automaticallymaintained while fitting Plug-in-boxes on to the bustrunking. Door interlocking and interlocking with bustrunking (for MCCB and SFU) can also be provided toensure “Plug-in” and “Plug-out” possible only in “OFF”condition. Rigid clamps are provided to ensure properfixing of Plug-in-boxes with bus trunking. Live contactsare isolated / properly shrouded to avoid anyaccidental contact when door of Plug-in-box is open.
MainMainMainMainMain Component sComponent sComponent sComponent sComponent s
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Phys icalPhys icalPhys icalPhys icalPhys ical DataDataDataDataData
All Dimensions are in mm
10
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BUS TRUNKINGCBC : Copper Bus TrunkingCBA: Aluminium Bus Trunking
BUSBAR JOINT CLAMP
Bus Clamp JointRatings in Amps.Copper 125~400Aluminium 160~250
Uniblock JointRatings in Amps.Copper 500~2000Aluminium 400~1250Ratings in Amps.
Copper 125~1000Aluminium 160~630
Ratings in Amps.Copper 1250~2000Aluminium 800~1250 SIDE VIEW CROSS SECTION
END FEED UNIT (LHS)(can be fitted on left side ofHorizontal Trunking)
END FEED UNIT (RHS)(Applicable for Rising mains & can befitted on right side of Horizontal Trunking)
360
250
500
CENTRE FEED UNIT
All Dimensions are in mm
FLANGED END
Ratings in Amps.Copper 125~1000Aluminium 160~630
Ratings in Amps.Copper 1250~2000Aluminium 800~1250
(RHS)
(RHS)(LHS)
(LHS)
END COVER
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VERTICAL / FLAT ELBOW - 1
A X B (for all ratings)300 x 300
All Dimensions are in mm
VERTICAL / FLAT CROSS
A x B x C x D (for all ratings)
300 x 300 x 300 x 300
A x B (for all ratings)300 x 300
HORIZONTAL / EDGE ELBOW - 1
HORIZONTAL / EDGE ELBOW - 2
A x B (for all ratings)300 x 300
VERTICAL / FLAT ELBOW - 2
A X B (for all ratings)300 x 300
Phys icalPhys icalPhys icalPhys icalPhys ical DataDataDataDataData
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VERTICAL / FLAT TEE - 1
A x B x C (for all ratings)300 x 300 x 300
HORIZONTAL / EDGE TEE - 1
A x B x C400 x 400 x 400
HORIZONTAL / EDGE CROSS
A x B x C x D400 x 400 x 400 x 400
HORIZONTAL / EDGE TEE - 2
A x B x C (for all ratings)300 x 300 x 300
VERTICAL / FLAT TEE - 2
A x B x C400 x 400 x 400
All Dimensions are in mm
Phys icalPhys icalPhys icalPhys icalPhys ical DataDataDataDataData
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All Dimensions are in mm
BRACKETS
CBK - 1
To suspend Horizontally - Rating (Amp.)Copper - 125 ~ 1000Aluminium - 160 ~ 630
CBK - 3
To suspend Vertically (Rising Mains)applicable for all ratings
CBK - 2
To suspend Horizontally - Rating (Amp.)Copper - 1250 ~ 2000Aluminium - 800 ~ 1250
Type O
L x W x H
300 x 140 x 120
Type B, C & D
L x W x H
450 x 250 x 230 - “B”
600 x 340 x 230 - “C”
With inbuilt IsolatorWith MCB : 32 & 63 Amps
With Fuse holder : 32 & 63 Amps (BS type)
With MCCB : upto 63 Amps (2 / 3 / 4 poles)(MCCB height < 130m)
With inbuilt IsolatorWith provision for door Interlocking & Interlocking withbus trunking (for MCCB and SFU)With Fuse Holder : 100 & 125 Amps (DIN type)
With MCCB : upto 125 Amps (2 / 3 / 4 poles)(MCCB height < 170m)
With SFU : 32 ~ 125 Amps (TPN / 4 Poles)(C & S make, DIN OR BS type)
With provision for door Interlocking & Interlocking withbus trunking (for MCCB and SFU)With Fuse Holders B : 200 Amps(DIN type) C : 250 ~ 400 Amps
With MCCB (2 / 3 / 4 poles)
Type B : 200 Amps. (MCCB height < 170)Type C : 250 ~ 400 Amps. (MCCB height < 270)
With SFU : (TPN / 4 Poles), C & S makeType C : 200A (BS type) &
: 250A (DIN), 315A (BS) & 400A (DIN)Type D : 800A, Available on request
Type A
L x W x H
380 x 250 x 170
PLUG - IN - BOX
Note : M10 Nuts & Bolts can be fitted in all slots
Copper, CBC Aluminium, CBA A B
125, 250 160 122 92
315, 400 250 137 107
500, 630 400 157 127
800 500 177 147
1000 630 197 167
Rating in Amps.
Table - 1
For Dimensions A & B refer Table 1 & 2
Copper, CBC Aluminium, CBA A B
1250 800 252 222
1500, 1750 1000 292 262
2000 1250 332 302
Rating in Amps.
Table - 2
Phys icalPhys icalPhys icalPhys icalPhys ical DataDataDataDataData
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OtherOtherOtherOtherOther ComponentsComponentsComponentsComponentsComponents
1. Fire Barriers are provision provided in standard bus trunking section against specific requirement.2. Recommended to be used at each floor and wall crossing.
FIRE BARRIER
Ref. Standard : UL 1479Rating : 2 hours
All Dimensions are in mm
REDUCER
400 230
500 340
HIGHER RATING BUSTRUNKING W d
COPPER 125~1000AAluminium 160~630A
Copper 1250~2000AAluminium 800~1250A
EXPANSION JOINT
1. Expansion joints are provision provided in standard Bustrunking Section against specific requirement2. Recommended to be used after continuous run of 40 mtrs. in case of Copper Bustrunking and 30 Mtrs. in case of Aluminium Bustrunking
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1 . 01 . 01 . 01 . 01 . 0 General PreparationGeneral PreparationGeneral PreparationGeneral PreparationGeneral Preparation
1.1 First check that the intended route for the bustrunking is clear of all obstructions and that allapertures in walls and floors are of correct sizeand at correct location. Apertures shouldgenerally leave 50mm around the Bustrunkingenclosure. Please refer layout and assemblydrawings for any special features.
1.2 Determine fixed points of the installation (feedunits, flanged end, elbows, tees etc.) and thendecide support points.
1.3 Ensure there is sufficient horizontal and verticalclearance from the wall and ceiling to provideeasy access to joints, both for original installationand for any future maintenance requirements.
1.4 The bus trunking should be located away frompolluted atmosphere such as corrosive fumes,furnace gases and chemicals etc.
2 . 02 . 02 . 02 . 02 . 0 U n p a c k i n gU n p a c k i n gU n p a c k i n gU n p a c k i n gU n p a c k i n g
2.1 Care must be taken while unpacking. Cutter,should be used to cut all steel straps securing thepackage. Nail pullers should be used forunpacking wooden casings.
2.2 Carefully remove any support blocks or otherfittings which may have been used for shipping.
2.3 When Bustrunking is received, unpack temporarilyto inspect its physical condition. Also check andensure that the consignment is complete andcorrect as per the order. Restore the materials inoriginal packing condition, if it is required to bestored for longer period prior to installation.
2.4 It is recommended to remove the polythene sheet(covering the entire Bustrunking) only aftercompletion of installation, in order to protect theBustrunking from water, slurry & paint etc. duringinstallation.
3 . 03 . 03 . 03 . 03 . 0 S t o r a g eS t o r a g eS t o r a g eS t o r a g eS t o r a g e
3.1 Never keep the Bustrunking in inclined / verticalcondition. Stacking should be firmly supported toprevent any slippage.
3.2 Always store the Bustrunking products in originalpacking to avoid any damage, deformationsand entry of any contaminants like dust, moistureand vermins. Cover trunking with water proofsheets.
4 . 04 . 04 . 04 . 04 . 0 Protect ion From ContaminantsProtect ion From ContaminantsProtect ion From ContaminantsProtect ion From ContaminantsProtect ion From Contaminants
Bus trunking should be adequately protected fromliquids, moisture and other contaminants. Somecommon source of contaminants are :
4.1 Moisture / Water dripping
Bus trunking must be protected from thesecontaminants during installation. Bus trunking isnot weather resistant until completely installed withall covers & boxes fitted & secured.
4.2 Floor level liquids
Ideally water bank of min. 125mm height shouldbe installed around all floor openings for riser bustrunking to prevent liquid spillages from enteringin the opening and running down the bustrunking.
4.3 Leaking Roof
Protect bus trunking with a temporary protectivecover to prevent water from falling on to theBustrunking directly until the roof is repaired.
4.4 Pipes
Protect bus trunking with a temporary protectivecover to prevent water falling onto the busbar untilleaking pipes are repaired. Where pipes (especiallycold water pipes) pass directly above bus trunking,the busbar should be protected from drippingcondensate by insulating the pipe or permanentlyshielding the bus trunking.
4.5 Sprinklers
Protect bus trunking from direct spray of sprinklers.
5 . 05 . 05 . 05 . 05 . 0 Handl ing / Ho i s t ingHandl ing / Ho i s t ingHandl ing / Ho i s t ingHandl ing / Ho i s t ingHandl ing / Ho i s t ing
These guidelines are provided to reduce the riskof personal injury, equipment damage duringhandling and also to facilitate movement of thebus trunking sections and accessories at site.
5.1 Handle bus trunking with care to avoid damageto internal components and the enclosure.
5.2 While transporting, take care not to drop it or letit hit other object.
5.3 A fork lift may offer a more convenient method ofhandling and has the added advantage ofpermitting it to be hoisted between levels. Ensurethe load is stable and safely secured.
5.4 Platform lifts or elevators, either manually or poweroperated, can be used advantageously inmoving bus trunking equipments betweenelevations. Check that the weight of personnelplus trunking is within the capacity of the lift /elevator.
5.5 While lifting vertical lengths, take care to use anadequate sl ing and slinging method so that theequipment does not slip or fall. It is recommendedto fix vertical bracket (CBK-3) securely or to makesimilar arrangement to avoid slippage.
5.6 If a crane is used to install bus trunking, use nylonstraps and distribute the weight on each lift. Ifcables are used, insert thick pieces of foam orcorrugated cardboard between them to preventthe bus trunking from being damaged. Do notplace slings, cables or chains around bustrunking ends since damage can easily occur.
5.7 If a fork lift or similar hoist is used, properly positionthe bus trunking on the fork to distribute its weight.Careful approach is a must to avoid anydamage to the metal housing that would breakbusbar insulators and result in a failure.
Instal lat ionInstal lat ionInstal lat ionInstal lat ionInstal lat ion Instruct ionsInstruct ionsInstruct ionsInstruct ionsInstruct ions
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Rating Spacing (Meters)Min. Max.
CBC - 125, 250, 315, 400 2.0 3.0CBA - 160, 250, 400, 500
CBC - 500, 630, 800, 1000 1.5 2.25CBA - 630, 800, 1000, 1250
CBC - 1250, 1500, 1750 1.0 1.5
CBC - 2000 1.0 1.25
loading), more spacing can be consideredwhereas for one side plug-in-box fitting, closespacing need to be considered to avoid twistingof Bustrunking.
Ensure each element of Bustrunking run is supportedby at least one bracket.
As far as possible avoid fixing of bracket atBustrunking joint area and at plug-in point window.
6.1.2 Minimum clearance from wall, ceiling, beams /columns and between two trunking running parallel
Minimum distance between two Bustrunking willincrease if plug-in box/end feed unit/reducer etc.is fitted in between straight run. 50mm clearance
need to be considered between two boxes / unitinstalled on parallel runs. Space required for dooropening should also be considered. 50mm min.clearance should be considered in case oftrunking running close to beam / columns / pillars
Joint point should not come inside the wall crossingand behind any restricted area like pillars, trussesetc. Joint line should be clear by 150mm on bothsidesEdge wise installation is normally advisable due tofollowing :
Gives pleasant appearance with labels easilyreadableOperating end feed unit/centre feed unit ismore convenient especially if fitted withMCCB / SFU etc.“Plug-in”, “Plug-out” and opening of plug-in-box door is more convenientDirect cabling from Plug-in-Box to equipmentis easy.
5.8 Do not drag bus trunking across the floor or acrossother busbar sections.
5.9 While installing vertical section, it may be easierto lower the bus trunking from one floor abovewhere it will be installed. Vertical sections are oftenstored on the floor above their final location tofacilitate lowering them into position. Do notdamage end of trunking when raising fromhorizontal to vertical positions.
5.10 When the work is suspended dur ing theinstallation, the ends of the connecting sectionsshould be protected against water and dust bykeeping the trunking covered with polythene.
5.11 Never use busbars / conductors of Bustrunking forlifting sections.
6 . 06 . 06 . 06 . 06 . 0 Hanging / Suppor t ingHanging / Suppor t ingHanging / Suppor t ingHanging / Suppor t ingHanging / Suppor t ing
Fix hangers/support with ceiling/wall/structure toaccommodate brackets before proceeding withfixing of bus trunking.
Do not leave Bustrunking section unsupported atends while next section is being fitted as this couldcause damage. Use supports/brackets to ensuretrunking remains correctly aligned at all times.
Level and plumb Bustrunking (align vertically andhorizontally) before final tightening of all jointhardware.
In case the “Insulation Resistance” is foundabnormal after installation of complete route,much time is spent to detect faulty parts. It istherefore recommended that the insulationresistance checking be partially conducted by500V megger even during the installation.
6.1 Horizontal installation
When trunking is installed edgewise (i.e. plug-inoutlets in front & back), neutral shall be on bottomas standard practice.
6.1.1 Spacing between two brackets
Depending upon the weight of Bustrunking, followingspacing is recommended between two consecutivebrackets as min. & max. for horizontal installation.:
Following points also need to be considered fordeciding exact spacing :
Shape, strength, rigidness and distance of hangersfrom ceiling / wall.
Rating (Low/high) and numbers of plug-in boxes tobe fitted between two brackets.
By fitting plug-in-boxes on both side (for balanced
EDGE WISE
FLAT WISE
Installation InstructionsInstallation InstructionsInstallation InstructionsInstallation InstructionsInstallation Instructions
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7 . 07 . 07 . 07 . 07 . 0 Joint AssemblyJoint AssemblyJoint AssemblyJoint AssemblyJoint Assembly
Before joining two bus trunking sections, ensure thatthe conductor surface and insulating materials arenot damaged. Also check they are free of dustotherwise clean them thoroughly. Following stepswill make joining much easier.
7.1.1 Figure 1 shows view of BUS CLAMP joint applicablefor CBC 250 & 400 and CBA 160 & 250.
7.1.2 Figure 2 shows view of UNIBLOCK joint applicablefor CBC 500~2000 and CBA 400~1250.
7.2 Remove joint cover and channel blocks fitted on
one end of each section.
7.3 Match two section with same polarity and tighten
up M6 bolts at back of enclosure
7.4 Opposite polarity will not allow screw to fit in.
7.5 Ensure BUS CLAMP joint is already fitted on the
busbars of two section before step 7.3. It can beeasily slided over the busbar after taking out the
bolt and can be refitted after positioning it centrally.
7.6 UNIBLOCK joint need to be fitted after step 7.3Ensure bolt is fully opened (upto its stopper limit) for
easy entry.
7.7 Apply torque of 3.5 kg mtr. to BUS CLAMP joint
ensuring its correct alignment on busbars.
7.8 UNIBLOCK joint need to be subjected to torque of7.0 kg mtr.
7.9 Place the channel blocks on both sides.
7.10 Place the joint cover and tighten up four joining
screws ensuring channel blocks are well in position.
7.11 After fixing joint cover, channel blocks hardwarecan be fitted on both sides.
6.2 Vertical Installation (Rising Mains)When trunking is installed with plug-in outlets infront & back, neutral shall be on the left side asstandard practice.
6.2.1 Spacing between brackets
Following points to be considered for decidingbrackets spacing :
Minimum 2 brackets per floor for floor heightupto 3.5 mtrs. and 3 brackets for floor heightupto 5.0mtrs.Ensure each element of Bustrunking issupported once at each floor.Sufficient strength should be provided to wallsupport / hangers to bear the weight ofBustrunking (indicated in technical data).Care should be taken so that bracket is atleast 150mm away from joint line.
6.2.2 Floor opening and minimum Clearances
Following sizes of opening and clearances arerecommended for comfortable installation, operation
and maintenance (however actual decision will alwaysdepend upon the site condition)
Never fill floor opening with mortar / cement.Minimum clearances between two trunkingrunning parallel should be 50mm between plug-in-boxes /end feed units / reducers etc. Spacerequired for door opening should also beconsidered.Floor opening should be completely covered /sealed over WATER BANK with cover plate toprevent entry of contaminants as shown below:
Fig. 1
FLAT WISE
EDGE WISE
WATER BANK
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8 . 08 . 08 . 08 . 08 . 0 Mount ing of P lug- in-boxMount ing of P lug- in-boxMount ing of P lug- in-boxMount ing of P lug- in-boxMount ing of P lug- in-box
Lower rating plug-in-box upto 125 Amps are available with inbuilt off load isolator. Following are the mountingsteps:
8.1 Open the plug-in cover at desired position on bus trunking.
8.2 Box should always be plugged in with cover in open condition (no load condition). To open cover place the
ring of front lock in latch of cover and pull the lever about 150 degree. This will disengage shorting wedgeof Isolators.
8.3 Place the box parallel on to the bus trunking with cover in open condition and push it till it align completely.
8.4 Close the cover of box and place ring of front lock in latch of cover. Press lever of lock downwards to engageshorting wedge of Isolator.
8.5 Plug-in-box now can be energized.
Higher rating plug-in-box should also be inserted, in no-load condition. Boxes with MCCB/SFU have safetyinterlocking for this purpose i.e. plug-in possible with door-open condition only. Place the box parallel to bus
trunking and push it hard till it aligns completely. Loosen the clamps and fix it with the bus trunking enclosure.Plug-in-box thereafter can be energized after closing the door.
Fig. 2
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9 . 09 . 09 . 09 . 09 . 0 Ea r t h i ngEa r t h i ngEa r t h i ngEa r t h i ngEa r t h i ng
9.1 Bond the internal / external earthing busbars of
bustrunking system to main earthing of system with
adequate busbars or cable links as per standards
and electrical regulations.
9.2 Ensure earth connections are made properly, by
spring loaded clip in case of internal earthing and
by earthing links in case of external earthing during
JOINT ASSEMBLY.
9.3 Plug-in-boxes have integral earth clip which makes
automatic contact while plugging the box on to
the bustrunking.
10 .010 .010 .010 .010 .0 Inspect ion & TInspect ion & TInspect ion & TInspect ion & TInspect ion & Test ingest ingest ingest ingest ing
10.1 Inspection after installation
Before energizing check:
(a) Whether the bus trunking is not damaged.
(b) Whether the connecting parts are fixed
precisely.
(c) Whether the bolt connecting the equipment
are securely fastened.
(d) Whether the hangers are supporting the bus
trunking securely.
(e) Whether all the joint covers and tap off outlet
covers of bus trunking are closed.
(f) Whether all busbar joints are tightened to the
recommended torque.
(g) Whether end covers are fitted to the end of
all runs.
Thereafter INSULATION RESISTANCE of complete
installation (Run wise) shall be checked after
disconnecting all equipments either by opening
the isolator switch or setting the breakers in ‘OFF’
position. The insulation resistance value can not be
specified due to the difference of the length of run
/ route and the environmental condition, but if it
is a dried atmosphere, normally it shows a value
above 100MΩ (500V megger). In case it is below
10MΩ it has to be checked as it is most likely that
there may exist some factors which are reducing
the insulation. Megger value of bustrunking section
individually can be carried out by isolating joint
assembly to locate the fault. Reason for low
insulation value can be due to above mentioned
(a) to (g) factors, presence of moisture /
contaminants or breakage of busbar insulators /
joint insulators. Defective section may be put to hot
blowing air for drying the moisture and improving
megger value. If the insulation value does not
improve, contact the manufacturer.
10.2 Periodic checking
Even though the system is virtually maintenance
free following checks are recommended (for
guaranteeing safe usage of the bustrunking for a
long time) preferably once in a year.
(a) Check the external appearances
Check to ensure there is no deformation,
damage, dust etc. throughout the whole length
of the bus trunking and there is no dislocation,
bending and other abnormality of the
connecting covers, hangers and plug-in-
boxes.
(b) Environmental check
Environment where the bus trunking is used
sometimes changes after its installation. Check
that the environment is not hazardous even
part ial ly due to water, moisture, high
temperature, corrosive gas, immoderate
vibration, dust etc.
(c) Check the joint connections
Since the spring washers are employed in
busbar joints, there shall be no problem of joint
loosening. Therefore, periodical check is not
necessary if recommended torque is applied
to the joint clamp assembly during installation.
However it is advisable to re-check the
tightening after full loading of bustrunking to
the recommended torque.
(d) Check the load condition
Check and ensure that total load is not
exceeding the capacity of bustrunking.
Especially, pay attention when the main line
is branched by elbows, tee’s or crosses.
(e) Check the insulation resistance (IR)
Highly insulating, non-hygroscopic supports are
used for busbars, hence IR value should not
reduce at later stage. Still it is advisable to
check IR value by megger (500V) periodically.
11.0 Summary
11.1 Review all layout drawings and other technical
details very carefully.
11.2 Check description and identification of each piece
before installing it.
11.3 Follow the joint assembly instructions.
11.4 Check insulation resistance while fixing sections of
bustrunking during installation.
11.5 Check for possible source of contaminants that
may fall on the bus trunking during installation and
take preventive actions.
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Segregated Non-SegregatedPhase Busduct
(415V - 7.5kV, upto 5000 Amps.)
Isolated Phase Busduct(11-24kV, upto 20,000 Amps.)
Sandwich Insulated Busbar Trunking System (Low - Impedance)
(500 ~ 5000 Amps.)
Other Busbar Systems from C&SOther Busbar Systems from C&SOther Busbar Systems from C&SOther Busbar Systems from C&SOther Busbar Systems from C&S
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TTTTTypical Instal lat ionsypical Instal lat ionsypical Instal lat ionsypical Instal lat ionsypical Instal lat ions TTTTTypical Instal lat ionsypical Instal lat ionsypical Instal lat ionsypical Instal lat ionsypical Instal lat ions
Hotels
Bharat Hotels - Mumbai
ITC hotel - Mumbai
Le-Meridian Hotel - Pune
Maya Inn - Chandigarh
Sayaji Hotels - Indore
Hotel Kanishka - New Delhi
Multi Storey Buildings
Spenzer Plaza - Chennai
Hiranandani Gardens - Mumbai
S T Microelectronic - Noida
MMTC - Mumbai
IOCL - Mumbai / New Delhi
ONGC - Mumbai
Gold Hill Sqaure - Bangalore
Industries
APC - Bangalore
Auto Max - Gurgaon
Atlas Copco - Pune
Bajaj Auto - Pune/Aurangabad
Delphi India - Noida
Denso India Limited - Manesar
TVS Suzuki- Mysore
Kirloskar Motors - Chennai
Mercedes Benz - Pune
Hero Honda - Dhauwera
Hindustan Lever Limited - Assam
Subros - Noida
Escorts Farmatrac - Faridabad
Toyota Techno Park - Bangalore
BanksNABARD Bank - M umbai
Dena Bank - Mumbai
Union Bank of India - Mumbai
Software Parks
Adobe Software - Noida
Cadence Design Systems - Noida
Convergys technologies - Gurgaon
G.E. Capital - Hyderabad
IFlex - Bangalore
Mahindra British Telecom - Pune
Wipro technologies - Pune / Kolkatta / Chennai
Philips Software Centre - Bangalore
Tata Consulting Services - Calcutta
22
C-DOT, NEW DELHI
S T MICROELECTRONICS - NOIDA
GE CAPITAL - BANGALORE
PHILIPS SOFTWARE, BANGALORE
Major Installations
Hospitals
Appolo Hospital - Ahmedabad
Escorts Heart Institute - New Delhi
Jaideva Institute of Cardiology - Bangalore
Batra Hospital - New Delhi
G. P. Hospital - Mumbai
Maulana Azad - New Delhi
Govt. General Hospital - Chennai
Safdarjung Hospital - New Delhi
Dr. Hedgavers Arogya Sansthan - Delhi
Sir. Ganga Ram Hospital - New Delhi
Exhibition Halls
ITPO - New Delhi
ITPO - Chennai
M.P. Export facilitation Centre
CPWD / PWD
Parliament House - New Delhi
Parliament Library - New Delhi
Yojna Bhawan - New Delhi
Delhi Secretariat - New Delhi
Shastri Bhawan - New Delhi
Mayur Bhawan - New Delhi
Gene Bank (Pusa) - New Delhi
High Court - New Delhi
Railways
Northern Railway - Lucknow
Rail Bhawan - Delhi
Temple
Swamy Narayan Temple - Mumbai
Telecommunication
C-DOT - New Delhi
BSNL - New Delhi / Hyderabad
MTNL - Mumbai
DOT - Mumbai
Export Project
Alstom - South Africa
Cyber Tower, Ebene City - Mauritius
Evershine Trading Co. -Dubai
P. T. Prakasa Heavyndo - Malaysia
23
Major Installations
PARLIAMENT HOUSE, NEW DELHI
HIGH COURT - NEW DELHI
PARLIAMENT LIBRARY, NEW DELHI
DELHI SECRETARIAT, NEW DELHI
