FURUTEC

Busduct System

ABOUT FURUTEC
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 underlicensed 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 TV SD 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.

An Efficient Power Distribution System with Japanese Technology.

FURUTEC HP-Busduct
Phase Isolator High Tensile Joint Bolt Electro-Galvanized (EG) Sheet Steel Housing with Epoxy Powder Coating

Mylar Polyester Film

Leaf Spring Aluminium or Copper Conductor

1 2

4 TRANSFORMER
1 2 3 4 5 6 7 8 9 10 11 Edgewise Elbow with Flange End Busduct Straight Feeder Combination Elbow Flatwise Offset Flatwise Elbow with Flange End Flexible Link Edgewise Offset Flange End Box End Cap Tap Box Reducer 12 13 14 15 16 17 18 19 Vertical Spring Hanger Tap Off Unit Vertical Hanger Flatwise Elbow Busduct Joint Tee Elbow Edgewise Elbow End Closure

9 10

11

12 FLOOR SLAB

13

14 8

19 17

CABLE TRAY 15

16

18

SWITCHBOARD

CONTENT
About Furutec Busduct Design Layout Content Specification and Standards Testing & Certification Verification of Temperature Rise Limit Verification of Dieletric Properties Verification of Short Circuit Strength Verification of Effectiveness of the Protective Circuit Verification of Clearance and Creepage Distances Verification of Structural Strength Verification of Crushing Resistance Verification of Degree of Protection Verification of the Resistance of Insulating Materials to Abnormal Heat and Fire Verification of the Electrical Characteristics of the Busbar Trunking System Fire Resistance Test Physical Data HP-Busduct Copper & Aluminium Conductor Size Flange End / Flange End Box Flatwise Elbow / Edgewise Elbow TEE Elbow Flatwise Offset / Edgewise Offset Combination Elbow Elbow with Flange End / Flange End Box End Cap / End Closure Vertical Spring Hanger / Vertical Hanger Edgewise / Flatwise Hanger Expansion Unit Reducer Flexible Link Tap-Off Unit L-Duct Copper Conductor Size Flange End / Flange End Box Flatwise / Edgewise Elbow End Closure Vertical Spring Hanger / Vertical Hanger Flatwise / Edgewise Hanger Tap-Off Unit I II, III 01 02-05 06 06 07 08 08 08 08 09 09 10-11 12

13 14-15 16 17 18 19 20 21 22-23 24 25 26 27 28-29 30 31 32 32 33 34 34 35-37 38-44 45

Design Factors Installation & Maintenance Procedure Project Reference

CONTENTS | 01

SPECIFICATION & STANDARDS

General
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 class 2) Flexible and modular in design 3) Occupying lesser space 4) Fast installation and lower installation cost and easy maintenance 5) Lower voltage drop and higher short-circuit ratings 6) Good electro-magnetic shielding 7) Fire resistance and non-flammable propagation 8) Flexibility for future expansion 9) Strong mechanical strength, high degree of protection and applicable for large span installation

Design Standards
Furutec busduct system is designed and manufactured in accordance to the following international standards: IEC 60439-2 IEC 60439-1 JIS C 8364 IEC 60529:2001 BS 6387:1994 Particular Requirements for Busbar Trunking System (Busway) Low Voltage Switchgear and Controlgear Assemblies Japanese Industrial Standards for Busways Degree of Ingress Protection Performance Requirements for Cables required to Maintain Circuitry Integrity under Fire Conditions (Adoption) Method of Fire Resistance Test for Structural Parts of Buildings

JIS A 1304 BS 5486:Part 2 NEMA BU1 IEC60331 (Adoption)

System Voltage & Rated Current

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.

02 | SPECIFICATION & STANDARDS

System Configuration and Phase Sequence

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 todays modern buildings, harmonic current is an unavoidable effect that overheats 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.

L1 L2 L3

L1 L2 L3 N

50%E L1 L2 L3 N

3P3W
L1 L2 L3 200%N

3P4W
50%E L1 L2 L3 200%N

3P5W

3P4W 200% N

3P5W 200% N

Conductor and Insulation Material

Copper and aluminium conductors are of the conductivity 99.98% and 61%, respectively. Both conductors meet all electrical, 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.

Busduct Housing
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.

SPECIFICATIONS & STANDARDS | 03

Joint System
Furutec busduct joint features a maintenance-freedouble-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 causing distortion 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. HP-Busduct Joint Installation ( Indoor Type )
JOINT COVER M8 BOLT

M12 NUT

LEAF SPRING

ELECTRO-GALVANISED STEEL SHEET HOUSING

HIGH TENSILE M12 BOLT

LEAF SPRING

JOINT COVER

HP-Busduct Joint Installation ( Outdoor Type )

M6 NUTS OUTDOOR COVER M8 BOLT JOINT COVER

M12 NUT

LEAF SPRING
ELECTRO-GALVANISED STEEL SHEET HOUSING

HIGH TENSILE M12 BOLT

OUTDOOR COVER

LEAF SPRING

JOINT COVER

M6 SCREWS

04 | SPECIFICATION & STANDARDS

Method of Mounting
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.

Degree of Protection
Furutec busduct housing is designed and constructed to meet the requirement of indoor and outdoor installation. The degree of protection of Furutec busduct housing is verified and tested in accordance to IEC 60529 by ASTA, TV SD PSB and SIRIM Indoor Installation IP42, IP54 Outdoor Installation IP55, IP65, IP66 Long Period of Immersion IP68

Refer to page 9 for the definition of IP classification

Temperature Rise Limit

The temperature rise at any points of the external metal surface of busduct housing will not exceed 55oC above ambient temperature. The temperature rise at any points of external insulated conductors will not exceed 70oC above ambient temperature when operating 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 any derating effects.

SPECIFICATIONS & STANDARDS | 05

TESTING & CERTIFICATION

Furutec Busduct system has been tested and certified to IEC 60439-1 and IEC 60439-2 certified by ASTA and TV SD PSB.
PSB Singapore

Verification of Temperature Rise Limit

The following pictures illustrate some temperature rise tests successfully carried out on Furutec busduct system.

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.
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

Verification of Dielectric Properties

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 1.2/50s 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.

06 | TESTING & CERTIFICATION

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.
500 kA 250Ia 250 k/div -250-500 500 kA 250Ib 250 k/div -250-500 500 kA 250Ic 250 k/div -250-500

HP 660V 4000A U=310V

Ia=185.2kA Ib=190.0kA Ic=180.0kA I2t=37.49 GA2s Make break time: 1.05s

0.131

0.262

0.393

0.524

0.655

0.786

0.917

1.048

1.179 1.31
s

131 ms/div

Busduct Ratings (Ampere)

Short-time Withstand Current (kA/1 Sec)

Short-time Withstand Current (kA/3 Sec)

600A 800A 1000A 1200A 1350A 1500A 1600A 2000A 2500A 3200A 3500A 4000A 4500A 5000A 6000A

40 50 50 50 50 50 50 60 100 100 100 150 150 150 150

24 30 30 30 30 30 30 36 60 60 60 90 90 90 90

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 . 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 Clearance and Creepage Distances

Creepage is the shortest path between two conductive parts (or between a conductive part and the bounding surface of the equipment) 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 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 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.
Protection against ingress of solid objects
1mm

Protection against water

Protected against foreign objects greater than 1mm

0
1mm

No protection

15

Protected against foreign objects greater than 1mm

Drops of water falling at o up to 15 from the vertical

Dust protected

Projected water from all directions (limited ingress permitted)

Dust protected

Jets of water (limited ingress permitted)

Dust tight

Jets of water (limited ingress permitted)

Dust tight

Heavy jets of water (limited ingress permitted)

Dust tight

Effects of immersion between 15cm and 1m

1m

Dust tight

Long period of immersion under pressure

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.

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:

Aluminium Conductor
Busduct Ratings Frequency 50 Hz Resistance R Reactance X Impedance Z Resistance R Frequency 60 Hz Reactance X Impedance Z

600A 800A 1000A 1200A 1350A 1500A 1600A 2000A 2500A 3000A 3500A 4000A 4500A 5000A

1.257 0.848 0.641 0.518 0.436 0.378 0.360 0.286 0.218 0.180 0.143 0.126 0.120 0.095

0.323 0.235 0.185 0.152 0.129 0.113 0.107 0.084 0.065 0.054 0.042 0.038 0.036 0.028

1.297 0.879 0.667 0.540 0.454 0.394 0.375 0.298 0.228 0.188 0.149 0.131 0.125 0.099

1.385 0.851 0.645 0.523 0.443 0.386 0.367 0.293 0.221 0.184 0.146 0.129 0.122 0.098

0.387 0.282 0.222 0.183 0.155 0.135 0.128 0.101 0.078 0.064 0.051 0.045 0.043 0.034

1.438 0.896 0.682 0.554 0.469 0.409 0.389 0.310 0.235 0.195 0.155 0.136 0.130 0.103

(Unit = 10 -4

/m)

Copper Conductor
Busduct Ratings Frequency 50 Hz Resistance R Reactance X Impedance Z Resistance R Frequency 60 Hz Reactance X Impedance Z

600A 800A 1000A 1200A 1350A 1500A 1600A 2000A 2500A 3200A 3500A 4000A 4500A 5000A 6000A

0.974 0.784 0.530 0.405 0.331 0.331 0.282 0.235 0.166 0.141 0.123 0.110 0.094 0.082 0.078

0.380 0.323 0.235 0.185 0.152 0.152 0.129 0.107 0.076 0.065 0.056 0.051 0.043 0.038 0.036

1.045 0.848 0.580 0.445 0.364 0.364 0.311 0.259 0.182 0.155 0.135 0.121 0.104 0.091 0.086

0.977 0.789 0.536 0.412 0.338 0.338 0.289 0.241 0.169 0.144 0.127 0.113 0.096 0.084 0.080

0.456 0.387 0.282 0.222 0.183 0.183 0.155 0.128 0.091 0.078 0.068 0.061 0.052 0.045 0.043

1.078 0.879 0.606 0.468 0.384 0.384 0.328 0.273 0.192 0.164 0.143 0.126 0.109 0.096 0.091

(Unit = 10 -4

/m)

10 | TESTING & CERTIFICATION

Voltage Drop
Voltage Drop Calculation : V = 3 . I (Rcos + Xsin)
I 1 + ( 55 x ( I 0 )2 + 20 )

Where I

V I0 cos sin R R95 X

= Line-to-Line Voltage Drop (V/m) = Load Current (A) = Rated Current (A) = Load Power Factor = 1 - cos2

R95 x

1 + 75

= AC resistance at load current ( /m) = AC resistance at rated current (Io) ( /m) = Temperature coefficient of conductor at 20 oC = 3.85 x 10 3(Copper)/4.00 x 10 3 (Aluminium) = Reactance ( /m)

Line-to-Line Voltage Drop for 3-phase Aluminium Busduct

Busduct Ratings
600A 800A 1000A 1200A 1350A 1500A 1600A 2000A 2500A 3000A 3500A 4000A 4500A 5000A
Power Factor cos at 50Hz Power Factor cos at 60Hz

1.00 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

0.95 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

0.90 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

0.85 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

0.80 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

0.75 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

1.00 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

0.95 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

0.90 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

0.85 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

0.80 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

0.75 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

( Unit = Volt/m ) Line-to-Line Voltage Drop for 3-phase Copper Busduct

Busduct Ratings
600A 800A 1000A 1200A 1350A 1500A 1600A 2000A 2500A 3200A 3500A 4000A 4500A 5000A 6000A
Power Factor cos at 50Hz Power Factor cos at 60Hz

1.00 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

0.95 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

0.90 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

0.85 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

0.80 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

0.75 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

1.00 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

0.95 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

0.90 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

0.85 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

0.80 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

0.75 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

( Unit = Volt/m )

TESTING & CERTIFICATION | 11

Fire Resistance Test

Furutec Fire Rated Busduct is designed for essential electrical services. It is tested to JIS A 1304, BS 6387 (Adoption) and IEC 60331 (Adoption)
Polyester Film Mica Tape Conductor Mylar Polyester Film Fire-Rated Mica Tape Conductor

Resistance to Fire Alone IEC 60331 BS 6387 Category C JIS A 1304 : 3 hours at 750C : 3 hours at 950C : 30 mins at 840C

Resistance to Fire with Water BS 6387 Category W : 15 mins at 650C (with water spray 15 mins)

JIS A1304 Fire resistance test has been conducted on Furutec busduct system with joint section in an independant testing authority. Flame Temperature Test Voltage Test Duration Test Furnace : 840C : 660 V : 30 mins : Large scale fire resistant furnace, where the busduct is heated up to 840C from all directions.

BS 6387:1994 Category C Resistance to fire alone test has been conducted on Furutec busduct feeder and joint section in an independant testing authority. Flame Temperature Test Voltage Test Duration : 950 C : 660V : 3 hours

12 | TESTING & CERTIFICATION

PHYSICAL DATA
HP-BUSDUCT
Copper & Aluminium Conductor Size

Len ht aig Str m ard 000m nd 3 Sta

gth

MALE

FEMALE

3000mm ( Standard Straight Length )

Copper Conductor :
A
Busduct Ratings (Ampere) Model No. A (mm) 3P3W 3P4W 3P4W+E 3P5W B (mm) 3P3W 3P4W 3P4W+E 3P5W Figure Conductor Per Phase (mm) Total Weight (kg/m) 3P3W 3P4W 3P5W 3P4W+E

600A - 2000A Figure 1 A

600A 800A 1000A 1200A 1350A 1500A 1600A 2000A 2500A 3200A 3500A 4000A 4500A 5000A 6000A

HP600C HP800C HP1000C HP1200C HP1350C HP1500C HP1600C HP2000C HP2500C HP3200C HP3500C HP4000C HP4500C HP5000C HP6000C

115 125 150 175 200 200 225 260 400 450 500 600 675 750 780

100

120 2

One - 6 x 40 One - 6 x 50 One - 6 x 75 One - 6 x 100 One - 6 x 125 One - 6 x 125 One - 6 x 150 One - 6 x 185 Two - 6 x 125 Two - 6 x 150 Two - 6 x 175 Three - 6 x 125 Three - 6 x 150 Three - 6 x 175 Three - 6 x 185

14.0 16.0 20.9 25.8 30.8 30.8 35.7 42.6 61.5 71.4 81.2 92.3 107.0 121.8 127.7

16.2 18.7 25.0 31.3 37.6 37.6 43.9 52.7 75.3 87.9 100.4 112.9 131.8 150.7 158.2

17.3 20.1 27.1 34.1 41.1 41.1 48.1 57.8 82.1 96.1 110.1 123.2 144.2 165.1 173.5

Aluminium Conductor :
2500A - 3500A Figure 2 A
Busduct Ratings (Ampere) Model No. A (mm) 3P3W 3P4W 3P4W+E 3P5W B (mm) 3P3W 3P4W 3P4W+E 3P5W Figure Conductor Per Phase (mm) Total Weight (kg/m) 3P3W 3P4W 3P5W 3P4W+E

4000A - 6000A Figure 3

600A 800A 1000A 1200A 1350A 1500A 1600A 2000A 2500A 3000A 3500A 4000A 4500A 5000A

HP600A HP800A HP1000A HP1200A HP1350A HP1500A HP1600A HP2000A HP2500A HP3000A HP3500A HP4000A HP4500A HP5000A

125 150 175 200 225 250 260 315 450 520 630 750 780 945

100

120

One - 6 x 50 One - 6 x 75 One - 6 x 100 One - 6 x 125 One - 6 x 150 One - 6 x 175 One - 6 x 185 One - 6 x 240 Two - 6 x 150 Two - 6 x 185 Two - 6 x 240 Three - 6 x 175 Three - 6 x 185 Three - 6 x 240

10.2 12.3 14.3 16.4 18.4 20.4 21.3 25.8 36.8 42.5 51.5 61.3 63.8 77.3

11.1 13.5 16.0 18.4 20.9 23.3 24.3 29.7 41.8 48.7 59.5 70.0 73.0 89.2

11.5 14.1 16.8 19.5 22.1 24.8 25.9 31.7 44.3 51.7 63.5 74.4 77.6 95.2

PHYSICAL DATA | 13

Flange End / Flange End Box

600A~2000A Flange End
4-10 HOLES

600A~2000A Flange End Box

4-M8 BOLTS

TOP VIEW

A-60

TOP VIEW

A-30

OPENING B-60 E B

OPENING

REMOVABLE FRONT METAL COVER FRONT VIEW FRONT VIEW SIDE VIEW SIDE VIEW

150

150

6 C 100 100 100 C 100 100 100

450

NON-FERROUS MATERIAL BOTTOM COVER FOR CABLE TERMINATION

2500A~3500A Flange End

8-10 HOLES

2500A~3500A Flange End Box

4-M8 BOLTS

TOP VIEW

A-60

(A-30)/2

OPENING

TOP VIEW

OPENING B-60 E B F E

(A-30)/2

REMOVABLE FRONT METAL COVER

FRONT VIEW

150

150

FRONT VIEW

SIDE VIEW

SIDE VIEW

450 6 130 450

450

130

130

130

130

130

NON-FERROUS MATERIAL BOTTOM COVER FOR CABLE TERMINATION

14 | PHYSICAL DATA

4000A~5000A Flange End

10-10 HOLES

4000A~5000A Flange End Box

4-M8 BOLTS

OPENING A-60

TOP VIEW

(A-30)/2

TOP VIEW

OPENING B-60 E E B F F F E

(A-30)/2

REMOVABLE FRONT METAL COVER

F

FRONT VIEW

150

150

FRONT VIEW

SIDE VIEW

SIDE VIEW

6 450 130 130 130

450

130

130

130

NON-FERROUS MATERIAL BOTTOM COVER FOR CABLE TERMINATION

22

22

22

22

22

40

40

20

20

20

40

40

12 Fig. 1

20

20

40

D Fig. 2

D Fig. 4

D Fig. 5

Fig. 3

Busduct Ratings (Ampere) Figure Aluminium Copper 3P3W A 3P4W 3P4W+E 3P5W B

Dimensions (mm)

600 800 1000 1200 1350 1500 1600 2000 2500 3000 3500 4000 4500 5000

600 800 1000 1200 1350,1500 1600 2000 2500 3200 3500 4000 4500 5000 6000 -

1 1 2 2 3 3 4 4 5 3 3 4 4 5 3 3 4 4 5 410 540 350 450

175 185 210 235 260 285 310 320 375 460 510 560 580 690 660 735 810 840 1005

40 50 75 100 125 150 175 185 240 125 150 175 185 240 125 150 175 185 240

40 50 40 50 40 45 45 40 50 40 45 45 40 50 40 45 45

145 155 180 205 230 255 280 290 345 215 240 265 275 330 210 235 260 270 325 200 225 250 260 315 200 225 250 260 315 -

PHYSICAL DATA | 15

Flatwise Elbow / Edgewise Elbow

Edgewise Elbow
L1

L2

Busduct Ratings (Ampere) Aluminium Copper

Standard Lengths L1 x L2 (mm)

Minimum Lengths L1 x L2 (mm)

600 to 6000

400 x 400

270 x 270

Note : Maximum length of edgewise elbow (L1 + L2) is 2500mm

Flatwise Elbow
Busduct Ratings (Ampere) Aluminium Copper Standard Lengths L1 x L2 (mm) Minimum Lengths L1 x L2 (mm)

L2

600 800 1000 1200 1350 1500 1600 2000 2500 3000 3500 4000 4500 5000

600 800 1000 1200 1350,1500 1600 2000 2500 3200 3500 4000 4500 5000 6000 750 x 750 600 x 600 400 x 400

300 x 300 305 x 305 315 x 315 330 x 330 340 x 340 355 x 355 365 x 365 370 x 370 400 x 400 440 x 440 465 x 465 490 x 490 500 x 500 540 x 540 555 x 555 580 x 580 615 x 615 630 x 630 715 x 715

L1

Note : Maximum length of flatwise elbow (L1 + L2) is 2500mm

16 | PHYSICAL DATA

TEE Elbow

L1

L2

L3

Busduct Ratings (Ampere) Aluminium Copper

Standard Lengths L1 x L2 x L3 (mm)

Minimum Lengths L1 x L2 x L3(mm)

600 800 1000 1200 1350 1500 1600 2000 2500 3000 3500 4000 4500 5000

600 800 1000 1200 1350,1500 1600 2000 2500 3200 3500 4000 4500 5000 6000 750 x 750 x 750 600 x 600 x 600 400 x 400 x 400

235 x 235 x 235 240 x 240 x 240 250 x 250 x 250 265 x 265 x 265 275 x 275 x 275 290 x 290 x 290 300 x 300 x 300 305 x 305 x 305 335 x 335 x 335 375 x 375 x 375 400 x 400 x 400 425 x 425 x 425 435 x 435 x 435 475 x 475 x 475 490 x 490 x 490 515 x 515 x 515 550 x 550 x 550 565 x 565 x 565 650 x 650 x 650

Note : Maximum length of TEE elbow ( L1 + L2 + L3 ) is 2500mm

PHYSICAL DATA | 17

Flatwise Offset / Edgewise Offset

L1

L1

L2

L2

L3

L3

Flatwise Offset
Busduct Ratings (Ampere) Aluminium Copper Standard Lengths L1 x L2 x L3 (mm) Flatwise Offset Minimum Lengths L1 x L2 x L3 (mm)

Edgewise Offset
Edgewise Offset Standard Lengths L1 x L2 x L3 (mm) Minimum Lengths L1 x L2 x L3(mm)

600 800 1000 1200 1350 1500 1600 2000 2500 3000 3500 4000 4500 5000

600 800 1000 1200 1350,1500 1600 2000 2500 3200 3500 4000 4500 5000 6000 750 x 750 x 750 600 x 600 x 600 400 x 500 x 400

300 x 260 x 300 305 x 270 x 305 315 x 295 x 315 330 x 320 x 330 340 x 345 x 340 355 x 370 x 355 365 x 395 x 365 370 x 405 x 370 400 x 460 x 400 440 x 345 x 440 465 x 370 x 465 490 x 395 x 490 500 x 405 x 500 540 x 345 x 540 555 x 460 x 555 580 x 370 x 580 615 x 395 x 615 630 x 405 x 630 715 x 460 x 715 400 x 400 x 400 270 x 200 x 270

Note : Maximum length of offset elbow ( L1 + L2 + L3 ) is 2500mm

18 | PHYSICAL DATA

Combination Elbow

L1 L1

L2

L2

L3 L3

Busduct Ratings (Ampere) Aluminium Copper

Standard Lengths L1 x L2 x L3 (mm)

Minimum Lengths L1 x L2 x L3(mm)

600 800 1000 1200 1350 1500 1600 2000 2500 3000 3500 4000 4500 5000

600 800 1000 1200 1350,1500 1600 2000 2500 3200 3500 4000 4500 5000 6000 750 x 750 x 750 600 x 600 x 600 400 x 400 x 400

300 x 235 x 270 305 x 240 x 270 315 x 250 x 270 330 x 265 x 270 340 x 275 x 270 355 x 290 x 270 365 x 300 x 270 370 x 305 x 270 400 x 335 x 270 440 x 375 x 270 465 x 400 x 270 490 x 425 x 270 500 x 435 x 270 540 x 475 x 270 555 x 490 x 270 580 x 515 x 270 615 x 550 x 270 630 x 565 x 270 715 x 650 x 270

Note : Maximum length of combination elbow ( L1 + L2 + L3 ) is 2500mm

PHYSICAL DATA | 19

Elbow with Flange End / Flange End Box

L1

L3
L2

450

Edgewise Elbow with Flange End box

Busduct Ratings (Ampere) Aluminium Copper L1 Standard Lengths (mm) L2 L3 L4 L1

Flatwise Elbow with Flange End box

Minimum Lengths (mm) L2 L3 L4

600 800 1000 1200 1350 1500 1600 2000 2500 3000 3500 4000 4500 5000

600 800 1000 1200 1350, 1500 1600 2000 2500 3200 3500 4000 4500 5000 6000 750 600 600 400 400 275 275 400 400

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

Refer to page 14 and 15 for dimensions of A and B

20 | PHYSICAL DATA

450

L4

End Cap / End Closure

16

5m

B
A

A
35

End Closure

End Cap

Copper Busduct
Busduct Ratings (Ampere) A (mm) 3P3W 3P4W 3P4W+E 3P5W B (mm) 3P4W 3P4W+E 3P5W

Aluminium Busduct
Busduct Ratings (Ampere) A (mm) 3P3W 3P4W 3P4W+E 3P5W B (mm) 3P4W 3P4W+E 3P5W

3P3W

3P3W

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

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

PHYSICAL DATA | 21

Vertical Spring Hanger / Vertical Hanger

50

60
275 170 155 50

50

275

M10x30 BOLT 50 155 75 50

60 60
M10x30 BOLT 170

M10x30 BOLT

60

75 50

M10x30 BOLT

75

M12 STUD BOLT

SPRING M12 STUD BOLT

M12 STUD BOLT

SPRING M12 STUD BOLT

Vertical Hanger

Vertical Spring Hanger

Vertical Hanger

For 600A to 1000A HP-Busduct

For 1200A to 2000A HP-Busduct

M10x30 BOLT M10x30 BOLT 275 155 50 50

60 60
170

75 50

75

M12 STUD BOLT

SPRING M12 STUD BOLT

For 2500A HP-Busduct

Vertical hanger

Vertical Spring Hanger

M10x30 BOLT M10x30 BOLT 275 50 155 50

75

Vertical Spring Hanger

60

75 50

60

M12 STUD BOLT

SPRING M12 STUD BOLT

For 3000A to 3500A HP-Busduct

75 170

Vertical hanger

Vertical Spring Hanger

M10x30 BOLT M10x30 BOLT 275 155 50 50

60 60
170 75

75 50

M12 STUD BOLT

SPRING M12 STUD BOLT

For 4000A to 6000A HP-Busduct

Vertical Hanger

Vertical Spring Hanger

22 | PHYSICAL DATA

246 180

246 180

246 180

246 180 A A + 60 A A + 60 A + 60 A

120

600A - 1000A

A + 60

1200A - 2000A

2500A

3000A - 3500A

A A + 60

4000A - 6000A

246 120 60 BOLT HOLES 180 60 BOLT HOLES

246 180 60

A + 60 A

BOLT M10x30 50 50
50

140

140

140

50

50

155

155

155

50

STUD BOLT M12 BASE CHANNEL (BY CONTRACTORS)

75

75

FIRE BARRIER ( BY CONTRACTORS )

Vertical Hanger
246

FIRE BARRIER ( BY CONTRACTORS )

246 180 60

75

120 60 BOLT HOLES

180 60 BOLT HOLES

A + 60 A

BOLT M10x30 50 50
50 275 260 170

170

260

275

275

260

170

STUD BOLT M12 BASE CHANNEL (BY CONTRACTORS)

75

FIRE BARRIER ( BY CONTRACTORS )

75

Vertical Spring Hanger

FIRE BARRIER ( BY CONTRACTORS )

Refer to page 13 for the dimensions of A

75

PHYSICAL DATA | 23

Edgewise / Flatwise Hanger

Edgewise Hanger

ANGLE METAL BAR & HANGER ROD (BY CONTRACTORS)

ANGLE METAL BAR & HANGER ROD (BY CONTRACTORS)

EDGEWISE HANGER 2-M10 x 30 BOLT

B C

14 HOLES

EDGEWISE HANGER

Fig 1
A B

2-M10 BOLT ANGLE METAL BAR & HANGER ROD (BY CONTRACTORS)

14 HOLES

Fig 3

Flatwise Hanger

ANGLE METAL BAR & HANGER ROD

2-M10x30 BOLT
EDGEWISE HANGER
A B A B C

(BY CONTRACTORS)

14 HOLES

2-M10 BOLT

14 HOLES

Fig 2
Dimensions (mm) Busduct Ratings (Ampere) A Fig B C

Busduct Rating (Ampere) Aluminium Copper A

Dimensions (mm) B C

3P4W 3P4W 3P4W 3P3W 3P4W+E 3P3W 3P4W+E 3P3W 3P4W+E 3P5W 3P5W 3P5W

600 800 1000 1200 1350 1500 1600 2000 2500 3000 3200 3500 4000 4500 5000 6000

140

160

240

300

220 2 112 3 132 220

280

280

600 800 1000 1200 1350 1500 1600 2000 2500 3000 3500 4000 4500 5000

600 800 1000 1200 1350, 1500 1600 2000 2500 3200 3500 4000 4500 5000 6000 -

38 48 73 98 123 148 173 183 238 323 373 423 443 523 553 598 673 703 868

165 175 200 225 250 275 300 310 365 450 500 550 570 650 680 725 800 830 995

225 235 260 285 310 335 360 370 425 510 560 610 630 710 740 785 860 890 1055

24 | PHYSICAL DATA

Expansion Unit
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.

45

50

Busduct Ratings (Ampere) Aluminium Copper

A (mm)

600 800 1000 1200 1350 1500 1600 2000 2500 3000 3500 4000 4500 5000

600 800 1000 1200 1350,1500 1600 2000 2500 3200 3500 4000 4500 5000 6000 -

115 125 150 175 200 225 250 260 315 400 450 500 520 630 600 675 750 780 945

PHYSICAL DATA | 25

Reducer
Reducer is used to reduce busbar sizes to the final load. It provides users with more economic power transmission and distribution method. The minimum length (L) is 600mm and the reduction from one busbar size to another does not exceed 50%

L L

26 | PHYSICAL DATA

Flexible Link

BUSDUCT SYSTEM

FLANGE END

TRANSFORMER LV BOX (NOT THE SCOPE OF BUSDUCT MANUFACTURERS)

FLEXIBLE LINK

Dimension of Flexible Link according to busduct ratings

50 25 25 25 30 100 40 30 25 40 120 40 40 25 35 40 150 40 35 25 "T"

40

40

40

20

20

20

150

150

150

150

20

40

20

20

20

40

40

40

25

25

25

25

25 4-12 HOLES

30

40
FIG. 2

30 8-12 HOLES
Dimension

40

40
FIG. 3

40 8-12 H OLES

35

40
FIG. 4

40

35 12-12 HOLES
Dimension

FIG. 1

Busduct Ratings

Fig

Type

T (mm)

Busduct Ratings

Fig

Type

T (mm)

600A 800A 1000A 1200A 1350A 1500A 1600A

F5013 x 1

13

2000A 2500A 3000A 3200A 3500A 4000A 4500A 5000A 6000A

4 3 4 3 4 4

F15014 x 1 F12014 x 2 F15014 x 2 F12014 x 3 F15014 x 3 F15016 x 3

14.5 14 14.5 14 14.5 16

F10013 x 1

13

F12014 x 1

14

25

40

20

PHYSICAL DATA | 27

320

Tap-Off Units
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.

100AF, 225AF & 400AF Tap-Off Unit & Plug In Hole (Plug In Type)
PLUG IN HOLE COVER

PLUG IN HOLE

MCCB PLUG IN BOX

L

Phase Isolator To segregate the tapping position of each phase of the conductors

MCCB Rating

Fig

100AF 225AF 400AF

340 430 550

230 265 310

200 220 250

1 1 2

W
N

70

70

L3

L2

L1

Open E REMOVABLE BOTTOM COVER FOR CABLE TERMINATION E

160

REMOVABLE BOTTOM COVER FOR CABLE TERMINATION

Open

Fig 1

Fig 2

E L1 L2 L3 N

E L1 L2 L3 N

100AF & 225AF Plug In Box

Refer to the installation procedures of tap-off units on page 41

400AF Plug In Box

28 | PHYSICAL DATA

160

600AF, 800AF, 1000AF & 1200AF Tap Box and Tap Bar (Bolt On Type)
4-M6 Screw

REMOVABLE BOTTOM COVER FOR CABLE TERMINATION

TAP BAR

TAP BOX

MCCB Rating

600AF 800AF 1000AF 1200AF

373 373 488 488

908 998 1108 1108

200 200 290 290

PHYSICAL DATA | 29

L-Duct
Copper & Aluminium Conductor Sizes
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).

Conductors

Phase Isolator

Electro-Galvanized Sheet Steel Housing with Epoxy Powder Coating

167

L1

L2

L3

Copper Conductor :
Busduct Ratings (Ampere) 200A 300A 400A A (mm) 56 71 96 Conductor per Phase (mm) 3 x 20 3 x 35 3 x 60 Weight (kg/m) 7.5 9.5 12.5

30 | PHYSICAL DATA

Flange End / Flange End Box Flange End

4-10 HOLES

OPENING

B-60

B-30

OPENING A-60 E N L3 L2 A-30 A L1

L1 E D

L2 D

L3 D

Flange End Box

F G
NON-FERROUS MATERIAL BOTTOM COVER FOR CABLE TERMINATION

D D
H

20

REMOVABLE METAL FRONT COVER L3 L2 L1

11 HOLE

2-11 HOLE

Figure 1

Figure 2

Copper Busduct System :

Busduct Rating (Ampere) Fig A (mm) B (mm) C (mm) D (mm) E (mm) F (mm) G (mm) H (mm)

200A 300A 400A

1 1 2

360 360 450

150 165 190

120 120 160

70 70 100

20 35 60

350 350 400

350 350 500

120 135 160

PHYSICAL DATA | 31

20

40

Flatwise / Edgewise Elbow

E N L3 L2

E N L1 L3 L2

L1

Flatwise Elbow

Edgewise Elbow

End Closure

15

17

0
Copper Busduct System
Busduct Ratings (Ampere) A (mm)

200A 300A 400A

59 74 99

32 | PHYSICAL DATA

Vertical Spring Hanger / Vertical Hanger

167 STUD BOLT (M12x330) 250 A 250 BASE CHANNEL (BY CONTRACTORS) SPRING 167 30 A 50

FLAT HANGING CLAMP

BOLT M10x30 C/W CLAMP 20 50 40 140 STUD BOLT M12 BASE CHANNEL (BY CONTRACTORS)

145

FRONT VIEW

75

FIRE BARRIER (BY CONTRACTORS)

Vertical Spring Hanger

167 A STUD BOLT (M12x220) 250 250 FLAT HANGING CLAMP BASE CHANNEL (BY CONTRACTORS) 167 30 A 50

BOLT M10x30 C/W CLAMP 20 40 260 170

265

STUD BOLT M12 BASE CHANNEL (BY CONTRACTORS)

FRONT VIEW

75

Vertical Hanger
Busduct Ratings (Ampere) A (mm)

FIRE BARRIER (BY CONTRACTORS)

200A 300A 400A

56 71 96

Copper Busduct System

PHYSICAL DATA | 33

Flatwise / Edgewise Hanger

HOLDER

ANGLE METAL BAR & HANGER ROD (BY CONTRACTORS)

FLAT HANGING CLAMP

167

ANGLE METAL BAR & HANGER ROD (BY CONTRACTORS)

172

A B
208 288 348

Edgewise Hanger

Flatwise Hanger
Busduct Ratings (Ampere) A (mm) B (mm) C (mm)

200 300 400

128 143 168

208 223 248

268 283 308

Tap-Off Units
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.
W H 63 70
W L

E H

Open

REMOVABLE BOTTOM COVER FOR CABLE TERMINATION E

L3

L2

L1 E

MCCB Rating

W (mm)

L (mm)

H (mm)

100AF 225AF

195 230

400 500

118 118

Refer to the installation procedures of tap-off units on page 41

L1 L2 L 3 N

34 | PHYSICAL DATA

DESIGN FACTORS
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).

JOINT POINT JOINT POINT

190

(C)

Busduct Ratings (Ampere)

Dimension A (mm) 3P3W 3P4W/3P5W

Dimension B (mm) 3P3W 3P4W/3P5W

600 - 6000A

150

160

85

95

1.2 Outdoor Type (Edgewise Installation). Busduct joints installed side by side.
A A

Busduct joints installed deviating from each other (Dimension C is above 500mm).
B 110 B

110

JOINT POINT JOINT POINT

500

(C)

JOINT POINT

Busduct Ratings (Ampere)

Dimension A (mm) 3P3W 3P4W/3P5W

Dimension B (mm) 3P3W 3P4W/3P5W

600-6000A

170

190

130

150

DESIGN FACTORS | 35

60

1.3 Indoor / Outdoor Type (Flatwise Installation). Minimum clearance for busduct installed flatwise in parallel.

100

100

1.4 Plug-in Type Busduct Installation. Minimum clearance for plug-in busduct installed in parallel.

PLUG IN BUSDUCT

PLUG IN BOX

50

50

2. Minimum Clearance between busduct and wall, floor, etc. 2.1 Ceiling and Wall. 2.2 Beam.

CEILING

CEILING
200

CEILING

200

190 WALL WALL

50

200

200

JOINT POINT

36 | DESIGN FACTORS

2.3 Distance between busduct joint and wall surface for through wall installation Indoor Type Busduct.
WALL

Outdoor Type Busduct.

WALL

240

240

240

JOINT POINT (INDOOR TYPE)

JOINT POINT (INDOOR TYPE)

JOINT POINT (OUTDOOR TYPE)

2.3 Distance between busduct joint and floor/ceiling surface for through floor installation (A) and ceiling installation (B)

JOINT POINT

450 75

300

(A)

VERTICAL HANGER BASE CHANNEL (BY CONTRACTORS)

75

FLOOR SLAB

(A) FLOOR SLAB (B)

VERTICAL SPRING HANGER

240

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.

240

(B)

DESIGN FACTORS | 37

INSTALLATION & MAINTENANCE PROCEDURE

Common Practice
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
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.

38 | INSTALLATION & MAINTENANCE PROCEDURE

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.

M5 SCREW

JOINT COVER

PHASE ISOLATOR

M8 BOLT

BELLEVILLE WASHER SPRING WASHER M8 NUT

M6 SCREW

EXTERNAL EARTH BAR SIDE COVER

L1 L2 L3 N

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.

2
Insert Earth Jaw here

4
Plug in Clips

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

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.

Vertical Spring Hanger / Vertical Hanger

1. Drill 4 nos bolt holes of 12mm 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

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 M (500V Megger). In case, the measurement is less than 10M , 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 Furutecs 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 busduct system 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 the environment 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 operating temperature of busduct system. For the ease of maintenance, a thermal indicator can be placed onto the busduct housing. If the temperature rise of the busduct housing 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 manufacturers 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 to be 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 5M 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

PROJECT REFERENCE
Commercial Projects

Resort World Sentosa (Singapore)

Genting Highland (Malaysia)

Suria KLCC & Maxis Tower (Malaysia)

Crown Plaza Hotel (Singapore)

Four Point Hotel Sheraton (Malaysia)

Empire Subang (Malaysia)

OCBC Bank (Malaysia)

Asia City Shopping Mall (Malaysia)

Jusco Bandar Perda Penang (Malaysia)

Sunway Pyramid Mall (Malaysia)

Public Utility Projects

Serdang Hospital (Malaysia)

Sungai Buloh Hospital (Malaysia)

Nanyang Technology University NTU 4/5/6 (Singapore)

Supreme Court (Singapore)

Duke NUS Graduate Medical School (Singapore)

Industrial Projects

Renewable Energy Corporation - REC (Singapore)

Infineon Kulim (Malaysia)

Soitec Wafer Plant (Singapore)

Fuji Electric (Malaysia)

Residential Projects

Impian Meridian Mixed Development (Malaysia)

Hartamas Regency K2 (Malaysia)

Midvalley North Point Condominium & office Tower (Malaysia)

Bintang Fairlane Residences (Malaysia)

PROJECT REFERENCE | 45

Tel: +603-5637 8363 Fax: +603-5635 0538 Website: www.eita.com.my

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FURUTEC

Tel: +604-508 0228 Fax: +604-508 0227 E-mail: furutec@eita.com.my Website: www.furutec.com.my

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