FURUTEC - Konia-Group busduct system... · licensed Furukawa busduct system, Furutec is noted for ... IEC 60439-2 Particular Requirements for Busbar ... Furutec Busduct System is

FURUTECBusduct System

An Efficient PowerDistribution System withJapanese Technology.

Furutec Electrical Sdn Bhd was incorporated in Penang, Malaysia in 1995 to manufacture under-licensed Furukawa Busduct System. It is officially a wholly-owned subsidiary of the EITA Group of Companies with state-of-the-art CNC and laser cutting manufacturing facilities in 2008.

Having benefitted from more than a decade-long of experience in producing under- licensed Furukawa busduct system, Furutec is noted for its relentless and uncompromising commitment on quality and excellence as the Japanese manufacturing practice and culture have been firmly embedded into Furutec busduct system. Continuing with the tradition of stringent Japanese technology and accumulated 10 years of experience in producing Furukawa busduct system, Furutec busduct system is today a proud Malaysian brand of precision and quality.

The commitment towards quality products and services has enabled us to achieve ISO 9001:2008 Quality Management System.

Furutec Busduct System is tested and certified by ASTA, INTERTEK and TÜV SÜD PSB in accordance to IEC 60439-2, IEC 60439-1, IEC 60529:2001, BS 6387:1994, JIS A1304 and other international standards. In 2009, Furutec busduct system has successfully obtained its full type test certificates from ASTA UK in accordance to IEC60439-1 & IEC60439-2.

Furthermore, with our well-equipped and state-of-the-art R&D laboratory, our products are verified for temperature rise-limit test for current up to 6000A according to the international standards, namely IEC 60439-1, IEC 60439-2 , JIS C8364 and so on. We continue to innovate in order to meet our customers’ expectation and trust towards our products.

Our products are successfully installed in various prestigious projects in Malaysia as well as South East Asia for the past decade. We take pride in further expanding our success to more countries through our regional partners.

ABOUT FURUTEC

FURUTEC HP-Busduct

Phase Isolator

Mylar Polyester Film

Electro-Galvanized (EG)Sheet Steel Housing withEpoxy Powder Coating

Leaf Spring

High Tensile Joint Bolt

Aluminium or Copper Conductor1

2

TRANSFORMER

3

4

5

6

1 Edgewise Elbow with Flange End2 Busduct Straight Feeder3 Combination Elbow4 Flatwise Offset5 Flatwise Elbow with Flange End6 Flexible Link7 Edgewise Offset8 Flange End Box9 End Cap10 Tap Box11 Reducer

12 Vertical Spring Hanger13 Tap Off Unit14 Vertical Hanger15 Flatwise Elbow16 Busduct Joint17 Tee Elbow18 Edgewise Elbow19 End Closure

7

CABLETRAY

8

9

10

1112

13

14

15

17

18

19

16

SWITCHBOARD

FLOOR SLAB

About Furutec IBusduct Design Layout II, IIIContent 01

Specification and Standards 02-05

Testing & Certification Verification of Temperature Rise Limit 06 Verification of Dieletric Properties 06 Verification of Short Circuit Strength 07 Verification of Effectiveness of the Protective Circuit 08 Verification of Clearance and Creepage Distances 08 Verification of Structural Strength 08 Verification of Crushing Resistance 08 Verification of Degree of Protection 09 Verification of the Resistance of Insulating Materials to Abnormal Heat and Fire 09 Verification of the Electrical Characteristics of the Busbar Trunking System 10-11 Fire Resistance Test 12

Physical DataHP-Busduct Copper & Aluminium Conductor Size 13 Flange End / Flange End Box 14-15 Flatwise Elbow / Edgewise Elbow 16 TEE Elbow 17 Flatwise Offset / Edgewise Offset 18 Combination Elbow 19 Elbow with Flange End / Flange End Box 20 End Cap / End Closure 21 Vertical Spring Hanger / Vertical Hanger 22-23 Edgewise / Flatwise Hanger 24 Expansion Unit 25 Reducer 26 Flexible Link 27 Tap-Off Unit 28-29

L-Duct Copper Conductor Size 30 Flange End / Flange End Box 31 Flatwise / Edgewise Elbow 32 End Closure 32 Vertical Spring Hanger / Vertical Hanger 33 Flatwise / Edgewise Hanger 34 Tap-Off Unit 34

Design Factors 35-37

Installation & Maintenance Procedure 38-44

Project Reference 45

CONTENTS | 01

CONTENT

Furutec busduct system is designed to meet the requirement of commercial, industrial and residential applications. It carries up to 6000A with reduced energy losses and heat.

Furutec busduct system is known for:

1) Low current density in its class2) Flexible and modular in design3) Occupying lesser space4) Fast installation and lower installation cost and easy maintenance5) Lower voltage drop and higher short-circuit ratings6) Good electro-magnetic shielding7) Fire resistance and non-flammable propagation8) Flexibility for future expansion9) Strong mechanical strength, high degree of protection and applicable for large span installation

Furutec busduct system is designed and manufactured in accordance to the following international standards:

IEC 60439-2 Particular Requirements for Busbar Trunking System (Busway)IEC 60439-1 Low Voltage Switchgear and Controlgear AssembliesJIS C 8364 Japanese Industrial Standards for BuswaysIEC 60529:2001 Degree of Ingress ProtectionBS 6387:1994 Performance Requirements for Cables required to Maintain Circuitry Integrity under Fire Conditions (Adoption)JIS A 1304 Method of Fire Resistance Test for Structural Parts of BuildingsBS 5486:Part 2NEMA BU1IEC60331 (Adoption)

The maximum operating voltage of Furutec busduct is 660V. The rated current of HP-Busduct is from 600A to 6000A and L-Duct from 200A to 400A for both copper and aluminium busduct system.

General

Design Standards

System Voltage & Rated Current

02 | SPECIFICATION & STANDARDS

SPECIFICATION & STANDARDS

Busduct Housing

The compact sandwich design of HP-busduct can be configured to 3-phase 3-wire (3P3W), 3-phase 4-wire (3P4W) or 3-phase 5-wire (3P5W with integral earth bar).

Due to the existence of non-linear loads in today’s modern buildings, harmonic current is an unavoidable effect thatoverheats the neutral conductor and deteriorate the performance of equipment. Furutec HP-Busduct offers an additional neutral conductor as an option to minimize the harmonic effects.

Copper and aluminium conductors are of the conductivity 99.98% and 61%, respectively. Both conductors meet allelectrical, thermal and mechanical properties and comply to the relevant international standards, such as JIS H3140, ASTM B187M, BS EN 13601, etc.

Each aluminium or copper conductor (except at joint parts) is wholly insulated with multi-layer polyester films. The polyester film meets the requirement of Class B(130oC). Class F and Class H are optional. The rated insulation voltage is up to 1000V at 50Hz or 60Hz of frequency. Each conductor is tin-plated (silver-plated as an option) to provide protection from corrosion and high conductivity at the contact surface.

Furutec busduct system is of the low impedance type and totally enclosed for protection against mechanical damage and dust accumulation. The busduct housing is made of Electro-Galvanized sheet steel with epoxy powder coating.

Conductors are fully enclosed with the busduct housing, which provides an excellent heat dissipation, thus improving the power transmission efficiency and reducing voltage drop. The construction of busduct housing is compact and robust in design to meet the rated short-circuit ratings.

System Configuration and Phase Sequence

Conductor and Insulation Material

3P3W

L1

L2

L3

3P4W

L1

L2

L3

N

3P5W

50%E

L1

L2

L3

N

3P4W 200% N

L1

L2

L3

200%N

3P5W 200% N

50%E

L1

L2

L3

200%N

SPECIFICATIONS & STANDARDS | 03

Joint System

HP-Busduct Joint Installation ( Indoor Type )

HP-Busduct Joint Installation ( Outdoor Type )

JOINT COVER

HIGH TENSILE

LEAF SPRING

LEAF SPRING

JOINT COVER

ELECTRO-GALVANISEDSTEEL SHEET HOUSING M12 BOLT

M12 NUT

M8 BOLT

JOINT COVER

HIGH TENSILE

LEAF SPRING

LEAF SPRING

JOINT COVER

M12 BOLT

M8 BOLT

M12 NUT

M6 NUTS

M6 SCREWS

OUTDOOR COVER

OUTDOOR COVER

ELECTRO-GALVANISEDSTEEL SHEET HOUSING

Furutec busduct joint features a “maintenance-free”double-bolt joint design. This double-bolt joint system ensures a sufficient electrical contact area and good mechanical strength. Its high tensile clamping bolts in duct-to-duct jointing do not penetrate through the conductors. A spring steel material named as leaf spring that is wider than the conductors, is used to ensure a constant pressure on conductor contact area. It is believed that this clamped joints generate less heat at busduct joint as compared to bolted joint system, which necessitate the drilling or punching of holes through the conductors with the bolt holes causingdistortion to the lines of current flow. This clamped joint with leaf springs also has a more even contact pressure than the one using bolt-through joint.

04 | SPECIFICATION & STANDARDS

Method of Mounting

Degree of Protection

Temperature Rise Limit

For horizontal busduct installation, the edgewise/flatwise hanger or flat hanging clamp shall be installed in every 1500mm interval.

Vertical busduct system shall be supported adequately with vertical spring hanger / vertical hanger at each floor. Intermediate supports shall be provided if floor height exceeds 5000mm.

Furutec busduct housing is designed and constructed to meet the requirement of indoor and outdoor installation. The degreeof protection of Furutec busduct housing is verified and tested in accordance to IEC 60529 by ASTA, TÜV SÜD PSB and SIRIM

Refer to page 9 for the definition of IP classification

The temperature rise at any points of the external metal surface of busduct housing will not exceed 55oC above ambienttemperature.

The temperature rise at any points of external insulated conductors will not exceed 70oC above ambient temperature whenoperating at rated load current.

Both parameters are in line with IEC60439-1 and IEC60439-2.

Furutec busduct system is able to operate at full rated current at a maximum ambient air temperature of 40oC without anyderating effects.

Indoor Installation

IP42, IP54

Long Period of Immersion

IP68

Outdoor Installation

IP55, IP65, IP66

SPECIFICATIONS & STANDARDS | 05

Furutec Busduct system has been tested and certified to IEC 60439-1and IEC 60439-2 certified by ASTA and TÜV SÜD PSB.

Verification of Temperature Rise Limit

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

Verification of Dielectric Properties

Furutec Busduct System is capable of carrying full rated current continuously in ambient condition of 95% relative humidity and maximum ambient temperature of 40oC. When busduct is installed in a higher ambient temperature, the busduct current ratings shall be derated according to the factors as illustrated in the table below.

It comprises two tests, namely dielectric test voltage and impulse voltage withstand test. They are applied to all live parts and interconnected exposed conductive parts of the busduct system.

For the impulse voltage withstand test, the busduct is tested with a test voltage of 7.4kVpk. The 1.2/50µs impulse voltage applied 3 times at the interval of 1s minimum.

For the dielectric test voltage, it is carried out after the type tests, such as temperature rise test, short circuit strength test, degree of protection test, structural strength test, crushing resistance test, etc in order to ensure that no electricity current leaking occurs.

Ambient Temperature oC

40

45

50

55

60

65

70

Derating Factor

1.00

0.95

0.90

0.85

0.80

0.74

0.67

PSB Singapore

06 | TESTING & CERTIFICATION

TESTING & CERTIFICATION

600A800A

1000A1200A1350A1500A1600A2000A2500A3200A3500A4000A4500A5000A6000A

Short-time Withstand Current(kA/3 Sec)

Short-time Withstand Current(kA/1 Sec)

Busduct Ratings(Ampere)

4050505050505060

100100100150150150150

243030303030303660606090909090

500

Ia250 k/div

HP660V4000A

Make break time: 1.05s

U=310V

Ia=185.2kAIb=190.0kAIc=180.0kAI2t=37.49 GA2s

250-

-250-

-500

kA

500

Ib250 k/div

250-

-250-

-500

kA

500

Ic250 k/div

250-

-250-

-500

kA

0131 ms/div s

0.131 0.262 0.393 0.524 0.655 0.786 0.917 1.048 1.179 1.31

Verification of Short-Circuit Strength

Short-circuit tests have been conducted on Furutec HP-Busduct system. The above left picture illustrates an example of a 4000A HP-Busduct tested with 180kA/sec short-circuit condition.

TESTING & CERTIFICATION | 07

Verification of the Effectiveness of the Protective Circuit

This test is conducted in 2 sessions. The first test is to verify effective connection between the exposed conductive parts of busduct and the protective circuit, where the resistance between the incoming protective conductor and the relevant exposed conductive part must not exceed 0.1 Ω. The second test is to verify the short-circuit strength of the protective circuit, where the single phase test between protective conductor and the nearest phase conductor. The value of the prospective short circuit current used is 60% of the value of the prospective short circuit current of the 3 phases short circuit withstand test of the busduct system.

Verification of Structural Strength

The verification of structural strength has been conducted on a horizontal installation of HP-Busduct. Mechanical loads are applied to both HP-Busduct feeder and joint section for the duration of five minutes.

Verification of Clearance and Creepage Distances

Creepage is the shortest path between two conductive parts (or between a conductive part and the bounding surface of theequipment) measured along the surface of the insulation. A proper and adequate creepage distance protects against tracking, a process that produces a partially conducting path of localized deterioration on the surface of an insulating material as a result of the electric discharges on or close to an insulation surface. Clearance is the shortest distance between two conductive parts (or between a conductive part and the bounding surface of the equipment) measured through air. Clearance distance helps prevent dielectric breakdown between electrodes caused by the ionization of air. The dielectric breakdown level is further influenced by relative humidity, temperature, and degree of pollution in the environment. For this verification test, the minimum distance for the creepage and clearance involves phase to phase & phase to earth of the busduct system.

Verification of Crushing Resistance

A HP-busduct straight feeder, which is supported horizontally on a flat surface, is tested and verified to withstand a crushing force of at least four times its linear mass (kg/m) for the duration of five minutes on minimum four different locations of the busduct.


Verification of Degree of Protection

The enclosure of Furutec Busduct System is tested in accordance to IEC60529:2001 Classification of Degree of Protection. Furutec Busduct System is verified to comply with IP6X and IPX6 requirement.

The IP classification is categorized into 2 parts; The first digit denotes protection against ingress of solid objects and the second digit denotes protection against water.

Verification of the Resistance of Insulating Materials to Abnormal Heat and Fire

The glow wire test is used to simulate the effect of heat as it may arise in malfunctioning electrical equipment, such as with overloaded or glowing components. The glow wire test is conducted according to IEC 60695-2-10 and IEC 60695-2-11 on the insulating material taken from the Busduct. A test specimen is held for 30 seconds against the tip of the glow wire. The glow wire heated through electricity resistance with the temperature heated up to 960oC.

Protection against ingress of solid objects Protection against water

Protected against foreign objects greater than 1mm

Protected against foreign objects greater than 1mm

Dust protected

Dust protected

Dust tight

Dust tight

Dust tight

Dust tight

No protection

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

Projected water from all directions (limited ingress permitted)

Jets of water(limited ingress permitted)

Jets of water(limited ingress permitted)

Heavy jets of water(limited ingress permitted)

Effects of immersion between 15cm and 1m

Long period of immersion under pressure

4 0

2

4

5

5

6

7

8

4

5

5

6

6

6

6

1mm

15O

1m

1mm


Verification of the Electrical Characteristics of the Busbar Trunking System

Due to low impedance, the voltage drop of busduct system is low compared to conventional cable system. Therefore, busduct system is a more efficient power transmission media as compared to conventional cable system. The value of resistance, reactance and impedance of HP-Busduct at both 50Hz and 60Hz 3-Phase AC are illustrated in the tables below:

BusductRatings Resistance

R

600A800A1000A1200A1350A1500A1600A2000A2500A3000A3500A4000A4500A5000A

1.2570.8480.6410.5180.4360.3780.3600.2860.2180.1800.1430.1260.1200.095

ReactanceX

Frequency 50 Hz

0.3230.2350.1850.1520.1290.1130.1070.0840.0650.0540.0420.0380.0360.028

ImpedanceZ

1.2970.8790.6670.5400.4540.3940.3750.2980.2280.1880.1490.1310.1250.099

ResistanceR

1.3850.8510.6450.5230.4430.3860.3670.2930.2210.1840.1460.1290.1220.098

ReactanceX

Frequency 60 Hz

0.3870.2820.2220.1830.1550.1350.1280.1010.0780.0640.0510.0450.0430.034

ImpedanceZ

1.4380.8960.6820.5540.4690.4090.3890.3100.2350.1950.1550.1360.1300.103

Aluminium Conductor

BusductRatings

600A800A1000A1200A1350A1500A1600A2000A2500A3200A3500A4000A4500A5000A6000A

0.9740.7840.5300.4050.3310.3310.2820.2350.1660.1410.1230.1100.0940.0820.078

Frequency 50 Hz

0.3800.3230.2350.1850.1520.1520.1290.1070.0760.0650.0560.0510.0430.0380.036

1.0450.8480.5800.4450.3640.3640.3110.2590.1820.1550.1350.1210.1040.0910.086

0.9770.7890.5360.4120.3380.3380.2890.2410.1690.1440.1270.1130.0960.0840.080

Frequency 60 Hz

0.4560.3870.2820.2220.1830.1830.1550.1280.0910.0780.0680.0610.0520.0450.043

1.0780.8790.6060.4680.3840.3840.3280.2730.1920.1640.1430.1260.1090.0960.091

ResistanceR

ReactanceX

ImpedanceZ

ResistanceR

ReactanceX

ImpedanceZ

Copper Conductor

(Unit = 10 -4 Ω/m)

(Unit = 10 -4 Ω/m)


Voltage Drop

Voltage Drop Calculation :

V = 3 . I (RcosØ + XsinØ)

R = R95 x1 + α( 55 x ( )2 + 20 )

1 + 75α

I

I0

V = Line-to-Line Voltage Drop (V/m)

I = Load Current (A)

I0 = Rated Current (A)

cosØ = Load Power Factor

sinØ =

R = AC resistance at load current (Ω/m)

R95 = AC resistance at rated current (Io) (Ω/m)

α = Temperature coefficient of conductor at 20 oC = 3.85 x 10 –3(Copper)/4.00 x 10 –3 (Aluminium)

X = Reactance (Ω/m)

1 - cos2 Ø

Where

BusductRatings

600A

800A

1000A

1200A

1350A

1500A

1600A

2000A

2500A

3000A

3500A

4000A

4500A

5000A

0.131

0.118

0.111

0.108

0.102

0.098

0.100

0.099

0.094

0.094

0.087

0.087

0.094

0.082

0.135

0.122

0.115

0.112

0.106

0.102

0.104

0.103

0.098

0.098

0.090

0.091

0.098

0.086

0.132

0.120

0.114

0.111

0.105

0.101

0.103

0.102

0.097

0.096

0.089

0.090

0.096

0.085

0.129

0.117

0.111

0.108

0.103

0.099

0.100

0.100

0.095

0.094

0.087

0.088

0.094

0.083

0.125

0.114

0.108

0.105

0.100

0.096

0.098

0.097

0.092

0.092

0.085

0.086

0.092

0.080

0.120

0.110

0.104

0.102

0.096

0.093

0.094

0.094

0.089

0.089

0.082

0.083

0.089

0.078

0.144

0.118

0.112

0.109

0.104

0.100

0.102

0.101

0.096

0.096

0.089

0.089

0.095

0.085

0.149

0.124

0.118

0.115

0.110

0.106

0.103

0.107

0.101

0.101

0.094

0.095

0.101

0.090

0.147

0.123

0.117

0.114

0.109

0.106

0.107

0.107

0.101

0.101

0.093

0.094

0.100

0.089

0.144

0.121

0.115

0.112

0.107

0.104

0.105

0.105

0.099

0.099

0.092

0.092

0.098

0.088

0.139

0.118

0.112

0.110

0.105

0.101

0.103

0.102

0.097

0.096

0.089

0.090

0.096

0.086

0.135

0.114

0.109

0.107

0.102

0.098

0.100

0.099

0.094

0.094

0.087

0.088

0.093

0.083

1.00 0.95 0.90 0.85 0.80 0.75 1.00 0.95 0.90 0.85 0.80 0.75

Power Factor cos φ at 50Hz Power Factor cos φ at 60Hz

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

( Unit = Volt/m )

BusductRatings

600A

800A

1000A

1200A

1350A

1500A

1600A

2000A

2500A

3200A

3500A

4000A

4500A

5000A

6000A

0.101

0.109

0.092

0.084

0.077

0.086

0.078

0.081

0.072

0.073

0.075

0.076

0.073

0.071

0.081

0.109

0.117

0.100

0.092

0.085

0.094

0.085

0.089

0.079

0.080

0.081

0.083

0.080

0.078

0.089

0.108

0.117

0.100

0.093

0.085

0.095

0.086

0.089

0.079

0.081

0.082

0.084

0.081

0.078

0.089

0.107

0.116

0.099

0.092

0.085

0.094

0.085

0.089

0.078

0.080

0.081

0.083

0.080

0.078

0.089

0.105

0.114

0.098

0.090

0.083

0.093

0.084

0.087

0.077

0.079

0.080

0.082

0.079

0.077

0.087

0.102

0.111

0.096

0.089

0.082

0.091

0.082

0.086

0.076

0.077

0.078

0.081

0.077

0.075

0.086

0.102

0.109

0.093

0.086

0.079

0.088

0.080

0.083

0.073

0.075

0.077

0.078

0.075

0.073

0.083

0.111

0.121

0.103

0.096

0.088

0.098

0.090

0.093

0.082

0.084

0.086

0.088

0.084

0.081

0.093

0.112

0.122

0.105

0.097

0.090

0.100

0.091

0.094

0.083

0.085

0.087

0.089

0.085

0.082

0.094

0.111

0.121

0.105

0.097

0.090

0.100

0.091

0.094

0.083

0.085

0.087

0.089

0.085

0.082

0.094

0.110

0.120

0.104

0.096

0.089

0.099

0.090

0.093

0.082

0.084

0.086

0.088

0.084

0.052

0.093

0.107

0.117

0.102

0.095

0.088

0.097

0.088

0.092

0.081

0.083

0.085

0.087

0.083

0.080

0.092

1.00 0.95 0.90 0.85 0.80 0.75 1.00 0.95 0.90 0.85 0.80 0.75

Power Factor cos φ at 50Hz Power Factor cos φ at 60Hz

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

( Unit = Volt/m )


Fire Resistance Test

Conductor

Mica Tape

Polyester Film

Resistance to Fire AloneIEC 60331 : 3 hours at 750°CBS 6387 Category ‘C’ : 3 hours at 950°CJIS A 1304 : 30 mins at 840°C

Resistance to Fire with WaterBS 6387 Category ‘W’ : 15 mins at 650°C (with water spray 15 mins)

JIS A1304Fire resistance test has been conducted on Furutec busduct system with jointsection in an independant testing authority.Flame Temperature : 840°CTest Voltage : 660 VTest Duration : 30 minsTest Furnace : Large scale fire resistant furnace, where the busduct is heated up to 840°C from all directions.

BS 6387:1994 Category ‘C’

Resistance to fire alone test has been conducted on Furutec busduct feederand joint section in an independant testing authority.

Flame Temperature : 950 °C Test Voltage : 660VTest Duration : 3 hours

Furutec Fire Rated Busduct is designed for essential electrical services. It is tested to JIS A 1304, BS 6387 (Adoption)and IEC 60331 (Adoption)

Mylar Polyester Film

Fire-Rated Mica Tape

Conductor


Copper & Aluminium Conductor Size

HP-BUSDUCT

BusductRatings

(Ampere)

ConductorPer Phase (mm)

Model No. A (mm)

3P3W3P4W

3P4W+E3P5W

3P3W 3P4W3P4W+E3P5W

3P3W

B (mm) Figure Total Weight (kg/m)

600A800A

1000A1200A1350A1500A1600A2000A2500A3200A3500A4000A4500A5000A6000A

HP600CHP800C

HP1000CHP1200CHP1350CHP1500CHP1600CHP2000CHP2500CHP3200CHP3500CHP4000CHP4500CHP5000CHP6000C

115125150175200200225260400450500600675750780

14.016.020.925.830.830.835.742.661.571.481.292.3

107.0121.8127.7

3P4W

16.218.725.031.337.637.643.952.775.387.9

100.4112.9131.8150.7158.2

3P5W3P4W+E

17.320.127.134.141.141.148.157.882.196.1

110.1123.2144.2165.1173.5

One - 6 x 40One - 6 x 50One - 6 x 75

One - 6 x 100One - 6 x 125One - 6 x 125One - 6 x 150One - 6 x 185Two - 6 x 125Two - 6 x 150Two - 6 x 175

Three - 6 x 125Three - 6 x 150Three - 6 x 175Three - 6 x 185

100 120

1

2

3

BusductRatings

(Ampere)

ConductorPer Phase (mm)

Model No. A (mm)

3P3W3P4W

3P4W+E3P5W

3P3W 3P4W3P4W+E3P5W

3P3W

B (mm) Figure Total Weight (kg/m)

600A800A

1000A1200A1350A1500A1600A2000A2500A3000A3500A4000A4500A5000A

HP600AHP800A

HP1000AHP1200AHP1350AHP1500AHP1600AHP2000AHP2500AHP3000AHP3500AHP4000AHP4500AHP5000A

125150175200225250260315450520630750780945

10.212.314.316.418.420.421.325.836.842.551.561.363.877.3

3P4W

11.113.516.018.420.923.324.329.741.848.759.570.073.089.2

3P5W3P4W+E

11.514.116.819.522.124.825.931.744.351.763.574.477.695.2

One - 6 x 50One - 6 x 75

One - 6 x 100One - 6 x 125One - 6 x 150One - 6 x 175One - 6 x 185One - 6 x 240Two - 6 x 150Two - 6 x 185Two - 6 x 240

Three - 6 x 175Three - 6 x 185Three - 6 x 240

100 120

1

2

3

Aluminium Conductor :

BB

B

A

A

A

3000mm

( Standard Straight Length )

3000mm

( Standard Straight Length )

MALE FEMALE

Copper Conductor :

Figure 1

Figure 2

Figure 3

600A - 2000A

2500A - 3500A

4000A - 6000A

PHYSICAL DATA | 13

PHYSICAL DATA

Flange End / Flange End Box

2500A~3500A Flange End

150

A-6

0

C

A

(A-3

0)/2

(A-3

0)/2

B-60

B

EE

C

F

8-Ø10 HOLES

OPE

NIN

G

OPENING

130130130

6


C

150

BE

B-60

A

A-3

0

A-6

0

4-Ø10 HOLES

OPENING

OPE

NIN

G

100100100

6

600A~2000A Flange End Box

B

450 C

150

B

A

4-M8 BOLTS

REMOVABLE FRONTMETAL COVER

NON-FERROUS MATERIAL BOTTOMCOVER FOR CABLE TERMINATION

NON-FERROUS MATERIAL BOTTOM COVER FOR CABLE TERMINATION

6

100100100

450

A


CC

F

450

B

150

B

A

4-M8 BOLTS

130130130

6

450

A


TOP

VIEW

TOP

VIEW

TOP

VIEW

TOP

VIEW

SID

E VI

EW

SID

E VI

EW

SID

E VI

EW

SID

E VI

EW

FRO

NT

VIEW

FRO

NT

VIEW

FRO

NT

VIEW

FRO

NT

VIEW

14 | PHYSICAL DATA

22

4020

DDD

22

4020

DD

4020

D

2222

12

4020

22

4020

DDD D

Fig. 4Fig. 3Fig. 2Fig. 1 Fig. 5

NON-FERROUS MATERIAL BOTTOM COVER FOR CABLE TERMINATION


Busduct Ratings (Ampere) Dimensions (mm)

Aluminium

Figure A

B3P3W

3P4W3P4W+E3P5W

Copper

-

600

800

1000

1200

1350

1500

1600

2000

-

2500

-

3000

3500

-

-

4000

4500

5000

175

185

210

235

260

285

310

320

375

460

510

560

580

690

660

735

810

840

1005

1

1

2

2

3

3

4

4

5

3

3

4

4

5

3

3

4

4

5

350 450

410 540

600

800

1000

1200

1350,1500

1600

-

2000

-

2500

3200

3500

-

-

4000

4500

5000

6000

-

C

40

50

75

100

125

150

175

185

240

125

150

175

185

240

125

150

175

185

240

D

-

-

40

50

40

50

40

45

45

40

50

40

45

45

40

50

40

45

45

E

145

155

180

205

230

255

280

290

345

215

240

265

275

330

210

235

260

270

325

F

-

200

225

250

260

315

200

225

250

260

315


150

A-6

0

OPENING B-60

C C

10-Ø10 HOLES

OPE

NIN

G A

(A-3

0)/2

(A-3

0)/2

B

EEE

C

FF

130130130

6


C CC

F F

4-M8 BOLTS

450

B

150

A

B

450

A

130130130

6

TOP

VIEW

SID

E VI

EW

FRO

NT

VIEW

TOP

VIEW

SID

E VI

EW

FRO

NT

VIEW

PHYSICAL DATA | 15

Flatwise Elbow / Edgewise Elbow

Busduct Ratings (Ampere) Standard LengthsL1 x L2 (mm)

Minimum LengthsL1 x L2 (mm)

Aluminium Copper

600 to 6000 400 x 400 270 x 270

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

Busduct Ratings (Ampere) Standard LengthsL1 x L2 (mm)

Minimum LengthsL1 x L2 (mm)

Aluminium Copper

-600800100012001350150016002000

-2500

-3000

-3500

-400045005000

60080010001200

1350,15001600

-2000

-250032003500

-4000

-450050006000

-

300 x 300305 x 305315 x 315330 x 330340 x 340355 x 355365 x 365370 x 370400 x 400440 x 440465 x 465490 x 490500 x 500540 x 540555 x 555580 x 580615 x 615630 x 630715 x 715

400 x 400

600 x 600

750 x 750

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

L2

L1

L1

L2

Edgewise Elbow

Flatwise Elbow

16 | PHYSICAL DATA

TEE Elbow

Busduct Ratings (Ampere) Standard LengthsL1 x L2 x L3 (mm)

Minimum LengthsL1 x L2 x L3(mm)

Aluminium Copper

-600800

100012001350150016002000

-2500

-3000

-3500

-400045005000

600800

10001200

1350,15001600

-2000

-250032003500

-4000

-450050006000

-

235 x 235 x 235240 x 240 x 240250 x 250 x 250265 x 265 x 265275 x 275 x 275290 x 290 x 290300 x 300 x 300305 x 305 x 305335 x 335 x 335375 x 375 x 375400 x 400 x 400425 x 425 x 425435 x 435 x 435475 x 475 x 475490 x 490 x 490515 x 515 x 515550 x 550 x 550565 x 565 x 565650 x 650 x 650

400 x 400 x 400

600 x 600 x 600

750 x 750 x 750

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

L1

L2

L3

PHYSICAL DATA | 17

Busduct Ratings (Ampere) Flatwise Offset Edgewise Offset

Standard LengthsL1 x L2 x L3 (mm)

Minimum LengthsL1 x L2 x L3 (mm)


Standard LengthsL1 x L2 x L3 (mm)

Aluminium Copper

-600800100012001350150016002000

-2500

-3000

-3500

-400045005000

600800

10001200

1350,15001600

-2000

-250032003500

-4000

-450050006000

-


400 x 400 x 400 270 x 200 x 270

600 x 600 x 600

400 x 500 x 400

750 x 750 x 750

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

Flatwise Offset / Edgewise Offset

Flatwise Offset Edgewise Offset

L2

L1

L3

L2

L1

L3

18 | PHYSICAL DATA

Combination Elbow

Busduct Ratings (Ampere) Standard LengthsL1 x L2 x L3 (mm)


Aluminium Copper

-600800

100012001350150016002000

-2500

-3000

-3500

-400045005000

600800

10001200

1350,15001600

-2000

-250032003500

-4000

-450050006000

-


400 x 400 x 400

600 x 600 x 600

750 x 750 x 750

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

L2

L1

L3

L2

L1

L3

PHYSICAL DATA | 19

Elbow with Flange End / Flange End Box

Busduct Ratings (Ampere)

Aluminium Copper

Standard Lengths (mm)

L1 L2 L3 L4 L1 L2 L3 L4

Minimum Lengths (mm)

600

800

1000

1200

1350, 1500

1600

-

2000

-

2500

3200

3500

-

4000

-

4500

5000

6000

-

-

600

800

1000

1200

1350

1500

1600

2000

-

2500

-

3000

-

3500

-

4000

4500

5000

300

305

315

330

340

355

365

370

400

440

465

490

500

540

555

580

615

630

715

185

190

200

215

225

240

250

255

285

325

350

375

385

425

440

465

500

515

600

400 400 275 275

400 400

600

600

750

L2

L1

450

AB

L4

L3

BA

450

Flatwise Elbow with Flange End boxEdgewise Elbow with Flange End box

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

20 | PHYSICAL DATA

End Cap / End Closure

End Closure End Cap

B A

35

165mm B

A


A (mm) B (mm)Busduct Ratings(Ampere)

A (mm) B (mm)

600

800

1000

1200

1350

1500

1600

2000

2500

3200

3500

4000

4500

5000

6000

115

125

150

175

200

200

225

260

400

450

500

600

675

750

780

100 120

Copper Busduct

3P3W3P4W

3P4W+E3P5W

3P4W3P4W+E3P5W

3P3W3P4W

3P4W+E3P5W

3P3W

3P3W3P4W

3P4W+E3P5W

600

800

1000

1200

1350

1500

1600

2000

2500

3000

3500

4000

4500

5000

125

150

175

200

225

250

260

315

450

520

630

750

780

945

100 120

Aluminium Busduct

PHYSICAL DATA | 21

Vertical Spring Hanger / Vertical Hanger

For 600A to 1000A HP-Busduct For 1200A to 2000A HP-Busduct

For 2500A HP-Busduct

For 4000A to 6000A HP-Busduct

Vertical HangerVertical Hanger

Vertical hanger Vertical Spring Hanger

Vertical hanger Vertical Spring Hanger

Vertical Spring HangerVertical Hanger

For 3000A to 3500A HP-Busduct

60M10x30 BOLT

M12 STUDBOLT

50155

7550

Vertical Spring Hanger

170

75

275

50

M10x30 BOLT

SPRINGM12 STUDBOLT

60

5075

155 50

M12 STUDBOLT

M10x30 BOLT60


60

M12 STUDBOLT

SPRING

M10x30 BOLT

50

275

7517

0

170

75

275

50

M10x30 BOLT

SPRINGM12 STUDBOLT

60

60

5075

155 50

M12 STUDBOLT

M10x30 BOLT

60

M12 STUDBOLT

SPRING

50

275

7517

0

M10x30 BOLT

5075

155 50

M12 STUDBOLT

60

M10x30 BOLT

605050

7515

5

M10x30 BOLT

M12 STUDBOLT

60

7550

170

275

SPRINGM12 STUDBOLT

M10x30 BOLT

22 | PHYSICAL DATA

600A - 1000A

A

A +

60 A +

60

A +

60

A +

60

A +

60

120

246

180

1200A - 2000A

A

2500A 3000A - 3500A 4000A - 6000A

A

180

246


A

STUD BOLT M12

BOLT M10x30

75 75

275 26

0

5017

0

A + 60

60

180

246

60

7517

050

275 26

0

120

(BY CONTRACTORS)BASE CHANNEL

Vertical Hanger

75

BOLT M10x30

STUD BOLT M12

A

140

155 50

50

180

60

A + 60

246

60

7550

50

120

BOLT HOLES

BOLT HOLES

140

155

BASE CHANNEL(BY CONTRACTORS)

275 26

0

5017

0

60

180

246

246

180

60

140

155

7550

50

A

180

246

A

180

246

BOLT HOLES

BOLT HOLES

FIRE BARRIER( BY CONTRACTORS )




Refer to page 13 for the dimensions of A

PHYSICAL DATA | 23

Edgewise / Flatwise Hanger

Fig 1

Fig 2

Fig 3

Edgewise Hanger

Flatwise Hanger

EDGEWISE HANGER

Ø14 HOLESC

A

B

Ø14 HOLES

EDGEWISE HANGER

C

B

A

(BY CONTRACTORS)

ANGLE METAL BAR& HANGER ROD

(BY CONTRACTORS)


(BY CONTRACTORS)


Ø14 HOLES

EDGEWISE HANGER

2-M10 x 30 BOLT

2-M10 BOLT

2-M10 BOLT

C

B

A

BusductRatings

(Ampere) Fig3P3W

3P4W3P4W+E3P5W

3P3W3P4W

3P4W+E3P5W

3P3W3P4W

3P4W+E3P5W

A B

Dimensions (mm)

C

600800

10001200135015001600200025003000320035004000450050006000

140

112

1

2

3

160

132

220

240

220

280

300

280

Busduct Rating (Ampere) Dimensions (mm)

Aluminium Copper A B C

-600800100012001350150016002000

-2500

-3000

-3500

-400045005000

60080010001200

1350, 15001600

-2000

-250032003500

-4000

-450050006000

-

165175200225250275300310365450500550570650680725800830995

38487398123148173183238323373423443523553598673703868

225235260285310335360370425510560610630710740785860890

1055

2-M10x30 BOLT (BY CONTRACTORS)

C

A

B


Ø14 HOLES

24 | PHYSICAL DATA

Expansion Unit

Busduct Ratings (Ampere) A(mm)

Aluminium Copper

-600800

100012001350150016002000

-2500

-30003500

--

400045005000

60080010001200

1350,15001600

-2000

-250032003500

--

4000450050006000

-

115125150175200225250260315400450500520630600675750780945

500

A

450

The busduct system expands and contracts when the current loading varies and the ambient temperature changes.The expansion unit is the transition section compensating the thermal expansion and contraction.

PHYSICAL DATA | 25

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

Reducer

L

L

L

L

L

L

26 | PHYSICAL DATA

Flexible Link

Busduct Ratings Fig

Dimension

T (mm)Type

600A

800A

1000A

1200A

1350A

1500A

1600A

1 F5013 x 1

F10013 x 1

F12014 x 1

2

3

13

13

14

Busduct Ratings Fig

Dimension

T (mm)Type

2000A2500A3000A3200A3500A4000A4500A5000A6000A

F15014 x 1

F15014 x 2

F12014 x 3

F15014 x 3

F15016 x 3

14.5

14.5

4

4

4

4

3

3 14

14

14.5

16

F12014 x 2

Dimension of Flexible Link according to busduct ratings

"T"

320

120

4040

8-Ø12 H OLES

2020

150

25

40 40 40

25

40 40 40

150

12-Ø12 HOLES

150

2020

4040

2525

3535 40 40

3535 40 40

150

8-Ø12 HOLES

4030

2020

4040

2525

30

100

4030 30

50

4-Ø12 HOLES

4040

2020

150

25

25 25

25

2525

FIG. 2 FIG. 3 FIG. 4FIG. 1

PHYSICAL DATA | 27

FLEXIBLE LINK

TRANSFORMER LV BOX(NOT THE SCOPE OF BUSDUCT MANUFACTURERS)

FLANGE END

BUSDUCT SYSTEM

Tap-Off Units

MCCB Rating L

100AF225AF400AF

340430550

W

230265310

H

200220250

Fig

112

Plug in box is mechanically interlocked with the busduct housing to prevent installation or removal while the MCCB is in ‘ON’ position. It is equipped with an operating handle to control the switching mechanism. The plug in box makes positive ground connection to the busduct housing before making contact to the phase conductors.

PLUG IN BOXMCCB

PLUG IN HOLE COVER

PLUG IN HOLE

L

W

H

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

100AF & 225AF Plug In Box 400AF Plug In Box

Fig 2Fig 1

Open

Open

E L1 L2 L3 N E L1 L2 L3 N

L

160

HW W H70 70

160

L

Phase IsolatorTo segregate the tapping position of each phase of the conductors

E

REMOVABLE BOTTOM COVERFOR CABLE TERMINATION REMOVABLE BOTTOM COVER

FOR CABLE TERMINATION

E

E E

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

NL3

L2L1 E

28 | PHYSICAL DATA

MCCB Rating W L H

600AF800AF

1000AF1200AF

908998

11081108

373373488488

200200290290

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

TAP BOX

TAP BAR

H

L

W4-M6 Screw

REMOVABLE BOTTOM COVERFOR CABLE TERMINATION

PHYSICAL DATA | 29

Copper & Aluminium Conductor Sizes

L-Duct


Conductor per Phase(mm)A (mm) Weight (kg/m)

200A

300A

400A

56

71

96

3 x 20

3 x 35

3 x 60

7.5

9.5

12.5

Copper Conductor :

A

167

L1 L2 L3 N E

Conductors Phase Isolator

The air-insulated type of L-Duct can be configured as 3-phase 3-wire (3P3W), 3-phase 4-wire (3P4W with external earth bar) and 3-phase 5-wire (3P5W with integral earth bar).

Electro-Galvanized Sheet Steel Housing with Epoxy Powder Coating

30 | PHYSICAL DATA

L3L2

NE

L1

Flange End / Flange End Box

Busduct Rating(Ampere) Fig

A(mm)

200A300A400A

360360450

B(mm)

150165190

C(mm)

120120160

D(mm)

7070

100

E(mm)

203560

F(mm)

350350400

G(mm)

350350500

H(mm)

120135160

112

Copper Busduct System :

Flange End

Flange End Box20

Ø11 HOLE

4020

2-Ø11 HOLE

Figure 1 Figure 2

D

D

GF

H

NON-FERROUS MATERIAL BOTTOMCOVER FOR CABLE TERMINATION

REMOVABLE METALFRONT COVER

D

A

A-30

C

E D

L1 L2 L3 N

DD

A-60OPENING

4-Ø10 HOLES

OPE

NIN

G

B

B-30

B-60

L3L2

NE

L1

PHYSICAL DATA | 31

Flatwise / Edgewise Elbow

End Closure

Copper Busduct System


A(mm)

200A300A400A

597499

155

A

170

Edgewise Elbow

L2L1

NL3

E

Flatwise Elbow

L3N

E

L1L2

32 | PHYSICAL DATA


Copper Busduct System


A(mm)

200A300A400A

567196

Vertical Hanger


BASE CHANNELFLAT HANGING CLAMP

STUD BOLT

(BY CONTRACTORS)

(M12x220)

FRONT VIEW


(M12x330)STUD BOLT

FLAT HANGING CLAMP

SPRING

FRONT VIEW

BOLT M10x30

STUD BOLT M12

A

C/W CLAMP

167

250

250

754020

140

145 50

50

30

BASE CHANNEL

FIRE BARRIER(BY CONTRACTORS)

FIRE BARRIER(BY CONTRACTORS)

(BY CONTRACTORS)

167

A

20 4017

075

265 26

0

250

167

C/W CLAMP

A

STUD BOLT M12

BOLT M10x30

30


A

167

50

250

PHYSICAL DATA | 33

Flatwise / Edgewise Hanger

Tap-Off Units

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

200300400

208223248

128143168

268283308

MCCB Rating W (mm) L (mm) H (mm)

100AF225AF

400500

195230

118118

Plug in box is mechanically interlocked with the busduct housing to prevent installation or removal while the MCCB is in ‘ON’ position. It is equipped with an operating handle to control the switching mechanism. The plug in box makes positive ground connection to the busduct housing before making contact to the phase conductors.

L1L2

N L3

E

L

W

H

HOLDER

172

C

B

A

Edgewise Hanger

208

288

348

(BY CONTRACTORS)


(BY CONTRACTORS)


FLATHANGINGCLAMP

167

Flatwise Hanger

L1 L2 L3 N

63W

E

L

H

70

Open

REMOVABLE BOTTOM COVERFOR CABLE TERMINATION

E

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

34 | PHYSICAL DATA

1. Minimum Distance Between Parallel-Installed Busduct System.

1.1 Indoor Type (Edgewise Installation).

Busduct joints installed side by side. Busduct joints installed deviating from each other (Dimension “C” is above 190mm).

A A

JOINT POINT

B

190

JOINT POINT

(C)

B


3P3W

Dimension “A” (mm)

150600 - 6000A

3P4W/3P5W

160

3P3W

85

3P4W/3P5W

95

Dimension “B” (mm)

1.2 Outdoor Type (Edgewise Installation).

Busduct joints installed side by side. Busduct joints installed deviating from each other (Dimension “C” is above 500mm).

Busduct Ratings(Ampere) 3P3W

Dimension “A” (mm)

170600-6000A

3P4W/3P5W

190

3P3W

130

3P4W/3P5W

150

Dimension “B” (mm)

A A

JOINT POINT

110

BB

500

JOINT POINT

(C)

110

60

JOINT POINT

DESIGN FACTORS | 35

DESIGN FACTORS

1.3 Indoor / Outdoor Type (Flatwise Installation).

Minimum clearance for busduct installed flatwise in parallel.

1.4 Plug-in Type Busduct Installation.

Minimum clearance for plug-in busduct installed in parallel.

2. Minimum Clearance between busduct and wall, floor, etc.

2.1 Ceiling and Wall. 2.2 Beam.

200

200

200

200

100 100

50190

JOINT POINT

50 50W W W

PLUG IN BOX

PLUG IN BUSDUCT

CEILING

WA

LL

WA

LL

CEILING CEILING

36 | DESIGN FACTORS

Busduct joints must not be installed in between the wall and floor. The busduct joints shall be at least 240mm from the ceiling surface. If vertical spring hanger is installed on the floor, the distance between busduct joint and base channel shall be at least 450mm. If vertical hanger is installed on the floor, the distance between busduct joint and base channel shall be at least 300mm. The height of base channel is recommended to be 75mm.

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

2.3 Distance between busduct joint and wall surface for through wall installation

Indoor Type Busduct. Outdoor Type Busduct.

JOINT POINT

240

(INDOOR TYPE)

WALL WALL

JOINT POINT

240

JOINT POINT

240

(OUTDOOR TYPE)(INDOOR TYPE)

BASE CHANNEL

FLOOR SLAB FLOOR SLAB

(BY CONTRACTORS)

450

7524

0

(A)

(B)

JOINT POINT

300

7524

0

VERTICAL SPRING HANGER

VERTICAL HANGER

(A)

(B)

DESIGN FACTORS | 37

Common Practice

Installation Procedures

Storage and Preparation Prior to Installation

1. When the busduct arrives at project site, check the type and quantity of busduct feeders and accessories from delivery orders. Inspect for any physical damages caused during transportation and unloading.

2. Keep the busduct at dry place, away from water and moisture, preferably under the roof protected from rain. Cover the busduct with water-proof material if necessary.

3. Do not lay the busduct directly onto the ground or in an upright position. Always place pieces of wood under the busduct and stack up firmly.

4. For long period storage, ensure that the busduct is placed at a dry place free from condensation.

Installation Procedures

1. To prevent the joint of the busduct from being soiled, wrap both ends with water-proof material while unpacking.

2. Use sufficiently strong materials and equipment for transportation and lifting.

3. Insert thick pieces of rag or corrugated cardboard when hanging busduct with rope to prevent the busduct from being damaged or scratched. For busduct rated 2500A and above, pieces of strong wood should be used when rope is applied, in order to prevent the busduct housing from being deformed.

4. Before installing the busduct joint, examine the conductor contact surface or insulation materials for any damages. Besides, ensure that the joint areas are not soiled with dust, dirt and other foreign matter.

5. During the busduct joint installation, it is recommended to perform Megger test for every busduct feeder during installation works. In case of the megger value is found abnormal after installation of the whole busduct route, extra time will be required to determine the faulty busduct feeders.

6. Ensure that the ends of busduct are protected against water and dust if the installation halted during construction.

INSTALLATION & MAINTENANCE PROCEDURE

38 | INSTALLATION & MAINTENANCE PROCEDURE

1

4

5

2

4

6

3

5

7

Busduct Joint

HP-Busduct Joint Assembly

1. Determine the male and female sides of the busduct feeders to be connected.

2. Align the busducts feeders end to end.

3. Align the leaf springs so that the high tensile bolts can be fitted through the busduct housing.

4. Tighten the two bolts alternately to ensure even distribution of force is applied to the busduct joint. Tighten them until the leaf springs become almost flat and until the snap-pin-hole on the high tensile bolt is visible.

5. Insert the snap pins into the pin holes.

6. Cover the busduct joint section with joint covers on both sides.

7. The installation is complete.

INSTALLATION & MAINTENANCE PROCEDURE | 39

L-Duct Joint Assembly

1. Align two L-Duct busduct feeders by overlapping the conductors.

2. Fix busduct housing with side covers on both sides.

3. Connect each phase conductor with screws, nuts, plain washes and spring washes. Make sure that the screws are fully tightened.

4. Insert a phase isolator to the joint section.

5. Connect the external earth bars to the earth bars at the side of busduct housing.

6. Install the joint cover on both sides of busduct housing to complete the joint assembly.

L3N

L2L1

E

M6 SCREW

SIDE COVER

M8 BOLT

PHASE ISOLATOR

M5 SCREW

JOINT COVER

BELLEVILLE WASHER

SPRING WASHER

M8 NUT

EXTERNALEARTH BAR

JOINT COVER

M5 SCREW


Tap Off Units (Plug In Type)

1. Check the drawings to identify the location of tap-off units to be installed.

2. Remove the cover of each plug-in hole.

3. Ensure that the MCCB handle is in ‘OFF’ position.

4. By using the earth jaw of the plug in box as guidance, insert the plug in clips into the plug in hole of the busduct.

5. Open the top cover of the plug in box. Fasten the duct-fixing screws in the box to firmly attach the plug in box to the busduct.

6. Terminate cables to the outgoing terminal of MCCB and insert internal barriers (perspex) to prevent accidental contact with the live parts at the terminals of MCCB.

7. Installation is complete.

1

3

5

2

4

5

2

4

5

7

Insert EarthJaw here

Plug inClips

Tap-off units shall make positive ground connection with busduct housing or earth conductors before making contact with the phase conductors.

Make sure that the MCCB is in ‘OFF’ position before carrying out any live installation works of tap-off unit to the plug in holes of busduct system.



1. Drill 4 nos bolt holes of Ø12mm on the housing of the busduct.

2. Install the vertical hanger and fix to the busduct tightly.

3. Connect the busduct in sequence and install the vertical spring hangers to each floor accordingly.

Refer to page 22 and 23 (HP-Busduct) and page 33 (L-Duct) for the details of dimension of vertical spring hanger and vertical hanger

Tap Box (Bolt On Type)

1. Remove the tap bar cover. If the busduct is 3P5W type, extra care is required in order not to damage the earth during removal of the cover.

2. Open the cover of the Tap Box and insert the tap bar through the opening of the tap box and fix the box to the tap bar flange by fastening the screws.

3. Fix the box to the busduct housing using flat hanging clamps provided by Furutec

4. Fix the top cover of the box.

5. Installation is complete.

Horizontal Hanger (Edgewise/Flatwise Hangers)

1. Prepare the angle metal support for busduct prior to the horizontal hanger installation.

2. Hang the hanger rods from the ceiling and attach the angle metals at the height of the busduct to be laid.

3. The horizontal hangers should be installed in every internal of at least 1500mm (1.5m) including the busduct elbows.

Refer to the details of Edgewise / Flatwise Hanger on page 24 (HP-Busduct) and page 34 (L-Duct)


Inspection and Testing upon Completion of Busduct Installation

1. After the completion of busduct installation at project site, it is advisable to carry out a thorough inspection on the whole busduct route, followed by measurement of insulation resistance / Megger.

2. Before conducting the measurement of insulation resistance, all the equipment connected to busduct system should be disconnected and MCCB rotary handle of tap-off units should be in ‘OFF’ position.

3. The insulation resistance value cannot be specified due to different length of the busduct and environmental condition. But if it is installed in a dry atmosphere, the value of resistance should be approximately 100 MΩ (500V Megger). In case, the measurement is less than 10MΩ, thorough examination is required as there might be some external factors, which decrease the insulation strength and energizing of busduct system is not recommended.

4. The following inspection procedures should be carried out. Determine whether:-

4.1) The busduct feeders are physically damaged.

4.2) All the connecting parts are fixed precisely (e.g. flange end box, tap-off units, etc)

4.3) The bolts for connecting to the equipment are securely fastened.

4.4) The busduct joint are tightened in accordance to Furutec‘s requirement and recommendation.

4.5) The hangers support the busduct securely.

Maintenance

The following maintenance procedures and periodical inspection are recommended to ensure a safe operation of busductsystem for long terms.

1. Period of Inspection

1.1 An inspection on busduct once a year or once every two years is recommended. If busduct system is installed in unfavourable conditions such as, temperature and/or humidity is high, there is a lot of dust or in similar environment, the periodical inspection must be conducted.

1.2 In the event of the following unusual conditions, inspection must be carried out immediately in each case:

a.) After severe earthquake

b.) After being involved in a fire

c.) After being exposed to water

d.) After an electrical fault

2. Maintenance and Routine Inspection

2.1 Inspection on External Appearance

Check whether :-

There is any deformation, damage, dirt, etc throughout the whole length of busduct systems

There is any dislocation, bending and other abnormality of the connecting covers, hangers and plug-in appliances


2.2 Environmental Inspection

The environment, where the busducts are installed, sometimes changes after the installation works. Check whether theenvironment has become hazardous due to water, moisture, high temperature, corrosive gas, immoderate vibration, dust, etc.

2.3 Inspection for Abnormal Heat

A high-tech Infra Red Thermography instrument is recommended to detect abnormal heat and measure the operatingtemperature of busduct system.

For the ease of maintenance, a thermal indicator can be placed onto the busduct housing. If the temperature rise of the busducthousing exceeds the limit, the colour of the indicator will change. e.g. from white to red colour.

2.4 Inspection on Connection Sections

Check whether :-

HP-Busduct is securely fastened with joint bolts and nuts and both sides of the busduct joint sections are held with a pair of leaf springs. Leaf springs are flat and the pin holes are inserted with snap pins Screws and nuts at the overlapping conductor of L-Duct joint sections are not loose due to thermal expansion and contraction

Busduct is supported by vertical spring hangers, vertical hangers, edgewise / flatwise horizontal hangers according to manufacturer’s requirement and recommendation. All the connecting parts, such as leaf springs, hangers, busduct joints, joint covers, etc are fixed precisely

2.5 Inspection on Load Condition

After the installation of plug-in busduct feeders, increase of electrical load is expected at the early stage. An inspection has tobe carried out to ensure that the total connected load does not exceed the rated current of the busduct before the load is increased.

2.6 Measurement of Insulation Resistance

Measure the insulation resistance between each conductor and between conductor and housing. When it is less than 5MΩ or far below the previous value, the possibility of existence of defect is very high. When the measurement is carried out, the electrical loads and connected equipment shall be disconnected.

2.7 Inspection on Rust or Peeling of Paint on Busduct Housing

If there are some peeled-off paint or rust on the busduct housing, cleaning work and touch-up painting are recommended.


Resort World Sentosa(Singapore)

Genting Highland(Malaysia)

Suria KLCC & Maxis Tower (Malaysia)

Empire Subang(Malaysia)

OCBC Bank (Malaysia) Asia City Shopping Mall (Malaysia)

Crown Plaza Hotel(Singapore)

Four Point Hotel - Sheraton (Malaysia)

Commercial 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)

Public Utility Projects

Renewable Energy Corporation - REC(Singapore)

Infineon Kulim (Malaysia)

Soitec Wafer Plant(Singapore)

Fuji Electric(Malaysia)

Industrial Projects

Impian Meridian Mixed Development(Malaysia)

Hartamas Regency K2(Malaysia)

Midvalley North Point Condominium & office Tower (Malaysia)

Bintang Fairlane Residences (Malaysia)

Residential Projects

Jusco Bandar Perda -Penang (Malaysia)

Sunway Pyramid Mall(Malaysia)

PROJECT REFERENCE

PROJECT REFERENCE | 45

Sales & Marketing contact :

(member of EITA Group of companies)Plot 89, Lorong Perindustrian Bukit Minyak 11,Kawasan Perindustrian Bukit Minyak, MK 13, 14100 Seberang Perai Tengah, Penang, MalaysiaTel: +604-508 0228 Fax: +604-508 0227E-mail: [email protected]: www.furutec.com.my

FURUTEC Electrical Sdn. Bhd. (057207-W)

Lot 4, Block A, Jalan SS13/7Subang Jaya Industrial Estate47500 Subang JayaSelangor Darul Ehsan, MalaysiaTel: +603-5637 8363 Fax: +603-5635 0538Website: www.eita.com.my

* The information is subject to change without prior notice. Consult Furutec at the time of order.

FTAug10@2010. All rights reserved.

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