Mission & Quality policy

Corporate Mission
The Controls & Switchgear Co. Ltd
aims to be the world's leading
BUSDUCT / BUSTRUNKING manufacturer.
It will seek to be the industry benchmark
in terms of quality and reliability of product
and speed and efficiency of execution.

The Controls & Switchgear Co. Ltd

intends to achive this leadership status
by leveraging the combination of
world class product design,
manufacturing infrastructure, engineering
acumern and customer service.

QUALITY POLICY
We are committed to achieve excellence in design
and Manufacturing of Busduct and Busbartrunking
System through:

Upgrading Equipments & QA system as per

latest Standards and Customers Requirements.

Quick readdressal of Customer Concern taking

corrective and preventive actions.

Providing adequate resources including Infrastructure

& Competent Personnel.

We are committed to review our Quality

Management Systems to achieve continual improvements.

2
Manufacturing Unit

Manufacturing Plant at Hardwar

LTD.
PANY
COM
GEAR
ITCH
& SW
NT ROLS
CO

3
 Manufacturing facilities

AMADA, CNC TURRET PUNCHING

AUTOMATIC BUSBAR CUTTING MACHINE

EPOXY POWDER COATING PLANT

BUSBAR SLEEVING MACHINE

INSULATION CUTTING MACHINE - lASER

4
 Contents

Technical Parameters 6-9

Standard & Specifications 10

Bustrunking System 11

Main Components

A) Feeder Bustrunking, Plug-in Bustrunking 12

B) Uni-Block Busbar Joint 13

C) Horizontal elbow, Horizontal offset elbow 14

D) Vertical elbow, Vertical offset elbow, Vertical Tee Section 15

E) Certification & Approvals 16 - 17

F) Standard Flange End 18

G) Flange End Box, Rubber Bellow & Flexibles 19

h) Plug in Boxes 20

I) Spring & Rigid Hanger 21

Other Components 22

Complete Engineering Solution 23

Installation Instructions 24 - 27

Major installations 28 - 29

Major Export orders 30

Other Busbar Systems 31

5
 Technical Parameters

Technical Data :
SBC (Copper Sandwich Insulated Bus Trunking)
CURRENT RATING
PARAMETER UNIT SINGLE TIER TWO TIER
Product code SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC
50N1 70N1 100N1 125N1 150N1 175N1 200N1 230N1 125N2 150N2 175N2 200N2 230N2

Rated current (In) A 800 1000 1250 1500 1750 2000 2250 2500 3000 3600 4000 4500 5000
Busbar size (Copper) mm 6x50 6x70 6x100 6x125 6x150 6x175 6x200 6x230 6x125 6x150 6x175 6x200 6x230
3 Phases & Neutral
No. of conductors per Nos. 1 1 1 1 1 1 1 1 2 2 2 2 2
Phase / Neutral
Rated short time current kArms 45 50 65 65 75 75 100 100 120 120 120 180 180
for 1 second (Icw)
Rated peak short kA 84 105 143 143 165 165 220 220 264 264 264 396 396
time curent (Ipk)

OVERALL DIMENSION & WEIGHT

PARAMETER UNIT SINGLE TIER TWO TIER
Product code SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC
50N1 70N1 100N1 125N1 150N1 175N1 200N1 230N1 125N2 150N2 175N2 200N2 230N2

Overall dimension of 147x H 95 115 145 170 195 220 245 275 340 390 440 490 550
Busbar Trunking (mm)
(without Internal Earthing)

Weight of Busbar Trunking Kg / m 22 28 35 42 48 54 60 67 84 96 108 120 134

(without Internal Earthing)

Overall dimension of 150x H 95 115 145 170 195 220 245 275 340 390 440 490 550
Busbar Trunking (mm)
(with Internal Earthing)

Weight of Busbar Trunking Kg / m 25 31 39 47 53 60 67 74 94 106 120 134 148

(with 50% Internal Earthing )

6
 Technical Parameters

·
Voltage Drop Calculation Formulas
Dv =Ö3· I (RcosØ + SinØ) R95 : AC resistance at rated current(I0)(W /m)
where D
v : Line-to-Line voltage drop (v/m) (Shown in the table)
I : Load Current (A) a : Temperature coefficient of conductor at 20oc
-3 -3
CosØ: Load power factor 3.85 x 10 (copper), 4.00 x 10 (aluminum)
2
sinØ = Ö 1- cos ø I0 : Rated Current
R: AC resistance at load current (W /m) X : Reactance (shown in the table) (W )

Technical Data :
2
1+a
(55x(1/1 ) +20) 0
R=R x 95
1+75a
SBC (Copper Sandwich Insulated Bus Trunking)
ELECTRICAL RESISTANCE / REACTANCE & IMPEDANCE - 50 Hz
PARAMETER UNIT SINGLE TIER TWO TIER
Product code SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC
50N1 70N1 100N1 125N1 150N1 175N1 200N1 230N1 125N2 150N2 175N2 200N2 230N2

Resistance m /m 0.0616 0.0431 0.0304 0.0243 0.0202 0.0173 0.0151 0.0131 0.0121 0.0101 0.0086 0.0076 0.0066
@ +200C (R20)
Resistance at thermal m /m 0.077 0.055 0.04 0.033 0.028 0.024 0.021 0.019 0.016 0.014 0.012 0.011 0.01
conditions (R)

Reactance m /m 0.038 0.03 0.022 0.018 0.016 0.014 0.012 0.01 0.009 0.008 0.007 0.006 0.005
@ 50Hz (X)

Impedance at thermal m /m 0.0859 0.0626 0.0457 0.0376 0.0322 0.0278 0.0242 0.0215 0.0184 0.0161 0.0139 0.0125 0.0112
conditions (Z)

VOLTAGE DROP - 50 Hz
PARAMETER UNIT SINGLE TIER TWO TIER

Product code SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC SBC

Composite Voltage Drop, 50N1 70N1 100N1 125N1 150N1 175N1 200N1 230N1 125N2 150N2 175N2 200N2 230N2
mV/m/A
at full load concentrated
P. F. 0.7 0.1404 0.1038 0.0757 0.0623 0.0537 0.0464 0.0403 0.0354 0.0305 0.0269 0.0232 0.0208 0.0183
at the end.
These values will become mV/m/A
half if load is distributed P. F. 0.8 0.1462 0.1074 0.0783 0.0644 0.0554 0.0478 0.0416 0.0367 0.0315 0.0277 0.0239 0.0215 0.0191
along the run.
mV/m/A
P. F. 0.9 0.1487 0.1084 0.0790 0.0650 0.0557 0.0480 0.0418 0.0372 0.0317 0.0279 0.0240 0.0217 0.0194

mV/m/A
P.F.1.0 0.1334 0.0953 0.0693 0.0572 0.0485 0.0416 0.0364 0.0329 0.0277 0.0242 0.0208 0.0191 0.0173

7
 Technical Parameters

Technical Data :
SBA (Aluminum Sandwich Insulated Bus Trunking)

ELECTRICAL RESISTANCE / REACTANCE & IMPEDANCE

PARAMETER UNIT SINGLE TIER TWO TIER
Product code SBA SBA SBA SBA SBA SBA SBA SBA SBA SBA SBA

50N1 70N1 100N1 125N1 150N1 175N1 200N1 125N2 150N2 175N2 200N2

Resistance m /m 0.0993 0.0704 0.0490 0.0391 0.0325 0.0278 0.0243 0.0194 0.0162 0.0139 0.0122
@ +200 C (R20)
Resistance at thermal m /m 0.1250 0.0900 0.0640 0.0520 0.0440 0.0380 0.0340 0.0260 0.0220 0.0190 0.0170
conditions (R)

Reactance m /m 0.0340 0.0260 0.0190 0.0150 0.0130 0.0110 0.0100 0.0070 0.0060 0.0060 0.0050
@ 50Hz (X)

Impedance at thermal m /m 0.1295 0.0937 0.0668 0.0541 0.0459 0.0396 0.0354 0.0269 0.0228 0.0199 0.0177
conditions (Z)

VOLTAGE DROP
PARAMETER UNIT SINGLE TIER TWO TIER
Product code SBA SBA SBA SBA SBA SBA SBA SBA SBA SBA SBA
50N1 70N1 100N1 125N1 150N1 175N1 200N1 125N2 150N2 175N2 200N2

Composite Voltage Drop, P. F. 0.7 0.1936 0.1413 0.1011 0.0816 0.0537 0.0597 0.0536 0.0402 0.0341 0.0305 0.0268
mV/m/A
at full load concentrated
at the end.
P. F. 0.8 0.2085 0.1517 0.1084 0.0876 0.0554 0.0641 0.0575 0.0433 0.0367 0.0326 0.0288
These values will become mV/m/A
half if load is distributed
P. F. 0.9 0.2205 0.1599 0.1141 0.0924 0.0557 0.0675 0.0606 0.0458 0.0388 0.0342 0.0303
along the run. mV/m/A

P.F.1.0 0.2165 0.1559 0.1108 0.0572 0.0901 0.0658 0.0589 0.0450 0.0381 0.0329 0.0294
mV/m/A

8
 Technical Parameters

Technical Data :
SBA (Aluminum Sandwich Insulated Bus Trunking)

CURRENT RATING
PARAMETER UNIT SINGLE TIER TWO TIER
Product code SBA SBA SBA SBA SBA SBA SBA SBA SBA SBA SBA

50N1 70N1 100N1 125N1 150N1 175N1 200N1 125N2 150N2 175N2 200N2

Rated current (In) A 500 630 800 1000 1250 1350 1600 2000 2500 2750 3200
Busbar size (Aluminium) mm 6x50 6x70 6x100 6x125 6x150 6x175 6x200 6x125 6x150 6x175 6x200
3 Phases & Neutral
No. of conductors per Nos. 1 1 1 1 1 1 1 2 2 2 2
Phase / Neutral
Rated short time current k Arms 30 40 50 65 75 75 85 100 120 120 150
for 1 second (Icw)

Rated peak short kA 63 84 105 143 165 165 187 220 264 264 330
time curent (Ipk)

OVERALL DIMENSION & WEIGHT

PARAMETER UNIT SINGLE TIER TWO TIER
Product code SBA SBA SBA SBA SBA SBA SBA SBA SBA SBA SBA

50N1 70N1 100N1 125N1 150N1 175N1 200N1 125N2 150N2 175N2 200N2

Overall dimension of 147x H 95 115 145 170 195 220 245 340 390 440 490
Busbar Trunking (mm)
(without Internal Earthing)
Weight of Busbar Trunking Kg/m 15 17 20 22.5 25 27.5 30 45 50 55 60
(without Internal Earthing)
Overall dimension of 150x H 95 115 145 170 195 220 245 340 390 440 490
Busbar Trunking (mm)
(with Internal Earthing)
Weight of Busbar Trunking Kg/m 16 18 21.5 24 27 29.5 32 48 54 59 64
(with50%Internal Earthing)

9
 Standard & Specifications

1. Compliance of standard IEC 60439 (1&2) & IS 8623 (1&2)

2. Independent certification authority ASTA- UK, KEMA - Holland, DAMSTRA - Nether Land, CPRI - India.

3. System 3Phase, full neutral

4. Current Rating
a) Copper Bustrunking SBC 800A ~ 5000A
b) Aluminium Bustrunking SBA 500A ~ 3200A

5. Rated operational voltage (Ue) 1000 Volt, AC

6. Rated insulation voltage (Ui) 1000 Volt, AC

7. Rated impulse withstand voltage(Uimp) 12 KV(1.2/50 s)

8. Rated frequency 50 Hz/60 Hz*

9 Enclosure material 1.6 mm (16 SWG GI)

10. Paint shade Epoxy polyster powder coated pebble grey shade(RAL-7032)

11. Busbar material (full round edge)

a) Copper 99.9% pure ETP grade
b) Aluminium 99.5% pure 19501 grade

12. Busbar insulation Multi layer insulation of CLASS - ‘F’

13. Maximum temp rise As per IEC 60439(1&2) & IS 8623(1&2)

14. Degree of protection IP 54 for plug in type

(Tested as per IEC 60529) IP 55 for feeder bustrunking (suitable with canopy for outdoor application)

15. Busbar configuration 3P+N+PE

3P+N+PE+External Earth
3P+2N+PE
3P+N+PE + Internal Earth

* R X Z values for 60 Hz available on request

10
 Bustrunking System

General Rising Main Distribution

Busbar Trunking System for electrical distribution is an alternative to cumbersome
conventional cable distribution system .

Decentralized distribution is the main highlight of this distribution system. Third Floor
EN
D
CL
OS

This system eliminates separate requirement of distribution & panel boards.

U RE

SPRING VERTICAL
HANGER

Loads can be fed from Plug-in Boxes unlike cables where each floor /machine is
D
EN
GE
AN
FL

to be fed separately from the main switchboard.

AL
IC
RT
Second Floor VE OW
B
EL

EXPANSION JOINT

Can be installed quickly with minimum technical expertise and have good asthetics.
E

Any section of bustrunking can be removed without distrurbing adjacent sections.

IS
W
AT R D
FL NGE EN
L HA GE
RI TA AN
G ON FL
HA ID V RIZ
NG ER HO
ER TI E
CA
L TE

System is maintenance free and adds elegance to the surrounding.

PLUG IN HOLE
First Floor
PLUG IN UNIT

RE
DU
CE
R

RIGID VERTICAL
L HANGER
TA
ON
HO RIZ ET
ME RI HO FF-S
DI EL Z O BASE CHANEL
HA U BO ON
NG M W TA

Salient Features
ER L

D
GE
AN OX FEED IN BOX
FL B
D

Close proximity of busbars doesn’t allow mutual inductance between

VE EN E
RT IS
TE IC W
E AL GE R
ED NGE TR END FLANGED
HA

phases yeilding low reactance, low impedance, low voltage drop and
END BOX

TRANSFORMER

low power loss.

Basement AY
TR
E
BL
CA
R
EA
HG
ITC
SW

Specially designed housing tightened at every 250 mm act as a heat

sink to yeild improved thermal characteristic, high mechanical and
short circuit strength.

Due to elimination of air there is no rise of chimney effect, so no fire

barriers are required.
Horizontal Distribution
Due to compactness system can be installed in lesser space.
FLANGED
END BOX

Automatic polarity is maintained during installation.

VERTICAL
ELBOW
INSULATED BUSDUCT

INSULATED
BUSDUCT HORIZONTAL
ELBOW

System can be mounted edgewise OR flatewise,

INSULATED BUSDUCT

EDGEWISE FEED IN BOX

horizontally or vertically in any direction with all kinds

HANGER

HORIZONTAL
OFF-SET

of bends and tees etc.

FEED IN BOX
FLANGED END CABLE

L.V. PLUG IN BUSDUCT

SWITCHGEAR

Flexible and safe distribution system leads to easy

PLUG IN BOX

PLUG IN BOX PLUG IN BOX

and fast installation. FEED IN BOX

PLUG IN
BOX END CLOSURE

END CLOSURE

System is completely re-usable. PLUG IN

BOX

END CLOSURE

PLUG IN
BOX

END CLOSURE

11
 Main Components

Feeder Bustrunking
Straight length is used for the purpose of power transmission.
Transformer to Panel
Main Panel to Sub Panel
Generator to Panel
Panel to rising mains..

L - 3 Meter Standard Length

Plug-in Bustrunking
Where branch loads are to be fed from the main line.
Vertical Rising mains to various floors with help of Plug - in Boxes.
Plug-in Points shown are indicative only. m
0 0m
Rating and Number of plug-in-points shall be as per the site requirement . 30

12
 Main Components

UNI-BLOCK BUSBAR JOINT

1
2

1
2

1. DMC Insulation
1
2
2. Conductor CU/AL
1 3. End Plates
2
4. Belleville Washers

5
4 3 1 5. HTS Bolt

Joint block is operatable by one / two HTS bolts.

Joint assembly can be removed / installed in installed condition.
Disc spring washer are used to uniformly distribute pressure.
Recommended torque for tightening is 7 Kgf-mtr.
Specially designed to accommodate thermal expansion of busbars and housing.
With single bolt (For busbar size upto 6x125mm)
With double bolt (For busbar size 6x150 to 6x230mm)

13
 Main Components

Horizontal Elbow
Standard Length &
Current Rating
A Min. Length A x B (mm)
B Copper 800~2500A
Aluminum 500~1750A
Copper 3000~5000A 300 x 300mm
Aluminum 2000~3200A

Horizontal Offset [Z] Elbow

Standard Length &
Current Rating
Min. Length A x B x C (mm)
Copper 800~2500A
Aluminum 500~1750A
600 x 600 x 600mm
Copper 3000~5000A
Aluminum 2000~3200A
A
B

14
 Main Components

Vertical Elbow

B
Standard Length &
Current Rating
Min. Length A x B (mm)
Copper 800~2500A
400 x 400 mm
Aluminum 500~1750A
Copper 3000~5000A
500 x 500 mm
Aluminum 2000~3200A
A

Vertical Offset [Z] Elbow

C

B
Standard Length &
Current Rating
Min. Length A x B x C(mm)
Copper 800~2500A
400 x 400 x 400mm
Aluminum 500~1750A
Copper 3000~5000A
500 x 500 x 500mm
Aluminum 2000~3200A

Vertical Tee Seciton

C

Standard Length &

Current Rating
Min. Length A x B x C(mm)
Copper 800~2500A
400 x 400 x 400mm
Aluminum 500~1750A
Copper 3000~5000A B
500 x 500 x 500mm
Aluminum 2000~3200A
A

15
 Certification & Approvals

16 17
 Main Components

Standard Flange End

14(Type)
Æ
50

50

50

50
50 50 50 50
50 50
W
W W W

Fig.4 Fig.5 Fig.6 Fig.7

690
60 = 150= 60

60
690
60 = 150= 60
60

60 = 150 = 60
60

A
A

15TYP
196

A
60

5TYP
60

15TYP

60
148 148 148
16

16
16

X X
300

300

X X
300

X X
200

300

300

120
150 150 150 150 150 150
120 120

N L1 L2 L3
N L1 L2 L3 N L1 L2 L3

Fig.1 (1 Tier) Fig.2 (2 Tier) Fig.3 (3 Tier)

DIMENSIONS Terminal Busbar No.of Appliable Standrad

S.No Product Code Flange End Box Bellow
A W Detail Hole Detail Basbar

01. SBC/SBA 50N1 155 50 Fig. 1 Fig. 4 1

02. SBC/SBA 70N1 175 70 Fig. 1 Fig. 4 1 A
03. SBC/SBA 100N1 206 100 Fig. 1 Fig. 5 1
04. SBC/SBA 125N1 231 125 Fig. 1 Fig. 5 1
05. SBC/SBA 150N1 256 150 Fig. 1 Fig. 6 1
06. SBC/SBA 175N1 281 175 Fig. 1 Fig. 6 1
07. SBC/SBA 200N1 306 200 Fig. 1 Fig. 7 1 B
08. SBC 230N1 336 230 Fig. 1 Fig. 7 1
09. SBC/SBA 100N2 352 100 Fig. 2 Fig. 5 2
10. SBC/SBA 125N2 402 125 Fig. 2 Fig. 5 2
11. SBC/SBA 150N2 452 150 Fig. 2 Fig. 6 2
12. SBC/SBA 175N2 502 175 Fig. 2 Fig. 6 2 C
13. SBC/SBA 200N2 552 200 Fig. 2 Fig. 7 2
14. SBC 230N2 612 230 Fig. 2 Fig. 7 2
15. SBC/SBA 150N3 552 150 Fig. 3 Fig. 6 3 D

18
 Main Components

Flange End Box cum Termination Detail

A+80 Flange Dimension (in mm)

20 A 20 S.No End Box A
Application for
B C D E F G H I J K (Recommended)
TOTAL NUMBER OF HOLE (H)X DISTANCE BETWEEN HOLE(I)

01. BOX A 500 250 250 120 540 4 180 3 145 290 50 SBC/SBA-50N1, 70N1, 100N1, 125N1
B+80

02. BOX B 500 350 250 120 540 4 180 3 195 390 100 SBC/SBA-150N1, 175N1, 200N1, 230N1
B
J

D D D
03. BOX C 700 620 350 150 740 5 185 5 165 660 150 SBC/SBA-100N2, 150N2, 175N2, 200N1, 230N2

04. BOX D 700 800 350 150 740 5 185 5 210 840 150 SBC/SBA-150N3, 175N3, 200N3
20 E 20
TOTAL NUMBER OF HOLE (F)X DISTANCE BETWEEN HOLE(G)
L3
L2
L3
N

SECTION XX’
300

PE
X X’ 14(Typ)

NOT IN C&S SCOPE

C

NOT IN C&S SCOPE

50 50 50

N L3 L2 L1 K

PANEL/TRANSFORMER/DISEL GENRATOR FLANGE

Rubber Bellow Laminated Copper Flexible

Holes to be drilled at site
23 50 25 as per requirement
25 25
50

50

98
98
L
Bustrunking Side Switchgear side
(Panel/D.G./TFR.)

Thickness (t)
as per Rating
A+80
20 A 20
t
TOTAL NUMBER OF HOLE (H)X DISTANCE BETWEEN HOLE(I)

copper Flexible code For Ordering

B+80
J

COPPER FLEXIBLE CODE FOR ORDERING CFX L

E 20
Rating Lengh
20
TOTAL NUMBER OF HOLE (F)X DISTANCE BETWEEN HOLE(G)

PLAN M.S. CHANNEL

C

19
 Main Components

Plug-in Boxes - IP 54 Type O

Overall Dimensions (in mm)
4P - 280(L) X 135(W) X 117(H)
5P - 280(L) X 160(W) X 117(H)
With in-built Isolator
With MCB : 32 & 63 Amps
With Fuse holder : 32 & 63 Amps (BS type)
With MCCB : upto 63 Amps
2 / 3 / 4 poles) (MCCB height < 130m)

Type A

Overall Dimensions (in mm)

4P - 370(L) X 135(W) X 115.5(H)
5P - 370(L) X 160(W) X 115.5(H)
With in-built Isolator
With provision for door Interlocking & Interlocking
with bus trunking (for MCCB and SFU)
With Fuse Holder : 100 & 125 Amps (DIN type)
With MCCB : upto 125 Amps (2 / 3 / 4 poles)
(MCCB height < 170m)
With SFU : 32 ~ 125 Amps (TPN / 4 Poles)
(C & S make, DIN or BS type)

Type B, C & D

Overall Dimensions(in mm)

Type B - 4P & 5P - 435(L) X 250(W) X 170(H)
Type C - 4P & 5P - 600(L) X 340(W) X 230(H)
Type D - 4P & 5P - 800(L) X 400(W) X 250(H)
With provision for door Interlocking &
Interlocking with bus trunking (for MCCB and SFU)
With Fuse HoldersB:200 Amps
(DIN type)C:250 ~ 400 Amps
With MCCB (2 / 3 / 4 poles)
Type B : 200 Amps. (MCCB height < 170)
Type C : 250 ~ 400 Amps. (MCCB height < 270)
With SFU: (TPN / 4 Poles), C & S make
Type C: 200A (BS type),
: 250A (DIN), 315A (BS) & 400A (DIN)

Interlocking with bustrunking to ensure “Plug-in” and 4 Pole isolator upto 125A.
“Plug-out” possible only in ‘OFF’ condition is Earth contact of Plug-in boxes makes first & breaks last.
available as an optional For cables entry, provision of gland plates on three sides.
Live contacts silver plated are isolated / properly Contacts of Plug-in are silver plated.
shrouded. Sheet thickness 1.6 mm CRCA, Epoxy powder coated.

20
 Spring & Rigid Hanger

Vertical Spring Hanger

2nd Floor

N L1

U clamp(Clamped tightened
with bustrunking)
Floor Height

ISMC 150x75
Not in Scope of Supply) ISMC 150x75
Not in Scope of Supply)

Plug-in Box Vertical Spring Hanger

Spring Hanger

First Floor

L SUPPORT

Plug-in Point
Enlarge view of U/L clamp

Vertical Rigid Hanger

(At lowest floor only)
ISMC 150x75
Not in Scope of Supply) ISMC 150x75
Not in Scope of Supply)

Gr. Floor
Vertical Rigid Hanger

Installation - Spring Hanger

N L1
Floor Thickness

Fit the Spring Hanger to the ‘U’ clamp already fitted to both side

Basement
of the bustrunking (Rising Mains)..
Remove nut A from Rigid hanger assembly, and pass the
To End Feed Unit / Panel
M16 bolt thru the holes in the ‘C’ channel already grouted on the floor/wall
Due to bustrunking weight the spring will compress and creates a gap
Installation - Rigid Hanger between nut ‘C’ and L support. Tighten nut ‘C’ to eliminate the gap.
Fit the Rigid Hanger to the ‘U’ clamp already fitted to both side of Adjust nut B on both sides of bustrunking until it reaches desired level
the lowest bustrunking in the ground floor. for fixing joint with lower bustrunking. Ensure that nut B is adjusted equally
Remove nut A from Rigid hanger assembly, and pass the M16 bolt on both sides to install bustrunking vertically straight.
thru the holes in the ‘C’ channel already grouted on the floor/wall Lock nut A from lower end of bolt to the ‘C’ channel.
Position the bustrunking height as per layout drawing by rotating Repeat steps for subsequent bustrunking.
the nut B until bustrunking reaches desired level. Loosen nut C to allow enough gap for spring to expand
Lock nut A from lower end of bolt to the ‘C’ channel. under thermal conditions after complete installation.

21
 Other Components

Reducer
These are required to connect two dissimilar rating / type of bustrunking. Reducer may be designed with switching or isolating device.

630 A

400 A

End Feed Box (Direct)

To feed bustrunking through cables, Direct End Feed Unit (EFU) is available with sufficient space for direct connection through lugs and bolts. MCCB,
SFU, Isolators and Fuse Holders etc. can be fitted in End Feed Unit as per specific requirement. 375mm length of bustrunking is integrally fitted
(measured and charged with bustrunking) along with End Feed Unit as standard practice so that joint between End Feed Unit and bustrunking is
exactly same as of two normal bustrunking lengths.
Undrilled cable gland plate is provided for multiple cable feeding option. End Feed unit can be made LHS or RHS type as per site requirement.

Sectional Isolator Unit

These are required to Isolate the bustrunking run in between, for various reasons. Section Isolator Unit can be fitted with Load Break Switches / SFU’s
/ MCCB’s.

End Cover
These are required to close the open end of Rising main / bustrunking at the end and it provides necessary IP level.

Vertical Support
One set of Vertical Support is recommended per floor per rising main along with rigid or spring hanger (as applicable) when the floor height is more
than 3.5mtrs to avoid horizontal swing in bustrunking sections.

22
 Complete Engineering Solution

(Typical Horizontal Layout ) (Typical Rising Mains )

END COVER

1300
TERACE FLOOR

750

3000
4030

750
750
590
THIRD FLOOR

1300
750

3000
4030

750
750
590

SECOND FLOOR

(Typical End termination)

1280
750

3000
750
750

SPRING HANGER
590

FIRST FLOOR
1280

BEAM(TYP.)
Plug In Point (TYP.)
750

3000
4030

750

PLUG-IN BOX
750

RIGID HANGER
620

1100

GROUND FLOOR
280 (TYP.)

147

23
 Installation Instructions

General Preparation Handling / Hoisting

First check that the intended route for the bus trunking is clear of all obstructions These guidelines are provided to reduce the risk of personal injury, equipment damage
an that all apertures in walls and floors are of correct size and at correct location. during handling and also to facilitate movement of the bus trunking sections and
Apertures should generally leave 50mm around the Bustrunking enclosure. Please accessories at site.
refer layout and assembly drawings for any special features. Handle bus trunking with care to avoid damage to internal components and the enclosure.
Determine fixed points of the installation (feed units, flanged end, elbows, tee While transporting, take care not to drop it or let it hit other object. A fork lift may offer a
etc.) anthen decide support points. more convenient method of handling and has the added advantage of permitting it to be
Ensure there is sufficient horizontal and vertical clearance from the wall and
hoisted between levels. Ensure the load is stable and safely secured.
ceiling to provide easy access to joints, both for original installation and for any
Platform lifts or elevators, either manually or power operated, can be used
future maintenance requirements.
The bus trunking should be located away from polluted atmosphere such as advantageously in moving bus trunking equipments between elevations. Check that the
corrosive fumes, furnace gases and chemicals etc. weight of personnel plus trunking is within the capacity of the lift / elevator.
While lifting vertical lengths, take care to use an adequate sling and slinging method so
Unpacking that the equipment does not slip or fall.
Care must be taken while unpacking. Cutter, should be used to cut all steel straps If a crane is used to install bus trunking, use nylon straps and distribute the weight on
securing the package. Nail pullers should be used for unpacking wooden casings.
each lift. If cables are used, insert thick pieces of foam or corrugated cardboard between
Carefully remove any support blocks or other fittings which may have been used
for shipping. them to prevent the bus trunking from being damaged. Do not place slings, cables or
When Bustrunking is received, unpack temporarily to inspect its physical condition. chains around bus trunking ends since damage can easily occur.
Also check and ensure that the consignment is complete and correct as per the If a fork lift or similar hoist is used, properly position the bus trunking on the fork to
order. Restore the materials in original packing condition, if it is required to be distribute its weight. Careful approach is a must to avoid any damage to the metal
stored for longer period prior to installation.
housing that would break busbar insulators and result in a failure.
It is recommended to remove the polythene sheet (covering the entire
Bustrunking) only after completion of installation, in order to protect the Do not drag bus trunking across the floor or across other busbar sections.
Bustrunking from water, slurry & paint etc. during installation. While installing vertical section, it may be easier to lower the bus trunking from one floor
above where it will be installed. Vertical sections are often stored on the floor above their
Storage final location to facilitate lowering them into position. Do not damage end of trunking
Never keep the Bustrunking in inclined / vertical condition. Stacking should be
when raising from horizontal to vertical positions.
firmly supported to prevent any slippage.
Always store the Bustrunking products in original packing to avoid any damage, When the work is suspended during the installation, the ends of the connecting sections
deformations and entry of any contaminants like dust, moisture and vermins. should be protected against water and dust by keeping the trunking covered with
Cover trunking with water proof sheets. polythene.
When the work is suspended during the installation, the ends of the connecting sections
Protection From Contaminants should be protected against water and dust by keeping the trunking covered with
Bus trunking should be adequately protected from liquids, moisture and other
contaminants. Some common source of contaminants are : polythene.
Moisture / Water dripping Never use busbars / conductors of Bustrunking for lifting sections.
Bus trunking must be protected from these contaminants during installation. Bus
trunkin is not weather resistant until completely installed with all covers & boxes Hanging / Supporting
fitted & secured. Fix support with ceiling/wall/structure to accommodate bustrunking hangers before
Floor level liquids proceeding with fixing of bustrunking.
Ideally water bank of min. 125mm height should be installed around all floor Do not leave Bustrunking section unsupported at ends while next section is being fitted as
openings for riser bus trunking to prevent liquid spillages from entering in the
this could cause damage. Use supports/brackets to ensure trunking remains correctly
opening and running down the bus trunking.
aligned at all times.
Leaking Roof
Level and plumb Bustrunking (align vertically and horizontally) before final tightening of
Protect bus trunking with a temporary protective cover to prevent water from
falling on to the Bustrunking directly until the roof is repaired. all joint hardware.
Pipes In case the “Insulation Resistance” is found abnormal after installation of complete route,
Protect bus trunking with a temporary protective cover to prevent water much time is spent to detect faulty parts. It is therefore recommended that the insulation
falling onto the busbar until leaking pipes are repaired. Where pipes (especially resistance checking be partially conducted by 500V megger even during the installation.
cold water pipes) pass directly above bus trunking, the busbar should be protected
from dripping condensate by insulating the pipe or permanently shielding the bus
trunking.

24
 Installation Instructions

Horizontal installation Vertical Installation

Two types of horizontal supports are available . Choose one depending upon For Vertical Installation two types of hangers are provided :
Edgewise installtion as shown in diagram. It is generally preferred to Rigid hanger at lowest floor and spring hanger for all balance floors.
install edgewise. Floor opening and minimum Clearances
After hangers have been installed with tie rods (Not part of bustrunking supply), Following sizes of opening and clearances are recommended for comfortable
bustrunking length may be joined starting from EFU / Flanged End. installation, operation and maintenance (however actual decision will always

To connect one length to the other please refer Figure-1 depend upon the site condition).

Horizontal support need to be tighten with hanger once the run is completed.
Spacing between two brackets
It is recommended to support Bustrunking at intervals of around 1.5 meters
(1.0mtr minimum & 2 meters maximum) depending upon following points:
Shape, strength, rigidness and distance of hangers from ceiling / wall.
Rating (Low/high) and numbers of plug-in boxes to be fitted between two brackets.
Ensure each element of Bustrunking run is supported by at least one bracket.
As far as possible avoid fixing of bracket at Bustrunking joint area and at plug-in point
window.
Minimum distance between two Bustrunking will increase if plug-in box/end fe ed
unit/reducer etc. is fitted in any of the straight run. 100mm clearance need to be
considered between two boxes / unit installed on parallel runs. Space required for
door opening should also be considered. 100mm min. clearance should be considered
in case of trunking running close to beam / columns / pillars
FLOOR CUT - OUT
Never fill floor opening with mortar / cement.

Minimum clearances between two trunking running parallel should be 100mm.

between plug-in-boxes /end feed units / reducers etc. Space required for door

opening should also be considered.

Floor opening should be completely covered /sealed.

WALL
HORIZONTAL EDGE WISE

A= 200 Mini without EFU/Reducer etc.

A= 550 Mini without EFU/Reducer etc.

WALL

* Not in C&S scope

A
A= 200 Mini without EFU/Reducer etc.
A= 550 Mini without EFU/Reducer etc.

25
 Installation instructions

Joint assembly

1.Fix Bottom Joint Cover ensuring

gap between enclosure of two
section as 250 mm.( Figure1)

Figure. 1

2. Loose Joint Hex nut(M12) & fit

Uniblock Joint till it rests on Bottom
joint cover. Do not attempt direct
hammer force to fit joint.(figure 2)

Figure. 2

3. Apply 7.0 Kgf-mtr. torque to

tighten Joint Hex nut .(figure 3)

Figure. 3

4.Fix both Side Joint Covers &

then Top Joint Cover.(figure 4)

Figure. 4

26
 Installation Instructions

Earthing Periodic checking

Bond the internal / external earthing busbars of bustrunking to main earthing of Even though the system is virtually maintenance free following checks are
system with adequate busbars or cable links as per standards and electrical recommended (for guaranteeing safe usage of the bustrunking for a long
regulations. time) preferably once in a year.

For bustrunking with internal earth, continuity is maintained through joints. And (a) Check the external appearances
for bustrunking with external earth continuity is maintained through external Check to ensure there is no deformation, damage, dust etc. through
links. Plug-in-boxes have integral earth clip which makes automatic contact out the whole length of the bus trunking and there is no dislocation,
while plugging the box on to the bustrunking. bending and other abnormality of the connecting covers, hangers an
plug-in- boxes.
Inspection & Testing
Inspection after installation (b) Environmental check
Environment where the bus trunking is used sometimes changes after
Before energizing check: its installation. Check that the environment is not hazardous even
(a) Whether the bus trunking is not damaged. partially due to water, moisture, high temperature, corrosive gas,
immoderate vibration, dust etc.
(b) Whether the connecting parts are fixed precisely.
(c) Check the joint connections
Since the spring washers are employed in busbar joints, there shall be
(c) Whether the bolt connecting the equipment are securely fastened.
no problem of joint loosening. Therefore, periodical check is not
necessary if recommended torque is applied to the joint clamp
(d) Whether the hangers are supporting the bus trunking securely.
assembly during installation. However it is advisable to re-check the
tightening after full loading of bustrunking for 24 hou
(e) Whether all the joint covers and tap off outlet covers of bus trunking
are closed. (d) Check the load condition
Check and ensure that total load is not exceeding the capacity of
(f) Whether all busbar joints are tightened to the recommended torque. bustrunking. Especially, pay attention when the main line is branched
by elbows, tee’s or crosses.
(g) Whether end covers are fitted to the end of all runs.
(e) Check the insulation resistance (IR)
Thereafter INSULATION RESISTANCE of complete installation (Run wise) Highly insulating, non-hygroscopic Insulation material are used for
shall be checked after disconnecting all equipments either by opening the busbars, hence IR value should not reduce at later stage. Still it is
isolator switch or setting the breakers in ‘OFF’ position. The insulation advisable to check IR value by megger (500V) periodically.
resistance value can not be specified due to the difference of the length of
run / route and the environmental condition, but if it is a dried Summary
atmosphere, normally it shows a value above 100Mega ohms (500V Review all layout drawings and other technical details very carefully.
megger).
Check description and identification of each piece before installing it.
In case it is below 10Mega ohms it has to be checked as it is most likely
that there may exist some factors which are reducing the insulation. Follow the joint assembly instructions.
Megger value of bustrunking section individually can be carried out by
isolating joint assembly to locate the fault. Check insulation resistance while fixing sections of bustrunking during
installation.
Reason for low insulation value can be due to above mentioned
(a) to (g) factors, presence of moisture /contaminants or breakage of joint Check for possible source of contaminants that may fall on the bus trunking
insulators Defective section may be put to hot blowing air for drying the during installation and take preventive actions.
moisture and improving megger value.

If the insulation value does not improve, contact the C&S.

27
 Major Installations

Hotels
n Four Season - Mumbai
n Inter Continental The Grand- Mumbai
n ITC hotel - Mumbai
n Le-Meridian Hotel - Pune / Bangalore
n Maya Inn - Chandigarh
n Sayaji Hotel - Indore
n Shangri-La Hotel - New Delhi

Multi Storey Buildings

n Gold Hill Sqaure - Bangalore
n Hiranandani Gardens - Mumbai
n IOCL - Mumbai / New Delhi
n MMTC - Mumbai
n ONGC Corporate Office - Mumbai
n Ranbaxy Corporate Office - Gurgaon
n Spenzer Plaza - Chennai
n State Trading Corporation-New Delhi
n S T Microelectronic - Noida
n TATA Memorial Centre

Industries
n APC - Bangalore
n Atlas Copco - Pune
n Ashok Leyland - Chennai, Gurgaon
n Auto Max - Gurgaon
n Bajaj Auto - Pune/Aurangabad
n Delphi India - Noida
n Denso India Limited - Manesar
n Dhampur Sugar Mills - Dhampur
n Escorts Farmatrac - Faridabad
n Kirloskar Motors - Chennai
n Hero Honda - Dhauwera
n Hindustan Lever Limited - Assam
n Jindal Steel & Power - Raigarh
n Maruti Suzuki - Manesar
n Mercedes Benz - Pune
n New Holland - Greater Noida
n Subros - Noida
n Thai Summit - Pant Nagar
n Toyota Techno Park - Bangalore
n TVS Suzuki- Mysore

Software Parks
Adobe Software - Noida
n

Cadence Design Systems - Noida

n

Convergys technologies - Gurgaon

n

CTS - Pune
n

Dell Computer - Chandigarh

n

G.E. Capital - Hyderabad

n

HCL Technologies -Noida

n

IBM - Noida
n

IFlex - Bangalore
n

Infosys - Banglore/Chandigarh/ Chennai/ Mysore

n

Karbay - Hydrabad
n

K. Raheja IT Park - Hydrabad

n

Mahindra British Telecom - Pune

n

Philips Software Centre - Bangalore

n

RMZ Aerospace - Banglore

n

Tata Consulting Services - Calcutta

n

Wipro Technologies - Pune / Kolkatta / Chennai

n

28
Major Installations

Hospitals
Appolo Hospital - Ahmedabad
n

Artemis Hospital - Gurgaon

n

Batra Hospital - New Delhi

n

Dr. Hedgavers Arogya Sansthan - Delhi

n

Escorts Heart Institute - New Delhi

n

G. P. Hospital - Mumbai
n

Govt. General Hospital - Chennai

n

Jaideva Institute of Cardiology - Bangalore

n

Maulana Azad - New Delhi

n

Safdarjung Hospital - New Delhi

n

Sir. Ganga Ram Hospital - New Delhi

n

Exhibition Halls
ITPO - Chennai
n

ITPO - New Delhi

n

M.P. Export facilitation Centre

n

CPWD / PWD
Delhi Secretariat - New Delhi
n

Gene Bank (Pusa) - New Delhi

n

High Court - New Delhi

n

Parliament House - New Delhi

n

Parliament Library - New Delhi

n

Mayur Bhawan - New Delhi

n

Shastri Bhawan - New Delhi

n

Yojna Bhawan - New Delhi

n

Railways
n Northern Railway - Lucknow
n Rail Bhawan - Delhi

Temple
n Swamy Narayan Temple - Mumbai

Telecommunication
BSNL - New Delhi / Hyderabad
n

C-DOT - New Delhi

n

DOT - Mumbai
n

MTNL - Mumbai
n

29
 Major Export Orders

1. KYCR Coil Industries - Bangladesh

2. Dafna Tower - Doha
3. Doha Tower - Doha
4. 81 flats at AI-Sadd - Doha
5. B+G+5 Flats - Doha
6. B+G+6 Flats - Doha
7. G+11 Building - Doha
8. Westbay 44 Tower - Doha
9. Shk Falak Twin Tower - Doha
10. Mellineium Tower - Doha
11. Mushreif Tower - Doha
12. Port Saeed - Dubai
13. Evershine Trading - Dubai
14. Baiji Power Plant - IRAQ
15. LDPE Project Bandar Imam - Iran
16. P.T. Indo - Bharat Rayon - Indonensia
17. Magadi Soda plant - Kenya
18. AL Nazzar Tower - Jordan / Kuwait
19. Al Mazaya Tower - Kuwait
20. Kuwait National Petroleum Corporation - Kuwait
21. Kirby Building System - Kuwait
22. Holiday Inn - Kuwait
23. P.T Prakasa Heavyndo - Malaysia
24. Cyber Tower, Ebene city - Mauritius
25. Rusail Power Project - Oman
26. Haima West Power station - Oman
27. Salalah Power Project -Oman
28. OMIFCO -Oman
29. E-Services - Manila, Philipines
30. P.S Bank - Philipines
31. Victoria Tower - Philipines
32. Alstom - South Africa
302
 Mission & Quality policy

Isolated Phase Busducts

(11 - 24 kV up to 20,000 Amps.)

Segregated Non-Segregated
Phase Busduct
(415 - 15.0KV, upto 5000 Amps.)

Air Insulated
Busbar Trunking System
(125 2000 Amps.)

Lighting Trunking
(32 - 63A)

31