Power Distribution Solutions

Godrej S.M.A.R.T. Busduct System.

Power Distribution Solutions

VISION
Be the most trusted solution provider in the electrical and electronic technologies.

MISSION
Energizing industry through advanced technology.

VALUES
l l l l

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Preface Why Godrej S.M.A.R.T busduct system? Joint Construction Construction Features Elements of the IP (Ingress Protection) and their meanings Technical features Calculations to be Considered The selection of Godrej S.M.A.R.T. Busduct system according to the voltage drop. Impedance Typical Rising Mains Configuration of the Godrej S.M.A.R.T Busduct system A Typical Busduct and rising mains layout describing all the components Single bolt jointing mechanism Copper / Aluminum Content and weight Flange End busbar to busbar Dimensions Busbar Flange End Connection Holes Flange End Conductor Dimensions Dimensions for Horizontal Hanger Flange end dimensions Special Flange End to Suit Various Requirements Wall flange dimensions Standard products Horizontal Supports Expansion Joints Flexible jumpers Tap off boxes End feed units Flexible rubber bellows Vertical spring hangers Vertical fixed hangers Test Certificates How to select the busduct trunking system.

4 5 6 7 8 9 10 11 12 13 14 15 16 16 17 17 18 19 19 20 21 22 25 25 26 27 27 27 28 29 30 38

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PREFACE
Electrical power supply has increased dramatically over the years, due to its high demand in the industrial sector,which is based on the rapid global economic growth. It was justified by the increase of projects in the industries such as highrise office buildings / complexes / factories, which required more elevators, cooling & heating, water treatment system, machineries, etc. The cable system has dominated the electrical power distribution market for years, but however, busduct system is widely being used in the recent years due to high reported fire cases. Besides, there is limited flexibility for cable installation whereby it may have difficulty for future expansion and it needs more attention during the maintenance period. Hence, electrical equipment such as busduct systems have been highly recommended in the electrical installation of high rise buildings, factories, industry plants, etc. The busduct system provides huge advantages and outstanding features in an electrical installation system, whereby it occupies a small space due to its compactness at the same time capable of carrying large current. It is also able to distribute the electricity easily through its plug-in (tap-off) design with an advantage of fire-stop ability and its aesthetic looks. We at Godrej & Boyce Mfg. Co. Ltd. are serving the Indian Market for over 115 years, Godrej & Boyce Mfg. Co. Ltd. offers a high-tech and S.M.A.R.T.BUSDUCTS to cater the rapid growth globally in the electricalsegment. With over300 installations worldwide, Godrej & Boyce Mfg.Co. Ltd. has become the leading pioneers in sandwiched busduct systems, rising mains and lighting trunking solution provider. Rising mains, bus ducts aremanufactured in the state of the art manufacturing facility of Godrej & Boyce Mfg. Co. Ltd. and serviced by ourteam ofexperienced Engineers. The Godrej S.M.A.R.T. BUSDUCT SYSTEM designed for power transport and distribution and is especially suitable in the electrical panel room both as a transformer to switchboard or switchboard to switchboard connection and as the main power distribution system for industrial, commercial and service industry. The Godrej S.M.A.R.T. busduct trunking system isbeing offered both in Copper and Aluminum Conductors up to 6300A and 5000A respectively.

Godrej S.M.A.R.T BUSDUCT SYSTEM IS MONEY INVESTED RIGHTLY.

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Why Godrej S.M.A.R.T. BUSDUCT SYSTEM?

S SANDWICH Godrej S.M.A.R.T. BUSDUCTSYSTEM is a Sandwich design which is compact in size. This technology guarantees the product's high performance in relation to voltage drop values for high current and long length runs. M MODULAR Godrej S.M.A.R.T. BUSDUCT SYSTEM is modular in design which reduces the installation time to a bare minimum.Being compact in design the busducts require less space for installation. A AESTHETIC Godrej S.M.A.R.T. BUSDUCT SYSTEM is aesthetic in nature because of its sleek powder coated housings and with a complete set of accessories enables the busduct to be laid as per the site conditions, as against cables which require a large bending radius. R RELIABLE Godrej S.M.A.R.T. BUSDUCT SYSTEM is subjected to stringent quality checks at various stages of manufacturing as per international quality standards. T TESTED GODREJ S.M.A.R.T BUSDUCT SYSTEM is fully tested and verified at the Central Power Research Institute(CPRI) as per IEC 60439 Part 1 & 2. Hence Godrej S.M.A.R.T BUSDUCT SYSTEM is highly reliable, safe, and compact for delivering large currents in the electrical system.

Power Distribution Solutions

Power Distribution Solutions

CONSTRUCTION FEATURES
l Conductor

Godrej S.M.A.R.T BUSDUCT SYSTEM are fabricated from high conductivity Copper conductor or Aluminum conductor of 99.9% purity. The conductors have fully rounded edges which make a smooth and easy connection between feeders.
l Enclosure

The enclosure is made from1.6mmthick electro-galvanized steel sheet to impart strength to the housing with epoxy powder coating, in ordertoprevent corrosion. The Standard Color of the Godrej S.M.A.R.T BUSDUCT SYSTEM RAL 7032. The final assembly is either bolted or riveted for a tamper proof design.
l Insulation

The conductors are fully insulated by using an extrusion technology, whereby the conductor is coaxially coated with epoxy insulation. The insulation is non-hygroscopic, halogen free, high thermal conductivity, of 1.6mm thickness. (Class F / Class H - 155 / 180C).
l Heat sink

There is an Aluminum C Channel being used in the housing of the Godrej S.M.A.R.T. Busduct System which gives strength to the assembly, acts as an earthing connector and also a heat sink to dissipate the heat developed in the system.
l Joint Connections

The load and supply ends are made as male-female contacts, which are tightened using a single bolt jointing mechanism. Belleville washers at both sides of the joint maintain constant pressure, and ensure a more secure, reliable maintenance free installation. The whole system is tightened with a maintenance free double nut which shears when a torque of 14kgm is applied, preventing any further tightening to the system thus ensuring a tight locking system.
l Accessories

A wide range of accessories are available to suit the busduct run along the required path. Which are but not limited to, Vertical or Horizontal Elbows, Combination Elbows, Vertical or Horizontal Offset Elbows, reducers, Expansion Joints, etc Also we provide feeders with plugin holes, and Tap-Off boxes to tap out supply. End feed units, Electrical panels can be provided on request.
l

Simple to Install with Less Cost Godrej S.M.A.R.T BUSDUCT SYSTEM is simple to install with "Single Bolt Maintenance Free" joint system, whereby all the joint sections are to be tighten with maintenance free double headed nut. This design is mainly to ease the installation work and to reduce the cost of installation.

l Compact & Lightweight

Being modular in design, with pre-fabricated numbered sections, the construction of Godrej S.M.A.R.T BUSDUCT SYSTEM is totally different from the conventional type of busway (air insulated type), and cables whereby it is fully insulated and is compact in design and lightweight.
l Ingress of Protection (IP).

The housing is totally enclosed with its fully insulated conductor to provide dust, water & insect protection, as according to IEC 60529 standards. Thus the degree of protection shall be min. IP 54 and up to max of IP68, which is widely applicable to power plants, petrochemical, LNG, oil & gas plants.
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Elements of the IP (Ingress Protection) and their meanings Reference IEC 60529 clause 4.2 page 21

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TECHNICAL FEATURES
l

Short Circuit Strength Godrej S.M.A.R.T BUSDUCT SYSTEMS have higher short circuit strength capacity whereby it can withstand more than the rated short circuit current specified by IEC standards.

Low Voltage Drop Godrej S.M.A.R.T BUSDUCT SYSTEMS have excellent low voltage drop values, due to its high technology design and compact type of construction with non-magnetic housing and low resistance.

Housing Construction The housing is fully enclosed based on compact type of construction that provides a stable temperature throughout the entire Godrej S.M.A.R.T BUSDUCT SYSTEMS, no matter with horizontal or vertical type of installation.

Fire Stop System Godrej S.M.A.R.T BUSDUCT SYSTEMS have the ability to stop any fire propagation, due to its compact design which provides un-circulated air inside the Godrej S.M.A.R.T BUSDUCT SYSTEMS.

Standards and Configuration IEC 60439 part 1 and part 2 AC rated voltage: up to AC 1000V, 50/60Hz DC rated voltage: up to DC 1000V, Rated current: up to 6300A Configuration: 1PH3W, 3PH3W, 3PH4W, 3PH5W and 3PH6W

l Power Distribution Godrej S.M.A.R.T BUSDUCT SYSTEMS will have plugin and tap off type of power distribution method. Rated current from 400 to 2500A can be available in tapoff type. All plug in/tap off units come with mechanical interlock. l

Service Condition Temperature: -15 to 50. Celsius Advantages Nominal rating guaranteed both for flat and edgewise installations (no de-rating) Protection degree guaranteed both for flat and edge-wise installation Maintenance free single bolt jointing system Customized design An engineering department at your disposal for site measurements, busduct run evaluations and electrical equipment connection study (panel, transformer etc)
A Green Product

The Godrej S.M.A.R.T. Busduct System are 100% reusable in case it is necessary to change its layout. 100% of the product material is recyclable and the distinctive production process is able to reduce manufacturing time and also minimize energy consumption according to common standards for minor environmental impact.

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Calculations to be considered
The calculation of the operational current (Ib) for a 3 phase Godrej S.M.A.R.T. Busduct system can be made using the following formula.

Where P power which is total of the connected load (kW) F load factor (diversity factor) Ue Operating Voltage Example: Requirement for an industrial unit catering to 18 terminals, and a single terminal of 150kW, Voltage is of 440V and considering the value of Cos to be 0 .95

Thus Total power Factor

Ib
18 x 150kw = 2700 kW or 2700000W 0.8
(P) (F)

After considering a 20% margin for safety 2984 + 20% = 3580A Therefore the Godrej S.M.A.R.T. busduct of 4000A rating either in Aluminum or Copper can be used.

Voltage Drop Calculation:Voltage drop formula according to IEC 60439 2 page # 47, Annex: J The voltage drop of the busbar trunking system can be calculated using the followingformulae:

Where u composite voltage drop of the system (V) k Load distribution factor IB Current of the circuit being considered (A) R1 Mean resistance of the system ( /m) X1 mean reactance of the system ( /m) L Length of the system being considered (m) Cos Load power factor The load distribution factor could be suitably selected from any of the 3 values below

a) k = 1 If the load is concentrated at the end of the busbar trunking run. b) If the load is uniformly spread between n branches. c) The load distribution factor k to calculate the voltage drop of a branch situated at a distance d from the origin of the busbar trunking run is taken as equal to length L of the busbar trunking run. in case of loads spread uniformly along the

Cos Sin

0.75 0.66

0.8 80 0.6 60

0.85 0.53
9

0.90 0.44

0.95 0 0 0.31

1.00 0.00

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The selection of Godrej S.M.A.R.T. Busduct system according to the voltage drop. Voltage Drop chart
For 3-phase alternating current of voltage drop per 100 meter of Copper and Aluminum are as under.
Vo oltage Drop 3 3 50Hz Power Fac ctor 1.00
4.95 7.59 8.94 8.83 8.72 7.59 7.59 6.71 7.37 6.55 6.86 6.94 6.50 7.42

Ampere A R Rating
400 630 800 1000 1250 1600

Busbar Sizes (mm)

One 5 x 50 One 5 x 60 One 6 x 60 One 6 x 75 One 6 x 100 One 6 x 140 One 6 x 175 One 6 x 240 T Two 6 x 140 T Two 6 x 175 T Two 6 x 185 T Three 6 x 140 T Three 6 x 175 T Three 6 x 185

Unit : volt/100m Voltage Drop D 3 60Hz z

Powe er Factor 0.75
5.01 7.23 8.66 8.55 8.31 7.27 7.43 6.90 7.32 6.55 6.79 6.75 6.48 7.30

0.95
5.3 32 7.9 94 9.4 42 9.3 30 9.1 12 7.9 96 8.0 03 7.2 25 7.8 85 7.0 00 7.2 29 7.3 32 6.9 93 7.8 87

0.90
5.31 7.84 9.34 9.22 9.01 7.87 7.98 7.27 7.82 6.98 7.26 7.26 6.90 7.82

0.85
5 5.24 7 7.67 9 9.16 9 9.04 8 8.82 7 7.71 7 7.84 7 7.19 7 7.70 6 6.87 7 7.14 7 7.13 6 6.80 7 7.69

0.80
5.14 7.46 8.93 8.81 8.58 7.50 7.65 7.06 7.53 6.73 6.98 6.95 6.65 7.51

1.00
4.97 7.64 8.99 8.90 8.77 7.68 7.69 6.84 7.59 6.79 7.14 7.09 6.75 7.64

0.95
5.46 8.16 9.67 9.57 9.38 8.21 8.33 7.54 8.25 7.43 7.77 7.74 7.31 8.24

0.90 0
5.50 0 8.13 3 9.67 7 9.56 6 9.35 5 8.19 9 8.36 6 7.61 1 8.28 8 7.48 8 7.81 1 7.78 8 7.33 3 8.25 5

0.85
5.47 8.02 9.55 9.44 9.22 8.07 8.27 7.57 8.21 7.43 7.74 7.71 7.25 8.16

0.8 80
5. .39 7. .85 9. .36 9. .25 9. .03 7. .90 8. .13 7. .47 8. .07 7. .32 7. .62 7. .59 7. .12 8. .01

0.75
5.29 7.64 9.14 9.03 8.80 7.70 7.94 7.34 7.89 7.18 7.46 7.43 6.96 7.82

COPPER

2000 2500 3200 3600 4000 4500 5000 6300

Unit : volt/100m
Ampere A R Rating
400 630 800 1000 1250

Busbar Sizes (mm)

O 5 x 60 One O 6 x 60 One O 6 x 75 One O 6 x 100 One O 6 x 140 One O 6 x 185 One O 6 x 240 One T Two 6 x 140 T Two 6 x 175 T Two 6 x 185 T Two 6 x 240 Th hree 6 x 175 Th hree 6 x 220 Th hree 6 x 240

1.00
8.24 12.28 10.88 10.95 8.53 7.65 7.72 7.49 7.43 6.97 7.14 7.01 7.18 7.24

Vo oltage Drop 3 3 50Hz Power Fac ctor 0.95 0.90 0.85 0.80
8.40 0 12.38 11.0 06 11.19 8.91 1 8.00 0 8.06 6 7.87 7 7.83 3 7.21 1 7.36 6 7.17 7 7.14 4 7.22 2 8.21 12.05 10.80 10.95 8.81 7.91 7.96 7.80 7.77 7.09 7.24 7.03 8.92 7.01 7. .97 11 1.65 10 0.46 10 0.64 8. .62 7. .74 7. .79 7. .64 7. .63 6. .92 7. .05 6. .82 5. .84 6. .70 7.69 11.20 10.09 10.27 8.38 7.53 7.57 7.45 7.44 6.70 6.83 6.59 8.34 8.48

0.75
7.39 10.73 9.69 9.88 8.12 7.29 7.33 7.22 7.22 6.47 6.59 6.34 8.06 8.19

1.00
8.27 12.31 10.90 11.02 8.60 7.70 7.83 7.58 7.59 7.15 7.34 7.17 7.48 8.19

Voltage Drop D 3 60Hz z Powe er Factor 0.95 0.90 0 0.85 0.8 80

8.54 12.59 11.25 11.41 9.19 8.23 8.25 8.10 8.18 7.53 7.63 7.40 7.40 8.20 8.40 12.33 3 11.06 6 11.23 3 9.16 8.20 8.18 8.08 8.19 7.47 7.52 7.27 7.22 7.98 8.19 11.97 10.77 10.95 9.03 8.08 8.02 7.97 8.09 7.33 7.34 7.08 5.97 7.56 7.9 94 11.57 10.4 44 10.62 8.8 84 7.9 91 7.8 82 7.8 80 7.9 94 7.1 14 7.1 12 6.8 86 6.5 58 7.5 50

0.75
7.66 11.13 10.07 10.26 8.61 7.70 7.59 7.60 7.75 6.93 6.88 6.62 6.38 7.03

ALUMINUM

1600 2000 2500 3200 3600 4000 4500 5000 5500

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Impedance The values of impedance of Copper and Aluminum for 3 phase alternating current are mentioned under (Unit: 10-5/m)
Ampere A R Rating
400 630 800 1000 1250 1600

Busbar Sizes (mm)

O 5 x 50 One O 5 x 60 One O 6 x 60 One O 6 x 75 One O 6 x 100 One O 6 x 140 One O 6 x 185 One O 6 x 240 One T Two 6 x 140 T Two 6 x 175 T Two 6 x 185 Th hree 6 x 140 Th hree 6 x 175 Th hree 6 x 185

3 50H Hz R1
7.15 6.96 6.45 5.10 4.03 2.74 2.19 1.55 1.33 1.08 0.99 0.89 0.75 0.68

3 60Hz

X1
2.83 2.12 2.14 1.68 1.23 0.86 0.76 0.65 0.49 0.41 0.36 0.30 0.28 0.24

R12 + X 12
7.69 9 7.28 8 6.80 0 5.37 7 4.21 1 2.87 7 2.32 2 1.68 8 1.42 2 1.16 6 1.05 5 0.94 4 0.80 0 0.72 2

R1
7.1 18 7.0 00 6.4 49 5.1 14 4.0 05 2.7 77 2.2 22 1.5 58 1.3 37 1.1 12 1.0 03 0.9 91 0.7 78 0.7 70

X1
3 3.40 2 2.65 2 2.61 2 2.05 1.55 1.06 0 0.95 0 0.77 0 0.60 0 0.52 0 0.46 0 0.41 0 0.33 0 0.29

R12 + X 12
7.94 7.48 7.00 5.53 4.34 2.97 2.41 1.76 1.50 1.23 1.13 1.00 0.85 0.76

COPPER

2000 2500 3200 3600 4000 4500 5000 6300

(Unit: 10-5/m)
Ampere A R Rating
400 630 800 1000 1250

Busbar Sizes (mm)

O 5 x 50 One O 5 x 60 One O 6 x 60 One O 6 x 75 One O 6 x 100 One O 6 x 140 One O 6 x 240 One Two 6 x 140 T Two 6 x 175 T Two 6 x 185 T Two 6 x 240 Th hree 6 x 175 Th hree 6 x 220 Th hree 6 x 240

3 50H Hz R1
11.90 11.25 7.85 6.32 3.94 2.76 2.23 1.73 1.34 1.15 1.03 0.90 0.83 0.76

3 60Hz

X1
2.63 2.11 1.67 1.46 1.20 0.85 0.67 0.56 0.45 0.31 0.27 0.21 0.12 0.12

R12 + X 12
12.19 9 11.45 8.03 3 6.49 9 4.12 2 2.89 9 2.33 3 1.82 2 1.41 1 1.19 9 1.06 6 0.92 2 0.77 7 0.77 7

R1
11.94 11.28 7.8 87 6.3 36 3.9 97 2.7 78 2.2 26 1.7 75 1.3 37 1.1 18 1.0 06 0.9 92 0.8 87 0.7 79

X1
3 3.17 2 2.63 2 2.06 1.74 1.51 1.05 0 0.75 0 0.67 0 0.56 0 0.39 0 0.30 0 0.24 0 0.14 0 0.16

R12 + X 12
12.35 11.58 8.14 6.59 4.25 2.97 2.38 1.87 1.48 1.24 1.10 0.95 0.87 0.81

ALUMINIUM

1600 2000 2500 3200 3600 4000 4500 5000 5500

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Typical Rising Mains

End closure Straight Feeder with Plug in hole to mount the Tap off Box

External Fire Barrier

Single Bolt Joint Mechanism

Tap off Box

Vertical Fixed Hanger

Wall clamp

End Feed Unit

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Configuration of the Godrej S.M.A.R.T Busduct System.

The Godrej S.M.A.R.T. busduct system is available in four distinctive configurations in which the conductor cross-sectional area and the housing changes as per the current rating and needs.

The active conductors R, Y, B, and N of the Godrej S.M.A.R.T. busduct system, even though they have equal cross-sectional area (except in the case of busduct system having 200% N), they are fixed in the trunking units (flange ends, straight feeders,elbows, etc) in a proper methodology. As a result the phase sequence is constant throughout the whole busduct run. The jointing section has been given special bends so as to guaranty the order of the phase sequence from the beginning to the end of the busduct run with the mechanical connections.

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The trunking elements, not limited to straight feeder, elbows, combination elbows, offset elbows, reducers, etc..., are used to supply electricity allowing any kind of run, according to the equipment characteristics and to the room and/ or to the buildings characteristics.

Expansion Joint

Verti ical Elbow w

End d Clos sure

Spring Hanger

Red ducer

Tap Off Box

Stra aight Fee eder

Fixed Hanger

Horizontal Support Horizontal Elbow Vertical Offset Elbow T Elbow

A Typical Busduct and rising mains layout describing all the components

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SINGLE JOINT BOLT MECHANISM

Co opper Conte ent & Weigh ht

Rating in Amps 400 630 800 1000 0 1250 0 1600 0 2000 0 2500 0 3200 0 3600 0 4000 0 4500 0 5000 0 6300 0 Busduct Height mm 115 125 125 140 165 205 240 305 405 475 495 605 710 740 Fig g. 2 Ty ype Conductor r size mm One 5 x 50 One 5 x 60 One 6 x 60 One 6 x 75 One 6 x 100 One 6 x 140 One 6 x 175 One 6 x 240 Two 6 x 140 Two 6 x 175 Two 6 x 185 Three 6 x 140 Three 6 x 175 Three 6 x 185 Weight Kg/m K 3PH 4W W 25 27 30 32 43 50 62 80 93 114 123 140 171 179 125 Width (W) mm 3PH 4W W Rating in Amps 400 630 800 1000 1250 1600 2000 2500 3200 3600 4000 4500 5000 5500

Aluminium Content & weight

Busduct Height mm 125 125 140 165 205 250 305 405 475 495 605 710 845 905 Fig. 2 Type Conductor size emm One 5x60 One 6 x 60 One 6 x 75 One 6 x 100 One 6 x 140 0 One 6 x 185 5 One 6 x 240 0 Two 6 x 140 0 Two 6 x 175 5 Two 6 x 185 5 Two 6 x 240 0 Three 6 x 175 Three 6 x 22 0 Three 6 x 24 0 Weight Kg/m m 3PH 4W 22 24 28 34 39 46 54 59 74 65 85 89 95 100 125 Width (W) mm 3PH 4W

Fig g. 1

Fig. 1

Fig.3

Fig. 3

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Flange e End Busbar r to Busbar Dimensions D Ampe ere Ratin ng 400 0 630 0 800 0 1000 1250 1600 2000 2500 3200 3600 4000 4500 5000 6300 Copp per Width (mm) One e 5 x 50 One e 5 x 60 One e 6 x 60 One e 6 x 75 One 6 x 100 One 6 x 140 One 6 x 175 One 6 x 240 Two 6 x 140 Two 6 x 175 Two 6 x 185 Three e 6 x 140 Three e 6 x 175 Three e 6 x 185 Housing 115 125 125 140 165 205 240 305 405 475 495 605 710 740 Fig. 1 3P 3W (W) Fig. 2 3P 4W (W W) Amper re Rating g 400 630 800 1000 0 1250 0 1600 0 2000 0 2500 0 3200 0 3600 0 4000 0 4500 0 5000 0 5500 0 Alum minum Width h (mm) One 5 x 60 One 6 x 60 One 6 x 75 One 6 x 100 One 6 x 140 One 6 x 185 One 6 x 240 Two 6 x 140 Two 6 x 175 Two 6 x 185 Two 6 x 240 Three 6 x 175 Three 6 x 220 Three 6 x 240 H Housing 125 125 140 165 205 250 305 405 475 495 605 710 845 905

100

100

130

130

Busb bar Flange End d Connection n Holes Ampe ere Ratin ng 400 0 630 0 800 0 1000 1250 1600 2000 2500 3200 3600 4000 4500 5000 6300 Copper Width W (mm) One e 5 x 50 One e 5 x 60 One e 6 x 60 One e 6 x 75 One 6 x 100 One 6 x 140 One 6 x 175 One 6 x 240 Two 6 x 140 Two 6 x 175 Two 6 x 185 Three e 6 x 140 Three e 6 x 175 Three e 6 x 185 Housing 115 125 125 140 165 205 240 305 405 475 495 605 710 740 Type Type Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 3 Fig. 4 Fig. 5 Fig. 4 Fig. 5 Fig. 5 Amper re Rating g 400 630 800 1000 0 1250 0 1600 0 2000 0 2500 0 3200 0 3600 0 4000 0 4500 0 5000 0 5500 0 Aluminum Width W (mm) One 5 x 60 One 6 x 60 One 6 x 75 One 6 x 100 One 6 x 140 One 6 x 185 One 6 x 240 Two 6 x 140 Two 6 x 175 Two 6 x 185 Two 6 x 240 Three 6 x 175 Three 6 x 220 Three 6 x 240 Housing 125 125 140 165 205 250 305 405 475 495 605 710 845 905

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

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Flang ge End Condu uctor Dimens sions Ampe ere Copp per Width Housing Ratin ng W W (mm) 400 0 One e 5 x 50 115 630 0 One e 5 x 60 125 800 0 One e 6 x 60 125 1000 One e 6 x 75 140 1250 One 6 x 100 165 1600 One 6 x 140 205 2000 One 6 x 175 240 2500 One 6 x 240 305 3200 Two 6 x 140 405 3600 Two 6 x 175 475 4000 4500 5000 6300 Two 6 x 185 Three e 6 x 140 Three e 6 x 175 Three e 6 x 185 495 605 710 740

Ty ype

Fig. 1

Amper re Rating g 400 630 800 1000 0 1250 0 1600 0 2000 0 2500 0 3200 0 3600 0 4000 0 4500 0 5000 0 5500 0

Alum minum Width W (mm) One 5 x 60 One 6 x 60 One 6 x 75 One 6 x 100 One 6 x 140 One 6 x 185 One 6 x 240 Two 6 x 140 Two 6 x 175 Two 6 x 185 Two 6 x 240 Three 6 x 175 Three 6 x 220 Three 6 x 240

Housing 125 125 140 165 205 250 305 405 475 495 605 710 845 905

Fig. 2

Fig. 3

Dime ensions for Horizontal Han nger Ampe ere Copp per Width Height Ratin ng (mm) W 400 0 One e 5 x 50 115 630 0 One e 5 x 60 125 800 0 One e 6 x 60 125 1000 One e 6 x 75 140 1250 One 6 x 100 165 1600 One 6 x 140 205 2000 One 6 x 175 240 2500 One 6 x 240 305 3200 Two 6 x 140 405 3600 Two 6 x 175 475 4000 Two 6 x 185 495 4500 Three e 6 x 140 605 5000 Three e 6 x 175 710 6300 Three e 6 x 185 740

Widt th A 3P 3W 3P 4W

105

125

Amper re Rating g 400 630 800 1000 0 1250 0 1600 0 2000 0 2500 0 3200 0 3600 0 4000 0 4500 0 5000 0 5500 0

Alum minum Width h (mm) One 5 x 60 One 6 x 60 One 6 x 75 One 6 x 100 One 6 x 140 One 6 x 185 One 6 x 240 Two 6 x 140 Two 6 x 175 Two 6 x 185 Two 6 x 240 Three 6 x 175 Three 6 x 220 Three 6 x 240

Height H W 125 125 140 165 205 250 305 405 475 495 605 710 845 905

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Flang ge End Dimen nsions Copper Ampe ere 3P 3W W 3P 4W W Ratin ng A A 400 0 630 0 800 0 1000 350 0 450 1250 1600 2000 2500 3200 3600 4000 4500 450 0 540 5000 6300

B 175 185 185 200 225 265 300 365 465 535 555 665 770 800

Type

Fig. 1

Ampere Rating 400 630 800 1000 1250 1600 2000

3P 3W A

Aluminum A 3P 4W A

B 185 185 200 225 265 310 365 465 535 555 665 770 905 965

Type

350

450

Fig. 1

Fig. 2

Fig. 3

2500 3200 3600 4000 4500 5000 5500

Fig. 2

450

540

Fig. 3

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Special Flange End to Suit Equipment Requirements

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Wall Flange Dimensions

Ampe ere Ratin ng 400 0 630 0 800 0 1000 1250 1600 2000 2500 3200 3600 4000 4500 5000 6300 Copper Wall Open ing 3P 3W W 3P 4W A A B 190 200 200 215 240 280 315 180 200 380 480 550 570 680 785 815 Aluminum Wall Opening 3P P 4W 3P 3W A A A Amp pere Rat ting 40 00 63 30 80 00 10 000 1250 16 600 1 180 200 20 000 2500 3200 3500 40 000 4500 50 000 5500

C 250 260 260 275 300 340 375 440 540 610 630 740 845 875

C 260 260 275 300 340 385 440 540 610 630 740 845 980 1040

B 200 200 215 240 280 325 380 480 550 570 680 785 920 980

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DIMENSIONS OF THE STANDARD PRRODUCTS.

STR RAIGHT FEED DER LENGTH (L L) mm RATI ING ST TD MIN 400A 1000A 30 000 500 30 000 500 1250A 2000A 2500 0A 30 000 500 3200A 4000A 30 000 500 5000A 6300A 30 000 500

HORI IZONTAL EL BOW. S x L (m mm) RATI ING ST TD MIN 400A 1000A 500 x 500 300 x 300 1250A 2000A 500 x 500 300 x 300 2500 0A 500 x 500 300 x 300 3200A 4000A 500 x 500 300 x 300 5000A 6300A 500 x 500 300 x 300

VER RTICAL ELBO OW RATI NG 400A 1000A 1 1250A 2000A 2500 0A 3200A 3600A 4000 0A 5000A 6300A S x L (m mm) ST TD MIN 500 x 500 350 x 350 500 x 500 400 x 400 500 x 500 475 x 475 600 x 600 500 x 500 700 x 700 550 x 550 800 x 800 750 x 750

RATIN NG 400A 1 000A 1250A 2000A 2 2500A A 3200A 3600A 3 4000A A 5000A 6300A 6

FL LANGE END L LENGTH (L) - (mm) STD MIN 500 300 500 300 500 300 500 300 500 300 500 300

HOR RIZONTAL EL LBOW WITH FLANGE EN ND. SxL RATIN NG STD D MIN 400A 10 000A 500 x 500 5 300 x 300 1250A 2000A 2 500 x 500 5 300 x 300 2500A A 500 x 500 5 300 x 300 3200A 3600A 3 500 x 500 5 300 x 300 4000A A 500 x 500 5 300 x 300 5000A 6300A 6 500 x 500 5 400 x 400

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Power Distribution Solutions

VERTICAL ELB BOW WITH FL LANGE END D. S x L (mm m) RATIN NG STD D MIN 400A 12 250A 500 x 500 5 350 x 350 1600A A 500 x 500 5 400 x 400 2000A A 500 x 500 5 450 x 450 2500A A 600 x 600 6 475 x 475 3200A 3600A 3 700 x 700 7 550 x 550 5000A 6300A 6 800 x 800 8 775 x 775

COMB BINATION EL LBOW S x L1 x L2 RATI NG ST TD MIN 400A 1000A 1 500 x 50 00 x 500 3 x 250 x 35 300 50 1250 0A 500 x 50 00 x 500 3 x 275 x 37 300 75 1600 0A 500 x 50 00 x 500 3 x 300 x 40 300 00 2000 0A 500 x 50 00 x 500 3 x 325 x 40 300 00 2500 0A 500 x 50 00 x 500 3 x 350 x 45 300 50 2500 0A 500 x 50 00 x 500 4 x 350 x 45 450 50 3200 0A 600 x 50 00 x 500 5 x 450 x40 500 00 3600 0A 600 x 50 00 x 500 5 x 500 x 40 550 00 4000 0A 700 x 70 00 x 700 6 x 600 x 50 600 00 5000A 6300A 800 x 70 00 x 800 7 x 700 x 75 750 50

VERT TICAL "T" EL LBOW S x L1 x L2 RATI NG ST TD MIN 400A 1000A 1 500 x 50 00 x 500 4 x 400 x 40 400 00 1250A 3600A 500 x 50 00 x 500 4 x 450 x 45 450 50 4000A 6300A 700 x 70 00 x 700 6 x 650 x 65 650 50

EXP PANSION JO OINT RATI NG 400A 2000A 2 2500A 3600A 4000A 6300A SxL ST TD 300 x 300 MIN -

500 x 500 700 x 700

REDUCER RATIN NG 400A 2000A 2 2500A 3600A 3 4000A 6300A 6 L (mm) STD D 150 00 150 00 150 00 MIN 1000 1000 1000

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HORIZONT TAL OFFSET T ELBOW S x L1 x L2 L RATIN NG STD D MIN 400A 2000A 2 500 x 500 0 x 500 30 00 x 250 x 30 00 2500A 3600A 3 500 x 500 0 x 500 30 00 x 250 x 30 00 4000A 6300A 6 500 x 500 0 x 500 30 00 x 250 x 30 00

VERTICA AL OFSET ELBOW E S x L1 x L2 L RATIN NG STD D MIN 400A A 500 x 500 0 x 500 40 00 x 300 x 40 00 630A A 500 x 500 0 x 500 40 00 x 300 x 40 00 800A A 500 x 500 0 x 500 40 00 x 300 x 40 00 1000 0A 500 x 500 0 x 500 40 00 x 300 x 40 00 1250 0A 500 x 500 0 x 500 40 00 x 350 x 40 00 1600 0A 500 x 500 0 x 500 40 00 x 400 x 40 00 2000 0A 500 x 500 0 x 500 45 50 x 450 x 45 50 2500 0A 500 x 500 0 x 500 45 50 x 475 x 45 50 2500 0A 500 x 500 0 x 500 45 50 x 475 x 45 50 3200 0A 600 x 600 0 x 600 55 50 x 500 x 55 50 3600 0A 600 x 600 0 x 600 55 50 x 550 x 55 50 4000 0A 700 x 700 0 x 700 60 00 x 600 x 60 00 5000 0A 800 x 700 0 x 800 75 50 x 700 x 75 50 6300 0A 800 x 700 0 x 800 75 50 x 700 x 75 50

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Horizontal Support
SUPPORT HANGER JOINT SECTION

LOAD
1.5 m 1.5 m

SUPPLY

NOTE :SUPPORT HANGERS SHOULD NOT BE INSTALLED OVER A JOINT SECTION ELBOWS, TO BE SUPPORTED SEPARATELY.

Note: - Horizontal Support Hangers should not be over a Joint Section.

Support Hanger Load

Am mpere Rating 4 1250A 400 16 600 2500A 25 500 6300A Steel Angle e Size (mm) 40 x 40 x 5 (Thick) 50 x 50 x 5 (Thick) 65 x 65 x 5 (Thick) ding Screw Thread on Rod in mm m M 12 M 12 M 12 Weight (kg/m) 3.00 3.80 4.90

Expansion Joint
Supporting g Condition Both en nds free One en nd free One end fixed Both end ds fixed Branch hing Branched at each floor Branched at each floor Not bran nched Branched at each floor Not bran nched Fig. I II III IV V Length (L) 120 (m) 90 (m) 45 (m) 60 (m) 30 (m)

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Flexible Conductor / Jumpers

Flexible conductors / jumpers are available in either Copper or Aluminum, and are either braided or laminated type. They are used to connect the busduct with the panel / transformer / DG sets, and also can be used for expansion of the busducts. The copper flexible conductors / jumpers are tin coated for excellent contacting properties.

Dimensions of Flexible conductors / Jumpers

Ampere Rating 4 400 630 800 10 000 12 250 16 600 20 000 25 500 32 200 36 600 40 000 45 500 50 000 63 300 Co opper Conduc ctor Type Conduct tor Width One 5 x 50 One 5 x 60 Fig. 1 One 6 x 60 One 6 x 75 Fig. 2 One 6 x 100 Fig. 3 One 6 x 140 Fig. 4 One 6 x 175 Fig. 5 One 6 x 240 Fig. 3 Two 6 x 140 Two 6 x 175 Fig. 4 Two 6 x 185 Fig. 3 Three 6 x 140 Three 6 x 175 Fig. 4 Three 6 x 185
25

Alumin numConducto or Conductor Width W Type One 5 x 60 One 6 x 60 Fig. 1 One 6 x 75 One 6 x 100 Fig. 2 One 6 x 140 Fig. 3 One 6 x 185 Fig. 4 One 6 x 240 Fig. 5 Two 6 x 140 Fig. 3 Two 6 x 175 Fig. 4 Two 6 x 185 Two 6 x 240 Fig. 5 Three 6 x 175 Fig. 4 Three 6 x 220 Fig. 5 Three 6 x 240 Fig. 5

Ampere Rating 400 630 800 100 00 125 50 160 00 200 00 250 00 320 00 350 00 400 00 450 00 500 00 550 00

Power Distribution Solutions

Tap Off Boxes

This unit is used to take power from the busduct trunking straight elements. The tap-off-box can be equipped with either, a MCB / MCCB / Isolator. On request we provide with energy meters too.

Cu urrent Ra ating 32A 100A 125A A 250A 320A A 400A

D mm m 250 275 325

W mm 250 300 325

H mm 450 600 750

End Feed Unit

This unit is used as a busduct trunking feeder. The standard version is offered with either, a MCB / MCCB / ACB / Isolator.On request we provide with energy meters too.

630A 6 8 800A 10 000A 12 250A

D m mm 550 50 550 50

W mm 350 400 400 450

H mm 1000 1 1200 1 1200 1 1500 1

Flexible Rubber Bellow

Flexible rubber unit is connected between the busduct trunking and the generator. This unit is normally made to order as per site conditions.

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Power Distribution Solutions

Vertical Spring Hangers

205 125 40

StudBolt (M12 X250) "C"Cha nnel

25 60 30

Bolt/Nut (M10x30 )
65 160

75

275

250

75

Floo r

50 25 50 15

min

FRONT VIEW

SIDE VIEW

Vertical Spring Hanger (1250A 3200A)

205 125

Stud Bolt (M12X250) "C"Channe l

40 25 60 30

Bolt/Nut (M10x30 )
65 160

275

250

75

Floo r

75

50

min

25 50

15

FRONT VIEW

SIDE VIEW

Vertical Spring Hanger (3600A 6300A)

255 140

Stud Bolt (M12X250) "C"Channe l

40 25 60 30

Bolt/Nut (M10x30 )
65 160

275

250

75

Floo r

75

50

min

25 50

15

FRONT VIEW

SIDE VIEW

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Power Distribution Solutions

Vertical Fixed Hanger

Vertical Fixed Hanger (400A - 1000A)

205 125

Stud Bolt (M12X110 ) "C"Channe l

40 25 60 30

Bolt/Nut (M10x30 )

50 65

75

155

110

75

Floor

50 25 50 15

min

FRONT VIEW

SIDE VIEW

Vertical Fixed Hanger (1250A - 3200A)

20 5 12 5

Stud Bolt (M12X110) "C"Cha nnel

40 25
60

Bolt/Nut (M10x30 )

75 50 65 15 5

110

Floor

75

30

min

25 50

15

Vertical Hanger (3600A - 6300A)

255 140

Stud Bolt (M12X110 ) "C" Channe l

40 25 60 30

65

155

110

50

50

Bolt/Nut (M1 0x30 )

75

Floor

75

50

min

25 50

15

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Power Distribution Solutions

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Power Distribution Solutions

Power Distribution Solutions

Power Distribution Solutions

HOW TO SELECT THE BUSBAR TRUNKING SYSTEM

The selection of the rating, material, protection degree etc... must be done according to the ambient conditions in which the busduct trunking system will be installed and according to the electrical characteristics necessary to satisfy the electrical system requirements. It is very important to know all this information previously in order to choose the busduct trunking system. Below you will find a checklist of basic information to help you select correctly your busduct trunking system. Please fill it and send it to our engineering office who will propose the most suitable solution.

Ambient Conditio ons Indoor Ins stallation Outdoor Installation

Mini imum Protect tion degr ree required Cond ductor material

IP Al

______ Cu

Type of Bus Duct System Minimum Ambient Tempera ture t Indoor Outdoor

____C ____C

Ambient temperature t (24hour daily d average)

Indoor Outdoor

____C ____C

Feed der busduct fr rom trans sformer to pa anel Feed der busduct fr rom pane el to panel Feed der busduct fr rom DG to t panel Risin ng mains with h Plug in Ho oles for Tap Off O Units Tota l Length m m m m

Elect trical Data Rated Cur rrent Demand Current C

Amps Amps

der Feed Distr ribution Risin ng mains Flexible Jum mper requirem ments Betw ween busduct t and pane el Betw ween busduct t and trans sformer Tap Off Boxe es Empty With h MCCB With h MCCB and Ener rgy Meter Types of req quired suppor rts Horizontal suppo rts Vert ical Fixed Han ngers Vert ical spring Ha angers

Configuration

1PH 3 W 3PH 3W 3PH 4W 3PH 5W 3PH 6W V AC DC

Yes Yes

No No

erational Rated Ope Voltage Phase rate ed short circuit wit thstand current

kA (1s)

Power Distribution Solutions

Rising mains
If the busduct has a vertical rise, some further information is nessary as requested under. Number of Floors Slab Thickness Distance between the Slabs Number of Tap Off Boxes for each Floor and power of each (kW) (P) Tap Off Boxes position on each floor Isometric document for Busduct system run sketch Please draw the busduct run with the related dimensions on the graph given below. (F) (S) (D) (N)

Power Distribution Solutions

Power Distribution Solutions

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Power Distribution Solutions

Godrej & Boyce Mfg. Co. Ltd.

Power Distribution Solutions Gate No. 4, Plant No. 1, Electricals & Electronics Pirojshanagar, Vikhroli (West) Mumbai - 400 079. Tel. : +91 (022) 6796 2291 / 2193 / 2293 Fax : +91 (022) 6796 1540 Email : puran@godrej.com, cyrusi@godrej.com, sangeeta@godrej.com, vijay@godrej.com Mobile: +91-9820314328, +91-9769934787, + 91-9833032428, + 91-9820466577 Visit us at : www.godrej.com

Bangalore Power Distribution Solutions Godrej & Boyce Mfg. Co. Ltd. Karnataka Film Chamber of Commerce Bldg, 1st, 2nd & 3rd Floor, No.28, 1st Main Cresant Road, High Grounds, Near Shivanand Circle, Bangalore - 560 001. Tel: +91-80-66472000 Fax: +91-80-22374673 Mob: +91-9916129135 Email: dsrao@godrej.com New Delhi Power Distribution Solutions, Godrej & Boyce Mfg. Co. Ltd. Godrej Bhavan, 2nd Floor, Sher Shah Suri Marg, Okhla, New Delhi 110065 Tel: +91 - 11 - 66507191 Fax: +91-11-66507056 Mob: +91-99994 07198; +91-99997 09228 Email: jalam@godrej.com; sbhanot@godrej.com

Chennai Power Distribution Solutions, Godrej & Boyce Mfg. Co. Ltd. 1, Sidco, Industrial Estate, Ambattur, Chennai, 600 098. Tel; +91-44-66544414 Fax: +91-44 - 66544445 Mob: +91-89399 23363 Email: dheena@godrej.com Kolkata Power Distribution Solutions Godrej & Boyce Mfg. Co. Ltd. Block G.N, Sector V, Salt Lake City, Kolkata 700 091, India. Tel: +91-33-66013500 Fax: +91-33-23578271 Mob: +91-9836112225 Email: ravis@godrej.com Hyderabad Mob: +91-88864 88774 Email: aniketh@godrej.com

Ahemedabad Power Distribution Solutions Godrej & Boyce Mfg. Co. Ltd. 4th Floor, APM Shopping Mall, Opp. IOCL Petrol Pump, 100 Feet Road, Near Shamal Crossing, Satelite, Ahmedabad 380 015 Phone: +91-79-66060606 Fax: +91-79-66060700 Godrej & Boyce Mfg. Co. Ltd. Is committed to the value of continuous Mob: +91-9979868211 improvement and product development, and thus, reserves the right to Email: sathaye@godrej.com supply products which may differ in detail from those shown in this publication without prior intimation.