Federal Busway Catalouge - Final

FEDERAL

FEDE

RAL

federal

federal busway

Wilmar International LLC, has been incorporated in USA by a consortium of Highly Qualified, Skilled professionals who bring in Tremendous Experience in Electrical, Electronics and Lighting Designs to offer Energy Efficient & Application Specific Solutions based on Technological Evolution for Power Distribution, Lighting, Controls and Automation needs of Infrastructure, Industrial, Commercial and Residential Building Segments in line with International Standards. M/s Wilmar thro’ its associate companies has also established Technology Centers for research & development of new products and adoption of latest technology to benefit customers.

Acquisitions & Technical Collaborations with companies from various geographies, have helped Wilmar International LLC to provide state of the art technology & products to its customers from different geographies while increasing its resources for development of products and customers. This GLOCALIZATION Approach, aimed at serving local customers promptly with quality products of global repute at affordable prices by manufacturing them locally, has resulted in an initiative to set up State of the Art Manufacturing Facility spread over an area of 55000 Sq. Meters for Switchboards and Sandwich Busways thro’ an associate company - M/s Federal Electricals in Abu Dhabi under FEDERAL Brand.

This ISO & OHSAS certified State of the Art Switchgear & Busway Production Facility built & set up on the LEAN, Six Sigma principals ensures reduced production time and helps in improvement of delivery lead times of Finished Products in compliance with Design Specifications and Quality Standards followed internationally. Quality Assurance being Top Priority of our Organization, strict quality control measures and processes are followed at our factory starting from raw material procurement to delivery of final products in line with customer’s needs.

Federal Busways have been type tested and approved by ASTA and UL confirming compliance to applicable standards such as IEC 61439-1 & 6. Federal Busways have been designed to meet stringent operational conditions more efficiently and safely, this has been possible because of continuous research and development activities at our technology center-which is equipped with high end testing, measuring and monitoring equipment to carry out checks and tests on products during its developmental stages enabling us to derive optimum design criteria for final product, keeping in view requirements of our end users.

Our commitment to add value in projects undertaken by our esteemed clients has made us a partner of choice and we endeavor to excel in our services to customer for achieving their satisfaction and continued patronage.

About Us

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federal busway

Vision and Mission

Our Vision

At Wilmar International LLC, our vision is to become a preferred Manufacturer and Solution Provider in GCC Region for Electrical Products in Transmission, Distribution Segments.

Our Mission

At Wilmar International LLC, part of Wilmar International Inc. USA, we manufacture and supply Electrical Products and Energy Efficient Solutions demonstrating value added by our experience and services. Our established network of services, sales and distribution channel to respond quickly to customer needs, has played a vital role in ensuring continued patronage of our customers, which we enjoy a lot and has been inspirational for us to explore new opportunities for expanding our business.

Acquisitions and Addition of local manufacturing facilities in GCC Region, has earmarked our expansion plan for Middle East and North Africa Region, with an aim to provideGlobal Products and Solutions in Energy Vertical for Local needs by using our strong value chain, knowledge and expertise. With this, we thrive to offer more Efficient, Safe and Reliable Products to our valued customers by becoming their GLOCAL (Global +Local) partner of choice.

Creating a Pride for our Stakeholders for their faith in us, is our driving force in this journey and with our highly motivated team, we intend to create a record of achievement for above Goals.

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Our Values

Perform

ance Commitment to E

xcel

Int

egrit

y

People Innovation

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45

46

15

16

19

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Content

1. Power Distribution & Layout Solution

2. Advantages of federal Sandwich Busway

3. Product Features & Advantages – Safety, Reliability & Efficiency

4. Manufacturing Facility at a Glance

5. Reference Standards & Certificates

6. Technical Data

7. Accessories & Physical Data

8. Thermographic Survey – Necessity and its advantages

9. Ordering Information

10. Project Reference List

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federal busway

System Description

Use of Federal sandwich busway system benefits distribution scheme by some of its unique features, viz. Higher Efficiency, Low Losses, Ease of Operation and Installation. This safe and robust system contributes greatly in making overall distribution scheme more reliable and efficient.

Sandwich Busway Product Line (630Amp to 6300Amp) with Copper conductor in 3Ph3W, 3Ph4W, 3Ph5W, System in IP54 to IP67 version rated at 690 V, 50Hz, 60Hz, make them suitable for all applications, in segments such as Commercial, Residential & Industrial.

Study has confirmed higher life span offered by Federal Busways is possible due to its unique construction allowing better surface area for faster dissipation of heat, joint design - it’s assembling pattern and quality of insulation. Corrosive Resistant Housing and duly tested Insulation for its di-electric strength, relative thermal index, resistance to fire, play a major role in ensuring extended service life of entire system even in stringent atmospheric conditions. Unique Temperature Alarm Controller, providing facility of monitoring temperature of system under operation and providing alarm in case of abnormal temperature rise, is a result of our continuous efforts towards innovations aimed at providing benefits to our customers while ensuring their and their investment’s safety. In case required, these Temperature Alarm Controllers can be integrated with third party BMS (Building Management System) or Any Central Alarm Monitoring System as desired by client/consultants for remote monitoring and status check.

Besides this, extensive testing carried out as per IEC 61439 part 1 & 6 (at ASTA/Intertek & UL) to validate design and verify performance of system, makes us a preferred choice of customers & consultants eyeing for satisfactory performance of busway system required for their prestigious projects. We also welcome visit of customers to our factory, to witness manufacturing and testing of busways ordered by them, this has helped us to win their confidence and continued patronage.

Constructed with 1.6 mm thick sheet steel housing “Federal Busways”, offers enough strength required for withstanding electrodynamic forces expected during abnormal events like short circuit. Structure of enclosure, special arrangements of tools and jigs allow Maximum flexibility while handling and installation of units.jigs.

View above, Federal busway system is an ideal choice for various applications, our team will be pleased to undertake application studies for your requirements and assist in freezing scope of supply and related zengineering works. From initial stage of projects, our team of experienced engineers will be available to support you for Design, Selection of Bus Trunking Components, Site Measurement and Drawing preparation activities, Inspection, Supervision Services during installation and thermographic surveys post installation - which we believe ensures satisfactory execution of the project and performance of the system over extended period of time.

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1. Power Distribution & Layout Solution

federal busway

6

2. Advantages of Federal Sandwich Busway

Applications – Power Distribution in Horizontal and Vertical Runs

Compact and Safer Design -

Federal Sandwich Busway Systems, referred based on sandwich type arrangement of insulated conductors in metal enclosure making it a compact design, offer higher short circuit withstand capacities and are being preferred in place of conventional means of electrical power distribution via cables, air insulated busducts.

Use of superior insulation, specially designed components and assembly, offer resistance to fire in building penetrations and resistance to flame propagation in compliance with IEC Standards making these systems more safer, durable and reliable.

Installation and Maintenance Free Operation -

Federal Sandwich Busway Systems are easier to handle during installation. They offer flexibility in routing and are easier to relocate if the need arises.

New Plug in Boxes can be easily plugged in, decreasing cost of modification – which in case of conventional distribution methods would require additional expense of sub distribution board in addition to extra time.

Quicker installation, efficient operations with maintenance free joints reduce installation and operational costs of these systems making them preferred.

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3. Product Features – Safety, Reliability & Efficiency

3.1 Unique Structure –

Specially developed enclosure design, involving 1.6 mm thick sheet steel offers excellent strength to withstand electrodynamic forces originating during short circuits and can act as an integral ground. Larger surface area offered vide this design ensures faster transfer of heat resulting lesser temperature rise and increase in life of insulation, which in turn extends service life of entire system. In addition to this, housing design and its assembling method retains adequate position of conductors, vital for ensuring safe connection of units during installation.

Automated Pretreatment and Electrostatic Powder Coating ensures that these enclosures offer resistance to corrosion and chemicals, which are likely to prevail in stringent operational conditions. This has been verified and certified by special tests conducted at internationally accredited laboratories. Enclosure designs for Indoor and Outdoor Application based on protection against ingress of dust, water are also offered as standard.

Our Application Engineering Team can offer services which include site survey, study of application, project modelling to propose suitable solution and product specification in line with requirements of application. This way of engagement with customers has made us their preferred choice.

3.2 Assembly Design –

True Sandwich Design achieved with the help of precise fabrication of housing and perfectly insulated conductors, eliminate pathways for propagation of Flame, Gas, Smoke referred to as “Chimney Effect”, thus making Sandwich Busways Safer.

Assembly of precisely fabricated housing components is done in such a way that desired Ingress Protection is maintained without any additional welding work.

Fig. No. 8.1

Fig. No. 8.2

Epoxy Insulation

Tin Coating

Copper Conductor99.99% Pure

CAUTION

Do Not Touch During Opertion

Warning : High Voltage

CAUTION

Do Not Touch During Opertio

n


CAUTION

Do Not Touch During Opertio

n


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federal busway

Fig.No. 9.2

3.3 Conductors

Federal busway systems, demonstrate their excellence in performance also due to careful selection of conductors, from globally reputed suppliers. Copper Conductors with Tin plating are available as standard, Silver Plated conductors can be offered upon request. These conductors in round edge comply to JIS, ASTM Standards. Copper Conductors with 99.9% Purity and 100% Conductivity, are available in standard offerings. Our QA and Test Labs, are equipped with facilities to check copper purity, resistance and other chemical, mechanical properties of conductor material essential for achieving best performance of our system.

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Fig.No. 9.1

3.4 Smart and Intelligent Features -

In sandwich busway systems Mechanical Interlocks and special joint bolts ensure error free and reliable connections to prevent hazards like temperature rise due to loose connections. Furthermore, Temperature Alarm Controllers can be useful to monitor healthiness of system and initiate preventive measures, incorporation of this feature benefiting our customers is possible due to design & patented technology, which has been developed at our research Centre. This feature has been admired by many of our customers, consultants and they have conferred “Smart & Intelligent” title for our busways.

Fig.No. 9.3 Fig.No. 9.4

Mains 24V DC

Relay Outputs

7 Segment Display

LED Indication

Functional Keys

Sensor Input

federal busway

As per requirement of application, we can produce insulated conductors by using above process and select epoxy powders, insulation materails to achieve appropriate insulation thickness. Above methods of insulation have also been applauded for elimination of air gaps, voids and improper thickness. Insulated Conductors produced by above systems then undergo Quality and Performance Check. Our Quality Control Department, inspects and tests quality of each bar by conducting special tests which also includes high voltage tests.

3.5 Superior and Reliable Insulation –

Durable Epoxy Insulation having longer service life, has been used for Conductors of “Federal Sandwich Busway Systems”. Benefits of Epoxy, such as Resistance to Water, Moisture, Chemicals, and Mechanical Impact besides dielectric strength, flame retardant properties make them preferred choice as insulation materials. While selecting insulation material, we have also given consideration to factors playing vital role in ageing of insulation. Some these factors are electrical (creepage currents, partial discharge, interfacial processes), Chemical, Thermal, Mechanical (Vibration, Shock, Impact), environmental (UV Radiation, Exposure to Salt Fog).

Selection of insulation material has been done carefully by conducting special tests, which included verification of their electrical, mechanical properties, dielectric, impact strength in conditions exposed to heat, cold, humidity, and vibrations to name a few. As insulation plays a vital role in overall performance and service life expectancy of busway system, our above approach reflects our efforts to provide our customers, a product offering excellent performance in harsh conditions for extended service life.

Application specific testing and verification of insulated conductors, involving RTI (Relative Thermal Index), Flammability Rating, maximum and minimum thickness of insulation and its performance under mechanical impacts, have also been done to demonstrate value for customer’s money.

Class “B” (130 Deg C) Epoxy insulation is offered as a standard. To meet requirements of higher insulation temperatures (Relative Thermal Index), Class “F” (155 Deg C) Grade insulation, is also available upon request.

3.6 Insulation Process –

Our plant is equipped with state of the art coating machines for applying insulation on conductors. Selection of insulation coating machine, has been done based on coating process - which vary based on Pretreatment for Conductor, Type of Insulation Material, and Application Process & Sequence. These machines not only ensure production of insulated conductors with best quality and durability, but also can handle increasing demand by producing them quickly in shortest possible time. This makes us feel proud, about our capacity to cater to larger scale projects with guaranteed quality of products.

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Fig.No. 10.1

Automated Electrostatic coating uses special spray guns to ensure uniform thickness of insulation with a great reliability to perform. It also prevents entry of moisture, chemicals during coating operations and provides optimum strength to insulation achieved by coating. Properties of Epoxy, resulting in smoother finish after undergoing this process help in achieving closer conductor spacing, which is essential for better performance of Busways having sandwich type assembly.

3.7 Automated Electrostatic Coating –

federal busway

3.8 Plug in Box features for Safe, Reliable and Easy Operations

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Plug in Contacts are Maintenance Free, these silver plated plug in contacts have been specially designed to maintain proper contact pressure with less resistance throughout the life of busways. Base insulator, facilitating mounting of Plug in contacts on the rear side of plug in box and termination of cables from Protective Device, has slot and rib structure in “C” Shape to offer mechanical and electri-cal protection to plug in contacts during installation and service. It also acts as a guide for proper inser-tion and removal of plug in box, while in use with plug in feeders.During insertion and removal of Plug in Box, Earth Contact of Plug in Box is designed to connect first and break last from busbar conductors so as to ensure continuity of earth connection for improved safety.Adequate Enclosure Design, with Extended Ground and Neutral Conductors are offered as standard. Our Design also takes care of space required for cable entry from top or bottom and its termination. During engineering stage client can specify such requirements and avail necessary proposals and options to address such needs from our end.Plug in Box has been Successfully Type Tested for Ingress Protection, Short Circuit Withstand, Mechanical Operations, and Thermal Cycling as per Latest IEC 61439 Standards.Padlocking Feature to prevent opening of Plug-in Box Door, while Protective Device when it is in “ON” Condition is offered as standard. Operating Mechanisms mounted on Doors of Plug in Boxes provide “ON, “OFF”, and “Trip” Indications during inspections.Mechanical Interlock to prevent removal of Plug in Box from energized feeder, while the Protective Device is “ON”, can be provided as an option. Please contact our Sales and Application Engineering Team member for further details.Advanced Series Plug in Boxes are available with surge protection modules and Communication based energy meters, multifunction meters. Our Application Engineering team can provide further details on selection of such PIBs.Universal Design PIBs offered by us are, suitable for any Brand of Circuit Breakers, Switch Fuse Units and Ratings of Busways as specified by Customers at the time of ordering. Plug in Boxes are interchangeable between various Ratings of Busway having similar configuration.

Fig.No. 11.2Fig.No. 11.1

ON

OFF

TRIP

lON

TRIP

OFF

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3.9 Proven Design for Joints

Joint facilitates physical and electrical connection between busway units to complete point to point distribu-tion system. They also play an important role in ensuring satisfactory performance of the system. Under normal current carrying conditions, heat is generated at conductor contact area due to their contact resis-tance. Effective management of this heat, either by reducing or transferring it to external environment is essential for safe operation and extended life of entire system.

View this, direct male-female type jointing system having lesser hot spots (contributing largely in reducing temperature rise at joint areas) has been adopted by us. Besides this, we have provided advanced arrange-ment similar to heat sink design at joint areas, it is found beneficial for faster heat dissipation. We have also provided special insulators having adequate thermal resistance at contact areas, these insulators and method of joining conductors needing connection, ensure quick transfer of heat from core of the joint to the external housing. These are few key points of our design which help in reducing overall temperature of joint and extend life of system.

Our Design also eliminates possibilities of incorrect jointing. Proper assembly and installation of joint can accommodate + 3mm thermal expansion of conductors.

Insertion and Removal of any section of feeder or busway unit, by removing joint bolts has been made easy by using self-guided joint bolts and arrangement of insulation barriers which ensure integrity of system during such insertion and removals.

“UL” Certified Material has been used for Insulation Barriers fitted alongside conductors at Joint Area and they have also been type tested at UL to verify their performance and withstand capacity in case of tempera-ture rise. To ensure increased level of safety they have also been verified for their performance while offering resistance to fire.

Fig. No.12.1 Fig. No.12.2

300

LOAD SUPPLY

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3.10 Straight Feeders, Plug In and Tap Off Section

Feeder Busways Offered by us are suitable for Indoor and Outdoor Installation. Busway Feeders for outdoor application, are provided with additional covers, this alongside design of enclosure ensure integrity of protec-tion required against ingress. According to application and site conditions, client can choose these feeders with IP65, IP66 and IP67 Degree of Protection for outdoor application.

Various environmental, atmospheric, installation conditions can influence performance of outdoor busway. Our application Engineering team does review of these factors influencing performance of busways and can recommend specifications and configuration of busway system to customer - they can be also approached to inspect execution of installation works, which is vital for ensuring satisfactory performance of the system offered.

Feeder busways for indoor application offer ingress protection for IP54 and IP55 range. Reckoning other services running nearby these systems, location of installation, selection of ingress protection from available range can be done.

Fig. No.13.1 Fig. No.13.2

CAUTIONDo Not Touch During Opertion


lON

OFF

TRIP



3.11 Thermal Expansion –

Considering effects of thermal expansion, use of Expansion Joints is recommended in Busway Systems. They become essential when busway systems cross building expansion joints. Long straight runs where both ends are connected in fixed positions also require expansion joints. Flexible conductors inside the expansion joint allow/accommodate movement caused due to expansion.

3.12 Fire Barrier –

During Fire, temperatures around busway penetrating from wall/slab, can go up in excess of melting temperature of Material used for Housing, Conductors (e.g. Aluminum, Copper). Such excess temperatures can cause melting of enclosure and conductors, thus creating deformities/voids in sections (walls or slabs) from where busways are passing through. These voids can allow, transfer of smoke and fire from one area to another, which can result in further damages/harms.

To curb such harmful situations, fire barriers have been recommended to prevent the propagation of fire, for a specified time, under fire conditions and same is verified by tests recommended in ISO834 Standard. Federal Busway Systems have been tested and certified for 120 Mins and 240 Mins Ratings by internationally renowned lab.

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4. Manufacturing Facility at a Glance

Automated punching and bending machine that’s equipped with high capacity tool rack.

A CNC machine or computer controlled machine is operated with the pre-set computer controlled programs which enable automatic performance of the machine to deliver the specific task. CNC machines are known for the automated and high production capacities and quality of operations they perform. As controlled with computer, these machines enable continuous working and constant operation with better consistency and accuracy.


4.1 Automatic Assembly Lines –

To ensure prompt delivery with uncompromised quality, we have automated our busway assembly lines. Major steps involved in assembly and testing of various parts of busway unit have been automated by using high end PLC Controllers and Sensors, which have been further integrated with Production and Process Monitoring Systems for further planning and co-ordination.

5. Reference Standards & Certificates

Reference Standards

Federal busway system & Solutions, complies to standards listed below :

IEC60947-2:1997

IEC60439-1:2004

IEC60439-2:2005

IEC60529

IEC 61439-1:2011

IEC 61439-6:2012

These type tests have been condcuted at internationally acceptable and approved laboratories and certifi-cates in this regard have been issed from auithorities such as UL, ASTA/Intertek.

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federal busway

6. Technical Data

CURRENT RATINGS

Product Code

Rated Operational Voltage (Ue)

Rated Insulation Voltage (Ui)

Rated Impulse Voltage

Rated Frequency

1 Second - Icw (kA)

Peak Value - Ipk (kA)

Rated Short Circuit with Stand Current

Ratings (In)

DIMENSIONS

Bus Bar Dimension (mm)

3PH, 3W

3PH, 4W/3PH, 4W+G

3PH, 5W/3PH, 5W+G

No. of Stack

IP Rating

Cross Section Area (mm )2

Enclosure Dimensions Width x Height (mm)

105x115 105x125 105x140 105x165 105x205 105x225 105x265

125x115 125x125 125x140 125x165 125x205 125x225 125x265

125x115 125x125 125x140 125x165 125x205 125x225 125x265

Single

IP54 / IP65 / IP67

23.2 25.4 28.5 33.9 42.7 51.4 60.1

25.6 28.3 32.2 38.8 49.6 60.8 71.8

27.1 30.1 34.4 41.7 53.7 65.5 77.7

28.1 31.2 35.9 43.7 56.4 70.2 83.5

29.6 33.0 38.1 46.6 60.5 74.9 89.4

0.0690 0.0575 0.0460 0.0345 0.0246 0.0180 0.0144

0.0893 0.0744 0.595 0.0446 0.0319 0.0233 0.0186

0.0330 0.0300 0.0240 0.0190 0.0136 0.0111 0.0085

0.0952 0.0802 0.0642 0.0485 0.0347 0.0258 0.0205

0.095 0.107 0.107 0.098 0.093 0.088 0.087

0.097 0.110 0.110 0.100 0.095 0.089 0.088

0.098 0.111 0.111 0.101 0.096 0.089 0.089

0.093 0.103 0.103 0.093 0.088 0.081 0.081

0.0690 0.0575 0.0460 0.0345 0.0246 0.0180 0.0144

0.0893 0.0744 0.0595 0.0446 0.0319 0.0233 0.0186

0.0396 0.036 0.0288 0.0228 0.0163 0.0133 0.0102

0.0977 0.0827 0.0661 0.0501 0.0358 0.0268 0.0212

0.099 0.112 0.112 0.103 0.098 0.092 0.091

0.101 0.114 0.114 0.104 0.099 0.093 0.092

0.101 0.115 0.115 0.104 0.099 0.093 0.092

0.093 0.103 0.103 0.093 0.088 0.081 0.081

630AID06CS ID08CS ID10CS

800A 1000AID12CS ID16CS ID20CS ID25CS1250A 1600A 2000A 2500A

690V, AC

1000V, AC

3Phase, 3Wire (R Y B)

3Phase, 4Wire + 50% Internal Ground (R Y B N G)

3Phase, 5Wire (R Y B N N)

APPROXIMATE WEIGHT OF BUSWAY (kg/m)

3Phase, 4Wire (R Y B N)

3Phase, 5Wire + 50% Internal Ground(R Y B N N G)

Resistance at 20 C (R )o

20

Impedence (Z) at 95oC

Reactance (x)

ELECTRICAL PARAMETERS @ 50 HZ

RESISTANCE (m /m)

REACTANCE(m /m)

IMPEDENCE (m /m)

VOLTAGE DROP PER METER @ FULL LOAD (V / m / A)

o95Resistance at 95 C (R )

oVoltage Drop @ 0.85 P.F. ( V) at 95 C


oVoltage Drop @ 0.90 P.F. ( V) at 95 Co

Voltage Drop @ 1.00 P.F. ( V) at 95 C


20


1.0Voltage Drop @ 0 P.F. ( V) at 95 Co

Reactance (x)


RESISTANCE (m /m)


REACTANCE (m /m)

IMPEDENCE (m /m)

o95Resistance at 95 C (R )

oVoltage Drop @ 0.85 P.F. ( V) at 95 CoVoltage Drop @ 0.90 P.F. ( V) at 95 C


COPPER

8KV

50 / 60 Hz

30 30 50 65 85 100 120

66 66 110 143 187 220 264

75x5 100x5 140x5 160x6 200x650x5 60x5

375 500 700 960 1200250 300

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federal busway

6.1 Technical Data

COPPER

DIMENSIONS

CURRENT RATINGS

Product Code

Rated Operational Voltage (Ue)

Rated Insulation Voltage (Ui)

Rated Impulse Voltage

Rated Frequency

1 Second - Icw (kA)

Peak Value - Ipk (kA)

Rated Short Circuit with Stand Current

Ratings (In)

Bus Bar Dimension (mm)

Cross Section Area (mm )

3PH, 3W

3PH, 4W/3PH, 4W+G

3PH, 5W/3PH, 5W+G

No. of Stack

IP Rating

2

Enclosure Dimensions Width x Height (mm)

3Phase, 3Wire (R Y B)

3Phase, 4Wire + 50% Internal Ground (R Y B N G)

3Phase, 5Wire (R Y B N N)

APPROXIMATE WEIGHT OF BUSWAY (Kg/Mtr)


20

o95


o

o

o

o

Reactance (x)


RESISTANCE (m /m)

REACTANCE(m /m)

IMPEDENCE (m /m)


Resistance at 20 C (R )o20

o95


1.0Voltage Drop @ 0 P.F. ( V) at 95 C

o

o

o

o

Reactance (x)


RESISTANCE (m /m)


REACTANCE (m /m)

IMPEDENCE (m /m)

105x405

125x405

125x405

105x405

125x405

125x405

105x475

125x175

125x175

105x495

125x495

125x495

105x605

125x605

125x605

105x710

125x710

125x710

105x740

125x740

125x740

180

396

180

396

180

396

180

396

180

396

180

396

180

396

175x6(2) 185x6(2) 140x6(3) 175x6(3) 185x6(3)140x6(2) 140x6(2)

2100 2220 2520 3150 33301680 1680

Double Triple

IP54 / IP65 / IP67

85.9

102.3

110.5

118.7

126.9

85.9

102.3

110.5

118.7

126.9

99.5

120.1

130.4

140.5

150.9

104.4

126.7

137.0

148.3

159.2

124.2

148.8

161.2

173.4

185.7

147.2

178.0

193.5

208.7

224.2

154.1

186.6

203.0

219.1

235.4

0.0103

0.0133

0.0068

0.0149

0.082

0.082

0.083

0.074

0.0103

0.0133

0.0070

0.0150

0.090

0.091

0.091

0.081

0.0082

0.0106

0.0055

0.0120

0.082

0.083

0.083

0.074

0.0078

0.0101

0.0060

0.0117

0.091

0.091

0.091

0.078

0.0068

0.0089

0.0043

0.0098

0.083

0.085

0.085

0.077

0.0068

0.0089

0.0043

0.0098

0.083

0.085

0.085

0.077

0.0052

0.0067

0.0037

0.0077

0.083

0.083

0.083

0.073

0.0133 0.0133 0.0106 0.0101 0.0089 0.0089 0.0067

0.0082 0.0082 0.0072 0.0072 0.0054 0.0054 0.0037

0.0156 0.0156 0.0128 0.0124 0.0104 0.0104 0.0077

0.086 0.094 0.089 0.096 0.089 0.089 0.083

0.087 0.095 0.089 0.096 0.090 0.090 0.083

0.086 0.094 0.088 0.095 0.089 0.089 0.083

0.074 0.081 0.074 0.078 0.077 0.077 0.073

0.0103 0.0103 0.0082 0.0078 0.0068 0.0068 0.0052

ID32CS ID35CS ID40CS ID45CS ID50CS ID60CS ID63CS

3200A 3500A 4000A 4500A 5000A 6000A 6300A

690V, AC

1000V, AC

8KV

50 / 60 Hz

3Phase, 4Wire (R Y B N)

3Phase, 5Wire + 50% internal Ground(R Y B N N G)

Resistance at 95 C (R )





Resistance at 95 C (R )




Fig. No. 18.1

Fig. No. 18.2

RYB3 Phase 3 Wire

RYBN3 Phase 4 Wire

RYBNG3 Phase 4 Wire

With 50% Internal Ground

RYBNNG3 Phase 4 Wire

With 200% NeutralWith 50% Internal Ground

GRYBNG3 Phase 4 Wire

With 50% Internal Ground

18

W

Single StackBusway

Double StackBusway

Triple StackBusway

W

H

W

H

H

Busway Configurations and Types

Busway Configurations

Busway Types:

Full Protection of IP54 to IP67 Busway System

630A - 2500A Single Stack Busway

3200 - 4500A Double Stack Busway

3200 - 6300A Triple Stack Busway

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7. Accessories & Physical Data

Accessories

A. FEEDER



Feeder can be installed either horizontally or vertically, the standard length is 3000mm. The Minimum length is 500mm. A Technical Guide, Paper detailing basis on which minimum dimension and maximum dimension details of products have been derived is available for reference and further our application engineering team will be pleased to assist you in selecting appropriate minimum and maximum dimensions of feeder unit.

Fig. No. 19.1

B. PLUG-IN FEEDER



Provision for accommodating future loads of expansion within the capacity installed and to allow flexibility to accommodate new load distribution points without the need of changing already installed busway, we can provide specially designed plug-in length with a possibility of having plug in points on its both sides. A maxi-mum of 5 outlets can be fixed on both side of standard 3mtr length. Each plug-in outlet shall have, plug-in cover to ensure protection against contact with live conductors.”“Standard length of Plug-in Feeder is 3000mm. The minimum length is 1000mm”

Fig. No. 19.2

federal busway

C. Expansion Unit



Considering effects of thermal expansion, use of expansion unit is recommended in busway systems. They become essential especially when busway systems cross building expansion joints. Long straight runs where both ends are connected in fixed position also require expansion joints. Flexible conductors inside the expan-sion joint allow/accommodate movement caused due to expansion and contraction of busway system

Fig. No. 20.1 Fig. No. 20.2

Expansion Unit Box Type

Fig. No. 20.3

Expansion Unit Installation

Supporting Condition

Branching Fig. No.Length(L in Mtrs.)

which needs expansion joint

Both Ends Free

One End Free

Both Ends Free

Branched at each storey

Not Branched


Not Branched


Not Branched

A

B

C

D

E

F

<120

<90

<90

<60

<60

<40

20

federal busway

CAUTION



Expansion Unit Feeder Type

federal busway

21

D. Reducer

This reducer section is used for reducing busbar size to the final load, it provides users with more economic power transmission and distribution method. Furthermore, these reducers can be designed with protective devices / isolating devices.

E. Transposition Unit

Transposition unit is used for changing phase sequence of the busbar; The Phase sequence of both sides has to be provided by the customer.


Reducer (Direct) Reducer (Circuit Breaker)

Fig.No. 21.3

CAUTION





TRIP

lON

OFF

CAUTION



22

F. Cable Feed Unit Box

Cable feed unit boxes are used where busway run is fed by cable or to connect cable to the end of the busway run. Cable feed units are used to install at the end or beginning of busway run.

We offer cable feed unit box with circuit breaker with sufficient space for connection through cable.

Flange End with End tap box

The end tap box can be manufactured according to the size of the flange end plate, it can be connected directly with end tap box.

G. Terminal Cover / End Enclosure

Terminal Cover/Enclosure is used for protecting conductors of an assembly and are normally used at end point of busway section.

Cable Feed End Box Direct Cable Feed End Box Circuit Breaker



CAUTION



TRIP

lO

N

OFF

federal busway

23

H. Plug-in Box / Tap off Unit

LV Bus plug/plug-in box is used to tap electrical power directly to the load from the busway system to offer safety & protection. Bus plugs are supplied with MCCB or Fuse Plug-in box /Tap off unit enclosure is made from G.I with side hinged door.For cable entry, provision of gland plates are provided on both sides(top & bottom) as per requirement.

Unique fail-safe plug-in contacts:

The plug-in box is equipped with a positioning device that prevents incorrect phase installations.Plug-in contacts are silver plated to improve the electrical conductivity.Thermal Cycling Test as per IEC 61439 has been conducted on PIBs to ensure their design and perfor-mance meets to specifications / requirements of critical applications including those where frequent insertion and removal

Plug-In Box / Tap Off Box

RatingW

Widthin mm

HHeightin mm

DDepthin mm

60-100A

100- 200A

200-400A

400-630A

250

250

300

350

400

500

600

800

250

250

300

300

(In mm)

PLUG-IN BOX TAP OFF BOX

W D

H

Fig.No. 23.1

H

W D

federal busway

federal busway

24

7.2 Physical Data

Feeder

Ampere Standard (L) Minimum(L)

630

800

1000

1250

1600

2000

2500

3200

3500

4000

4500

5000

6000

6300

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

500

500

500

500

500

500

500

500

500

500

500

500

500

500

(In mm)

Feeder with Plug-in Hole


630

800

1000

1250

1600

2000

2500

3200

3500

4000

4500

5000

6000

6300

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

1000

1000

1000

1000

1000

1000

1000

1000

1000

1000

1000

1000

1000

1000

(In mm)

Fig.No. 24.1

Fig.No. 24.2





L

L

25

Flange End


630

800

1000

1250

1600

2000

2500

3200

3500

4000

4500

5000

6000

6300

500

500

500

500

500

500

500

500

500

500

500

500

500

500

300

300

300

300

300

300

300

300

300

300

300

300

300

300

(In mm)

Flang End with Vertical Elbow

Ampere Supply(S) Load(L)

630

800

1000

1250

1600

2000

2500

3200

3500

4000

4500

5000

6000

6300

200

200

200

200

250

250

300

350

350

400

400

450

450

450

350

350

350

350

400

400

400

450

450

500

500

600

700

700

(In mm)

Fig.No. 25.1

Fig.No. 25.2

CA

UTI

ON

Do N

ot To

uch

Durin

g O

perti

onW

arni

ng :

High

Vol

tage

CA

UT

ION

Do

No

t To

uch

Du

rin

g O

pe

rtio

nW

arn

ing :

Hig

h V

olta

ge

L

S

L

federal busway

26

federal busway

Horizontal Elbow

Ampere Supply (S) Load(L)

630

800

1000

1250

1600

2000

2500

3200

3500

4000

4500

5000

6000

6300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

Flange End with Vertical Combination Elbow

Ampere Supply(S) Load(L1)

630

800

1000

1250

1600

2000

2500

3200

3500

4000

4500

5000

6000

6300

200

200

200

200

250

250

300

350

350

400

400

450

450

450

300

300

300

300

350

350

350

400

400

400

400

500

500

500

Load(L2)

350

350

350

350

400

400

400

500

500

500

500

600

600

600



Fig.No. 26.2

Fig.No. 26.1

CA

UT

ION

Do N

ot To

uch D

urin

g O

pe

rtio

nW

arn

ing

: H

igh

Voltag

e

(In mm)

(In mm)

S

L1

L2

L

S

27

Vertical Elbow


630

800

1000

1250

1600

2000

2500

3200

3500

4000

4500

5000

6000

6300

350

350

350

350

400

400

400

450

450

500

500

600

700

700

350

350

350

350

400

400

400

450

450

500

500

600

700

700

Horizontal Offset Elbow


630

800

1000

1250

1600

2000

2500

3200

3500

4000

4500

5000

6000

6300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

250

250

250

250

250

250

250

250

250

250

250

250

250

250

Load(L2)

300

300

300

300

300

300

300

300

300

300

300

300

300

300



Fig.No. 27.1

Fig.No.27.2

CAUTION

Do Not T

ouch Durin

g Opertio

n

Warning : High Volta

ge

(In mm)

(In mm)

L

S

L2

L1

S

federal busway

28

Vertical Offset Elbow


630

800

1000

1250

1600

2000

2500

3200

3500

4000

4500

5000

6000

6300

350

350

350

350

400

400

400

450

450

500

500

600

700

700

300

300

300

300

350

350

350

400

400

400

500

500

500

500

Load(L2)

350

350

350

350

400

400

400

450

450

500

500

600

700

700

(In mm)

Horizontal Combination Elbow


630

800

1000

1250

1600

2000

2500

3200

3500

4000

4500

5000

6000

6300

350

350

350

350

350

350

350

350

350

350

350

350

350

350

300

300

300

300

350

350

350

400

400

400

400

500

500

500

Load(L2)

350

350

350

350

400

400

400

500

500

500

500

600

600

600

(In mm)

CAUTION



Fig.No. 28.2



Fig.No. 28.1

L2

S

L1

L1

L2

S

federal busway

federal busway

29

Vertical Combination Elbow


630

800

1000

1250

1600

2000

2500

3200

3500

4000

4500

5000

6000

6300

350

350

350

350

350

350

350

350

350

350

350

350

350

350

300

300

300

300

350

350

350

400

400

400

400

500

500

500

Load(L2)

350

350

350

350

400

400

400

500

500

500

500

600

600

600

(In mm)

Fig.No. 29.2

Vertical Tee Elbow


630

800

1000

1250

1600

2000

2500

3200

3500

4000

4500

5000

6000

6300

300

300

300

300

350

350

350

400

400

450

450

500

500

500

300

300

300

300

350

350

350

400

400

450

450

500

500

500

Load(L2)

300

300

300

300

350

350

350

400

400

450

450

500

500

500

(In mm)





Fig.No. 29.1

L2

L1

S

L2

S

L1

30

Expansion Unit Box Type


630

800

1000

1250

1600

2000

2500

3200

3500

4000

4500

5000

6000

6300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

300

A B C

450

450

450

450

450

450

450

540

540

540

540

540

540

540

500

500

500

500

500

500

500

500

500

500

500

500

500

500

175

185

200

225

265

285

325

465

465

535

555

665

800

800

Fig.No. 30.1

Fig.No. 30.2



Expansion Unit Feeder Type


630

800

1000

1250

1600

2000

2500

3200

3500

4000

4500

5000

6000

6300

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

1500

1500

1500

1500

1500

1500

1500

1500

1500

1500

1500

1500

1500

1500

(In mm)



(In mm)

L

A

C

B

L

S

federal busway

31

federal busway

Fig.No. 31.1

Fig.No. 31.2

Reducer


630

800

1000

1250

1600

2000

2500

3200

3500

4000

4500

5000

6000

6300

350

350

350

350

400

400

450

500

500

500

500

500

500

500

350

350

350

350

400

400

450

500

500

500

500

500

500

500

(In mm)

Reducer with Circuit Breaker


630

800

1000

1250

1600

2000

2500

3200

3500

4000

4500

5000

6000

6300

350

350

350

350

400

400

450

500

500

500

500

500

500

500

350

350

350

350

400

400

450

500

500

500

500

500

500

500

A B C

450

450

450

450

450

450

450

1150

1150

1350

1350

1400

1450

1500

250

250

300

300

400

500

500

Dimensions is subject to different circuit breaker

(In mm)

TRIP

lON

OFF

CAUTION



CAUTION



S

L

CS

B

L

A

32

Fig.No. 32.1

Fig.No. 32.2

TRIP

lO

N

OFF

Cable Feed Unit box

Ampere Standard(L) Minimum(L)

630

800

1000

1250

1600

2000

2500

3200

3500

4000

4500

5000

6000

6300

500

500

500

500

500

500

500

500

500

500

500

500

500

500

300

300

300

300

300

300

300

300

300

300

300

300

300

300

A B C

450

450

450

450

450

450

450

540

540

540

540

540

540

540

500

500

500

500

500

500

500

500

500

500

500

500

500

500

175

185

200

225

265

285

325

465

465

535

555

665

800

800

CAUTION



Cable Feed Unit Box with Circuit Breaker

Ampere Standard(L) Minimum(L)

630

800

1000

1250

1600

2000

2500

3200

3500

4000

4500

5000

6000

6300

500

500

500

500

500

500

500

500

500

500

500

500

500

500

300

300

300

300

300

300

300

300

300

300

300

300

300

300

A B C

450

450

450

450

450

450

450

800

800

800

800

800

800

800

250

250

300

300

400

500

500

Dimensions is subject to different circuit breaker

(In mm)

(In mm)

B

L

CA

B

L

CA

federal busway

33

Fig.No. 33.1 Fig.No. 33.2 Fig.No. 33.3

Flange End Dimensional Details:

Flange End Details

Sr. No. Rating3PH.3W 3PH.4W/5W Fig.

No.

Conductor Sizein mm No.

of StackT D

H(mm)

W (mm)

3W B C A B C4W/5W

210

210

210

210

210

210

210

255

255

255

255

255

255

255

33.1

33.1

33.1

33.1

33.1

33.1

33.1

33.2

33.2

33.2

33.2

33.3

33.3

33.3

175

185

200

225

265

285

325

465

465

535

555

665

770

800

450

450

450

450

450

450

450

540

540

540

540

540

540

540

1

2

3

4

5

6

7

8

9

10

11

12

13

14

630A

800A

1000A

1250A

1600A

2000A

2500A

3200A

3500A

4000A

4500A

5000A

6000A

6300A

5

5

5

5

5

6

6

6

6

6

6

6

6

6

50

60

75

100

140

160

200

140

140

175

185

140

175

185

1

1

1

1

1

1

1

2

2

2

2

3

3

3

105

105

105

105

105

105

105

105

105

105

105

105

105

105

115

125

140

165

205

225

265

405

405

475

495

605

710

740

125

125

125

125

125

125

125

125

125

125

125

125

125

125

Enclosure Dimension

A

350

350

350

350

350

350

350

450

450

450

450

450

450

450

175

185

200

225

265

285

325

465

465

535

555

665

770

800

160

160

160

160

160

160

160

210

210

210

210

210

210

210

Fig No 33 1 Fig No 33 2 Fig No 33 3

AC C

B

A

C C

B

B

B-6

0

A

A-60

A

A-60

A

A-60

B-6

0

A

C C

B-6

0

15

15

15

15

15

15

15

15

15

15

15

15

15

15

15

15

15

15

15

15

15

15

15

15

(In mm)

Flange end and end tap box can be used in connecting with any type of switchgear cabinets and trans-formers. Flange end bus bar spacing can be customized on specific application.All the dimension provided are for standard products. Please contact our engineer for customized dimensions.

federal busway

34

federal busway


Fig.No. 34.3

Flange End Termination Details–

Flange End Termination Details

Sr. No. Rating B C W Fig. No.3W 4W/5W

1

2

3

4

5

6

7

8

9

10

11

12

13

14

630A

800A

1000A

1250A

1600A

2000A

2500A

3200A

3500A

4000A

4500A

5000A

6000A

6300A

100

100

100

100

100

100

100

130

130

130

130

130

130

130

100

100

100

100

100

100

100

130

130

130

130

130

130

130

50

60

75

100

140

160

200

140

140

175

185

140

175

185

-

-

-

50

50

50

50

50

50

60

60

50

60

60

115

125

140

165

205

225

265

405

405

475

495

605

710

740

34.1 & 35.1

34.1 & 35.1

34.1 & 35.1

34.1 & 35.2

34.1 & 35.3

34.1 & 35.3

34.1 & 35.4

34.2 & 35.3

34.2 & 35.3

34.2 & 35.3

34.2 & 35.3

34.3 & 35.3

34.3 & 35.3

34.3 & 35.3

A

(In mm)

195

A AA 70

t t t t t 195

W

B

100 19

5

A AA 70

t t t t t 195

W

B B

100

W

195

B B B

10019

5

A AA 70

t t t t t

35

100

B

2040

BC

100

B

100

CBC CC C

2040

2040

2040 10

0

Fig.No. 35.1 Fig.No. 35.2 Fig.No. 35.3 Fig.No. 35.4

Configuration Details of Flange End –

3PH.3W.

195

A A

t t t

3PH.4W.

195

A AA

t t t t

3PH.5W.

195

A AA

t t t tt

Fig.No. 35.5 Fig.No. 35.6 Fig.No. 35.7

Fig.No. 35.8

3PH.4W.+G

195

A AA 70

t t t t t

3PH.5W.+G

195

A AA 70

t t t t tt

Fig.No. 35.9

federal busway

36

Horizontal Hanger Support Details and Installation

Edge Wise Installation

C

W+30

W+130

W+180

W

H

Ø12mm ROD

Hanger Clamp

12mm ROD

Hanger Clamp

Ø

Fig.No. 36.1

Edge Wise Support Details

60

30

15

30

155

305

2525

50 50

12565 65

Ø10Ø10 Ø10

Ø10

60

305

25 50 155 50 25

305

255

155

60

30

Fig.No. 36.2

federal busway

37

Flat Wise Installation

Flat wise Support Details

Fig.No. 37.1

Ø10Ø10 Ø10

Ø10

60

H+160

2585.4 H-60 85.4

25H+110

30

H+110H+160

H-60

H80 80 60

30

15

H+160

H+110

H-60

60

30

Fig.No. 37.2

federal busway

C

H+110

H+160

12mm ROD

Hanger Clamp

H-60

H

W

Ø12mm ROD

Hanger Clamp

Ø

38

Sr. No. RatingNo. of

StackH

(mm)W (mm)

3W 4W/5W

1

2

3

4

5

6

7

8

9

10

11

12

13

14

630A

800A

1000A

1250A

1600A

2000A

2500A

3200A

3500A

4000A

4500A

5000A

6000A

6300A

1

1

1

1

1

1

1

2

2

2

2

3

3

3

105

105

105

105

105

105

105

105

105

105

105

105

105

105

115

125

140

165

205

225

265

405

405

475

495

605

710

740

125

125

125

125

125

125

125

125

125

125

125

125

125

125

Enclosure Dimension

Horizontal Support Table (in mm)Fix horizontal hanger to the 12mm threaded Rod and adjust it for correct elevation.

Lay the busway on the horizontal hanger drawings.

Fix hanger clamps on both side of the busway termination.

Ensure the busway is aligned in straight line integrity.

Additional horizontal hanger supports shall be provided such as elbow etc.

In Busways having horizontal runs,

Horizontal support hangers are recommended at every 1.5 meters. (See Fig.No. 38.1)

Horizontal Supporting Details of Busway

3000mm

1500mm 1500mm 1500mm

3000mm

1500mm 1500mm

(Standard length) (Standard length)

JOINT SECTION JOINT SECTION JOINT SECTION

Fig.No.38.1

federal busway

39


Fig.No. 39.3

Vertical Hanger Support Details and Installation

Vertical Spring Hanger

Vertical spring hanger is used to secure mounting & support busway feeder units while they are installed in vertical position.

Design and Selection of these supports is done considering load/weight of busway feeders/plug in feeders used in vertical run, their distribution of load/weight at each floor.

The maximum distance between vertical spring hangers should not exceed 4 meters. Intermediate spring hangers.

W

205

80125

6516

075

120

300

'C' ChannelNot Supply

275

200

(MIN. OPENING)W+30

200

H

40

25

250

275 12

0

(MIN. OPENING)

H+30

Floor

Opening Hole (M12)

For Installation

W

205

80125 Opening Hole (M12)

For Installation

6516

075

120

300


275

200

(MIN. OPENING)

W+30

200

H

40

25

250

275 12

0

(MIN. OPENING)

H+30

Floor


Bolt/Nut

M(10X30)

Vertical Spring Hanger


Stack

H(mm)

W (mm)

3W 4W/5W

1

2

3

4

5

6

7

8

9

10

11

12

13

14

630A

800A

1000A

1250A

1600A

2000A

2500A

3200A

3500A

4000A

4500A

5000A

6000A

6300A

1

1

1

1

1

1

1

2

2

2

2

3

3

3

105

105

105

105

105

105

105

105

105

105

105

105

105

105

115

125

140

165

205

225

265

405

405

475

495

605

710

740

125

125

125

125

125

125

125

125

125

125

125

125

125

125

Fig. No.

39.1

39.1

39.1

39.2

39.2

39.2

39.2

39.3

39.3

39.3

39.3

39.3

39.3

39.3

(in mm)

Floor

Opening Hole (M12)

For Installation

6516

075

120

300

275

200

'C' Channel

Not Supply

(MIN. OPENING)

200

W+30

'C' Channel

Not Supply

Bolt/Nut

(M10x30)

(MIN. OPENING)

H+30

H

4025

250

275 12

0

W

240

80

federal busway

40

Vertical Fix Hanger

Opening Hole (M12)

For Installation

W

205

6550

75

'C' Channel

Not Supply

Floor

H

40

25

90

(MIN. OPENING)

165 11

0

W+30

200

(MIN. OPENING)

H+30

190

12580

165


Vertical fix hanger must be installed at starting Point of vertical busway & on first floor of riser.

Vertical Fix Hanger


Stack

H(mm)

W (mm)

3W 4W/5W

1

2

3

4

5

6

7

8

9

10

11

12

13

14

630A

800A

1000A

1250A

1600A

2000A

2500A

3200A

3500A

4000A

4500A

5000A

6000A

6300A

1

1

1

1

1

1

1

2

2

2

2

3

3

3

105

105

105

105

105

105

105

105

105

105

105

105

105

105

115

125

140

165

205

225

265

405

405

475

495

605

710

740

125

125

125

125

125

125

125

125

125

125

125

125

125

125

Fig. No.

40.1

40.1

40.1

40.2

40.2

40.2

40.2

40.3

40.3

40.3

40.3

40.3

40.3

40.3

(in mm)

Fig.No. 40.3

40

25

'C' Channel

Not Supply

Bolt/Nut(M10x30)

(MIN. OPENING)

H

165 11

0

H+30

Opening Hole (M12)

For Installation


Floor

(MIN. OPENING)

200

80

6550

75

90

16519

0

W

205

W+30

federal busway

W

205

6550

75

'C' Channel

Not Supply

Floor

80

125

90

165

190

Opening Hole (M12)

For Installation

W+30

200

(MIN. OPENING)

H

4025


Bolt/Nut(M10x30)

165 11

0

(MIN. OPENING)

H+30

41

Fig.No. 41.1

Installation Procedure for IP54Busway Joint

CAUTION

Do Not T

ouch Durin

g Opertio

n


ge

BELLEVILLE WASHER Ø40mm

BELLEVILLE WASHER Ø78mm JOINT COVER BOLT M8 X 20

JOINT NUT M14

JOINT SUPPORT

INSULATED JOINT BOLT M14 X 160

JOINT COVER BOLT M8 X 20

GASKET

Complete Assembled View

federal busway

Fig.No. 42.1

Installation Procedure for IP65/IP67Busway Joint

Complete Assembled View

CAUTION

Do Not T

ouch Durin

g Opertio

n


ge

HEXGON BOLT M8x16

FLAT WASHER M8

JOINT NUT M14JOINT SUPPORT

INSULATED JOINT BOLT M14x160

GASKET

42

federal busway

43

8. Thermographic Survey – Necessity and its advantages

The temperature of electrical components and connections are indicative of their health. Excessive heat will be generated due to increased electrical resistance (Joule's law can bereferred for details), by faulty components and by loose or deteriorated connections, short-circuit, overload, mismatched or improperly installed components. Equipment running hot can also be related to load imbalance, failure of cooling, increase in resistance at joint area (joint area of busway system also experiences heat due to contact resistance), abnormal working conditions etc. These conditions may cause anomalies in insulation system disrupting operation of system/equipment.

View above, Temperature monitoring and analyzing Temperature Readings of Systems carrying current becomes essential and Thermographic Surveys by using Infrared Cameras, which is non-destructive, non-contact, on line and safe mapping system for temperature recording has been preferred by most of the end users. Thermographic Surveys including Quantitative Infrared Scan - which include infrared examination, provides images of exceptions (Hot Spots) and Temperature Readings/Data, have been found beneficial for examining healthiness of Electrical Equipment.

IEC 61439 Part 1 & 6 the Standard, applicable for Low Voltage Busbar Trunking System also verifies rating and performance of Busbar Trunking System by conducting temperature rise test and verifies temperature rise results w.r.t. Temperature Rise Limits, ambient temperature Specified therein. For Busway Enclosure 55 Deg C and Joints 70 Deg C Temp Rise over Ambient of 35 Deg C has been allowed by IEC or as recommended by manufacturer.

Thermographic Surveys have been recommended in NEMA BU 1.1 – an International Standard Applicable for Handling and Installation of Busway Systems.

As mentioned in Clause 9.4 of above standard, upon completion of satisfactory inspection of Busway System installed at site, it is desirable to perform infrared temperature scan on Electrical Connections after Busway System is energized and their temperatures stabilize as per operating load conditions.ASTM-E 1934-99a – Standard giving guidelines for Examination of Electrical and Mechanical Equipment’s with Thermography reporting can also be referred to know importance of Thermographic Survey and Contents of Report on such surveys.

It is also recommended to keep permanent record of readings taken during the scan at healthy operating conditions (Including record of Satisfactory Electrical Parameters Such as Voltage, Power Factor, Load Current, Ambient Temperatures, Insulation Resistance Values, Torque Levels for Firm and Proper Connections) so that these can be referred for initiating corrective/troubleshooting measures if these readings change with time. Possible reasons bringing change in these readings are Loose/Deteriorated Connections, Overloads, Load Imbalances, faulty or improperly installed components. Furthermore, record of readings taken during healthy conditions come handy for future referral during trouble shooting/analysis for establishing healthiness of the system.

8.1 Thermal Imaging: An Important Maintenance Tool

Thermal imaging or infrared thermography is a non-destructive maintenance method that uses infrared cameras to measure the amount of thermal radiation emitted by objects {All materials, which are above 0 degrees Kelvin (-273 degrees C), emit infrared energy.}, which is converted to temperature. Normally, to measure the temperature of objects near room temperature requires the detection of radiation in the infrared wavelength range (which is much longer than that of visible light, i.e. approximately 400–700 nanometers).

federal busway

44



A thermal imaging camera (also known as an infrared camera, thermal imager or IR camera) works by producing thermal or heat pictures of equipment. It contains a very special lens, capable of focusing infrared light emitted by the objects in the thermal imaging camera’s line of view. This focused light is turned into a thermogram, which is a detailed temperature pattern. The thermogram is then translated into electric impulses, which in turn converts the impulses into data for the display on the thermal imager. The data is represented as various colors, depending on the infrared emission intensity.

Infrared images are normally colorized so that objects that emit more thermal radiation than others will appear as brighter colours (yellow, red, and white). Cooler objects appear in darker blue, purple, or green colors. Although thermal imaging normally detects only surface temperatures, infrared signatures often indicate temperatures inside structures.

8.2 Thermal Image of Electrical Distribution Busway – Sample Picture

Conduct Thermographic Survey for recording temperatures and thermal images at hotspot areas, electrical connections by using Infrared Technology based Thermal Imager.

This includes, Study of Temperature Readings and Thermal Images taken during the Survey to identify abnormal temperature differences w.r.t. Permissible Temperature Rise Limits allowed for such systems reckoning Ambient Temperature, Surrounding Environment.

Generation of Report in soft & hard copy format, on the basis of Survey Result and Analysis incorporating recommendations in case any to client for conducting further maintenance / service / repair activity as applicable and recommended by manufacturer.

federal busway

9. Ordering Information

Rated Current

Sr. No. Rating

630A

800A

1000A

1250A

1600A

2000A

2500A

3200A

3500A

4000A

4500A

5000A

6000A

6300A

06

08

10

12

16

20

25

32

35

40

45

50

60

63

Code

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Conductor Material

Sr. No. Rating

Copper

Aluminum

C

A

Code

1

2

Enclosure Material

Sr. No. RatingSteel

Aluminum

S

A

Code1

2

Configuration

Sr. No. Rating

3PH. 3Wire

3PH. 4Wire

3PH. 4Wire + G

3PH. 5Wire

3PH. 5Wire + G

01

02

03

04

05

Code

1

2

3

4

5

Enclosure Material

Busway Configuration

Conductor Material

Busway Rating

Busway Series

‘ID’ Series Busway System Numbering

ID 06 C 03 S

45

federal busway

10. Project Reference List

CISCO Commercial Building in Emirates, Dubai.

Export Dev. Bank in Iran

46

federal busway

federal switchgear ltd. llc

FE

DE

RA

L/11

16/V

ER

-ID

-00

federal busway

P.O. Box - 9769, Plot No.-17 AR17, 18, 19 ICAD-II, Abu Dhabi, United Arab Emirates.Tel No. : +971 2 5512375, 788

Fax : +971 2 5512328.Email : [email protected]

Web : federalswitchgear.com

Date post:	05-Dec-2021
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Federal Busway Catalouge - Final

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