Copper Busbar Trunking Systems with 100% Internal Copper Ground busbar (Technical Specifications) 1.
General
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a. All busbar trunking shall be copper busbars of low impedance sandwiched type technology, comprise three phase, full size neutral and 100% copper ground busbar with fully aluminium housing ground (totally enclosed in extruded fully aluminium housing), of the rating as shown on the Specification Drawings.
c.
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b. The busbar trunking system must be manufactured under an ISO9001 certified facility. The busbar trunking system must have more than 10 years of operation references. Busbar Trunking System must be of Operational Voltage rated to 690VAC and with a pollution degree of 3 to EN 60947.
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The busbar trunking system shall have both Damp heat, constant as per IEC 600682-78 and Damp Heat, Cyclic, as per IEC 60068-2-30 compliance. d. The system shall be complete with all necessary fittings, tap off units, universal fixing brackets. For vertical busbar riser provision of tap off points is allowed on one side when the other side is inaccessible. For horizontal busbar, every 3 metres length of busbar trunking, a minimum of 3 to 5 tap-off points can be designed and allowed for on both sides of the busbar trunking. Actual required tap-off openings shall follow that of the drawings provided.
Horizontal runs of busbar trunking shall be supported by universal fixing brackets at every 2 metres, vertical runs of busbar riser shall be supported with wall mounted universal fixing brackets not more than 2m apart
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f.
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e. The busbar trunking shall be capable of being mounted in any position without derating. Plug in and feeder sections shall be interchangeable without the use of special adaptor joint covers. The complete installation shall be co-coordinated throughout and where possible, shall consist of 3m sections with special sections and fittings provided to suit the installation.
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g. Care on support works should also be taken into account when the busbar with tapoff slots run flat wise. Support brackets should be positioned such that they do not obstruct the placement of the tap-off unit. This thus maximizes the available tap-off slots for use. h. Support brackets should not be positioned underneath joint blocks. i.
Vertical installed busbar trunkings shall be supported at each floor by a spring support system which shall be capable of supporting the full weight of the busbar trunkings beneath and shall make allowance for thermal expansion. Where floor to floor distance exceeds 5 meters, intermediate spring supports shall be provided.
d.
Plug-In Busbar trunking (horizontal/vertical) runs should be terminated by ‘end covers’.
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CDDM/4.2.3/BD-SIVACON-8PS/001 24.12.2004
Annexure – 2.C
2.
Conformity of standards
3.
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It shall be constructed in accordance with the applicable requirements of the latest edition BSEN 60439-1 & 2 / IEC 439-1 & 2 and tested by an independent test laboratory, LOVAG, for rated short-circuit current carrying capacity.
Environment
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The busbar shall be suitable for continuous operation without de-rating according to IEC o 439-1 at a Min./Max/Mean level ambient temperature of up to -5/+40/+35 C over 24 hrs. Busbars
The busbars shall be of hard drawn high conductivity copper with full size neutral of the same cross-sectional area as the phase conductor, it shall be provided for all busbar ratings.
b)
Busbars must be tinplated through out it’s length
c)
Each busbar trunking shall be LOVAG type tested and certified for short circuit rating for one second covering phase, neutral and fully aluminum housing as protective earth conductor.
d)
The minimum certified short circuit ratings of the busbar trunking should be as follows:
The insulation material shall be of Mylar insulation with a 130 C (Class B insulation class). It must be non-hygroscopic and self extinguished in case of fire. This material must not emit toxic gases when burning.
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CDDM/4.2.3/BD-SIVACON-8PS/001 24.12.2004
Annexure – 2.C
5.
Temperature Rise
6.
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The maximum hot spot temperature rise at any point in the busway at continuous rated o o and shall not exceed 55 C above the maximum ambient temperature of 40 C in any position. Joints
7.
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Electrical jointing shall be achieved by means of a quick make, non reversible and removable joint pack comprising of a double-headed, torque indicating joint bolt with a high visibility disc for visual indication of unmade joints. Enclosure
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The housing of the busbar trunking shall be constructed from extruded aluminum of thickness not less than 3mm for each side and 3mm for top and bottom to provide maximum protection against corrosion and provide maximum strength and rigidity. The fully aluminum housing shall be painted finish to RAL7035 and fully fault rated. Part Steel and Part Alum housing type are not allowed.
Busway shall be of indoor construction with degree of protection IP54 in accordance to BSEN 60529 / IEC 529 and rated for both horizontal and vertical mounting positions.
8.
Protective Conductor
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The degree of protection indicated shall apply to the complete system including tapping windows and joints.
A 100% Internal Copper Ground Busbar must be provided.
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The use of Integral Housing as ground is not allowed.
9.
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The ground conductor must be the same material as phase conductor copper.
Tap Off Outlets
All tap-off outlets shall be equipped with manufacturer designed and fitted with automatic safety shutters to prevent accidental contact of the busbar conductors and providing degree of personal protection & safety to IP2X in accordance to BSEN60529 / IEC 529. The automatic safety shutters shall activate only upon insertion of the tap-off unit. When not in use, tap-off outlet opening shall have a protective cover over it. The plug in points shall also provide positive engagement by the grounding stab of the plug in device.
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CDDM/4.2.3/BD-SIVACON-8PS/001 24.12.2004
Annexure – 2.C
10.
Tap Off Box
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Tap-off boxes shall be constructed of zinc plated sheet steel and shall be complete with hinged lids with a protective standard of IP54 with RAL7035 paint finish. Tap-off boxes shall be from the same manufacturer as the busbar system and shall be provided with for circuit breakers according to ratings as indicated in the drawings.
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All circuit breakers used shall be the same as the busbar manufacturer and to be three (3) Pole. The MCCB operating mechanism shall be independent of operating speed and the over centre toggle action shall provide a quick-made and quick-break switching. Handles shall be trip-free.
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Covers of all plug-in units must have releasable type interlocks to prevent the covers from being opened while the breaker is in the ‘ON’ position. Handle with lock attachments capable of locking the MCCB either in the open or closed position shall be provided. Tap-off boxes up to 630A shall be of the plug-in type for ease of installation and removal. Tap-off boxes up to 630A can be changed when the busbar system is in a ‘live’ condition. 800A tap-off box and above shall be the bolt-on type which installation is only permissible when the system is isolated. All parts of the busbar trunking system must be certified to be Halogen free.
12.
The busbar trunking system must complied to DIN4102 Part 9 for Fire Rated Installation
13.
The busbar trunking system must be tested under IEC 439-2-2000 Clause 8.2.14 for Verification of Resistance to Flame Propagation.
14.
The busbar trunking must be tested under IEC439-2-2000 Clause 8.2.13 for Glow Wire Test.
15.
CE Marking All busbar trunking shall include a CE mark on its labels in accordance with the Low Voltage directive number 73/23/EEC
16.
Installation
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11.
Fully detailed installation manuals shall be supplied describing topics such as handling, storage, installation, energising and maintenance.
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