its ISO 9001:2008 Certification for Quality Management System

Furutec Electrical started to manufacture busduct system in Penang, Malaysia since 1995 under the license from Furukawa Electric, Japan. In 2008, EITA Resources ventured into designing and manufacturing busduct system and Furutec became a wholly-owned subsidiary of EITA Resources.

Having benefitted from more than a decade-long of technical collaboration with Furukawa, Furutec is noted for its relentless and uncompromising commitment on quality and excellence as the Japanese manufacturing practice and culture have been firmly embedded into Furutec busduct system. Today, Furutec has more than 15 years of experience in the manufacturing of busduct system that meets international standards. This product is of the finest quality and reliability, utilising the stringent Japanese know-how and technology. Moreover, Furutec is committed towards quality and services as stipulated in accordance to its ISO 9001:2008 Certification for Quality Management System.

HP-ES product range (from 400A to 6300A) has been type tested and certified by a reputable independent testing authority which is KEMA or DEKRA complying to IEC 60439-2.

List of Type testing according to IEC 60439-2:

• Verification of Temperature Rise Limits (8.2.1)• Verification of Dielectric Properties (8.2.2)• Verification of Short-circuit Strength (8.2.3)• Verification of the Effectiveness of the Protective Circuit (8.2.4)• Verification of Clearance and Creepage Distances (8.2.5)• Verification of the Degree of Protection (8.2.7)• EMC Tests (8.2.8)• Verification of the Resistance of Insulating Materials to Abnormal Heat and Fire (8.2.9)• Verification of Structural Strength (8.2.10)• Verification of Crushing Resistance (8.2.12)• Verification of the Electrical Characteristics of the Busbar Trunking System (8.2.13)• Verification of Resistance to Flame propagation (8.2.14)• Verification of Fire Resistance in Building Penetration (8.2.15)

With our well-equipped R&D laboratory, our product could be verified in the temperature rise-limit test for current ratings up to 6000A according to the international standards. We will continue to innovate in order to meet our customers’ expectation and trust towards our products.

Our product has been accepted globally and successfully installed in various prestigious projects in Malaysia as well as around the world. We take pride in further expanding our success to more countries through our regional partners.

ABOUT FURUTEC

Busduct Design Layout 01-02

Specification and Standards 03-08

Physical DataHP-ES Busduct Conductor Size 09 Flange End / Flange End Box 10-11 Flatwise Elbow / Edgewise Elbow 12 Flatwise Tee Elbow 13 Flatwise Offset Elbow / Edgewise Offset Elbow 14 Combination Elbow 15 Elbow with Flange End / Flange End Box 16 End Cap / End Closure 17 Vertical Spring Hanger / Vertical Hanger 18-19 Edgewise / Flatwise Hanger 20-21 Reducer 21 Expansion Unit 22 Flexible Link 23 Tap-Off Unit 24-25

Design Factors 26-28

Installation & Maintenance Procedure Storage and Preparation prior to Installation Works 29 Busduct Joint 30 Tap Off Units (Plug In Type) 31 Tap Box (Bolt On Type) 32 Vertical Spring Hanger / Vertical Hanger 32 Edgewise / Flatwise Hanger 33 Connection with Equipment 33 Inspection & Testing upon Completion of Busduct Installation 34 Recommended Maintenance Procedures 34-35 Project Reference 36

An Efficient Power Distribution System Innovated with Japanese Technology.

CONTENT

CONTENTS |

Furutec HP-ES busduct system is designed to meet the requirement of commercial, industrial and residential applications. It carries up to 6300A with reduced energy losses and heat as compared to conventional cable system.

Furutec busduct system is known for :

1) Flexible and modular in design.2) Occupying lesser space.3) Fast installation and lower installation cost and easy maintenance.4) Lower voltage drop.5) Low power frequency magnetic field.6) Fire resistance (optional) and non-flammable propagation.7) Flexibility for future expansion.8) Strong mechanical strength and higher short-circuit rating. 9) Higher degree of protection.

Furutec busduct system provides a flexible and reliable electrical distribution system with a wide range of current carrying capacity from 400A to 6300A with operating voltage up to 690V.

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

IEC 60439-2 Particular Requirements for Busbar Trunking System (Busway).IEC 60439-1 Low Voltage Switchgear and Controlgear Assemblies.IEC 60529:2001 Degree of Ingress Protection.

Optional standards for fire-rated busduct system :

BS 6387:1994 Performance Requirements for Cables required to Maintain Circuit Integrity under Fire Conditions (Adoption).

General

Design Standards

System Voltage & Rated Current

03 | SPECIFICATION & STANDARDS

SPECIFICATION & STANDARDS

Busduct Housing

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

Due to the existence of non-linear loads in today’s modern buildings, high harmonic neutral current overheats the neutralconductor and deteriorate the performance and life span of equipment. 200% neutral bar is offered to handle the overheating and increased neutral current caused by the harmonic effect.

Copper conductor is of the conductivity 99.98%. It meets all electrical, thermal and mechanical properties and comply to the relevant international standards, such as JIS H3140, ASTM B187M, BS EN 13601, etc.

Each copper conductor (except at joint parts) is insulated with polyester films (-70oC to +150oC). The rated insulation voltage is up to 1000V at 50Hz or 60Hz of frequency. Each conductor is tin-plated to provide protection from corrosion and high conductivity at the contact surface.

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

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

System Configuration and Phase Sequence

Conductor and Insulation Material

3P3W

L1

L2

L3

3P4W

L1

L2

L3

N

3P5W

50%E

L1

L2

L3

N

3P4W 200% N

L1

L2

L3

200%N

3P5W 200% N

50%E

L1

L2

L3

200%N

SPECIFICATIONS & STANDARDS | 04

Joint System

Busduct Joint Installation (IP42, IP54, IP55, IP65)

Busduct Joint Installation (IP66)

JOINT COVER

HIGH TENSILE

LEAF SPRING (BCN)

LEAF SPRING (BCB)

JOINT COVER

ELECTRO-GALVANISED STEEL SHEET HOUSING(COATED WITH EPOXY POWDER) M12 BOLT

M12 NUT & WASHER

M8 BOLT, WASHER & NUT

JOINT COVER

HIGH TENSILE

LEAF SPRING (BCN)

LEAF SPRING(BCB)

JOINT COVER

M12 BOLT

M8 BOLT, WASHER & NUT

M12 NUT & WASHER

M8 NUT

M8 BOLT & WASHER

EXTERNAL JOINT COVER

EXTERNAL JOINT COVER

ELECTRO-GALVANISED STEEL SHEET HOUSING(COATED WITH EPOXY POWDER)

Furutec busduct joint features a maintenance free double-bolt joint design. This double-bolt joint system ensures a sufficient electrical contact area and good mechanical strength. Its high tensile clamping bolts in duct-to-duct jointing do not penetrate through the conductors. A spring steel material named as leaf spring that is wider than the conductors, is used to ensurea sufficient pressure on conductor contact area. This clamped joint having benefitted from a decade-long Japanese Technologygenerates less heat at busduct joint as compared to bolted joint system, which necessitate the drilling or punching of holes through the conductors with the bolt holes causing distortion to the lines of current flow. This clamped joint with leaf springs also has a more even contact pressure than the one using bolt-through joint.


Method of Mounting

Degree of Protection

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

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

Furutec busduct housing is designed and constructed to meet the requirement of indoor and outdoor installation. The degreeof protection of Furutec busduct housing is verified and tested to meet the requirement of IP42, IP54, IP55, IP65, IP66 and IP68in accordance to IEC 60529 by independent testing authority.

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

Protection against ingress of solid objects Protection against water

Protected against foreign objects greater than 1mm

Protected against foreign objects greater than 1mm

Dust protected

Dust protected

Dust tight

Dust tight

Dust tight

Dust tight

No protection

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

Projected water from all directions (limited ingress permitted)

Jets of water(limited ingress permitted)

Jets of water(limited ingress permitted)

Heavy jets of water(limited ingress permitted)

Effects of immersion between 15cm and 1m

Long period of immersion under pressure

4 0

2

4

5

5

6

7

8

4

5

5

6

6

6

6

1mm

15O

1m

1mm

SPECIFICATIONS & STANDARDS | 06

Voltage Drop Calculation :

Voltage Drop

V = Line-to-Line Voltage Drop (V/m)I = Load Current (A)I0 = Rated Current (A)cosØ = Load Power FactorsinØ = R = AC resistance at load current (Ω/m)R0 = AC resistance at rated current (Io) (Ω/m)α = Temperature coefficient of conductor at 20 oC = 3.85 x 10 –3(Copper)X = Reactance (Ω/m)

1 - cos2 Ø

Due to low impedance, the voltage drop of busduct system is lower compared to conventional cable system. Therefore,busduct system is a more efficient power transmission media as compared to conventional cable system.

Short-Circuit Strength

Busduct Rating Short Circuit Rating(kA/1 Sec)

Short Circuit Rating(kA/3 Sec)

400A600A700A800A

1000A1250A

202035454560

111120252534



1600A1800A2000A2200A2500A3000A

6060858585

120

343450505070



3500A4000A4500A5000A6300A

120120120120150

7070707087

Temperature Rise Limit

Ambient Temperature °C Derating Factor

40455055606570

1.000.950.900.850.800.740.67

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

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

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

Furutec busduct system is able to operate at full rated current at a maximum ambient air temperature of 40oC without any derating effects. When busduct system is installed in a higher ambient temperature, its current rating will be derated according to the factors as illustrated in the table on the right.

Conductor Width(Thickness=6mm)

BusductRating

20mm30mm40mm45mm60mm75mm110mm125mm150mm175mm200mm110mm125mm150mm175mm200mm175mm

400A600A700A800A1000A1250A1600A1800A2000A2200A2500A3000A3500A4000A4500A5000A6300A

195.5142.999.388.767.349.035.831.325.422.319.017.115.613.010.78.72.2

81.954.245.243.333.127.319.816.715.416.713.48.98.36.75.66.77.7

211.9152.8109.198.775.156.140.935.529.727.823.219.317.714.612.011.08.0

0.1350.1490.1200.1230.1170.1070.0990.0980.0880.0850.0820.0890.0950.0900.0830.0750.024

0.1460.1590.1310.1350.1290.1200.1110.1090.1000.1000.0960.0990.1060.1000.0930.0900.049

0.1470.1580.1320.1370.1300.1220.1130.1110.1020.1040.0990.1000.1070.1010.0940.0930.058

0.1450.1560.1310.1360.1290.1220.1130.1100.1030.1060.1000.1000.1070.1010.0940.0950.065

0.1420.1530.1290.1340.1280.1210.1120.1090.1020.1060.1010.0990.1060.1000.0930.0950.070

0.1390.1490.1270.1320.1250.1190.1110.1080.1010.1060.1000.0970.1040.0980.0910.0950.074

50 Hz

Power factor Ø at 50 Hz

Voltage Drop at Full Load Current

Resistance,R (µΩ/m)

Reactance,X (µΩ/m)

Impedance,Z (µΩ/m) 1.00 0.95 0.90 0.85 0.80 0.75

Voltage Drop


Fire-Rated Busduct

Maintaining Circuit Integrity during Fire Conditions

Conductor

Fire Rated Mica Tape

Polyester Film

BS 6387:1994 Category ‘C’ (Resistance to Fire Alone Test) Flame Temperature : 950oC ± 40oCTest Voltage : 660VTest Duration : 3 hours

Fire Rated Busduct is provided as an option for the incoming and outgoing circuits of emergency main switchboard.The copper conductors of fire rated busduct are insulated with 2 layers of mica tape and 2 layers of polyester film.

Besides complying to verification of resistance to flame propagation (8.2.14) and verification of fire resistance in building penetration (8.2.15) stated in IEC60439-2, Furutec busduct system has also been type tested to BS 6387:1994 (Performance Requirement of maintaining circuit integrity during fire conditions) by independent testing authority.

Polyester Film

Fire-Rated Mica Tape

Conductor

Busduct Feeder Busduct Joint Section

SPECIFICATION & STANDARDS | 08

Conductor Size

HP-ES BUSDUCT

3000mm

( Standard Straight Length )

MALE FEMALE

3000mm

( Standard Straight Length )

B B

AA

BusductRating

Conductor Sizeper Phase (mm)

Model No. A (mm)

3P3W3P4W

3P4W+E3P5W

3P3W 3P4W3P4W+E3P5W

3P3W

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


HP-ES400CHP-ES600CHP-ES700CHP-ES800CHP-ES1000CHP-ES1250CHP-ES1600CHP-ES1800CHP-ES2000CHP-ES2200CHP-ES2500CHP-ES3000CHP-ES3500CHP-ES4000CHP-ES4500CHP-ES5000CHP-ES6300C

115115115120135150185200225250275370400450500550750

100 120

10.2611.9413.6214.5617.4320.4927.2530.3935.2640.4145.3454.5060.7970.5180.8190.67120.04

11.4413.6715.9217.1420.8424.7533.4637.4543.7150.2756.6166.9374.9187.43100.53113.21149.59

11.9814.4917.0118.3522.4626.7836.4440.8447.7755.0062.0272.8881.6895.55110.01124.04163.80

3P4W 3P5W3P4W+E

One - 6 x 20One - 6 x 30One - 6 x 40One - 6 x 45One - 6 x 60One - 6 x 75One - 6 x 110One - 6 x 125One - 6 x 150One - 6 x 175One - 6 x 200Two - 6 x 110Two - 6 x 125Two - 6 x 150Two - 6 x 175Two - 6 x 200

Three - 6 x 175

1

2

3

Copper Busduct :

Figure 1 Figure 2

400A - 2500A 3000A - 5000A

B

A

Figure 3

6300A

09 | PHYSICAL DATA

PHYSICAL DATA

Flange End / Flange End Box

3000A~5000A Flange End

150

C

A

170

170

170

B

EE

C

F

10-Ø10 HOLESOPENING B-60

400A~2500A Flange End

C

150

BE

A

170

OPE

NIN

G A

-60

OPE

NIN

G A

-60

125

125

8-Ø10 HOLEOPENING B-60

100100100

6

400A~2500A Flange End Box

B

450 C

150

B

A

8-M8 BOLT

REMOVABLE FRONTMETAL COVER

NON-FERROUS MATERIAL BOTTOMCOVER FOR CABLE TERMINATION

NON-FERROUS MATERIAL BOTTOM COVER FOR CABLE TERMINATION

450

A

3000A~5000A Flange End Box

CC

F

450

150

B

A

10-M8 BOLTS

450

AB

TOP

VIEW

TOP

VIEW

TOP

VIEW

TOP

VIEW

SID

E VI

EW

SID

E VI

EW

SID

E VI

EW

SID

E VI

EW

FRO

NT

VIEW

FRO

NT

VIEW

FRO

NT

VIEW

FRO

NT

VIEW

6

100100100

130130130

6 150

130130

6


130

PHYSICAL DATA | 10

2240

20

DDD

22

4020

DD

4020

D

2222

12

4020

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

2-Ø11 2-Ø12x22 4-Ø12x22 6-Ø12x22 8-Ø12x22

40

C

20

Fig. 1

C C C C

Busduct Rating FigureA (mm)

B(mm)3P3W

3P4W3P4W+E3P5W

400A

600A

700A

800A

1000A

1250A

1600A

1800A

2000A

2200A

2500A

3000A

3500A

4000A

4500A

5000A

6300A

175

175

175

180

195

210

245

260

285

310

335

430

460

510

560

610

810

1

1

2

2

2

3

3

4

4

5

5

3

4

4

5

5

5

350 450

410 540

C(mm)

20

30

40

45

60

75

110

125

150

175

200

110

125

150

175

200

175

D(mm)

-

-

-

-

-

40

50

40

50

40

50

50

40

50

40

50

40

E(mm)

145

145

145

150

165

180

215

230

255

280

305

200

215

240

265

290

260

F(mm)

-

-

-

-

-

-

-

-

-

-

-

185

200

225

250

275

250

NON-FERROUS MATERIAL BOTTOM COVER FOR CABLE TERMINATION


6300A Flange End

150

OPENING B-60

C C

12-Ø10 HOLES

A

170

170

170

B

EEE

C

FF

6300A Flange End Box

C CC

F F

12-M8 BOLTS

450

B

150

A

B

450

A

130130130

6

TOP

VIEW

SID

E VI

EW

FRO

NT

VIEW

TOP

VIEW

SID

E VI

EW

FRO

NT

VIEW

Busbar hole of Flange End / Flange End box is designed for switchboard / cable termination. Refer to Flexible Link on page 23 for Flange End termination at transformer.

OPE

NIN

G A

-60

130130130

6

11 | PHYSICAL DATA

Flatwise Elbow / Edgewise Elbow

Busduct Rating Standard LengthsL1 x L2 (mm)

Minimum LengthsL1 x L2 (mm)

400A to 6300A 400 x 400 270 x 270

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

Busduct Rating Standard LengthsL1 x L2 (mm)

Minimum LengthsL1 x L2 (mm)


300 x 300300 x 300300 x 300300 x 300310 x 310315 x 315335 x 335340 x 340355 x 355365 x 365380 x 380425 x 425440 x 440465 x 465490 x 490515 x 515615 x 615

400 x 400

550 x 550

650 x 650

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

L2

L1

L1

L2

Edgewise Elbow

Flatwise Elbow

PHYSICAL DATA | 12

Flatwise Tee Elbow

Busduct Rating Standard LengthsL1 x L2 x L3 (mm)

Minimum LengthsL1 x L2 x L3(mm)

400A600A700A800A

1000A1250A1600A1800A2000A2200A2500A3000A3500A4000A4500A5000A6300A

270 x 270 x 270270 x 270 x 270270 x 270 x 270270 x 270 x 270280 x 280 x 280285 x 285 x 285305 x 305 x 305310 x 310 x 310325 x 325 x 325335 x 335 x 335350 x 350 x 350395 x 395 x 395410 x 410 x 410435 x 435 x 435460 x 460 x 460485 x 485 x 485585 x 585 x 585

400 x 400 X 400

500 x 500 x 500

600 x 600 x 600

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

L1

L2

L3

13 | PHYSICAL DATA

Busduct Rating Flatwise Offset Edgewise Offset

Standard LengthL1 x L2 x L3 (mm)

Minimum LengthL1 x L2 x L3 (mm)


Standard LengthL1 x L2 x L3 (mm)


300 x 265 x 300300 x 265 x 300300 x 265 x 300300 x 265 x 300310 x 280 x 310315 x 295 x 315335 x 330 x 335340 x 345 x 340355 x 370 x 355365 x 395 x 365380 x 420 x 380425 x 330 x 425440 x 345 x 440465 x 370 x 465490 x 395 x 490515 x 420 x 515615 x 395 x 615

400 x 400 x 400 270 x 200 x 270

650 x 450 x 650

550 x 450 x 550

400 x 450 x 400

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

Flatwise Offset Elbow / Edgewise Offset Elbow

Flatwise Offset Elbow Edgewise Offset Elbow

L2

L1

L3

L2

L1

L3

PHYSICAL DATA | 14

Combination Elbow

Busduct Rating Standard LengthL1 x L2 x L3 (mm)


400A600A700A800A

1000A1250A1600A1800A2000A2200A2500A3000A3500A4000A4500A5000A6300A

300 x 235 x 270300 x 235 x 270300 x 235 x 270300 x 235 x 270310 x 245 x 270315 x 250 x270335 x 270 x 270340 x 275 x 270355 x 290 x 270365 x 300 x 270380 x 315 x 270425 x 360 x 270440 x 375 x 270465 x 400 x 270490 x 425 x 270515 x 450 x 270615 x 550 x 270

400 x 400 x 400

550 x 550 x 550

650 x 650 x 650

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

L2

L1

L3

L2

L1

L3

15 | PHYSICAL DATA

Elbow with Flange End / Flange End Box

Busduct RatingStandard Length (mm)

L1 L2 L3 L4 L1 L2 L3 L4

Minimum Length (mm)

400A

600A

700A

800A

1000A

1250A

1600A

1800A

2000A

2200A

2500A

3000A

3500A

4000A

4500A

5000A

6300A

300

300

300

300

310

315

335

340

355

365

380

425

440

465

490

515

615

185

185

185

185

195

200

220

225

240

250

260

310

325

350

375

400

500

400 400 275 275

400

400

650

550

650

L2

L1

450

AB

L4

L3

BA

450

Flatwise Elbow with Flange End boxEdgewise Elbow with Flange End box

Refer to page 10 and 11 for dimensions of A and B

PHYSICAL DATA | 16

End Cap / End Closure

End Closure End Cap

B A

35mm165mm B

A

Busduct Rating A (mm) B (mm)

400A

600A

700A

800A

1000A

1250A

1600A

1800A

2000A

2200A

2500A

3000A

3500A

4000A

4500A

5000A

6300A

115

115

115

120

135

150

185

200

225

250

275

370

400

450

500

550

750

100 120

3P3W3P4W

3P4W+E3P5W

3P4W3P4W+E3P5W

3P3W

17 | PHYSICAL DATA

Vertical Spring Hanger / Vertical Hanger

For 400A to 1250A Busduct For 1600A to 2500A Busduct

For 3000A to 3500A Busduct

For 6300A Busduct

Vertical HangerVertical Hanger

Vertical hanger Vertical Spring Hanger

Vertical hanger Vertical Spring Hanger

Vertical Spring HangerVertical Hanger

For 4000A to 5000A Busduct

60M10x30 BOLT

M12 STUDBOLT

50155

7550

Vertical Spring Hanger

170

75

275

50

M10x30 BOLT

SPRINGM12 STUDBOLT

60

5075

155 50

M12 STUDBOLT

M10x30 BOLT60


60

M12 STUDBOLT

SPRING

M10x30 BOLT

50

275

7517

0

170

75

275

50

M10x30 BOLT

SPRINGM12 STUDBOLT

60

60

5075

155 50

M12 STUDBOLT

M10x30 BOLT

60

M12 STUDBOLT

SPRING

50

275

7517

0

M10x30 BOLT

5075

155 50

M12 STUDBOLT

60

M10x30 BOLT

605050

7515

5

M10x30 BOLT

M12 STUDBOLT

60

7550

170

275

SPRINGM12 STUDBOLT

M10x30 BOLT

PHYSICAL DATA | 18

400A - 1250A

A

A +

60 A +

60

A +

60

A +

60 A

+ 6

0

120

246

180

1600A - 2500A

A

3000A - 3500A 4000A - 5000A 6300A

A

180

246


A

STUD BOLT M12

BOLT M10x30

75 75

275 26

0

5017

0

A + 60

60

180

246

60

7517

050

275 26

0

120

(BY CONTRACTORS)BASE CHANNEL

Vertical Hanger

75

BOLT M10x30

STUD BOLT M12

A

140

155 50

50

180

60

A + 60

246

60

7550

50

120

BOLT HOLE

BOLT HOLE

140

155

BASE CHANNEL(BY CONTRACTORS)

275 26

0

5017

0

60

180

246

246

180

60

140

155

7550

50

A

180

246

A

180

246

BOLT HOLE

BOLT HOLE

FIRE BARRIER( BY CONTRACTORS )




Refer to page 9 for the dimensions of A

19 | PHYSICAL DATA

400A - 2500A 3000A - 5000A

6300A

Edgewise / Flatwise Hanger

Edgewise Hanger

(Fig 2)

Ø14 HOLE

EDGEWISE HANGER

C

B

A

(BY CONTRACTORS)

ANGLE METAL BAR& HANGER ROD

2-M10 BOLT

(Fig 1)

(BY CONTRACTORS)


Ø14 HOLE

EDGEWISE HANGER

2-M10 x 30 BOLTC

B

A

BusductRating

FigA B C

Dimension (mm)

400A600A700A800A

1000A1250A1600A1800A2000A2200A2500A3000A3500A4000A4500A5000A6300A

140

112

1

2

3

160

132

220

240

220

280

300

280

3P3W 3P3W 3P3W3P4W

3P4W+E3P5W

3P4W3P4W+E3P5W

3P4W3P4W+E3P5W

(Fig 3)

EDGEWISE HANGER

Ø14 HOLEC

A

B

(BY CONTRACTORS)


2-M10 BOLT

PHYSICAL DATA | 20

Flatwise Hanger

Busduct Rating Dimension (mm)

A B C

400A600A700A800A

1000A1250A1600A1800A2000A2200A2500A3000A3500A4000A4500A5000A6300A

165165165170185200235250275300325420450500550600800

383838435873

108123148173198293323373423473673

225225225230245260295310335360385480510560610660860

2-M10x30 BOLT (BY CONTRACTORS)

C

A

B


Ø14 HOLEC

A

B



Ø14 HOLE

C

A

B



Ø14 HOLE

L

L L

Reducer is used to reduce busbar sizes to the final load. It provides users with more economic power transmission anddistribution method. The minimum length (L) is 600mm and the reduction from a higher busduct rating to a lower busduct rating should not exceed 45%.

Reducer

400A - 2500A

6300A

3000A - 5000A

Remark: If the reduction is more than 45%, a protective device (e.g. circuit breaker) must be installed in between both busduct feeders.

21 | PHYSICAL DATA

Expansion Unit

Busduct Rating A (mm)


115115115120135150185200225250275370400450500550750

Both ends free

One end free

One end fixed

Both ends fixed

Plug in hole on each floor


No Plug in hole


No Plug in hole

≤ 120 mtr

≤ 90 mtr

≤ 30 mtr

≤ 30 mtr

≤ 15 mtr

1

2

3

4

5

SupportingCondition

Fig.Use of Plug in hole Maximum Length (L)without expansion unit

500 mm

500 mm (min)

500 mm (min)

A

Vertical springhanger

Plug-in box

Verticalhanger

Flangeend box

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

450 mm

The busduct system expands and contracts when the electrical load and the ambient temperature vary. The expansion unit is the transition section compensating the thermal expansion and contraction. The requirement of expansion unit in a vertical installation is determined by the method of how both ends of busduct system are supported. The use of plug in hole and total length of vertical busduct are important factors of determining the requirement of expansion unit.

L 2L 1

L L L LL

Remark: If the reduction is more than 45%, a protective device (e.g. circuit breaker) must be installed in between both busduct feeders.

L 1 =L 2

15

PHYSICAL DATA | 22

Flexible Link

Dimension of Braided Type Copper Flexible Link

"T"

320

120

4040

8-Ø12 HOLE

2020

150

25

40 40 40

25

40 40 40

150

12-Ø12 HOLE

150

2020

4040

2525

3535 40 40

3535 40 40

150

8-Ø12 HOLE

4030

2020

4040

2525

30

100

4030 30

50

4-Ø12 HOLE

4040

2020

150

25

25 25

25

2525

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

Busduct Rating Conductor Sizeper Phase (mm)

Dimension “T”(mm)

Fig Model

400A600A700A800A

1000A1250A1600A1800A2000A

1F5013 x 1

F5013 x 2F10013 x 1

F12014 x 1

F15014 x 1

2

3

4

13

1313

14

14.5

One - 6 x 20One - 6 x 30One - 6 x 40One - 6 x 45One - 6 x 60One - 6 x 75

One - 6 x 110One - 6 x 125One - 6 x 150

Busduct Rating Conductor Sizeper Phase (mm)

Dimension “T”(mm)

Fig Model

2200A2500A3000A3500A4000A4500A5000A6300A

F15016 x 2

F15016 x 1

F15014 x 2

F12014 x 23

4

4

4

4

16

14

F15016 x 3 16

14.5

16One - 6 x 175One - 6 x 200Two - 6 x 110Two - 6 x 125Two - 6 x 150Two - 6 x 175Two - 6 x 200

Three - 6 x 175

23 | PHYSICAL DATA

FLEXIBLE LINK

TRANSFORMER LV BOX(NOT THE SCOPE OF BUSDUCT MANUFACTURERS)

FLANGE END

BUSDUCT SYSTEM

Tap-Off Units

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

PLUG IN BOXMCCB

PLUG IN HOLE COVER

PLUG IN HOLE

L

W

H

100AF & 225AF Plug In Box 400AF & 630AF Plug In Box

Fig 2Fig 1

FRONT

BOTTOM BOTTOM

SIDE FRONT SIDE

Open

Open

E L1 L2 L3 N E L1 L2 L3 N

L

160

HW W H70 70

160

L

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

E

REMOVABLE NON-FERROLLS BOTTOM COVERFOR CABLE TERMINATION REMOVABLE NON-FERROLLS BOTTOM COVER

FOR CABLE TERMINATION

E

E E

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

100AF225AF400AF630AF

230265310365

340430550950

200220250320

1122

NL3

L2L1 E

Plug-In Box & Plug-In Hole

PHYSICAL DATA | 24

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

630AF800AF

1000AF1200AF

908998

11081108

373373488488

200200290290

Tap Box & Tap Bar

TAP BOX

TAP BAR

H

L

W4-M6 SCREW

REMOVABLE NON-FERROLLSBOTTOM COVER FORCABLE TERMINATION

Note : Customized plug in type 800AF, 1000AF & 1200AF tap-off units are available upon request.

25 | PHYSICAL DATA

1. Minimum Distance Between Parallel-Installed Busduct System.

1.1 Edgewise Installation (IP42, IP54, IP55, IP65)

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

A A

BUSDUCT JOINT SECTION




B

190

(C)

B

BUSDUCT JOINTSECTION

BUSDUCT JOINTSECTION

Busduct Rating

3P3W

Dimension “A” (mm)

150400A - 6300A

3P4W/3P5W

160

3P3W

85

3P4W/3P5W

95

Dimension “B” (mm)

1.2 Edgewise Installation (IP66)

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

Busduct Rating

3P3W

Dimension “A” (mm)

170400A-6300A

3P4W/3P5W

190

3P3W

130

3P4W/3P5W

150

Dimension “B” (mm)

A A

110

BB

500

(C)

110

60

DESIGN FACTORS | 26

DESIGN FACTORS

1.3 Flatwise Installation

Minimum clearance for busduct installed in flatwise position.

1.4 Plug-in Type Busduct Installation.

Minimum clearance for plug-in type busduct installed in parallel.

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

2.1 Ceiling and Wall. 2.2 Beam.

200

200

200

200

100 100

50190


50 50W W W

PLUG IN BOX

PLUG IN TYPE BUSDUCT

CEILING

WA

LL

WA

LL

CEILING CEILING

BEAM

27 | DESIGN FACTORS

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

2.3 Distance between busduct joint section and floor/ceiling surface for floor penetration

2.3 Distance between busduct joint section and wall surface for wall penetration

BUSDUCT JOINT SECTION(IP65 and below)

BUSDUCT JOINT SECTION(IP65 and below) BUSDUCT JOINT SECTION (IP66)

240

WALL

FIRE STOP MATERIAL(BY CONTRACTORS)

FIRE STOP MATERIAL(BY CONTRACTORS)

WALL

240 240

BASE CHANNEL

FLOOR SLAB FLOOR SLAB

(BY CONTRACTORS)

450

7524

0

BUSDUCTJOINT POINT

300

7524

0

VERTICAL SPRING HANGER

VERTICAL HANGER

BUSDUCTJOINT SECTION

DESIGN FACTORS | 28

Storage and Preparation Prior to Installation Works

1. Upon the arrival of busduct at project site, check the type and quantity of busduct feeders and accessories from shipping document. Inspect for possible physical damages caused during transportation and unloading.

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

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

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

5. To prevent the busduct joint from being soiled, wrap both busduct ends with water-proof material during unpacking. Before busduct joint installation, examine the conductor contact surface or insulation materials for any damages. Besides, ensure that the joint sections are not soiled with dust, dirt and other foreign matter. 6. Sufficiently strong materials and equipment must be used during handling and lifting to reduce the risk of personal injury and equipment damage at site. Busduct must be handled with care to avoid damage to internal components and metal housing.

7. During transporting, do not drop it or impact with other objects. Do not drag busduct across the floor or across other busduct sections. Forklift may provide a more convenient method of handling and has advantage of permitting it to be lifted between levels.

8. Platform/Scissor lifts or elevators, either manually or power operated, can be used efficiently to move the busduct between elevations. But, ensure that total weight of working crews and busduct is within the capacity of the lift/ elevator.

9. If a crane is deployed to move the busduct, use nylon straps and distribute the weight on each lift. If rope is used, insert thick pieces of rag, foam or corrugated cardboard between them to prevent the busduct from being damaged/scratched. Do not place slings, rope or chains around the busduct ends as these would easily damage the busduct. For busduct rated 2500A and above, pieces of strong wood should be used when rope is applied, in order to prevent the busduct housing from being deformed.

10. If forklift or similar hoist is used, properly position the busduct on the fork to distribute its weight. Careful approach is a must to avoid any damage to the metal housing that would break the phase isolators (ISP).

11. While installing vertical busduct, it may be easier to lower the busduct feeder from one floor above where it will be installed. The busduct feeders are usually stored on the floor above their final location to facilitate lowering them into position. Protect both busduct ends when rising from horizontal to vertical positions.

12.When the installation work is suspended or halted at job site, the end section of the connecting busduct feeders shall be protected against water and dust by covering them with polythene or other appropriate materials.

29 | INSTALLATION & MAINTENANCE PROCEDURE

INSTALLATION & MAINTENANCE PROCEDURE

5. To prevent the busduct joint from being soiled, wrap both busduct ends with water-proof material during unpacking. Before busduct joint installation, examine the conductor contact surface or insulation materials for any damages. Besides, ensure that the joint sections are not soiled with dust, dirt and other foreign matter. 6. Sufficiently strong materials and equipment must be used during handling and lifting to reduce the risk of personal injury and equipment damage at site. Busduct must be handled with care to avoid damage to internal components and metal housing.

7. During transporting, do not drop it or impact with other objects. Do not drag busduct across the floor or across other busduct sections. Forklift may provide a more convenient method of handling and has advantage of permitting it to be lifted between levels.

8. Platform/Scissor lifts or elevators, either manually or power operated, can be used efficiently to move the busduct between elevations. But, ensure that total weight of working crews and busduct is within the capacity of the lift/ elevator.

9. If a crane is deployed to move the busduct, use nylon straps and distribute the weight on each lift. If rope is used, insert thick pieces of rag, foam or corrugated cardboard between them to prevent the busduct from being damaged/scratched. Do not place slings, rope or chains around the busduct ends as these would easily damage the busduct. For busduct rated 2500A and above, pieces of strong wood should be used when rope is applied, in order to prevent the busduct housing from being deformed.

10. If forklift or similar hoist is used, properly position the busduct on the fork to distribute its weight. Careful approach is a must to avoid any damage to the metal housing that would break the phase isolators (ISP).

11. While installing vertical busduct, it may be easier to lower the busduct feeder from one floor above where it will be installed. The busduct feeders are usually stored on the floor above their final location to facilitate lowering them into position. Protect both busduct ends when rising from horizontal to vertical positions.

12.When the installation work is suspended or halted at job site, the end section of the connecting busduct feeders shall be protected against water and dust by covering them with polythene or other appropriate materials.

Busduct Joint

HP-ES Busduct Installation Procedures

1 2 3

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

Align the busduct feeders endto end.

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

4 5

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

6

Cover the busduct joint section with joint covers on both sides. The installation is complete.

Insert the snap pins into the pin holes.

INSTALLATION & MAINTENANCE PROCEDURE | 30

1 2

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

Remove the cover of each plug-in hole.

43

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

5

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

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

Tap Off Units (Plug In Type)

Duct-fixing Screws

Plug In Hole Cover

Earth Jaw

Plug In HolePlug In Hole

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

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

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


Vertical Spring Hanger / Vertical Hanger

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

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

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

Refer to the details of dimension of vertical spring hanger and vertical hanger on page 18 and 19

Tap Box (Bolt On Type)

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

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

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

4. Fix the front cover of the box.

5. The Installation is complete.

Nut 2 Nut 1

Nut 1

Nut 2

Before After

After the installation, Nut 2 must be moved towards Nut 1and both nuts must be tightened together.



Edgewise/Flatwise Hangers

1. Prepare the angle metal bars and hanger rods prior to the installation of horizontal busduct.

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

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

Connection with Equipment

Flange end / flange end box is used for cable or busbar termination. Where connections are to be made to a switchboard or transformer, the phase sequence of transformer and switchboard shall be coordinated and matched before busduct fabrication and installation works. Braided type of copper flexible link bars are connected between busduct flange end and LV terminals of transformer.

For vertical busduct installed in the electrical riser room, the flange end box must not be fixed permanently to the wall and floor. However, the flange end box can only be permanently secured provided that all the busduct installation works are completed (if unavoidable).

Refer to the details of Edgewise / Flatwise Hanger on page 20 and 21

Flatwise Hanger

Edgewise Hanger


Inspection and Testing upon Completion of Busduct Installation

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

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

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

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

4.1) The busduct feeders are physically damaged.

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

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

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

4.5) The hangers support the busduct securely.

Recommended Maintenance Procedures

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

1. Period of Inspection

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

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

a.) After severe earthquake

b.) After being involved in a fire

c.) After being exposed to water

d.) After an electrical fault

2. Maintenance and Routine Inspection

2.1 Inspection on External Appearance

Check whether :-

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

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

2.2 Environmental Inspection

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


2.3 Inspection for Abnormal Heat

An Infra Red Thermography instrument is recommended to detect any abnormal heat and measure the operatingtemperature of busduct system.

As an option, a thermal indicator can be placed onto the busduct housing. If the temperature rise of the busduct housing exceeds the limit, the colour of the indicator will change. e.g. from white to red colour.

2.4 Inspection on Connection Sections

Check whether:-

Busduct joint section is securely fastened with joint bolts and both sides of the busduct joint section are held with a pair of leaf springs.

Leaf springs are almost flat and the pin holes are inserted with snap pins.

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

2.5 Inspection on Load Condition

After the busduct installation, increase of load is expected. An inspection has to be carried out to ensure that the total connected load does not exceed the rated current of the busduct before the load is increased.

2.6 Measurement of Insulation Resistance

Measure the insulation resistance between each conductor and between conductor and housing. When the measurement is carried out, the electrical loads and connected equipment shall be disconnected.

2.7 Inspection on Rust or Peeling of Paint on Busduct Housing

If there are sign of peeling paint or rust on the busduct housing, cleaning work and touch-up painting are recommended.

The metal housing /enclosure of busduct must not be dismantled by any parties without the official authorization from themanufacturer for any purposes. Any violation or abuse will result the respective party to be responsible for all the consequences and compensation. Furthermore, the manufacturer reserves the right to void the warranty if any proof of violation or any sign of abuse is found.

Snap Pin.

Leaf Spring.

High Tensile Joint Bolt.

Busduct Joint Section


Commercial

Public Utility

Residential

Industrial

Project Country

Empire Gallery, Subang

Maxis HQ Tower, Kuala Lumpur

Genting First World Hotel, Genting Highlands

Sungai Buloh Hospital, Selangor

Four Point Hotel by Sheraton, Kuching

Asia City Shopping Mall, Kota Kinabalu

Sunway Pyramid Shopping Mall, Selangor

Pusat Perubatan Universiti Malaya, Kuala Lumpur

MEMC Solar Water Plant, Kuching

KSL Mixed Development - Shopping Mall, Hotel &

Office Towers, Johor Bahru

Penang Time Square

Nippon Electric Glass (NEG), Shah Alam

Miyazu Proton city, Perak

OCBC HQ, Kuala Lumpur

Mid Valley City, Kuala Lumpur

Bank Negara, Kuala Lumpur

Grand Hyatt Hotel, Kuala Lumpur

Singtel Data Centre, Singapore

Resort World Sentosa

Renewable Energy Cororation (REC)

Soitec Water Plant

Civic, Cultural & Commercial Building at Rochester

(CCRC)

National Art Gallery

Oasis Hotel & Novena Specialist Centre,

Sinaran drive

DUKE NUS Graduate Medical School

Crown Plaza Hotel, Singapore Changi Airport

Wyeth Suaco, Manila

SMART Communications, Manilla

National Health Research Institute

Chi Mei Medical Centre

Kaoshiung Medical University Hospital

Charoenchai/Trasfor New Factory

Jakarta Eyes Centre, Jakarta

Exedy Indonesia

Indonesia Nippon Steel Pipe, West Java

Zaheen Spinning Mill

Rupashi Knit Wears Ltd

Maksuda Spinning Mill

TBC-Ball Beverage Can Factory, HCMC

Maple Tree Business City, HCMC

Malaysia

Malaysia

Malaysia

Malaysia

Malaysia

Malaysia

Malaysia

Malaysia

Malaysia

Malaysia

Malaysia

Malaysia

Malaysia

Malaysia

Malaysia

Malaysia

Malaysia

Singapore

Singapore

Singapore

Singapore

Singapore

Singapore

Singapore

Singapore

Singapore

Philippines

Philippines

Taiwan

Taiwan

Taiwan

Thailand

Indonesia

Indonesia

Indonesia

Bangladesh

Bangladesh

Bangladesh

Vietnam

Vietnam

PROJECT REFERENCE | 36

PROJECT REFERENCE

Sales & Marketing contact :

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

Lot 4, Block A, Jalan SS13/7Subang Jaya Industrial Estate47500 Subang JayaSelangor Darul Ehsan, MalaysiaTel: +603-5635 7088 Fax: +603-5635 6099Website: www.eita.com.my

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

FT(ES)@2012/08. All rights reserved.

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its ISO 9001:2008 Certification for Quality Management System