POWER DISTRIBUTION EQUIPMENT MANUFACTURING LLC

Advantages of Busduct Systems over Cables

 Busbar trunkings are functional, and flexible, can quickly accommodate changes in lines or extensions
 No additional ducting or piping is required.
 Can be expanded, changed, replaced and reused, according to needs and requirements, and installed in
any structure as it comes modular in nature.
 Easier to achieve load balancing.
 Joints can be done with ease.
 Individual floor metering can be achieved with the busbar rising system.
 Zero maintenance, low installation & operating costs, can be installed in as much shorter time frame. And
giving a much aesthetic and modern look.
 Comes in a metal housing.
 Voltage drop can be measured as the values are known in advance.
 Helps in space management, as the dimensions are compact.
 Reduces the number and sizes of the distribution panel.
 Low heat dissipation and transfer, higher short circuit withstand capacities, fire retardant and seismic
compliance systems.
 Power can be tapped off using plugin systems, not affecting the other working lines.
The State of the Art Manufacturing Unit at Dubai
Certified by Intertek for ISO 9001:2015, ISO 14001:2015, OHSAS 18001:2007
USP of The GuardeX by RR Busduct Systems
 Tested and certified by ASTA-UK for all type tests as per IEC 61439-1&6, IEC 60529 and our plant is
accredited with ASTA DIAMOND certification.
 Tested for fire resistance test for 4 hrs and flame propagation tests for 40 min
 Tested for Seismic Zone-5 as per IEEE 693
 Dielectric withstand up to 2.5kV for 1 minute (IEC requirement 2.2kV for 1 sec)
 Extruded aluminium epoxy coated housing passed for IK10 tests
 Fully automated polyester insulation machine help to reduced production time as well as ensure
high accuracy on level of insulation across entire busbar length.
 Self-piercing riveted design (no nut and bolts)
 Unique design of earth side plates (with cooling fins and of 5 mm thickness) to ensure better heat
dissipation.
 Double headed nuts ensure correct tightening of torque.
 Anti-rust hardware ensuring long life of system.
 Complete technical assistance throughout the project.
USP of The GuardeX by RR Busduct Systems
 Site measurement & Site Survey.
 Auto cad 2-D/3-D drawings
 Thermography test on actual load condition.
 Contact resistance test at site after joint installation.
 Delivery of site measure (last element) element within 4 working days from factory.
 Site supervision & site testing.
 Each element tested by CNC machine for routine test.
 In house temperature rise lab approved by ASTA (In case client desires to witness random selected
piece for factory test).
 Manufacturing unit certified by INTERTEK for quality management system ISO9001, Environment
ISO 14001 and Health and safety OSHAS 18001.
Specifications
 Compliance IEC 61439-6 & 1.
 Product Certification by ASTA-UK.
 Sandwich Construction.
 Copper Conductors – 800A to 6300A, with options of RYBN, RYBN+50%E, RYBNN, RYBN+100%
E, RYBNN+50%E
 Aluminum Conductors – 800A to 5000A, with options of RYB, RYBN, RYBNN.
 Extruded Aluminum Housing.
 IP 54 for plug-in holes section and IP65 as Standard/IP 67 on request for feeder sections
 Class-F Thermal Resistance Polyester Insulation
 Uni-block Joint with Shear off Nuts
 Plug-in Tap off up to 800A
 Fire Resistance up to 4 hours
 Seismic Compliance for Zone-5
Applications
 High raised buildings:
 Feeder between transformers to main distribution Tap off Box
panel boards,
 Distribution of energy to the floors by vertical Riser
application, Busbar
 Feeder to equipment's and panels at horizontal lines.
 Hospitality
 Feeder between transformers to main distribution
panel boards,
 Distribution of energy to the floors by vertical
application.
 Industrial plants: Feeder
 Feeder between transformers to main distribution Busbar
panel boards,
 Distribution of energy by vertical and horizontal
application
Design Feature
 Fully automated polyester insulation machine help to reduced production time as well as ensure
high accuracy on level of insulation across entire busbar length.

 Compact sandwich construction reduces impedance & voltage drop.

 Riveted epoxy coated enclosure (no nuts & bolts).

 Unique design of earth side plates (with cooling fins) ensure better heat dissipation.

 Heavy Joint side plates (5mm thick extruded aluminium) help in joint cooling.

 Double headed nuts ensure correct tightening of torque.

 Anti rust hardware ensure long life of system.

Advantages of Busway Systems
 RR Bus trunking system is less in weight due to extruded aluminum housing and easy to install as compare
with cable.
 Scope for future expansion, changes, replacement.
 Modern aesthetic look.
 Low installation cost.
 Conductors fabricated form high strength 100% conductivity [IACS] Copper / 61% [IACS] Aluminum.
 Better overload capacity –All insulation materials used in BBT are Class F (155°C), while cable is generally
rated at 95°C.
 Excellent Heat Dissipation due to innovative design & Aluminum housing.
 Better voltage regulations.
 Zero electromagnetic interference on Data System.
 Designed to operate +50°C ambient.
 No Chimney effect because of compact construction, 4 hours Fire rating.
 Robust structure, higher short circuit withstands capacities.
 Cables are subjected to damage during mishandling resulting in Insulation damage and finally resulting into
short circuit whereas RR Bus bar trunking is rigid & compact to withstand such mishandling and designed to
handle mechanical loads as per IEC.
Advantages of Polyester over Epoxy Insulation
 Epoxy coating is single layer insulation on the Busduct application.
 Procedure is subject to lot of variables (temperature of curing, consistency of thickness etc..), have definite
chances of pin holes or weak points, leading to failure after use over time on when operated at full capacity.
 The chances of failure due to pin holes in the multi-layered polyester sheet (Class – F, 155 °C) is totally
eliminated.
 Epoxy insulation for bends and tees are more prone to pin holes which is very difficult to control. Such
element has to be insulated with polyester sheet even if the system is insulated.
 Due to load fluctuations, there is an expansion & contraction of conductor because of relative movement of
conductor with regard to epoxy coated layer, small but continuous rubbing action takes place, hence a 100%
fail proof system is not guaranteed.
 System with multilayered polyester will have a definite longer life as it can work satisfactorily with two
layers.
 The break down voltage of epoxy insulation is in the range of 10kV whereas the polyester film has greater
breakdown voltage in the range of 20kV / layer.
 Dielectric strength of polyester is larger than the epoxy insulation, 3kV in epoxy as compared to 5kV with
polyester insulation.
 For round edged conductors, to maintain uniform minimum thickness at the edges is very difficult with
epoxy insulation, resulting in failures.
 List of Type Tests
Characteristic Verified Clause / Sub Clause
Resistance to corrosion 10.2.2
Thermal stability 10.2.3.1
Resistance of insulating materials to normal heat 10.2.3.2
Resistance to ultra-violet (UV) radiation 10.2.4
Lifting 10.2.5
Mechanical impact 10.2.6
Marking 10.2.7
Degree of protection of enclosures 10.3
Clearances & creepage distances 10.4
Effective continuity between the exposed conductive parts of the BTS and protective circuit 10.5.2
Effectiveness of the assembly of the BTS for external faults 10.5.3
Power-frequency withstand voltage 10.9.2
Impulse withstand voltage 10.9.3
Temperature rise limits 10.10
Short-circuit withstand strength 10.11
Electromagnetic compatibility (EMC) 10.12 + Annex J
Mechanical operation 10.13
Ability to withstand mechanical loads 10.2.101
Thermal cycling test 10.2.102
Resistance to flame propagation 10.101
Fire resistance in building penetration 10.102
Seismic test for zone 5 IEEE693
Rating Chart
Copper Aluminum
Overall Overall
Rating Bus bar CSA Rating Bus bar CSA
STACKS Dimensions STACKS Dimensions
(Amps) (mm) (mm2) (Amps) (mm) (mm2)
(mm) (mm)
800 50 x 6 1 300 110 x 140 800 60 x 6 1 360 120 x140
1000 60 x 6 1 360 120 x 140 1000 80 x 6 1 480 140 x 140
1250 70 x 6 1 420 130 x 140 1250 110 x 6 1 660 170 x140
1600 100 x 6 1 600 160 x 140 1600 150 x 6 1 900 210 x 140
2000 125 x 6 1 900 210 x 140 2000 200 x 6 1 1200 260 x 140
2500 2 x 80 x 6 2 960 310 x 140 2500 2 x 125 x 6 2 1500 400 x 140
3200 2 x 110 x 6 2 1320 370 x 140 3200 2 x 150 x 6 2 1800 450 x 140
4000 2 x 150 x 6 2 1800 450 x 140 4000 2 x 200 x 6 2 2400 550 x 140
5000 2 x 200 x 6 2 2400 550 x 140 5000 3 x 200 x 6 3 3600 840 x 140
6300 3 x 150 x 6 3 2700 690 x 140
Advantages of Aluminum over G.I. Enclosure

Aluminum
Properties G. I. Housing Remarks
Housing

Magnetic Non Magnetic Magnetic Aluminum is better

Eddy current/
Less More Aluminum is better
hysteresis losses

Temperature Rise less More Aluminum is better

Low, good
High, not good
Impedance enough for Aluminum is better
for earthing
earthing
Aluminum has approximately
Weight Less More
1/3rd the density of steel,
Bus Bar Elements

Combination Elbow Panel Flange

Edge Offset Elbow

Flat Offset Elbow
Busbar Manufacturing Process

• Copper Conductor
• Al Conductor
Store

• Cut Size as per

CNC Busbar Element Design
Cutting M/c BUSBAR PUNCHING & CUTTING MACHINE

• Bending For
Feeder Length
CNC Busbar • Bending for Panel
Bending M/c Flange & Elbows
BUSBAR BENDING MACHINE
Automated Busbar Insulation Wrapping
• Polyester Sheet
• Nomex Paper
Store

• Cut Size as per

CNC Element Design
Insulation
Cutting
m/c

• Bending For
Feeder Length
Insulation • Bending for Panel
Wrapping Flange & Elbows
Busbar Assembly CNC Riveting Machine

• Housing
Busbar • Conductors
Assembly

• CNC Automatic
Riveting of Busbar
CNC Busbar Assembly
Riveting M/c
Busbar CNC Di Electric & Insulation Testing Machine

• CNC Di Electric
Di Electric Test Machine
Test

• CNC Insulation
Insulation Test Machine
Test
Temperature Rise Test facility up to 6300A
(Approved by ASTA- Intertek)

The temperature rise test ensure the safety and reliability of the bus trunking components
like insulation, busbar supports………

The bus trunking system is loaded to its rated current till the temperature of BBT is
stabilized , normally it takes 4~ 6 hrs. for stabilization of temperature.
Verification of Resistance to Flame Propagation
Application of flame for 40 minute on assembled BBT has met the following condition:
• BBT didn’t ignite.
• The maximum extent of the charred portion (external or internal)of the BBT was under 2.5 m
from the bottom edge of the burner.
Verification of Fire Resistance in Building Penetration
The test ensures that NO FIRE spread through bus trunking in case of fire in building.
The duration for fire resistance is 240 minute.
Support & Services

 Complete technical assistance throughout the projects.

 Site measurement & Site Survey.

 Training for designer and contractor.

 Auto cad 2-D/3-D drawings.

 Site measure (last elements) pieces delivery within four working days.

 Site testing.

 Thermography test on actual load condition.