Power Distribution Solutions

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

 Power Distribution Solutions

VISION

Be the most trusted solution provider in the electrical and

electronic technologies.

MISSION

Energizing industry through advanced technology.

VALUES
l Integrity
l Commitment
l Team Work
l Continuous Learning
Environment Sustainability

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 Power Distribution Solutions

Preface 4
Why Godrej S.M.A.R.T busduct system? 5
Joint Construction 6
Construction Features 7
Elements of the IP (Ingress Protection) and their meanings 8
Technical features 9
Calculations to be Considered 10
The selection of Godrej S.M.A.R.T. Busduct system according to the voltage drop. 11
Impedance 12
Typical Rising Mains 13
Configuration of the Godrej S.M.A.R.T Busduct system 14
A Typical Busduct and rising mains layout describing all the components 15
Single bolt jointing mechanism 16
Copper / Aluminum Content and weight 16
Flange End busbar to busbar Dimensions 17
Busbar Flange End Connection Holes 17
Flange End Conductor Dimensions 18
Dimensions for Horizontal Hanger 19
Flange end dimensions 19
Special Flange End to Suit Various Requirements 20
Wall flange dimensions 21
Standard products 22
Horizontal Supports 25
Expansion Joints 25
Flexible jumpers 26
Tap off boxes 27
End feed units 27
Flexible rubber bellows 27
Vertical spring hangers 28
Vertical fixed hangers 29
Test Certificates 30
How to select the busduct trunking system. 38

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 Power Dis Solu ns

PREFACE
Electrical power supply has increased dramatically over the years, due to its high demand in the
industrial sector,which is based on the rapid global economic growth. It was justified by the increase
of projects in the industries such as highrise office buildings / complexes / factories, which required
more elevators, cooling & heating, water treatment system, machineries, etc.

The cable system has dominated the electrical power distribution market for years, but however,
busduct system is widely being used in the recent years due to high reported fire cases. Besides,
there is limited flexibility for cable installation whereby it may have difficulty for future expansion and it
needs more attention during the maintenance period.

Hence, electrical equipment such as busduct systems have been highly recommended in the
electrical installation of high rise buildings, factories, industry plants, etc. The busduct system
provides huge advantages and outstanding features in an electrical installation system, whereby it
occupies a small space due to its compactness at the same time capable of carrying large current.

It is also able to distribute the electricity easily through its plug-in (tap-off) design with an advantage of
fire-stop ability and its aesthetic looks. We at Godrej & Boyce Mfg. Co. Ltd. are serving the Indian
Market for over 118 years, Godrej & Boyce Mfg. Co. Ltd. offers a high-tech and
S.M.A.R.T.BUSDUCTS to cater the rapid growth globally in the electricalsegment. With over300
installations worldwide, Godrej & Boyce Mfg.Co. Ltd. has become the leading pioneers in
sandwiched busduct systems, rising mains and lighting trunking solution provider.

Rising mains, bus ducts aremanufactured in the state of the art manufacturing facility of Godrej &
Boyce Mfg. Co. Ltd. and serviced by ourteam ofexperienced Engineers.

The Godrej S.M.A.R.T. BUSDUCT SYSTEM designed for power transport and distribution and is
especially suitable in the electrical panel room both as a transformer to switchboard or switchboard to
switchboard connection and as the main power distribution system for industrial, commercial and
service industry.

The Godrej S.M.A.R.T. busduct trunking system isbeing offered both in Copper and Aluminum
Conductors up to 6300A and 5000A respectively.

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

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

S – SANDWICH
Godrej S.M.A.R.T. BUSDUCTSYSTEM is a Sandwich design which is compact in size. This technology
guarantees the product's high performance in relation to voltage drop values for high current and long length
runs.

M – MODULAR
Godrej S.M.A.R.T. BUSDUCT SYSTEM is modular in design which reduces the installation time to a bare
minimum.Being compact in design the busducts require less space for installation.

A – AESTHETIC
Godrej S.M.A.R.T. BUSDUCT SYSTEM is aesthetic in nature because of its sleek powder coated housings and
with a complete set of accessories enables the busduct to be laid as per the site conditions, as against cables
which require a large bending radius.

R – RELIABLE
Godrej S.M.A.R.T. BUSDUCT SYSTEM is subjected to stringent quality checks at various stages of
manufacturing as per international quality standards.

T – TESTED
GODREJ S.M.A.R.T BUSDUCT SYSTEM is fully tested and verified at the “Central Power Research
Institute”(CPRI) as per IEC 60439 Part 1 & 2.

Hence Godrej S.M.A.R.T BUSDUCT SYSTEM is highly reliable, safe, and compact for delivering large currents
in the electrical system.

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CONSTRUCTION FEATURES

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

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

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

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

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

l Accessories
A wide range of accessories are available to suit the busduct run along the required path. Which are but not
limited to, Vertical or Horizontal Elbows, Combination Elbows, Vertical or Horizontal Offset Elbows, reducers,
Expansion Joints, etc…

Also we provide feeders with plugin holes, and Tap-Off boxes to tap out supply. End feed units, Electrical
panels can be provided on request.

l Simple to Install with Less Cost

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

l Compact & Lightweight

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

l Ingress of Protection (IP).

The housing is totally enclosed with its fully insulated conductor to provide dust, water & insect protection, as
according to IEC 60529 standards. Thus the degree of protection shall be min. IP 54 and up to max of IP68,
which is widely applicable to power plants, petrochemical, LNG, oil & gas plants.

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Elements of the IP (Ingress Protection) and their meanings

– Reference IEC 60529 clause 4.2 page 21

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TECHNICAL FEATURES

l Short Circuit Strength

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

l Low Voltage Drop

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

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

l Fire Stop System

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

l Standards and Configuration

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

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

l Service Condition
Temperature: -15° to 50°. Celsius

l Advantages
• Nominal rating guaranteed both for flat and edgewise installations (no de-rating)
• Protection degree guaranteed both for flat and edge-wise installation
• Maintenance free single bolt jointing system
• Customized design
• An engineering department at your disposal for site measurements, busduct run evaluations and
electrical equipment connection study (panel, transformer etc…)

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

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

Where
P power which is total of the connected load (kW)
F load factor (diversity factor)
Ue Operating Voltage

Example: Requirement for an industrial unit catering to 18 terminals, and a single terminal of 150kW,
Voltage is of 440V and considering the value of Cosφ to be 0 .95

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

After considering a 20% margin for safety

2984 + 20% = 3580A

Therefore the Godrej S.M.A.R.T. busduct of 4000A rating either in Aluminum or Copper can be used.
Voltage Drop Calculation:-
Voltage drop formula according to IEC 60439 – 2 – page # 47, Annex: J
The voltage drop of the busbar trunking system can be calculated using the followingformulae:

Where u – composite voltage drop of the system (V)

k – Load distribution factor
IB – Current of the circuit being considered (A)
R1 – Mean resistance of the system ( /m)
X1 – mean reactance of the system ( /m)
L – Length of the system being considered (m)
Cos – Load power factor

The load distribution factor could be suitably selected from any of the 3 values below

a) k = 1 – If the load is concentrated at the end of the busbar trunking run.

b) – If the load is uniformly spread between “n” branches.
c) The load distribution factor “k” to calculate the voltage drop of a branch situated at a distance “d” from the origin

of the busbar trunking run is taken as equal to in case of loads spread uniformly along the
length “L” of the busbar trunking run.

Cosφ 0.75 0.8

80 0.85 0.90 0.95
0 1.00
Sinφ 0.66 0.6
60 0.53 0.44 0
0.31 0.00

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The selection of Godrej S.M.A.R.T. Busduct system according to the voltage drop.

Voltage Drop chart

For 3-phase alternating current of voltage drop per 100 meter of Copper and Aluminum are as under.
Unit : volt/100m
Vo
oltage Drop 3ø
3 50Hz Voltage Drop
D 3ø 60Hzz
Ampere
A Busbar Sizes
Power Facctor Poweer Factor
R
Rating (mm)
1.00 0.95 0.90 0.85 0.80 0.75 1.00 0.95 0.90
0 0.85 0.8
80 0.75
400 One – 5 x 50 4.95 5.3
32 5.31 5
5.24 5.14 5.01 4.97 5.46 5.50
0 5.47 5..39 5.29

630 One – 5 x 60 7.59 7.9

94 7.84 7
7.67 7.46 7.23 7.64 8.16 8.13
3 8.02 7..85 7.64

800 One – 6 x 60 8.94 9.4

42 9.34 9
9.16 8.93 8.66 8.99 9.67 9.67
7 9.55 9..36 9.14

1000 One – 6 x 75 8.83 9.3

30 9.22 9
9.04 8.81 8.55 8.90 9.57 9.56
6 9.44 9..25 9.03

1250 One – 6 x 100 8.72 9.1

12 9.01 8
8.82 8.58 8.31 8.77 9.38 9.35
5 9.22 9..03 8.80

1600 One – 6 x 140 7.59 7.9

96 7.87 7
7.71 7.50 7.27 7.68 8.21 8.19
9 8.07 7..90 7.70
COPPER

2000 One – 6 x 175 7.59 8.0

03 7.98 7
7.84 7.65 7.43 7.69 8.33 8.36
6 8.27 8..13 7.94

2500 One – 6 x 240 6.71 7.2

25 7.27 7
7.19 7.06 6.90 6.84 7.54 7.61
1 7.57 7..47 7.34

3200 T
Two – 6 x 140 7.37 7.8
85 7.82 7
7.70 7.53 7.32 7.59 8.25 8.28
8 8.21 8..07 7.89

3600 T
Two – 6 x 175 6.55 7.0
00 6.98 6
6.87 6.73 6.55 6.79 7.43 7.48
8 7.43 7..32 7.18

4000 T
Two – 6 x 185 6.86 7.2
29 7.26 7
7.14 6.98 6.79 7.14 7.77 7.81
1 7.74 7..62 7.46

4500 T
Three – 6 x 140 6.94 7.3
32 7.26 7
7.13 6.95 6.75 7.09 7.74 7.78
8 7.71 7..59 7.43

5000 T
Three – 6 x 175 6.50 6.9
93 6.90 6
6.80 6.65 6.48 6.75 7.31 7.33
3 7.25 7..12 6.96

6300 T
Three – 6 x 185 7.42 7.8
87 7.82 7
7.69 7.51 7.30 7.64 8.24 8.25
5 8.16 8..01 7.82

Unit : volt/100m
Vooltage Drop 3ø
3 50Hz Voltage Drop
D 3ø 60Hzz
Ampere
A Busbar Sizes
Power Facctor Poweer Factor
R
Rating (mm)
1.00 0.95 0.90 0.85 0.80 0.75 1.00 0.95 0.900 0.85 0.8 80 0.75
400 O – 5 x 60
One 8.24 8.40
0 8.21 7..97 7.69 7.39 8.27 8.54 8.40 8.19 7.9
94 7.66

630 O – 6 x 60
One 12.28 12.38 12.05 11
1.65 11.20 10.73 12.31 12.59 12.33
3 11.97 11.57 11.13

800 O – 6 x 75
One 10.88 11.0
06 10.80 10
0.46 10.09 9.69 10.90 11.25 11.06
6 10.77 10.4
44 10.07

1000 O – 6 x 100
One 10.95 11.19 10.95 10
0.64 10.27 9.88 11.02 11.41 11.23
3 10.95 10.62 10.26

1250 O – 6 x 140
One 8.53 8.91
1 8.81 8..62 8.38 8.12 8.60 9.19 9.16 9.03 8.8
84 8.61

1600 O – 6 x 185
One 7.65 8.00
0 7.91 7..74 7.53 7.29 7.70 8.23 8.20 8.08 7.9
91 7.70
ALUMINUM

2000 O – 6 x 240
One 7.72 8.06
6 7.96 7..79 7.57 7.33 7.83 8.25 8.18 8.02 7.8
82 7.59

2500 T
Two – 6 x 140 7.49 7.87
7 7.80 7..64 7.45 7.22 7.58 8.10 8.08 7.97 7.8
80 7.60

3200 T
Two – 6 x 175 7.43 7.83
3 7.77 7..63 7.44 7.22 7.59 8.18 8.19 8.09 7.9
94 7.75

3600 T
Two – 6 x 185 6.97 7.21
1 7.09 6..92 6.70 6.47 7.15 7.53 7.47 7.33 7.1
14 6.93

4000 T
Two – 6 x 240 7.14 7.36
6 7.24 7..05 6.83 6.59 7.34 7.63 7.52 7.34 7.1
12 6.88

4500 Th
hree – 6 x 175 7.01 7.17
7 7.03 6..82 6.59 6.34 7.17 7.40 7.27 7.08 6.8
86 6.62

5000 Th
hree – 6 x 220 7.18 7.14
4 8.92 5..84 8.34 8.06 7.48 7.40 7.22 5.97 6.5
58 6.38

5500 Th
hree – 6 x 240 7.24 7.22
2 7.01 6..70 8.48 8.19 8.19 8.20 7.98 7.56 7.5
50 7.03

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Impedance

The values of impedance of Copper and Aluminum for 3 phase alternating current are mentioned under
(Unit: 10-5Ω/m)

3ø 50H
Hz 3ø 60Hz
Ampere
A Busbar Sizes
R
Rating (mm)
R1 X1 R12 + X 12 R1 X1 R12 + X 12
400 O – 5 x 50
One 7.15 2.83 7.69
9 7.1
18 3
3.40 7.94
630 O – 5 x 60
One 6.96 2.12 7.28
8 7.0
00 2
2.65 7.48
800 O – 6 x 60
One 6.45 2.14 6.80
0 6.4
49 2
2.61 7.00
1000 O – 6 x 75
One 5.10 1.68 5.37
7 5.1
14 2
2.05 5.53
1250 O – 6 x 100
One 4.03 1.23 4.21
1 4.0
05 1.55 4.34
1600 O – 6 x 140
One 2.74 0.86 2.87
7 2.7
77 1.06 2.97
COPPER

2000 O – 6 x 185
One 2.19 0.76 2.32
2 2.2
22 0
0.95 2.41
2500 O – 6 x 240
One 1.55 0.65 1.68
8 1.5
58 0
0.77 1.76
3200 T
Two – 6 x 140 1.33 0.49 1.42
2 1.3
37 0
0.60 1.50
3600 T
Two – 6 x 175 1.08 0.41 1.16
6 1.1
12 0
0.52 1.23
4000 T
Two – 6 x 185 0.99 0.36 1.05
5 1.0
03 0
0.46 1.13
4500 Th
hree – 6 x 140 0.89 0.30 0.94
4 0.9
91 0
0.41 1.00
5000 Th
hree – 6 x 175 0.75 0.28 0.80
0 0.7
78 0
0.33 0.85
6300 Th
hree – 6 x 185 0.68 0.24 0.72
2 0.7
70 0
0.29 0.76

(Unit: 10-5Ω/m)

3ø 50H
Hz 3ø 60Hz
Ampere
A Busbar Sizes
R
Rating (mm)
R1 X1 R12 + X 12 R1 X1 R12 + X 12
400 O – 5 x 50
One 11.90 2.63 12.19
9 11.94 3
3.17 12.35
630 O – 5 x 60
One 11.25 2.11 11.45 11.28 2
2.63 11.58
800 O – 6 x 60
One 7.85 1.67 8.03
3 7.8
87 2
2.06 8.14
1000 O – 6 x 75
One 6.32 1.46 6.49
9 6.3
36 1.74 6.59
1250 O – 6 x 100
One 3.94 1.20 4.12
2 3.9
97 1.51 4.25
1600 O – 6 x 140
One 2.76 0.85 2.89
9 2.7
78 1.05 2.97
ALUMINIUM

2000 O – 6 x 240
One 2.23 0.67 2.33
3 2.2
26 0
0.75 2.38
2500 Two – 6 x 140 1.73 0.56 1.82
2 1.7
75 0
0.67 1.87
3200 T
Two – 6 x 175 1.34 0.45 1.41
1 1.3
37 0
0.56 1.48
3600 T
Two – 6 x 185 1.15 0.31 1.19
9 1.1
18 0
0.39 1.24
4000 T
Two – 6 x 240 1.03 0.27 1.06
6 1.0
06 0
0.30 1.10
4500 Th
hree – 6 x 175 0.90 0.21 0.92
2 0.9
92 0
0.24 0.95
5000 Th
hree – 6 x 220 0.83 0.12 0.77
7 0.8
87 0
0.14 0.87
5500 Th
hree – 6 x 240 0.76 0.12 0.77
7 0.7
79 0
0.16 0.81

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Typical Rising Mains

End closure

Straight Feeder with

Plug in hole to mount the Tap off Box

External Fire Barrier

Single Bolt Joint Mechanism

Tap off Box

Vertical Fixed Hanger

Wall clamp

End Feed Unit

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

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

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

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

Expansion
Joint

Vertiical
Elboww

End
d Spring
Clossure Hanger

Tap Off
Red
ducer Box

Straaight
Fixed
Feeeder
Hanger

Horizontal
Support

Horizontal
Elbow

Vertical
Offset
Elbow

“T” Elbow

A Typical Busduct and rising mains layout describing all the components

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SINGLE JOINT BOLT MECHANISM

Co
opper Conteent & Weigh
ht Aluminium Content & weight
Width (W) Width (W)
Rating Busduct Weight Kg/m
K Rating Busduct Weight Kg/m
m
mm mm
in in
Amps Height Conductorr size Amps Height Conductor sizee -
Tyype 3PH 4W
W 3PH 4W
W Type 3PH 4W 3PH 4W
mm – mm mm mm
400 115 One – 5 x 50 25 400 125 One – 5x60 22
630 125 One – 5 x 60 27 630 125 One – 6 x 60 24
800 125 One – 6 x 60 30 800 140 One – 6 x 75 28
10000 140 One – 6 x 75 32 1000 165 Fig. 1 One 6 x 100 34
Figg. 1
12500 165 One – 6 x 100 43 1250 205 One – 6 x 1400 39
16000 205 One – 6 x 140 50 1600 250 One – 6 x 1855 46
20000 240 One – 6 x 175 62 2000 305 One – 6 x 2400 54
125 125
25000 305 One – 6 x 240 80 2500 405 Two – 6 x 1400 59
32000 405 Two – 6 x 140 93 3200 475 Two – 6 x 1755 74
Fig. 2
36000 475 Figg. 2 Two – 6 x 175 114 3600 495 Two – 6 x 1855 65
40000 495 Two – 6 x 185 123 4000 605 Two – 6 x 2400 85
45000 605 Three – 6 x 140 140 4500 710 Three – 6 x 175 89
50000 710 Fig.3 Three – 6 x 175 171 5000 845 Fig. 3 Three – 6 x 22 0 95
63000 740 Three – 6 x 185 179 5500 905 Three – 6 x 24 0 100

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Flangee End Busbarr to Busbar Dimensions

D
Ampe ere Copp
per Width Fig. 1 Fig. 2 Amperre Alum
minum
Housing H
Housing
Ratin
ng (mm) 3P 3W (W) 3P 4W (WW) Ratingg Widthh (mm)
4000 One
e – 5 x 50 115 400 One – 5 x 60 125
6300 One
e – 5 x 60 125 630 One – 6 x 60 125
8000 One
e – 6 x 60 125 800 One – 6 x 75 140
1000 One
e – 6 x 75 140 1000
0 One – 6 x 100 165
100 100
1250 One – 6 x 100 165 1250
0 One – 6 x 140 205
1600 One – 6 x 140 205 1600
0 One – 6 x 185 250
2000 One – 6 x 175 240
2000
0 One – 6 x 240 305
2500 One – 6 x 240 305
3200 Two – 6 x 140 405 2500
0 Two – 6 x 140 405
3600 Two – 6 x 175 475 3200
0 Two – 6 x 175 475
4000 Two – 6 x 185 495 3600
0 Two – 6 x 185 495
4500 Three
e – 6 x 140 605 130 130 4000
0 Two – 6 x 240 605
5000 Three
e – 6 x 175 710 4500
0 Three – 6 x 175 710
5000
0 Three – 6 x 220 845
6300 Three
e – 6 x 185 740
5500
0 Three – 6 x 240 905

Busb
bar Flange End
d Connection
n Holes
Ampeere Copper Width – Amperre Aluminum
Housing Type Type Housing
Ratin
ng W (mm) Ratingg Width – W (mm)
4000 Onee – 5 x 50 115 400 One – 5 x 60 125
6300 Onee – 5 x 60 125 Fig. 1 630 One – 6 x 60 125
Fig. 1
8000 Onee – 6 x 60 125 800 One – 6 x 75 140
1000 Onee – 6 x 75 140 Fig. 2 10000 One – 6 x 100 165
1250 One – 6 x 100 165 Fig. 2 Fig. 3 12500 One – 6 x 140 205
1600 One – 6 x 140 205 Fig. 3 Fig. 4 16000 One – 6 x 185 250
2000 One – 6 x 175 240 Fig. 4
Fig. 5 20000 One – 6 x 240 305
2500 One – 6 x 240 305 Fig. 5
3200 Two – 6 x 140 405 Fig. 3 Fig. 3 25000 Two – 6 x 140 405
3600 Two – 6 x 175 475 32000 Two – 6 x 175 475
Fig. 4 Fig. 4
4000 Two – 6 x 185 495 36000 Two – 6 x 185 495
4500 Threee – 6 x 140 605 Fig. 3 Fig. 5 40000 Two – 6 x 240 605
5000 Threee – 6 x 175 710 Fig. 4 45000 Three – 6 x 175 710
Fig. 4 Fig. 5 50000 Three – 6 x 220 845
6300 Threee – 6 x 185 740
Fig. 5 55000 Three – 6 x 240 905

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Flangge End Condu

uctor Dimenssions
Ampeere Coppper Width Amperre Alumminum
Housing Tyype Housing
Ratin
ng “W
W” (mm) Ratingg Width “W”
“ (mm)
4000 Onee – 5 x 50 115 400 One – 5 x 60 125
6300 Onee – 5 x 60 125 630 One – 6 x 60 125
8000 Onee – 6 x 60 125 800 One – 6 x 75 140
1000 Onee – 6 x 75 140 10000 One – 6 x 100 165
Fig. 1
1250 One – 6 x 100 165 12500 One – 6 x 140 205
1600 One – 6 x 140 205 16000 One – 6 x 185 250
2000 One – 6 x 175 240
20000 One – 6 x 240 305
2500 One – 6 x 240 305
3200 Two – 6 x 140 405 25000 Two – 6 x 140 405
3600 Two – 6 x 175 475 32000 Two – 6 x 175 475
Fig. 2
36000 Two – 6 x 185 495
4000 Two – 6 x 185 495
40000 Two – 6 x 240 605
4500 Threee – 6 x 140 605 45000 Three – 6 x 175 710
5000 Threee – 6 x 175 710 Fig. 3 50000 Three – 6 x 220 845
6300 Threee – 6 x 185 740 55000 Three – 6 x 240 905

Dimeensions for Horizontal Han

nger
Ampeere Coppper Width Height Widtth “A” Amperre Alum
minum Height
H
Ratin
ng (mm) “W” 3P 3W 3P 4W Ratingg Width
h (mm) “W”
4000 Onee – 5 x 50 115 400 One – 5 x 60 125
6300 Onee – 5 x 60 125 630 One – 6 x 60 125
8000 Onee – 6 x 60 125 800 One – 6 x 75 140
1000 Onee – 6 x 75 140 1000
0 One – 6 x 100 165
1250 One – 6 x 100 165 1250
0 One – 6 x 140 205
1600 One – 6 x 140 205 1600
0 One – 6 x 185 250
2000 One – 6 x 175 240 2000
0 One – 6 x 240 305
105 125
2500 One – 6 x 240 305 2500
0 Two – 6 x 140 405
3200 Two – 6 x 140 405 3200
0 Two – 6 x 175 475
3600 Two – 6 x 175 475 3600
0 Two – 6 x 185 495
4000 Two – 6 x 185 495 4000
0 Two – 6 x 240 605
4500 Threee – 6 x 140 605 4500
0 Three – 6 x 175 710
5000 Threee – 6 x 175 710 5000
0 Three – 6 x 220 845
6300 Threee – 6 x 185 740 5500
0 Three – 6 x 240 905

17
 Power Distribution Solutions

Flangge End Dimennsions

Copper Aluminum
A
Ampeere 3P 3W
W 3P 4W
W Ampere 3P 3W 3P 4W
“B” Type “B” Type
Ratin
ng “A” “A” Rating “A” “A”
4000 175 400 185
6300 185 630 185
8000 185 800 200
1000 200 1000 225
3500 450 Fig. 1 350 450 Fig. 1
1250 225 1250 265
1600 265 1600 310
2000 300
2000 365
2500 365
3200 465 2500 465
3600 535 Fig. 2 3200 535 Fig. 2
4000 555 3600 555
4500 4500 540 665 4000 450 540 665
5000 770 4500 770
Fig. 3 Fig. 3
5000 905
6300 800
5500 965

18
 Power Distribution Solutions

Special Flange End to Suit Equipment Requirements

19
 Power Distribution Solutions

Wall Flange Dimensions

Copper Aluminum
Ampe ere Wall Open ing Wall Opening Amp pere
Ratin
ng 3P 3W
W 3P 4W 3P P 4W 3P 3W Ratting
“A” “A” “B” “C” “C” “B” “A” “A
A”
400
0 190 250 260 200 40
00
630
0 200 260 260 200 63
30
800
0 200 260 275 215 80
00
1000 215 275 300 240 10
000
1250 240 300 340 280 1250
1600 280 340 385 325 16
600
2000 315 375
440 380 20
000
2500 180 200 380 440 1
180 200
3200 480 540 540 480 2500
3600 550 610 610 550 3200
630 570 3500
4000 570 630
740 680 40
000
4500 680 740 845 785 4500
5000 785 845 980 920 50
000
6300 815 875 1040 980 5500

20
 Power Distribution Solutions

DIMENSIONS OF THE STANDARD PRRODUCTS.

STR
RAIGHT FEED
DER
LENGTH (L
L) mm
RATIING
ST
TD MIN
400A – 1000A 30
000 500
1250A – 2000A 30
000 500
25000A 30
000 500
3200A – 4000A 30
000 500
5000A – 6300A 30
000 500

HORIIZONTAL EL BOW.
S x L (m
mm)
RATIING
STTD MIN
400A – 1000A 500 x 500 300 x 300
1250A – 2000A 500 x 500 300 x 300
25000A 500 x 500 300 x 300
3200A – 4000A 500 x 500 300 x 300
5000A – 6300A 500 x 500 300 x 300

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

FL
LANGE END
L
LENGTH (L) - (mm)
RATIN
NG
STD MIN
400A – 1 000A 500 300
1250A – 2000A
2 500 300
2500AA 500 300
3200A – 3600A
3 500 300
4000AA 500 300
5000A – 6300A
6 500 300

HOR RIZONTAL EL
LBOW WITH FLANGE EN
ND.
SxL
RATINNG
STDD MIN
400A – 10000A 500 x 500
5 300 x 300
1250A – 2000A
2 500 x 500
5 300 x 300
2500AA 500 x 500
5 300 x 300
3200A – 3600A
3 500 x 500
5 300 x 300
4000AA 500 x 500
5 300 x 300
5000A – 6300A
6 500 x 500
5 400 x 400

21
 Power Distribution Solutions

VERTICAL ELB
BOW WITH FL
LANGE END D.
S x L (mm
m)
RATINNG
STD
D MIN
400A – 12250A 500 x 500
5 350 x 350
1600AA 500 x 500
5 400 x 400
2000AA 500 x 500
5 450 x 450
2500AA 600 x 600
6 475 x 475
3200A – 3600A
3 700 x 700
7 550 x 550
5000A – 6300A
6 800 x 800
8 775 x 775

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

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

EXP
PANSION JO
OINT
SxL
RATI NG
STTD MIN
400A – 2000A
2 300 x 300 -
2500A – 3600A 500 x 500 -
4000A – 6300A 700 x 700 -

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

22
 Power Distribution Solutions

HORIZONT
TAL OFFSET T ELBOW
S x L1 x L2
L
RATINNG
STDD MIN
400A – 2000A
2 500 x 500
0 x 500 30
00 x 250 x 30
00
2500A – 3600A
3 500 x 500
0 x 500 30
00 x 250 x 30
00
4000A – 6300A
6 500 x 500
0 x 500 30
00 x 250 x 30
00

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

23
 Power Distribution Solutions

Horizontal Support

JOINT SECTION
SUPPORT HANGER

LOAD
1.5 m 1.5 m
SUPPLY
NOTE :-
SUPPORT HANGERS SHOULD NOT BE INSTALLED OVER A JOINT SECTION
ELBOWS, TO BE SUPPORTED SEPARATELY.

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

Support Hanger Load

ding
Screw Thread
Am
mpere Rating Steel Anglee Size (mm) Weight (kg/m)
on Rod in mm
m

4 – 1250A
400 40 x 40 x 5 (Thick) M 12 3.00

16
600 – 2500A 50 x 50 x 5 (Thick) M 12 3.80

25
500 – 6300A 65 x 65 x 5 (Thick) M 12 4.90

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

24
 Power Distribution Solutions

Flexible Conductor / Jumpers

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

Dimensions of Flexible conductors / Jumpers

Co
opper Conducctor Alumin
numConducto
or
Ampere Rating Type Conducttor Width Conductor Width
W Type Ampere Rating
4
400 One – 5 x 50 One – 5 x 60 400
630 One – 5 x 60 One – 6 x 60 Fig. 1 630
Fig. 1
800 One – 6 x 60 One – 6 x 75 800
10
000 One – 6 x 75 One – 6 x 100 Fig. 2 10000
12
250 Fig. 2 One – 6 x 100 One – 6 x 140 Fig. 3 12550
16
600 Fig. 3 One – 6 x 140 One – 6 x 185 Fig. 4 16000
20
000 Fig. 4 One – 6 x 175 One – 6 x 240 Fig. 5 20000
25
500 Fig. 5 One – 6 x 240 Two – 6 x 140 Fig. 3 25000
32
200 Fig. 3 Two – 6 x 140 Two – 6 x 175 32000
Fig. 4
36
600 Two – 6 x 175 Two – 6 x 185 35000
Fig. 4
40
000 Two – 6 x 185 Two – 6 x 240 Fig. 5 40000
45
500 Fig. 3 Three – 6 x 140 Three – 6 x 175 Fig. 4 45000
50
000 Three – 6 x 175 Three – 6 x 220 Fig. 5 50000
Fig. 4
63
300 Three – 6 x 185 Three – 6 x 240 Fig. 5 55000

25
 Power Distribution Solutions

Tap – Off – Boxes

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

Cu
urrent D W H
Raating mm
m mm mm
32A – 100A 250 250 450
125AA – 250A 275 300 600
320AA – 400A 325 325 750

End Feed Unit

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

D W H
m
mm mm mm
630A
6 550 350 1000
1
8
800A 50 400 1200
1
10
000A 550 400 1200
1
12
250A 50 450 1500
1

Flexible Rubber Bellow

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

26
 Power Distribution Solutions

Vertical Spring Hangers

205

125

40
25
StudBolt 60 Bolt/Nut
(M12X250) (M10x30)

30
65
"C"Channel

160

250
275
75

75

50
Floor min

25 15

50

FRONT VIEW SIDE VIEW

Vertical Spring Hanger (1250A – 3200A)

205

125

40
Stud Bolt
25
(M12X250) 60 Bolt/Nut
(M10x30)
30
65

"C"Channel
160

250
275

50
75

75

Floor min

25 15

50

FRONT VIEW SIDE VIEW

Vertical Spring Hanger (3600A – 6300A)

255

140

40
Stud Bolt
25
(M12X250) 60 Bolt/Nut
(M10x30)
30
65

"C"Channel
160

250
275

50
75

75

Floor min

25 15

50

FRONT VIEW SIDE VIEW

27
 Power Distribution Solutions

Vertical Fixed Hanger

Vertical Fixed Hanger (400A - 1000A)

205

125

40
Stud Bolt
25
(M12X110) Bolt/Nut
60
(M10x30)

30
50 65
"C"Channel

110
155
75

75

50
Floor min

25 15

50

FRONT VIEW SIDE VIEW

Vertical Fixed Hanger (1250A - 3200A)

205
125
40
Stud Bolt 25
(M12X110) 60 Bolt/Nut
(M10x30)
30
75 50 65

"C"Channel
110
155

75

Floor min
50

25 15
50

Vertical Hanger (3600A - 6300A)

255

140

40
Stud Bolt
25
(M12X110) Bolt/Nut
60
(M10x30)
30
65

"C"Channel
110
50
155

50
75

75

Floor min

25 15

50

28
 Power Distribution Solutions

29
 Power Distribution Solutions

30
Power Distribution Solutions
 Power Distribution Solutions

1
 Power Distribution Solutions

HOW TO SELECT THE BUSBAR TRUNKING SYSTEM

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

Ambient Conditio
ons Miniimum Protecttion
IP ______
degrree required
Indoor Insstallation Condductor material Al Cu
Outdoor Installation

Type of Bus Duct System

Minimum Ambient Indoor ____°C Feedder busduct frrom

Tempera ture
t Outdoor ____°C transsformer to paanel
Feedder busduct frrom
paneel to panel
Ambient temperature
t Indoor ____°C Feedder busduct frrom
(24hour daily
d average) Outdoor ____°C DG to
t panel
Risin
ng mains withh Plug
in Ho
oles for Tap Off
O
Units

Tota l Length m
Electtrical Data
Rated Currrent Amps Feedder m
Demand Current
C Amps Distrribution m
Risin
ng mains m

Flexible Jum
mper requirem
ments
Configuration 1PH 3 W Betw
ween busductt and
Yes No
3PH 3W paneel
3PH 4W Betw
ween busductt and
Yes No
3PH 5W transsformer
3PH 6W
Tap Off Boxees
Rated Opeerational V Empty
Voltage AC DC With
h MCCB
With
h MCCB and
Phase rateed short Enerrgy Meter
circuit witthstand kA (1s)
current Types of req
quired supporrts
Horizontal suppo rts
Vert ical Fixed Hanngers
Vert ical spring Haangers
 Power Distribution Solutions

Rising mains

If the busduct has a vertical rise, some further

information is nessary as requested under.

(F) Number of Floors

(S) Slab Thickness
(D) Distance between the Slabs
(N) Number of Tap Off Boxes for each Floor
and power of each (kW)
(P) Tap Off Boxes position on each floor

Isometric document for Busduct system run

sketch

Please draw the busduct run with the related

dimensions on the graph given below.
Power Distribution Solutions
 Power Distribution Solutions

Airports Railways
Oil and Gas Sector Banking Sector
Hotels Government Sector
Nuclear Power Plants IT Parks/Industries
Residential Complexes Telecom Industries
Automobile Sector Educational Institutes
 Power Distribution Solutions

Godrej & Boyce Mfg. Co. Ltd.

Power Distribution Solutions
Gate No. 4, Plant No. 1, Electricals & Electronics
Pirojshanagar, Vikhroli (West) Mumbai - 400 079.

Tel. : +91 (022) 6796 2291 / 2193 / 2293

Fax : +91 (022) 6796 1540
Email : puran@godrej.com, cyrusi@godrej.com, sangeeta@godrej.com, vijay@godrej.com
Mobile: +91-9820314328, +91-9769934787, + 91-9833032428, + 91-9820466577
Visit us at : www.godrej.com

Bangalore Chennai
Power Distribution Solutions Power Distribution Solutions,
Godrej & Boyce Mfg. Co. Ltd. Godrej & Boyce Mfg. Co. Ltd.
1, Sidco, Industrial Estate, Ambattur,
Karnataka Film Chamber of Commerce Bldg,
Chennai, 600 098.
1st, 2nd & 3rd Floor, No.28,
Tel; +91-44-66544414
1st Main Cresant Road, Fax: +91-44 - 66544445
High Grounds, Near Shivanand Circle, Mob: +91-89399 23363
Bangalore - 560 001. Email: dheena@godrej.com
Tel: +91-80-66472000
Fax: +91-80-22374673 Kolkata
Mob: +91-9916129135 Power Distribution Solutions
Email: dsrao@godrej.com Godrej & Boyce Mfg. Co. Ltd.
Block G.N, Sector V, Salt Lake City,
Kolkata 700 091, India.
New Delhi
Tel: +91-33-66013500
Power Distribution Solutions, Fax: +91-33-23578271
Godrej & Boyce Mfg. Co. Ltd. Mob: +91-9836112225
Godrej Bhavan, 2nd Floor, Sher Shah Suri Marg, Email: ravis@godrej.com
Okhla, New Delhi 110065
Tel: +91 - 11 - 66507191 Hyderabad
Fax: +91-11-66507056 Mob: +91-88864 88774
Mob: +91-99994 07198; +91-99997 09228 Email: aniketh@godrej.com
Email: jalam@godrej.com; sbhanot@godrej.com

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