43@tbllocalcat filenames ilinetrunkingsys cat 0207

Catalogue

07Applications & SpecificationsClass 5600

I-LINE BusbarTrunking Systems

Building a New Electric World

Delivering Powerto the People

I-LINE busbar trunking system was first introducedby Square D in 1961 in its production facility in Oxford,Ohio U.S.A. and has acquired worldwide recognitionin a variety of busway applications.

I-LINE busbar trunking system is designed withmaximum flexibility, ease of installation and electricalefficiency in the distribution of power of 600V andbelow, for both commercial and industrial application. Itis available in ratings from 250A to 4000A withaluminium conductors; and 250A to 5000A with copperconductors. Configuration offered are TP and TP&Nwith 100% capacity, neutral, and the 50% capacityintegral earthing conductor.

To cope with rapid expansion of power network inthe Greater China and South East Asia, SchneiderElectric, set up a manufacturing facility in 1997 inGuangzhou Economic & Technological DevelopmentDistrict of PR China, namely Schneider Busway(Guangzhou) Ltd., to manufacture I-LINE busbartrunking system. Apart from I-LINE, the Company is alsomarketing Canalis lighting busway to the regions.

I-LINE busbar trunking system manufactured inGuangzhou achieves a high level of quality and productexcellence. It complies with international standards ofUL857, NEMA, CSA, ZBK, IEC439 and GB; and wasaccredited of ISO9001 and CCIB. The product alsopassed testing of ASTA and China Electrical EquipmentTesting Centre, Low Voltage Equipment Testing Centre.To ensure product is of the highest standard in themarket, specialists from Oxford facility visit Guangzhoufactory regularly to conduct training and audit. Inreturn, Guangzhou products are sent to U.S.A. forperiodical testing and inspection on a quarter basis.

trunking system, for sure, should be attributed to thetechnological expertise and quality assurance of theproduct itself. Yet merit should also go to the dedicatedsales and after-sales supports from the Hong Kong office

meticulous solution can be tailored to every uniqueapplication requirements. Empowered by the electricalengineers who master sound knowledge and practical

project management services to customers, from on-sitemeasurement, proposal on the best busducts routing, toinstallation assistance at site and “missing link units”arrangement. We trust this is the definite asset of

I-LINE busbar trunking system? Please contact our HongKong office as printed on this publication.

Square D facility in Oxford, Ohio U.S.A. is an ISO 9001

registered busbar trunking manufacturing facility.

Certificate No.FM23076

NATIONALACCREDITATION

OF CERTIFICATIONBODIES

ISO 9001: 2000Certificate No. 0086-1999-AQ-RGC-RvA

SQUARE D COMPANYREGISTERED TO ISO 9001CERTIFICATE NO. A2194

UL®UL®

Schneider Busway (Guangzhou) Ltd. was certified to

achieve ISO9001 quality management system.

Schneider Busway (Guangzhou) Electrical Equipment Ltd. receivesproduct certification from ASTA and ISO system accreditation fromDNV.

Schneider Electric I-LINE busbar trunking is designed andmanufactured in a facility that is quality system registered by UL and

Schneider Electric's success in launching I-LINE busbar

of Schneider Electric, only with which a total and

experience, Schneider Electric can provide diversified

Schneider Electric that you can always count on.

Want to know more about Schneider Electric or

BSI to ISO 9001.

1

I-LINE Busbar TrunkingContents

Table of Contents

Product Features ...................................................................2

Construction ........................................................................4

Ordering Check List .................................................................8

Busbar Trunking Applications ..................................................9

Connection Devices ..........................................................16

Special Features .............................................................17

Services ..............................................................................18

Busbar Trunking Layout and Design ..................................19

Busbar Trunking Measuring ...............................................21

I-LINE Physical Data .........................................................24

I-LINE Electrical Data .........................................................30

I-LINE II Physical Data ........................................................31

I-LINE II Electrical Data ........................................................44

Plug-in Unit ..........................................................................46

Busbar Trunking Specifications ...........................................57

Notes ...................................................................................59

2

I-LINE Busbar Trunking

Simple to install and maintain

Square D pioneered the Single Bolt Joint in 1961 when itintroduced I-LINE Busbar Trunking. Continuing research andimprovements have led to our current design. I-LINE BusbarTrunking Systems feature the following time-saving installationand maintenance features:

Joint-PakJoint-Pak is standard onI-LINE II Systems. Itallows for quick removalof lengths from thebusbar trunking runs forload shifting ormaintenance. It also canbe removed andrelocated on theopposite end of thelength for last minutechanges.

The VISI-TITE bolt

equal pressure across thecomplete joint contact area toassure proper electrical contact.

Universal fittingsUniversal fittings, which are standard on I-LINE II Systems,allow feeders and plug-in ducts to be connected withoutspecial joint covers. All fittings are also universal allowingsimpler installation and maintenance of your system.

Broad range of productsThe I-LINE Busbar Trunking Systems come in two basicranges of products:

• I-LINE - From 225 to 600 amperes, aluminium or copperconductors.

• I-LINE II - From 800 to 4000 amperes with aluminiumconductors, and

• From 800 to 5000 amperes with copper conductors.

• I-LINE is provided as a plug-in system only, andI-LINE II is available as a feeder or plug-in system.

Product Features

Totally enclosed housing – no de-rating necessaryThe I-LINE Busbar Trunking Systems have a “totally enclosed”housing design which requires no de-rating, regardless of themounting position. No longer do you have to worry aboutpreferred mounting positions or de-rating factors. With the‘I-LINE’ family of busbar trunking, the 100% current ratingsremain constant in any mounting position.

Another advantage of our totallyenclosed housing versusventilated trunking is superiorprotection from accidentalcontact with busbars and fromaccumulation of dirt on exposedbusbars through the ventilatingscreens.

I-LINE busbar trunking is available in an indoor version only.The I-LINE II plug-in and feeder are available in indoor andindoor drip-resistant versions. There is also a version ofI-LINE II feeder busbar trunking suitable for outdoor use.

Harmonics and electrical equipment neutralsHarmonics and the effects of nonlinear loads on electricalequipment neutral conductors are subjects of concern.Nonlinear load devices, such as variable speed drives,electronic ballast lighting, computers, printers, and faxmachines, generate harmonics, and their use is increasing.Harmonic effects are often exaggerated and singled out asthe cause for overloading electrical equipment neutrals.The research by Square D indicates that oversized neutralsare an unnecessary expense to most customers. In480Y/277 systems, neutral currents normally do not exceed100 percent of the neutral rating. In 208Y/120 systems, neutraloverloads occur only in rare, unusual cases. Therefore,oversized neutrals are an unnecessary expense to customers.

Nonlinear loads, such as computers and electronic ballastlighting, create harmonics. In rare cases in 208Y/120 systems,distortion from harmonics may necessitate the use of oversizedneutral conductors in applications of 600 amperes and below.In 480Y/277 systems, oversized neutrals are not required.

For more in-depth information on this subject, please orderour document no. 0104ED9501, Neutral Currentsin Three Phase Wye Systems, by R. Arthur andR. A. Shanahan, P.E. or 0104PD9501, Harmonics andElectrical Equipment Neutrals.

Internal smoke/gas barriersContinuous air spaces inside I-LINE II busbar trunking housingare closed off with special barriers to help prevent the spreadof smoke and gases in the event of a fire in the area of thebusbar trunking installation. This standard internal barrierallows busbar trunking to extend through walls or floors withoutcreating open space for a “chimney effect” fire path.

I-LINE busbar trunking from 225 to 600A requires installationof a special internal barrier for wall or floor penetrations.

TheVISI-TITE bolt is standard onall I-LINE Busbar Trunking. Thedouble head design, introducedby Square D in 1967 allows thecustomer to tighten the joint tothe proper torque using astandard spanner. The outerhead will break off when thecorrect torque is achieved.Whenthe head breaks off, a red plastic“VISI-TITE” disc drops off,indicating that the joint is properlytorqued. A second bolt headremains to allow for jointmaintenance or busbarrelocation. No need to purchasea replacement bolt. A cupped“Belleville” washer provides

3


High grade conducting and insulationmaterial

I-LINE Busbar Trunking Systems use either high grade tinplated aluminium or silver flashed copper for their conductingmaterial. The conductors are plated over their entire surfacefor better corrosion protection. All busbars are insulated usingClass B 130° C vendor certified polyester film (Mylar) or epoxypowder coating for long insulation life. I-LINE Busbar Trunkinginsulation consists of two layers of 7.5 mil heat formed polyesterfilm surrounding each busbar. I-LINE II Busbar Trunking usesthe same two layers of polyester film to insulate the busbarsin indoor trunking while outdoor trunking utilizes powder coatedepoxy insulation for the busbars. Both types of insulation offerhigh quality dielectric strength and long life expectancy.

Short circuit strength and testingThe I-LINE Busbar Trunking design gives high short circuitstrength suitable for today’s industrial and commercial electricalsystems. The systems are certified at a 3 cycle rating byUnderwriters Laboratories.

Schneider Electric also tests its products frequently at its own testing laboratory in Cedar Rapids, Iowa, USA, to ensure the high standards of quality and performance that I-LINE Busbar Trunking Systems have come to symbolize.

Integral earthing conductorThe I-LINE Busbar Trunking Systems are available with a 50%capacity integral aluminium earthing conductor as an option.The conductor is unique in that it is a part of the housing itself,which provides an effective path to earth for high level groundfaults.

I-LINE II is furnished with the integral earthing bus as standard.The earthing bus is the bus housing itself and completelyencloses the bus sandwich. Like I-LINE, it is rated at 50%capacity.

Schneider Electric believes an earthing conductor is extremely important, to provide the maximum amount of protection for a distribution system in today’s ever expanding electrical systems. With our design, we have given the maximum amount of protection in an economical package.

Product Features

I-LINE IIBusbar TrunkingCross SectionIncludingStandard IntegralEarth Bus

Earth Bus/HousingTop (1.6mmAluminium Busbar)

Earth Bus/Housing Bottom(1.6mm AluminiumBusbar)

Busbars

Steel side channel(2) for mechanicalstrength

Top

Continuous bonding betweentop and bottom earth bus

Integral EarthBus:How it Works

Degrees of Protection (IEC-529)Schneider Electric offers the I-LINE II busbar trunking system in a variety of housing constructions to meet your application and needs. Choose from the following styles:

Location Type of Trunking Degree of Protection t

Indoor Feeder and Plug-in IP-40

Indoor, Drip Feeder andResistant Plug-in IP-54

Outdoor Feeder only IP-66 t IEC 529:1976

4


What is I-LINE busbar trunking?

I-LINE Busbar Trunking systems are a time proven designwith installations all over the world. Available in two rangeswith ratings from 225 through 600 amperes and 800 through5000 amperes, this low impedance “sandwich type” plug-inand feeder busbar trunking accepts existing I-LINE plug-in(225A to 600A) units (subject to trunking amperagerestrictions).

Systems:TP and TP and N (100%Neutral Capacity) for ACSystems, SP and TP forDC Systems.

Ratings:From 225 to 600 amperesin aluminium or copperplated conductors. The 600volts maximum busbartrunking is fully rated formounting in eitherhorizontal or verticalpositions.

Earthing conductor:Rated at 50% of thenameplate rating of theBusbar Trunking. Theconductor is aluminiumand the top part of thehousing itself.

VISI-TITE bolt:Double headed boltsare supplied on all jointconnections to assureproper torque on thejoint connector. Only astandard spanner isrequired to tightenthe bolt until the outsidehead breaks off. A76mm Belleville washerwith a cupped surfacedispenses uniformpressure across the fulljoint surface area.

Hangers:I-LINE Busbar Trunkingrequires support every 3metres when runhorizontally flatwise and 4.8metres vertically. It must besupported every 1.5 metresin the horizontal edgewiseposition.

Enclosure:A three-piece formed steelhousing with plug-inopenings, supported bymoulded rigid insulators.Available in indoorenclosures only.

Plug-in openings:All I-LINE BusbarTrunking has a plug-inopening for plug-inunits every 610mm onboth sides of thetrunking. The openingsare covered by hingeddoors which cover theopenings when not inuse.

I-LINE Busbar Trunking (225A to 600A)

The features of the design include the VISI-TITE bolt, platedaluminium or copper busbars and the integral earth conductor.I-LINE II busbar trunking has the additional standard featuresof internal barriers, the Joint-Pak assembly, and universal tiechannels.

1

2

3

Construction

5


Moulded plug-inOpening insulator:Adds insulation andsupport at plug-incontact area.

Joint Pak connectorassembly:Includes commonphase connector onhigher amperageratings utilizing morethan one conductor perphase (plug-in busbartrunking only.)

Systems:TP and TP and N (100%Neutral Capacity) for ACSystems, SP and TP forDC Systems.

Ratings:From 800 to 4000amperes with aluminiumand from 800 to 5000amperes with copperconductors. Busbars areplated over their entirelength. 600 Voltsmaximum busbar trunkingis fully rated for mounting in either vertical or horizontal positions.

Internal barriers:Internal barriers arestandard on I-LINE IIfeeder and plug-in BusbarTrunking. All interiorspaces are barriered toprotect against heatedgasses.

Sandwich Construction:I-LINE II plug-in BusbarTrunking also includesfeatures depicted onPage 6 for I-LINE II feedertrunking.

Available in indoor (IP-40)or indoor, drip resistant(IP-54) construction.

Earth jaw for plug-inunit:“Blow-on” designsimilar to phase jawconnection.This “blow-on” designprovides maximumstrength at contactareas during faultcurrent conditions.

Fittings:Elbows, tees andflanged ends are easilyremoved and refittedwith the use of ourJoint-Pak assemblywithout disturbingadjacent lengths.

1

2

3

4

Construction

I-LINE II Plug-in Busbar Trunking (800A to 5000A)

6


Indoor Feeder Busbar Trunking (800A to 5000A)

Construction

11Systems:

TP and TP and N (100%Neutral Capacity) for ACSystems, SP and TP forDC Systems.

Ratings:From 800 to 4000amperes with aluminiumand from 800 to 5000amperes with copperconductors. Busbars areplated over their entirelength. 600 Voltsmaximum busbar trunkingis fully rated for mountingin either vertical orhorizontal positions.

2

Earthing conductor:Provided as standardon I-LINE II Systemsand consists of two1.6mm thick aluminiumbusbars. The earthingconductor is formed toserve as the top andbottom of the trunkinghousing.

Joint Pak connector:Removable for isolationand maintenance ofsystem. The VISI-TITEbolt is included.

3 Common housing:For I-LINE II plug-inand feeder busbarTrunking. Sameaccessories fit both.Steel side channels andaluminum housing.

Insulation:Indoor (IP-40 & IP-54)busbars are insulatedwith two full length heatformed layers of ClassB 130° C polyester film.

4

Fiberglass tape andepoxy resin:Available as an option forhigh interrupting capacity(AFH2, CFH2) busbartrunking systems.

Electrodepositionpaint process providescorrosion-resistant,long-lasting uniformappearance.

7


covers with the quickfasten nut seal the jointfrom contamination bywater.

Insulation:Outdoor (IP-66)busbars are insulatedwith epoxy powdercoating material ratedat 130° C.

Completed Joint:The assembled jointwith all installationactivities complete.

1

2

3

4

Outdoor Feeder Busbar Trunking (800A to 5000A)

Construction

5

Indoor transition devicesare available which directly connect an outdoor (IP-66) device to an indoor (IP-40 or IP-54) device. (Suffix-IV or ISV)

Hangers are required on1.5 metre centres forvertical or horizontalmounting.

Joint Covers:Two piece joint coverwith quick-fasten nut forspeedy installation ofthe busbar trunking.

EZ JOINT PAK:The same joint packused on our indoorI-LINE II trunking iscontinued in ourOutdoor Feeder design.

Flanged Collar:Simple installation ofthe joint covers isassisted by a smoothflange surface with thejoint sealant stripfactory installed.Removal of thesealant’s protectivepaper covering andinstallation of the joint

8


1 2 3 4

S H V T

E O E I

R R R E

V I T

I Z I R

C O C U

E N A N

T L

A

L

✔ ✔ ✔ ✔ A. Layout sketch of trunking run

✔ ✔ ✔ ✔ B. All necessary dimensions

✔ ✔ ✔ ✔ C. Positions of equipment (Front or Rear)

✔ ✔ ✔ ✔ D. Phasing of existing equipment or equipment by others

✔ ✔ ✔ E. Location of walls (if applicable)

✔ F. Location of floors (floor to floor dimensions)

✔ ✔ ✔ G. Wall thickness (if applicable)

✔ H. Floor thickness

✔ ✔ I. Location of roof (if applicable)

✔ ✔ J. Roof thickness (if applicable)

✔ ✔ ✔ ✔ K. Special requirements noted on trunking sketch (that is: Special lugs, Critical Dimensions)

✔ L. Indicate appropriate service device (that is, Tap box, Service head, X’fmer. tap, Bussed)

✔ ✔ ✔ ✔ M. Equipment details if connecting trunking to other than Schneider Electric equipment

✔ ✔ N. Indicate location of Plug-in trunking on sketch

✔ O. Indicate the side of the trunking that the plug-in units are to be mounted

✔ P. Indicate if there are any curbs where trunking passes through floors

✔ Q. Curb Thickness (in addition to the floor thickness)

✔ R. Indicate type of vertical hangers (Spring or Fixed)

✔ ✔ ✔ ✔ S. If connecting to existing I-LINE I, indicate bolt or slot connection

✔ ✔ ✔ ✔ T. If connecting to other than Schneider Electric trunking, send a piece of that trunking to the factory

✔ ✔ ✔ ✔ U. Switchboard identification markings noted on trunking sketch

NOTES: 1. For detailed illustrations reference pages 10 through 23.2. Lack of all required information may cause delays in order processing and can affect delivery schedule.

Type of Application

Ordering Checklist

Important information when ordering Busbar Trunking Systems

The following checklist should be used to make sure that all information is available for the factory to engineer and manufacturethe busbar trunking devices.

Listed Below are the Four Basic Types of Trunking Applications:

(1) Service Entrance Connection (3) Plug-in Type Vertical Riser Installation

(2) Plug-in Type Horizontal Run (4) Feeder Type Tie Run

The information needed to engineer a busbar trunking run is listed below. A busbar trunking run may consist of more than onetype of application

BUSBAR TRUNKING ORDER ENTRY CHECKLIST

Order Number: _________________ Completed by: _______________

Office: _________________ Date: ________________

(✔) = REQUIRED INFORMATION

9


Horizontal feeder runsThese runs are for delivering power from point to point.Typically the runs are from one distribution switchboard toanother.

Service entrance connectionsThese installations are for connection from a transformer to aDistribution Switchboard to bring power into a building.

Where should I-LINE busbar trunking be used?

There are four basic types of installations for I-LINE busbar trunking.

43

1 2

Rear

of

SWBD

Front

of

SWBD

XFMR

RearofSWBD

Wall

Application

FrontofSWBD

Top

Top

Horizontal plug-in busbar trunkingThese installations are run horizontally in an industrial facilityfor simple feeding of industrial equipment.

Front

of

SWBD

3rd Floor

Fusible Plug-inUnits MountThis Side

2nd Floor

TOP

TOP

TOP 1st Floor

Vertical riser installationsVertical Risers are for multi-story building installations whichhave requirements for power at each floor or to take largeamounts of power to a point high in the building.

10


PhasingMany transformers are phased CBAN. If a bussed transformerconnection is to be used, this will require the switchboard atthe other end of the run to be phased similarly. Specific phasingrequirements must be supplied to the factory.

Other service entrance connectionsOccasionally, you will require a service entrance connectionthat differs from our standard. In this case, be sure to let thefactory know of any special dimensions, such as requiredheight of the throat box from ground or floor, spacing betweenphase bars, phasing, and so forth.

1Service entrance connections

This type of connection is typically from a transformerto a distribution switchboard (Figure 1). The connection

to the transformer is through a low voltage throat collar by abussed throat box. This type of connection will include flexiblebus connectors from the low voltage spades of the transformerto the busbar trunking connectors. These flexible connectorsare used to eliminate the effects of busbar expansion andcontraction of the low voltage spades. Positioning of theseflexible connectors is critical for proper alignment between thebusbar trunking and transformer.

The factory must have all of the dimensions shown inFigure 1 plus those shown for the transformer throat collarand spade terminals. This information must be provided alongwith the phasing so proper phasing can be designed for theswitchboard. Typically the connection to the switchboard willbe through a flanged end, but other means of termination areavailable. With this information the proper busbar trunking canbe ordered so the installation will go smoothly.

Application

Indicate number of holes,diameter of holes, and spacing between holes.

TransformerTank Wall

"X" Number andDiameter of Holes

LV Spade Detail

"X" Thickness

Top View of Transformer

LV Throat

LV Spades

CL of Bushing

Outdoor

Indoor

Top of Transformer

CL Bushing

Edge ofThroat Collar

Side View ofTransformer

XX X

X

X

X

X X X X

XX

X

X

X

X X X

X X

X

X

X

X

XX

X

Front of SWBD

Front

Information Needed for Transformer Connection

Note: Often the floor level andoutdoor ground level will be atdifferent heights.

All “X” dimensions mustbe known.

Figure 1 – Measurements Needed for Bussed Transformer (Throat Type)


11

2 Horizontal plug-in busbar trunking

Plug-in busbar trunking in a horizontal run is usedas a means of bringing power from a distribution

switchboard to multiple loads throughout a building. Thedimensions needed are shown in Figure 2.

PhasingThe typical I-LINE plug-in run is shown in Figure 2. The phasingshown is EABCN top to bottom, with the top label located asshown for a horizontal run. This phasing arrangement mustalways be followed so that proper phasing of the plug-in unitswill be ensured (Figure 2 Detail A). Because this busbarphasing must be followed, it is the busbar trunking thatdetermines the phasing of the switchboard in Figure 2. Notethat the plug-in trunking has the integral earth bus plug-in jawon the top side only.

Application

XP

P

P

P

Rear of SWBD

P

P

NCBAE

All “X” dimensions must be known. Indicates plug-in trunking devices.

UnfusedReducer

EndClosure

EndClosure

EABCN E

ABCN

Plug-InUnit

X

X X

X

X

X

X

X

X

CL

Top

Top

Top

Top

Top

Detail “A”“Hook-Swing” Mounting

Notches in top rail position unit.Hooks support weight of deviceduring installation.

Top

EABCN

Figure 2 – Measurements Needed for a Typical Plug-In Type Run

12


A

B

Edge OfJoint Channel

Dimension "B" must begreater than dimension "A".

Tie Channel

Wall

CLJoint

Busbar trunking fittings

Busbar Trunking fitting is a term which encompasses everytrunking component (that is, flanged ends, elbows, tap boxes,tees, reducers, expansion fittings, end-hangers and so forth)except straight lengths.

All fittings on 800 amperes and above plug-in runs are madewith feeder busbar trunking. On Figure 2 on Page 11 any piecenot marked “P” is a feeder device.

All fittings under 800 amperes are made with plug-in busbartrunking. No feeder to plug-in connections can be made under800 amperes. Connections to switchboards under 800 amperesare normally made with plug-in cable tap boxes (see Figure 3)However, flanged ends are available.

Plug-In CableTap Box

End Closure

End Closure

EABCN

FrontofSWBD

Top

Busbar trunking through wall and flanges

When 800 amperes and above busbar trunking extendsthrough a wall, I-LINE II feeder or plug-in trunking can beused. For runs under 800 amperes, plug-in trunking will beused throughout. Factory installed internal barriers (optional)are available where the trunking passes through a wall forruns 600 amperes and below.

I-LINE Busbar Trunking is designed so that no part of thejoint channel can be inside of the wall. Therefore the distancefrom the centre line of the joint to the wall must be at leastequal to the distance from the centre to the edge of the jointchannel (See Figure 4). If the dimensions of the joint channelcannot easily be determined, it is best to keep the joint atleast 305mm from the wall. This will ensure proper joint clear-ance for any type of busbar trunking passing through the wall.

Application

Figure 3 – Typical Plug-in Run-225A 600A

Wall and floor flangesWall and floor flanges are meant to be used for covering thehole in a wall or floor where busbar trunking passes through.These flanges will not aid in maintaining the fire rating of thewall or floor. They are not required for installation, but are oftenrequested by the customer.

TeesPlug-in tees (PTT) are available in the 225, 400, and 600Aratings. These devices mount into any plug-in opening to feedan additional run of busbar trunking.

ReducingThe reduction of the busbar trunking either with or without anovercurrent device is easily achieved with I-Line and I-Line IIbusbar trunking. The requirements for the reduction need tobe forwarded with the busbar trunking details so it can becorrectly engineered.

Expansion jointsSchneider Electric recommends that an expansion fitting should be used under the following conditions: whenever a busbar trunking run crosses a building expansion; when a long straight run of trunking does not contain any elbows or both ends of the run are fixed. The busbar trunking expansion joint allows ± 38mm movement.

Figure 4 – Busbar Trunking Joint Accessibility


13

Front ofSWBD

Feeder

Plug-In

3rd Floor

End Closure

1st Floor

2nd Floor

120.003050

120.003050

1.0025

27.00685

15.00380

15.00380

12.00305

120.003050

83.002108

.50152

150.003810

105.002670

192.004877

Top

Top

NCBAE

NCBAE

25

3050

3050

3810

4877

2670

380

380

305

685

3050

2108

152

Front ofSWBD

FusiblePlug-InUnits MountThis Side

2nd Floor

End Closure

1st Floor

3rd Floor

All “X” dimensionsmust be known.

X

X

X

X

X

X

X

X

X

NCBAE

NCBAE

Figure 6 – Typical Layout 800A and Above RiserFigure 5 – Typical information Needed for Riser

3 Vertical busbar risers

I-LINE and I-LINE II busbar trunking can be utilizedfor vertical risers in multi-story buildings. These

installations can be of plug-in type which allows access oneach floor for plug-in units or of feeder type to feed a distributionswitchboard or a motor control centre on an upper floor.

I-LINE busbar trunking (225-600 amperes) is plug-in only andrequires an internal smoke barrier for each floor partition.

I-LINE II busbar trunking (800-5000 amperes) does not requireinternal barriers for either feeder or plug-in type. The internalbarriers are standard in the design.

DimensionsFigure 5 shows typical dimensions that must be known beforerelease: floor to floor height, floor thickness, exact layout ofmultiple run risers, closet dimensions, the type and quantityof plug-ins, and (if necessary) the desired height of the plugsfrom the floor.

The riser in Figure 5 has been dimensioned in Figure 6. Notethat the two 3050mm sections of busbar trunking on the secondand third floors do not have a joint located in or near the floor.

Application

All Dimensions Millimetres

14


Phasing

When plug-in units are being supplied for a riser installationthe location of the plug-in determines the phasing of the busbartrunking. The trunking must be oriented with the correct sideavailable for the plug-ins. (See Figure 7.)

Due to the complications involved, it is best to have the factoryor representative determine the correct trunking orientation. Theinformation they require is the side the plug-ins mount on andthe orientation of the switchboard phasing.

Special manufacturers recommendationSchneider Electric recommends that a waterproof curb (See Figure 8 below) be installed at each floor opening where busbar trunking passes through. An unprotected floor opening acts as a funnel for plumbing leaks, sprinkler system leaks, fluid spills and other types of contamination.

The cost of removing a contaminated busbar trunking riserand replacing it far exceeds the cost for including a waterproofcurb.

Once the busbar trunking is installed through a floor opening,the remaining unused area should be filled to prevent smokefrom passing floor-to-floor (chimney effect) in case of fire inthe building. Some recommended materials available are firerated foam and caulk. Grouting is also acceptable but mustbe applied in a very dry form to prevent water andcontaminants from entering the busbar trunking once thegrouting cures and the water leeches out.

Plug-in unitsWhen entering an order, the factory must know not only whichside of the busbar trunking the plug-ins will mount on, but thequantity of plug-ins to be used on each floor.

HangersFixed and spring hangers are available for use in supportingbusbar trunking in riser installations. When using fixedhangers, the weight of the riser is distributed between each

Application


NCBAE

ON

OF

F

Top

Figure 7 – Riser Phasing Considerations

Floor

BusbarTrunking

Curb

4.00102102

Figure 8 – Waterproof Curb Recommended Floor Openingfloor.


15

4 Horizontal feeder runs

Feeder type runs are normally used for distributingpower to loads that are concentrated in one area.

Typical connections are switchboard to switchboard tie runs,and a switchboard feeding remote concentrated loads.

PhasingIn Figure 9, the phasing of switchboard A cannot be identicalto switchboard B. It is the busbar trunking that must determinethe phasing of the switchboard. The proper phasing must besupplied to the factory manufacturing the switchboard or aninstallation problem will occur.

The front and rear of each switchboard must be known for thephasing to be determined correctly.

Feeder elbows (800-5000 amperes)As Figure 10 below illustrates, there are two standard typesof 90° elbows: flatwise and edgewise. No matter whatorientation the busbar trunking is installed, the busbars offlatwise elbows stay in the same plane after elbowing andedgewise elbow busbars change planes.

Since feeder elbows are symmetrical, there are no TOP orFRONT sides. Note in Figure 10 that the phasing will runacross the 149mm dimension of the busbar trunking.

Elbows for I-LINE busbar trunking (225-600 amperes) are notsymmetrical and require notation of the Front and Top whenordering.

Application


Figure 9 – Measurements Needed for Feeder Type Run

X

X X

X

X

Front of SWBD

“A”

Front of SWBD

“B”

All “X” dimensionsmust be known.

Wall

X

X

NCBAE

EABCN

Through wallsWith the design of I-LINE II busbar trunking, feeder or plug-intrunking can be installed through walls and floors.

Figure 10 – Elbows: 800A-5000A Feeder

11.00279

11.00279

Edgewise Elbow (LEM)

EPHPHPHPHE

279

279

LL

5.87149

EPHPHPHPHE

Flatwise Elbow (LFM)“L” will vary depending on width of Busbar Trunking (See Page 38)

149

16


28.00711

BA

C

10.00254

End Cable Tap Box (ETB)

(A, B and C dimensions vary with amperage rating of tap box.)

711

254

Fittings

Qwik Flange and Flanged End - switchboardconnectionsA flanged end (see Figure 11) is a feeder trunking fitting thatallows busbar trunking to be interconnected to other equipmentsuch as motor control centres and switchgear.

Occasionally, a customer wants to make a cable connectionto switchboard. As Figure 11 illustrates, standard flanged endsare designed for a single bolt type connection and the spacingbetween phases may be inadequate for adding lugs.

Schneider Electric can manufacture flanged ends with lugs toaccommodate the customer’s needs. The phase spacing, size,type and quantity of lugs will need to be known to order theflanged end with lugs.

The switchgear manufacturer should note we recommend useof 76mm cupped “Belleville” washers when terminating thebus of his switchboard to our Flanged End. These washersassure equal pressure across the contact surface for a cool,efficient connection. (See Page 36.)

The Schneider Electric “Qwik Flange” is another device which can be used to connect I-LINE II busbar trunking to a switchgear. This device is similar to a Flanged End but is preinstalled into the switchgear by the switchgear manufacturer. See Figure 12.

With the Qwik Flange installed, the connection of the busbartrunking to the switchgear is as easy as making a trunkingjoint. This eliminates the time needed to install the normalFlanged End at the job site. This device must be installed bythe switchgear manufacturer. Contact your local salesrepresentative for more information.

Connection Devices

10.00254254


Figure 11 – Standard Flanged End (FE)

28.20716

23.50597

24.00610

15.00381

6.25158

11.50292

11.50292

0.5013

1.1228

3.0076

10.50267

0.5013

9.00229

CL

CL

28

267

13

292

292

610

716158

13

381

597

229

76

Figure 12 – Qwik FlangeCatalogue Number Suffix - QF

Tap boxesSchneider Electric manufactures two types of tap boxes. One style, the plug-in tap box, is designed to connect to plug-in busbar trunking at any of the plug-in openings. The plug-in tap boxes range from 225A - 1600A (see Figure 13).

The other style tap box is the end cable tap box (seeFigure 14). As the name implies, the end tap box (ETB) mountson the end of a run.

All tap boxes are constructed of all-steel enclosures for usewith armoured cable. Screw type mechanical lugs arestandard. If a larger lug than normal or a compression lug is required, notify the factory at time of order.

We also manufacture a centre cable tap box in the I-LINE IIrange of products for applications which require that type ofconnection to a busbar trunking installation.

Figure 13– Plug-In Tap Box (800A - 1600A Style Shown)(For connection into plug-in opening 800A - 5000A)

Figure 14 – Plug-In and End Cable Tap Boxes


17

Finger protection to IP 2XWe have developed this unique new feature for those areasof the world that require extra personal protection. This optionalfactory installed feature includes a busbar barrier which fitsinto the base mold of our plug-in opening. It provides improvedprotection against accidental contact with live parts at theplug-in opening. No modification of our I-LINE plug-in unit isrequired to accept this feature.

This feature is designed to meet the IEC 529 standard whichdefines the degrees of protection provided by enclosures. Thestandard establishes a range of IP codes which defines anenclosure’s protection from elements such as solid objects,water, and dust.

The degree of protection provided by the IP 2X code is definedby the IEC standard as shown in the table below. This featurecomplies with this standard.

Order this feature by adding a “Y” suffix to a standard I-LINE IIplug-in trunking catalog number (example: AP2510G10STY).

Special Features

Note: The second characteristic numeral is not used and is denoted by an "X"

Degree of protection against access to hazardous parts indicated by the first characteristic numeralDegree Of Protection

First Characteristic Numeral Brief Description Definition

Protected against access to The jointed test finger of 12mm PH, 80 mm length 2 hazardous parts with a finger shall have adequate clearance from hazardous parts

Special Busbar Trunking Construction

Customers occasionally have requirements for busbartrunking systems with features other than our standard. Wehave listed below the most often-requested special features:

Special paintI-LINE Trunking can be provided in colours other than ANSI49 grey for a price add-on. The special colour requestedshould be specified by an industrial colour code at the time oforder entry. With typically lengthened lead times for specialcolour parts, it is imperative to provide this information asearly as possible in the order process so deliverycommitments can be maintained.

Low current density trunkingSome customers require a lower current density trunking thanour standard for rigorous duty in their installation. We havedeveloped a range of trunking for the most commonlyrequested current density of 1000 amperes per 645 squaremillimetres (one square inch) for copper trunking. If you requirethis current density for your installation, please feel free tospecify it and we can meet your need. If you have requestsfor another specific current density, please feel free to contactyour local representative.

Riser plug-in trunkingWe also offer an I-LINE II plug-in trunking specifically designedfor installation in riser closets of high-rise buildings. Thisplug-in trunking has a plug-in door on the front side whichfaces out into the room. The back of the trunking, facing thewall utilizes a feeder bus side rail.

This design provides a plug-in trunking ideally suited for risercabinets and gives the customer only the necessary numberof plug-in openings to meet the application. The catalognumber for this device is the same as our plug-in trunking,except an R is substituted for the P. (Example: if the standardplug-in trunking prefix is AP2512G, the riser trunking prefix isAR2512G).

18


Service programs

We pride ourselves in providing excellent service to ourcustomers the world over. We offer a wide range of servicesto make the use of I-LINE busbar trunking as simple and easyas possible. A summary of these services follows:

Emergency serviceTrained and qualified busbar trunking personnel are on call24 hours a day, 7 days a week, to assist in your emergencybusbar trunking needs. Call any time at our field sales office.

Missing linkOur “Missing Link” program guarantees shipment of afactory-built straight length or elbow in five working days afterthe final dimensions are received. This program is designedspecifically to help a customer correct last minute changes toa project using trunking. Those changes could include anunplanned obstruction requiring the trunking to be rerouted,incorrect measurement of the trunking run or the need to orderseveral pieces to supplement trunking lengths ordered fromstock.

The program applies only to standard I-LINE II Indoor FeederTrunking variable straight lengths, elbows, standard tap boxesand flanged ends (800A-5000A). Straight lengths areconstructed as feeder busbar trunking and are available in25.4mm increments from 406 to 3048mm. Elbows are availablein leg lengths from our standard through 914mm. The programis limited to a maximum of four pieces of trunking per run and20 pieces per order. This service is included as part of ourstandard service to our customers.

How to properly measure your missing link(s)ALL missing link dimensions should be measured to thenearest 25mm from centreline of joint to centreline of joint, orcentreline of joint to centreline of busbar trunking.

As shown in Diagram B, the centreline of the joint is located atthe joint bolt on the end with a joint-pak installed. If thejoint-pak is not installed, the centreline of the joint is 25.4mmfrom the end of the busbars.

If it is necessary to measure an elbow, the dimensions X andY (shown in Diagram B) are all that is needed. Be sure tomeasure from centreline of joint (as described above) tocentreline of trunking housing. You must also specify whetheran edgewise or flatwise elbow is required. The table on Page43 lists the standard minimum elbow dimensions for eachamperage.

Services

Customer service

Design and manufactureI-LINE busbar trunking systems receive design andmanufacturing support from the Oxford, Ohio, USA plant. Theobjective of this support is to provide the best service possiblefor I-LINE busbar trunking systems no matter where it is soldin the world. The plant is staffed by experienced engineers togive support to customers who purchase I-LINE busbartrunking systems.

Packing and shippingEach piece of I-LINE busbar trunking once manufactured mustpass a 7000 Volt DC “hi-pot” test before packing and shipmentfrom the factory. International orders are carefully packed andcrated and marked prior to shipment to the site. This will helpensure receipt of the trunking in good condition for installationin sites throughout the world.

After sales serviceSchneider Electric’s large worldwide field sales force isavailable to assist you in answering any questions about thesystem you have purchased. It is our objective to provide thebest service possible to ensure satisfaction by ourcustomers. If you encounter a question or problem withyour I-LINE busbar trunking system, please contact our field


Oxford Distribution Centre

Diagram B

CL

CL

CL Joint

CL Joint

CLBus

CL Bus

Endof Bars

X

A - Straight Lengths B - ElbowsWithoutJoint Pak

WithJoint Pak

WithJoint Pak

JointBolt

WithoutJoint Pak

YX

Endof Bars

1.0025

1.002525 25

sales office.


19

Example 1 (below) illustrates a simple take-off. As previouslymentioned in 5(b), a sketch of the run being taken off is help-ful. Following Example 1 are useful aids in preparing singleline drawings.

How to make a shorthand drawing(Single line type)

After the take-off has been made, a sketch of the run shouldbe made. Single line drawings are the easiest way to illustratean I-LINE busbar trunking run. Remember that you mustprovide the factory with all pertinent information. The procedureis as follows:

1) Select the type of devices you will need to draw (see nextPage).

2) Draw your run. Be sure to label each run and show crosssections where applicable.

3) Show the phasing at each end of the run.

4) Show the location of each type of run (that is, location ofweatherproof and plug-in busbar trunking).

5) Indicate quantity and, if necessary, location of plugs.

Take-Off

How to do a trunking take-off fromdrawings

The guidelines listed below should allow you to perform atrunking take-off in the field.

1) First check the drawing list to ensure you have all thedrawings for a complete and accurate take-off. Generally,you will need the structural steel and mechanical/civildrawings to confirm that the trunking has an unobstructedpath.

2) Carefully read the specifications and note any deviationsto Schneider Electric’s I-LINE system. If there arediscrepancies between what is specified and what can beprovided, ask your local representative for assistance.

3) Check the one-line electrical diagrams and count thenumber of runs. If the voltage, ampacity, and rundesignations (that is, run MCC 1) are stated, list these items.When the take-off is complete, this listing can be used toensure that your bill-of-material is complete.

4) If multiple runs are shown on each drawing and arecontinued on subsequent drawings, a complete run-by-runtake-off is recommended. Check the scale on each drawingand detail, sometimes they vary.

5) To obtain the lengths and the number of fittings (that is,elbows, flanged ends, wall flanges, and so forth):

a. Measure the lengths of the run by scaling to centrelineof the busbar trunking and fittings.

b. A simple sketch of each run is very helpful. Referencedimensions from known column lines to the trunking andshow them on your sketch, also note the trunkingelevation(s).

c. List the number of fittings for each run.

6) Once all the runs have been grouped according toamperage ratings, the per metre pricing and fittingscharges can be worked out by a Schneider Electricrepresentative to obtain the busbar trunking costs.

7) If tap boxes and overcurrent devices are not listed as partof the take-off, a careful examination of the drawings needsto be made to compile the list.

A

B

C

D

E

F

G

6 5 4 3 2 1

60A TPPlug-in

30A TPPlug-in

30A TPPlug-in

30A TPPlug-in

30A TPPlug-in

30A TPPlug-in

60A TPPlug-in

800A TP + E Alum.Bus Mounted Aprox.

4267 Aff.

3000ATP + N + EAlum. Bus

Duct ServiceEntrance Run

4267 Aff.

800A TP + E Alum.Bus Mounted Aprox.

3658 Aff.

30A TPPlug-in

30A TPPlug-in

240.006096

240.006096

240.006096

240.006096

240.006096

240.006096

240.006096

240.006096

240.006096

240.006096

240.006096

Note: The Switchboard is 1780 high. “AFF” means “above finished floor”.Drawing is not to scale. Use the columns to approximate the distances.

6096

6096

6096

6096

6096

6096

6096 6096 6096 60966096

Example 1– Typical Customer Drawing for a Plug-in Bus Run


20

I-LINE Busbar TrunkingTake-Off

1B Typical Single Line Sketch of Plug-In Run

240.006096

27.95710

27.95710

24.0261084.02

2134

12.01305Wall

12.01305Wall

192.014877

192.014877

60.041525

60.041525

1104.0228042

864.0221946

480.0012192

CBA

Rear SWBD

AF/AP 2308G800A TP + E

Aluminum Busbar Trunking

Plug-in Units(9) PQ3603G(2) PQ3603G

3000A TP + N + EService Entrance

AOF 2530G

FrontSWBD

ABCN

NCBA

ABC

12192

60961525

1525

610

Check sketch 1B above to see how well you did on thetake-off. Is your bill of material similar to that given?

The Busbar Trunking Order Entry Checklist on Page 8 is auseful tool to check your work before submitting theinformation to your representative for quotation.

ServiceHead

ExpansionFitting

WallPenetration

VerticalEdgeFlat

FlangedEnd

ABCN

Elbows EndClosure

Orientations

Reducer

2000A

1600A

End CableTap Box

Plug-inCable Tap Box

These are typical symbols used when makinga single line drawing

TopEABCNE

8.84225

5.88149

1600A Al

149

225

Helpful hints to lay out and measure abusbar trunking job

Laying out and measuring a job does not require specializedtools or skills. The following list of tools should handle all ap-plications:

30 metre tape measure felt tip marker or crayon

7.5 metre tape measure

plumb line/chalk line

Let’s assume you want to feed a new Motor Control Centre(MCC) with trunking from a new distribution switchboard. Usingillustrations, we will go step-by-step through the layout processto determine the orientation and dimensions. When completed,we will have a single line isometric drawing showing theproposed layout.

Known informationFrom the bid documents, specifications, and/or factorydrawings the following information is known:

• System is 1600A, TP & N 50% Earth, 240/415 voltaluminium feeder type (Width is determined to be 225mm.)

• Switchboard (SWBD) is 2318mm high, 914mm wide,610mm deep, connection to be in top centre

• Motor Control Centre is 2318mm high with a 305mmadditional height pull box for trunking connection, 508mmwide, 508mm Deep connection in top centre

• Bottom of busbar trunking (B.O.B.) to be installed 4877mmabove finished floor (AFF) unless obstructed



21

Measuring

How to begin1) Determine the physical size of the trunking housing (see

Page 24 and 32). This information lets us know how far tostay away from obstructions. In our example, the trunkingis 225mm wide and 149mm high.

2) Review the area where the trunking could be installed (ifnot already specified). Note any special conditions suchas: building expansion joints, steel changes, HVACequipment, plumbing, and so forth.

3) All dimensions should be measured from fixed points suchas: columns, walls, or other building structures. Try to leavea minimum of 100mm between the trunking and anyobstructions.

* A sketch (SK-1 below) showing the SWBD and MCClocation, the obstructions, and the dimensions to fixedpoints is very helpful.

4) If the run originates from a SWBD, start dimensional layoutfrom the fixed end. A tap box at the beginning of a runmay reduce the number of special pieces and reducedelivery time.

Sketch the proposed routing making notes about elevationsand obstructions (see SK-2 Page 22).

5) Unless specified, for most industrial applications thetrunking should be run above the bottom chord of thebuilding steel. This will protect it from damage by fork-liftsor other equipment. Also keep in mind that the trunkingmust be supported by drop rods or from below. Do notroute it where it cannot be supported.

6) When selecting the elevation for plug-in trunking, rememberthat the tap off units require different mounting clearances(see Page 50).

Going back to the sample layout (SK-2), enough informationis known to tabulate the amount of length needed and therequired fittings (i.e. flanged ends, elbows, etc.). The sketch,SK-2, could be given to your local representative for pricingand forwarded on to the factory for record or approvaldrawings, and returned.

SK-3 on Page 22 represents a typical dimensioned one-linedrawing from which the customer could confirm the busbartrunking dimensions and the routing.

SK-1 Plan View of SWBD, MCC and Obstructions

CL

CL

CL

10.00254

45.001143

36.00914

360.009144

240.006096

(Typical)

50.001270

3.94100

A

B

6

C

5

EABCN Front

ofSWBD

23.94608

73.001854

3.94100

(Typical)

12.00304

Front ofMCC

NCBAE 20.00508

20.00508

20.00508

30.00762

Columns300 x 300(Typical)

76 Steam lineBottom of pipe (B.O.P.)

4877 A.F.F.

152 Condensate lineB.O.P. 4877 A.F.F.

North

9144

914

1854

2541143

608

1270

100

508

508

508

304

6096(Typical)

100(Typical)

762


22


SK-2 Proposed Busbar Trunking Layout

CL

CL

10.00254 45.00

1143

Rise up2616 (B.O.B. 4877 A.F.F.)

(E 4953 A.F.F.)

360.009144

240.006096

50.001270

3.94100

A

B

6

C

5

Frontof

SWBS

23.94608

Offset up12.00

304

73.001854

Offset down12.00

305

12.00304

18.00457

B.O.B. 5182A.F.F.

B.O.B. 4877A.F.F.

91.002311

300 Columns300 x 300(Typical)

76 Steam lineBottom of pipe (B.O.P.)

4877 A.F.F.

76 Condensate lineB.O.P. 4877 A.F.F.

North

CL

Front ofMCC

NCBAE 20.00508

20.00508

20.00508

30.00762

3.94100

(Typical)

EABCN

9144

100(Typical)

1854

1143254

6096

1270

100

608

304

457

305 508

2311

508

762

508

304

A120.003050

103.002616

18.00457

24.00610

91.252318

240.006100

(Typical)

230.005842

12.00305

360.009150

73.001854 30.00

764

287.207295

20.00508

20.00508

91.502324

12.00305

91.2523183.95

10072.001830

18.00457 137.00

3482

5

6

B

7

C

B.O.B. 5182AFF

B.O.B. 4877AFF

EABCN

SWBDCL

B.O.B. 4877AFF

MCC

NCBAE

3050

2616

457

610

2318

5842

6100(Typical)

305

1001830

3482457

1854764

7295

508508

2324

305

2318

9150

SK-3 Single Line Drawing of Completed Layout

Measuring

Riser applications (apartments, high-rise offices, etc.) are easier to lay outand measure. Once the busbar trunking is brought over to the floorpenetration area, generally it is routed straight up.The dimensions needed for riser applications were discussedunder the “Vertical Riser” section, Page 13.



23

Measuring

Preparing to install I-LINE busbar trunking

To make the installation proceed as quickly and efficiently aspossible, a few preliminary steps should be taken.

1) Inspect trunking for damage when received. Store in aclean, dry location.

2) Familiarize yourself with the routing. If record drawings weresupplied by the factory, have a copy accessible to theinstallers.

3) Carefully read the installation instructions for all devicesbefore the actual installation. Note the instructions call forthe busbar trunking to be insulation tested before and afterinstallation. A 1000V Insulation tester is recommended forthis test.

4) Install hangers and supports. The most common methodof supporting the hangers is threaded drop rods (or allthread) which the installer must supply.

5) Anticipate the weight of the objects being installed so thenecessary lifting devices and manpower are available.

6) Have the following recommended tools available for theinstallation

a) 1/2" Imperial nut driver or socket and ratchet

b) Straight blade screwdriver

c) Torque wrench or breaker bar with 5/8" Imperial head

d) 3/4" Imperial socket for torque wrench or breaker bar

e) Busbar trunking assembly tool (AT-2) for 800A-5000A(provided by Schneider Electric)

f) Level

g) Tape measure

h) Insulation tester 1000V (recommended)

7) If any problems are encountered or questions arise, contactyour local sales representative.

Maintenance Recommendations

We have always striven to design products to the highestquality standards. We also recognize the performance of aproduct is directly affected by the quality of how it is installed,operated, and maintained. We feel that to protect yourinvestment in Schneider Electric busbar trunking, certainoperation and maintenance procedures should be followed.

As part of this philosophy, we provide with each busbartrunking project NEMA Publication BU1.1-1991 which is aguide for proper installation, operation, and maintenance oftrunking products. This publication addresses such areas asinspection of all electrical joints and terminals for tightness,prevention of entry of water and contaminants into thetrunking, instructions for what to do if water and contaminantsdo enter the trunking, and other maintenance topics. Thispublication is also available upon request by contacting yourlocal representative.

DANGER

Hazard of electrical shock, burn, or explosion.• Electrical equipment should be serviced only by

qualified electrical maintenance personnel, and thismanual should not be viewed as sufficient instructionfor those who are not otherwise qualified to operate,service, or maintain the equipment discussed. Althoughreasonable care has been taken to provide accurateand authoritative information in this manual, noresponsibility is assumed by Schneider Electric for anyconsequences arising out of the use of this manual.

• The successful operation of trunking depends uponproper handling, storage, installation, operation, andmaintenance. Neglecting fundamental installation andmaintenance requirements may lead to personal injuryas well as damage to electrical equipment or otherproperty.

• Hazardous voltages in electrical equipment can causesevere personal injury or death. Energizing trunking forthe first time after initial installation or maintenance ispotentially dangerous. Unless otherwise specified,inspect and perform preventive maintenance only ontrunking and equipment to which power has been turnedoff, disconnected, and electrically isolated so that noaccidental contact can be made with energized parts.

Failure to follow these instructions will result in deathor serious injury.

DANGER

24


Top

120.003048

3.1981

6.50165

24.00610

24.00610

24.00610

24.00610

17.50445

3.3184

3.1981

6.50165

24.00610

24.00610

24.00610

24.00610

17.50445

3.3184

Front

445

84

81 165 610

610 610

610

610

610

610

610

165 81

84

445

3048

Straight Lengths

Physical Data

The following tables are self explanatory and provide useful information when installing and selecting I-LINE busbar trunking.

I-LINE busbar trunking (225A-600A)

Top

Top

Front

Front

Top

Front

Joint CL

12.25369

6.50165 2.88

73

9.38239

18.75476

165

73

239

476

369

Joint Detail

Content and weightAluminum

Width Weights BasicAmpere W Bus Bars Per Phase 3 Pole 4-Pole Catalogue numberRating mm mm kg/m kg/m TP+E TP+N+E

225 57 One – 6 x 24 9.1 9.5 AP302G AP502G

400 86 One – 6 x 51 11.2 11.8 AP304G AP504G

600 121 One – 6 x 86 14.0 15.8 AP306G AP506G

Copper

Width Weights BasicAmpere W Bus Bars Per Phase 3 Pole 4-Pole Catalogue numberRating mm mm kg/m kg/m TP+E TP+N+E

225 57 One – 6 x 24 9.8 10.4 CP302G CP502G

400 86 One – 6 x 51 18.0 20.7 CP304G CP504G

600 86 One – 6 x 51 18.0 20.7 CP306G CP506G

Catalogue Number Suffix -10 -6

Standard Lengths — Feet 10 6

Standard Lengths — Meters 3.05 1.83

Number of Plug-In Openings 10 6

For straight lengths other than standard indicate length in multiples of 25.4mm.

6.00152

W

Top

EABCN

152

Catalogue Numbering System:The numbering system used for the busbartrunking is the basic catalogue number of thetrunking and the addition of the appropriate suffixfor the device desired. A 3.05 metre length ofcopper 225A TP+N+E trunking would be:CP502G-10. Other fittings are ordered in a similarmanner, such as elbows, expansion fittings andso forth.

Cross Section

I-LINE Physical Data



25

Cable Tap Boxes

Cable tap boxesLugs per Earth Catalogue Number

Ampere A B C D E Phase and Lug (with Earth Bus)Rating mm mm mm mm mm Neutral mm2 mm2 TP+E TP+N+E

225 416 216 102 84 267 1-150 1-50 PTB-302G PTB-502G

400 659 468 248 191 356 2-240 1-240 PBTB-306G PBTB-506G

600 659 468 248 191 356 2-240 1-240 PBTB-306G PBTB-506G

TeesAmpere Rating (Tee Leg) Catalogue Number (With Earth Bus)Aluminum Copper TP+E TP+N+E

225 225 PTT-2-3WG PTT-2-4WG

400 400 PTT-3-3WG PTT-3-4WG

— 600 PTT-3-3WG PTT-3-4WG

600 — PTT-4-3WG PTT-4-4WG

Note: Accessories such as Cable Tap Boxes, Tees and other accessories are listed by a separate catalogue number. These should be ordered in additon to the busbar trunking.

Tees

5.88149

8.12206

6.88175

6.00152Top

Top

Front

149

152

175206



4.29109

7.50191

3.8899

14.00356

CCL Plug-in Opening

CL Plug-in Opening

Required M

ounting Clearance

0.02 Dia. Hole 0.56

B

A

D

E

0.9023

CL

400A/600A

10914 Dia. Hole

23

356

191

997.75197

B

D

E

C

A

225A

CL Plug-in Opening

197

26


Top

Top

Front

18.00457

18.00457

457

457

Top

Top

Front

18.00457

18.00457457

457

15.76400

7.6319412.00

305

36.00914

60.001524

9.40239

8.13206

17.20437

Note: Expansion joint permits+_38mm expansion. Userecommended only when trunkingpasses through buildingexpansion joint.

Top

Front

A

305

914

1524

400

194

239

206

437

Top

Front

18.00457

18.00457

457 457

Top

Front

Front

18.00457

18.00457

457

457

Top Inside ElbowCatalogue Number Suffix – LTI

Front Inside ElbowCatalogue Number Suffix – LFI

Front Inside ElbowCatalogue Number Suffix – LFO

Top Outside ElbowCatalogue Number Suffix – LTO

Expansion FittingCatalogue Number Suffix – EJ

Expansion FittingAmpere Rating A

Aluminium Copper mm

225 225 114

400 400 141

— 600 141

600 — 176

Unfused ReducerBolt End Catalogue Number SuffixAmpere Slot End Ampere RatingRating 225 400 600

225 — — —

400 -R02 — —

600 -R02 -R04q —

q Aluminium busbar trunking only.

36.00914

18.00457

18.00457

Top

Front

914457

457

Unfused Reducer




27

Ampere Rating H W V TAluminium Copper mm mm mm mm

225 225 340 113 62 87

400 400 340 140 89 114

— 600 340 140 89 114

600 — 340 175 124 149

A

ContactSurface

2.0051

7.00178 4.00

102

Figure 2

2.0051

5.00127

1.0025 A

ContactSurface

Figure 1

5125

127178

51

102

Flanged End Details

Ampere Rating AAluminium Copper Figure mm

225 225 1 24

400 400 2 51

— 600 2 51

600 — 2 86

12.00305

Front

Top

H

Neutral

W

Flanged End

305

0.5013

3.6994

5.00127

0.31 Dia. 8 (6 Holes)

3.6994

0.3810

11.62295

0.3810

0.5013 V

Top

HFlangedCollar

Cutout

T

W

Flanged Collar

Neutral

CL

13 13

10

295

10

94

127

94

8 Dia.(6 Holes)

Flanged End Cutout and Drilling TemplateCatalogue Number Suffix – FES 12 (Slot end) – FEB 12 (Bolt end)

4-Pole

N C B A

3.0076

3.0076

3.0076

CL Top

76 76 76


All Dimensions Millimeters

4-Pole with Earth Bus

N C B A

Top

E

CN B A E 0.13

3.0076

3.0076

3.0076

CL

76 76 76

3

4-Pole with Earth Bus(Bottom View)

Flanged Collar

N C B A E

5.12125

CL

CL

125

Flexible Connector

Ampere Rating Catalogue No. Piece required per(A) phase & neutral

250 FLEX502 1

400 FLEX504 1

630 FLEX506 2

Note: Please refer to Page 36 for dimension

28


0.62 Dia. Hole 16

Drop RodBy Customer

1.5038

0.8822

1.9048

6.44163 1.87

47

AB

CL

16 Dia. Hole

47

22

163

48

38

Edgewise Hanger

5.50140

2.0051

0.6216

2.1254

0.256

0.56 Dia. Hole 14

Drop Rod By CustomerB

A

CL

51

6

54

14 Dia. Hole

16

140

Flatwise Hanger

Ampere Rating A B CatalogueAluminium Copper mm mm Number

225 225 160 91 HP-3-E

400 400 160 91 HP-3-E

— 600 160 91 HP-3-E

600 — 195 108 HP-5-E

Hanger spacing on 1.5 metre centres maximum when mounted edgewise.


225 225 67 27 HP-2-F

400 400 94 36 HP-3-F

— 600 94 36 HP-3-F

600 — 129 72 HP-5-F

0.50 Drop Rod 13 and Beam Clamp by Customer

Sway Brace(As Required)by Customer

BuildingSupport

4.62117

8.00203Note: When required the

recommended spacing is6 metre centres.

13

203

117



Sway Brace CollarCatalogue Number HP–1–SBC


29

Ampere Rating A CatalogueAluminium Copper mm Number

225 225 68 ACP - 2 -EC

400 400 89 ACP - 3 -EC

— 600 89 ACP - 3 -EC

600 — 124 ACP - 4 -EC

Vertical Hanger

Wall and floor flangeAmpere Rating A B Catalogue Number

Aluminium Copper mm mm Wall flange Floor Flange

225 225 160 212 ACP-2-WF ACP-2-FF

400 400 186 239 ACP-3-WF ACP-3-FF

— 600 186 239 ACP-3-WF ACP-3-FF

600 — 221 274 ACP-4-WF ACP-4-FF

Note: To be used only as a barrier to cover hole in wall/floor where busbar trunking penetrates. Not to be used as a trunking support.

10.00254

2.0051

2.0051

3.0076

3.0076

2.0652

2.0652

10.00254

2.0652

2.0652

A B

Wall Flange Floor Flange

51 51

52

52

254

76 76

52

52

254

6.10155

3.95100

A

Joint CL

100

155

End Closure



225 225 109 166 HP-2-V

400 400 135 192 HP-3-V

— 600 135 192 HP-3-V

600 — 170 228 HP-4-V

Note: Dimensions shown apply to 1829mm and 3048mm straight lengths only. Consultfactory for dimensions that apply for fractional straight lengths.


4.30109

9.38238

2.1254

11.50292

3.1881

1.1228

Top

Top Bottom

A

B

FloorLevel

CL Joint

To secure hanger totrunking, attach mountingscrew on bottom of trunkingto hanger brace through slot.

18mm diameter holes for access tomounting screw on trunkingwhen securing hanger totrunking mounting.

Note: Waterproof curbingis recommended around flooropening shown.

Customer to locate and drillfour (4) 8mm diameter holesfor securing mountingchannel to hanger.

Channel iron and12mm diameter bolts bycustomer.

109

81 28

238 292

54

30


Resistance Values for Aluminium Integral Earth BusAmpere Rating DC Resistance (Milliohms per Metre)

TP+E & TP+E+N Aluminium Phase Conductors Copper Phase Conductors

225 .266 .266

400 .210 .210

600 .174 .210

Resistance values for the Integral Earth Bus are at a 20°C operating temperature.

50 Hz Impedance ValuesLine to Neutral in milliohms per metre

Aluminium Copper

AmpereRating R X50 R X50

225 .222 .086 .123 .095

400 .113 .066 .064 .058

600 .062 .040 .064 .058

50 Hz Voltage drop average TP line-to-line voltage drop in volts per metreAluminium busbar trunking Copper Busbar trunking

Ampere Power Factor Power Factor

Rating 100 90 80 70 50 30 20 100 90 80 70 50 30 20

225 .087 .093 .090 .085 .073 .058 .051 .048 .060 .061 .060 .056 .050 .046

400 .044 .051 .051 .049 .044 .038 .034 .025 .033 .034 .034 .032 .029 .027

600 .024 .029 .029 .028 .026 .022 .020 .025 .033 .034 .034 .032 .029 .027

Note: 1. For balanced 3-Phase Line-to-Neutral voltage drop, multiply values from table by 0.577.

2. For other than rated current, multiply values from table by Actual CurrentRated Current .

3. For different lengths, multiply values from table by Actual Length (metres) 30.5 metres .

Note: Short Circuit Ratings for I-LINE busbar trucking arelisted on Page 44 of this manual.

Straight Flanged Flat Elbow Wall Thickness Edge Elbow Wall ThicknessAmpere Rating Length Ends 100 200 300 400 500 600 100 200 300 400 500 600

Aluminium Copper Yt W Yt W W Yt Yt W

225 225 152 152 203 254 305 356 406 457 152

400 400 178 203 178 381 203 229 279 330 381 431 483 178 330 381 431 483 533 584

— 600 178 178 229 279 330 381 431 483 178

600 — 203 203 279 330 381 431 483 533 203

t Dimension allows clearance for vertical hanger. Subtract 25 mm for horizontal mounted busbar trunking

Y

W

Required Wall Openings

I-LINE Electrical Data


31

I-LINE II Physical Data

C P J 2 – 5 20 G ––FE M


Catalogue numbers are composed of 2 basics parts – the PREFIX (as below) plus the SUFFIX of each individual busbar trunkingcomponent.

The PREFIX contains necessary trunking information except individual component descriptive details which are defined by theSUFFIX. The catalogue number PREFIX will generally remain unchanged throughout a trunking system while the SUFFIX willvary with each individual length or fitting selected. A table of the standard SUFFIX designations can be found on page 43.

A few devices, such as hangers and wall flanges, do not follow the exact pattern described above. For these exceptions, a morecomplete listing of device catalogue numbers is shown with the individual device drawing(s) beginning on page 40.

*I-LINE busbar (250A - 630A) is available for indoor feeder or plug-in system

** Not applicable in I-LINE busway (250A - 630A)

*** IP65 available for feeder system only

SUFFIXof each individual busbar

trunking component

Busbar Material:A = AluminiumC = Copper

Fittings available:FE = Flange endEJ = Expansion fittingETB = End cable tap boxCTB = Centre cable tap box

Degree of protection**(for indoor only):– – = IP4041 = IP4154 = IP5465 = IP65***

PREFIX

Number of Poles5 = TP+N+E

Ampere Rating:in hundreds of ampere(i.e. 20 = 2000 ampere)

Earth Bus:G = 50% capacityintegral earth bus

Type of Busbar Trunking:F = Indoor feederP = Plug-inO = Outdoor feederR = Riser plug-in

Special Features (Optional):F = Outdoor feederJ = 1sec/3sec high circuit breaking forindoor trunking

2 = I-LINE II busbar (800A - 5000A)no number designation= I-LINE busbar* (250A - 630A)

32


Aluminium content and weight Bus Bars Per Phase Weights-Feeder Weights-Plug-in

Ampere W TP+E TP+N+E TP+E TP+N+ERating mm Figure mm kg/m kg/m kg/m kg/m

800 110 A One-6 X 76 13.5 14.9 16.7 18.0

1000 136 A One-6 x 102 15.0 16.8 18.2 19.9

1200 161 A One-6 x 127 16.5 18.6 19.6 21.7

1350 186 A One-6 x 152 18.0 20.5 21.1 23.7

1600 225 A One-6 x 191 20.5 23.5 23.7 26.6

2000 323 B Two-6 x 114 28.4 33.5 31.5 36.6

2500 412 B Two-6 x 152 32.9 39.7 36.0 39.9

3000 475 B Two-6 x 191 37.3 45.5 40.5 48.7

4000 650 C Three-6 x 165 50.4 60.1 53.6 63.2

Copper content and weight Bus Bars Per Phase Weights-Feeder Weights-Plug-in

Ampere W TP+E TP+N+E TP+E TP+N+ERating mm Figure mm kg/m kg/m kg/m kg/m

800 98 A One-6 x 64 18.0 21.7 21.1 24.8

1000 110 A One-6 x 76 20.5 24.9 23.7 28.0

1200 136 A One-6 X 102 25.0 31.0 28.1 34.1

1350 148 A One-6 X 114 27.2 33.9 30.4 37.1

1600 171 A One-6 X 137 31.4 40.9 34.5 44.0

2000 199 A One-6 X 165 36.2 45.8 39.3 49.0

2500 323 B Two-6 x 114 57.6 71.0 60.7 74.1

3000 387 B Two-6 X 127 63.5 76.9 65.2 80.1

3200 412 B Two-6 X 152 70.3 87.6 76.1 93.9

4000 599 C Three-6 x 114 87.9 108.0 91.1 111.2

5000 638 C Three-6 x 152 108.9 134.8 111.2 137.9

I-LINE II busbar trunking (800A - 5000A)


EABCNE

EABCNE

EABCNE

W

Top

W

Top

W

Top

5.88149

Figure A Figure B Figure C

149

Cross Sections - Fittings and All Outdoor Feeder

Cross Sections - Plug-In and Indoor Feeder Straight Length (IP-40 ,IP-54 and IP-65)


W

5.88149

.256

.256

Figure A

Note: Dotted line indicates the profile of the joint covers for Outdoor Feeder (IP-66) Busbar Trunking. The profile for indoor fittings is the same as the busbar trunking itself.

Figure B Figure C

W.256

.256 W.25

6.25

6

1.2030

1.2030

Nominal Clearance(Typical)

6666 66

149

30

30


33

Straight lengths -plug in

Catalogue number suffix -10 -8 -6 -4

Standard Lengths-Metres 3.05 2.44 1.83 1.22

Standard Lengths-Feet 10' 8' 6' 4'

Number of Plug-In Openings 10 8 6 4

Straight lengths – feeder

Catalogue number suffix -10ST -6 ST -18 ST

Standard Straight Lengths-Metres 3.05 1.83 0.46

Standard Straight Lengths-Feet 10' 6' 1'6"

For straight lengths other than standard indicate length to nearest 25mm. Consult Page 43for maximum and minimum lengths.

Note: All straight lengths and fittings of feeder trunking are fullycompatible, rating for rating, with straight lengths of plug-in trunking.Available in 25.4mm increments from 406mm to 3048mm.

120.0030483048

Straight Lengths - Feeder

Note: All straight lengths of plug-in trunking are fully compatible,rating for rating, with straight lengths and fittings of feeder trunking.

120.003048

24.00610

Square D Company

Square D Company

Top

Top

Square D Company

Top

Square D Company

Top

Square D Company

12.00305

12.00305

24.00610

24.00610

24.00610

305

610

610

3048 610

610

305

Straight Lengths - Plug-In



34


Flanged Collar and Cutout Dimensions 800A-5000A FeederAmpere Rating W W J

H G TP+E TP+N+EAluminium Copper mm mm mm mm mm

800 187 130

800 1000 187 130

— 1200 203 145

1000 1350 229 171

1200 — 254 196

1350 1600 279 222

1600 2000 352 295

2000 2500 403 346

2500 3000/3200 505 448

3000 — 578 521

4000 4000 730 673

— 5000 730 673

Flanged Collar Hole Location and Spacing 800A-5000A FeederAmpere Rating Hole location and Spacing

N A B C D K E FAluminium Copper Holes mm mm mm mm mm mm mm

800 10 162 81 — —

800 1000 10 162 81 — —

— 1200 10 178 89

1000 1350 10 203 102 — —

1200 — 10 229 114

1350 1600 10 254 127 — —

1600 2000 16 327 108 — —

2000 2500 16 378 127 — —

2500 3000/3200 18 480 121 119

3000 — 20 552 111 111

4000 4000 22 705 117 118 118

— 5000 22 705 117 118 118

4.00102

0.6216

0.6216

0.8822

0.8822

E

F

FK

G

A

B C D D C B

H

J

E

WFlangedCollar

0.31 Dia. 8 (Holes)

FlangedCollar

Cutout

10.00254254

16 16

22

22

8 Dia.(Holes)

102

Flanged Collar Cutout and Drilling Template 800A - 5000A Feeder

326 335 254

478 487 406

296 98 —

451 88 87


Catalogue Number Suffix – 10 FEB



35

AluminiumAmpere A B CRating Figure mm mm mm

800 1 76 — —

1000 1 102 — —

1200 1 127 — —

1350 1 152 — —

1600 1 191 — —

2000 2 114 289 60

2500 2 152 378 73

3000 2 191 441 60

4000 3 165 616 60

Ampere Rating S T U

Aluminium Copper mm mm mm

800

800 1000

— 1200 76 92 97

1000 1350

1200 —

1350 1600

1600 2000 76 169 173

2000 2500

2500 3000

3000 3200 127 169 173

4000 4000

— 5000


Flanged Collar

E E

T T


Flanged Collar

E E

U U


CL

CLCL

ECBAE


E E

Hex Head Bolt

SS

ENCBAE


E E

S SS

.1233

CopperAmpere A B C

Rating Figure mm mm mm

800 1 64 — —

1000 1 76 — —

1200 1 102 — —

1350 1 114 — —

1600 1 137 — —

2000 1 165 — —

2500 2 114 289 60

3000 2 127 353 99

3200 2 152 378 73

4000 3 114 565 111

5000 3 152 604 73

A

Figure 3Figure 2

AA C C

B

AA C

BFigure 1

A.62 Dia. Hole 16

7.00178

2.0051

CL

4.00102

ContactSurface

178

51

16 Dia. Hole

102

Flanged End Details


36

I-LINE Busbar TrunkingII Physical Data

Flanged end termination details

EE

Flexible Connector details

Busbar TrunkingFlanged Endor Quik Flange

Grade 5 Hardware

Large Belleville Washers

Switchboard Bussing

Tie Connector(Used on 2 and 3 StackConfigurations Only)

Flexible Connector (Supplied by vendor)Ampere Rating Catalogue No. No. of Pieces required per(A) phase & neutral

800 FLEX508 2

1000 FLEX510 3

1200 FLEX512 3

1350 FLEX513 4

1600 FLEX516 4

2000 FLEX520 5

2500 FLEX525 7

3000 FLEX530 8

3200 FLEX532 8

4000 FLEX540 10

5000 FLEX550 13

NOTES: 1. INSERT CABLE STRANDS IN THE CHAMFERED END OFTHE TERMINAL TUBES.

2. CABLE STRANDS SHOULD BE POSITIONED NO MORETHAN .06 (MAX.) INSIDE END OF TERMINAL TUBE AFTERFLATTENING.

3. USE A BELT SANDER TO TOUCH UP STRANDS STICKINGBEYOND THE END OF THE TERMINAL TUBE.

15.75

SEE NOTES2 & 3

44.45

95.25

184.15

SEE NOTE 1

14.23 DIA

95.25

44.45

38.10

19.05

6.35304.80

Detail of Phase Bussing Connections in a Swichboard


37

Cable tap box – end

Ampere Rating A B t C Lugs Per PH&N Earth Lugs

Aluminium Copper mm mm mm 240mm2 150mm2

800 800 740 279 406 3 2

1000 1000 740 279 406 4 3

1200 1200 740 279 406 4 3

1350 1350 740 378 406 5 3

1600 1600 740 378 406 6 4

— 2000 740 378 406 7 5

2000 — 740 429 406 7 5

2500 2500 1000 530 660 9 6

— 3000 1000 530 660 10 7

3000 — 1000 604 660 10 7

— 3200 1000 530 660 11 7

4000 4000 1000 756 660 14 9

— 5000 1000 756 660 17 11t This dimension increases by 50mm for outdoor end tap boxes

Cable tap box – centre

Ampere Rating A B C D Lugs Per PH&N Earth Lugs

Aluminium Copper mm mm mm mm 240mm2 150mm2 240mm2

800 800 889 356 406 185 3 2 —

1000 1000 889 356 406 185 4 3 —

1200 1200 889 356 406 185 4 3 —

1350 1350 889 356 406 185 5 3 —

1600 1600 889 356 406 185 6 4 —

— 2000 889 356 406 185 7 5 —

2000 — 1059 508 447 261 7 5 —

— 2500 1059 508 447 261 9 6 —

2500 — 1059 508 447 261 9 6 —

— 3000 1270 559 660 261 10 — 10

3000 — 1524 559 660 406 10 — 10

— 3200 1270 610 660 261 11 — 11

4000 4000 1600 813 660 483 14 — 14

— 5000 1600 813 660 483 17 — 17


28.00711

B

C

A

D

48.001219

711

1219

Cable Tap Box-CentreCatalogue Number Suffix – CTB

Cable Tap Box-Bolt On

28.00711

BA

C

10.00254

711

254

Cable Tap Box-EndCatalogue Number Suffix – ETBMB

28.20716

23.50597

24.00610

15.00381

6.25158

11.50292

11.50292

0.5013

1.1228

3.0076

10.50267

0.5013

9.00229

CL

CL

28

267

13

292

292

610

716158

13

381

597

229

76


Cable tap box – bolt onLugs Per Catalogue Number

Ampere Phase and EarthRating Neutral Lugs TP+E TP+N

800

1000

1200 6-240mm2 2-240mm2 PTB-316G PTB516G

1350

1600

L

Notes For Cable Tap Box- Bolt-On1. Gutter can be moved to opposite end in field. 711mm clearance required from C ofbusbar trunking, for mounting bolt-on tap boxes when gutter is on top; and 610mmrequired mounting clearance when gutter is on the bottom.

2. May be used only on plug-in busbar trunking with the same number of poles: that is, donot use TP units on TP & N busbar trunking or TP & N units on TP busbar trunking.

3. Cannot be mounted in the last opening on either side of a busbar trunking run.

4. Cannot be used on 800A copper I-LINE II busbar trunking.

5. This unit requires a special hanger which is mounting orientation specific. Add“H” on the end of the catalogue number for units which will be mounted horizontally and“V” for units which will be mounted vertically. These mounting frames are NOTinterchangeable.

38


Flatwise Elbow DetailsAmpere Rating L Catalogue NumberAluminium Copper mm Suffix

— 800 279 -LFM11

800 1000 279 -LFM11

1000 1200 305 -LFM12

1200 1350 305 -LFM12

— 1600 305 -LFM12

1350 2000 330 -LFM13

1600 — 330 -LFM13

2000 2500 381 -LFM15

— 3000 406 -LFM16

2500 3200 432 -LFM17

3000 — 457 -LFM18

— 4000 533 -LFM21

— 5000 533 -LFM21

4000 — 559 -LFM22

Tees – FeederAmpere Rating L Catalogue NumberAluminium Copper mm Suffix

— 800 279 -TFM11

800 1000 279 -TFM11

1000 1200 305 -TFM12

1200 1350 305 -TFM12

— 1600 305 -TFM12

1350 2000 330 -TFM13

1600 — 330 -TFM13

2000 2500 381 -TFM15

— 3000 406 -TFM16

2500 3200 432 -TFM17

3000 — 457 -TFM18

— 4000 533 -TFM21

— 5000 533 -TFM21

4000 — 559 -TFM22

L

L

L

Tees - FeederCatalogue Number Suffix–TFM



LL

Elbow - FlatwiseCatalogue Number Suffix–LFM

Elbow - EdgewiseCatalogue Number Suffix–LEM11

11.00279

11.00279

279

279


39

Unfused reducerCatalogue Number Suffix

Bolt End Slot End Ampere Rating

Ampere Rating 400 600 800 1000 1200 1350 1600 2000 2500 3000

800 -R04 -R06 — — — — — — — —

1000 -R04 -R06 -R08 — — — — — — —

1200 -R04 -R06 -R08 -R10 — — — — — —

1350 — -R06 -R08 -R10 -R12 — — — — —

1600 — -R06 -R08 -R10 -R12 -R13 — — — —

2000 — — -R08 -R10 -R12 -R13 -R16 — — —

2500 — — — -R10 -R12 -R13 -R16 -R20 — —

3000 — — — -R10 -R12 -R13 -R16 -R20 -R25 —

3200 — — — -R10 -R12 -R13 -R16 -R20 -R25 -R30

4000 — — — — — — -R16 -R20 -R25 -R30

5000 — — — — — — — -R20 -R25 -R30

Fused reducerFused or MCCB reducers are available. Contact your representative for details.

Unfused Reducer


Expansion FittingCatalogue Number Suffix–EJ

Aluminium Copper W

800 800 343

1000 1000 343

1200 1200 343

1350 1350 442

1600 1600 442

— 2000 442

2000 2500 / 3200 492

2500 3000 594

3000 — 667

4000 4000 819

— 5000 819

Note: Expansion fitting permits 38mm of expansion or contraction.An expansion fittingshould be used under the following conditions: whenever the busbar trunking crosses abuilding expansion; when a long straight run of busbar trunking does not contain anyelbows or both ends of the run are fixed.

24.00610

12.00305

12.00305

610

305

305


28.00711

40.001016

W

1016

711

40


Wall and floor flangeAmpere Rating A

Aluminium Copper mm Catalogue Number

— 800 186 ACF-38-WF

800 1000 199 ACF-43-WF

1000 1200 224 ACF-53-WF

— 1350 237 ACF-58-WF

1200 — 237 ACF-63-WF

— 1600 260 ACF-67-WF

1350 — 275 ACF-73-WF

— 2000 288 ACF-78-WF

1600 — 313 ACF-88-WF

2000 2500 360 ACF-13-WF

— 3000 475 ACF-15-WF

2500 3200 500 ACF-17-WF

3000 — 564 ACF-19-WF

— 4000 688 ACF-24-WF

— 5000 726 ACF-25-WF

4000 — 738 ACF-26-WF

Required wall and floor openingsStraight Flanged Flat Elbow Wall Thickness Edge Elbow Wall Thickness

Ampere Rating Length Ends 100 200 300 400 500 600 100 200 300 400 500 600

Aluminium Copper Y W Y W W Y Y

— 800 152 203 254 381 203 229 279 330 381 432 483 150 305 356 406 457 509 559

800 1000 152 203 254 381 203 254 305 356 406 457 508 150 305 356 406 457 509 559

1000 1200 178 203 279 381 203 305 356 406 457 508 559 176 305 356 406 457 509 559

— 1350 203 203 305 381 203 305 356 406 457 508 559 203 305 356 406 457 509 559

1200 — 203 203 330 381 203 330 381 432 483 533 584 203 305 356 406 457 509 559

1350 1600 229 203 356 381 203 356 406 457 508 559 610 229 305 356 406 457 509 559

— 2000 254 203 432 533 203 381 432 483 533 584 635 254 305 356 406 457 509 559

1600 — 279 203 432 533 203 432 483 533 584 635 686 279 305 356 406 457 509 559

2000 2500 381 203 483 533 203 559 610 660 711 762 813 381 305 356 406 457 509 559

— 3000 432 203 584 533 203 660 711 762 813 864 914 432 305 356 406 457 509 559

2500 3200 457 203 584 533 203 686 737 787 838 889 940 457 305 356 406 457 509 559

3000 — 533 203 660 533 203 787 838 889 940 991 1041 533 305 356 406 457 509 559

— 4000 660 203 813 533 203 940 991 1041 1092 1143 1194 660 305 356 406 457 509 559

— 5000 686 203 813 533 203 1016 1067 1118 1168 1219 1270 686 305 356 406 457 509 559

4000 — 711 203 813 533 203 1016 1067 1118 1168 1219 1270 711 305 356 406 457 509 559

End closureAmpere Rating A

Aluminium Copper mm Catalogue Number

— 800 110 ACF-38-EC

800 1000 123 ACF-43-EC

1000 1200 148 ACF53--EC

— 1350 161 ACF-58-EC

1200 - 174 ACF-63-EC

— 1600 184 ACF-67-EC

1350 — 199 ACF-73-EC

— 2000 212 ACF-78-EC

1600 — 237 ACF-88-EC

2000 2500 336 ACF-13-EC

— 3000 399 ACF-15-EC

2500 3200 425 ACF-17-EC

3000 — 488 ACF-19-EC

— 4000 612 ACF-24-EC

— 5000 650 ACF-25-EC

4000 — 663 ACF-26-EC

A

9.26235235

Wall and Floor Flange


End Closure

A1.0025

7.06179179

25Y

W

Required Wall and Floor Openings


41

8.70221

.50 Drop Rod 13 by Customer

221

13mm

Hanger - Flat

Hanger-flat (for single run)Ampere Rating Catalogue NumberAluminium Copper Number

— 800 HF-38-F

800 1000 HF-43-F

1000 1200 HF-53-F

— 1350 HF-58-F

1200 - HF-63-F

— 1600 HF-67-F

1350 — HF-73-F

— 2000 HF-78-F

1600 — HF-88-F

Hanger-edgeAmpere Rating A CatalogueAluminium Copper mm Number

800 800 212 HF-43-E

— 1000 212 HF-43-E

1000 1200 250 HF-58-E

— 1350 250 HF-58-E

1200 1600 276 HF-67-E

1350 2000 301 HF-78-E

1600 — 339 HF-88-E

2000 2500 438 HF-13-E

— 3000 501 HF-15-E

2500 3200 527 HF-16-E

3000 — 613 HF-19-E

— 4000 714 HF-24-E

4000 5000 752 HF-26-E

A

.50 Drop Rod 13 by Customer

13mm

Hanger - Edge

2.2557

B

B

A

A

.50 Drop Rods 13 by Customer

57

13mm

Hanger - Flat

Hanger-flatAmpere Rating Catalogue NumberAluminium Copper A B Number

2000 2500 92 114 HF-13-F

— 3000 85 152 HF-15-F

2500 3200 85 165 HF-16-F

3000 — 92 191 HF-19-F

— 4000 90 254 HF-24-F

— 5000 84 279 HF-25-F

4000 — 90 279 HF-26-F



42

I-LINE Busbar TrunkingI-LINE II Physical Data


Spring HangersAmpere Rating Catalog

Aluminum Copper Number

800 800 HF-VS1

1000 1000 HF-VS1

1200 1200 HF-VS1

1350 — HF-VS1

1600 — HF-VS1

— 1350 HF-VS2

— 1600 HF-VS2

2000 2000 HF-VS2

2500 — HF-VS2

— 2500 HF-VS8

3000 3000 / 3200 HF-VS8

4000 4000 HF-VS8

— 5000 HF-VS8

9.62244

2.2557

2.2557

6.00152

FinishedFloor

1.5038

1.5038

HousingWidth

Hanger - Vertical Spring

Channel by customer.Hardware to securechannel to floor and hanger to channelalso by customer.

244

2.2557

32 32

57

152

57

or Curb

9.62244

Channel by customer.Hardware to securechannel to floor and hanger to channelalso by customer.

2.2557

HousingWidth

FinishedFloor or Curb

Catalog Number HF-V

Note: Allow 337mm above curb or floor to CL of jointto allow for proper installation of tie channel cover.

Hanger - Vertical Fixed

32 32

244

57

Note: One HF-VS2 Hanger is shown inthe above detail.

Note: Allow 533mm above curb or floor to CL of jointto allow for proper installation of tie channel cover.

Spring Hangers


43

I-Line II indoor feeder minimums and maximums (in millimetres)DR/DL OF OE LEFE LFFE

LE FE LF Double Offset Offset Edge Elbow Flat ElbowEdge Flanged Flat Elbow Elbow Flat Elbow Edge and FE and FE

Ampere Rating Elbow End Elbow Min Min Min Min Min

Aluminium Copper Min/Max Min/Max Min/Max (A) (B) (C) (D) (E)

800 800/1000 279-1067 254-1219 279-1524 178 102 152 152 204

1000 1200 279-1067 254-1219 305-1524 203 102 152 152 204

— 1350 279-1067 254-1219 305-1524 203 102 152 152 229

1200 1600 279-1067 254-1219 305-1524 203 152 152 152 229

1350 — 279-1067 254-1219 330-1524 228 229 152 152 229

— 2000 279-1067 254-1219 330-1524 228 229 152 152 254

1600 — 279-1067 254-1279 330-1524 228 254 152 152 254

2000 2500 279-1067 254-1219 381-1524 279 356 152 152 305

2500 — 279-1067 254-1219 432-1524 330 406 152 152 356

— 3000 279-1067 254-1219 406-1524 330 406 152 152 330

3000 — 279-1067 254-1219 457-1524 356 457 152 152 381

— 3200 279-1067 254-1219 432-1524 330 406 152 152 356

4000 — 279-1067 254-1219 559-1524 457 635 152 152 457

— 4000/5000 279-1067 254-1219 533-1524 432/457 584/635 152 152 457

Note: All dimensions are to centrelines and adjustable in 25.4mm increments (1 inch).


special devices such as offset elbows, and double elbowsto adapt to special situations in which standard deviceswill not work.

Listed below is a table showing minimums and maximumsfor these special devices so you will know the exactflexibility you have when designing and I-LINE II BusbarTrunking installation. We also show some of the devicesbelow the table to better give you a picture of what we canfurnish.

Special devices – I-LINE II busbar trunking

Previously listed are the standard devices typically used indesigning and installing I-LINE II Busbar Trunking. Obviously, therewill be occasions when these will not work. Straight lengths canbe built in special lengths of 406mm to 3023mm for indoor andoutdoor, in 25.4mm increments.

We can also build special lengths in fittings such as elbows, flangedends, and combinations into single pieces which are similar to thedevices previously described in this manual. We can also build

RightHand

LeftHand

Double Elbow

Flat(OF) Edge

(OE)Offset Elbows

Flanged End and Elbow Combinations

Edge Elbow and FE(LEFE)

Flat Elbow and FE(LFFE)

(DR) (DL)

A

C

E

B

D

44


I-LINE short circuit rating at 3 cycles (RMS symmetrical kA at 60Hz)Ampere Aluminium Copper

Rating AF2/AOF2 AFH2/AOFH AP/AP2 APH/APH2 CF2/COF2 CFH2/COFH CP/CP2 CPH/CPH2

225 — — 22 — — — 22 —

400 — — 22 42 — — 22 42

600 — — 22 42 — — 22 42

800 50 85 50 75 50 85 50 75

1000 50 100 50 100 50 85 50 75

1200 50 100 50 100 50 100 50 100

1350 50 100 50 100 50 100 50 100

1600 50 100 50 100 50 100 50 100

2000 100 150 125 150 50 100 65 100

2500 100 150 125 150 100 150 125 150

3000 100 150 125 150 100 150 125 150

4000 150 200a 200 — 150 200 200a —

5000 — — — — 150 200 200a —

a Certain fittings are rated at 150 KA RMS symmetrical

I-LINE II Electrical Data

I-LINE short circuit rating (Tested values, RMS symmetrical kA at 50Hz)Ampere 3 cycles 1 Sec 3 sec

Rating Feeder Plug-in Feeder Plug-in Feeder Plug-in

250 22 22 - - - -

400 22/42* 22/42* - - - -

630 22/42* 22/42* - - - -

800 50 50 40 40 - -

1000 50 50 50 50 - -

1200 50 50 50 50 - -

1350 50 50 50 50 - -

1600 50 50 50 50 - -

2000 50 65 50 50 40 -

2500 100 125 75 75 40 -

3000 100 125 75 75 40 -

3200 100 125 75 75 40 -

4000 150 200 100 100 40 -

5000 150 200 100 100 40 -

a High breaking capacity type


45

I-LINE II Electrical Data

Notes:1) For balanced TP line-to-line voltage drop of TP & N

busbar trunking, use values from tables.

2) For balanced TP line-to-neutral voltage drop, multiplyvalues from tables by .577.

3) For single phase voltage drop, multiply values fromtables by 1.15.

4) For other than rated current, multiply values from tablesby Actual Current . Rated Current

Voltage Drop Values

Voltage drop values shown in the tables below are based on asingle, concentrated load at the end of the run. For distributedloading, multiply the values shown by 0.5. All impedance valuesare given at 80°C operating temperature.

I-LINE II Busbar trunking voltage drop is low. This helps tomaintain a stable voltage supply to delicate electronic andcomputer equipment. Even at low power factors, the extremelylow reactance of I-LINE Busbar trunking helps to minimizethe instantaneous voltage dips which can be caused by a motorstarting inrush currents, and so forth.50Hz voltage drop (at rated load) Average TP line-to-line voltage drop in volts per metreAmpere Aluminium Power Factor %Rating 100 95 90 85 80 75 70 60 50 40 30 20 10

800 .113 .117 .115 .113 .109 .106 .102 .093 .084 .075 .064 .054 .043

1000 .114 .118 .116 .114 .110 .107 .103 .094 .085 .075 .065 .055 .044

1200 .103 .107 .106 .104 .101 .098 .094 .087 .079 .070 .061 .052 .042

1350 .097 .102 .101 .099 .096 .093 .090 .083 .076 .068 .059 .050 .041

1600 .089 .094 .093 .092 .090 .087 .084 .078 .071 .064 .056 .048 .040

2000 .093 .098 .097 .096 .093 .091 .088 .081 .074 .066 .058 .050 .041

2500 .094 .099 .099 .097 .095 .092 .089 .083 .075 .068 .060 .051 .042

3000 .084 .089 .089 .087 .085 .093 .080 .074 .063 .061 .054 .046 .038

4000 .087 .090 .089 .087 .084 .082 .079 .072 .065 .058 .050 .042 .034

Ampere Copper Power Factor %Rating 100 95 90 85 80 75 70 60 50 40 30 20 10

800 .079 .087 .088 .087 .088 .085 .083 .078 .073 .067 .061 .054 .047

1000 .086 .095 .096 .095 .094 .092 .090 .085 .080 .073 .066 .059 .051

1200 .074 .083 .084 .084 .085 .082 .090 .076 .072 .066 .060 .054 .047

1350 .075 .084 .085 .085 .085 .083 .082 .078 .073 .068 .062 .055 .049

1600 .074 .084 .086 .086 .085 .084 .083 .079 .074 .069 .063 .057 .050

2000 .082 .092 .093 .093 .092 .091 .089 .085 .080 .074 .067 .060 .052

2500 .071 .081 .083 .083 .082 .081 .080 .077 .072 .067 .062 .056 .049

3000 .076 .086 .088 .088 .087 .086 .085 .081 .076 .071 .065 .059 .052

3200 .068 .077 .079 .080 .079 .079 .077 .074 .070 .066 .061 .055 .049

4000 .074 .081 .082 .082 .081 .079 .077 .073 .068 .062 .056 .050 .043

5000 .066 .074 .076 .076 .075 .074 .073 .069 .065 .060 .055 .049 .043

50 Hz Impedance ValuesLine-to-neutral in milliohms per metreAluminium Busbar Trunking Copper Busbar Trunking

AmpereRating R X50 R X50

800 .0814 .0232 .0567 .0280

1000 .0655 .0189 .0497 .0244

1200 .0494 .0152 .0357 .0192

1350 .0415 .0134 .0320 .0177

1600 .0320 .0113 .0268 .0155

2000 .0268 .091 .0238 .0128

2500 .0216 .076 .0165 .0098

3000 .0162 .058 .0146 .0085

3200 — — .0122 .0076

4000 .0125 .037 .0107 .0052

5000 — — .0076 .0043

Sample 11000 Ampere Aluminium Busbar Trunking at 50% power factor - 50 HzVoltage Drop

=√3 I (R cos PH + X sin PH)

=3 x 1000 (.0000655 x .50 + .000019 x .866)

=.0852volts/metre - Concentrated Load

Resistance values for aluminium integral earth busDC resistance in milliohms per metreAmpere RatingTP+E & TP+E+N Aluminium Phase Conductors Copper Phase Conductors

800 .131 .144

1000 .115 .131

1200 .105 .115

1350 .098 .112

1600 .092 .098

2000 .073 .098

2500 .066 .073

3000 .059 .066

3200 — .066

4000 .056 .056

5000 — .056

Resistance values for the integral earth bus are at a 20° C operating temperature.

Sample 21000 Ampere Copper Busbar Trunking at 50% power factor - 50 HzVoltage Drop

=√3 I (R cos PH + X sin PH)

=3 x 1000 (.0000497 x .50 + .000024x .866)

= .0790 volts/metre - Concentrated Load

= .0790 = .0395 volts/metre - Distributed Load 2

46


Interlock Earthing Spring

Plug-in Units

Plug-in device mountingPlug-in units are positioned along the busbar trunking lengthby notches in the busbar trunking housing top which acceptthe mounting hooks of the plug-in unit. This aligns the plug-inunit connectors with the plug-in opening. After the unit ispositioned on the busbar trunking it is allowed to swing downinto the plug-in opening where the connectors make contactwith the busbar. This is accomplished in “hook-swing”sequence of motions for the 30-600A units. 800-1600A plug-in units utilize a special mounting bracket.

“Hook-Swing” Mounting

Fusible switched and MCCB plug-in units

InterlockTable I on Page 49 indicates which units are interlocked withthe busbar. All devices incorporate an interlock to preventthe door over the disconnect from being opened when theunit is ON.

EarthingAll plug-in devices incorporate an earthing spring which cutsthrough the paint and forms an equipment earth between thehousing and the body of the device before the phase jawsmake contact with the busbars. Where ordered for use withan earth bus in the trunking, an additional larger capacity bladewill be provided which makes contact with a jaw mounted onthe earth bus itself.

I-LINE Plug-in units application data

CompatibilityAll plug-in units listed in this catalogue may be used on originalI-LINE busbar trunking as well as the newer I-LINE II busbartrunking. There is no need to stock two different types of units.

Fusible30, 60, 100, 200, 400, 600 ampere plug-in switches containa heavy duty safety switch mechanism.

Circuit breakersMoulded case circuit breaker plug-in devices are available inframe sizes of 100 amperes (FA) through 1600 amperes (PA)with standard or High-Interrupting capacity breakers. Plug-indevices with current limiting MCCBs are also available.

Operating handle gives visual tripped indication on all devicesas well as floor operable reset on all devices.

High visibilityON-OFF indication

Hook stick operatedmechanism

Bracket allows unitto be padlocked inoff position

Hinged door overswitch

Transparent Shield overLine Side Parts


47

Fusible Plug-in unitsType Ampere 600VAC 240/415VAC Type of BS88

of Rating TP&E TP&N&E FuseConnection Catalogue No Catalogue No.

30 PQ-3603-GE PQ-4603-GE TIA

60 PQ-3606-GE PQ-4606-GE TIS

100 PQ-3610-GE PQ-4610-GE TCP

200 PQ-3620-GE PQ-4620-GE TF

200 PS-3620-GE PS-4620-GE TF

400 PBQ-3640-GE PBQ-4640-GE TKF/TMF

600 PBQ-3660-GE PBQ-4660-GE TTM

800 PTQ-3680-GE PTQ-4680-GE

1000 PTQ-36100-GE PTQ-46100-GE

1200 PTQ-36120-GE PTQ-46120-GE

1600 PTQ-36160-GE PTQ-46160-GE

Trip 600 VAC 240/415VAC

Rating TP&E TP&N&EBreaker A Catalogue Number Catalogue Number

125 PKA-36125-G PKA-36125-GN

150 PKA-36150-G PKA-36150-GN

175 PKA-36175-G PKA-36175-GN

200 PKA-36200-G PKA-36200-GN

225 PKA-36225-G PKA-36225-GN

250 PKA-36250-G PKA-36250-GN

300 PBLA-36300-G PBLA-36300-GN

350 PBLA-36350-G PBLA-36350-GN

400 PBLA-36400-G PBLA-36400-GN

a These units require a special hanger which is mounting orientation specific. Add “H” on the end of the catalogue number for units which will be mounted horizontally and “V” for units whichwill be mounted vertically. These mounting frames are NOT interchangeable.

Type Trip 600 VAC 240/415VAC

Of Rating TP&E TP&N&EBreaker Connection A Catalogue Number Catalogue Number

500 PTMA-36500-G PTMA-36500-GN

600 PTMA-36600-G PTMA-36600-GN

700 PTMA-36700-G PTMA-36700-GN

800 PTMA-36800-G PTMA-36800-GN

900 PTMA-36900-G PTMA-36900-GN

1000 PTMA-36100-G PTMA-36100-GN

1000 PTPA-36100-G PTPA-36100-GN

1200 PTPA-36120-G PTPA-36120-GN

1400 PTPA-36140-G PTPA-36140-GN

1600 PTPA-36160-G PTPA-36160-GN

Circuit breaker unitsTrip 415VAC 240/415VAC 600VACRating TP&E TP&N&E TP&E

Breaker A Catalogue No. Catalogue No. Catalogue No.

15 PFA-34015-G PFA-34015-GN PFA-36015-G

20 PFA-34020-G PFA-34020-GN PFA-36020-G

30 PFA-34030-G PFA-34030-GN PFA-36030-G

40 PFA-34040-G PFA-34040-GN PFA-36040-G

50 PFA-34050-G PFA-34050-GN PFA-36050-G

60 PFA-34060-G PFA-34060-GN PFA-36060-G

70 PFA-34070-G PFA-34070-GN PFA-36070-G

90 PFA-34090-G PFA-34090-GN PFA-36090-G

100 PFA-34100-G PFA-34100-GN PFA-36100-G

PAa

MAa

FA

Plug-in Units

Bolt-on

Bolt-onLA

KA

Bolt-on a

Plug-in

48


High fault rating circuit breaker units Extra high fault rating circuit breaker units Current limiting circuit breaker units

Trip 600 VAC 240/415VAC 240/415VAC 240/415VACType of Rating TP&E TP&N&E TP&N&E TP&N&E

Breaker Connection A Catalogue Number Catalogue Number Catalogue Number Catalogue Number

15 PFH-36015-G PFH-36015-GN PFC-34015-GN PFI-34015-GN









125 PKH-36125-G PKH-36125-GN PKC-34125-GN PKI-34125-GN






300 PBLH-36300-G PBLH-36300-GN PBLC-34300-GN PBLI-34300-GN



500 PTMH-36500-G PTMH-36500-GN — PTMA-36500-GNCLa






a Current limiting circuit breaker units are supplied with Square D standard breaker plus a set of three coordinated current limiting fuses.Note: PFI, PKI, and PBLI devices are supplied with Square D Current Limiting Circuit Breakers.

FA Plug-in

KA Plug-in

LA Plug-in

MA Bolt-on

Plug-in Units


49

Type PQ Fusible Switch Type PBLA Circuit Breaker Type PTMA Circuit BreakerLow Ampere Plug-in Connection High Ampere Plug-in Connection High Ampere Bolt-on Connection

Plug-in Units

Table ll: Interrupting capacity of circuitbreaker plug-in units tCatalogue Trip RMS SymmetricalNumber Range Amp. —(3Hz)

Prefix (Amperes) 415/240V-50Hz 480VAC-60Hz 380/225-50Hz

With moulded case circuit breakers

PFA 15-100 18,000 18,000 18,000

PKA 125-225 25,000 25,000 25,000

PBLA 250-400 35,000 30,000 42,000

PTMA 500-1000 35,000 30,000 50,000

PTPA 1200-1600 50,000 50,000 50,000

With moulded case circuit breakers-high interrupting capacity

PFH 15-100 25,000 25,000 25,000

PKH 125-225 30,000 35,000 35,000

PBLH 250-400 35,000 35,000 42,000

PTMH 500-1000 50,000 50,000 50,000

PTPH 1200-1600 — 100,000 —

With molded case circuit breaker - extra high interrupting capacity

PFC 15-100 65,000 65,000 65,000

PKC 125-225 65,000 65,000 65,000

PBLC 300-400 65,000 65,000 65,000

Table ll: Interrupting capacity of circuitbreaker plug-in units tCatalogue Trip RMS SymmetricalNumber Range Amp—(3Hz)

Prefix (Amperes) 415/240V-50Hz 480VAC-60Hz 380/225-50Hz

With moulded case l-LIMITER current limiting circuit breakers

PFI 15-100 100,000 100,000 100,000

PKI 125-250 100,000 100,000 100,000

PBLI 250-400 200,000 200,000 200,000

With electronic trip circuit breakers

PBLX 100-600 65,000 65,000 65,000

PTMX 450-800 65,000 65,000 65,000

PTPX 600-2500 100,000 100,000 100,000

TABLE l. Catalogue designation and typeCatalogue Number Prefix Type Ampere Rating Door Interlock Interlock with BusBar Hook Stick Operable

PQ Fusible-Switched 30-200 Yes Yes Yes

PS Fusible-Switched 200 Yes No Yes

PBQ Fusible-Switched 400 Yes No Yes

PBQ Fusible-Switched 600 Yes No Yes

PFA,PFH Circuit Breaker 15-100 Yes Yes Yes

PFI,PFC Circuit Breaker 15-100 Yes Yes Yes

PKA,PKH Circuit Breaker 125-250 Yes Yes Yes

PKI,PKC Circuit Breaker 125-250 Yes Yes Yes

PBLI,PBLC Circuit Breaker 300-400 Yes No Yes

PBLA, PBLH, PBLX Circuit breaker 300-400 Yes No Yes

PTMA, PTMH, PTMX Circuit Breaker 500-1000 Yes No Yes

PTPA, PTPH, PTPX Circuit Breaker 1000-1600 Yes No Yes

t IEC 157 Part 1

50


Fusible SwitchA F H

Catalogue Number Prefix Ampere Rating mm mm mm

30 387 203 203

60 387 203 203

100 387 304 203

PQ 200 699 381 381

PS 200 699 229 305

PBQ 400 1524 184 457

PBQ 600 1524 184 457

Vertical mounting – Fusible UnitsFusible switch plug-in units (30A - 100A) Mount on either sideof the vertical busbar trunking. With the unit mounted on oneside of the busbar trunking, the operating handle is on thetop, and when mounted on the opposite side, the handle is on the bottom.

The 200A fusible unit (“PS”) mounts only on the front of thebusbar trunking (The TOP sticker on the busbar trunking is onthe right). The operating handle is on the right side of themounted unit.

The 400A - 1600A fusible units mount only on the front of thebusbar trunking. The handle is on the cover.

IMPORTANT: Orientation of the busbar trunking is essentialfor proper mounting of plug-in units. The busbar trunking mustbe positioned as shown above so that the top marking is tothe right and the neutral position to the left.

Circuit Breaker Units:Circuit breaker plug-in units may be installed on both sides ofa riser.

PQ

Circuit BreakerA F H

Catalogue Number Prefix Amperes Rating mm mm mm

PFA,PFH 15-100 530 54 254

PFC,PFI 15-100 651 73 279

PKA,PKH 125-250 651 60 279

PKI,PKC 125-250 651 60 279

PBLA,PBLH 250-400 906 142 381

PBLX,PBLC,PBLI 250-400 889 203 508

PTMA,PTMH,PTMX,PTME 500-1000 894 159 406

PTPA,PTPH,PTPX,PTPE 1000-1600 1332 260 610

Plug-in Units

AE

B

C

N

Top

CL

H

2.0051

Min.

HousingWidth

A

F

NCBAE

ON

OF

F

Top51

Min.



51

Fusible Switch Plug-in Units 30A-100AWeight Lugs Per Phase Lugs Per Neutral Earth Lugs A B

Cat. No. Prefix Amperes Rating Kg Qty. Size Qty. Size Qty. Size mm mm

30/60 33.0 1 35mm2 1 35mm2 1 25mm2 379 203

100 37.5 1 35mm2 1 35mm2 1 25mm2 480 304

ON

OFF

4.63118

5.42138

A

B

8.00203

1.0527

8.85225

1.6341

Front

Top

EABCN

Required Mounting Clearance

138 118

225 4127

203

Fusible Switch Plug-in Units 30A- 100A

Fusible Switch Plug-in Unit: 200A (Type “PQ”)Weight (Approx) Lugs Per Phase & Neutral Earth Lugs

Cat No. Prefix Ampere Rating Kg Qty. Size Qty. Size

PQa 200 32 1 150mm2 1 70mm2

a 200A, “PQ” Units are for use primarily on horizontally mounted busbar. Refer to “PS” units for use primarily on vertically mounted busbar.

PQ

Plug-in Units


ON

OFF

CL9.72247

16.17411

14.40366

11.44291

15.00381

15.00381

3.4888

1.1329

22.48571

.5614

EABCN

Required Mounting Clearance14

247

291

411 29

571

366

381

88

381

Fusible Switch Plug-in Unit: 200A (Type “PQ”)

52


Fusible Switch Plug-in Units: 400 and 600AWeight (Approx) Lugs Per Phase & Neutral Earth Lugs

Cat No. Prefix Ampere Rating Kg Qty. Size Qty Size

PBQa 400 89 2 300mm2 1 300mm2

PBQa 600 89 2 300mm2 1 300mm2

a “PBQ” Unit plugs into one opening but requires space equal to two plug-in openings.Note: For vertical riser applications for I-LINE@ II Busway, order auxlliary kit catalog number PBQ-4060-RMK. This kit is not suitable for installation on I-LINE Busway from 250 ampere to 600

ampere in a vertical riser mounting.

Fusible Switch Plug-in Unit: 200A (Type “PS”)Weight (Approx.) Lugs Per Phase & Neutral Earth Lugs

Cat. No. Prefix Ampere Rating (A) Kg Qty. Size Qty. Size

PSa 200 32 1 150mm2 1 70mm2

a 200A “PS” unit is for use on one side of vertically mounted busbar trunking only. To determine proper mounting side for this unit, position busbar trunking “TOP” marking to the right (sameside as unit operating handle) and the neutral busbar to the left as shown in top view of drawing.

Fusible Switch Plug-In Unit: 200A

Fusible Switch Plug-In Unit: 400A and 600A

Plug-in Units

OFF

ON

EABCN

Top

18.00457

8.93227

4.00102

4.34110

42.001067

1.2732

20.95532

13.75349

1.4036

6.14156


CL

110

349

36

1067 32

532

102

227

457

156

ON

OFF

CL

14.22361

22.48571

1.1128

3.7194

11.44291

9.09231

16.17411

18.00457

1.1329


Top

NCBAE

291

457

29411

231

28

571

361

94



53

Circuit Breaker Plug-in Units 15A–250AA B C D E F G H

Cat. No. Prefix Trip Range (Amperes) mm mm mm mm mm mm mm mm

PFA, PFH 15-100A 330 210 168 219 28 28 51 254

PKA,PKH,PKC 125-250A 416 216 203 232 25 35 51 279

PFC 15-100A 416 216 203 232 25 35 51 279

Circuit Breaker Plug-In Units 15A-250A

Circuit Breaker Plug-in Units 15A–250AWeight Lugs Per Phase & Neutral Earth Lugs

Cat No. Prefix Trip Range (Amperes) Kg Qty. Size Qty. Size

PFA, PFH 15-30A 13 1 16mm2 1 35mm2

PFA,PFH 35-100A 13 1 50mm2 1 35mm2

PKA,PKH, PKC 125-250A 18 1 150mm2 1 70mm2

PFC 15-30A 25 1 16mm2 1 35mm2

PFC 35-100A 25 1 50mm2 1 35mm2

Top


CL

H

D

E

F

G

Front

Top

ON

OFF

1.3835

3.2583

C

B

A

CL

EABCN

EABCN

35 83

Plug-in Units


54


I-LIMITER Current Limiting Circuit Breaker Plug-In Units 15A - 250AA B C D E F G H

Cat. No. Prefix Trip Range (Amperes) mm mm mm mm mm mm mm mm

PFI 15-100A 416 216 203 232 25 35 51 279

PKI 125-250A 416 216 203 232 25 35 51 279

I-LIMITER Current Limiting Circuit Breaker Plug-In Units 15A - 250AWeight Lugs Per Phase & Neutral Earth Lugs

Cat No. Prefix Trip Range (Amperes) Kg Qty. Size Qty. Size

PFI 15-30A 15 1 16mm2 1 35mm2

PFI 35-100A 15 1 50mm2 1 35mm2

PKI 125-250A 24 1 150mm2 1 70mm2

I-LIMITER Current Limiting Circuit Breaker Plug-In Units 15A - 250A

Top


CL

H

D

E

F

G

Front

Top

ON

OFF

1.3835

3.2583

C

B

A

CL

EABCN

EABCN

35 83

Plug-in Units


Note: For vertical riser applications for I-LINE® II Busway, order auxlliary kit catalog nuber PBQ-4060-RMK.This kit is not suitable for installation on I-LINE Busway from 250 ampere to 600ampere in a vertical riser mounting.


55

Circuit Breaker Plug-In Units 250A- 400AWeight Lugs Per Phase and Neutral Earth Lugs

Cat. No. Prefix Trip Range(Amperes) Kg Qty. size Qty. Size

PBLA, PBLHa 250-400 35 1 300mm2 1 150mm2

a PBLA and PBLH units plug into one opening but require space equal to two plug-in openings.

37.87962

EABCN


CL

CL

OFF ON

Front

Top

18.00457

9.77248

0.47 Dia. 12(2 Holes)

4.34110

1.2532

5.38137

20.00508

7.07180

Drop Rod byCustomer

4.00102

18.05458

508

137

180

102

458

32

457

110

12(2 Holes) 248

962

Plug-in Units


ON

OFFAE

Top

BCN


CL

Front

15.00381

15.25387

7.13181

17.00432

27.31694

1.1028

4.50114

5.75146

3.6292

381

146

432 28 694

387

92

114

181

Circuit Breaker Plug-In Units 250A- 400A

I-LIMITER Current Limiting Circuit Breaker Plug-In Units 250A-400A

I-LIMITER Current Limiting Circuit Breaker Plug-In Units 250A-400AWeight(Approx.) Lugs Per Phase Earth Lugs Lugs on Neutral

Cat No. Prefix Triple Range(Amperes) Kg Qty. Size Qty. Size Qty Size

PBLIa 250-400 58 2 300mm2 1 150mm2 3 300mm2

a PBLI units plug into opening but require space equal to two plug-in openings.

56


Circuit Breaker Bolt-On Units 500A - 2000AA B C D E F G H

Cat No. Prefix Trip Range (Amperes) mm mm mm mm mm mm mm mm

†PTMA, PTMH, PTMX 500-1000 803 359 318 422 70 133 390 406

†PTPA, PTPH, PTPX 1000-2000 1505 656 406 510 229 235 648 610

Circuit Breaker Bolt-On Units 500A - 2000AWeight(Approx) Lugs Per Phase & Neutral Earth Lugs

Cat. No. Prefix Trip Range (Amperes) Kg Qty. Size Qty. Size

†PTMA, PTMH, PTMX 500-1000 73 3 240mm2 2 240mm2

†PTPA, PTMH, PTPX 1000-2000 159 6 240mm2 3 240mm2

† PTMA, PTMH, PTPA, PTMX, PTPX, and PTPH units plug into one opening but require space equal to two or three plug-in openings (See A Dimension).

Circuit Breaker Plug-In Units 300A - 600AWeight(Approx) Lugs Per Phase Earth Lugs Lugs On Neutral

Cat. No. Prefix Trip Range(Amperes) Kg Qty. Size Qty. Size Qty. Size

PBLC 300-600 58 2 #4-300MCM 1 #6-300MCM 3 3/0-500MCM

PBLC units plug into one opening but require space equal to two plug-in openings.

EACBN

Top

D

Drop Rod byCustomer


CL

CL

H

G

F

E

OFF ON

Front B

C

Top

A

I

Circuit Breaker Bolt-On Units 700A - 1600A

Plug-in Units


37.87962

EABCN


CL

CL

OFF ON

Front

Top

18.00457

9.77248

0.47 Dia. 12(2 Holes)

4.34110

1.2532

5.38137

20.00508

7.07180

9.77 Drop Rod by 248 Customer

4.00102

18.05458

508

137

180

102

458

32

457

110

12(2 Holes) 248

962

248

Circuit Breaker Plug-In Units 300A - 600A


57

Suggested Busbar Trunking Specifications

Specifications

I-LINE and I-LINE II busbar trunking systems

General

Quality AssuranceA. All busbar trunking products shall be manufactured in a

facility which is Quality Systems Registered byUnderwriters Laboratories to ISO9001: 1994:EN29001:1994 BS5750 Part 1: 1994: ANSI/ASQCQ91: 1994.

Regulatory RequirementsA. Underwriters Laboratories Listing

1. All straight lengths, fittings, and plug-in units shall beUL Listed.

2. This listing shall include mounting of the busbar trunk-ing in any position (i.e. horizontal flatwise, horizontaledgewise, and vertical) without derating.

Delivery, Storage and HandlingA. Refer to NEMA Publication BU1.1 which is a guide for

proper installation, operation, and maintenance ofbusbar trunking products.

MaintenanceA. Refer to NEMA Publication BU1.1 which is a guide for

proper installation, operation, and maintenance ofbusbar trunking products.

Product

ManufacturersA. All busbar trunking shall be I-LINE/ I-LINE II busbar

trunking manufactured by Schneider Electric.

Manufactured UnitsA. General

1. Furnish and install a complete low impedanceprefabricated busbar trunking distribution system asshown on the plans.

2. Busbar trunking shall be _____ volts, _____ phase,_____ wire with 50% capacity integral earth bus.

3. The ampere ratings, approximate footage, fitting,plug-in units etc. are shown on the plan. The electricalcontractor shall be responsible for routing the busbartrunking to coordinate with the other trades. Final fieldmeasurements shall be made by the contractor priorto release of the busbar trunking for fabrication bythe manufacturer.

B. Short Circuit Rating and Tests

1. The short circuit rating of the busbar trunking shallbe (consulting engineer’s calculated required rating)______ rms symmetrical amperes which is theultimate anticipated short circuit current available atthe source.

2. The short circuit rating of the busbar trunking shallbe determined according to UL standards No. 857.This rating must be based upon actual tests at therated short circuit current.

Basic ConstructionA. Housing

1. The busbar trunking housing shall be constructed ofcode gauge steel and aluminium to reduce hysteresisand eddy current loses and shall be provided with asuitable protective finish of ANSI 49 gray epoxy paint.

2. The busbar trunking housing shall be totally enclosednon-ventilated for protection against mechanicaldamage and dust accumulation.

3. The totally enclosed housing shall be manufacturedby the busbar trunking manufacturer. Modifications ofbusbar trunking to make it totally enclosed by otherthan the busbar trunking manufacturer voids themanufacturer’s warranty. Busbar trunking so modifiedis unacceptable without the written consent of themanufacturer.

B. Joint

1. The busbar trunking joint shall be of the one-bolt typewhich utilizes a high strength steel bolt(s) andBelleville washers to maintain proper pressure overa large contact surface area.

2. The bolt shall be torque indicating and at earthpotential.

3. The bolt shall be two-headed design to indicate whenproper torque has been applied and require only astandard long handle wrench to be properly activated.

4. Access shall be required to only one side of the busbartrunking for tightening joint bolts.

5. On busbar trunking 800A and above, it shall bepossible to remove any joint connection assembly toallow electrical isolation or physical removal of abusbar trunking length without disturbing adjacentbusbar trunking lengths.

C. Busbars

1. Busbars shall be tin plated aluminium or silver flashedcopper.

2. Each busbar shall be insulated with Class B rated130° C vendor certified polyester film or epoxy powdercoated materials.

3. The temperature rise at any point in the busbartrunking shall not exceed 55° C rise above ambienttemperature when operating at rated load current.

4. Both feeder and plug-in busbar trunking (800A andabove) shall be of sandwich construction, meaningno air gap shall exist between busbars except atplug-in openings.

58

I-LINE Busbar TrunkingSuggested Busbar Trunking Specifications

D. Plug-in Openings

1. On plug-in busbar trunking there shall be five deadfront, hinged cover type plug-in openings on each sideof ten foot lengths.

2. All openings shall be usable simultaneously.

3. Busbar trunking shall be installed so that plugs areside mounted to permit practical use of all ten plug-inopenings.

4. It shall be possible to inspect the plug-in opening andbusbars prior to the installation of the plug-in unit.

Support of Busbar TrunkingA. Hanger spacing shall be noted on layout drawings and

shall not exceed manufacturer's recommendations.

B. Indoor feeder and plug-in busbar trunking shall beapproved for hanger spacing of up to 3 metres forhorizontally mounted runs and 4.88 metres for verticallymounted runs. Outdoor feeder busbar trunking shall beapproved for spacing of up to 1.5 metres for horizontallyor vertically mounted runs.

Voltage DropA. The voltage drop (input voltage minus output voltage)

specified shall be based on the busbar trunking operatingat full rated current and at stabilized operatingtemperature.

B. The three-phase, line-to-line voltage drop shall notexceed 3.1 volts per hundred feet at 40% power factorconcentrated load which may exist during motor starting.

C. The line-to-line voltage drop shall not exceed 4.0 voltsper hundred feet at the load power factor which producesmaximum voltage drop in the busbar trunking.

Plug-in UnitsA. Plug-in units shall be (circuit breaker type) (fusible switch

type with visible blade quick-make and quick-breakmechanism).

B. Plug-in units which cannot be operated directly from thefloor shall be equipped with suitable means for hookstickoperation.

C. The interrupting rating of circuit breaker plug-in unitsshall be _____ rms symmetrical amperes.

Plug-in Unit Safety DevicesA. Plug-in enclosures shall make positive earth connection

with the earth bus before the jaws make contact withthe phase bars.

1. The earthing method shall be such that it cuts throughpainted surfaces to make the positive earthconnection.

B. The plug-in units shall be equipped with internal barriersto prevent accidental contact of fish tape and conductorswith live parts on the line side of the protective deviceduring time of wire pulling.

C. Covers of all plug-in units must have interlocks to preventthe cover from being opened when the switch is in theON position.

InstallationA. Install busbar trunking and accessories in accordance

with manufacturer’s instructions. Additional instructionsare detailed in NEMA publication BU1.1 which isprovided with the equipment by the electr icalmanufacturer.

B. Install busbar trunking length with expansion fitting ateach location where busbar trunking run crossesbuilding expansion.

C. Provide curb around interior floor penetrations.

D. Install busbar trunking with integral weather seal locatedwhere busbar trunking penetrates (exterior wall )(roof).Provide (wall) (roof) flange and seal around opening tomaintain weather tight installation.


59

Notes

60

I-LINE Busbar TrunkingNotes

Quality Accreditations

ASTA certificate TILVA certificate

ISO 9002 certificate UL certificateCCIB certificate

02/2007SEHK/DOC/ILINE01

Schneider Electric (HK) Ltd.

13th Floor, East Wing, Warwick House,Taikoo Place, 979 King's Road, Quarry Bay, Hong KongTel :(852) 2565 0621 Fax :(852) 2811 1029

Macau Branch Office

Suite D, 13th Floor, The Macau Square,Avenida do Infante D. Henriqne, No. 47-53, MacauTel :(853) 2871 7488 Fax :(853) 2871 7499

www.schneider-electric.com.hk

Production Facility :Schneider Busway (Guangzhou) Limited85 Jun Ye Lu, Northern Part of Eastern Section ofGuangzhou Economic & TechnologicalDevelopment District, Guangzhou, PR ChinaPostal Code : 510530Tel : (8620) 8226 4242Fax : (8620) 8226 4032/8226 4497

As standards, specifications and designschange from time to time, please ask forconfirmation of the information given in thispublication.

Customer Care Centre: (852) 2579 6999

43@tbllocalcat filenames ilinetrunkingsys cat 0207

Documents

hong kong

electronic

technological

800a tp

rms symmetrical

line physical

cos ph

motor control