GE ENERGY
Overhead Busbar System
Overhead Busbar System
Why an Overhead Busbar System? Durability and long life exceptionally
robust and rigid construction. All
G E Power Controls overhead busbar ferrous materials are rust-proofed
system provides the most efficient and before priming and finishing.
optimum distribution of medium voltage
power in industries where concepts of Construction
2 planned production and scientific factory
layouts are applied, ensur ing complete The overhead busbar system consists of a
safety. robust busbar chamber, flanges of which Two sections of 200 Amps.
are connected together with a tie-bolt. The busbars coupled together.
With an increasing need to alter shop sheet-steel par ts are rust-proofed with
layouts and changes in production patter ns anticorrosive chemicals prior to the
to meet the ever-demanding market, application of unicoat stoved enamel finish.
overhead busbars provide the necessary The busbar run through this chamber
flexibility to make such changes quickly, with suppor ted by fire-retardant phenolic
minimum power shutdown, utilising the moulds, which also serve as plug-in points.
existing cables, conduits and fittings. This
system provides for installation outputs that The overhead busbars are supplied in
can be maintained at peak levels. Thus, in standard lengths of 3.65 mtrs. (200A) and
this context, the need for an overhead 2.44 mtrs (400A). The busbars are made
busbar system in industries, becomes a of high conductivity aluminium complying
priority automatically. to specification 63401 T6 of lS 5082-1981.
The busbars are completely shrouded in
Many years of operating experience has PVC sleeves throughout their length,
proved that the G E Power Controls Ltd., Two sections of 400 Amps.
except at the plug-in points to enable
busbars coupled together.
over head busbar system gives troublefree connection of outgoing circuits by means
ser vice throughout its life, with practically no of plug-in boxes.
maintenance.
Bus bar Couplings
Ratings
Busbar lengths can be coupled
The system is available in TPN arrangement mechanically and any length of run in
with ratings of 200A and 400A for an multiples of the standard length may be
operational voltage of up to 500AC. thus achieved. Electrical contact is
achieved by bolting together overlapping
Salient Features ends of the busbars and securing the Plug-in Boxes 32A, 63A & 100A
screws with locking plates. Detachable
Maximum flexibility - With plug-in points blank-end-covers are available for These are compact sheet-steel boxes with
provided at inter vals of 60.96 cm. along enclosing the free ends of the busbar run. hinged-doors housing the fuse-holders,
with busbars. which are solidly connected to high
A connector-assembly is supplied loose, conductivity copper clip-on contacts
Complete safety - Fully insulated plug-in with each length for coupling two length, reinforced by spring steel strips. These clip-
and comprises- on contacts plug directly on to the busbars
points ensure safety for operating and
at the plug-in points. For additional safety,
maintenance personnel.
- Rubber locating ring two earth-pins are located at the two ends
of these boxes. While inser ting these boxes
No shut-down - Plug-in boxes can be - Busbar insulating tube into the plug-in points, the ear th pins
plugged into live busbars quickly and
- Connector insulating tube engage first in the special ear th bushes
safely.
provided on the underside of the busbar
chamber before the main contacts make.
Easy extensions - Ratings of busbars While withdrawing these boxes, the earth
and numerous plug-in points ensure connection is maintained even after the
ample accommodation for future loads. main contacts are isolated.
Busbars can be extended easily by
coupling with new lengths.
Guaranteed protection - HBC fuse-links
at all plug-in points ensure positive and
reliable shor t-circuit protection.
Overhead Busbar System
Method of Securing If multi-crore PVC cables are used, care
should be taken at the site to suppor t the
The plug-in boxes inser ted into the plug-in cable, to avoid additional strain on fuse-
points are fastened by wing-nuts provided. fitting contact with cable connection, thus
For plug-in boxes used in 400A rating preventing failure of contacts.
extended wing-nuts are to be used for
negotiating greater depth. While connecting aluminium cables directly
3
to fuse fitting contacts, care should be taken
Important as mentioned in instruction sheet supplied
While ordering for plug-in boxes suitable for with PIB.
400A overhead busbars, please specify the
Blank end-covers should be ordered and
busbar rating so that the plug-in boxes can
provided at either end of the length to avoid
be supplied with extended wing-nuts.
entry of vermin.
Incoming Supply
Tests
The incoming supply connections for the
overhead busbars are made through a Each length of overhead busbar undergoes
connector housing. This housing is the following tests before despatch:
mounted preferably on the top of the a. A high voltage insulation withstand test
chamber at inter vals of 2 feet from either for 2 kV for 1 minute.
end, or in the centre. It consists of a steel b. An earth impedance test.
Diagram showing a busbar layout for small factories enclosure with interconnections for
connections for connecting to the main Short Circuit Protection
busbar.
I/C The rapid operation and high breaking
S Installation capacity of G E Power Controls fuselinks
The usual method of installation is to lay enable them to meet the need for reliable
the busbar system on roof trusses, but if short circuit ‘back up’ protection of motor
(S) Supply point required can be suspended from the roof control gear. Correctly chosen fuselinks will
(l/C Incomer Housing using brackets to suit site conditions. This discriminate with the overcurrent trip device,
busbar system can also be installed in permitting it to operate an faults within its
factories equipped with overhead cranes, capacity.
by mounting it on supporting stanchions
S I/C below the gantry level or on supports For normal industrial installation fuselinks
specially provided to carry them 2 metres may be used from the fuse rating as given in
above ground level. The unsuppor ted span the table, which are based on average
should not exceed 2 metres. conditions for direct online or assisted star t
Diagram showing busbars being fed from the centre motors where special drives involve high
where load is evenly distributed. Centre - feeding torque motors, frequent start duties or
effectively doubles the current carrying capacity of the Connection to plug-in boxes are
recommended, using conduit pipe to extended starting times, fuse-links of higher
system.
conduit glands supplied with PIB. rating may be required.
Dimensions are in millimeteres unless otherwise specified
‘A’ A B C Size of conduit gland
Ref. Description in plug-in box (Both
‘B’ For T.P.N TP & TPN
Wing Nut Fastener
1 200/300A. OHBB WITH 251 219 98 FOR 1 1/4” CONDUIT
3/8” Tie Bolt 32 & 63 PLUG-IN BOX
2 200/300 A. OHBB WITH 251 219 98 FOR 2” CONDUIT
‘C’
Side Channel Earthing Stud 100A PLUG-IN BOX
Busbar Support
Ear th Bushing 3 400 A. OHBB WITH 251 219 133 FOR 1 1/4” CONDUIT
Neutral Link 32 & 63 PLUG-IN BOX.
Contact
4 400 A. OHBB WITH 251 219 133 FOR 2” CONDUIT
‘D’
100 A. PLUG-IN BOX
Plug-in Box Alternative Gland Positions
Hinged Cover
Fuse Fitting for
HBC Fuse-links Conduit Gland
Ample Wiring Space
Overhead Busbar System
Technical Data
Overhead busbars
Rating Overall Dim in mm No. of plug-in points Weight in Kg.
200A 3658x248x76 6 46
400A 2440x248x108 4 40
Plug - in box
Rating Code Associated fuse link
32A RRF 303 - N4 TIS, TSA
63A RRF 603 - N4 TSA, TSS
100A RRR 1003 - N4 TSD
Recommended fuse ratings for motor starting 400 Volts 3-phase
Motor H.B.C. Fuse-link Rating Amps.
Horse Power Full load Amp. D.O.L Start Assisted Start
0.5 1.5 4 2
1 2 6 2
2 3.5 15 6
3 5 20 10
4 6.5 20 15
5 8 25 15
7.5 12 30 20
10 15 40 25
12.5 18 50 25
15 21 60 30
20 28 80 40
25 35 100 50
30 41 100 60
35 48 - 80
40 55 - 80
45 62 - 100
50 69 - 100
GE Energy
GE India Industrial Private Limited
Plot No. 42/1 & 45/14
Electronic City – Phase II
Bangalore - 560100
Ph: (080) 41113000
Fax:(080)285 28469/552
