Busbar Trunking System

L&T - Megaduct
 L&T - Building Electricals
Larsen & Toubro Limited - India's leading technology-driven engineering and construction
organization - offers India's widest range of low-tension switchgear. Each product in the switchgear range
carries the L&T insignia of reliability and accuracy, and is backed by prompt after-sales service. For your
offices, commercial & residential requirements choose from L&T’s complete range of building electricals.

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Power Gear Final Distribution Products

1 Air Circuit Breaker 5 Busbar Trunking System
2 Molded Case Circuit Breaker 6 Wires
7 Modular Devices (MCB, ELCB, ELMCB, DB)

Energy & Metering Building Automation Products

3 Capacitors 8 Tebis - Home Automation
4 Energy Meters 9 Atmos - HVAC control
10 Login - Access control
11 Powerman - Energy Monitoring System
 L&T - Megaduct Busbar Trunking System
Busbar trunking system (BBT), performs the function of
transporting current form one point to the other.
Traditionally cables were used for this function.
BBT goes beyond what cables do. BBT can tap off power
to switchgear for further distribution using tap of boxes.
In comparison to cables, BBT can thus serve as
distribution panels at different stages (at floors of a
building). BBT thus continues as a single systems to
replace cables as well as distribution boards at floor level
for building (commercial or industrial).
IT/ITES
Hotels
Areas of
Application
Industries
Airports
L&T introduces world-class sandwich Busbar Trunking
System (BBT) under the brand ‘L&T-Megaduct’ to its
valued Indian customers. The BBT is totally enclosed,
non-ventilated design busbar and is fully insulated using
halogen free fire retardant epoxy insulation.L&T-
Megaduct BBT system offer a superior alternative to
cables and other bus trunking options through this
compact and scalable range of system thus providing an
enhanced solution to power transmission and
distribution in buildings as well as industry.
Hospitals
Apartments
Assembly lines in factories
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 Types of Busbar Trunking System

Busbar trunking system is of two types:

1) Sandwich : Epoxy or Cast Resin type

2) Air Insulated : Fabricated Air Insulated type

Sandwich Busbar trunking system is preferred widely due to its advantages over Air insulated busbars as
well as cables, some of which are mentioned below.

Benefits of Sandwich Construction :

Compactness : Sandwich construction render to the BBT system more compact than air
insulated bus bar system, thus making them a preferred choice in plant room
and building applications.

Energy efficiency : Compactness of sandwich construction results in higher efficiency due to lower
voltage drop and impedance. This ensures all connected equipment run cooler.

Flexible : Additions of floor to a building or any expansion to an existing system is

extremely simple with sandwich BBT. They are scalable & elegant.

Safe & Sure : Higher mechanical strength over long runs, better electrical conductivity and
lower mV drop which ensures high reliability. Ability to withstand high short
circuit currents make them doubly safe.

Fire retardant : Sandwich construction do not have air gap due to which natural progression of
fire is inhibited. Epoxy insulation, being flame retardant provides better
resistance to spread of fire.

Economical : Inherently flexible design ensures easy installation and maintenance thus
resulting in lower installation and maintenance costs.

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 L&T - Megaduct Busbar Trunking System

L&T Megaduct busbar trunking system is of sandwich construction, totally enclosed, well insulated
design. It is used (as feeder busbar) for interconnection between transformer/generator to power
distribution centers and as plug-in (busbar risers) in building power systems. Cast resin busduct are
also available for outdoor application. These busducts are suitable for operation in a 600/1000V system.

The diagram below familiarises you with L&T-Megaduct busbar trunking system:

6 2
4

1
1 - Flange End

2 - Straight Busduct

3 - Single Bolt Bridge Joint

4 - Elbow

5 - Tap-off Unit

6 - Terminal End Cover

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 Components of Busbar Trunking System

1
Flange End
Flange End is the incoming unit of a busbar trunking Flange End Box can be provided on request with flange
system. The power is fed at the flange End to energise end for accommodating protective devices like
the busbar trunking system. Flange End is provided ACB/MCCB.
with sufficient space for direct cable connections by nuts
and bolts. (details can be given on request)

2
Straight Busduct
These straight bus duct run along the length of connection and the body of the bus trunking system.
Types of straight busduct are:

Feeder type: Straight busbar trunking unit with no Plug in type: Straight busbar trunking unit having tap
tap off facility. off points on one or many faces.

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 Ingress Protection
Conductor Neutral
Indoor Outdoor
Al Cu IP42 IP55 IP66 IP67 100% 200%
Feeder
Type
Plug-in
Type

System Voltage : Epoxy Insulation

600V and up to maximum 1000V / 3P / 50 Hz or 60 Hz

constructed in various configurations of 3 phase 3 wire
or 3 phase 4 wire with or without 50% integral housing
ground and separate earth bar. The earth bar (50% or
100%) can be installed. To counter excessive harmonic
effects, 200% neutral can also be provided on request.

Current Ratings :
Wide range of current rating from 100A to 6300A for
Copper Conductor and upto 5000A for Aluminium
Conductors.

Epoxy Insulation : Horizontal / Vertical BusBars :

All Busbars have Class H -180°C standard epoxy coating
as insulation material which provides 100% water
proofing and high mechanical strength. This insulation
has been tested in accordance with IEC 60-439-2 and
BS 5486.
Benefits of using epoxy coating as insulation :
Withstands glitch and spikes in electrical system so
that system is stable & runs reliably.
Provides rooms for expansion/contraction during
peak and off-peak hours to avoid tracking in surface
of insulation.
Capable of withstanding heat shock thus minimising
chances of failure due to spark or excess heat.
High mechanical strength so that insulation damage
by accidental impact is reduced.
High thermal conductivity to provide uniform
distribution of heat, hence system runs cooler.
Water and chemical resistant which makes it suitable
for use in corrosive and humid environment.
All L&T Megaduct copper busbars are of high
conductivity (IACS 99.98%) copper bar with high purity
(>99.95%), or aluminum bars with conductivity >61%.
All copper busbars are fully tin or silver plated and fully
epoxy insulated.
The busbars are tropicalised to withstand higher
temperature rise of 50O C- 55OC.
Standard lengths of 3M / 2M / 1M up to 0.45M. Other
lengths will be made available as required.
Housing :
L&T Megaduct Busbar Trunking have a rugged housing
profile and provide the most efficient way to dissipate
heat through conduction and natural convection. All
housings are constructed from 1.6mm electro-
galvanized steel sheet coated with oven baked polyester
powder paint or epoxy coated powder which also
provides maximum mechanical strength against
electromagnetic stresses.

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 3
Single Bolt Bridge Joints

The straight bus ducts are expected to carry their full
rated current for required lengths and in order to
overcome extreme rugged conditions at site, the new
L&T Megaduct joint has been designed precisely and
manufactured using the highest quality of materials to
minimize all possible problems and enhance system
performance.
Benefits of Single Bolt Bridge Joint:
Incorporates a 5mm thermal expansion and
movement at every joint.
Allows ±15mm of lateral adjustment (total 30mm) to
correct site measurement inaccuracies.
Ability to tilt at an angle of ± 5° (total 10 °> along
single axis)
Longer overlapping length (>40 mm) to increase
contact area.
Single bolt bridge joint system.
Bolts and nuts can be stainless steel, galvanized or
chromed black High Tensile Steel
Entire System is designed and tested for protection of IP
42 / IP55 / IP 66 / IP 67.
Easy to remove / install joints without removing the
main busduct.
Water / Chemical Resistant DMC / SMC insulation Plates.
Optional shear off twin headed bolts to required torque
of 70Nm.

1 - Disc Spring
5
2 - Joint Backing Plate
4
3 3 - Joint End Insulator (DMC)
8
2 4 - Joint Copper Bar 4.5mm
1
5 - Joint Phase Insulator (DMC)
6 - Nylon Locknut
6 7 - Fiber Tube
7
8 - Joint Bolt (Single/Double Headed)

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 4
Elbow
Busbar Trunking elbows are angle units which enable
the Busbar Trunking system to change directions.
Various types of elbows can be provided as per
customers requirement. Like,
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Tap-Off Units (TOU)
Tap-Off Units are required to tap power from the straight
bus ducts. Typically, Tap-Off units are used in plug in
type busbar trunking systems (vertical risers). TOUs
are installed at specified intervals for tapping power from
a bus trunking system. TOU is provided with non-fused
Flatwise Elbow (Horizontal Elbow)
Edgewise Elbow (Vertical Elbow)
Edgewise offset ( Double Elbow)
Combination Elbow (Combines Vertical & Horizontal)
circuit breakers (MCCB) or SDFs of various current
ratings. Generally, 2 tap-off units per side are installed.
Provision of up to five tap-off units per length of 3M
busduct can be given depending upon the size of MCCBs.
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 Features of Tap-Off Units:

All Tap-Off units can be interlocked to prevent removal

when outgoing device is in ‘ON’ position.
When the tap-off unit cover is ‘OPEN’, it is interlocked
such that MCCB cannot be turned ‘ON’.
Tap-Off units are suitable for all types of MCCBs ie.
3 pole / 4 pole of ratings from 16A to 1600A.
Tap-Off units can also be used with MCBs and Fuse
Switch Breaker
Plug in outlet
Self interlocking clamp Metering facility can be provided on request.
Bolt-on type plug-in units is available for MCCB
Guide port
ratings >600A.

Guide clamp

6 7

Terminal End Cover Supports

Component for sealing the last bus bar trunking unit in
the system. Typically, one such end cover would be
required for termination of one run of the system.
Required for spacing Busbar Trunking System
horizontally and vertically.
Horizontal hanger supports are required for Horizontal
installations and Vertical rigid/ spring supports for
vertical installations.

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 Technical Data

Aluminium Conductor

Bus Bar Bus Bar No. Impedance Line to Line Voltage

Concentrated Dimensions Wt. micro-ohm Drop in mV/m at Rated
Size Of (kg/m)
Rated Current (w x h) (mm) Stacks per metre at Current & Various
in mm 95 degree celcius Power factors
3P4W R X Z
1/2E 1 0.8 0.6 0.4 0.2 0

100 150 x 65 3 x 40 1 14 365.7 117.51 384.12 63.34 62.88 54.28 43.99 32.61 20.35
200 150 x 65 3 x 40 1 14 365.7 117.51 384.12 126.68 125.76 108.56 87.98 65.22 40.7
300 150 x 78 6 x 40 1 15 268.5 82.12 280.78 185.99 182.93 157.11 134.89 92.94 58.89
400 150 x 78 6 x 40 1 16 268.50 82.12 280.73 185.99 182.93 157.11 126.54 92.94 58.89
600 150 x 88 6 x 50 1 18 151.70 75.42 169.4 157.63 173.13 157.28 134.89 108.32 78.38
800 150 x 113 6 x 75 1 19 98.40 20.16 100.44 136.35 125.84 104.16 80.14 54.64 27.93
1000 150 x 138 6 x 100 1 22 65.63 15.68 67.48 113.67 107.23 89.93 70.36 49.34 27.16
1250 150 x 163 6 x 125 1 25 47.33 11.26 48.65 102.47 96.61 80.99 63.33 44.38 24.38
1750 150 x 188 6 x 150 1 28 35.75 9.76 37.06 108.36 104.44 88.68 70.46 50.66 29.58
2000 150 x 238 6 x 200 1 37 29.87 7.97 30.92 103.47 99.34 84.17 66.69 47.75 27.61
2500 150 x 326 6 x 125 2 49 23.04 6.75 24.01 99.77 97.35 83.24 66.69 48.59 29.23
3000 150 x 376 6 x 150 2 55 18.86 5.02 19.52 98.00 94.05 79.67 63.11 45.96 26.08
4000 150 x 564 6 x 150 3 82 11.92 2.32 12.14 82.58 75.71 62.41 47.77 32.27 16.07
5000 150 x 714 6 x 200 3 97 7.85 1.24 7.95 67.98 63.48 52.91 41.08 28.45 15.16

Copper Conductor
Bus Bar Bus Bar No. Impedance Line to Line Voltage
Concentrated Dimensions Wt. micro-ohm Drop in mV/m at Rated
Size Of (kg/m)
Rated Current (w x h) (mm) Stacks per metre at Current & Various
in mm 95 degree celcius Power factors
3P4W
(AMP) R X Z 1 0.8 0.6 0.4 0.2 0
1/2E
100 150 x 60 3 x 20 1 15 210.61 107.11 236.28 36.48 40.31 36.73 31.59 25.47 18.55
200 150 x 65 3 x 25 1 17 201.8 105.31 227.63 69.9 77.81 71.13 61.4 49.72 36.48
300 150 x 80 3 x 40 1 18 175.37 99.91 201.83 91.12 104.05 96.21 84.03 69.09 51.92
400 150 x 65 6 x 25 1 20 157.57 93.31 184.83 109.29 127.45 118.96 104.87 87.24 66.73
600 150 x 78 6 x 40 1 24 96.62 85.48 129.01 100.41 133.63 131.31 121.58 107.12 88.83
800 150 x 88 6 x 50 1 27 69.64 25.40 74.13 96.50 98.31 86.05 70.86 53.78 35.20
1000 150 x 113 6 x 75 1 33 50.75 19.38 54.32 87.90 90.46 79.60 65.92 50.47 33.57
1250 150 x 138 6 x 100 1 40 37.89 14.84 40.59 82.03 84.91 74.92 62.26 47.89 32.13
1750 150 x 163 6 x 125 1 48 30.24 11.86 32.48 91.66 94.90 83.76 69.61 53.55 35.95
2000 150 x 188 6 x 150 1 55 25.15 9.80 27.00 87.12 90.07 79.43 65.96 50.69 33.95
2500 150 x 238 6 x 200 1 70 18.95 7.57 20.41 82.06 85.31 75.46 62.87 48.53 32.78
3250 150 x 326 6 x 125 2 95 15.12 6.05 16.29 78.57 81.72 72.29 60.24 46.52 31.44
4500 150 x 489 6 x 125 3 142 10.08 4.15 10.90 78.57 82.26 73.02 61.07 47.41 32.35
5500 150 x 564 6 x 150 3 164 8.38 3.43 9.05 72.57 75.88 67.31 56.25 43.62 29.71
6300 150 x 714 6 x 200 3 207 7.25 2.87 7.80 75.34 78.17 69.07 57.47 44.29 29.80

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 Typical Busbar Trunking Layout

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8

10

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14

6
4

15

13

2
16

1
1 - Flange End 9 - Reducer T-Section

2 - Vertical Feeder Busbar 10 - Vertical Plug-in Busbar Sw

itc
3 - Horizontal Feeder Busbar 11 - Tap-off Unit h
Bo
4 - Flat-Wise Elbow 12 - End Cover ar
d
5 - Double Elbow 13 - End-Feed Cable Box

6 - Horizontal Plug-in Busbar 14 - Horizontal Hanger

7 - Edge-Wise Elbow 15 - Vertical Spring Support

8 - T-Section 16 - Cables

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 Certifications & Approvals

L&T Megaduct Busbar Trunking Systems

are tested as a composite system (including
tap off units) and certified by ASTA & CPRI
to comply with:

BS 5486 Part 2, 1990

IEC 60439-2, 2000
CPRI
Conform to the relevant codes and
requirements of:
UL 857 / ANSI
IEE / IEEE
NEMA BU 1
JIS 8364
IEC 529
SEISMIC PROTECTION CERTIFICATION

All busducts are factory tested to 2.5 kV / 5.0 kV for

60 seconds.

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 Notes

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Notes

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 Electrical Standard Products (ESP) Branch Offices:

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Product improvement is a continuous process. For the latest information and special applications, please contact any of our offices listed here.

Electrical Standard Products

Larsen & Toubro Limited
Powai Campus, Mumbai 400 072
Tel: 022-6705 0505
Fax: 022-6705 1746
E-mail: ebg-esp@LNTEBG.com
Website: www.LNTEBG.com

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