43@tbllocalcat Filenames ILineTrunkingSys Cat 0207

I-LINE Busbar Trunking Systems
Catalogue
Applications & Specifications Class 5600
07
Building a New Electric World
Delivering Power to the People

I-LINE busbar trunking system was first introduced by Square D in 1961 in its production facility in Oxford, Ohio U.S.A. and has acquired worldwide recognition in a variety of busway applications. I-LINE busbar trunking system is designed with maximum flexibility, ease of installation and electrical efficiency in the distribution of power of 600V and below, for both commercial and industrial application. It is available in ratings from 250A to 4000A with aluminium conductors; and 250A to 5000A with copper conductors. Configuration offered are TP and TP&N with 100% capacity, neutral, and the 50% capacity integral earthing conductor. To cope with rapid expansion of power network in the Greater China and South East Asia, Schneider Electric, set up a manufacturing facility in 1997 in Guangzhou Economic & Technological Development District of PR China, namely Schneider Busway (Guangzhou) Ltd., to manufacture I-LINE busbar trunking system. Apart from I-LINE, the Company is also marketing Canalis lighting busway to the regions. I-LINE busbar trunking system manufactured in Guangzhou achieves a high level of quality and product excellence. It complies with international standards of UL857, NEMA, CSA, ZBK, IEC439 and GB; and was accredited of ISO9001 and CCIB. The product also passed testing of ASTA and China Electrical Equipment Testing Centre, Low Voltage Equipment Testing Centre. To ensure product is of the highest standard in the market, specialists from Oxford facility visit Guangzhou factory regularly to conduct training and audit. In return, Guangzhou products are sent to U.S.A. for periodical testing and inspection on a quarter basis. Schneider Electric's success in launching I-LINE busbar trunking system, for sure, should be attributed to the technological expertise and quality assurance of the product itself. Yet merit should also go to the dedicated sales and after-sales supports from the Hong Kong office of Schneider Electric, only with which a total and meticulous solution can be tailored to every unique application requirements. Empowered by the electrical engineers who master sound knowledge and practical experience, Schneider Electric can provide diversified project management services to customers, from on-site measurement, proposal on the best busducts routing, to installation assistance at site and missing link units arrangement. We trust this is the definite asset of Schneider Electric that you can always count on. Want to know more about Schneider Electric or I-LINE busbar trunking system? Please contact our Hong Kong office as printed on this publication.
Square D facility in Oxford, Ohio U.S.A. is an ISO 9001 registered busbar trunking manufacturing facility.
Schneider Busway (Guangzhou) Ltd. was certified to achieve ISO9001 quality management system.
Schneider Busway (Guangzhou) Electrical Equipment Ltd. receives product certification from ASTA and ISO system accreditation from DNV.
ISO 9001: 2000 Certificate No. 0086-1999-AQ-RGC-RvA
Schneider Electric I-LINE busbar trunking is designed and manufactured in a facility that is quality system registered by UL and BSI to ISO 9001.
NATIONAL ACCREDITATION OF CERTIFICATION BODIES
UL
Certificate No. FM23076
SQUARE D COMPANY REGISTERED TO ISO 9001 CERTIFICATE NO. A2194
I-LINE Busbar Trunking Contents
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
I-LINE Busbar Trunking Product Features
Simple to install and maintain

Square D pioneered the Single Bolt Joint in 1961 when it introduced I-LINE Busbar Trunking. Continuing research and improvements have led to our current design. I-LINE Busbar Trunking Systems feature the following time-saving installation and maintenance features: Joint-Pak Joint-Pak is standard on I-LINE II Systems. It allows for quick removal of lengths from the busbar trunking runs for load shifting or maintenance. It also can be removed and relocated on the opposite end of the length for last minute changes.
Totally enclosed housing no de-rating necessary The I-LINE Busbar Trunking Systems have a totally enclosed housing design which requires no de-rating, regardless of the mounting position. No longer do you have to worry about preferred mounting positions or de-rating factors. With the I-LINE family of busbar trunking, the 100% current ratings remain constant in any mounting position. Another advantage of our totally enclosed housing versus ventilated trunking is superior protection from accidental contact with busbars and from accumulation of dirt on exposed busbars through the ventilating screens. I-LINE busbar trunking is available in an indoor version only. The I-LINE II plug-in and feeder are available in indoor and indoor drip-resistant versions. There is also a version of I-LINE II feeder busbar trunking suitable for outdoor use. Harmonics and electrical equipment neutrals Harmonics and the effects of nonlinear loads on electrical equipment neutral conductors are subjects of concern. Nonlinear load devices, such as variable speed drives, electronic ballast lighting, computers, printers, and fax machines, generate harmonics, and their use is increasing. Harmonic effects are often exaggerated and singled out as the cause for overloading electrical equipment neutrals. The research by Square D indicates that oversized neutrals are an unnecessary expense to most customers. In 480Y/277 systems, neutral currents normally do not exceed 100 percent of the neutral rating. In 208Y/120 systems, neutral overloads occur only in rare, unusual cases. Therefore, oversized neutrals are an unnecessary expense to customers. Nonlinear loads, such as computers and electronic ballast lighting, create harmonics. In rare cases in 208Y/120 systems, distortion from harmonics may necessitate the use of oversized neutral 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 order our document no. 0104ED9501, Neutral Currents in Three Phase Wye Systems , by R. Arthur and R. A. Shanahan, P.E. or 0104PD9501, Harmonics and Electrical Equipment Neutrals. Internal smoke/gas barriers Continuous air spaces inside I-LINE II busbar trunking housing are closed off with special barriers to help prevent the spread of smoke and gases in the event of a fire in the area of the busbar trunking installation. This standard internal barrier allows busbar trunking to extend through walls or floors without creating open space for a chimney effect fire path. I-LINE busbar trunking from 225 to 600A requires installation of a special internal barrier for wall or floor penetrations.
The VISI-TITE bolt The VISI-TITE bolt is standard on all I-LINE Busbar Trunking. The double head design, introduced by Square D in 1967 allows the customer to tighten the joint to the proper torque using a standard spanner. The outer head will break off when the correct torque is achieved. When the head breaks off, a red plastic VISI-TITE disc drops off, indicating that the joint is properly torqued. A second bolt head remains to allow for joint maintenance or busbar relocation. No need to purchase a replacement bolt. A cupped Belleville washer provides equal pressure across the complete joint contact area to assure proper electrical contact.
Universal fittings Universal fittings, which are standard on I-LINE II Systems, allow feeders and plug-in ducts to be connected without special joint covers. All fittings are also universal allowing simpler installation and maintenance of your system. Broad range of products The I-LINE Busbar Trunking Systems come in two basic ranges of products: I-LINE - From 225 to 600 amperes, aluminium or copper conductors. I-LINE II - From 800 to 4000 amperes with aluminium conductors, and From 800 to 5000 amperes with copper conductors. I-LINE is provided as a plug-in system only, and I-LINE II is available as a feeder or plug-in system.
I-LINE Busbar Trunking Product Features
High grade conducting and insulation material

I-LINE Busbar Trunking Systems use either high grade tin plated aluminium or silver flashed copper for their conducting material. The conductors are plated over their entire surface for better corrosion protection. All busbars are insulated using Class B 130 C vendor certified polyester film (Mylar) or epoxy powder coating for long insulation life. I-LINE Busbar Trunking insulation consists of two layers of 7.5 mil heat formed polyester film surrounding each busbar. I-LINE II Busbar Trunking uses the same two layers of polyester film to insulate the busbars in indoor trunking while outdoor trunking utilizes powder coated epoxy insulation for the busbars. Both types of insulation offer high quality dielectric strength and long life expectancy. Short circuit strength and testing The I-LINE Busbar Trunking design gives high short circuit strength suitable for todays industrial and commercial electrical systems. The systems are certified at a 3 cycle rating by Underwriters 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 conductor The 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 ground faults. I-LINE II is furnished with the integral earthing bus as standard. The earthing bus is the bus housing itself and completely encloses 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 todays ever expanding electrical systems. With our design, we have given the maximum amount of protection in an economical package.
Integral Earth Bus: 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 Indoor Indoor, Drip Resistant Outdoor
t IEC 529:1976
Steel side channel (2) for mechanical strength Earth Bus/Housing Top (1.6mm Aluminium Busbar)
Type of Trunking Feeder and Plug-in Feeder only
Degree of Protection t IP-40 IP-54 IP-66
Feeder and Plug-in
Busbars Earth Bus/ Housing Bottom (1.6mm Aluminium Busbar)
Top
I-LINE II Busbar Trunking Cross Section Including Standard Integral Earth Bus
Continuous bonding between top and bottom earth bus
I-LINE Busbar Trunking Construction
What is I-LINE busbar trunking?

I-LINE Busbar Trunking systems are a time proven design with installations all over the world. Available in two ranges with ratings from 225 through 600 amperes and 800 through 5000 amperes, this low impedance sandwich type plug-in and feeder busbar trunking accepts existing I-LINE plug-in (225A to 600A) units (subject to trunking amperage restrictions). The features of the design include the VISI-TITE bolt, plated aluminium or copper busbars and the integral earth conductor. I-LINE II busbar trunking has the additional standard features of internal barriers, the Joint-Pak assembly, and universal tie channels.
I-LINE Busbar Trunking (225A to 600A)
Systems: TP and TP and N (100% Neutral Capacity) for AC Systems, SP and TP for DC Systems. Ratings: From 225 to 600 amperes in aluminium or copper plated conductors. The 600 volts maximum busbar trunking is fully rated for mounting in either horizontal or vertical positions.
1 Earthing conductor:
3 Plug-in openings:
Rated at 50% of the nameplate rating of the Busbar Trunking. The conductor is aluminium and the top part of the housing itself.
2 VISI-TITE bolt:
Double headed bolts are supplied on all joint connections to assure proper torque on the joint connector. Only a standard spanner is required to tighten the bolt until the outside head breaks off. A 76mm Belleville washer with a cupped surface dispenses uniform pressure across the full joint surface area.
All I-LINE Busbar Trunking has a plug-in opening for plug-in units every 610mm on both sides of the trunking. The openings are covered by hinged doors which cover the openings when not in use.
Hangers: I-LINE Busbar Trunking requires support every 3 metres when run horizontally flatwise and 4.8 metres vertically. It must be supported every 1.5 metres in the horizontal edgewise position. Enclosure: A three-piece formed steel housing with plug-in openings, supported by moulded rigid insulators. Available in indoor enclosures only.
I-LINE II Plug-in Busbar Trunking (800A to 5000A)
Systems: TP and TP and N (100% Neutral Capacity) for AC Systems, SP and TP for DC Systems. Ratings: From 800 to 4000 amperes with aluminium and from 800 to 5000 amperes with copper conductors. Busbars are plated over their entire length. 600 Volts maximum busbar trunking is fully rated for mounting in either vertical or horizontal positions.
1 Moulded plug-in
Opening insulator: Adds insulation and support at plug-in contact area.

2 Joint Pak connector
3 Earth jaw for plug-in
assembly: Includes common phase connector on higher amperage ratings utilizing more than one conductor per phase (plug-in busbar trunking only.)
unit: Blow-on design similar to phase jaw connection. This blow-on design provides maximum strength at contact areas during fault current conditions.
4 Fittings:
Internal barriers: Internal barriers are standard on I-LINE II feeder and plug-in Busbar Trunking. All interior spaces are barriered to protect against heated gasses. Sandwich Construction: I-LINE II plug-in Busbar Trunking also includes features depicted on Page 6 for I-LINE II feeder trunking. Available in indoor (IP-40) or indoor, drip resistant (IP-54) construction.
Elbows, tees and flanged ends are easily removed and refitted with the use of our Joint-Pak assembly without disturbing adjacent lengths.
Indoor Feeder Busbar Trunking (800A to 5000A)
Systems: TP and TP and N (100% Neutral Capacity) for AC Systems, SP and TP for DC Systems. Ratings: From 800 to 4000 amperes with aluminium and from 800 to 5000 amperes with copper conductors. Busbars are plated over their entire length. 600 Volts maximum busbar trunking is fully rated for mounting in either vertical or horizontal positions.
1 Earthing conductor:
3 Common housing:
Provided as standard on I-LINE II Systems and consists of two 1.6mm thick aluminium busbars. The earthing conductor is formed to serve as the top and bottom of the trunking housing.
2 Joint Pak connector:
For I-LINE II plug-in and feeder busbar Trunking. Same accessories fit both. Steel side channels and aluminum housing.
4 Insulation:
Fiberglass tape and epoxy resin: Available as an option for high interrupting capacity (AFH2, CFH2) busbar trunking systems. Electrodeposition paint process provides corrosion-resistant, long-lasting uniform appearance.
Removable for isolation and maintenance of system. The VISI-TITE bolt is included.
Indoor (IP-40 & IP-54) busbars are insulated with two full length heat formed layers of Class B 130 C polyester film.
Outdoor Feeder Busbar Trunking (800A to 5000A)
1 Joint Covers:
Two piece joint cover with quick-fasten nut for speedy installation of the busbar trunking.
2 EZ JOINT PAK:
covers with the quick fasten nut seal the joint from contamination by water.
4 Insulation:
The same joint pack used on our indoor I-LINE II trunking is continued in our Outdoor Feeder design.
3 Flanged Collar:
Outdoor (IP-66) busbars are insulated with epoxy powder coating material rated at 130 C.
5 Completed Joint:
Indoor transition devices are 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 on 1.5 metre centres for vertical or horizontal mounting.
Simple installation of the joint covers is assisted by a smooth flange surface with the joint sealant strip factory installed. Removal of the sealants protective paper covering and installation of the joint
The assembled joint with all installation activities complete.
I-LINE Busbar Trunking 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 manufacture the busbar trunking devices. Listed Below are the Four Basic Types of Trunking Applications: (1) Service Entrance Connection (2) Plug-in Type Horizontal Run (3) Plug-in Type Vertical Riser Installation (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 one type of application
Type of Application
1 S E R V I C E
2 H O R I Z O N T A L
3 V E R T I C A L
4 T I E R U N
BUSBAR TRUNKING ORDER ENTRY CHECKLIST

Order Number: _________________ Completed by: _______________ Office: _________________ Date: ________________
() = REQUIRED INFORMATION
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, Xfmer. 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.
I-LINE Busbar Trunking Application
Where should I-LINE busbar trunking be used?

There are four basic types of installations for I-LINE busbar trunking.
Service entrance connections These installations are for connection from a transformer to a Distribution Switchboard to bring power into a building.
Horizontal plug-in busbar trunking These installations are run horizontally in an industrial facility for simple feeding of industrial equipment.
1
a o r SWf BD Re
2
To p To p
M XF
Wall
Fr on o t SWf BD
Vertical riser installations Vertical Risers are for multi-story building installations which have requirements for power at each floor or to take large amounts of power to a point high in the building.
Horizontal feeder runs These runs are for delivering power from point to point. Typically the runs are from one distribution switchboard to another.
3
Fusible Plug-in Units Mount This Side
T O P
4
3rd Floor 2nd Floor 1st Floor
t on Fr f o D B SW
T O P
T O P
t on Fr f o D B SW
ar Ref o D B SW
Service entrance connections
This type of connection is typically from a transformer to a distribution switchboard (Figure 1). The connection to the transformer is through a low voltage throat collar by a bussed throat box. This type of connection will include flexible bus connectors from the low voltage spades of the transformer to the busbar trunking connectors. These flexible connectors are used to eliminate the effects of busbar expansion and contraction of the low voltage spades. Positioning of these flexible connectors is critical for proper alignment between the busbar trunking and transformer. The factory must have all of the dimensions shown in Figure 1 plus those shown for the transformer throat collar and spade terminals. This information must be provided along with the phasing so proper phasing can be designed for the switchboard. Typically the connection to the switchboard will be through a flanged end, but other means of termination are available. With this information the proper busbar trunking can be ordered so the installation will go smoothly.
Phasing Many transformers are phased CBAN. If a bussed transformer connection is to be used, this will require the switchboard at the other end of the run to be phased similarly. Specific phasing requirements must be supplied to the factory. Other service entrance connections Occasionally, you will require a service entrance connection that differs from our standard. In this case, be sure to let the factory know of any special dimensions, such as required height of the throat box from ground or floor, spacing between phase bars, phasing, and so forth.
Information Needed for Transformer Connection
Front Outdoor X X Indoor LV Throat X
LV Spades
X X
Top View of Transformer
C of Bushing L X
X X X
Top of Transformer
X X C Bushing L
X X Front of SWBD X Indicate number of holes, diameter of holes, and spacing between holes.
Side View of Transformer

X X X X X
Edge of Throat Collar
Note: Often the floor level and outdoor ground level will be at different heights. All X dimensions must be known. X
Transformer Tank Wall
X X "X" Number and Diameter of Holes
"X" Thickness
LV Spade Detail Figure 1 Measurements Needed for Bussed Transformer (Throat Type)
10
Horizontal plug-in busbar trunking
Plug-in busbar trunking in a horizontal run is used as a means of bringing power from a distribution switchboard to multiple loads throughout a building. The dimensions needed are shown in Figure 2. Phasing The typical I-LINE plug-in run is shown in Figure 2. The phasing shown is EABCN top to bottom, with the top label located as shown for a horizontal run. This phasing arrangement must always be followed so that proper phasing of the plug-in units will be ensured (Figure 2 Detail A). Because this busbar phasing must be followed, it is the busbar trunking that determines the phasing of the switchboard in Figure 2. Note that the plug-in trunking has the integral earth bus plug-in jaw on the top side only.
E A B C N
Notches in top rail position unit. Hooks support weight of device during installation.
Top
Detail A Hook-Swing Mounting

C L
P
X
p To
P
X
To p
P
X X
X
p To
Unfused Reducer
P
To
End Closure
E A B C N
X Plug-In Unit
p To
E A B C N
NC
BA E
End Closure X
All X dimensions must be known. P Indicates plug-in trunking devices. Rear of SWBD
Figure 2 Measurements Needed for a Typical Plug-In Type Run
11
Busbar trunking fittings

Busbar Trunking fitting is a term which encompasses every trunking 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 made with feeder busbar trunking. On Figure 2 on Page 11 any piece not marked P is a feeder device. All fittings under 800 amperes are made with plug-in busbar trunking. No feeder to plug-in connections can be made under 800 amperes. Connections to switchboards under 800 amperes are normally made with plug-in cable tap boxes (see Figure 3) However, flanged ends are available.
End Closure E A B C N
C L Joint Dimension "B" must be greater than dimension "A".
To
Wall
Edge Of Joint Channel
A B Tie Channel
Figure 4 Busbar Trunking Joint Accessibility
Plug-In Cable Tap Box
End Closure
Wall and floor flanges Wall and floor flanges are meant to be used for covering the hole in a wall or floor where busbar trunking passes through. These flanges will not aid in maintaining the fire rating of the wall or floor. They are not required for installation, but are often requested by the customer. Tees Plug-in tees (PTT) are available in the 225, 400, and 600A ratings. These devices mount into any plug-in opening to feed an additional run of busbar trunking. Reducing The reduction of the busbar trunking either with or without an overcurrent device is easily achieved with I-Line and I-Line II busbar trunking. The requirements for the reduction need to be forwarded with the busbar trunking details so it can be correctly engineered. Expansion joints Schneider 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.
on o t SWf BD
Fr
Figure 3 Typical Plug-in Run-225A 600A
Busbar trunking through wall and flanges

When 800 amperes and above busbar trunking extends through a wall, I-LINE II feeder or plug-in trunking can be used. For runs under 800 amperes, plug-in trunking will be used throughout. Factory installed internal barriers (optional) are available where the trunking passes through a wall for runs 600 amperes and below. I-LINE Busbar Trunking is designed so that no part of the joint channel can be inside of the wall. Therefore the distance from the centre line of the joint to the wall must be at least equal to the distance from the centre to the edge of the joint channel (See Figure 4). If the dimensions of the joint channel cannot easily be determined, it is best to keep the joint at least 305mm from the wall. This will ensure proper joint clearance for any type of busbar trunking passing through the wall.
12
Vertical busbar risers

Dimensions Figure 5 shows typical dimensions that must be known before release: floor to floor height, floor thickness, exact layout of multiple run risers, closet dimensions, the type and quantity of plug-ins, and (if necessary) the desired height of the plugs from the floor. The riser in Figure 5 has been dimensioned in Figure 6. Note that the two 3050mm sections of busbar trunking on the second and third floors do not have a joint located in or near the floor.
I-LINE and I-LINE II busbar trunking can be utilized for vertical risers in multi-story buildings. These installations can be of plug-in type which allows access on each floor for plug-in units or of feeder type to feed a distribution switchboard or a motor control centre on an upper floor. I-LINE busbar trunking (225-600 amperes) is plug-in only and requires an internal smoke barrier for each floor partition. I-LINE II busbar trunking (800-5000 amperes) does not require internal barriers for either feeder or plug-in type. The internal barriers are standard in the design.
NCBAE
End Closure
End Closure
1.00 25
25
105.00 2670
2670
X 3rd Floor X Fusible Plug-In Units Mount This Side
3rd Floor
NCBAE T o p 3810
120.00 3050
3050 Plug-In
150.00 3810
15.00 380
380
120.00 3050
3050 2nd Floor T o p 380 15.00 380
2nd Floor X X X X X
NC BA E
27.00 685
685 Feeder
12.00 305
305
120.00 3050
3050
192.00 4877
4877
83.00 2108
2108
1st Floor
Front of SWBD
NC
BA
E
Front of SWBD
1st Floor
All X dimensions must be known. X
152 .50 152
Figure 5 Typical information Needed for Riser
Figure 6 Typical Layout 800A and Above Riser
All Dimensions Millimetres
13
Phasing
When plug-in units are being supplied for a riser installation the location of the plug-in determines the phasing of the busbar trunking. The trunking must be oriented with the correct side available for the plug-ins. (See Figure 7.) Due to the complications involved, it is best to have the factory or representative determine the correct trunking orientation. The information they require is the side the plug-ins mount on and the orientation of the switchboard phasing.
OFF ON
Special manufacturers recommendation Schneider 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 riser and replacing it far exceeds the cost for including a waterproof curb. Once the busbar trunking is installed through a floor opening, the remaining unused area should be filled to prevent smoke from passing floor-to-floor (chimney effect) in case of fire in the building. Some recommended materials available are fire rated foam and caulk. Grouting is also acceptable but must be applied in a ver y dry form to prevent water and contaminants from entering the busbar trunking once the grouting cures and the water leeches out. Plug-in units When entering an order, the factory must know not only which side of the busbar trunking the plug-ins will mount on, but the quantity of plug-ins to be used on each floor. Hangers Fixed and spring hangers are available for use in supporting busbar trunking in riser installations. When using fixed hangers, the weight of the riser is distributed between each floor.
Floor
Top
NCBAE
Figure 7 Riser Phasing Considerations
Busbar Trunking Curb
4.00 102
102
Figure 8 Waterproof Curb Recommended Floor Opening
14
Feeder type runs are normally used for distributing power to loads that are concentrated in one area. Typical connections are switchboard to switchboard tie runs, and a switchboard feeding remote concentrated loads. Phasing In Figure 9, the phasing of switchboard A cannot be identical to switchboard B. It is the busbar trunking that must determine the phasing of the switchboard. The proper phasing must be supplied to the factory manufacturing the switchboard or an installation problem will occur. The front and rear of each switchboard must be known for the phasing to be determined correctly.
Horizontal feeder runs

Feeder elbows (800-5000 amperes) As Figure 10 below illustrates, there are two standard types of 90 elbows: flatwise and edgewise. No matter what orientation the busbar trunking is installed, the busbars of flatwise elbows stay in the same plane after elbowing and edgewise elbow busbars change planes. Since feeder elbows are symmetrical, there are no TOP or FRONT sides. Note in Figure 10 that the phasing will run across the 149mm dimension of the busbar trunking. Elbows for I-LINE busbar trunking (225-600 amperes) are not symmetrical and require notation of the Front and Top when ordering.
X X
X X
11.00 279
279
Wall
CN EAB
E PH PH PH PH E
Front of SWBD B
11.00 279
279
BAE NC
Edgewise Elbow (LEM)

Front of SWBD A X
All X dimensions must be known.
L L
Figure 9 Measurements Needed for Feeder Type Run
Through walls With the design of I-LINE II busbar trunking, feeder or plug-in trunking can be installed through walls and floors.
E PH PH PH PH E
5.87 149
149
Flatwise Elbow (LFM) L will vary depending on width of Busbar Trunking (See Page 38) Figure 10 Elbows: 800A-5000A Feeder
15
I-LINE Busbar Trunking Connection Devices
Fittings
Qwik Flange and Flanged End - switchboard connections A flanged end (see Figure 11) is a feeder trunking fitting that allows busbar trunking to be interconnected to other equipment such as motor control centres and switchgear.
Tap boxes Schneider 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).
1.12
28
0.50
13 13
24.00 610 11.50 292

610 292
10.50 267
267 C L
11.50 292
292 13 0.50
10.00 254
254
76 3.00 76
6.25 158 158
13
28.20 716
716
Figure 11 Standard Flanged End (FE)
C L
15.00
381 381
9.00 229
229
Occasionally, a customer wants to make a cable connection to switchboard. As Figure 11 illustrates, standard flanged ends are designed for a single bolt type connection and the spacing between phases may be inadequate for adding lugs. Schneider Electric can manufacture flanged ends with lugs to accommodate the customers needs. The phase spacing, size, type and quantity of lugs will need to be known to order the flanged end with lugs. The switchgear manufacturer should note we recommend use of 76mm cupped Belleville washers when terminating the bus of his switchboard to our Flanged End. These washers assure 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.
23.50 597
597
Figure 13 Plug-In Tap Box (800A - 1600A Style Shown) (For connection into plug-in opening 800A - 5000A)
The other style tap box is the end cable tap box (see Figure 14). As the name implies, the end tap box (ETB) mounts on the end of a run.
B A
28.00 711
711
10.00
254 254
End Cable Tap Box (ETB)

(A, B and C dimensions vary with amperage rating of tap box.)
Figure 14 Plug-In and End Cable Tap Boxes
All tap boxes are constructed of all-steel enclosures for use with armoured cable. Screw type mechanical lugs are standard. If a larger lug than normal or a compression lug is required, notify the factory at time of order.
Figure 12 Qwik Flange Catalogue Number Suffix - QF
With the Qwik Flange installed, the connection of the busbar trunking to the switchgear is as easy as making a trunking joint. This eliminates the time needed to install the normal Flanged End at the job site. This device must be installed by the switchgear manufacturer. Contact your local sales representative for more information.
We also manufacture a centre cable tap box in the I-LINE II range of products for applications which require that type of connection to a busbar trunking installation.
16
I-LINE Busbar Trunking Special Features
Special Busbar Trunking Construction

Customers occasionally have requirements for busbar trunking systems with features other than our standard. We have listed below the most often-requested special features: Special paint I-LINE Trunking can be provided in colours other than ANSI 49 grey for a price add-on. The special colour requested should be specified by an industrial colour code at the time of order entry. With typically lengthened lead times for special colour parts, it is imperative to provide this information as early as possible in the order process so delivery commitments can be maintained. Low current density trunking Some customers require a lower current density trunking than our standard for rigorous duty in their installation. We have developed a range of trunking for the most commonly requested current density of 1000 amperes per 645 square millimetres (one square inch) for copper trunking. If you require this current density for your installation, please feel free to specify it and we can meet your need. If you have requests for another specific current density, please feel free to contact your local representative. Riser plug-in trunking We also offer an I-LINE II plug-in trunking specifically designed for installation in riser closets of high-rise buildings. This plug-in trunking has a plug-in door on the front side which faces out into the room. The back of the trunking, facing the wall utilizes a feeder bus side rail. This design provides a plug-in trunking ideally suited for riser cabinets and gives the customer only the necessary number of plug-in openings to meet the application. The catalog number for this device is the same as our plug-in trunking, except an R is substituted for the P. (Example: if the standard plug-in trunking prefix is AP2512G, the riser trunking prefix is AR2512G). Finger protection to IP 2X We have developed this unique new feature for those areas of the world that require extra personal protection. This optional factory installed feature includes a busbar barrier which fits into the base mold of our plug-in opening. It provides improved protection against accidental contact with live parts at the plug-in opening. No modification of our I-LINE plug-in unit is required to accept this feature. This feature is designed to meet the IEC 529 standard which defines the degrees of protection provided by enclosures. The standard establishes a range of IP codes which defines an enclosures protection from elements such as solid objects, water, and dust. The degree of protection provided by the IP 2X code is defined by the IEC standard as shown in the table below. This feature complies with this standard. Order this feature by adding a Y suffix to a standard I-LINE II plug-in trunking catalog number (example: AP2510G10STY).
Degree of protection against access to hazardous parts indicated by the first characteristic numeral
Degree Of Protection First Characteristic Numeral 2 Brief Description Protected against access to hazardous parts with a finger Definition The jointed test finger of 12mm PH, 80 mm length shall have adequate clearance from hazardous parts
Note: The second characteristic numeral is not used and is denoted by an "X"
17
I-LINE Busbar Trunking Services
Customer service
Design and manufacture I-LINE busbar trunking systems receive design and manufacturing support from the Oxford, Ohio, USA plant. The objective of this support is to provide the best service possible for I-LINE busbar trunking systems no matter where it is sold in the world. The plant is staffed by experienced engineers to give support to customers who purchase I-LINE busbar trunking systems. Packing and shipping Each piece of I-LINE busbar trunking once manufactured must pass a 7000 Volt DC hi-pot test before packing and shipment from the factory. International orders are carefully packed and crated and marked prior to shipment to the site. This will help ensure receipt of the trunking in good condition for installation in sites throughout the world. After sales service Schneider Electrics large worldwide field sales force is available to assist you in answering any questions about the system you have purchased. It is our objective to provide the best service possible to ensure satisfaction by our customers. If you encounter a question or problem with your I-LINE busbar trunking system, please contact our field sales office.
Service programs
We pride ourselves in providing excellent service to our customers the world over. We offer a wide range of services to make the use of I-LINE busbar trunking as simple and easy as possible. A summary of these services follows: Emergency service Trained and qualified busbar trunking personnel are on call 24 hours a day, 7 days a week, to assist in your emergency busbar trunking needs. Call any time at our field sales office. Missing link Our Missing Link program guarantees shipment of a factory-built straight length or elbow in five working days after the final dimensions are received. This program is designed specifically to help a customer correct last minute changes to a project using trunking. Those changes could include an unplanned obstruction requiring the trunking to be rerouted, incorrect measurement of the trunking run or the need to order several pieces to supplement trunking lengths ordered from stock. The program applies only to standard I-LINE II Indoor Feeder Trunking variable straight lengths, elbows, standard tap boxes and flanged ends (800A-5000A). Straight lengths are constructed as feeder busbar trunking and are available in 25.4mm increments from 406 to 3048mm. Elbows are available in leg lengths from our standard through 914mm. The program is limited to a maximum of four pieces of trunking per run and 20 pieces per order. This service is included as part of our standard service to our customers. How to properly measure your missing link(s) ALL missing link dimensions should be measured to the nearest 25mm from centreline of joint to centreline of joint, or centreline of joint to centreline of busbar trunking. As shown in Diagram B, the centreline of the joint is located at the joint bolt on the end with a joint-pak installed. If the joint-pak is not installed, the centreline of the joint is 25.4mm from the end of the busbars. If it is necessary to measure an elbow, the dimensions X and Y (shown in Diagram B) are all that is needed. Be sure to measure from centreline of joint (as described above) to centreline of trunking housing. You must also specify whether an edgewise or flatwise elbow is required. The table on Page 43 lists the standard minimum elbow dimensions for each amperage.
Oxford Distribution Centre
A - Straight Lengths Without With Joint Pak Joint Pak C L 1.00 End 25 25 of Bars X
C L Bolt
B - Elbows
With Joint Pak
Joint
C C Bus L L C Joint Bus L X 1.00 25 25 Without End Joint Pak of Bars Y
C Joint L
Diagram B
18
I-LINE Busbar Trunking Take-Off
How to do a trunking take-off from drawings

The guidelines listed below should allow you to perform a trunking take-off in the field. 1) First check the drawing list to ensure you have all the drawings for a complete and accurate take-off. Generally, you will need the structural steel and mechanical/civil drawings to confirm that the trunking has an unobstructed path. 2) Carefully read the specifications and note any deviations to Schneider Electrics I-LINE system. If there are discrepancies between what is specified and what can be provided, ask your local representative for assistance. 3) Check the one-line electrical diagrams and count the number of runs. If the voltage, ampacity, and run designations (that is, run MCC 1) are stated, list these items. When the take-off is complete, this listing can be used to ensure that your bill-of-material is complete. 4) If multiple runs are shown on each drawing and are continued on subsequent drawings, a complete run-by-run take-off is recommended. Check the scale on each drawing and 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 centreline of the busbar trunking and fittings. b. A simple sketch of each run is very helpful. Reference dimensions from known column lines to the trunking and show them on your sketch, also note the trunking elevation(s). c. List the number of fittings for each run. 6) Once all the runs have been grouped according to amperage ratings, the per metre pricing and fittings charges can be worked out by a Schneider Electric representative to obtain the busbar trunking costs. 7) If tap boxes and overcurrent devices are not listed as part of the take-off, a careful examination of the drawings needs to be made to compile the list.
Example 1 (below) illustrates a simple take-off. As previously mentioned in 5(b), a sketch of the run being taken off is helpful. Following Example 1 are useful aids in preparing single line drawings.
Example 1 Typical Customer Drawing for a Plug-in Bus Run

A
240.00 6096
6096 B 60A TP Plug-in 6096 30A TP Plug-in
800A TP + E Alum. Bus Mounted Aprox. 3658 Aff. 800A TP + E Alum. Bus Mounted Aprox. 4267 Aff.
3000A TP + N + E Alum. Bus Duct Service Entrance Run 4267 Aff.
240.00 6096
C 30A TP Plug-in 6096
30A TP Plug-in 30A TP Plug-in
240.00 6096
D
240.00 6096
6096 E
30A TP Plug-in
240.00 6096
6096 F 30A TP Plug-in 30A TP Plug-in
240.00 6096
6096 G
60A TP Plug-in
6 6096 240.00 6096
5 6096 240.00 6096
4 6096 240.00 6096
3 6096 240.00 6096
2 6096 240.00 6096
Note: The Switchboard is 1780 high. AFF means above finished floor. Drawing is not to scale. Use the columns to approximate the distances.
How to make a shorthand drawing (Single line type) After the take-off has been made, a sketch of the run should be made. Single line drawings are the easiest way to illustrate an I-LINE busbar trunking run. Remember that you must provide the factory with all pertinent information. The procedure is as follows: 1) Select the type of devices you will need to draw (see next Page). 2) Draw your run. Be sure to label each run and show cross sections where applicable. 3) Show the phasing at each end of the run. 4) Show the location of each type of run (that is, location of weatherproof and plug-in busbar trunking). 5) Indicate quantity and, if necessary, location of plugs.
19
I-LINE Busbar Trunking Take-Off
1104.02
28042 ABC
24.02 84.02 240.00 6096

2134
610 610
192.01
4877
864.02
21946
6096
12.01
305 Wall
60.04 1525
1525
27.95
710
Front SWBD ABCN
27.95
710
192.01
4877
12192 480.00
12.01
305 Wall Plug-in Units (9) PQ3603G (2) PQ3603G
NCBA
12192
60.04
1525 1525
3000A TP + N + E Service Entrance AOF 2530G
AF/AP 2308G 800A TP + E Aluminum Busbar Trunking
CBA Rear SWBD
1B Typical Single Line Sketch of Plug-In Run
Check sketch 1B above to see how well you did on the take-off. Is your bill of material similar to that given? The Busbar Trunking Order Entry Checklist on Page 8 is a useful tool to check your work before submitting the information to your representative for quotation.
Helpful hints to lay out and measure a busbar trunking job

Laying out and measuring a job does not require specialized tools or skills. The following list of tools should handle all applications: 30 metre tape measure 7.5 metre tape measure plumb line/chalk line Lets assume you want to feed a new Motor Control Centre (MCC) with trunking from a new distribution switchboard. Using illustrations, we will go step-by-step through the layout process to determine the orientation and dimensions. When completed, we will have a single line isometric drawing showing the proposed layout. Known information From the bid documents, specifications, and/or factory drawings the following information is known: felt tip marker or crayon
These are typical symbols used when making a single line drawing
C AB
Flanged End
Elbows
End Closure
System is 1600A, TP & N 50% Earth, 240/415 volt

Flat Edge Vertical
aluminium feeder type (Width is determined to be 225mm.) 610mm deep, connection to be in top centre
Switchboard (SWBD) is 2318mm high, 914mm wide, Motor Control Centre is 2318mm high with a 305mm
additional height pull box for trunking connection, 508mm wide, 508mm Deep connection in top centre above finished floor (AFF) unless obstructed
Orientations
Bottom of busbar trunking (B.O.B.) to be installed 4877mm
A 2000 1600 A
Reducer
Expansion Fitting
Wall Penetration
Top
5.88 149
149
E A B C N E 1600A Al
8.84 225
End Cable Tap Box Service Head Plug-in Cable Tap Box
225
20
I-LINE Busbar Trunking Measuring
How to begin 1) Determine the physical size of the trunking housing (see Page 24 and 32). This information lets us know how far to stay away from obstructions. In our example, the trunking is 225mm wide and 149mm high. 2) Review the area where the trunking could be installed (if not already specified). Note any special conditions such as: building expansion joints, steel changes, HVAC equipment, plumbing, and so forth. 3) All dimensions should be measured from fixed points such as: columns, walls, or other building structures. Try to leave a minimum of 100mm between the trunking and any obstructions. * A sketch (SK-1 below) showing the SWBD and MCC location, the obstructions, and the dimensions to fixed points is very helpful. 4) If the run originates from a SWBD, start dimensional layout from the fixed end. A tap box at the beginning of a run may reduce the number of special pieces and reduce delivery time.
Sketch the proposed routing making notes about elevations and obstructions (see SK-2 Page 22). 5) Unless specified, for most industrial applications the trunking should be run above the bottom chord of the building steel. This will protect it from damage by fork-lifts or other equipment. Also keep in mind that the trunking must be supported by drop rods or from below. Do not route it where it cannot be supported. 6) When selecting the elevation for plug-in trunking, remember that the tap off units require different mounting clearances (see Page 50). Going back to the sample layout (SK-2), enough information is known to tabulate the amount of length needed and the required fittings (i.e. flanged ends, elbows, etc.). The sketch, SK-2, could be given to your local representative for pricing and forwarded on to the factory for record or approval drawings, and returned. SK-3 on Page 22 represents a typical dimensioned one-line drawing from which the customer could confirm the busbar trunking dimensions and the routing.
360.00 9144
9144 6 C L E A B C N 5
73.00 1854
1854 A C L
North
10.00 254
254
45.00 1143
1143
36.00 914
914
Front of SWBD
100 3.94 100 (Typical) (Typical)
240.00 6096
6096 (Typical) (Typical)
Columns 300 x 300 (Typical) B
23.94 608
608
12.00
304 304 76 Steam line Bottom of pipe (B.O.P.) 4877 A.F.F. 152 Condensate line B.O.P. 4877 A.F.F.
50.00 1270
1270
100 3.94 100
20.00 508
508 Front of MCC
NCBAE
50820.00 508 50820.00 508 C L
30.00 762
762
SK-1 Plan View of SWBD, MCC and Obstructions
21
360.00 9144
9144 6 C L E A B C N Rise up 2616 (B.O.B. 4877 A.F.F.) (E 4953 A.F.F.) 5
73.00 1854
1854 A C L
North Front of SWBS
10.00 254
254
45.00 1143
1143
100 3.94 (Typical) 100 (Typical)
240.00 6096
6096
23.94 608
608
Offset up 304 12.00 304
300 Columns 300 x 300 (Typical)
12.00
304 304 76 Steam line Bottom of pipe (B.O.P.) 4877 A.F.F. 76 Condensate line B.O.P. 4877 A.F.F.
50.00 1270
1270
457
3.94 100
100 B.O.B. 5182 A.F.F.
18.00
457 Offset down 12.00 305 305
20.00 508
508 Front of MCC
NCBAE
B.O.B. 4877 A.F.F.
50820.00 508 50820.00 508 C L
91.00 2311
C 2311
30.00 762
762
SK-2 Proposed Busbar Trunking Layout
120.00
3050 3050
240.00 6100 103.00 2616

2616 6100 (Typical) (Typical)
230.00 5842
5842 457 18.00 457
B.O.B. 4877 AFF 7 B 1830 3.95 72.00 1830 100 100 305 12.00 305 457 18.00 457 3482 137.00 3482
MC C
91.25 2318
2318
BD SW
610 24.00 610 B.O.B. 4877 AFF
C L
91.25 2318
2318
EABCN B.O.B. 5182 AFF
12.00 305 305 91.50 2324 2324
287.20 7295
7295 508 20.00 508 508 20.00 508 NCBAE 6 1854 73.00 1854 C
30.00 764
764
9150 360.00 5 9150
Riser applications (apartments, high-rise offices, etc.) are easier to lay out and measure. Once the busbar trunking is brought over to the floor penetration area, generally it is routed straight up. The dimensions needed for riser applications were discussed under the Vertical Riser section, Page 13.
SK-3 Single Line Drawing of Completed Layout
22
Preparing to install I-LINE busbar trunking

To make the installation proceed as quickly and efficiently as possible, a few preliminary steps should be taken. 1) Inspect trunking for damage when received. Store in a clean, dry location. 2) Familiarize yourself with the routing. If record drawings were supplied by the factory, have a copy accessible to the installers. 3) Carefully read the installation instructions for all devices before the actual installation. Note the instructions call for the busbar trunking to be insulation tested before and after installation. A 1000V Insulation tester is recommended for this test. 4) Install hangers and supports. The most common method of supporting the hangers is threaded drop rods (or all thread) which the installer must supply. 5) Anticipate the weight of the objects being installed so the necessary lifting devices and manpower are available. 6) Have the following recommended tools available for the installation 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, contact your local sales representative.
Maintenance Recommendations
We have always striven to design products to the highest quality standards. We also recognize the performance of a product is directly affected by the quality of how it is installed, operated, and maintained. We feel that to protect your investment in Schneider Electric busbar trunking, certain operation and maintenance procedures should be followed. As part of this philosophy, we provide with each busbar trunking project NEMA Publication BU1.1-1991 which is a guide for proper installation, operation, and maintenance of trunking products. This publication addresses such areas as inspection of all electrical joints and terminals for tightness, prevention of entry of water and contaminants into the trunking, instructions for what to do if water and contaminants do enter the trunking, and other maintenance topics. This publication is also available upon request by contacting your local representative.
DANGER DANGER
Hazard of electrical shock, burn, or explosion. Electrical equipment should be serviced only by qualified electrical maintenance personnel, and this manual should not be viewed as sufficient instruction for those who are not otherwise qualified to operate, service, or maintain the equipment discussed. Although reasonable care has been taken to provide accurate and authoritative information in this manual, no responsibility is assumed by Schneider Electric for any consequences arising out of the use of this manual.
The successful operation of trunking depends upon proper handling, storage, installation, operation, and maintenance. Neglecting fundamental installation and maintenance requirements may lead to personal injury as well as damage to electrical equipment or other property. Hazardous voltages in electrical equipment can cause severe personal injury or death. Energizing trunking for the first time after initial installation or maintenance is potentially dangerous. Unless otherwise specified, inspect and perform preventive maintenance only on trunking and equipment to which power has been turned off, disconnected, and electrically isolated so that no accidental contact can be made with energized parts.
Failure to follow these instructions will result in death or serious injury.
23
I-LINE Busbar Trunking I-LINE Physical Data
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)
17.50 445 3.31 84
84 445
24.00 610
610
24.00 610
610
24.00 610
610
24.00 610
610
6.50 165
165
3.19 81
81
Top
3.31 84 3.19 81
81
6.50 165
165
24.00 610
610
24.00 610
610
24.00 610
610
24.00 610
610
17.50 445
445
84
Front
120.00 3048
3048
Straight Lengths
Top
Catalogue Number Suffix Standard Lengths Feet Standard Lengths Meters Number of Plug-In Openings
-10 10 3.05 10
-6 6 1.83 6
E A B C N
6.00 152
152
For straight lengths other than standard indicate length in multiples of 25.4mm.
Cross Section
Catalogue Numbering System: The numbering system used for the busbar trunking is the basic catalogue number of the trunking and the addition of the appropriate suffix for the device desired. A 3.05 metre length of copper 225A TP+N+E trunking would be: CP502G-10. Other fittings are ordered in a similar manner, such as elbows, expansion fittings and so forth.
Content and weight

Aluminum Ampere Rating 225 400 600 Copper Ampere Rating 225 400 600 Width W mm 57 86 86 Bus Bars Per Phase mm One 6 x 24 One 6 x 51 One 6 x 51 Weights 3 Pole 4-Pole kg/m kg/m 9.8 18.0 18.0 10.4 20.7 20.7 Basic Catalogue number TP+E TP+N+E CP302G CP304G CP306G CP502G CP504G CP506G Width W mm 57 86 121 Bus Bars Per Phase mm One 6 x 24 One 6 x 51 One 6 x 86 Weights 3 Pole 4-Pole kg/m kg/m 9.1 11.2 14.0 9.5 11.8 15.8 Basic Catalogue number TP+E TP+N+E AP302G AP304G AP306G AP502G AP504G AP506G
Top
Top
6.50 165
165
Front
2.88 18.75 476

73 73 476
9.38 239
239 Joint C L
Top
12.25 369
369
Front
Front
Joint Detail
24
4.29
109
0.02 Dia. Hole

14 0.56Dia. Hole C L E
E
B
0.90 23 23
o dM ire qu Re
un
tin
l gC
ea
ran
ce
14.00 356
356 C C Plug-in L Opening
7.75 197
197
A
99 3.88 99
C Plug-in L Opening
225A
C Plug-in L Opening D
191 7.50 191
400A/600A
Cable Tap Boxes
Cable tap boxes

Ampere Rating 225 400 600 A mm 416 659 659 B mm 216 468 468 C mm 102 248 248 D mm 84 191 191 E mm 267 356 356 Lugs per Phase and Neutral mm2 1-150 2-240 2-240 Earth Lug 2 mm 1-50 1-240 1-240 Catalogue Number (with Earth Bus) TP+E TP+N+E PTB-302G PBTB-306G PBTB-306G PTB-502G PBTB-506G PBTB-506G
5.88 149
149
6.00 152
Top 152 Top
Front
206 8.12 206
175 6.88 175
Tees
Tees
Ampere Rating (Tee Leg) Aluminum 225 400 600 Copper 225 400 600 Catalogue Number (With Earth Bus) TP+E PTT-2-3WG PTT-3-3WG PTT-3-3WG PTT-4-3WG TP+N+E PTT-2-4WG PTT-3-4WG PTT-3-4WG 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.
25
18.00 457
457 Top Top
Top
18.00 457
457
18.00 457
457
Front
Front
18.00 457
457
Top Inside Elbow Catalogue Number Suffix LTI
Front Inside Elbow Catalogue Number Suffix LFI
Top Top
18.00 457
457
18.00 457
457 Front
18.00 457
457
Top
Front
Front
18.00 457
457
Top Outside Elbow Catalogue Number Suffix LTO
Front Inside Elbow Catalogue Number Suffix LFO
Expansion Fitting
A
17.20 437
437
Ampere Rating Aluminium Copper 225 400 600
A mm 114 141 141 176
8.13 206
206 Front 305 12.00 305
225 400
15.76 400
400
9.40 239
239 194 Top
600
7.63 194 36.00 914

914
60.00 1524
1524 Note: Expansion joint permits +38mm expansion. Use _ recommended only when trunking passes through building expansion joint.
Expansion Fitting Catalogue Number Suffix EJ
Unfused Reducer
Top
18.00 457
457
Bolt End Ampere Rating
Catalogue Number Suffix Slot End Ampere Rating 225 400 -R02 -R02 -R04q
600
36.00 914
914
225 400 600

457
18.00 457
Front
q Aluminium busbar trunking only.
Unfused Reducer
26
12.00 305
305 Top W
0.38 10
10
0.50 13
13
0.50 13
13
Top
3.69 94
94
11.62 295
295
Front
5.00 127
127
H Flanged Collar
Neutral
H Neutral
Cutout C L T W
3.69 94
94
10 0.38
Flanged End
10
8 Dia. 0.31 Dia. (6 Holes) 8 (6 Holes)
Flanged Collar
Flanged End Cutout and Drilling Template Catalogue Number Suffix FES 12 (Slot end) FEB 12 (Bolt end) Ampere Rating Aluminium 225 400 600 H mm 340 340 340 340 W mm 113 140 140 175 V mm 62 89 89 124 T mm 87 114 114 149
Copper 225 400 600
Ampere Rating Aluminium
Copper 225 400 600
Figure 1 2 2 2
A mm 24 51 51 86
5.00 127
127
7.00 178
178
4.00 102
51 2.00 51 A
Contact 102 Surface
225 400 600
25 1.00 25 A
51 2.00 51
Contact Surface
Figure 1
Flanged End Details
Figure 2
N C B
A E
C L
Top
C L
Top
0.1 3
3
C L
5.12 125
3.00 3.00 3.00 76 76 76
76 76 76
3.00 3.00 3.00 76 76 76

76 76 76
C L Flanged Collar
125
4-Pole with Earth Bus

(Bottom View)
4-Pole
Flexible Connector
Ampere Rating (A)
250
400
630
Catalogue No.
FLEX502
FLEX504
FLEX506
Piece required per phase & neutral

1
1
2
Note: Please refer to Page 36 for dimension

All Dimensions Millimeters
27
0.56 Hole 14 Dia. Dia. Hole 14 0.62

16 16 16 Dia. Hole 0.62 Dia. Hole 16
B A
Drop Rod By Customer
6.44 163
163
2.00
51
1.90
48
Drop Rod By Customer
1.87 47
47
0.25 6
6
2.12 54
54
22 0.88 B A C L 22
5.50 140
140 C L
1.50 38
38
Flatwise Hanger
Edgewise Hanger
Ampere Rating Aluminium 225 400 600
Copper 225 400 600
A mm 67 94 94 129
B mm 27 36 36 72
Catalogue Number HP-2-F HP-3-F HP-3-F HP-5-F
Copper 225 400 600
A mm 160 160 160 195
B mm 91 91 91 108
Catalogue Number HP-3-E HP-3-E HP-3-E HP-5-E
Hanger spacing on 1.5 metre centres maximum when mounted edgewise.
Building Support
0.50 Drop Rod 13

13 Sway Brace (As Required) by Customer
and Beam Clamp by Customer
4.62 117
117 Note: When required the recommended spacing is 6 metre centres.
8.00 203
203
Sway Brace Collar Catalogue Number HP1SBC
28
Top
3.18 81
81
1.12 28
28
4.30 109
109
To secure hanger to trunking, attach mounting screw on bottom of trunking to hanger brace through slot. A Customer to locate and drill four (4) 8mm diameter holes for securing mounting channel to hanger. Channel iron and 12mm diameter bolts by customer.
B Top C Joint L Bottom
9.38 238
238
11.50 292
292
Note: Waterproof curbing is recommended around floor opening shown. 18mm diameter holes for access to mounting screw on trunking when securing hanger to trunking mounting.
Floor Level 54 2.12

54
Vertical Hanger
Ampere Rating Aluminium 225 400
Copper 225 400 600
A mm 109 135 135 170
B mm 166 192 192 228
Catalogue Number HP-2-V HP-3-V HP-3-V HP-4-V
6.10
155
600
Note: Dimensions shown apply to 1829mm and 3048mm straight lengths only. Consult factory for dimensions that apply for fractional straight lengths.
Joint C L
3.95 100
100 A
End Closure
A
B
Copper 225 400 600
A mm 68 89 89 124
Catalogue Number ACP - 2 -EC ACP - 3 -EC ACP - 3 -EC ACP - 4 -EC
2.00 51
51
2.00 51
51
3.00 76
76
3.00 76
76
2.06 52
52
2.06 52
52
10.00 254
254
10.00 254
254
2.06 52
52
2.06 52
52
Wall Flange
Floor Flange
Wall and floor flange

Ampere Rating Aluminium 225 400 600 Copper 225 400 600 A mm 160 186 186 221 B mm 212 239 239 274 Catalogue Number Wall flange ACP-2-WF ACP-3-WF ACP-3-WF ACP-4-WF Floor Flange ACP-2-FF ACP-3-FF ACP-3-FF 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.
29
I-LINE Busbar Trunking I-LINE Electrical Data
Required Wall Openings
Ampere Rating Aluminium 225 400 600 Copper 225 400 600
Straight Length Yt 152 178 178 203 203 W
Flanged Ends Yt 152 178 381 178 203 W
Flat Elbow Wall Thickness 100 200 300 W 203 203 229 229 279 254 279 279 330 Yt 305 330 330 381
400
500
600
Edge Elbow Wall Thickness 100 200 300 400 500 600 Yt W
356 381 381 431
406 431 431 483
457 483 483 533
152 178 178 203 330 381 431 483 533 584
t Dimension allows clearance for vertical hanger. Subtract 25 mm for horizontal mounted busbar trunking
50 Hz Impedance Values
Line to Neutral in milliohms per metre Aluminium Ampere Rating 225 400 600 R .222 .113 .062 X50 .086 .066 .040 R .123 .064 .064 Copper X50 .095 .058 .058
Resistance Values for Aluminium Integral Earth Bus

Ampere Rating DC Resistance (Milliohms per Metre) TP+E & TP+E+N Aluminium Phase Conductors Copper Phase Conductors 225 400 600 .266 .210 .174 .266 .210 .210
Resistance values for the Integral Earth Bus are at a 20C operating temperature.
50 Hz Voltage drop average TP line-to-line voltage drop in volts per metre

Aluminium busbar trunking Ampere Rating 225 400 600
Note:
Copper Busbar trunking Power Factor
Power Factor 100 .087 .044 .024 90 .093 .051 .029 80 .090 .051 .029 70 .085 .049 .028 50 .073 .044 .026 30 .058 .038 .022 20 .051 .034 .020
100 .048 .025 .025
90 .060 .033 .033
80 .061 .034 .034
70 .060 .034 .034
50 .056 .032 .032
30 .050 .029 .029
20 .046 .027 .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 Current Rated Current . 3. For different lengths, multiply values from table by Actual Length (metres) 30.5 metres . Short Circuit Ratings for I-LINE busbar trucking are listed on Page 44 of this manual.
30
I-LINE Busbar Trunking I-LINE II Physical Data
I-LINE Busbar Trunking

Catalogue numbers are composed of 2 basics parts the PREFIX (as below) plus the SUFFIX of each individual busbar trunking component. The PREFIX contains necessary trunking information except individual component descriptive details which are defined by the SUFFIX. The catalogue number PREFIX will generally remain unchanged throughout a trunking system while the SUFFIX will vary 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 more complete listing of device catalogue numbers is shown with the individual device drawing(s) beginning on page 40.
2 = I-LINE II busbar (800A - 5000A) no number designation = I-LINE busbar* (250A - 630A) Special Features (Optional): F = Outdoor feeder J = 1sec/3sec high circuit breaking for indoor trunking
Number of Poles 5 = TP+N+E
Ampere Rating: in hundreds of ampere (i.e. 20 = 2000 ampere)
Type of Busbar Trunking: F = Indoor feeder P = Plug-in O = Outdoor feeder R = Riser plug-in
Earth Bus: G = 50% capacity integral earth bus
Busbar Material: A = Aluminium C = Copper
2 5 20
FE
M
SUFFIX
PREFIX
of each individual busbar trunking component
Fittings available: FE = Flange end EJ = Expansion fitting ETB = End cable tap box CTB = Centre cable tap box
*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
Degree of protection** (for indoor only): = IP40 41 = IP41 54 = IP54 65 = IP65***
31
I-LINE II busbar trunking (800A - 5000A)

Top E A B C N E Top E A B C N E Top E A B C N E
5.88 149
149
Figure A
Figure B
Figure C
Cross Sections - Plug-In and Indoor Feeder Straight Length (IP-40 ,IP-54 and IP-65)
30
1.20
30
Nominal Clearance (Typical)
30
5.88 149
149
1.20
30
.25 6
6
.25 6
6
.25 6
6
.25 .25 6 6
6
.25 6
6
Figure A
Figure B Cross Sections - Fittings and All Outdoor Feeder
Figure C
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.
Aluminium content and weight

Bus Bars Per Phase Ampere Rating 800 1000 1200 1350 1600 2000 2500 3000 4000 W mm 110 136 161 186 225 323 412 475 650 Figure A A A A A B B B C mm One-6 X 76 One-6 x 102 One-6 x 127 One-6 x 152 One-6 x 191 Two-6 x 114 Two-6 x 152 Two-6 x 191 Three-6 x 165 TP+E kg/m 13.5 15.0 16.5 18.0 20.5 28.4 32.9 37.3 50.4 Weights-Feeder TP+N+E kg/m 14.9 16.8 18.6 20.5 23.5 33.5 39.7 45.5 60.1 Weights-Plug-in TP+E kg/m 16.7 18.2 19.6 21.1 23.7 31.5 36.0 40.5 53.6 TP+N+E kg/m 18.0 19.9 21.7 23.7 26.6 36.6 39.9 48.7 63.2
Copper content and weight

Bus Bars Per Phase Ampere Rating 800 1000 1200 1350 1600 2000 2500 3000 3200 4000 5000 W mm 98 110 136 148 171 199 323 387 412 599 638 Figure A A A A A A B B B C C mm One-6 x 64 One-6 x 76 One-6 X 102 One-6 X 114 One-6 X 137 One-6 X 165 Two-6 x 114 Two-6 X 127 Two-6 X 152 Three-6 x 114 Three-6 x 152 TP+E kg/m 18.0 20.5 25.0 27.2 31.4 36.2 57.6 63.5 70.3 87.9 108.9 Weights-Feeder TP+N+E kg/m 21.7 24.9 31.0 33.9 40.9 45.8 71.0 76.9 87.6 108.0 134.8 Weights-Plug-in TP+E kg/m 21.1 23.7 28.1 30.4 34.5 39.3 60.7 65.2 76.1 91.1 111.2 TP+N+E kg/m 24.8 28.0 34.1 37.1 44.0 49.0 74.1 80.1 93.9 111.2 137.9
32
120.00 3048
3048
Note: All straight lengths and fittings of feeder trunking are fully compatible, rating for rating, with straight lengths of plug-in trunking. Available in 25.4mm increments from 406mm to 3048mm.
Straight Lengths - Feeder
Sq uare D
Com pany
12.00 305
305
To
Sq uare D
Com pany
24.00 610
610
To p Sq uare D Com pany
24.00 610
610
To p Sq uare D Com pany
120.00 3048
3048
24.00 610
610
To p
Sq uare D Com pany
24.00 610
610 Note: All straight lengths of plug-in trunking are fully compatible, rating for rating, with straight lengths and fittings of feeder trunking.
12.00 305
305
Straight Lengths - Plug-In
Straight lengths feeder

Catalogue number suffix Standard Straight Lengths-Metres Standard Straight Lengths-Feet -10ST 3.05 10' -6 ST 1.83 6' -18 ST 0.46 1'6"
Straight lengths -plug in

Catalogue number suffix Standard Lengths-Metres Standard Lengths-Feet Number of Plug-In Openings -10 3.05 10' 10 -8 2.44 8' 8 -6 1.83 6' 6 -4 1.22 4' 4
For straight lengths other than standard indicate length to nearest 25mm. Consult Page 43 for maximum and minimum lengths.
33
0.62 16
16
0.62 16
16
0.88 22
22 E F J Cutout
K W Flanged Collar
4.00 102
102 F E
10.00 254
254
0.88 22
22 B C D A H Flanged Collar D C B
Catalogue Number Suffix 10 FEB
0.31 Dia. 8 Dia. 8 (Holes) (Holes)
Flanged Collar Cutout and Drilling Template 800A - 5000A Feeder
Flanged Collar and Cutout Dimensions 800A-5000A Feeder

Ampere Rating Aluminium Copper 800 800 1000 1200 1350 1600 2000 2500 3000 4000 1000 1200 1350 1600 2000 2500 3000/3200 4000 5000 H mm 187 187 203 229 254 279 352 403 505 578 730 730 G mm 130 130 145 171 196 222 295 346 448 521 673 673 478 487 406 326 335 254 W TP+E mm W TP+N+E mm J mm
Flanged Collar Hole Location and Spacing 800A-5000A Feeder

Ampere Rating Aluminium Copper 800 800 1000 1200 1350 1600 2000 2500 3000 4000 1000 1200 1350 1600 2000 2500 3000/3200 4000 5000 N Holes 10 10 10 10 10 10 16 16 18 20 22 22 Hole location and Spacing A mm 162 162 178 203 229 254 327 378 480 552 705 705 B mm 81 81 89 102 114 127 108 127 121 111 117 117 119 111 118 118 118 118 451 88 87 C mm D mm 296 98 K mm E mm F mm
34
7.00 178
178
C L
2.00 51
51 A A C B A A C A B C A
4.00 102
Contact 102 Surface
16 .62 Dia. Hole 16
Figure 1
Figure 2
Figure 3
Flanged End Details Aluminium Ampere Rating 800 1000 1200 1350 1600 2000 2500 3000 4000 Copper Ampere Rating 800 1000 1200 1350 1600 2000 2500 3000 3200 4000 5000
Flanged Collar Flanged Collar
ECBAE ENCBAE
Figure 1 1 1 1 1 2 2 2 3
A mm 76 102 127 152 191 114 152 191 165
B mm 289 378 441 616
C mm 60 73 60 60
A Figure 1 1 1 1 1 1 2 2 2 3 3 mm 64 76 102 114 137 165 114 127 152 114 152
B mm 289 353 378 565 604
C mm 60 99 73 111 73
Hex Head Bolt
.12 3
3 E
C L
C L T T U
C L U
S S S S S

(Bottom View)

(Bottom View)
Ampere Rating Aluminium Copper 800 800 1000 1200 1350 1600 2000 2500 3000 4000 1000 1200 1350 1600 2000 2500 3000 3200 4000 5000
S mm
T mm
U mm
76
92
97
76
169
173
127
169
173
35
I-LINE Busbar Trunking II Physical Data
Flanged end termination details
Busbar Trunking Flanged End or Quik Flange Tie Connector (Used on 2 and 3 Stack Configurations Only)
Grade 5 Hardware
Large Belleville Washers
Switchboard Bussing
Detail of Phase Bussing Connections in a Swichboard
Flexible Connector details
15.75
44.45 95.25
184.15 95.25
44.45
SEE NOTE 1
38.10 SEE NOTES 2&3 14.23 DIA 304.80 19.05
6.35
NOTES: 1. INSERT CABLE STRANDS IN THE CHAMFERED END OF THE TERMINAL TUBES. 2. CABLE STRANDS SHOULD BE POSITIONED NO MORE THAN .06 (MAX.) INSIDE END OF TERMINAL TUBE AFTER FLATTENING. 3. USE A BELT SANDER TO TOUCH UP STRANDS STICKING BEYOND THE END OF THE TERMINAL TUBE.
Flexible Connector (Supplied by vendor)

Ampere Rating (A) 800 1000 1200 1350 1600 2000 2500 3000 3200 4000 5000 Catalogue No. FLEX508 FLEX510 FLEX512 FLEX513 FLEX516 FLEX520 FLEX525 FLEX530 FLEX532 FLEX540 FLEX550 No. of Pieces required per phase & neutral 2 3 3 4 4 5 7 8 8 10 13
36

1.12
B
28
0.50
13 13
B C
24.00 610 11.50 292

610 292
10.50 267
267 C L
D
11.50 292
292 13 0.50
28.00 711
711
28.00 711
711
10.00
254 254
76 3.00 76
6.25 158 158
13
28.20 716
716
C
C L
15.00
381 381
9.00 229
48.00 1219
229
Cable Tap Box-End Catalogue Number Suffix ETBMB

1219
23.50 597
597
Cable Tap Box-Centre Catalogue Number Suffix CTB
Cable Tap Box-Bolt On
Cable tap box end

Ampere Rating Aluminium 800 1000 1200 1350 1600 2000 2500 3000 4000 Copper 800 1000 1200 1350 1600 2000 2500 3000 3200 4000 5000 A mm 740 740 740 740 740 740 740 1000 1000 1000 1000 1000 1000 Bt mm 279 279 279 378 378 378 429 530 530 604 530 756 756 C mm 406 406 406 406 406 406 406 660 660 660 660 660 660 Lugs Per PH&N 240mm2 3 4 4 5 6 7 7 9 10 10 11 14 17 Earth Lugs 150mm2 2 3 3 3 4 5 5 6 7 7 7 9 11
t This dimension increases by 50mm for outdoor end tap boxes
Cable tap box centre

Ampere Rating Aluminium 800 1000 1200 1350 1600 2000 2500 3000 4000 Copper 800 1000 1200 1350 1600 2000 2500 3000 3200 4000 5000 A mm 889 889 889 889 889 889 1059 1059 1059 1270 1524 1270 1600 1600 B mm 356 356 356 356 356 356 508 508 508 559 559 610 813 813 C mm 406 406 406 406 406 406 447 447 447 660 660 660 660 660 D mm 185 185 185 185 185 185 261 261 261 261 406 261 483 483 Lugs Per PH&N 240mm2 3 4 4 5 6 7 7 9 9 10 10 11 14 17 Earth Lugs 150mm2 2 3 3 3 4 5 5 6 6 240mm2 10 10 11 14 17
Cable tap box bolt on

Ampere Rating 800 1000 1200 1350 1600 6-240mm2 2-240mm2 PTB-316G PTB516G Lugs Per Phase and Neutral Catalogue Number Earth Lugs TP+E TP+N
Notes For Cable Tap Box- Bolt-On 1. Gutter can be moved to opposite end in field. 711mm clearance required from C of L busbar trunking, for mounting bolt-on tap boxes when gutter is on top; and 610mm required 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, do not 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 NOT interchangeable.
37
Tees Feeder
L L
Ampere Rating Aluminium 800
Copper 800 1000 1200 1350 1600 2000 2500 3000 3200 4000 5000
L mm 279 279 305 305 305 330 330 381 406 432 457 533 533 559
Catalogue Number Suffix -TFM11 -TFM11 -TFM12 -TFM12 -TFM12 -TFM13 -TFM13 -TFM15 -TFM16 -TFM17 -TFM18 -TFM21 -TFM21 -TFM22
1000 1200 1350 1600 Tees - Feeder Catalogue Number SuffixTFM 2000 2500 3000 4000
L L
Flatwise Elbow Details

Ampere Rating Aluminium 800 1000 1200 Copper 800 1000 1200 1350 1600 2000 2500 3000 3200 4000 5000 L mm 279 279 305 305 305 330 330 381 406 432 457 533 533 559 Catalogue Number Suffix -LFM11 -LFM11 -LFM12 -LFM12 -LFM12 -LFM13 -LFM13 -LFM15 -LFM16 -LFM17 -LFM18 -LFM21 -LFM21 -LFM22
Elbow - Flatwise Catalogue Number SuffixLFM
1350 1600 2000 2500 3000
11.00 279
279
4000
11.00 279
279
Elbow - Edgewise Catalogue Number SuffixLEM11
38
12.00 305 24.00 610

610 305
12.00 305
305
Unfused Reducer
Unfused reducer
Bolt End Ampere Rating 800 1000 1200 1350 1600 2000 2500 3000 3200 4000 5000 Catalogue Number Suffix Slot End Ampere Rating 400 -R04 -R04 -R04 600 -R06 -R06 -R06 -R06 -R06 800 -R08 -R08 -R08 -R08 -R08 1000 -R10 -R10 -R10 -R10 -R10 -R10 -R10 1200 -R12 -R12 -R12 -R12 -R12 -R12 1350 -R13 -R13 -R13 -R13 -R13 1600 -R16 -R16 -R16 -R16 -R16 2000 -R20 -R20 -R20 -R20 -R20 2500 -R25 -R25 -R25 -R25 3000 -R30 -R30 -R30
Fused reducer Fused or MCCB reducers are available. Contact your representative for details.
Aluminium 800
W
Copper 800 1000 1200 1350 1600 2000 2500 / 3200 3000 4000 5000
W 343 343 343 442 442 442 492 594 667 819 819
1000 1200 1350
28.00 711
711
1600 2000 2500
40.00 1016
1016
3000 4000
Expansion Fitting Catalogue Number SuffixEJ
Note: Expansion fitting permits 38mm of expansion or contraction.An expansion fitting should be used under the following conditions: whenever the busbar trunking crosses a building expansion; when a long straight run of busbar trunking does not contain any elbows or both ends of the run are fixed.
39
9.26 235
235
7.06 179
179
1.00 25
25
Wall and Floor Flange
Required Wall and Floor Openings
End Closure
Wall and floor flange

Ampere Rating Aluminium 800 1000 1200 1350 1600 2000 2500 3000 4000 Copper 800 1000 1200 1350 1600 2000 2500 3000 3200 4000 5000 A mm 186 199 224 237 237 260 275 288 313 360 475 500 564 688 726 738 Catalogue Number ACF-38-WF ACF-43-WF ACF-53-WF ACF-58-WF ACF-63-WF ACF-67-WF ACF-73-WF ACF-78-WF ACF-88-WF ACF-13-WF ACF-15-WF ACF-17-WF ACF-19-WF ACF-24-WF ACF-25-WF ACF-26-WF
End closure
Ampere Rating Aluminium 800 1000 1200 1350 1600 2000 2500 3000 4000 Copper 800 1000 1200 1350 1600 2000 2500 3000 3200 4000 5000 A mm 110 123 148 161 174 184 199 212 237 336 399 425 488 612 650 663 Catalogue Number ACF-38-EC ACF-43-EC ACF53--EC ACF-58-EC ACF-63-EC ACF-67-EC ACF-73-EC ACF-78-EC ACF-88-EC ACF-13-EC ACF-15-EC ACF-17-EC ACF-19-EC ACF-24-EC ACF-25-EC ACF-26-EC
Required wall and floor openings

Ampere Rating Aluminium 800 1000 1200 1350 1600 2000 2500 3000 4000 Copper 800 1000 1200 1350 1600 2000 2500 3000 3200 4000 5000 Straight Length Y W Flanged Ends Y W Flat Elbow Wall Thickness 100 200 300 W 229 254 305 305 330 356 381 432 559 660 686 787 940 1016 1016 279 305 356 356 381 406 432 483 610 711 737 838 991 1067 1067 Y 330 356 406 406 432 457 483 533 660 762 787 889 1041 1118 1118 381 406 457 457 483 508 533 584 711 813 838 940 1092 1168 1168 432 457 508 508 533 559 584 635 762 864 889 483 508 559 559 584 610 635 686 813 914 940 400 500 600 Y 150 150 176 203 203 229 254 279 381 432 457 533 660 686 711 305 305 305 305 305 305 305 305 305 305 305 305 305 305 305 356 356 356 356 356 356 356 356 356 356 356 356 356 356 356 406 406 406 406 406 406 406 406 406 406 406 406 406 406 406 457 457 457 457 457 457 457 457 457 457 457 457 457 457 457 509 509 509 509 509 509 509 509 509 509 509 509 509 509 509 559 559 559 559 559 559 559 559 559 559 559 559 559 559 559 Edge Elbow Wall Thickness 100 200 300 400 500 600
152 203 254 381 203 152 203 254 381 203 178 203 279 381 203 203 203 305 381 203 203 203 330 381 203 229 203 356 381 203 254 203 432 533 203 279 203 432 533 203 381 203 483 533 203 432 203 584 533 203 457 203 584 533 203 533 203 660 533 203 660 203 813 533 203 686 203 813 533 203 711 203 813 533 203
991 1041 1143 1194 1219 1270 1219 1270
40
Hanger-flat (for single run)

Ampere Rating Aluminium 800 1000 1200 1350 1600 Copper 800 1000 1200 1350 1600 2000 Catalogue Number Number HF-38-F HF-43-F HF-53-F HF-58-F HF-63-F HF-67-F HF-73-F HF-78-F HF-88-F
13mm Drop Rod .50 13 by Customer
8.70 221
221
Hanger - Flat
Hanger-flat
Ampere Rating Aluminium 2000 2500 3000 4000 Copper 2500 3000 3200 4000 5000 A 92 85 85 92 90 84 90 B 114 152 165 191 254 279 279 Catalogue Number Number HF-13-F HF-15-F HF-16-F HF-19-F HF-24-F HF-25-F HF-26-F
A B
2.25 57
57
.50 13mm Drop Rods 13 by Customer
Hanger - Flat
Hanger-edge
Ampere Rating Aluminium 800 1000 1200 1350 1600 2000 2500 3000 4000 Copper 800 1000 1200 1350 1600 2000 2500 3000 3200 4000 5000 A mm 212 212 250 250 276 301 339 438 501 527 613 714 752 Catalogue Number HF-43-E HF-43-E HF-58-E HF-58-E HF-67-E HF-78-E HF-88-E HF-13-E HF-15-E HF-16-E HF-19-E HF-24-E HF-26-E
A
.50 13mm Drop Rod 13 by Customer
Hanger - Edge
41
Channel by customer. Hardware to secure channel to floor and hanger to channel also by customer.
9.62 244
244
Catalog Number HF-V

32 Housing Width 32 Note: Allow 337mm above curb or floor to C of joint L to allow for proper installation of tie channel cover.
2.25 57
57 Finished Floor or Curb
Hanger - Vertical Fixed
Channel by customer. Hardware to secure channel to floor and hanger to channel also by customer.
Spring Hangers
Note: One HF-VS2 Hanger is shown in the above detail. Note: Allow 533mm above curb or floor to C of joint L to allow for proper installation of tie channel cover.
9.62 244
244
Spring Hangers
Ampere Rating Aluminum 800 Copper 800 1000 1200 1350 1600 2000 2500 3000 / 3200 4000 5000 Catalog Number HF-VS1 HF-VS1 HF-VS1 HF-VS1 HF-VS1 HF-VS2 HF-VS2 HF-VS2 HF-VS2 HF-VS8 HF-VS8 HF-VS8 HF-VS8
1.50 32
38
Housing Width
1.50 32
38
1000 1200
2.25 57
57
1350 1600
6.00 152
152
2000 2500
2.25 57
57 Finished Floor or Curb
3000 4000
Hanger - Vertical Spring
42
Special devices I-LINE II busbar trunking

Previously listed are the standard devices typically used in designing and installing I-LINE II Busbar Trunking. Obviously, there will be occasions when these will not work. Straight lengths can be built in special lengths of 406mm to 3023mm for indoor and outdoor, in 25.4mm increments. We can also build special lengths in fittings such as elbows, flanged ends, and combinations into single pieces which are similar to the devices previously described in this manual. We can also build special devices such as offset elbows, and double elbows to adapt to special situations in which standard devices will not work. Listed below is a table showing minimums and maximums for these special devices so you will know the exact flexibility you have when designing and I-LINE II Busbar Trunking installation. We also show some of the devices below the table to better give you a picture of what we can furnish.
I-Line II indoor feeder minimums and maximums (in millimetres)

LE Edge Elbow Copper 800/1000 1200 1350 1600 2000 2500 3000 3200 4000/5000 Min/Max 279-1067 279-1067 279-1067 279-1067 279-1067 279-1067 279-1067 279-1067 279-1067 279-1067 279-1067 279-1067 279-1067 279-1067 FE Flanged End Min/Max 254-1219 254-1219 254-1219 254-1219 254-1219 254-1219 254-1279 254-1219 254-1219 254-1219 254-1219 254-1219 254-1219 254-1219 LF Flat Elbow Min/Max 279-1524 305-1524 305-1524 305-1524 330-1524 330-1524 330-1524 381-1524 432-1524 406-1524 457-1524 432-1524 559-1524 533-1524 DR/DL Double Elbow Min (A) 178 203 203 203 228 228 228 279 330 330 356 330 457 432/457 OF Offset Elbow Flat Min (B) 102 102 102 152 229 229 254 356 406 406 457 406 635 584/635 OE Offset Elbow Edge Min (C) 152 152 152 152 152 152 152 152 152 152 152 152 152 152 LEFE Edge Elbow and FE Min (D) 152 152 152 152 152 152 152 152 152 152 152 152 152 152 LFFE Flat Elbow and FE Min (E) 204 204 229 229 229 254 254 305 356 330 381 356 457 457
Ampere Rating Aluminium 800 1000 1200 1350 1600 2000 2500 3000 4000
Note: All dimensions are to centrelines and adjustable in 25.4mm increments (1 inch).
Flanged End and Elbow Combinations

D E
Right Hand
Left Hand
(DR)
Double Elbow
(DL)
Flat Elbow and FE (LFFE)
Edge Elbow and FE (LEFE)
B C
Flat (OF) Offset Elbows
Edge (OE)
43
I-LINE Busbar Trunking I-LINE II Electrical Data
I-LINE short circuit rating at 3 cycles (RMS symmetrical kA at 60Hz)

Ampere Rating 225 400 600 800 1000 1200 1350 1600 2000 2500 3000 4000 5000 Aluminium AF2/AOF2 50 50 50 50 50 100 100 100 150 AFH2/AOFH 85 100 100 100 100 150 150 150 200a AP/AP2 22 22 22 50 50 50 50 50 125 125 125 200 APH/APH2 42 42 75 100 100 100 100 150 150 150 Copper CF2/COF2 50 50 50 50 50 50 100 100 150 150 CFH2/COFH 85 85 100 100 100 100 150 150 200 200 CP/CP2 22 22 22 50 50 50 50 50 65 125 125 200a 200a CPH/CPH2 42 42 75 75 100 100 100 100 150 150
a Certain fittings are rated at 150 KA RMS symmetrical
I-LINE short circuit rating (Tested values, RMS symmetrical kA at 50Hz)

Ampere Rating 250 400 630 800 1000 1200 1350 1600 2000 2500 3000 3200 4000 5000 Feeder 22 22/42* 22/42* 50 50 50 50 50 50 100 100 100 150 150 3 cycles Plug-in 22 22/42* 22/42* 50 50 50 50 50 65 125 125 125 200 200 Feeder 40 50 50 50 50 50 75 75 75 100 100 1 Sec Plug-in 40 50 50 50 50 50 75 75 75 100 100 Feeder 40 40 40 40 40 40 3 sec Plug-in -
a High breaking capacity type
44
I-LINE Busbar Trunking I-LINE II Electrical Data
Voltage Drop Values

Voltage drop values shown in the tables below are based on a single, concentrated load at the end of the run. For distributed loading, multiply the values shown by 0.5. All impedance values are given at 80C operating temperature.
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, multiply values from tables by .577.
I-LINE II Busbar trunking voltage drop is low. This helps to 3) For single phase voltage drop, multiply values from maintain a stable voltage supply to delicate electronic and tables by 1.15. computer equipment. Even at low power factors, the extremely 4) For other than rated current, multiply values from tables low reactance of I-LINE Busbar trunking helps to minimize by Actual Current . the instantaneous voltage dips which can be caused by a motor Rated Current starting inrush currents, and so forth. 50Hz voltage drop (at rated load) Average TP line-to-line voltage drop in volts per metre
Ampere Rating 800 1000 1200 1350 1600 2000 2500 3000 4000 Ampere Rating 800 1000 1200 1350 1600 2000 2500 3000 3200 4000 5000 Aluminium 100 .113 .114 .103 .097 .089 .093 .094 .084 .087 Copper 100 .079 .086 .074 .075 .074 .082 .071 .076 .068 .074 .066 Power Factor % 95 90 .117 .118 .107 .102 .094 .098 .099 .089 .090 .115 .116 .106 .101 .093 .097 .099 .089 .089 85 .113 .114 .104 .099 .092 .096 .097 .087 .087 85 .087 .095 .084 .085 .086 .093 .083 .088 .080 .082 .076 80 .109 .110 .101 .096 .090 .093 .095 .085 .084 80 .088 .094 .085 .085 .085 .092 .082 .087 .079 .081 .075 75 .106 .107 .098 .093 .087 .091 .092 .093 .082 75 .085 .092 .082 .083 .084 .091 .081 .086 .079 .079 .074 70 .102 .103 .094 .090 .084 .088 .089 .080 .079 70 .083 .090 .090 .082 .083 .089 .080 .085 .077 .077 .073 60 .093 .094 .087 .083 .078 .081 .083 .074 .072 60 .078 .085 .076 .078 .079 .085 .077 .081 .074 .073 .069 50 .084 .085 .079 .076 .071 .074 .075 .063 .065 50 .073 .080 .072 .073 .074 .080 .072 .076 .070 .068 .065 40 .075 .075 .070 .068 .064 .066 .068 .061 .058 40 .067 .073 .066 .068 .069 .074 .067 .071 .066 .062 .060 30 .064 .065 .061 .059 .056 .058 .060 .054 .050 30 .061 .066 .060 .062 .063 .067 .062 .065 .061 .056 .055 20 .054 .055 .052 .050 .048 .050 .051 .046 .042 20 .054 .059 .054 .055 .057 .060 .056 .059 .055 .050 .049 10 .043 .044 .042 .041 .040 .041 .042 .038 .034 10 .047 .051 .047 .049 .050 .052 .049 .052 .049 .043 .043
Power Factor % 95 90 .087 .095 .083 .084 .084 .092 .081 .086 .077 .081 .074 .088 .096 .084 .085 .086 .093 .083 .088 .079 .082 .076
50 Hz Impedance Values Line-to-neutral in milliohms per metre

Aluminium Busbar Trunking Ampere Rating 800 1000 1200 1350 1600 2000 2500 3000 3200 4000 5000 R .0814 .0655 .0494 .0415 .0320 .0268 .0216 .0162 .0125 X50 .0232 .0189 .0152 .0134 .0113 .091 .076 .058 .037 Copper Busbar Trunking R .0567 .0497 .0357 .0320 .0268 .0238 .0165 .0146 .0122 .0107 .0076 X50 .0280 .0244 .0192 .0177 .0155 .0128 .0098 .0085 .0076 .0052 .0043
Resistance values for aluminium integral earth bus DC resistance in milliohms per metre
Ampere Rating TP+E & TP+E+N 800 1000 1200 1350 1600 2000 2500 3000 3200 4000 5000 Aluminium Phase Conductors Copper Phase Conductors .131 .115 .105 .098 .092 .073 .066 .059 .056 .144 .131 .115 .112 .098 .098 .073 .066 .066 .056 .056
Resistance values for the integral earth bus are at a 20 C operating temperature.
Sample 2
1000 Ampere Copper Busbar Trunking at 50% power factor - 50 Hz Voltage 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
Sample 1
1000 Ampere Aluminium Busbar Trunking at 50% power factor - 50 Hz Voltage Drop =3 I (R cos PH + X sin PH) =3 x 1000 (.0000655 x .50 + .000019 x .866) =.0852volts/metre - Concentrated Load
45
I-LINE Busbar Trunking Plug-in Units

I-LINE Plug-in units application data
Compatibility All plug-in units listed in this catalogue may be used on original I-LINE busbar trunking as well as the newer I-LINE II busbar trunking. There is no need to stock two different types of units. Fusible 30, 60, 100, 200, 400, 600 ampere plug-in switches contain a heavy duty safety switch mechanism. Plug-in device mounting Plug-in units are positioned along the busbar trunking length by notches in the busbar trunking housing top which accept the mounting hooks of the plug-in unit. This aligns the plug-in unit connectors with the plug-in opening. After the unit is positioned on the busbar trunking it is allowed to swing down into the plug-in opening where the connectors make contact with the busbar. This is accomplished in hook-swing sequence of motions for the 30-600A units. 800-1600A plugin units utilize a special mounting bracket.
High visibility ON-OFF indication
Bracket allows unit to be padlocked in off position
Hook stick operated mechanism

Hinged door over switch
Circuit breakers Moulded case circuit breaker plug-in devices are available in frame sizes of 100 amperes (FA) through 1600 amperes (PA) with standard or High-Interrupting capacity breakers. Plug-in devices with current limiting MCCBs are also available. Operating handle gives visual tripped indication on all devices as well as floor operable reset on all devices.
Hook-Swing Mounting
Fusible switched and MCCB plug-in units Interlock Table I on Page 49 indicates which units are interlocked with the busbar. All devices incorporate an interlock to prevent the door over the disconnect from being opened when the unit is ON. Earthing All plug-in devices incorporate an earthing spring which cuts through the paint and forms an equipment earth between the housing and the body of the device before the phase jaws make contact with the busbars. Where ordered for use with an earth bus in the trunking, an additional larger capacity blade will be provided which makes contact with a jaw mounted on the earth bus itself.
Transparent Shield over Line Side Parts
Interlock
Earthing Spring
46
Circuit breaker units

Trip Rating A 15 20 30 FA 40 50 60 70 90 100 415VAC TP&E Catalogue No. PFA-34015-G PFA-34020-G PFA-34030-G PFA-34040-G PFA-34050-G PFA-34060-G PFA-34070-G PFA-34090-G PFA-34100-G 240/415VAC TP&N&E Catalogue No. PFA-34015-GN PFA-34020-GN PFA-34030-GN PFA-34040-GN PFA-34050-GN PFA-34060-GN PFA-34070-GN PFA-34090-GN PFA-34100-GN 600VAC TP&E Catalogue No. PFA-36015-G PFA-36020-G PFA-36030-G PFA-36040-G PFA-36050-G PFA-36060-G PFA-36070-G PFA-36090-G PFA-36100-G
Fusible Plug-in units

Type Ampere 600VAC TP&E Catalogue No PQ-3603-GE PQ-3606-GE PQ-3610-GE PQ-3620-GE PS-3620-GE PBQ-3640-GE PBQ-3660-GE PTQ-3680-GE 240/415VAC TP&N&E Catalogue No. PQ-4603-GE PQ-4606-GE PQ-4610-GE PQ-4620-GE PS-4620-GE PBQ-4640-GE PBQ-4660-GE PTQ-4680-GE Type of BS88 Fuse TIA TIS TCP TF TF TKF/TMF TTM of Rating Connection 30 60 100 Plug-in 200 200 400 600 800 Bolt-on a 1000 1200 1600
Breaker
PTQ-36100-GE PTQ-46100-GE PTQ-36120-GE PTQ-46120-GE PTQ-36160-GE PTQ-46160-GE
Trip Breaker Rating A 125 150 KA 175 200 225 250 300 LA 350 400
600 VAC TP&E Catalogue Number PKA-36125-G PKA-36150-G PKA-36175-G PKA-36200-G PKA-36225-G PKA-36250-G PBLA-36300-G PBLA-36350-G PBLA-36400-G
240/415VAC TP&N&E Catalogue Number PKA-36125-GN PKA-36150-GN PKA-36175-GN PKA-36200-GN PKA-36225-GN PKA-36250-GN PBLA-36300-GN PBLA-36350-GN PBLA-36400-GN PAa MAa
Type
Trip
600 VAC
240/415VAC
Of Rating Breaker Connection A 500 600 Bolt-on 700 800 900 1000 1000 Bolt-on 1200 1400 1600
TP&E TP&N&E Catalogue Number Catalogue Number PTMA-36500-G PTMA-36600-G PTMA-36700-G PTMA-36800-G PTMA-36900-G PTMA-36100-G PTPA-36100-G PTPA-36120-G PTPA-36140-G PTPA-36160-G PTMA-36500-GN PTMA-36600-GN PTMA-36700-GN PTMA-36800-GN PTMA-36900-GN PTMA-36100-GN PTPA-36100-GN PTPA-36120-GN PTPA-36140-GN PTPA-36160-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 which will be mounted vertically. These mounting frames are NOT interchangeable.
47
High fault rating circuit breaker units Type of Connection Trip Rating A 15 20 30 40 FA Plug-in 50 60 70 90 100 125 150 KA Plug-in 175 200 225 250 300 LA Plug-in 350 400 500 600 700 MA Bolt-on 800 900 1000 600 VAC TP&E Catalogue Number PFH-36015-G PFH-36020-G PFH-36030-G PFH-36040-G PFH-36050-G PFH-36060-G PFH-36070-G PFH-36090-G PFH-36100-G PKH-36125-G PKH-36150-G PKH-36175-G PKH-36200-G PKH-36225-G PKH-36250-G PBLH-36300-G PBLH-36350-G PBLH-36400-G PTMH-36500-G PTMH-36600-G PTMH-36700-G PTMH-36800-G PTMH-36900-G PTMH-36100-G 240/415VAC TP&N&E Catalogue Number PFH-36015-GN PFH-36020-GN PFH-36030-GN PFH-36040-GN PFH-36050-GN PFH-36060-GN PFH-36070-GN PFH-36090-GN PFH-36100-GN PKH-36125-GN PKH-36150-GN PKH-36175-GN PKH-36200-GN PKH-36225-GN PKH-36250-GN PBLH-36300-GN PBLH-36350-GN PBLH-36400-GN PTMH-36500-GN PTMH-36600-GN PTMH-36700-GN PTMH-36800-GN PTMH-36900-GN PTMH-36100-GN
Extra high fault rating circuit breaker units 240/415VAC TP&N&E Catalogue Number PFC-34015-GN PFC-34020-GN PFC-34030-GN PFC-34040-GN PFC-34050-GN PFC-34060-GN PFC-34070-GN PFC-34090-GN PFC-34100-GN PKC-34125-GN PKC-34150-GN PKC-34175-GN PKC-34200-GN PKC-34225-GN PKC-34250-GN PBLC-34300-GN PBLC-34350-GN PBLC-34400-GN
Current limiting circuit breaker units 240/415VAC TP&N&E Catalogue Number PFI-34015-GN PFI-34020-GN PFI-34030-GN PFI-34040-GN PFI-34050-GN PFI-34060-GN PFI-34070-GN PFI-34090-GN PFI-34100-GN PKI-34125-GN PKI-34150-GN PKI-34175-GN PKI-34200-GN PKI-34225-GN PKI-34250-GN PBLI-34300-GN PBLI-34350-GN PBLI-34400-GN PTMA-36500-GNCLa PTMA-36600-GNCLa PTMA-36700-GNCLa PTMA-36800-GNCLa PTMA-36900-GNCLa PTMA-36100-GNCLa
Breaker
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.
48
Type PQ Fusible Switch Low Ampere Plug-in Connection
Type PBLA Circuit Breaker High Ampere Plug-in Connection
Type PTMA Circuit Breaker High Ampere Bolt-on Connection
TABLE l. Catalogue designation and type

Catalogue Number Prefix PQ PS PBQ PBQ PFA,PFH PFI,PFC PKA,PKH PKI,PKC PBLI,PBLC PBLA, PBLH, PBLX PTMA, PTMH, PTMX PTPA, PTPH, PTPX Type Fusible-Switched Fusible-Switched Fusible-Switched Fusible-Switched Circuit Breaker Circuit Breaker Circuit Breaker Circuit Breaker Circuit Breaker Circuit breaker Circuit Breaker Circuit Breaker Ampere Rating 30-200 200 400 600 15-100 15-100 125-250 125-250 300-400 300-400 500-1000 1000-1600 Door Interlock Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Interlock with BusBar Yes No No No Yes Yes Yes Yes No No No No Hook Stick Operable Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Table ll: Interrupting capacity of circuit breaker plug-in units t

Catalogue Number Prefix Trip Range (Amperes) RMS Symmetrical Amp. (3Hz) 415/240V-50Hz 480VAC-60Hz 380/225-50Hz
Table ll: Interrupting capacity of circuit breaker plug-in units t

Catalogue Number Prefix Trip Range (Amperes) RMS Symmetrical Amp(3Hz) 415/240V-50Hz 480VAC-60Hz 380/225-50Hz
With moulded case circuit breakers PFA PKA PBLA PTMA PTPA 15-100 125-225 250-400 500-1000 1200-1600 18,000 25,000 35,000 35,000 50,000 18,000 25,000 30,000 30,000 50,000 18,000 25,000 42,000 50,000 50,000
With moulded case l-LIMITER current limiting circuit breakers PFI PKI PBLI 15-100 125-250 250-400 100,000 100,000 200,000 100,000 100,000 200,000 100,000 100,000 200,000
With electronic trip circuit breakers PBLX 100-600 450-800 600-2500 65,000 65,000 100,000 65,000 65,000 100,000 65,000 65,000 100,000
With moulded case circuit breakers-high interrupting capacity PFH PKH PBLH PTMH PTPH 15-100 125-225 250-400 500-1000 1200-1600 25,000 30,000 35,000 50,000 25,000 35,000 35,000 50,000 100,000 25,000 35,000 42,000 50,000
PTMX PTPX
t IEC 157 Part 1
With molded case circuit breaker - extra high interrupting capacity PFC PKC PBLC 15-100 125-225 300-400 65,000 65,000 65,000 65,000 65,000 65,000 65,000 65,000 65,000
49
Housing Width A H E A C B L C N 51 2.00 Min. 51 Min. F Top Top
NCBAE
OFF
ON
Vertical mounting Fusible Units Fusible switch plug-in units (30A - 100A) Mount on either side of the vertical busbar trunking. With the unit mounted on one side of the busbar trunking, the operating handle is on the top, and when mounted on the opposite side, the handle is on the bottom. The 200A fusible unit (PS) mounts only on the front of the busbar trunking (The TOP sticker on the busbar trunking is on the right). The operating handle is on the right side of the mounted unit. The 400A - 1600A fusible units mount only on the front of the busbar trunking. The handle is on the cover. Fusible Switch
Catalogue Number Prefix Ampere Rating 30 PQ 60 100 PQ PS PBQ PBQ 200 200 400 600 A mm 387 387 387 699 699 1524 1524
IMPORTANT: Orientation of the busbar trunking is essential for proper mounting of plug-in units. The busbar trunking must be positioned as shown above so that the top marking is to the right and the neutral position to the left. Circuit Breaker Units: Circuit breaker plug-in units may be installed on both sides of a riser.
F mm 203 203 304 381 229 184 184
H mm 203 203 203 381 305 457 457
Circuit Breaker
Catalogue Number Prefix PFA,PFH PFC,PFI PKA,PKH PKI,PKC PBLA,PBLH PBLX,PBLC,PBLI PTMA,PTMH,PTMX,PTME PTPA,PTPH,PTPX,PTPE Amperes Rating 15-100 15-100 125-250 125-250 250-400 250-400 500-1000 1000-1600 A mm 530 651 651 651 906 889 894 1332 F mm 54 73 60 60 142 203 159 260 H mm 254 279 279 279 381 508 406 610
50
5.42 138
138 Top
4.63 118
118 Required Mounting Clearance
8.85 225
225
1.63 41
41
1.05
27
8.00 203
203
ON
OFF
E A B C N
B Front
Fusible Switch Plug-in Units 30A- 100A
Fusible Switch Plug-in Units 30A-100A

Weight Cat. No. Prefix PQ Amperes Rating 30/60 100 Kg 33.0 37.5 Lugs Per Phase Qty. 1 1 Size 35mm2 35mm
2
Lugs Per Neutral Qty. 1 1 Size 35mm2 35mm

2
Earth Lugs Qty. 1 1 Size 25mm2 25mm

2
A mm 379 480
B mm 203 304
9.72 247
247
C L
11.44 291
291
.56 14
14.40 366
366
16.17 411
411
1.13 29
29
15.00 381
381
3.48 88
ON
OFF
22.48 571
571
E A B C N
88
15.00 381
381
Fusible Switch Plug-in Unit: 200A (Type PQ)
Fusible Switch Plug-in Unit: 200A (Type PQ)

Weight (Approx) Cat No. Prefix PQa Ampere Rating 200 Kg 32 Lugs Per Phase & Neutral Qty. 1 Size 150mm2 Earth Lugs Qty. 1 Size 70mm2
a 200A, PQ Units are for use primarily on horizontally mounted busbar. Refer to PS units for use primarily on vertically mounted busbar.
51
NCBAE Top
9.09 231
231 C L
11.44 291
291
18.00 457
16.17 411
411
1.13 29
29
1.11 28
28
14.22 361
361
3.71 94
ON
94
OFF
22.48 571
571
Fusible Switch Plug-In Unit: 200A
Fusible Switch Plug-in Unit: 200A (Type PS)

Weight (Approx.) Cat. No. Prefix PSa Ampere Rating (A) 200 Kg 32 Lugs Per Phase & Neutral Qty. 1 Size 150mm2 Earth Lugs Qty. 1 Size 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 (same side as unit operating handle) and the neutral busbar to the left as shown in top view of drawing.
4.34 110
110
C L
13.75 349
349
1.40 36 36
Required Mounting Clearance
42.00 1067
1067
1.27
32
4.00 102
102
ON
18.00 457 8.93 227

227 Top 457
20.95 532
532
E A B C N
OFF
6.14 156
156
Fusible Switch Plug-In Unit: 400A and 600A
Fusible Switch Plug-in Units: 400 and 600A

Weight (Approx) Cat No. Prefix PBQa PBQa Ampere Rating 400 600 Kg 89 89 Lugs Per Phase & Neutral Qty. 2 2 Size 300mm2 300mm2 Earth Lugs Qty 1 1
Size 300mm2 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.
52
Top C L
1.38 35
35
3.25 83
83
Required Mounting Clearance D H G E E A B C N F
Top
ON
C L
Front B
OFF
E A B C N
Circuit Breaker Plug-In Units 15A-250A
Circuit Breaker Plug-in Units 15A250A

Cat. No. Prefix PFA, PFH PKA,PKH,PKC PFC Trip Range (Amperes) 15-100A 125-250A 15-100A A mm 330 416 416 B mm 210 216 216 C mm 168 203 203 D mm 219 232 232 E mm 28 25 25 F mm 28 35 35 G mm 51 51 51 H mm 254 279 279
Circuit Breaker Plug-in Units 15A250A

Cat No. Prefix PFA, PFH PFA,PFH PKA,PKH, PKC PFC PFC Trip Range (Amperes) 15-30A 35-100A 125-250A 15-30A 35-100A Weight Kg 13 13 18 25 25 Lugs Per Phase & Neutral Qty. Size 1 1 1 1 1 16mm
2
Earth Lugs Qty. 1 1
Size 35mm2 35mm2 70mm2 35mm2 35mm2
50mm2 150mm 16mm2 50mm

2 2
1 1 1
53
Top C L
1.38 35
35
3.25 83
83
Required Mounting Clearance D H G E E A B C N F
Top
ON
C L
Front B
OFF
E A B C N
I-LIMITER Current Limiting Circuit Breaker Plug-In Units 15A - 250A

Cat. No. Prefix PFI PKI Trip Range (Amperes) 15-100A 125-250A A mm 416 416 B mm 216 216 C mm 203 203 D mm 232 232 E mm 25 25 F mm 35 35 G mm 51 51 H mm 279 279

Weight Cat No. Prefix PFI PFI PKI Trip Range (Amperes) 15-30A 35-100A 125-250A Kg 15 15 24 Lugs Per Phase & Neutral Qty. 1 1 1 Size 16mm2 50mm2 150mm
2
Earth Lugs Qty. 1 1 1 Size 35mm2 35mm2 70mm2
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 600 ampere in a vertical riser mounting.
54
4.34 110
110
C L
Top
12 0.47 Dia.
12 (2 Holes) (2 Holes)
9.77 248
248
Drop Rod by Customer
18.05 458
458
37.87 962
962
20.00 508
508
4.00 102
102 137
5.38 137
C L E A B C N
32 1.25 32 Front
OFF ON
18.00 457
457
7.07 180
180
I-LIMITER Current Limiting Circuit Breaker Plug-In Units 250A-400A
I-LIMITER Current Limiting Circuit Breaker Plug-In Units 250A-400A

Weight(Approx.) Cat No. Prefix PBLIa Triple Range(Amperes) Kg 250-400 58 Lugs Per Phase Qty. 2 Size 300mm2 Earth Lugs Qty. 1 Size 150mm2 Lugs on Neutral Qty 3 Size 300mm2
a PBLI units plug into opening but require space equal to two plug-in openings.
4.50 114
114
C L
7.13 181
181
17.00 432
432
1.10 28
28
27.31 694
694
15.00 381
381
5.75 146
146 Top E A B C N
ON
Front
OFF
15.25 387
387
3.62 92
92
Circuit Breaker Plug-In Units 250A- 400A
Circuit Breaker Plug-In Units 250A- 400A

Weight Cat. No. Prefix PBLA, PBLHa Trip Range(Amperes) 250-400 Kg 35 Lugs Per Phase and Neutral Qty. 1 size 300mm2 Earth Lugs Qty. 1 Size 150mm2
a PBLA and PBLH units plug into one opening but require space equal to two plug-in openings.
55
4.34 110
110
C L
Top
12 0.47 Dia.
12 (2 Holes) (2 Holes)
9.77 248
248
248 9.77 Drop Rod by 248 Customer
18.05 458
458
37.87 962
962
20.00 508
508
4.00 102
102 137
5.38 137
C L E A B C N
32 1.25 32 Front
OFF ON
18.00 457
457
7.07 180
180
Circuit Breaker Plug-In Units 300A - 600A
Circuit Breaker Plug-In Units 300A - 600A

Weight(Approx) Cat. No. Prefix PBLC Trip Range(Amperes) 300-600 Kg 58 Lugs Per Phase Qty. 2 Size #4-300MCM Earth Lugs Qty. 1 Size #6-300MCM Lugs On Neutral Qty. 3 Size 3/0-500MCM
PBLC units plug into one opening but require space equal to two plug-in openings.
I C L
Top C
Required Mounting Clearance Drop Rod by Customer H G E E A C B N F Top Front

OFF ON
C L
Circuit Breaker Bolt-On Units 700A - 1600A

A Cat No. Prefix PTMA, PTMH, PTMX PTPA, PTPH, PTPX Trip Range (Amperes) 500-1000 1000-2000 mm 803 1505 B mm 359 656 C mm 318 406 D mm 422 510 E mm 70 229 F mm 133 235 G mm 390 648 H mm 406 610

Weight(Approx) Cat. No. Prefix
PTMA, PTMH, PTMX PTPA, PTMH, PTPX
Lugs Per Phase & Neutral Qty. 3 6 Size 240mm2 240mm2
Earth Lugs Qty. 2 3 Size 240mm2 240mm2
Trip Range (Amperes) 500-1000 1000-2000
Kg 73 159
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).
56
I-LINE Busbar Trunking Suggested Busbar Trunking Specifications
Specifications
I-LINE and I-LINE II busbar trunking systems
General
Quality Assurance A. All busbar trunking products shall be manufactured in a facility which is Quality Systems Registered by Underwriters Laboratories to ISO9001: 1994:EN29001: 1994 BS5750 Part 1: 1994: ANSI/ASQCQ91: 1994. Regulatory Requirements A. Underwriters Laboratories Listing 1. All straight lengths, fittings, and plug-in units shall be UL Listed. 2. This listing shall include mounting of the busbar trunking in any position (i.e. horizontal flatwise, horizontal edgewise, and vertical) without derating. Delivery, Storage and Handling A. Refer to NEMA Publication BU1.1 which is a guide for proper installation, operation, and maintenance of busbar trunking products. Maintenance A. Refer to NEMA Publication BU1.1 which is a guide for proper installation, operation, and maintenance of busbar trunking products. Basic Construction A. Housing 1. The busbar trunking housing shall be constructed of code gauge steel and aluminium to reduce hysteresis and eddy current loses and shall be provided with a suitable protective finish of ANSI 49 gray epoxy paint. 2. The busbar trunking housing shall be totally enclosed non-ventilated for protection against mechanical damage and dust accumulation. 3. The totally enclosed housing shall be manufactured by the busbar trunking manufacturer. Modifications of busbar trunking to make it totally enclosed by other than the busbar trunking manufacturer voids the manufacturers warranty. Busbar trunking so modified is unacceptable without the written consent of the manufacturer. B. Joint 1. The busbar trunking joint shall be of the one-bolt type which utilizes a high strength steel bolt(s) and Belleville washers to maintain proper pressure over a large contact surface area. 2. The bolt shall be torque indicating and at earth potential. 3. The bolt shall be two-headed design to indicate when proper torque has been applied and require only a standard long handle wrench to be properly activated. 4. Access shall be required to only one side of the busbar trunking for tightening joint bolts. 5. On busbar trunking 800A and above, it shall be possible to remove any joint connection assembly to allow electrical isolation or physical removal of a busbar trunking length without disturbing adjacent busbar trunking lengths. C. Busbars 1. Busbars shall be tin plated aluminium or silver flashed copper. 2. Each busbar shall be insulated with Class B rated 130 C vendor certified polyester film or epoxy powder coated materials. 3. The temperature rise at any point in the busbar trunking shall not exceed 55 C rise above ambient temperature when operating at rated load current. 4. Both feeder and plug-in busbar trunking (800A and above) shall be of sandwich construction, meaning no air gap shall exist between busbars except at plug-in openings.
Product
Manufacturers A. All busbar trunking shall be I-LINE/ I-LINE II busbar trunking manufactured by Schneider Electric. Manufactured Units A. General 1. Furnish and install a complete low impedance prefabricated busbar trunking distribution system as shown 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 electrical contractor shall be responsible for routing the busbar trunking to coordinate with the other trades. Final field measurements shall be made by the contractor prior to release of the busbar trunking for fabrication by the manufacturer. B. Short Circuit Rating and Tests 1. The short circuit rating of the busbar trunking shall be (consulting engineers calculated required rating) ______ rms symmetrical amperes which is the ultimate anticipated short circuit current available at the source. 2. The short circuit rating of the busbar trunking shall be determined according to UL standards No. 857. This rating must be based upon actual tests at the rated short circuit current.
57
I-LINE Busbar Trunking Suggested Busbar Trunking Specifications
D. Plug-in Openings 1. On plug-in busbar trunking there shall be five dead front, hinged cover type plug-in openings on each side of ten foot lengths. 2. All openings shall be usable simultaneously. 3. Busbar trunking shall be installed so that plugs are side mounted to permit practical use of all ten plug-in openings. 4. It shall be possible to inspect the plug-in opening and busbars prior to the installation of the plug-in unit. Support of Busbar Trunking A. Hanger spacing shall be noted on layout drawings and shall not exceed manufacturer's recommendations. B. Indoor feeder and plug-in busbar trunking shall be approved for hanger spacing of up to 3 metres for horizontally mounted runs and 4.88 metres for vertically mounted runs. Outdoor feeder busbar trunking shall be approved for spacing of up to 1.5 metres for horizontally or vertically mounted runs. Voltage Drop A. The voltage drop (input voltage minus output voltage) specified shall be based on the busbar trunking operating at full rated current and at stabilized operating temperature. B. The three-phase, line-to-line voltage drop shall not exceed 3.1 volts per hundred feet at 40% power factor concentrated load which may exist during motor starting. C. The line-to-line voltage drop shall not exceed 4.0 volts per hundred feet at the load power factor which produces maximum voltage drop in the busbar trunking. Plug-in Units A. Plug-in units shall be (circuit breaker type) (fusible switch type with visible blade quick-make and quick-break mechanism). B. Plug-in units which cannot be operated directly from the floor shall be equipped with suitable means for hookstick operation. C. The interrupting rating of circuit breaker plug-in units shall be _____ rms symmetrical amperes.
Plug-in Unit Safety Devices A. Plug-in enclosures shall make positive earth connection with the earth bus before the jaws make contact with the phase bars. 1. The earthing method shall be such that it cuts through painted surfaces to make the positive ear th connection. B. The plug-in units shall be equipped with internal barriers to prevent accidental contact of fish tape and conductors with live parts on the line side of the protective device during time of wire pulling. C. Covers of all plug-in units must have interlocks to prevent the cover from being opened when the switch is in the ON position. Installation A. Install busbar trunking and accessories in accordance with manufacturers instructions. Additional instructions are detailed in NEMA publication BU1.1 which is provided with the equipment by the electrical manufacturer. B. Install busbar trunking length with expansion fitting at each location where busbar trunking run crosses building expansion. C. Provide curb around interior floor penetrations. D. Install busbar trunking with integral weather seal located where busbar trunking penetrates (exterior wall )(roof). Provide (wall) (roof) flange and seal around opening to maintain weather tight installation.
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I-LINE Busbar Trunking Notes
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I-LINE Busbar Trunking Notes
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Quality Accreditations
ASTA certificate
TILVA certificate
ISO 9002 certificate
CCIB certificate
UL certificate
Schneider Electric (HK) Ltd.

13th Floor, East Wing, Warwick House, Taikoo Place, 979 King's Road, Quarry Bay, Hong Kong Tel :(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, Macau Tel :(853) 2871 7488 Fax :(853) 2871 7499 Customer Care Centre: (852) 2579 9699 www.schneider-electric.com.hk
Production Facility : Schneider Busway (Guangzhou) Limited 85 Jun Ye Lu, Northern Part of Eastern Section of Guangzhou Economic & Technological Development District, Guangzhou, PR China Postal Code : 510530 Tel : (8620) 8226 4242 Fax : (8620) 8226 4032/8226 4497
As standards, specifications and designs change from time to time, please ask for confirmation of the information given in this publication.
SEHK/DOC/ILINE01
02/2007

43@tbllocalcat Filenames ILineTrunkingSys Cat 0207

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I-LINE Busbar Trunking Systems

Applications & Specifications Class 5600

Building a New Electric World

Delivering Power to the People

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

NATIONAL ACCREDITATION OF CERTIFICATION BODIES

Certificate No. FM23076

SQUARE D COMPANY REGISTERED TO ISO 9001 CERTIFICATE NO. A2194

I-LINE Busbar Trunking Contents

I-LINE Busbar Trunking Product Features

Simple to install and maintain

I-LINE Busbar Trunking Product Features

High grade conducting and insulation material

Type of Trunking Feeder and Plug-in Feeder only

Degree of Protection t IP-40 IP-54 IP-66

Feeder and Plug-in

Busbars Earth Bus/ Housing Bottom (1.6mm Aluminium Busbar)

I-LINE Busbar Trunking Construction

What is I-LINE busbar trunking?

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

I-LINE Busbar Trunking Construction

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

Opening insulator: Adds insulation and support at plug-in contact area.

3 Earth jaw for plug-in

I-LINE Busbar Trunking Construction

Indoor Feeder Busbar Trunking (800A to 5000A)

I-LINE Busbar Trunking Construction

Outdoor Feeder Busbar Trunking (800A to 5000A)

The assembled joint with all installation activities complete.

I-LINE Busbar Trunking Ordering Checklist

Important information when ordering Busbar Trunking Systems

BUSBAR TRUNKING ORDER ENTRY CHECKLIST

I-LINE Busbar Trunking Application

Where should I-LINE busbar trunking be used?

I-LINE Busbar Trunking Application

Service entrance connections

Information Needed for Transformer Connection

Front Outdoor X X Indoor LV Throat X

Top View of Transformer

Side View of Transformer

Edge of Throat Collar

Transformer Tank Wall

X X "X" Number and Diameter of Holes

I-LINE Busbar Trunking Application

Horizontal plug-in busbar trunking

Detail A Hook-Swing Mounting

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

I-LINE Busbar Trunking Application

Busbar trunking fittings

Edge Of Joint Channel

Figure 4 Busbar Trunking Joint Accessibility

Plug-In Cable Tap Box

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

Busbar trunking through wall and flanges

I-LINE Busbar Trunking Application

Vertical busbar risers

All X dimensions must be known. X

152 .50 152

Figure 5 Typical information Needed for Riser

Figure 6 Typical Layout 800A and Above Riser

All Dimensions Millimetres

I-LINE Busbar Trunking Application