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Installation Manual
SCM Busduct System
PREFACE
This manual describes the installation manners of Henikwon SCM Busduct System. Refer the manual carefully before setting
the installation and the maintenance. It guides the instructions for the proper handling, installation, operation and maintenance
and help personal injury equipment damage during handling, and to facilitate moving the busduct section.
Special attention on the handling of busduct is essential, as the product is for the usage of power distribution which is very costly.
However, it is recommended that the installation work be performed only by qualified person, who is familiar with the installation,
test / commission and operation of the busduct.
Should you have any queries on installation, you may contact us at e-mail: info@henikwon.com or +603-6140 8000.
Contents
1. General 2
2. Unpacking 2
3. Handling 3
4. Storage 3
5. Operation 4
7. Summary 5
8. Joint Assembly 6
14. Energizing 9
16. Maintenance 10
17. Disposal 13
18. Appendix
1. Insulation Test Report 14
2. Final Insulation Test Report 15
1
SAFETY PROCEDURE
Throughout this Operation & Maintenance Manual, reader (or installer) is to remember and follow the indication of the safety note
as being defined hereafter.
DANGER !
This notification denotes that, the handler or installer of the busduct system must strictly follow each of the processes and no
step should be skipped while carrying out installation or maintenance work. There is a risk of sudden death or major irreparable
equipment damage resulting from not following or skipping these steps.
WARNING !
This notification indicates that, a moderate level of harm to human and also to equipment should any steps contained therein is
not followed accordingly. Therefore, extra attention and careful judgment is required when installer is going through any of the
sections being marked with this symbol.
CAUTION !
Failing to follow instruction within this section will results in injury occur direct or indirectly from the busduct installation or
maintenance process.
1. General
1.1 Proper planning and coordination between trades, heating contractors and plumbing contractors are important for a good
busduct layout.
1.2 The successful operation of busduct is dependent upon proper handling, installation, operation and maintenance, as
well as upon proper design and manufacture. Neglecting certain fundamental installation and maintenance requirements
may lead to personal injury and damage to electrical equipment or other property.
1.3 Installation, operation, and maintenance of busduct should be conducted only by qualified personnel.
1.4 For purposes of these guidelines, a qualified person is one who is familiar with the installation, construction, and operation
of the equipment and the hazards involved. In addition, the person is:
1.4.1 Trained and authorized to test, energize, clear, ground, tag, and lockout circuits and equipment in accordance
with established safety practices, is
1.4.2 Trained in the proper care and use of protective equipment such as rubber gloves, hard hat, safety glasses or
face shields, and flash resistant clothing in accordance with established safety practices, is
1.4.3 Trained in rendering first aid.
WARNING !
Hazardous voltages in electrical equipment can cause severe personal injury or death. Unless otherwise specified,
installation, inspection and maintenance should only be performed on busduct and equipment to which power has been
turned off, disconnected and electrically isolated so that no accidental contact can be made with energized parts. Follow
all manufacturers warnings and instructions.
WARNING !
Operation of busduct which has been water or moisture damaged can cause property damage, severe personal injury,
or death. Observe the precautions in Section 6 and 7 to assure adequate insulation resistance and that source of
moisture are eliminated.
2. UNPACKING
2.1 Care must be used in unpacking. Band cutters should be used on all banding securing the package.
2.2 Nail pullers should be used for unpacking wooden crates to avoid damage.
2.3 Remove any support blocks which may have been used for shipping.
2
3. HANDLING
These guidelines are provided to help avoid personal injury and equipment damage during handling, and to facilitate moving
the busduct sections and fittings at the job site.
3.1 Handle busduct with care to avoid damage to internal components and the enclosure or its finish. Avoid subjecting
busduct to twisting, denting, impact and, in general, rough handling.
3.2 Do not use busbar ends for lifting busduct sections or fittings.
3.3 When the busduct is received, unpack it sufficiently to inspect it for concealed damage and to determine that the
shipment is complete and correct.
3.4 If busduct is to be stored prior to installation, restore the packing for protection during that period (See Section 4). When
conditions permit, leave the packing intact until the sections or fittings are at their final installation location.
3.5 Verify that the weights of any busduct sections or fittings are within the rated capacity of the handling equipment to be
used.
3.6 Platform dollies provide a simple method of moving busduct on one floor level if there is little or no incline. Balance the
load carefully.
3.7 A fork-lift truck may offer a more convenient method of handling busduct and has the added advantage of permitting it
to be hoisted between levels. Balance the load carefully.
3.8 Platform lifts or elevators, either manually or power operated, can be used advantageously in moving loads of busduct
between elevations.
4. STORAGE
4.1 Busduct sections and fittings which are not to be installed and energized immediately should be stored in a clean dry
space having a uniform temperature to prevent condensation. Preferably, they should be stored in a heated building
having adequate air circulation and protected from dirt, fumes, water, and physical damage.
4.2 It is recommended that busduct should not be stored outdoors. Protect busduct from dust and water by covering with
the waterproof sheet. (Fig. 1)
waterproof sheet
Chock
finished floor level
Fig. 1
4.3 If it must be stored outdoors, cover it securely to provide protection from weather and dirt. Temporary electrical heating
should be installed beneath the cover to prevent condensation.
4.4 Outdoor busduct is not weather resistant until completely and properly installed and should be treated exactly the same
as indoor busduct until after it is installed.
4.5 Busduct should always be placed on the floor horizontally and, the chocks or forms are placed underneath the busduct.
(Fig.2)
5. OPERATION
5.1 Provide sufficient horizontal and vertical clearance from walls and ceilings to provide easy access to joints, both for the
original installation and possible removal of a section when required.
DANGER !
Protection device and proper space clearance must be observed during hoisting of busducts.
3
5.2 Table 1 shows the approximate weight of busduct. However, the weight of special busduct (e.g. flanged end, expansion
joint and etc.) should be considered during transporting the units as it is heavier than the weight calculated.
Table 1
Copper Aluminum
Ampere
Indoor Busduct Outdoor Busduct Indoor Busduct Outdoor Busduct
A 3W 4W 5W 3W 4W 5W 3W 4W 5W 3W 4W 5W
400 11.0 13.2 15.5 15.5 17.8 20.0 8.0 9.6 11.1 12.6 14.2 15.7
630 14.5 17.8 21.2 19.0 22.3 25.7 9.6 11.4 13.1 14.3 16.0 17.7
800 16.1 20.0 23.9 20.7 24.5 28.4 11.2 13.2 15.3 15.8 17.8 19.9
1000 20.1 25.1 30.1 24.7 29.6 34.6 13.1 15.6 18.1 17.7 20.2 22.7
1250 25.0 31.4 37.8 29.5 35.9 42.3 15.1 18.0 20.9 19.7 22.6 25.5
1500 29.8 37.7 45.5 34.4 42.2 50.0 19.0 22.7 26.5 23.6 27.3 31.1
1600 34.7 44.0 53.2 39.3 48.5 57.7 19.7 23.7 27.6 24.3 28.3 32.2
2000 41.6 52.8 64.0 46.1 57.3 68.5 24.0 28.9 33.7 28.6 33.5 38.3
2500 50.7 64.4 78.2 55.2 68.9 82.7 34.0 40.7 47.3 38.6 45.3 51.9
3200 69.5 87.9 106.4 74.0 92.5 110.9 39.5 47.3 55.2 44.1 51.9 59.8
3500 79.3 100.6 121.8 83.8 105.1 126.4 44.9 53.9 63.0 49.5 58.5 67.6
4000 83.2 105.6 128.0 87.7 110.1 132.5 48.0 57.7 67.5 52.6 62.3 72.1
4500 96.9 123.2 149.6 101.4 127.8 154.1 59.2 71.0 82.7 63.8 75.6 87.4
5000 101.3 128.8 156.3 105.9 133.3 160.8 72.0 86.6 101.2 76.6 91.2 105.8
6300 124.8 158.4 192.0 129.3 162.9 196.5
5.3 Avoid subjecting busduct to twisting, denting, and impact and, in general, rough handling, especially busduct ends are not
hit against the structures or equipments and also not allowed to stand busduct against the walls or other structures.
5.4 Suitable and certified hoisting wire should be used to hoist the busduct for easy installation and also to avoid damage
to the busduct housing. (Fig. 4)
DANGER !
Ensure that proper distribution of the busduct weight is applied and careful approach is a must to avoid any damage to
the housing that could pinch the busduct insulation and result in a failure.
5.5 No direct fixing of hoisting wire to the joint cover hole on the housing for 2000A busduct and above, but instead, use
lifting jig for both horizontal and vertical busduct installation, as shown in Fig. 4. Any rating below 2000A may use joint
cover hole.
5.6 The joint hole should not be used for hoisting as it cannot withstand the weight of the busduct which would result break
on the welding parts or any damages.
WARNING !
Do not stand directly below the hoisted equipment at any given time.
Lifting
Jig
Fig. 4 Fig. 5
4
5.9 Hang one busduct unit with two hangers in principle.
5.10 Depending on the site condition, preferably Flanged End, Flanged End Box, Cable Feed Box shall be installed first,
followed by the sequent unit numbers. (Fig. 6)
CAUTION !
MATTER TO OBSERVE WHILE LIFTING BUSDUCT WITH HOIST.
1. A licensed, trained Safety and Health Officer must be present to monitor the entire process.
2. The supervisor for the hoisting process must be present to supervise and manage the process.
3. The hoisting zone must be condoned off by proper measure and site HSE standard to prevent any unauthorized
entry into the hoisting zone.
4. Weights of busducts are to be checked before any lifting is carried out to match the lifting wire/cable.
5. The hook/knot to hoist is to be check once the busduct has been lifted up not more than 500mm from the ground.
6. If the hook/knot to hoist is loose, the lifting must be stopped and all hook/knot to be fastened before commencing
the work again.
7. Worker must be trained to give proper instruction to the hoist operator during the entire lifting process. These
instructions include, stop, lift, move etc.
Fig. 6
7. SUMMARY
7.1 Review erection drawing very carefully.
7.2 Check the bill of material.
7.3 Check description and identification of each piece before installing it.
7.4 Follow instruction on each piece for torque requirement.
7.5 Follow manufacturers joint assembly instruction drawing for both indoor and outdoor procedure.
7.6 Conduct an insulation resistance test on each section of busduct before it is installed.
7.7 Conduct an insulation resistance test on the portion of each run already installed on a daily basis.
7.8 Check for possible source of water that may fall on indoor busduct, and take corrective action to prevent this.
5
8. JOINT ASSEMBLY
The joint section is heart of the busduct during its operation, so proper tightening of the joint bolt is important to ensure its
continuous satisfactory operation.
WARNING !
No worker is permitted to be under the busduct during installation process to prevent hurt by falling objects.
Suitable signage must be placed at suitable areas to notify all workers on the installation process.
8.1 Ensure all contact surfaces are clean and free of contaminants by using dry cloth.
8.2 Align the busduct ends of adjoining sections, verifying proper phase alignment, and slide the sections together as
illustrated in Fig. 7. It is done by inserting jointing tool inside the jointing holes.
Supply Load
Supply Load
Fig. 7
8.3 For easier connection of supply and load and less impact on the download of the
busduct weight, certain interval has to be kept. Use joint cover by screwing bolt on the
lower part of the joint cover then follow by the upper part of the joint cover. This would
enable easy jointing and accurate jointing interval. (Fig. 8.1, 8.2)
Fig. 8.1
Fig. 8.2
8.4 Assembly
8.4.1 Joint the two sections until the joint edge to edge distance is 300mm or to have adequate contact surfaces of
each phase to phase.
8.4.2 Ensure load and supply sides are aligned correctly by placing inserting tool.
8.4.3 Insert joint bolt with the joint support through the joint hole and tighten it with Plate Spring and MF Nut with the
tool.
rubber gasket Joint cover w/rubber gasket m8 spanner (not Supply)
on its entire length
2
mm
300
Joint Lock nut
Nut
(Maintenance-free Nut)
Joint Bolt
Joint cover w/ Side cover
Jointing Tool rubber gasket w/ rubber gasket
Bolt (M8x16)
Fig. 9.1 Fig. 9.2
6
8.5.4 For IP65 and IP67, install side covers with gasket and then fixed with bolt (M8x16) on both sides.
8.4.5 Install the joint cover with gasket on the top and bottom of the jointing section.
8.5 Ensure that all busduct installation is in straight alignment, either in horizontally or vertically in order to have proper
jointing system. (Fig. 10)
Fig. 10
hanger clamp
Horizontal Hanger
7
11. VERTICAL FIX HANGER INSTALLATION
Vertical Fix Hanger shall be installed to fix the first feeder unit, on the first floor, for firm hold of the busduct.
11.1 Temporarily support the busduct section in place. Fit the
C-Channel (customer supply) onto the Floor Flange. Fix on
Floor FlangE
the bolts (customer supply) onto the Slab in order to hold
the C-Channel firmly to the Slab.
C-Channel 11.2 Drill the C-Channel with opening hole of 14mm to
accommodate the fixed support rod. Locate the hole in line
with the centerline of the side of the busduct housing. The
C distance in between these two holes from center to center
B is 65mm [A]. Then, drill the busduct housing with opening
hole of 12mm with the height around 85mm [B] from the
A top of the C-Channel for installing the L-Channel Bracket
by using M10 bolts supplied. The distance in between these
two holes from center to center is 60mm [C].
Slab
L-Channel
Top Nut
11.3 Fix the rod to the top of the C-Channel together with the
nuts as shown in (1) Try to adjust the Top Nut on both
sides until the height from the top of the C-Channel to
the base of the L-Channel is around 50mm as shown
in [D] and it is aligned with the opening hole 12mm
on the busduct housing.
Then, fix the L-Channel together with the nuts as shown
in (2).
11.4 The process of installing Vertical Fix Hanger is
completed.
The following instructions are for fitting of Vertical Spring Hanger for Henikwon Busduct System.
12.1 Temporarily support the busduct section in place. Fit the
Floor C-Channel (customer supply) onto the Floor Flange. Fix on
Flange the bolts (customer supply) onto the Slab in order to hold
the C-Channel firmly to the Slab.
C-Channel
12.2 Drill the C-Channel with opening hole of 14mm to
G accommodate the fixed support rod. Locate the hole in line
F with the centerline of the side of the busduct housing. The
distance in between these two holes from center to center
is 65mm [E]. Then, drill the busduct housing with opening
hole of 12mm with the height around 190mm [F] from the
top of the C-Channel for installing the L-Channel Bracket by
using M10 bolts supplied. The distance in between these
Slab two holes from center to center is 60mm [G].
L-Channel
Top Nut
12.3 Fix the rod to the top of the C-Channel together with the
K
nuts as shown in [1]. Try to adjust the Top Nut on both
sides until the height from the bottom of the L-Channel H J
to the top of the C-Channel is around 155mm as shown
in [H] while the height from the bottom of L-Channel to
the bracket of the Vertical Spring Hanger is 100mm as
shown in [J]. Then, fix the L-Channel together with the
nuts as shown in [2].
12.4 Unscrew the top nut, 15mm [K] above the top of the
L-Channel. The process of installing Vertical Spring
Hanger is completed.
8
13. INSPECTION OF JOINT BOLT MF Nut Torque Wrench Neck
Nut A
Nut B
Nut A
Nut B
Torque Wrench
before After
MF Nut
MF NUT
Table 2
Bolt Size M8 M10 M14
Torque Value (kgcm) 90-110 180-230 1500
14. ENERGIZING
Before Energizing
14.1 Recheck all joint connections for tightness by following on the recommended torque value given as SECTION 13.3 Table
2. Ensure that outer head of MF nut is broken. If not, then retighten the nut until it is broken, before installing the side
covers.
14.2 Ensure that upper nut, is unscrewed 15mm above the upper part of spring hanger.
14.3 Isolate the busduct run by disconnecting all connections to transformers, switchboards, meters and so forth.
14.4 Conduct an insulation resistance test on the whole busduct connection after installation. The value of the insulation
resistance depends on the ampere rating, route length, and humidity which are generally more than 100M (1000V
megger). If the value is less than 10M, It has to be checked due to some factors that can reduce the insulation and
the other factors can be as follows;
a) Whether the busduct is damaged,
b) Whether the connecting parts are fixed precisely,
c) Whether the bolts for connecting the equipment are securely fastened,
d) Whether the hangers are supporting the busduct securely,
e) Whether the vertical spring hanger is fixed properly
After Energizing
When the equipment is energized for the first time, qualified electrical personnel should be present. If short circuits and ground
faults caused by damage or poor installation practices have not been detected in the check-out procedure, serious damage
can result when the power is turned on.
14.5 There should be no electrical load on the busduct when it is energized. Since busduct typically extends through several
rooms and floor levels, care should be taken to see that all devices fed from the busduct are in the OFF position.
14.6 The equipment should be energized in sequence by starting at the source end of the system and working toward the
load end. In other words, energize the main devices, then the feeder devices and then the branch-circuit devices. Turn
the devices to the ON position with a firm positive motion.
14.7 After all over current devices have been turned on, loads such as lighting circuits, contractors, heaters, and motors may
be turned ON.
14.8 Busduct, when operating properly, will have a moderate hum. Excessive noise may be an indication of hardware that
has not been tightened or of metal parts that have been improperly assembled.
14.9 Occurrence of sparking at any point along the busduct is not a normal condition. The busduct must be de-energized
immediately, and remain de-energized until the sparking condition has been corrected.
9
WARNING !
Hazardous voltages in electrical equipment can cause severe personal injury or death. Unless otherwise specified,
installation, inspection and maintenance should only be performed on busduct and equipment to which power has been
turned off, disconnected and electrically isolated so that no accidental contact can be made with energized parts. Follow
all manufacturers warnings and instructions.
WARNING !
Hazardous voltages in electrical equipment can cause severe personal injury or death. Unless otherwise specified,
installation, inspection and maintenance should only be performed on busduct and equipment to which power has been
turned off, disconnected and electrically isolated so that no accidental contact can be made with energized parts. Follow
all manufacturers warnings and instructions.
16. Maintenance
DANGER !
1. Do not touch the charging part (conductor, connection part) while in operation.
It can be the cause of death or serious injury due to electric shock
10
WARNING !
1. Differentiate between the joint bolt and the joint cover based on 3W or 4W.
It can be the cause of overheating, short circuit and fire due to the improper joint.
2. Clear away all the contaminants (such as dust, tools, cables, bolts, washers and etc.) after installation, checking and
maintenance at the joint has been completed.
It can be the cause of damage to the insulation, short circuit and fire.
3. Tighten the joint bolt (M14), general bolt and screw according to the required torque given.
It can be the cause of the over heating and fire.
4. Do not use longer joint bolt unless otherwise mentioned.
It can be the cause of short circuit and fire.
5. After completing the installation, checking and maintenance, ensure phase to phase terminations (connections) are
correctly done, before the energizing.
It can be the cause of short circuit and fire.
6. Before the energizing, ensure End Closure accessories are correctly assembled.
It can be the cause of short circuit and fire.
7. Joints must have a final check before the energizing.
It can be the cause of short circuit and fire.
8. Before the energizing, an insulation resistance check must meet the required value 10M.
It can be the cause of electric leakage and short circuit.
9. Fix Plug-in Unit after clean any contaminants in the Plug-in Hole.
It can be the cause of damage to the insulation, short circuit and fire.
10. Do not clean the exterior surface of the busduct system with wet cloth, after completing the installation, checking
and maintenance.
It can be the cause of an electric shock.
11. Ensure the phase sequence of Plug-in Hole in R, Y, B, N,(G) from left to right before fixing the Plug-in Unit.
It can be the cause of short circuit and fire.
12. Ensure that the hangers are fixed and used materials as per the manufacturers specification, without any missing
points.
It can be the cause of a fall or a serious injury.
13. Joint bolts (M14) shall be tightened from both sides to balance the tightness to the plate spring.
It can be the cause of an improper joint or a serious injury.
14. Maintenance inspection is done, after the current is being discharged,
It can be the cause of an electrical shock.
15. Shut off the main circuit breaker and Plug-in box circuit breaker before the maintenance inspection.
It can be the cause of an electrical shock.
16. During the energizing, do not insert any metal rod after the joint cover being removed.
It can be the cause of a serious injury, electric shock or short circuit.
17. A professional personnel should be checked and required
It can cause the faulty operation, a serious injury or electric shock.
CAUTION !
1. Do not use the busduct as a supporting unit of other equipments to lean against.
It will damage the unit and affects the quality.
2. Before the energizing, please turn off all MCCBs.
It will damage other devices.
3. Do not give hard impact on the unit during the energizing.
It will damage the unit and affects the quality.
4. Do not modify the busduct.
The warranty is not covered after modification is done.
2) Periodical inspection
It is to check on the busduct system function and operation as a whole and the schedule is for the period of 3-5
years interval.
3) Temporary inspection
It is to check on the any faulty or big accident occurred.
11
2) Review of Circuit diagram
3) Contact
Check the emergency contact points are available at all times.
4) Cautious on rated current and voltage
While checking the joint section, discharge remained electric charge with earth connection.
5) Check on the required parts and get them ready.
16.4 Record
Check points, repaired sections, condition of the faulty, time and date are to be recorded during spot maintenance,
regular maintenance or temporary maintenance, in order to refer for future incidents.
Would
Any smell or Yes After safety check, abnormality develop Yes
abnormality proceed with inspection to an out performance
defected? within the safety limit. of the
product?
No If necessary No
To arrange
Inspection Completed. Continue to supervisory run, and regular
Record maintenance record on the check list and plan maintenance
inspection result. on the maintenance schedule. inspection.
12
2) Periodical inspection
CONDUCTOR
CONDUCTOR
PLAT WASHER
BOLT
2. Tightness
Indicate a check mark to ensure that correct torque was achieved on each bolt.
(refer the below table)
Bolt Tightness Refer the torque value on various sizes of bolts used for structures.
Structure
Bolt size M8 M10 M14
Torque value (kgcm) 90-110 180-230 1500
Different torque value is applied for insulating material
Measurement of 1. Measurement insulation resistanace at 1000V megger.
insulation resistance
2. Insulation resistance value
It may vary due to the environmental factors. However, during the maintenance
inspection, the final value should be more than value 10M.
Replacement Parts 1. At the time of replacement, ensure to check on its specification and functions.
2. During replacement, ensure to have the correct joint connections and
correct torque for each bolt.
3. Any replacement, modification, extension and additional busduct units,
please contact the maintenance team or our sales dept.
13
16.7 Measures to take when emergency occur (continued)
17. Disposal
17.1 Based on ISO 14001, the busduct components as a whole need to be segregated into metal and non-metal items.
And components which are hazardous to environment and recyclable need to segregated and disposed at specified
location.
17.2 Since theres emission of poisonous gas (harmful to respiratory organs) during incineration process, the item shall be
disposed at an authorized location.
14
Appendix 1
15
Appendix 2
Final INSULATION TEST REPORT
(BEFORE ENERGIZATION)
METRE
TOTAL LENGTH OF RUN :__________________________
R-E
Y-E
B-E
N-E
R-Y
R-B
Y-B
R-N
Y-N
B-N
16
HENIKWON CORPORATION
( Co. No. 161535-W )
HENIKWON is committed to the policy of continuous development and improvement and thus, reserves the right to supply products which may
differ in detail from those shown in this publication without any prior notice.