Godrej S.M.A.R.T. Quick start guide

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Power Distribution Solutions
INSTALLATION AND
OPERATIONAL MANUAL
Godrej S.M.A.R.T.
BUSDUCT SYSTEM
IMS CERTIFIED CPRI / ASTA TESTED
Kindly read the manual for Safe Installation and Energizing the Godrej S.M.A.R.T Busduct System
Year 2019

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PREFACE
This manual describes the installation and inspection procedure of Godrej S.M.A.R.T. busduct systems.
Refer the manual carefully before setting the installation and the maintenance of the busduct system. It is
giving the proper instructions for proper handling, installation, operation and maintenance, and also helps
in minimizing personal injury, equipment damage during the handling of the busduct system, and to
facilitate the movement of the busduct sections.
Special care on the handling of the busduct is essential; as the product is for the usage of power
distribution which itself is very costly.
However it is recommended that the installation is performed only by qualified person, who is familiar with
the installation, testing / commissioning and operations of the busduct.
1
General
3
2
Unpacking
3
3
Handling
3
4
Storage
4
5
Operation
5
6
Protection Against Ingress Of Dust And Water
7
7
Summary
7
8
Joint Assembly
7
9
Horizontal Hanger Installation
11
10
Vertical Fixed Hanger Installation
11
11
Vertical Spring Hanger Installation
13
12
Inspection Of Joint Bolt
15
13
Fixing Tap-Off-Box
15
14
Energizing
16
15
Care And maintenance
16
16
Process Flow Chart for Installation
18
17
Appendix: -
1. Pre-Installation Checklist.
20
2. On Site IR Test Report Sheet.
21
3. Pre-Commissioning Checklist.
22
Formats can be photocopied, filled up and filed for future
reference
SAFETY FIRST: - READ THESE SIMPLE
GUIDELINES FOR COMPLETE INFORMATION.
NOT FOLLOWING THEM MAY BE DANGEROUS.

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1. GENERAL
1.1. Since construction sites are usually of poor conditions, proper planning and coordination between all
the Utilities, HVAC contractors, Plumbing contractors and Electrical contractors are important for a
good busduct installation.
1.2. The successful operation and performance of busduct is dependent upon proper handling,
installation, operation and maintenance. 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 Competent
personal.
1.4. For purpose of these guidelines, a competent person is one who is familiar with the installation,
construction, and operation of the equipment and the hazards involved. In addition, the person
should be:
1.4.1 Trained and authorized to test, energize, clear, ground, tag and lockout circuits and equipment
in accordance with established safety practices.
1.4.2 Trained in proper care and use of personal protective equipment such as rubber gloves, hard
hat, safety glasses or face shields, and flash resistant clothing in accordance with established
safety practices
1.4.3 Trained in rendering the first aid.
2. UNPACKING
2.1. Care must be taken while unpacking. Strip cutters should be used on all metal strips 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.
2.4. DO NOT REMOVE THE PLASTIC WRAPPING ON THE BUSDUCT AT THE LOAD AND SUPPLY
ENDS TILL THE BUSDUCT IT TAKEN UP FOR INSTALLATION, AS DUST, MOISTURE AND
ANY OTHER CONTAMINATION CAN OCCUR WHICH MAY RESULT IN THE FAILURE OF THE
BUSDUCT AFTER INSTALLATION.(see Fig No-4)
2.5. Check the material received as against the packing list of the package.
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, and impact and in general, rough handling.
3.2. Do not use busduct 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.
WARNING: HAZARDOUS VOLTAGES IN ELECTRICAL EQUIPMENT CAN CAUSE SEVERE
PERSONAL INJURY. ENSURE POWER HAS BEEN TURNED OFF, DISCONNECTED AND
ELECTRICALLY ISOLATED SO THAT NO ACCIDENTAL CONTACT CAN BE MADE WITH
ENERGIZED PARTS. FOLLOW ALL MANUFACTURER’S WARNING
AND
INSTRUCTIONS.
WARNING: OPERATION OF BUSWAY WHICH HAS BEEN WATER OR MOISTURE DAMAGED
CAN CAUSE PROPERTY DAMAGE, SEVRE PERSONAL INJURY. OBSERVE THE
PRECAUTIONS IN SECTION 6 AND 7 TO ASSURE ADEQUATE INSULATION
RESISTANCE AND THAT THE SOURCES OF MOISTURE ARE ELIMINATED.

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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 section 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. 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. Fig. 1
Fig. 1
3.7. Platform lifts or elevators, either manually or
power operated, can be used advantageously in
moving loads of busduct between elevations.
Fig. 2
Fig 2.
4. STORAGE
4.1. Busduct sections and fittings which are not to be installed and energized immediately should be
stored in a heated building having adequate air circulation and protection 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. 3)
Fig. 3
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. Bus duct should always be placed on the floor horizontally and, wooden battens or forms are placed
underneath the busduct.(Fig. 3 & Fig. 4)

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Wrong Method of Storing of the Busducts.
Correct Method of Storing of the Busducts.
Fig. 4
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.
Copper Size & Weight
Aluminum Size & weight
Rating in
Amps
Busduct
Weig
ht
Kg/m
Width
(W) mm
Rating in
Amps
Busduct
Weight
Kg/m
Width
(W) mm
Height
Type
Conductor size
–mm
3PH
4W
3PH 4W
Height
Type
Conductor size -
mm
3PH 4W
3PH 4W
mm
mm
400
115
Fig. 1
One –5 x 50
21
125
400
125
Fig. 1
One –5x60
15
125
630
125
One –5 x 60
27
630
125
One –6 x 60
15
800
125
One –6 x 60
27
800
140
One –6 x 75
17
1000
140
One –6 x 75
31
1000
165
One 6 x 100
20
1250
165
One –6 x 100
39
1250
205
One –6 x 140
26
1600
205
One –6 x 140
52
1600
240
One –6 x 175
30
2000
240
One –6 x 175
63
2000
305
One –6 x 240
38
2500
305
One –6 x 240
83
2500
405
Fig. 2
Two –6 x 140
45
3200
405
Fig. 2
Two –6 x 140
98
3200
475
Two –6 x 175
54
DO NOT REMOVE THE PLASTIC
WRAPPPING UNTIL TAKEN FOR
ASSEMBLY

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3600
475
Two –6 x 175
120
3600
495
Two –6 x 185
56
4000
495
Two –6 x 185
126
4000
605
Two –6 x 240
70
4500
605
Fig.3
Three –6 x 140
144
4500
710
Fig. 3
Three –6 x 175
78
5000
710
Three –6 x 175
176
6300
740
Three –6 x 185
186
5000
905
Three –6 x 240
102
Table 1
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.
5.3. Avoid subjecting busduct not only to twisting, denting, and impact and, in general, rough handling.
Especially busduct ends are not to be hit against the structures or equipment and also not allowed to
stand busduct against the wall 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 housing.
5.5. 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.
5.6. No direct fixing of hoisting wire to the joint cover hole on the housing for of the busduct, but instead,
use lifting jig for both horizontal and vertical busduct installation. (Fig. 5)
5.7. The joint hole should not be used for hoisting as it cannot withstand the weight of the busduct, which
result break on the wielding parts or any damages.
5.8. Do not drag the busduct across the floor.
5.9. When installing vertical riser, it is easier to lower the busduct from the floor above where it will be
installed. Vertical sections are often stored on the floor above their final location to facilitate lowering
them into position.
5.10. While hoisting any feeder ensure that the opposite side of the feeder being hoisted should be rested
on a support in order to prevent any damage to the joint.
5.11. Hang one busduct unit with two hangers in principle.
5.12. Depending on the site condition, preferably flanged end, flange end box, cable feed box shall be
installed first, followed by the sub-sequent unit numbers.(Fig 6)
5.13. While installing the busduct each unit of the busduct to be individually checked for IR value.
5.14. Also the IR to be checked during the various stages of installation.

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Using the lifting fixture the busduct is
raised.
It is lowered after proper alignment
with the load and supply of the
corresponding busduct
Perfectly meshed busduct.
Fig 5
Fig 6
6. PROTECTION AGAINST INGRESS OF DUST AND WATER
The ingress of dust and water into the busduct will decrease electrical and physical properties and
cause dielectric damage.
6.1. Some common sources of such contaminants are:
6.1.1. During construction –Indoor busduct must be protected from moisture during and after
installation. Special attention should be given to riser busduct during construction to protect
them from moisture from uncompleted roofs, walls, etc. Outdoor busduct is not weather
resistant, until completely and properly installed and should be treated exactly the
same as indoor busduct until it is completely installed.
6.1.2. Floor level liquids –Minimum curbs of four inches should be installed around all floor
openings for riser busduct to prevent floor level liquids (water / oil spills) from
entering the openings.
6.1.3. Leaking roof –protect indoor busduct with a temporary sheet metal shield or other
protective cover to prevent water from falling onto the busduct until the roof is repaired.
6.1.4. Pipes –protect indoor busduct with a temporary sheet metal shied or other protective cover
to prevent water from falling onto the busduct until the pipes are repaired. Where pipes
(especially cold water pipes) pass directly above indoor busduct, the busduct should be
protected from dripping condensate by insulating the pipe or permanently shielding the
busduct with sheet metal or plastic.
6.1.5. Sprinklers –protect indoor busduct from direct or indirect spray of sprinklers.
6.2. To prevent this, take precaution against the ingress of dust water during storage and installation.
6.2.1. Install busduct after the general construction works are completed.
6.2.2. Install busduct when possible leaking roof is sealed.
6.2.3. Install extra cover at the busduct end.

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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 installation it.
7.4. Follow instruction on each piece for torque requirement.
7.5. Follow manufacturer’s 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.
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 and satisfactory operation.
8.1. Ensure all contact surfaces are clean and free of contaminants by using dry cloth.
8.2. Align the bus duct ends of adjoining sections, verifying proper phase alignment,
a
n
d
s
l
a
nd slide the sections together as illustrated in Fig. 7. It is done by inserting jointing tool inside the
joining holes.
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. 7 (a)
Fig. 7 (b)
Fig. 7 (c)
Inserting Rod

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Fig. 8.1

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Fig. 8.2