IM2009-4

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

6. Protection Against Ingress Of Dust And Water 5

7. Summary 5

8. Joint Assembly 6

9. Fixing Plug-in Box 7

10. Horizontal Hanger Installation 7

11. Vertical Fix Hanger Installation 8

12. Vertical Spring Hanger Installation 8

13. Inspection Of Joint Bolt 9

14. Energizing 9

15. Care And Maintenance 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)

(X) (X) (O)

Fig. 2

Recommended Number of Stacks for Storage

Ampere (A) Number of Stacks
630 - 1000 Max. 5
1250 - 2000 4
2500 2
3200 - 6300 1

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.

5.7 Do not drag the busduct across the floor.

5.8 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.
Ensure that the weight of the feeder on the opposite side of the hoisting should be rest on the support in order to
prevent any damage to the joint. (Fig.5)

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.

Flanged End Flanged end box Cable feed box

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.
To prevent this, take precaution against the ingress of dust and water during storage and installation. Some common sources
of such contaminants are:
u During construction Indoor busduct must be protected form 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 after it is installed. It is not weather resistant until completely and properly installed.
u Floor level liquids 100mm minimum curbs should be installed around all floor openings for riser busduct to prevent
floor level liquids from entering the opening.
u 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.
u Pipes Protect indoor busduct with a temporary sheet metal shield or other protective cover to prevent water from falling
onto the busduct until leaking 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.
u Sprinklers Protect indoor busduct from direct spray of sprinklers.
u Snow Outdoor busduct should be mounted sufficiently above the ground or roof so that snow build-up does not surround
the busduct and result in water being forced into the busduct through weep holes.

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)

Plate Spring Joint Support Bolt (m8x16)

side cover w/
rubber gasket

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

9. FIXING PLUG-IN BOX

9.1 This work shall only be carried out by suitably qualified
persons.
Take off
9.2 Ensure that one end of the cable is terminated to the plug-in hole cover
plug-in box isolator and the other end is terminated and
isolated in the equipment to be connected.
9.3 Remove the plug-in hole cover. (Fig. 11)
9.4 Do not remove the plug-in hole plate as removal could
expose live busbars.
9.5 The orientation of the plug-in hole plate can be verified by
visual inspection. The earth bar must be visible through
the earth connection opening.
9.6 Ensure that the plug-in box isolator is switched off.
9.7 Align the plug-in box connection stabs with the plug-in
hole plate and push in fully.
9.8 Secure the plug-in box in position with the four fixing
clamps located on the back of the box. Note that incoming
side of the isolator may be live and care should be taken Fig. 11
not to displace any internal screens or shrouds.
9.9 When the box is secured in place, verify the phasing of the plug-in box before energizing equipment.

10. HORIZONTAL HANGER INSTALLATION

10.1 Fix horizontal hanger to the hanger rod and adjust it for correct elevation of the busduct as per site condition.
10.2 Lay the busduct on the horizontal hanger.
10.3 Install the hanger clamp on both side of the busduct for fixture.
10.4 Ensure the busduct is aligned in straight line.
10.5 Additional horizontal hangers shall be placed on elbows, such as vertical / horizontal elbow, offset elbow, combination
elbow and etc.
10.6 Supporting interval of horizontal hanger shall not exceed 1.5 metres.
hanger Rod

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.

12. VERTICAL SPRING HANGER INSTALLATION

For Vertical Spring Hanger, they are used on subsequent floors to absorb any expansion occurrence from busduct.Moreover,
immediate support shall be provided if the floor- to- floor distance exceeds 4 meters.

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

Henikwon Busduct System uses MF (Maintenance-Free) nut at the

jointing section which ensures the proper tightening of the bolt.
13.1 Tighten the MF nut with tool.
13.2 Ensure the tightness of the MF nut until the neck part of MF
nuts is broken. If the MF nut is not tightened properly, an
over-heating of the busduct may occur.
13.3 The torque values of tightening of the nuts are as shown in
Table 2.

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.

15. CARE AND MAINTENANCE

15.1 OUTDOOR BUSDUCT
15.1.1 Inspect busduct once each year or after any severe electrical short circuit or ground fault.
15.1.2 Perform an infra-red temperature scan on all electrical connections and busduct enclosure while busduct is
energized and operating under maximum load conditions. A permanent record should be kept. If readings change
with time, deterioration may be taking place and must be 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.

15.1.3 Turn off power to the busduct.

15.1.4 If there is appreciable accumulation of dust and dirt, clean it off by using a brush, vacuum cleaner, or clean
lint-free rags. In order to avoid blowing dust into busduct joints, circuit breakers, or other equipment, do not
use a blower or compressed air. Ensure that all drain holes are operating properly.
15.1.5 Check the insulation resistance prior to re-energizing the busduct. A permanent record should be kept of resistance
readings. If readings decrease appreciably with time, deterioration is taking place and must be corrected.

15.2 INDOOR BUSDUCT

15.2.1 Inspect busduct once each year or after any severe electrical short circuit or ground fault.
15.2.2 Perform an infra-red temperature scan on all electrical connections and busduct enclosure while busduct is
energized and operating under maximum load conditions. A permanent record should be kept. If readings change
with time, deterioration may be taking place and must be corrected.

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.

15.2.3 Turn off power to busduct.

15.2.4 Look for any moisture or signs of previous wetness or dripping onto the busduct or onto connection boxes from
leaky roofs, pipes, sprinklers or other sources of moisture. Look for any recent changes in sprinklers or other
plumbing that might now be a source of trouble to busduct.
15.2.5 Seal off any cracks or openings which have allowed moisture to enter the busduct or its connection boxes.
Eliminate source of any dripping onto the busduct and any other source of moisture See SECTION 6 for more
specific details on preventing liquid from getting onto the busduct.
15.2.6 Replace or thoroughly dry and clean any insulating material which is damp or wet or shows accumulation of
deposited material from previous wettings.
15.2.7 If there is appreciable accumulation of dust, clean it off by using a brush, vacuum cleaner, or clean lint-free
rags. In order to avoid blowing dust into busduct joints, circuit breakers, or other equipment, do not use a
blower or compressed air.
15.2.8 Carefully inspect all visible electrical joints and terminals.
15.2.9 Visually check connections to be certain that they are clean and secure. Loose and/or contaminated connections
increase electrical resistance which can cause overheating. Such overheating is indicated by discoloration or
flaking of insulation and/or metal parts. Pitting or melting of connecting surfaces is a sign of arcing due to a
loose or otherwise poor connection. Parts which show evidence of overheating or loosened should be cleaned
or replaced if damaged, contact manufacturer before torque joint bolts again.
15.2.10 Check the insulation resistance prior to re-energizing the busduct. A permanent record should be kept of resistance
readings. If readings decrease appreciably with time, deterioration is taking place and must be corrected. Also,
refer to SECTION 14.4

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.

16.1 Types of maintenance inspection

1) Spot inspection
It is to maintain busduct system operation thus, daily or monthly inspection without uninterruptible power 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.

16.2 Checklist before maintenance inspection

1) Strict preparation
Check the surrounding area and safety of the equipment, and emergency procedures to be taken.

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.

16.3 Checklist after maintenance inspection

1) Set up a plan in detail, if it cannot be finished within a given period.
2) After inspection, do not leave the matter unsettled, it could be occurred spread accident.

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.

16.5 Periodic Maintenance checklist

Section Check Point Check list
Joint 1) Joint Bolt Check the correct torque as per specification.
2) Inside Check on the condition of the insulation and any contaminants inside
the joint.
Branch 1) Tap-off bar Check tightness of the joint bolts at the termination.
2) Plug-in Hole Open the Plug-in Unit cover and check any contaminants and
condition of the bus bar.
Hanger fixture 1) Fixture Any deformation or missing of the clamp
2) Clamp Fixture Check on the tightness of the bolt and nut.
Plug-in Unit 1) MCCB Check on the tightness of the bolt at the termination.
Check on any damages, crack or deformation of the insulation.
Check on any discolouring at the termination or joint section, due to
overheating.
2) Operation Device Check on the on/off operation condition.
3) External Check on any contaminants and discolouring due to corrosion gas
on the surface.
Equipment 1) Termination Check on the correct torque applied as per specification.
Termination 2) Flange Check on the bolt tightness.
3) Conductors After short circuit, immediately check on the deformation of the
conductors, damage of the insulation and arc at the joint.
4) Ground termination Check on the bolt tightness.
5) Flexible conductor Check on the discolour due to overheating.
External 1) External condition Check on any contaminants and discolouring due to corrosion gas
on the surface.
Check on any trace of water penetration.
Check on any water leakage of the outdoor busduct system.
Insulation 1) Measurement Measure insulation resistance at DC 1000V megger.
Resistance of insulation
resistance

16.6 Maintenance arrangement

1) Spot inspection

Spot maintenance inspection

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.

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 2) Periodical inspection

Arrangement Method and Check points

Bolt Tightness 1. Tightening method
Termination Use the correct material and parts and refer specified torque.
1) Tighten the bolt using the different toque wrench according to the bolt size.
2) Tighten with turning the nut.
3) When more than 2 bolts are used, ensure each bolt has same torque.

SPRING WASHER
NUT
PLAT WASHER

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.

16.7 Measures to take when emergency occur

Section Check points Check list

Joint Joint bolt loosen up
Insulation damage due to generation of heat
Dust on the surface or penetration of the
contaminants.
Trace of water penetration.
Faulty assemble of joint cover.
Damage of Phase to Phase insulation
spacer
Comply to torque specification.
Inform manufacturer on the spot of
heat generation and its condition.
Wipe with dry cloth.
Wipe with dry cloth and check any
water penetration. Inform the manufacturer.
Reassemble according to installation
manual.
Check on its specification and inform the
manufacturer.

Flanged End Joint bolt loosen up. Comply to torque specification.

Damage of flexible conductor and
discolouring.
Trace of dust penetration.
Trace of water penetration.
Inform manufacturer on the condition.
Wipe with dry cloth.
Wipe with dry cloth and check any water
penetration. Inform the manufacturer.

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 16.7 Measures to take when emergency occur (continued)

Section Check points Check list

MCCB Faulty operation or shunt trip device. Inform the manufacturer.
Whole Line Low megger. If it is lower than the first measurement,
clean each unit.
Peel off of housing paint. Touch-up with the paint and clean with dry
cloth.
When corrosive gas, emission of steam Consider to either relocate the equipment
and high temp. equipments are installed that emits the steam or busduct.
near to the busduct.
Submersion in water. Check megger and inform the manufacturer.

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.

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 Appendix 1

HENIKWON BUSDUCT SYSTEM

INSULATION TEST REPORT

(BEFORE ENERGIZATION)

PROJECT NAME :_________________________________ DATE :_____________________________________

BUSDUCT RATING :_ ______________________________

BUSDUCT INSULATION RESISTANCE BY 1000VOLT MEGGER (M-OHM)

UNIT NO. R-E Y-E B-E N-E R-Y R-B Y-B R-N Y-N B-N

TESTED BY :_ ____________________________________ WITNESSED BY :_____________________________

DATE :___________________________________________ DATE :______________________________________

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 Appendix 2
Final INSULATION TEST REPORT
(BEFORE ENERGIZATION)

PROJECT NAME :_________________________________ DATE :_____________________________________

BUSDUCT RATING :_ ______________________________ MIN. M-OHM:_ ______________________________

METRE
TOTAL LENGTH OF RUN :__________________________

PHASE INSULATION RESISTANCE (M-OHM)

R-E

Y-E

B-E

N-E

R-Y

R-B

Y-B

R-N

Y-N

B-N

TESTED BY :_ ____________________________________ WITNESSED BY :_____________________________

DATE :___________________________________________ DATE :______________________________________

16
 HENIKWON CORPORATION
( Co. No. 161535-W )

Lot 16, Jalan Teknologi, Selangor Science Park 1, Kota Damansara,

47810 Petaling Jaya, Selangor, Malaysia.
Tel : +603-6140 8000
Fax : +603-6140 8509 / 8510
Email : info@henikwon.com
Web-site : www.henikwon.com
IM2009-4 / 8 09

Certificate No: SG08/01875 Certificate No: MY08/00096 Certificate No: SG08/01940

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.