Schneider Busway Systems

Technical Data Sheet

Square-D
I-Line II
(630 - 6300A)

GENERAL

• I-Line Busway manufactured by Square-D offers a complete line of compatible, sandwich-type feeder
and plug-in busway lengths and fittings. It allows maximum flexibility, ease of installation, and offers
electrical efficiency in the distribution of low voltage power for both commercial and industrial
applications.
• I-Line busway has been used to supply power in thousands of installations throughout the world for
more than three decades. Our broad range of I-Line busway products include: I-Line II Plug-in and
Feeder styles from 800A to 5000A with Bi-Metal conductors, and from 630A to 6300A with Copper
conductors. I-Line II busways is on instructed in three-pole and four-pole full neutral configurations for
system voltages to 1000 Volts and are rated to allow 100% of the current to flow continuously.
• Busway installation is quick and easy. The compact, totally enclosed design is lightweight and easy to
handle. Labour studies have shown that a 75% savings in installation time is not uncommon when
comparing I-Line busway with cable and conduit installations. This significant reduction in installation
time can result in total installed cost for busway being significantly lower than other distribution
methods.
• In addition, a wide variety of busway components and plug-in units are available from stock for fast
delivery.
• When you need busway, select the best I-Line busway. Our design and construction has been time-
tested in many years of use throughout the world. No matter how you compare, I-LINE busway is your
solid first choice.

• Schneider busway certified by IEC 61439-6 full type test in KEMA lab and the KEMA-KEUR certificate

Sandwich Construction
• I-Line feeder and plug-in busway both utilize sandwich-type construction to provide superior voltage
drop characteristics, even at low power factors.
• Steel housing sides and Aluminium tops and bottoms have been carefully designed to reduce
component eight and minimize the hysteresis and eddy current losses that are common in all steel
housings.
• Plug-in busway ratings that utilize two or three bus bars per phase have a phase paralleling feature at
the joint assembly of each straight length. This helps equalize bus bar loading when plugs are
mounted on one side only.
• The plug-in housing has notches along the top rail for easy alignment and installation of plug-in
units.
• Within the same ampere rating, all I-Line II busway lengths and fittings are fully compatible between
feeder and plug-In styles using standard universal tie channels (housing “splice plates”) supplied with
each component.

Product Description
• I-Line II busway uses the same two layers of polyester film to insulate the bus bars. Insulation offers
high quality dielectric strength and long life expectancy.

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Totally Enclosed Housing

Ventilated busway depends on free air movement through a

perforated housing to cool the bus bars. Unless mounted in its
preferred position (maximum bus bar cooling), ventilated
busway must be derated. Ventilated housing also permits dirt
accumulation and offers limited protection of bus bars due to
open ventilating slots in the housing

I-Line busway has a modern “totally enclosed” housing design

requiring no derating regardless of mounting position.
Because the housing has no ventilating holes, the entry of dirt
and possibility of accidental contact with bus bars is greatly
reduced.

Compact Size
• I-Line II busway is compact. The small size means it may be used in locations where feeder circuits
would not otherwise be possible. Efficient use of light-weight raw materials is an additional factor in
I-Line busway’s compact design.

Finish
• I-Line busway housing appearance has been further enhanced by the addition of a multi-million dollar
cationic electrode position paint system to our production facility. I-Line busway users get a tough,
durable uniform “E-Coat” epoxy paint finish, making their busway installations functional and
attractive for years to come.

• Electro-galvanized steel, better anti-corrosion.

• Paint: Epoxy electrostatic powder finish

• Colour: ANSI 49 gray, special colour are optional upon customer’s request.

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Insulation
• All bus bars are insulated using Class B rated (130 °C (266 °F) vendor certified) materials to prolong
insulation life. I-Line busway insulation consists of two layers of heat-formed polyester film
surrounding each bus bar. On plug-in busway lengths, all insulation is notched at the openings to
allow plug-in unit mounting.

• Two layers surrounding each bus bar

• Class B, 130ºC, Vendor certified polyester film (DuPont Mylar)
• Excellent dielectric performance
• Over 40 years of application record without failure
• Class F is optional upon request
• Halogen free, safe in fire

Earthing Bus
• I-Line II is furnished with integral earthing bus as a standard where the earthing bus is the bus housing
itself and completely encloses the bus sandwich, it’s rated at 50% capacity, the earthing bus is
continuous bonding between top and bottom bus.

Ref.: CFC25**G Ref.: CFC26**GG

4–Conductors 5-Conductors
N = Ph N = Ph
E = 50% Ph

• Internal Aluminum / Copper earthing bus is optional.

Dielectric Testing
• UL and CSA require a one-time dielectric test for all new busway designs prior to certification. This
test, at two times rated voltage plus 1000 Vac (2200 Vac), is intended to confirm the integrity of the
insulation system. I-LINE busway passes this test.
• Every length and fitting of our busway must also pass a 7500 Vdc “hi-pot” test before shipment from
the factory. This additional test helps ensure the highest quality busway possible for our customers.

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Internal Smoke/Gas Barriers

• Continuous air spaces inside I-Line II busway 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 busway installation.
This standard internal barrier allows busway to extend through walls or floors without creating open
space for a “chimney effect” fire path.

Voltage Drop
• Because of its extremely low reactance, I-Line busway voltage drop is low. This efficient design
allows power to be delivered in an installation with the highest efficiency possible. This makes I-
Line busway ideal for efficient power distribution in commercial or industrial facilities.

New Copper Busway I-Line II

• 99.9% Purity of Copper.

• Silver Plated Copper in full length.
• Minimize surface oxygenation, assure low surface contact resistance and low voltage drop.

New Aluminum with Copper Contact Busway I-Line II ( Bi-Metal Technology )

• Use silver plated Bi-metal cladding on Aluminum conductor though high current and high
pressure.
• Special process enabling molecular fusion of Copper and Aluminum though the use of very high
• Pressure and temperature.
• All Connection zone are silver to silver contacts.

Busway System Construction

Plug-in Busway

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1. Molded plug-in opening insulator—Adds NOTE: Internal barriers are standard on both feeder
insulation and support at plug-in contact area. and plug-in busway. All interior spaces are barriered
2. EZ Joint Pak connector assembly—Includes like- to stop hot gases.
phase connector on higher ampere ratings with NOTE: Hangers fit both feeder and plug-in
more than one conductor per phase (plug-in bus busway without blocking access to openings.
only).
3. Ground jaw for plug-in unit— Has a “blow-on” NOTE: I-Line plug-in units (15 A–1600 A) fit both
design similar to phase jaw connection. original and I-LINE II busway.
4. Fittings—Includes elbows, tees, and flanged NOTE: I-Line II plug-in busway with sandwich
ends that are easily removed and refitted with construction also includes features depicted for
the use of our EZ Joint Pak assembly without feeder style on page
disturbing adjacent lengths.

Feeder Busway

1. Steel housing channels—Provides mechanical

strength. NOTE: Electrode position paint process—Provides
2. Molded extra-strength glass fiber interphase lasting uniform appearance.
barriers.
3. EZ Joint Pak connector assembly—Removable NOTE: Housing sizes—Are the same for I-Line II
for isolation or maintenance. Includes Visi-Tite feeder and plug-in busway. Same accessories fit
bolt. both.
4. Steel/aluminum housing—Reduces hysteresis NOTE: Insulation— Is Class B rated (130 °C (266
and eddy current losses on feeder and plug-in °F) vendor certified) insulation.
busway.
5. Plated aluminum or copper bus bars.
6. Surge clamps for added short circuit strength.
7. Integral Ground Bus (IGB) —Two, 1/16-inch
thick aluminum bus bar. Also serves as top and
bottom housing.

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• Fire Resistance
As Required by standards, I-Line II busbar trunking complies with:
1- Material resistance to abnormal temperatures,
2- Flame propagation resistance,
3- Fire barrier function when going through a partition wall,
4- Conservation of all circuits for 0.5~2 hours in fire resistance sheath.

With Schneider Busway, no toxic emission in case

of fire
The busbar trunking has a low combustible load. Its
construction uses very little
consumable material and is halogen free.
In the event of a fire, the busbar trunking does not emit
any gas or toxic smoke.
The busbar trunking helps prevent the propagation of a
fire through partition walls
and floors.
Halogen-sensitive applications
■ Public buildings (infrastructures, hospitals, schools,
etc.),
■ Buildings with evacuation difficulties (high-rises, ships,
Example: etc.) and service-activity
Consequences of a fire in a 100 m2 office with buildings,
electrical distribution by cables. ■ Sensitive processes (production of electronic
200 kg of cables (i.e. 20 kg of PVC) produces: components, etc.).
■ 4400 m3 of smoke, Schneider Busway contains no PVCs
■ 7.5 m3 of hydrochloric acid, When PVCs burn, they produce large amounts of smoke
■ 3.7 kg of corroded steel. that can be a serious
safety hazard.
■ Reduced visibility:
□ risk of panic,
□ complicates rescue work,
■ Smoke toxicity:
□ hydrogen chloride gas (highly toxic),
□ carbon monoxide (danger of asphyxiation).
Schneider Busway reduces the risk of exposure to
electromagnetic fields
According to the WHO (World Health Organisation),
exposure to electromagnetic
fields can be a health hazard starting at levels as low as
0.2 micro-Teslas and
could represent a long-term risk of cancer. Some
countries have created standards
that stipulate limits
All electrical conductors generate magnetic fields
proportional to the distance
between them. The design of Schneider busbar trunking
with tightly spaced
conductors in a metal enclosure helps to considerably
reduce radiated
electromagnetic fields.
The electromagnetic field characteristics of Schneider
busbar trunking are welldefined
and measurements show that they are far below
potentially dangerous
levels.

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Trunking Cross-section

• Copper Busway

• Copper Contact Busway [ Bi-Metal ]

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Product Features Of I-Line II Plug-In Unit

Compatibility
All plug-in units are compatible with I-LINE II busbar trunking
system, regardless
whether they bear MCCB or fusible switch.
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 jaws with the plug-in opening. After the
unit is positioned
on the busway, it is allowed to swing down into the plug-in opening
where the plugin
jaws make contact with the bus bars. This is accomplished in “hook-
swing”.
Plug-in Jaws
The plug-in jaws contact to the bus bars directly with the silver
plated cooper
contact. The contact surface is fully silver plated to ensure a proper
contact force
and low contact resistance.
Earthing
Earthing established at first and switched off at last as to protect
worker against
electrical contact shock.
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.
Interlock
30 A to 250 A plug-in devices are interlocked with the busway
housing to prevent
installation or removal of the unit when the disconnect is turned ON.
All devices incorporates an interlock to prevent the door over the
disconnect
from being opened when the unit is ON. This door interlock can be
defeated from
outside the unit.
Operating handle
The side operating handle in the PIU makes the heavy duty switch
more
convenient and safer. When the PIU is installed in the high position,
you can easily
operate the PIU on the group by the side handle.

Protection function
Schneider Plug-in unit equipped with Schneider original protection
unit, which
can provide complete overload protection, short circuit protection
and earthing
malfunction protection. The maximum interrupting is 150KA.
■ Transparent shield over Line side parts - that means safety &
visible

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Category of I-LINE Plug-in Unit

■ Plug-in Unit with Merlin Gerlin’s MCCB, ampere rating from 15A to 1000A
■ Plug-in Unit with Square D’s MCCB, ampere rating from 15A to 1600A
■ Plug-in with Fusible Switch, ampere rating from 30A to 1600A

■ Plug-in Unit with Merlin Gerin’s MCCB

■ Plug-in type–PNS (15-250A), PBNS (350-500A)
■ Bolt-on type–PTNS (630-1000A) (different for horizontal/vertical
mounting)
■ Fitted with Compact NSEN/ NSES/ NSEH/ NSD / NSX / NSH /
NSL(on request)
■ available for 3-pole and 4 pole configurations
■ available for earth leakage current protection (Vigi)

Connection fittings Fixing supports

■ Supply connections allow the ■ Vertical support
busbar trunking to be connected to the □ Fix hanger
switchboard’s busbar or to the transformer. □ Spring hanger
□ Flanged end ■ Horizontal support
□ Qwik Flanged end □ Flatwise hanger
■ cable connection, transport current □ Edgewise hanger
between cable and busbar trunking.
□ End cable tap box
□ Center cable tap box

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Effects of harmonics on I-LINE II busbar trunking

Fundamental frequency: ih1 (50 Hz)

No current in the neutral.
The conductors are correctly sized.

Fundamental frequency: ih1 (50 Hz) and 33%

of H3
Abnormal temperature rise in the conductors
caused by current at a higher frequency in the
phases (skin effect) and current in the neutral
caused by summing of the H3 harmonics.

The only effective Fundamental frequency:

solution ih1 (50 Hz) and
33% H3

Reduce the current ensity

in ALL conductors by
using appropriately sized
trunking.

Example. For a total rms current of 2356 A, (estimation based on power drawn
by loads, including harmonics), the operational current is 2500 A.
THD is estimated at 30%. The appropriate trunking is I-LINE II 3000 A.

For more information on harmonics

See the Cahier Technique publications on the Schneider Electric web site:
www.schneider-electric.com

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PROJECT SPECIFICATION

Rating : 4000A Copper Busway

Rated Current : 4000A
Material of Conductors : Copper Grade A (99.9% Purity) with silver plated at full length
Conductors : 3P+N+PE integral earth bar (4-Wire )
Protection : IP 54
Rated Insulation Voltage : 1000V
Rated Operating Voltage : 1000V
Average Ambient Temperature : All bus bars are insulated using Class B rated (130 °C (266 °F) vendor certified)

Housing : Electro-galvanized steel, better anti-corrosion

Paint: Epoxy Electrostatic powder finish
Color: ANSI 49 gray
Short Circuit withstand Current : 100 KA/1sec.
( t=1sec.)
Allowable rated peak Current : 220 KA

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PROJECT SPECIFICATION

Rating : 2500A Copper Busway

Rated Current : 2500A
Material of Conductors : Copper Grade A (99.9% Purity) with silver plated at full length
Conductors : 3P+N+PE integral earth bar (4-Wire ) Plug-In Type
Protection : IP 54
Rated Insulation Voltage : 1000V
Rated Operating Voltage : 1000V
Average Ambient Temperature : All bus bars are insulated using Class B rated (130 °C (266 °F) vendor certified)

Housing : Electro-galvanized steel, better anti-corrosion

Paint: Epoxy Electrostatic powder finish
Color: ANSI 49 gray
Short Circuit withstand Current : 75 KA/1sec.
( t=1sec.)
Allowable rated peak Current : 165 KA

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