• Leader in Manufacturing Full Range Diversified Busbar

Trunking Systems
• Manufacturing Floor Space is one of the Biggest in Asia Pacific
Region
• Factory with Total Quality Management System and certified
to ISO 9001:2015
• Factory Capable of Manufacture and supply BTS for Small to
Very Large Complexes and on Fast Track Basis
• Factory is Environmental Friendly
2
 DBTS MEGATRONTM SANDWICH

INTRODUCTION
Introduction
DBTS is the leading manufacturer in the full range of busbar trunking systems. Our manufacturing floor space is
one of the largest in the Asia-Pacific region.
DBTS has been manufacturing High Quality Busbar Systems on the same factory floor since 1996, with Total Quality
Management System and certified to ISO 9001:2015
Factory Capable of Manufacture and supply BTS for Small to Very Large Complexes and on Fast Track Basis
Factory is Accredited to Environmental Friendly Green Standards

DBTS MEGATRONTM
MEGATRONTM is a world recognised trademark for Low Voltage Busbar Trunking Systems. It is maintenance-free,
and provides a complete and versatile busbar trunking system. This is ideal for installation in both indoor and
outdoor applications, where we prioritise the continuous supply of electricity to serve the wellbeing of the users.

Product Compliance Standards

MEGATRONTM is designed, manufactured and tested under stringent quality control in accordance to international
standards:
IEC61439-1, IEC61439-6, AS3439.2, IEC60529, IEC60331, IEC60332, IEC60947-2, BSEN61439, BS5486, UL-857,
BS6387, IEE/IEEE, JISC8364, Seismic Earthquake: NEBS-GR-G3 Zone 4, Richter Magnitude 8.3

Busbar Circuits

Available in: Single-phase, 2-phase, and 3-phase with options for:

a. 50%, 100%, 200% Neutral
b. 50%, 100% dedicated integral Earth bonded to housing
c. Insulated Earth

1
 DBTS MEGATRONTM SANDWICH

EPOXY INSULATION
DBTS blu-E-CoatTM Epoxy Insulation for Busbar

DBTS blu-E-CoatTM is DBTS’s proprietary registered trademark epoxy powder specially formulated to be applied
to form a protective coating. DBTS blu-E-CoatTM is a thermoset plastic (heat-irreversible), and has outstanding
electrical, thermal and mechanical properties. DBTS has a long relationship with international partners, leaders
in epoxy research and manufacturing, jointly developing the best insulation coating system that consistently
achieves an outstanding quality, uniform thickness and excellent surface finishing.

DBTS blu-E-CoatTM Technical Data

Epoxy Appearance Blue Epoxide Powder

Application Component Electrical Insulation

Powder Size 75 – 250 µm

Polymerisation Method Cured at high temperature by 3D cross-linking

Adhesion to Busbar Surface Excellent, liquid impermeable IP68, no condensation ≤71oC

Surface Appearance Blue, smooth, glossy, scratch-resistant

Surface Edge Appearance Fully rounded, 100% covered, uniform thickness

Water Absorption after 10 <0.5% , non-hydroscopic

days 20oC

Surface Fungus Resistance Excellent

Stable Properties >220oC (Rated above Class “F” 155oC), long term, stable overall
Temperature properties

Resistant to Abnormal Heat At 950oC, no visible glow or flame

Flame Resistance UL-94 V0 Self-extinguishing

Impact Strength High, >5J (1mm thick epoxy tested against Ø 3.2mm steel ball)

Coefficient of Thermal 17x10-6/oC, similiar to copper and aluminium, will not expand, peel or
Expansion crack at corners, edges and ends of busbar

Dielectric Constant 20oC 4.3

Dielectric Strength 50Hz, 34 kV mm-1

25oC

Surface Tracking Resistance Extremely high tracking and creepage resistant

Chemical Resistance Excellent, resistance to most chemical solvents

2
 DBTS MEGATRONTM SANDWICH

HOUSING & IP RATING

Housing Materials
The metal sections assembled into the busduct housing are designed to ensure mechanical strength to
withstand the vibrations during handling, transportation, installation and vibration. The metal sections are also
profiled with flanged surfaces and cooling heatsink fins to dissipate the heat produced by the current-carrying
conductors within busduct, effectively by creating natural air circulation on its surface.
The housing is pre-treated with anti-corrosion agents, then electrostatically sprayed with a uniform layer of
polyester coating and cured. The final finishing is glossy, scratch-resistant and resistant to UV light, suitable for
outdoor installation. The default colour paint, a dark grey RAL7033 also has a 0.95 radiation heat emissivity to
further reduce the busduct temperature. Unpainted natural aluminium finishing is available but not
recommended, especially in enclosed spaces.
Other metal housing materials such as GI steel and stainless steel also available.

IP Rating
DBTS fully comprehends the importance of preventing dielectric failure of busduct due to water/liquid
entering the housing and joint areas. Guidelines of Ingress Protection (IP) are outlined in IEC60529 as a
minimum, however busduct systems can be a part of critical electrical systems and a higher IP rating is strongly
recommended. Bolts that pass through the housing and joint should not be accepted as they are a cause of
busduct joint failure. Additional covers with gaskets over the joint are one of the most effective ways of IP
protection, it also prevents direct human contact with the joint and tampering. In this regard, it is
commonplace in industry for designers and maintenance specialists to specify that busduct to be rated IP54 as
minimum for indoor installation.
Higher IP65, 66, 67 are available on request. For IP68, MEGATRONTM busduct joints after commissioned, are
encapsulated with DBTS Cast Resin, a proven, perfect solution for outdoor IP68 installation, also removes the
need to checked on workmanship on joints.
MEGATRONTM plug-in opening with lid closed is rated IP66, with lid open IP2X
Tap-off Enclosure is rated IP55.

DWDA

3
 DBTS MEGATRONTM SANDWICH

JOINT FEATURES

MEGATRONTM Sandwiched Type Busduct Joint Unique Features

Low joint busbar current density (A/mm2)
• Complies with, in-house and independent temperature rise tests per IEC61439.
• Ensures that busduct is always within temperature rise limits, operates safely and able to be touched by
maintenance members.
• Also allows for extra capacity to absorb thermal energy during short-circuit or fault conditions, thereby
protecting the insulation and housing against thermal and deformation damage, making the busduct reusable
after the fault.
Rectangular Belleville Spring Plates and Tightening Bolt
• Rectangular shaped spring plates effectively transfer bolt tightening torque into pressure precisely onto the
joint contacts.
• Traditional rounded Belleville plates do not apply the pressure evenly onto the busbar contacts, making the
joint susceptible to failure.
• The tightening torque is fixed at 70Nm by special locked nuts, and re-torqueing is not required after
energising the busduct. The tightening of the bolt(s) form either sides with a tool is also easy for busduct
installed close to walls or tight spaces.
• Double-headed bolts are used as the tightening bolts to prevent human error in applying tightening torque. A
red tag will naturally fall off the bolt when the secondary head breaks as an indicator that the joint has been
properly tightened to the correct torque.
Bridge Type Monobloc Joints
• Allows for quick and easy joining between busduct sections in any orientation, vertical or horizontal.
• Last section of busduct can also be easily installed perpendicularly.
• High ampere busduct that consists of two busbar per phase are joined using the same monobloc with a
single, splice coupling conductor per phase.
• Current is shared and always balanced between the two busbars in the same phase. Voltage drop also follows
per design calculations.
• Very low contact resistance, typically a few µΩ.
• The Monobloc used is common to both metal housing and DBTS Cast Resin “CR” type busduct, allowing for
indoor-to-outdoor transition busduct installation and vice versa.
Fire Resistance
• The busbar insulation, phase separating insulation and bolt insulation are all tested for fire resistance per IEC
61439-6

Every MEGATRONTM busduct section is factory-fitted with a joint stack. After two connecting sections of busduct have been
joined together, the whole joint can also be slid out and removed without disturbing the remaining installed busduct
sections. This unique feature makes any site alterations a simple task. The joint can also be inspected at any time by
removing the joint covers.
The joint is designed to allow busbars longitudinal expansion or contraction by as much as 5mm, effectively compensating
for the thermal expansion of the busbars. The tightening force is calculated such that the joint efficiency remains
unchanged under all service conditions. This eliminates the need for expensive, custom-made expansion joints for any
length of busduct runs.

4
 DBTS MEGATRONTM SANDWICH

PLUG-IN BUSDUCT
DBTS MEGATRON Sandwich
DBTS MEGATRONTM is a world-recognised trademark for Low Voltage Busduct Trunking Systems. It is
maintenance-free and provides a complete, versatile busduct trunking system.

Sandwiched Type Feeder Plug-in Busduct

Feeder busduct is traditionally used to interconnect electrical power from transformers, generators
or load banks to main switchboard(MSB) or from MSB to Motor Control Centre (MCC). Plug-in
busduct serves the same function as the feeder but has additional tap off openings allowing electrical
power to be tapped via tap off box.
Feeder and plug-in busduct are made in standard 3 meters length. Shorter lengths are also made to
complete the connection. All DBTS busduct runs are of a bespoke manufacture. Every feeder or plug-
in busduct is fitted with a joint stack use for connecting to the next busduct at site.

5
 DBTS MEGATRONTM SANDWICH

PLUG-IN BUSDUCT
Plug-in Opening
Megatron busduct plug-in openings are designed with the highest
safety protection. Each plug-in opening has insulated cover over the live
busbars. When the opening is not used the hinged cover shall be closed
and screwed tight. Danger warning label is printed on the cover to
remind of the live parts if cover is open. The plug-in insulator is at
ground potential and is rated to IP2X when the cover is open and
untouchable by fingers; when cover closed is rated IP66.

Features & Dimensions of Tap-off Units With Circuit-breaker

Tap-off or plug-in units have all the safety and fool-proof features as per the requirements of the safety
regulations and practices. The tap-off unit can be engaged with the busbars in the correct assigned phase
sequence. The door can only be opened when the circuit-breaker is in the OFF position. The tap-off unit is
prevented from removal from its engagement with the busbars when the circuit-breaker is in ON position.
Clamping brackets are provided to securely mount the tap-off units onto the busduct, preventing dislodging
from position.

MCCB
AMPERE LENGTH WIDTH HEIGHT
RATING (mm) (mm) (mm)
(A)
10-100 445 250 230
125-250 445 250 230
300-400 528 300 280
500-800
(Utilize 2
920 400 300
Plug-in
holes)
1000-1200
(Utilize 2
1200 500 400
Plug-in
holes)

*MCCB rates more than 1200A also available. Please consult us for more details.

6
 DBTS MEGATRONTM SANDWICH

BUSBAR DIMENSIONS

Copper Busbar In Steel Or Extruded Aluminium Housing

AMPERE BUSBAR SIZE / PHASE DIMENSION 'H' in mm APPROXIMATE WEIGHT Kg/m
FIGURE
RATING in mm STEEL AL 4W 4W+50%E

630 6 x 40 93 95 17 18
800 6 x 50 103 105 20 21
1000 6 x 65 118 120 23 24
1250 6 x 75 128 130 26 27
1600 6 x 110 163 165 35 38
TYPE ‘A’
1800 6 x 125 178 180 39 42
2000 6 x 150 203 205 45 49
2250 6 x 160 213 215 48 52
2500 6 x 185 238 240 52 57
2800 6 x 200 253 255 57 63
3000 TYPE ‘B’ 2 x 6 x 110 279 278 66 72
3200 2 x 6 x 120 299 301 69 75
3500 2 x 6 x 140 339 341 79 85
4000 2 x 6 x 150 359 361 83 89
4200 TYPE ‘C’ 2 x 6 x 160 379 381 87 93
4500 2 x 6 x 175 409 411 96 104
5000 2 x 6 x 200 459 461 109 119
6300 2 x 6.3 x 260 579 581 139 147

Aluminium Busbar In Steel Or Extruded Aluminium Housing

AMPERE BUSBAR SIZE / PHASE DIMENSION 'H' in mm APPROXIMATE WEIGHT Kg/m
FIGURE
RATING in mm STEEL AL 4W 4W+50%E

400 6 x 40 93 95 10 11
630 6 x 50 103 105 11 12
800 6 x 75 128 130 13 15
1000 6 x 90 143 145 14 16
1250 6 x 100 153 155 15 17
1500 TYPE ‘A’ 6 x 125 178 180 17 20
1600 6 x 165 218 220 20 24
1800 6 x 175 228 230 21 25
2000 6 x 220 273 275 24 28
2250 6 x 230 283 285 26 30
2500 6 x 300 353 355 28 32
3000 2 x 6 x 165 389 391 30 37
3200 2 x 6 x 175 409 411 32 39
3500 2 x 6 x 200 459 461 35 43
TYPE ‘B’
4000 2 x 6 x 220 499 501 38 46
4200 2 x 6 x 230 519 521 40 49
4500 2 x 6 x 260 579 581 43 52
5000 TYPE ‘C’ 2 x 6 x 300 659 661 56 66
NOTE:
BUSBAR SIZE BASE ON DIFFERENT CURRENT DENSITY AND CONFIGURATIONS ARE AVAILABLE. PLEASE REQUEST FROM DBTS INFORMATION SHOWN
7
IS INTENDED AS GUIDE, READERS ARE ADVISED TO OBTAIN CONFIRMATION
 DBTS MEGATRONTM SANDWICH

ELBOWS
Sandwiched Type Flatwise Available Dimensions
AMPERE MAX LENGTH 'A' + 'B' ≤ 1750 mm
RATING MIN 'A' MAX 'A' MIN 'B' MAX 'B'
400
630
800
1000 250 1500 250 1500
1250
1500
1600
1800
2000 300 1450 300 1450
2250
2500
3000 350 1400 350 1400
3200
3500
4000
420 1330 420 1330
4200
4500
5000 500 1250 500 1250
6300 600 1150 600 1150

Sandwiched Type Edgewise Available Dimension

AMPERE MAX LENGTH 'A' + 'B' ≤ 1750 mm
RATING MIN 'A' MAX 'A' MIN 'B' MAX 'B'
400
630
800
1000
1250
1500
1600
1800
2000 250 1500 250 1500
2250
2500
3000
3200
3500
4000
4200
4500
5000

8
 DBTS MEGATRONTM SANDWICH

SPECIAL ELBOWS

T-Elbow Flatwise Type

AMPERE
A (mm) B (mm) C (mm)
RATING (A)
≤5000 500 500 500
6000 600 600 600

T-Elbow Edgewise Type

AMPERE
A (mm) B (mm) C (mm)
RATING (A)
All 1000 1000 1000

Offset (Double Elbow) Flatwise Type (Same as Flatwise

Table)
AMPERE MAX LENGTH 'A' + 'B' ≤ 1750 mm
RATING MIN 'A' MAX 'A' MIN 'B' MAX 'B'

400 - 1600 250 1500 250 1500

1800 - 2250 300 1450 300 1450

2500 - 3200 350 1400 350 1400

3500 - 4500 420 1330 420 1300

500 1250 500 1250
5000 - 6300
600 1150 600 1150

Offset (Double Elbow) Edgewise Type

AMPERE
A (mm) B (mm) C (mm)
RATING (A)
All 250 250 250

Flatwise & Edgewise Type Combination Elbow

AMPERE
A (mm) B (mm) C (mm)
RATING (A)
Refer
All 250 250 Flatwise
Table
Max A+B+C= 1750

9
 DBTS MEGATRONTM SANDWICH

FLANGE END
Flange End Termination to Switchboard or Transformer
Flange end provide connection between busduct and various type of low voltage appliances such
as transformer, switchboard, control panel or even factory machinery. The standard gap between
each connection flange is 100mm but it can be customize based on customer need.

Flange End Connection to Transformer

10
 DBTS MEGATRONTM SANDWICH

FLANGE END TECHNICAL DATA

Copper Busbar Termination Flange To Switchboard Or Transformer

AMPERE HOLES
PATTERN W1 W2 W3 W4 W5
RATING (A) FIGURE

630 A 1 20 20 60 90 130
800 A 1 25 25 70 100 140
1000 A 1 32.5 32.5 85 115 155
1250 A 1 37.5 37.5 95 125 165
1600 A 2 60 25 130 160 200
1800 A 3 40 22.5 145 175 215
2000 A 3 50 25 170 200 240
2250 A 3 50 30 180 210 250
2500 B 3 60 32.5 205 117.5 275
2800 B 3 70 30 220 125 290
3000 C 4 60 25 248 139 318
3200 C 5 40 20 268 149 338
3500 C 5 50 20 308 169 378
4000 C 5 50 25 328 179 398
4200 C 5 50 30 348 189 418
4500 C 5 60 27.5 378 204 448
5000 C 5 70 30 428 229 498
6300 D 6 65 32.5 548 193 618

Aluminium Busbar Termination Flange To Switchboard Or Transformer

AMPERE HOLES
PATTERN W1 W2 W3 W4 W5
RATING (A) FIGURE

400 A 1 20 20 60 90 130
630 A 1 25 25 70 100 140
800 A 1 37.5 37.5 95 125 165
1000 A 2 40 25 110 140 180
1250 A 2 50 25 120 150 190
1500 A 3 40 22.5 145 175 215
1600 A 3 60 22.5 185 215 255
1800 A 3 60 27.5 195 225 265
2000 B 4 55 27.5 240 135 310
2250 B 4 60 25 250 140 320
2500 B 5 60 30 320 175 390
3000 C 6 60 22.5 358 194 428
3200 C 6 60 27.5 378 204 448
3500 C 6 70 30 428 229 498
4000 C 7 55 27.5 468 249 538
4200 C 7 60 25 488 259 558
4500 D 7 65 32.5 548 193 618
5000 D 8 60 30 628 220 698
11
 DBTS MEGATRONTM SANDWICH

FLANGE END TECHNICAL DATA

Holes Figure for Copper Busduct

Holes Figure for Aluminium Busduct

NOTE:
CUSTOME-MAKE TYPE FLANGE ARE AVAILABLE ON REQUEST INFORMATION SHOWN IS INDENDED AS GUIDE, READERS ARE ADVISED TO OBTAIN CONFIMATION

12
 DBTS MEGATRONTM SANDWICH

FLEXIBLE LINKS
Flexible Link

Tinned Copper Braided Flexible Link

FLEXIBLE LINK A B
AMPERE RATING CU CONTACT PALM THICKNESS CU CONTACT PALM
(A) ±1mm WIDTH ±1mm
900 9 50
1100 12 55
1300 13 61
1500 15 72

BUSBAR AMPERE RATING (A) FLEXIBLE LINK LENGTH PER PHASE

400 1 X 900A
630 1 X 900A
800 1 X 900A
1000 1 X 1100A
1250 1 X 1300A
1600 2 X 900A
1800 2 X 900A
2000 2 X 1100A
2250 3 X 900A
2500 3 X 900A
3000 4 X 900A
3200 4 X 900A
3500 4 X 900A
4000 4 X 1100A
4500 6 X 900A
5000 6 X 900A
6300 6 X 1100A

13
 DBTS MEGATRONTM SANDWICH

HORIZONTAL & VERTICAL HANGER

Horizontal Hangers
Horizontal hangers are used to support
MEGATRON when installed on a horizontal
run.
Recommended to install minimum M12
vertical rod at maximum 1.5 m distance.

Vertical Hangers
Our vertical spring hangers are used to
support the full weight of the busduct
when installed in a vertical orientations
such as risers.

14
 DBTS MEGATRONTM SANDWICH

END FEED CABLE BOX

Sandwiched Type End Feed Cable Enclosure

End feed cable enclosure is a cable termination unit. Connecting busbars, rigidly supported and spaced
to suit cable size. Holes are provided on these busbars so that cable sockets can be securely bolted-on
with ease. The enclosure can be accessed from front, LH and RH sides as well as from bottom. Visual
inspection or testing can be carried out easily and conveniently. If required circuit-breaker or
disconnector can be added for O/L and short-circuit protection or simply for isolation purpose.

AMPERE
W1 W2 W3
RATING (A)

400 450 450 125

630 450 450 125
800 550 450 125
950 650 450 125
1000 650 450 125
1250 650 450 125
1600 650 450 125
1800 650 500 150
2000 650 500 150
2250 650 500 150
2500 650 500 200
*End feed cable enclosure ratings more than 2500A also available.
Please consult us for more details.

15
 DBTS MEGATRONTM SANDWICH

SPECIAL BUSDUCT
Due to unavoidable changes at construction site or unable to do site measurement accurately, Telescopic Feeders
are available to provide these solutions. Each Telescopic Feeder is 1500mm long with adjustment of +/- 100mm.
Telescopic Feeders will allow some changes at site and will not affect completion schedule or incur extra cost due to
unintended dimensional errors.

Busbar & Housing Linear Longitudinal Expansion

Consult DBTS for full dimensions.

Zone 4 Anti-Seismic Absorber & Expansion for Busduct

Rise
Design to Specification.
Consult DBTS for full dimensions.

Auto-leveling Expansion Unit for Structural Buildings

Settlement
Design to Specification.
Consult DBTS for full dimensions.

Phase Transposition Unit

Busbar phases before terminating to equipment are
being transposed to correct phase sequence.
Consult DBTS for full dimensions.

16
 DBTS MEGATRONTM SANDWICH

FIRE RESISTANT BUSDUCT

Fire Resistant Rated MEGATRON Busducts
Fire resistant rated MEGATRON busducts are available for essential electrical services. These feeder
busducts are designed and manufactured to comply with IEC331 and BS6387

Circuit Integrity Under Fire Conditions

Resistance to Fire Alone
• IEC 331 : 3 Hours at 750°C
• BS 6387 Category ‘c’ : 3 Hours at 950°C

Resistance to Fire with Water

• BS 6387 Category ‘w’: 15 mins at 650°C (Plus 15
mins with water spray

Resistance to Fire with Mechanical Shock

• BS 6387 Category ‘z’ : 15 mins at 950°C

We reserve the right to change the design details of our products without prior notice. Although significant modification to the
overall dimensions and ratings shall be advised as soon as possible.

17
 DBTS MEGATRONTM SANDWICH

TECHNICAL DATA
MEGATRONTM Sandwiched Type Busduct Electrical Characteristics And Voltage Drop
Frequency : 50 HZ Copper
LINE TO LINE VOLTAGE DROP IN mV/m AT
NO OF
AMPERE BUSBAR IMPEDANCE (μΩ/m) AT 95OC RATED FULL CURRENT AT POWER FACTOR AS
BAR
RATING (A) SIZE (mm) SHOWN
PHASE
R X Z 1.0 0.9 0.85 0.8
630 1 6x40 96.11 18.48 97.87 104.87 103.17 99.76 96.00
800 1 6x50 76.38 15.67 77.97 105.83 104.71 101.39 97.69
1000 1 6x65 58.39 12.88 59.80 101.14 100.75 97.72 94.30
1250 1 6x75 50.47 11.57 51.78 109.28 109.27 106.08 102.45
1600 1 6x110 34.22 8.73 35.32 94.84 95.90 93.36 90.38
1800 1 6x125 30.07 7.96 31.11 93.76 95.20 92.77 89.90
2000 1 6x150 25.02 7.01 25.98 86.66 88.58 86.45 83.90
2250 1 6x160 23.44 6.71 24.38 91.35 93.61 91.42 88.76
2500 1 6x185 20.25 6.09 21.15 87.69 90.41 88.42 85.97
2800 1 6x200 18.72 5.79 19.60 90.80 93.95 91.96 89.47
3000 2 6x110 17.11 5.33 17.92 88.91 92.08 90.15 87.73
3200 2 6x120 15.67 5.06 16.47 86.85 90.39 88.59 86.30
3500 2 6x140 13.41 4.63 14.19 81.30 85.41 83.89 81.88
4000 2 6x150 12.51 4.46 13.28 86.66 91.46 89.93 87.86
4200 2 6x160 11.72 4.31 12.49 85.26 90.39 88.97 87.00
4500 2 6x175 10.71 4.11 11.47 83.47 89.08 87.81 85.98
5000 2 6x200 9.36 3.84 10.12 81.07 87.47 86.44 84.82
6300 2 6.3x260 6.85 3.39 7.64 74.74 83.38 83.00 81.97

Frequency : 50 HZ Aluminium
LINE TO LINE VOLTAGE DROP IN mV/m AT
NO OF
AMPERE BUSBAR IMPEDANCE (μΩ/m) AT 95OC RATED FULL CURRENT AT POWER FACTOR AS
BAR
RATING (A) SIZE (mm) SHOWN
PHASE
R X Z 1.0 0.9 0.85 0.8
400 1 6x40 161.08 18.48 162.13 111.60 106.02 101.60 96.96
630 1 6x50 128.01 15.67 128.96 139.68 133.17 127.74 122.00
800 1 6x75 84.59 11.57 85.38 117.22 112.48 108.08 103.39
1000 1 6x90 70.29 10.11 71.01 121.75 117.20 112.70 107.90
1250 1 6x100 63.17 9.35 63.86 136.77 131.92 126.92 121.56
1500 1 6x125 50.40 7.96 51.03 130.95 126.88 122.21 117.18
1600 1 6x165 39.29 6.71 39.86 108.88 106.09 102.34 98.26
1800 1 6x175 35.90 6.31 36.45 111.91 109.30 105.50 101.34
2000 1 6x220 28.51 5.45 29.03 98.76 97.11 93.89 90.33
2250 1 6x230 27.26 5.30 27.77 106.25 104.62 101.19 97.38
2500 1 6x300 20.87 4.52 21.36 90.39 89.89 87.15 84.07
3000 2 2x6x165 19.04 4.24 19.51 98.96 98.66 95.71 92.37
3200 2 2x6x175 17.95 4.11 18.41 99.48 99.45 96.55 93.24
3500 2 2x6x200 15.69 3.84 16.15 95.12 95.76 93.12 90.07
4000 2 2x6x220 14.26 3.67 14.72 98.76 99.97 97.34 94.27
4200 2 2x6x230 13.63 3.60 14.10 99.17 100.65 98.07 95.03
4500 2 2x6x260 12.05 3.40 12.52 93.93 96.10 93.82 91.07
5000 2 2x6x300 10.44 3.21 10.92 90.39 93.46 91.47 88.98

18
 DBTS MEGATRONTM SANDWICH

TECHNICAL DATA
MEGATRONTM Sandwiched Type Busduct Electrical Characteristics And Voltage Drop
Frequency : 60 HZ Copper
LINE TO LINE VOLTAGE DROP IN mV/m AT
NO OF
AMPERE BUSBAR IMPEDANCE (μΩ/m) AT 95OC RATED FULL CURRENT AT POWER FACTOR AS
BAR
RATING (A) SIZE (mm) SHOWN
PHASE
R X Z 1.0 0.9 0.85 0.8
630 1 6x40 96.11 22.18 98.63 104.87 104.93 101.89 98.42
800 1 6x50 76.38 18.80 78.66 105.83 106.60 103.68 100.30
1000 1 6x65 58.39 15.45 60.40 101.14 102.69 100.07 96.97
1250 1 6x75 50.47 13.88 52.35 109.28 111.45 108.72 105.46
1600 1 6x110 34.22 10.47 35.79 94.84 98.01 95.90 93.29
1800 1 6x125 30.07 9.56 31.55 93.76 97.37 95.39 92.88
2000 1 6x150 25.02 8.41 26.39 86.66 90.70 89.01 86.81
2250 1 6x160 23.44 8.05 24.78 91.35 95.89 94.17 91.90
2500 1 6x185 20.25 7.30 21.53 87.69 92.71 91.20 89.13
2800 1 6x200 18.72 6.94 19.97 90.80 96.40 94.92 92.84
3000 2 6x110 17.11 6.39 18.27 88.91 94.50 93.07 91.05
3200 2 6x120 15.67 6.07 16.80 86.85 92.83 91.55 89.67
3500 2 6x140 13.41 5.56 14.52 81.30 87.85 86.85 85.25
4000 2 6x150 12.51 5.35 13.60 86.66 94.15 93.19 91.57
4200 2 6x160 11.72 5.17 12.81 85.26 93.12 92.27 90.76
4500 2 6x175 10.71 4.93 11.79 83.47 91.87 91.19 89.83
5000 2 6x200 9.36 4.61 10.43 81.07 90.37 89.94 88.81
6300 2 6.3x260 6.85 4.06 7.96 74.74 86.60 86.89 86.40

Frequency : 60 HZ Aluminium
LINE TO LINE VOLTAGE DROP IN mV/m AT
NO OF
AMPERE BUSBAR IMPEDANCE (μΩ/m) AT 95OC RATED FULL CURRENT AT POWER FACTOR AS
BAR
RATING (A) SIZE (mm) SHOWN
PHASE
R X Z 1.0 0.9 0.85 0.8
400 1 6x40 161.08 22.18 162.59 111.60 107.13 102.95 98.50
630 1 6x50 128.01 18.80 129.38 139.68 134.66 129.54 124.06
800 1 6x75 84.59 13.88 85.73 117.22 113.88 109.77 105.32
1000 1 6x90 70.29 12.13 71.33 121.75 118.73 114.55 110.00
1250 1 6x100 63.17 11.22 64.16 136.77 133.68 129.05 123.99
1500 1 6x125 50.40 9.56 51.30 130.95 128.68 124.39 119.66
1600 1 6x165 39.29 8.05 40.10 108.88 107.71 104.30 100.49
1800 1 6x175 35.90 7.58 36.69 111.91 111.02 107.57 103.70
2000 1 6x220 28.51 6.53 29.25 98.76 98.75 95.87 92.59
2250 1 6x230 27.26 6.36 27.99 106.25 106.42 103.36 99.86
2500 1 6x300 20.87 5.43 21.57 90.39 91.60 89.22 86.42
3000 2 2x6x165 19.04 5.08 19.71 98.96 100.57 98.03 95.01
3200 2 2x6x175 17.95 4.93 18.61 99.48 101.44 98.95 95.98
3500 2 2x6x200 15.69 4.61 16.35 95.12 97.79 95.57 92.86
4000 2 2x6x220 14.26 4.40 14.92 98.76 102.19 100.02 97.32
4200 2 2x6x230 13.63 4.31 14.30 99.17 102.93 100.83 98.17
4500 2 2x6x260 12.05 4.09 12.72 93.93 98.42 96.62 94.25
5000 2 2x6x300 10.44 3.85 11.12 90.39 95.88 94.39 92.31

19
 DBTS MEGATRONTM SANDWICH

TECHNICAL DATA
Short-circuit Withstand Current
AMPERE RATING (A) STC (kA,Sec) PEAK CURRENT (kA) STC (kA,3 Sec)
400 A 25 kA , 1 Sec 52.5 kA N.A.
630 A 43 kA , 1 Sec 90.3 kA 25 kA
800 A 50 kA , 1 Sec 105 kA 29 kA
1000 A 63 kA , 1 Sec 138.6 kA 36 kA
1250 A 63 kA , 1 Sec 138.6 kA 36 kA
1600 A 63 kA , 1 Sec 138.6 kA 36 kA
1800 A 63kA, 1 Sec 138.6 kA 36 kA
2000 A 75 kA , 1 Sec 165 kA 43 kA
2250 A 75 kA , 1 Sec 165 kA 43 kA
2500 A 80 kA , 1 Sec 176 kA 46 kA
3000 A 100 kA , 1 Sec 220 kA 58 kA
3200 A 100 kA , 1 Sec 220 kA 58 kA
3500 A 100 kA , 1 Sec 220 kA 58 kA
4000 A 100 kA , 1 Sec 220 kA 58 kA
4500 A 150 kA , 1 Sec 330 kA 87 kA
5000 A 160 kA , 1 Sec 352 kA 92 kA
6300 A 200 kA , 1 Sec 440 kA 115 kA

Voltage Drop Formula

u = k √ 3 ( R cos φ + X sin φ ) IB L
u - composite voltage drop of BTS, expressed in volts (V)
R&X - mean resistance & reactance expressed in ohms per meter (Ω/m)
IB - current of the circuit being considered, expressed in Amperes (A)
L - the length of the BTS being considered, expressed in meters (m)
cos φ - load power factor being considered
k - load distribution factor, calculated as follows:
=1 if the load is concentrated at the end of the BTS run

Pre-calculated voltage drop value are shown in the table below in milli-volt per meter BTS length at
different power factors for easy reference and quick calculations.

For practical application voltage drop is usually base on power factor 0.85 (cos φ =0.85) and for this reason
power factor up to 0.80 is tabulated only.

NOTE:
SHORT CIRCUIT RATING IS THE SAME FOR COPPER AND ALUMINIUM BUSDUCT

20
 DBTS MEGATRONTM SANDWICH

TECHNICAL DATA
DBTS MEGATRONTM SANDWICH TECHNICAL DATA SHEET
1. Compliance of Standards IEC61439-1, IEC61439-6, AS3439.2, IEC60529, IEC60 331,
IEC60332, IEC60947-2, BSEN61439, BS5486, UL-857 , BS6387,
IEE/IEEE, JISC8364

2. Independent Certification Authority ASTA United Kingdom

UL

3. Current Ratings 400A up to 6300A

4. Busbar Arrangement Sandwiched Type

5. Busbar Conductor Copper: >99.99% (>98% IACS conductivity)

Aluminium: >97.50% (up to 61% IACS conductivity)

6. Rated Insulation Voltage 1000VAC , 50 or 60 Hz

7. Rated Dielectric Voltage 3.5kVrms for 1 minute

8. Rated Impulse Voltage 6/8 kV 1.2/50 µs

9. Busbar Surface Plating Electrolytic Tinned, Silver Plating Optional

10. Busbar Insulation to IEC85 blu-E-Coat Epoxy Insulation

155OC (Class F), thickness – 1 mm

11. Neutral Busbar Size 50%, 100%, 150% or 200% of Phase Bar

12. Integral Earth Bar 50% or 100% of Phase Bar

13. Housing as Protective Earth Exceed 60% of three-phase short-circuit current

14. Maximum Temperature Rise 55oC Suitable for 50oC Ambient or to IEC61439-1 & -6

15. Housing Material Extruded Aluminium, Steel or Stainless Steel

16. Housing Colour Finishing Outdoor Suitable, Polyester Powder Coated, Standard in Light Grey

17. Ingress Protection to IEC60529 IP54, IP55 for indoor

18. Joint Phase Insulation High impact, fire resistant Glass-filled Polyester Compound (DMC)

19. Joint Tightening Bolt Double-headed, High Tensile, with Tag Indicator
20. Joint Plate for Double Stacked Design Single Conducting Plate (Electrically Common)

21
 DBTS MEGATRONTM COMPACT

INTRODUCTION
Introduction
DBTS is the leading manufacturer in the full range of busbar trunking systems. Our manufacturing floor space is
one of the largest in the Asia-Pacific region.
DBTS has been manufacturing High Quality Busbar Systems on the same factory floor since 1996, with Total Quality
Management System and certified to ISO 9001:2015
Factory Capable of Manufacture and supply BTS for Small to Very Large Complexes and on Fast Track Basis
Factory is Accredited to Environmental Friendly Green Standards

DBTS MEGATRONTM
MEGATRONTM is a world recognised trademark for Low Voltage Busbar Trunking Systems. It is maintenance-free,
and provides a complete and versatile busbar trunking system. This is ideal for installation in both indoor and
outdoor applications, where we prioritise the continuous supply of electricity to serve the wellbeing of the users.

Product Compliance Standards

MEGATRONTM is designed, manufactured and tested under stringent quality control in accordance to international
standards:
IEC61439-1, IEC61439-6, AS3439.2, IEC60529, IEC60331, IEC60332, IEC60947-2, BSEN61439, BS5486, UL-857,
BS6387, IEE/IEEE, JISC8364, Seismic Earthquake: NEBS-GR-G3 Zone 4, Richter Magnitude 8.3

Busbar Circuits

Available in: Single-phase, 2-phase, and 3-phase with options for:

a. 50%, 100%, 200% Neutral
b. 50%, 100% dedicated integral Earth bonded to housing
c. Insulated Earth

22
 DBTS MEGATRONTM COMPACT

PLUG-IN BUSDUCT
DBTS MEGATRONTM Compact Type Feeder Plug-in Busduct

Feeder busduct is traditionally used to interconnect electrical power from transformers,

generators or load banks to main switchboard(MSB) or from MSB to Motor Control Centre
(MCC). Plug-in busduct serves the same function as the feeder but has additional tap off
openings allowing electrical power to be tapped via tap off box.

Feeder and plug-in busduct are made in standard 3 meters length. Shorter lengths are also
made to complete the connection. All DBTS busduct runs are of a bespoke manufacture.

23
 DBTS MEGATRONTM COMPACT

BUSBAR DIMENSIONS

Copper in Steel or Extruded Aluminium Housing

BUSBAR DIMENSION ‘H’ (mm) APPROXIMATE WEIGHT (kg/m)

AMPERE
SIZE/PHASE
RATING (A) STEEL AL 4W 4W+50%E
(mm)

100 3 x 20 60 12 13
160 3 x 20 60 12 13
200 3 x 25 65 13 14
300 3 x 30 70 14 15
400 6 x 25 65 15 16
500 6 x 30 70 16 17
630 6 x 40 80 17 18
800 6 x 50 95 20 22

Aluminium in Steel or Extruded Aluminium Housing

BUSBAR DIMENSION ‘H’ (mm) APPROXIMATE WEIGHT (kg/m)

AMPERE
SIZE/PHASE
RATING (A) STEEL AL 4W 4W+50%E
(mm)

300 6 x 25 65 7 8
400 6 x 40 80 8 9
630 6 x 50 95 10 11

NOTE:
BUSBAR SIZE BASE ON DIFFERENT CURRENT DENSITY AND CONFIGURATIONS ARE AVAILABLE. PLEASE REQUEST FROM DBTS
INFORMATION SHOWN IS INTENDED AS GUIDE, READERS ARE ADVISED TO OBTAIN CONFIRMATION
24
 DBTS MEGATRONTM COMPACT

PLUG-IN BUSDUCT
Compact Type Features and Dimensions of Tap-Off Units
with Circuit-Breaker

Complying to UK ‘ The Electricity at Work’ Regulation 1989 live

parts shall be covered by insulation to prevent any person
working on or near from touching live parts and being injured.
Insulated and fire-resistant shutters rated IP65 (when cover
closed) are fitted at the plug-in opening. The shutters only open
during insertion of tap off units via built-in actuation pin. The
shutters automatically close when tap off unit is withdrawn.

MCCB
‘W’ ‘H’
RATING ‘L’ (mm)
(mm) (mm)
(A)
10-100 370 150 230
125-250 450 180 250
300-400 530 230 300
500-600
Utilize
two 940 300 400
plug-in
holes

*MCCB rates more than 1200A also available. Please consult us for more details.

25
 DBTS MEGATRONTM COMPACT

ELBOWS

Flatwise Elbow Edgewise Elbow

Min length A = 250mm, B = 250mm Min length A = 250mm, B = 250mm

T-Elbow Flatwise Type T-Elbow Edgewise Type

Min length A = 250mm, B = 250mm, C = 250mm Min length A = 250mm, B = 250mm , C = 250mm

Offset (Double Elbow) Flatwise Type Offset (Double Elbow) Edgewise Type
Min length A = 250mm, B = 250mm , C = 250mm Min length A = 250mm, B = 250mm , C = 250mm

Combination Elbow Flatwise + Edgewise

Min length A = 250mm, B = 250mm , C = 250mm

26
 DBTS MEGATRONTM COMPACT

FLANGE END
Flange End Termination to Switchboard or Transformer
Flange end provide connection between busduct and various type of low voltage appliances such
as transformer, switchboard, control panel or even factory machinery. The standard gap between
each connection flange is 100mm but it can be customize based on customer need.

AMPERE
DIM ‘W1’ DIM ‘W2’ DIM ‘W3’ HOLE SIZE
RATING (A)

COPPER
100 60 100 120
160 60 100 120
200 65 105 125
FIG1
300 70 110 130
400 65 105 125
500 70 110 130
630 80 120 140
FIG 2
800 95 135 155
ALUMINIUM
300 65 105 125 FIG 1
400 80 120 140
FIG 2
600 95 135 155

NOTE:
CUSTOM MAKE TYPE FLANGE ARE AVAILABLE ON REQUEST. INFORMATION SHOWN IS INDENDED AS GUIDE, READERS ARE
ADVISED TO OBTAIN CONFIRMATION.
27
END FEED CABLE BOX

AMPERE
RATING FIGURE DIM ‘W1’ DIM ‘W2’ DIM ‘W3’
(A)
COPPER
100 350 200 300
160 350 200 300
200 TYPE ‘A’ 350 200 300
300 350 200 300
400 350 200 300
500 450 300 360
630 TYPE ‘B’ 450 300 360
800 550 400 450
ALUMINIUM
300 TYPE ‘A’ 350 200 300
400 450 300 360
TYPE ‘B’
600 550 400 450

28
 DBTS MEGATRONTM COMPACT

ACCESSORIES

End Closers
End Closers are used to closed up the end part of a busduct run.

Horizontal Hangers
Horizontal hangers are used to support busduct when installed horizontally.

Vertical Mounting Hanger

Vertical Spring Hangers are recommended for busducts which to be installed in vertical riser. The
hangers are provided with special clamps to clamp to the busduct housing rigidly and they can be
clamped at any location along the busduct housing as shown in the diagram below. The compression of
the springs of the hanger are the factory set, and besides supporting the weight of the busduct the
springs also serve to absorb vibration and damping movement.

29
 DBTS MEGATRONTM COMPACT

TECHNICAL DATA
Megatron Compact Type Busduct Electrical Characteristics and Voltage Drop Data
Frequency: 50HZ Copper
LINE TO LINE VOLTAGE DROP IN mV/m AT
NO OF
AMPERE BUSBAR IMPEDANCE (μΩ/m) AT 95OC RATED FULL CURRENT AT POWER FACTOR AS
BAR
RATING (A) SIZE (mm) SHOWN
PHASE
R X Z 1.0 0.9 0.85 0.8
100 1 3 x 20 384.42 88.99 394.59 66.58 66.64 64.72 62.51
160 1 3 x 20 384.42 88.99 394.59 106.53 106.63 103.54 100.02
200 1 3 x 25 305.50 79.40 315.65 105.83 107.24 104.44 101.17
300 1 3 x 30 253.47 71.90 263.47 131.71 134.82 131.63 127.78
400 1 3 x 50 150.76 52.90 159.77 104.45 109.98 108.09 105.55
400 1 6 x 25 156.90 75.94 174.31 108.70 120.77 120.11 118.53
500 1 6 x 30 129.58 68.98 146.79 112.22 127.03 126.85 125.62
630 1 6 x 40 96.11 58.57 112.55 104.87 122.24 122.81 122.24
800 1 6 x 50 76.38 51.10 91.89 105.83 126.11 127.26 127.15

Frequency: 50HZ Aluminium

LINE TO LINE VOLTAGE DROP IN mV/m AT
NO OF
AMPERE BUSBAR IMPEDANCE (μΩ/m) AT 95OC RATED FULL CURRENT AT POWER FACTOR AS
BAR
RATING (A) SIZE (mm) SHOWN
PHASE
R X Z 1.0 0.9 0.85 0.8
300 1 6 x 25 262.97 75.94 273.71 176.10 140.18 136.93 132.99
400 1 6 x 40 161.08 58.57 171.39 152.18 118.13 116.23 113.63
630 1 6 x 50 128.01 51.10 137.83 195.44 150.02 148.10 145.20

Frequency: 60HZ Copper

LINE TO LINE VOLTAGE DROP IN mV/m AT
NO OF
AMPERE BUSBAR IMPEDANCE (μΩ/m) AT 95OC RATED FULL CURRENT AT POWER FACTOR AS
BAR
RATING (A) SIZE (mm) SHOWN
PHASE
R X Z 1.0 0.9 0.85 0.8
100 1 3 x 20 384.42 106.79 398.98 66.58 67.99 66.34 64.36
160 1 3 x 20 384.42 106.79 398.98 106.53 108.78 106.14 102.98
200 1 3 x 25 305.50 95.28 320.02 105.83 109.63 107.34 104.47
300 1 3 x 30 253.47 86.28 267.75 131.71 138.08 135.57 132.27
400 1 3 x 50 150.76 63.49 163.58 104.45 113.18 111.95 109.95
400 1 6 x 25 156.90 91.13 181.44 108.70 125.35 125.66 124.84
500 1 6 x 30 129.58 82.78 153.76 112.22 132.24 133.15 132.78
630 1 6 x 40 96.11 70.29 119.07 104.87 127.81 129.54 129.91
800 1 6 x 50 76.38 61.32 97.95 105.83 132.28 134.72 135.65

Frequency: 60HZ Aluminium

LINE TO LINE VOLTAGE DROP IN mV/m AT
NO OF
AMPERE BUSBAR IMPEDANCE (μΩ/m) AT 95OC RATED FULL CURRENT AT POWER FACTOR AS
BAR
RATING (A) SIZE (mm) SHOWN
PHASE
R X Z 1.0 0.9 0.85 0.8
300 1 6 x 25 262.97 91.13 278.31 184.00 143.62 141.09 137.73
400 1 6 x 40 161.08 70.29 175.74 160.29 121.66 120.51 118.50
630 1 6 x 50 128.01 61.32 141.94 206.60 154.88 153.98 151.89
NOTE:
SHORT CIRCUIT RATING IS THE SAME FOR COPPER AND ALUMINIUM BUSDUCT
30
 TECHNICAL DATA

Short Circuit Withstand Current

AMPERE RATING (A) STC (kA,Sec) PEAK CURRENT (kA) STC (kA,3 Sec)

100 A 20 kA , 0.1 Sec 40 kA N.A

160 A 20 kA , 0.1 Sec 40 kA N.A
200 A 20 kA , 0.1 Sec 46 kA N.A
300 A 20 kA , 0.1 Sec 40kA N.A
400 A 25 kA , 1 Sec 52.5 kA N.A
500 A 25 kA , 1 Sec 52.5 kA N.A
630 A 43 kA , 1 Sec 90.3 kA 25 kA
800 A 50 kA , 1 Sec 105 kA 29 kA
950 A 50 kA , 1 Sec 105 kA 29 kA

Voltage Drop Formula

u = k √ 3 ( R cos φ + X sin φ ) IB L
u - composite voltage drop of BTS, expressed in volts (V)
R&X - mean resistance & reactance expressed in ohms per meter (Ω/m)
IB - current of the circuit being considered, expressed in Amperes (A)
L - the length of the BTS being considered, expressed in meters (m)
cos φ - load power factor being considered
k - load distribution factor, calculated as follows:
=1 if the load is concentrated at the end of the BTS run

Pre-calculated voltage drop value are shown in the table below in milli-volt per meter BTS length at
different power factors for easy reference and quick calculations.

For practical application voltage drop is usually base on power factor 0.85 (cos φ =0.85) and for this reason
power factor up to 0.80 is tabulated only.

NOTE:
SHORT CIRCUIT RATING IS THE SAME FOR COPPER AND ALUMINIUM BUSDUCT

31
TECHNICAL DATA
DBTS MEGATRONTM COMPACT Technical Data Sheet
1. Compliance of Standards IEC61439-1, IEC61439-6, AS3439.2, IEC60529, IEC60 331,
IEC60332, IEC60947-2, BSEN61439, BS5486, UL-857 , BS6387,
IEE/IEEE, JISC8364

2. Independent Certification Authority ASTA United Kingdom

3. Current Ratings Copper: 100A up to 800A

Aluminium: 300A to 630A

4. Busbar Arrangement Sandwiched Type

5. Busbar Conductor Copper: >99.99% (>98% IACS conductivity)

Aluminium: >97.50% (up to 61% IACS conductivity)

6. Rated Insulation Voltage 1000VAC , 50 or 60 Hz

7. Rated Dielectric Voltage 3.5kVrms for 1 minute

8. Rated Impulse Voltage 6/8 kV 1.2/50 µs

9. Busbar Surface Plating Electrolytic Tinned, Silver Plating Optional

10. Busbar Insulation to IEC85 blu-E-Coat Epoxy Insulation

155OC (Class F), thickness – 1 mm

11. Neutral Busbar Size 50% or 100% of Phase Bar

12. Integral Earth Bar 50% or 100% of Phase Bar

13. Housing as Protective Earth Exceed 60% of three-phase short-circuit current

14. Maximum Temperature Rise 55oC Suitable for 50oC Ambient or to IEC61439-1 & -6

15. Housing Material Extruded Aluminium, Steel or Stainless Steel

16. Housing Colour Finishing Outdoor Suitable, Polyester Powder Coated, Standard in Light Grey

17. Ingress Protection to IEC60529 IP54, IP55 for indoor

18. Type of Jointing Overlapping

19. Type of Joint Bolt Bolt and Locked Nut

20. Joint Plate for Double Stacked Design Single Conducting Plate (Electrically Common)

32
TEST CERTIFICATE

33
TEST CERTIFICATE

34
ILLUSTRATION OF BUSDUCT TRUNKING SYSTEMS

35