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Installation & Maintenance Manual
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Definitions
Storage instruction
FORTHEPURPOSEOFTHISMANUAL,AQUALIFIEDPERSONISFAMILIARWITHTHEINSTALLATION,CONSTRUCTIONANDOPERATIONOFTHEEQUIPMENTANDTHEHAZARDSINVOLVED.
Theperson istrainedinthepropercareanduseofprotectiveequipmentsuchasrubbergloves,hardhat,safetyglassesorfaceshields,flashclothing,etc.,inaccordancewithestablishedsafetypractices.
DANGER
DANGER LABELINDICATESANIMMINENTLYHAZARDOUSSITUATIONWHICH,IFNOT AVOIDED,WILLRESULTINDEATHORSERIOUSINJURY.
CAUTION
WARNING
WARNING LABELINDICATESAPOTENTIALLYHAZARDOUSSITUATIONWHICH,IFNOTAVOIDED,COULDRESULTINDEATHORSERIOUSINJURY.
CAUTION LABELINDICATESAPOTENTIALLYHAZARDOUSSITUATIONWHICH,IFNOTAVOIDED,COULDRESULTINDEATHORSERIOUSINJURY.
Assoonasthebusway arriveatthesite,Inspecteachbusway pieceforpossibledamageorcontamination.
Contactsurfacesmustbeclean.However,donotattempttopolishtarnishedcontactsurfaces.
Ifthereisnodamage,restorethepackingtoitsoriginalconditiontoprepareforjobsitestorage.
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Donotlaythebusway directlyontheground.Alwaysplacepiecesofwoodunderthebusway andstackupfirmlyasshown.Neverputituprightinstorageorduringinstallation.
XX
Preparing for installation
Deliverbusway toinstallationlocationbeforeunpacking.Shippingcrates/cartons
displayexterioridentificationofthepackagedbusway components.
Eachbusway componentisfurtheridentifiedbyanitemnumberlocatedonthenameplate,whichcorrespondstothatsameitemnumberonthebusway installationdrawing(s).
Inspecteachbusway componentforpossibledamage.
Consultthefactoryifdamageisfound.Confirmthatcontactsurfacesarenotdamagedandarecleananddry.Abrasivesshouldnotbeusedonthesesurfacesbecausecontactsurfacesareelectroplated.Inspectjointinsulatorsforcrackingor
anysignofdamage.
Megger testeachbusway componentat1000volts,phasetophase(includingneutral)andphasetoground,todetectincorrectinstallationandverifyinsulationintegrity.Busway shouldbedisconnectedfromanylineorloaddeviceswhenperformingamegger test.
Ifreadingsarebelowthisminimum,donotassemblebusway orapplypowertotheinstalledbusway andcontactLSbusduct.
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Thoroughlycheckthebusway layingroutetoseeifthereareanyobstacles,heatsource,waterleakage,etc.checkalsothedimensionsofarrangementandbuildimgs andequipmentbeforehand.
Installthehangingboltsortrestlesforhangersbeforehand.Setthehangerpitchtosupporttwoplaceswithoneunitasastandard.
Investigatethesiteconditioninadvanceanddeterminethemost advantageouslayingorder.Theworkusuallystartfromconnectingthebusway tothetransformerortheswitchboard,butincaseitisimpossibleto determinepreciselythepositionofelbowsT-branch,andthenstartconstruction,andotheritemswhichserveasthepointsofbusway installation.
Phase sequence
Typical bus bar phase sequence is G-A-B-C-N top to bottom when internal (orisolated) ground and neutral are provided. Joint supports on the ends of eachbusway section include an arrow that points “up” to the "ground side" of thebusway. The rating nameplate is placed on the “neutral side”.
C
AB
G
3Phase, 4Wire
+Housing Ground,
+50%, 100% Ground bus
N
WARNING
Liftingbusway withouttheproperLiftingdevicesmayresultinbusway
damage,seriousinjuryordeath.
WARNING
WARNING: The embossed arrows on the Joint Covers must point in thesame direction as arrows on the Joint Supports.
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Installation of busway
1. Minimum clearance
Figureillustratestheminimumclearancesthatmustbemaintainedinvariousinstallationsituation.
HORIZONTAL MOUNTING VERTICAL MOUNTING
3-W AND
3-W
3-W AND
4W
4-W AND
4W
P1
P2
P3
110
150
190
135
175
215
130
180
230
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Jointing Method
TypicalbusbarphasesequenceisG-A-B-C-Ntoptobottomwheninternalgroundandneutralareprovided.Jointsupportsontheendsofeachbuswaysectionincludeanarrowthatpoints“up” tothe"groundside"ofthebusway.Theratingnameplateisplacedonthe“neutralside”.
Theitemnumbersequenceidentifiedontheseinstallationdrawingsmustbe
followedexactlytoinsureproperinstallation.
Housing mold Double head Joint Bolt
Bus barBus bar
Integral housing Ground
Integral Ground(End ramp)
A phase
B phase
C phase
N phase
Insulating plate
Joint bolt nut
Threadedhole
Housing mold Joint stack
Housing side ground plate(End ramp)
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Housingendrampsprovidegroundcontinuityaswellassealingsurfacesonwaterresistiveratings.Donotdamagethesehousingendrampspriortoorduringinstallation.
Waterresistiveratingsmaybejeopardizediftheendrampsaredamaged.
CAUTION
EnsurethatthebusbarsandhousingendrampsengageproperlybetweenthejointstackandinsulatorplatesasshowninFigure.
WARNING
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Check the contact surface has no
damage and contamination.
Inspect the busway run forstraightness in all planes
Insert the “bar ends” to joint kit
slowly.
Joint assembly instruction
Using the torque wrench,
tighten the outer bolt head of
joint bolt until break off (shear
torque =800kgf ·cm)
Joint kit
Bar end
1
2
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4
Attach the Side covers to joint
part(housing mold) by bolts.
3
Check the no gap between
joint cover and housing for
water-proof
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설 치
R S
T N
16
Plug in Box
Plug in Feeder
Plug In Box - Horizontal
Support
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설 치
Tap off Box
17/
Plug in Box - Vertical
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Horizontal support
TrapezeHangers,andsingledroprodhangersareusedtosupporthorizontalbusway runsonmaximum(3m)centers.(desired regularinterval
=1500mm)
Ø12mmsteeldroprodsandhardwarearetobefurnishedbytheinstaller.
Avoidpositioninghangersatbusway jointsandplug-inopenings,wherepossible.Maintaingoodalignmentalongthebusway run.
1. Trapeze Hangers Installation
2. Wall Hanger Installation
Centerbusway ontheWallHangeratdesiredlocation.Installahangerclamponeachsideofthebusway withthehardwareprovided.
Omissionofhangerclampmayresultinundesirablebusway rotationwheninstallingbusplugs.
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Vertical support
SpringHangersareusedtosupportvertical(riser)busway.Notethatnojointmaybe
installedlessthan500mmabovethefloor.Nojointcomponentshouldfallwithinthefloorpenetration.
Afterinstallingthebusway sectionthroughthefloor,performthefollowingprocedure:
1.Loosenthehangerbolt.
2.Assemblethehangerstoeachsideofthebusway.
3.Positionthehangersonthebusway sothatthebasechannelrestsonthefloororothersupport.Afloorflangemaybeplacedunderthehanger,butitwillnotsupportthe
busway weight.
Spring hanger
Rigid hanger
Hanger bolt
Base channelJam nut
Secondadjustingnut
Firstadjustingnut (take off
Hangerclamp
H
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4.Fitthehangerclampstothebusway housingandhandtightenthehangerbolts.
5.Anchorthebasechannelstotheirsupports.
6.Tightenthehangerbolts.
7.Installthenextlengthandmakethejointassembly
8.Ifspringsarefurnished,theymustbeadjustedasshownpicture.DeterminetherequireddimensionHofthehangersprings,foundonthelayoutdrawing.
UsingtheSecondadjustingnuts,setthespringsonthehangers tothedimensionH.Withthespringsadjusted,holdFirstadjustingnut inpositionandtightenjamnutagainstFirstadjustingnuttoretainthespring setting.
Tightenalljamnutsusingthisprocedure.
Actual measurement
Case 2.
Case 1.
L + 42
21 21
L - 250
L + 250
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Maintenance and checking
Thefollowingmaintenanceandcheckingarerecommendedforguaranteeingsafeusageofthebusway foralongtime.
Checkingtoseewhetherthereisdeformation,damage,dirt,etc. throughoutthewholelengthofthebusway andwhetherthereisdislocationbendingandotherabnormalityoftheconnectingcovers,hangerandplug-inappliances.
• The busway should be periodically inspected to spot trouble areas or
changes in operating condition.
• Remove any accumulations of dust, dirt, or other foreign matter.
• Eliminate moisture from leaks or condensation dripping from pipes.
• Check for any equipment installed near the busway that might cause
damage because of external heating.
Aftercompletinginstallation,recheckalljointboltswithatorquewrenchfor800kg-cmtorque.AJointBoltwithoutaredtagmaystillnotbetight.Theboltmayhavebeenloosenedtoadjustortestthebusway.
WARNING
1. External appearance
2. load condition
Aftertheconstructionofthepluginbusway,increaseofloadisexpectedattheearlystage.
Carryoutcheckingthetotalloadisnotexceedingthecapacityofthebusway atthetimetheloadisincreased.EspeciallypayattentionwhenthemainlineisbranchedbyT-branchorcross.
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1. Was there any shipping damage? Report any minor damage or issingparts to the factory. Be sure to include the item number.
Yes/No
2. Proper storage before actual installation. Yes/No
a. Were bus components kept clean and dry? Yes/No
b. Were bus components exposed to corrosive fumes, liquids, salts, orconcrete materials?
Yes/No
a. Were bus components kept clean and dry? Yes/No
b. Were bus components exposed to corrosive fumes, liquids, salts, orconcrete materials?
Yes/No
c. Was there any mechanical damage due to handling? Yes/No
4. Did each piece of bus get a pre-installation megohm test? (Individualpieces should megohm test as infinite resistance. Consult the factory ifyou experience a lower reading.)
Yes/No
5. Mounting and support. Yes/No
a. Is each 3m of bus run supported, including any vertical sections?(Closer supporting may be required, based on job specifications.)
Yes/No
b. Does any support interfere with a bus joint? Yes/No
c. Are any bus terminations to other equipment used as support?(Busway weight should not bear on equipment, such as switchgear,switchboards, or transformers.)
Yes/No
6. Is the bus installed level and plumb? Yes/No
7. Was a periodic megohm test performed as this run was installed?(After every two or three items or as critical items are installed. Jointsshould be tightened for all megohm testing.)
Yes/No
8. Has the bus been inspected for proper phasing? Yes/No
9. Are all joint bolts properly tightened to 800 kgf-cm torque? Yes/No10. On vertically mounted bus using spring hangers, were the correctsettings verified? (See in the installation instructions.) Yes/No
11. Did you check for proper clearances for the bus at floors, walls,ceilings, other bus, and trades? (Never use cement to seal between thebus and floors or walls.)
Yes/No
12. Have all shipping screws been removed from expansion lengths? Yes/No
13. Was all foreign material removed from the installed bus? Yes/No
14. Was a final megohm test performed when all bus was installed? Yes/No
3. Bus exposure during installation. Yes/No
Busway installation checklist
Project name : identification :