Installation & Maintenance Manual

Definitions

FOR THE PURPOSE OF THIS MANUAL, A QUALIFIED PERSON IS FAMILIAR WITH THE
INSTALLATION, CONSTRUCTION AND OPERATION OF THE EQUIPMENT AND THE
HAZARDS INVOLVED.

The person is trained in the proper care and use of protective equipment such as
rubber gloves, hard hat, safety glasses or face shields, flash clothing, etc., in
accordance with established safety practices.

DANGER
DANGER LABEL INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT
AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.

WARNING
WARNING LABEL INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH,
IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.

CAUTION
CAUTION LABEL INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH,
IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.

Storage instruction

As soon as the busway arrive at the site, Inspect each busway piece for
possible damage or contamination.
Contact surfaces must be clean. However, do not attempt to polish
tarnished contact surfaces.
If there is no damage, restore the packing to its original condition to
prepare for job site storage.
 Do not lay the busway directly on the ground. Always place pieces of wood
under the busway and stack up firmly as shown. Never put it upright in
storage or during installation.

X X

Preparing for installation

Deliver busway to installation location before unpacking. Shipping crates/cartons

display exterior identification of the packaged busway components.
Each busway component is further identified by an item number located on the
nameplate, which corresponds to that same item number on the busway installation
drawing(s).
Inspect each busway component for possible damage.
Consult the factory if damage is found. Confirm that contact surfaces are not
damaged and are clean and dry. Abrasives should not be used on these surfaces
because contact surfaces are electroplated. Inspect joint insulators for cracking or
any sign of damage.
Megger test each busway component at 1000 volts, phase to phase (including
neutral) and phase to ground, to detect incorrect installation and verify insulation
integrity. Busway should be disconnected from any line or load devices when
performing a megger test.
If readings are below this minimum, do not assemble busway or apply power to the
installed busway and contact LS busduct.
 Thoroughly check the busway laying route to see if there are any obstacles, heat
source, water leakage , etc. check also the dimensions of arrangement and
buildimgs and equipment beforehand.
Install the hanging bolts or trestles for hangers beforehand. Set the hanger pitch
to support two places with one unit as a standard.
Investigate the site condition in advance and determine the most advantageous
laying order. The work usually start from connecting the busway to the
transformer or the switchboard, but in case it is impossible to determine precisely
the position of elbows T-branch, and then start construction, and other items
which serve as the points of busway installation.

WARNING
Lifting busway without the proper Lifting devices may result in busway
damage, serious injury or death.

Phase sequence

G
A
B
C
N

3Phase, 4Wire
+Housing Ground,
+50%, 100% Ground bus

Typical bus bar phase sequence is G-A-B-C-N top to bottom when internal (or
isolated) ground and neutral are provided. Joint supports on the ends of each
busway section include an arrow that points “up” to the "ground side" of the
busway. The rating nameplate is placed on the “neutral side”.

WARNING
WARNING: The embossed arrows on the Joint Covers must point in the
same direction as arrows on the Joint Supports.
 Installation of busway

1. Minimum clearance

Figure illustrates the minimum clearances that

must be maintained in various installation situation.

HORIZONTAL MOUNTING VERTICAL MOUNTING

3-W AND 3-W AND 4-W AND

3-W 4W 4W
P1 110 135 130

P2 150 175 180

P3 190 215 230

 Jointing Method

Housing mold Joint stack

Housing side ground plate

(End ramp)

Housing mold Double head Joint Bolt

Integral housing Ground
Threaded
hole Integral Ground
(End ramp)

A phase
B phase
C phase
N phase

Insulating plate Bus bar

Bus bar
Joint bolt nut

Typical bus bar phase sequence is G-A-B-C-N top to bottom when internal
ground and neutral are provided. Joint supports on the ends of each busway
section include an arrow that points “up” to the "ground side" of the busway. The
rating nameplate is placed on the “neutral side”.
The item number sequence identified on these installation drawings must be
followed exactly to insure proper installation.
 CAUTION
Housing end ramps provide ground continuity as well as sealing surfaces
on water resistive ratings. Do not damage these housing end ramps prior
to or during installation.
Water resistive ratings may be jeopardized if the end ramps are
damaged.

WARNING

Ensure that the bus bars and housing end ramps engage properly
between the joint stack and insulator plates as shown in Figure.
Joint assembly instruction
1
Check the contact surface has no
damage and contamination.
Inspect the busway run for
straightness in all planes
Insert the “bar ends” to joint kit
slowly.
Bar end

Joint kit

2
Using the torque wrench,
tighten the outer bolt head of
joint bolt until break off (shear
torque =800kgf·cm)
 3

Attach the Side covers to joint

part(housing mold) by bolts.

Check the no gap between

joint cover and housing for
water-proof
 설치

Plug in Box

R T
S N
Plug in Feeder

Support

Plug In Box - Horizontal

16/31
 설치

Plug in Box - Vertical

Tap off Box

17/31
Horizontal support
1. Trapeze Hangers Installation
Trapeze Hangers, and single drop rod hangers are used to support
horizontal busway runs on maximum(3m) centers.(desired regular interval
= 1500mm)
Ø12mm steel drop rods and hardware are to be furnished by the installer.
Avoid positioning hangers at busway joints and plug-in openings, where
possible. Maintain good alignment along the busway run.

2. Wall Hanger Installation

Center busway on the Wall Hanger at desired location. Install a hanger clamp
on each side of the busway with the hardware provided.
Omission of hanger clamp may result in undesirable busway rotation when
installing bus plugs.
 Vertical support Hanger
Hanger bolt clamp
First
adjusting
nut (take off)

Second H
adjusting
nut

Base channel
Jam nut

Spring hanger

Rigid hanger

Spring Hangers are used to support vertical (riser) busway. Note that no joint may be
installed less than 500 mm above the floor. No joint component should fall within the
floor penetration.
After installing the busway section through the floor, perform the following procedure :
1. Loosen the hanger bolt.
2. Assemble the hangers to each side of the busway.
3. Position the hangers on the busway so that the base channel rests on the floor or
other support. A floor flange may be placed under the hanger, but it will not support the
busway weight.
4. Fit the hanger clamps to the busway housing and hand tighten the hanger
bolts.
5. Anchor the base channels to their supports.
6. Tighten the hanger bolts.
7. Install the next length and make the joint assembly
8. If springs are furnished, they must be adjusted as shown picture. Determine
the required dimension H of the hanger springs, found on the layout drawing.
Using the Second adjusting nuts , set the springs on the hangers to the
dimension H. With the springs adjusted, hold First adjusting nut in position and
tighten jam nut against First adjusting nut to retain the spring setting.
Tighten all jam nuts using this procedure.

Actual measurement
L + 42
Case 1.

21 21

L + 250
Case 2.

L - 250
Maintenance and checking

The following maintenance and checking are recommended for

guaranteeing safe usage of the busway for a long time.

1. External appearance
Checking to see whether there is deformation, damage, dirt, etc. throughout the
whole length of the busway and whether there is dislocation bending and other
abnormality of the connecting covers, hanger and plug-in appliances.

• 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.

2. load condition

After the construction of the plug in busway, increase of load is expected

at the early stage.
Carry out checking the total load is not exceeding the capacity of the
busway at the time the load is increased. Especially pay attention when
the main line is branched by T-branch or cross.

WARNING

After completing installation, recheck all joint bolts with a torque wrench
for 800kg-cm torque. A Joint Bolt without a red tag may still not be tight.
The bolt may have been loosened to adjust or test the busway.
 Busway installation checklist

Project name : identification :

1. Was there any shipping damage? Report any minor damage or issing
Yes/No
parts to the factory. Be sure to include the item number.
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, or
Yes/No
concrete materials?
3. Bus exposure during installation. Yes/No
a. Were bus components kept clean and dry? Yes/No
b. Were bus components exposed to corrosive fumes, liquids, salts, or
Yes/No
concrete materials?
c. Was there any mechanical damage due to handling? Yes/No
4. Did each piece of bus get a pre-installation megohm test? (Individual
pieces should megohm test as infinite resistance. Consult the factory if Yes/No
you experience a lower reading.)
5. Mounting and support. Yes/No
a. Is each 3m of bus run supported, including any vertical sections?
Yes/No
(Closer supporting may be required, based on job specifications.)
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, Yes/No
switchboards, or transformers.)
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. Joints Yes/No
should be tightened for all megohm testing.)
8. Has the bus been inspected for proper phasing? Yes/No
9. Are all joint bolts properly tightened to 800 kgf-cm torque? Yes/No
10. On vertically mounted bus using spring hangers, were the correct
settings 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 the Yes/No
bus and floors or walls.)
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