9 Busduct Installation Maintenance Rev2

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9 Busduct Installation Maintenance Rev2 Powered By Docstoc
					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 Instructions

   As soon as the busway arrives at the site, inspect each piece of busway for
   possible damage or contamination.
   Contact surfaces must be clean. However, do not attempt to polish
   tarnished contact surfaces.
   If there is no damage or contamination, repack the busway components in
   the original containers, and store in a clean and dry environment.
    Do not lay the busway directly on the ground. Always place pieces of wood
    under the busway and stack up firmly as shown. Never lean the busway in
    an upright position during storage or during installation.



           X                             X                                OK




 Preparing for Installation


Deliver busway to the installation site 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 prior to installation.
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 possible incorrect installation and to verify
insulation integrity. Busway should be disconnected from any line or load devices
when performing a megger test.
If readings are less than “infinite”, do not assemble busway or do not apply power to
the installed busway. Contact LS Busduct for further assistance.
 Thoroughly check the busway laying route for any obstacles, heat sources, water
 leakage, etc. Also verify the dimensions of the layout, the building and any
 equipment prior to installing the busway.
 Install the hanging bolts or trestles for hangers beforehand. Set the hanger pitch
 to support two places with even spacing.
 Inspect the site in advance and determine the most advantageous order of
 installation. The installation usually starts by connecting the busway to the
 transformer or the switchboard, but in some cases it is simpler to determine the
 exact location of an elbow or a T-branch, and begin construction from that point.



    WARNING
  Lifting busway without the use of 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 the arrows on the joint supports.
   Installation of Busway

      1. Minimum Clearance


Figures illustrating the minimum clearance that
must be maintained for various installation options.




           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 the 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 compromised 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 the figure.
 Joint Assembly Instructions
                                                 1
Check the contact surfaces for damage or
contamination.
Ensure proper alignment in all planes.
Slowly insert the bar ends in to joint kit.
If the insertion is too tight, slightly loosen
the joint kit bolt.
                                                                         Bar end

                                                        Joint kit




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


Attach the joint cover
components over the assembled
joint using the supplied
fasteners.




4




                                Check that there are no gaps
                                between the joint cover and
                                housing to ensure the
                                environmental integrity of the
                                joint.
   Plug in Box




                              R T
                                    S N
     Plug in Feeder




Support



                      Plug In Box - Horizontal




                                                 16/31
Plug in Box - Vertical




            Tap off Box
Horizontal Support
 1. Trapeze Hanger Installation
   Trapeze hangers and single drop rod hangers are used to support
   horizontal busway runs on 3 m (maximum) centers. (The recommended
   standard interval = 1.5 m)

   12mm Ø steel drop rods and hardware are to be furnished by the installer.
   Avoid positioning hangers at busway joints or plug-in openings, whenever
   possible. Maintain proper alignment along the entire busway run.




2. Wall Hanger Installation
Center busway on the wall hanger at the desired location. Install a hanger
clamp on each side of the busway using the hardware provided.
Omission of hanger clamps may result in undesirable busway twisting or
bending when installing plug-in devices.
     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 on 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 without additional reinforcement.
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 in the picture.
Determine the required dimension H of the hanger springs, found on the layout
drawing.
Using the second set of adjusting nuts, adjust the hanger springs to dimension
H. Once the springs are adjusted, hold the first adjusting nut in position and
then tighten the jam nut against the first adjusting nut to lock 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 Inspection

 The following maintenance and inspections are recommended for
 ensuring the safe operation and extended life of the busway.

1. External Appearance
 Check for any deformation, damage, dirt, etc. along the entire length of the
 busway. Inspect for any bending, twisting or other abnormal conditions of joint
 covers, hangers and plug-in devices.


 • The busway should be inspected periodically to detect trouble areas or
 possible changes in operating conditions.
 • Remove any accumulation of dust, dirt, or other foreign matter.
 • Avoid moisture from leaks or condensation dripping from overhead pipes.
 • Check for any equipment installed near the busway that might cause damage
 due to external heating.




2. Load Condition

 After the installation of a plug-in unit, an increase in power load is to be
 expected.
 Check to ensure that the total load on the busway does not exceed the
 rated capacity after a plug-in device has been added to the system. This is
 particularly important when the main line is branched by a Tee or cross-
 type fitting.


    WARNING

   After completing installation, recheck all joint bolts with a torque wrench
   for 800 kg-cm torque. A joint bolt without a red tag may still not be
   sufficiently tight. The bolt may have been loosened for adjustment or
   testing purposes during installation.
  Busway Installation Checklist

Project Name :                                      Identification :
1. Was there any shipping damage? Report any minor damage or missing
                                                                             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 support 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? (Refer to the installation instructions.)                 Yes/No

11. Did you check for proper clearances for the bus at floors, walls,
ceilings, other busway, and utilities? (Never use cement or concrete to      Yes/No
seal between the 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

				
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