InstallationMaintenance(EzWay-Rev1)

8/7/2019 InstallationMaintenance(EzWay-Rev1)

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Installation & Maintenance Manual



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.



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.



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.



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



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)



Housingendrampsprovidegroundcontinuityaswellassealingsurfacesonwaterresistiveratings.Donotdamagethesehousingendrampspriortoorduringinstallation.

Waterresistiveratingsmaybejeopardizediftheendrampsaredamaged.

CAUTION

EnsurethatthebusbarsandhousingendrampsengageproperlybetweenthejointstackandinsulatorplatesasshowninFigure.

WARNING



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



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



설 치

R S

T N

16

Plug in Box

Plug in Feeder

Plug In Box - Horizontal

Support



설 치

Tap off Box

17/

Plug in Box - Vertical



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.



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



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



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.



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 :

Documents

InstallationMaintenance(EzWay-Rev1)