WORK METHOD FOR BUS

DUCT INSTALLATION.

PROJECT BYTES

CONTRACTOR BYTES

SUB MARINE ELECTRICALS INDIA PVT LTD.

CONTRACTOR
.PREPARED BY.

PREPARED BY DESIGNATION SIGN

SUFIYAN KHEDEKAR SAFETY OFFICER

MR AKSHAY BORADE PROJECT ENGINEER

2.CHECKS AND APPROVAL

CHECKED BY DESIGNATION SIGN DATE

MR PROJECT MANAGER

MR HSE MANAGER

3.Team involved

UNLOADING INSTALLATION TESTING

SITE ENGINEER SITE ENGINEER SITE ENGINEER

01 01 02
SITE SUPERVISOR SITE SUPERVISOR SITE SUPERVISOR

01 01 01

SAFETY OFFICER SAFETY OFFICER SAFETY OFFICER

01 01 01

ELECTRICIAN ELECTRICIAN ELECTRICIAN

0 02 02

LABOUR LABOUR LABOUR

06 06 07

Kindly read the manual for Safe Installation and Energizing the MARINE ELECTRICAL INDIA PVT
LTD S.M.A.R.T Busduct System
 PREFACE
This manual describes the installation and inspection procedure of MARINE ELECTRICAL INDIA PVT LTD
S.M.A.R.T. busduct systems. Refer the manual carefully before setting the installation and the maintenance
of the busduct system. It is giving the proper instructions for proper handling, installation, operation and
maintenance, and also helps in minimizing personal injury, equipment damage during the handling of
the busduct system, and to facilitate the movement of the busduct sections.

Special care on the handling of the busduct is essential; as the product is for the usage of power
distribution which itself is very costly.

However it is recommended that the installation is performed only by qualified person, who is familiar with
the installation, testing / commissioning and operations of the busduct.

1 General 3
2 Unpacking 3
3 Handling 3
4 Storage 4
5 Operation 5
6 Protection Against Ingress Of Dust And Water 7
7 Summary 7
8 Joint Assembly 7
9 Horizontal Hanger Installation 10
10 Vertical Fixed Hanger Installation 11
11 Vertical Spring Hanger Installation 13
12 Inspection Of Joint Bolt 14
13 Fixing Tap-Off-Box 15
14 Energizing 16
15 Care And maintenance 16
16 Process Flow Chart for Installation 18
17 Appendix: -

1. Pre-Installation Checklist. 19

2. On Site IR Test Report Sheet. 20

3. Pre-Commissioning Checklist. 21

Formats can be photocopied, filled up and filed for future

reference
 SAFETY FIRST: - READ THESE SIMPLE GUIDELINES
FOR COMPLETE INFORMATION.

1. PURPOSE

To define the fixing & execution method statement for bus duct.

2. SYSTEM DESCRIPTION

The bus duct is intended to supply and distribute power from Transformer secondary to switchgear.

3. RELATED WORKS

All Civil Works related to the support structure in roof & floor need to be completed and
proper clear access for bringing in the bus duct should be available.

4. REFERENCE DRAWINGS

The drawings to be referred are:

a) General Arrangement Drawing of the Respective Location

b) Floor Opening Drawings of the RespectiveLocation

c) Manufacturer’s O&M Manual

d) Manufacturer’s drawings pertaining to handling of Equipment

e) Manufacturer’s drawings for the Switchgear Assembl

5. SAFETY

a) All personnel shall wear hardhat at all times when at site.

b) All personnel and operatives shall wear safety footwear at all times.

c) Work areas and access way are to be free from debris, materials and
all trippinghazard.

d) All hand tools and portable power tools shall be of good order And shall be
used for the purposeintended.
 e) All work on Energized Systems shall be done with a Permit to
WorkSystem.Proper Earthing / cordoning off to be done prior to Commencement
of work, if working in energized environment.

1. EQUIPMENTS / TOOLS TO BE USED

a) Air blower

b) Torque wrench

c) Meggar

d) Earth tester
e) Multimeter

2.PROCEDURE

 Examine the drawing of Bus duct erection layout withrespect To the general layout.
 Shift the Bus duct from stores to location by means ofsuitable Truck/lifting arrangement.
 Carryout physical verification or any possible damage.
 Check for necessary lifting tools &tackles in relation withload To be lifted and ensure safe lifting.
 Check for the level alignment of the foundation/ structure Before starting the erection.
 Assemble Bus duct at site and provide completesupporting Structures as required.
 Sections of bus duct installed out door shall be supportedfrom ground.
 Indoor sections shall be supported from ceiling and/or wall With GI/MS, brackets /hangers.
 Clean all Bus bar joints through with Carbon tetra chloride.
 Seal off wall bushings shall be provided where the
busduct Enters a building from its outdoor run as well as fromTransformer cell to switch-gear room.

SCAFFOLDINGS:

Scaffoldings will be inspected before use. Observations prior to allowing work on Scaffoldings.

a. All scaffoldings will be rigid and tubular cup-lock system.

b. Two jalleys shall be used as platforms-each width 300 mm.
c. Jalleys shall be secured with binding wire / coir rope.
d. All scaffoldings installed on firm base, straight vertical thoroughly inspected.
e. Half finished scaffolds shall not be allowed on site.
f. Mobile scaffoldings will have brake – systems for the wheels.
g. No one shall be allowed to work at elevated place (above 1.5 m.) Without wearing Helmet & Safety
belts with anchoring to rigid support.
h. Life line rope shall be provided at work area for horizontal movement of workers on scaffoldings.
Safety in-charge shall monitor lifeline rope when ever needed.
i. Scaffolding Tags ‘Safe / Unsafe’ to be displayed.
j. Scaffolding Erection & Dismantling will be done by trained , experienced & authorized persons.
k. Scaffolding materials shall be of standards & good conditioned.
l. Whenever the need for mobile scaffold arises a separate method statement,

HIRA will be provided as per site condition for approval along

1. GENERAL
1.1. Since construction sites are usually of poor conditions, proper planning and coordination between all
the Utilities, HVAC contractors, Plumbing contractors and Electrical contractors are important for a
good busduct installation.

1.2. The successful operation and performance of busduct is dependent upon proper handling,
installation, operation and maintenance, as well as upon proper design and manufacture. Neglecting
certain fundamental installation and maintenance requirements may lead to personal injury and
damage to electrical equipment or other property.

1.3. Installation, operation and maintenance of busduct should be conducted only by qualified personal.
1.4. For purpose of these guidelines, a qualified person is one who is familiar with the installation,
construction, and operation of the equipment and the hazards involved. In addition, the person
should be:

1.4.1 Trained and authorized to test, energize, clear, ground, tag and lockout circuits and equipment
in accordance with established safety practices.

1.4.2 Trained in proper care and use of personal protective equipment such as rubber gloves, hard
hat, safety glasses or face shields, and flash resistant clothing in accordance with established
safety practices

1.4.3 Trained in rendering the first aid.

WARNING: HAZARDOUS VOLTAGES IN ELECTRICAL EQUIPMENT CAN CAUSE SEVERE

PERSONAL INJURY. ENSURE POWER HAS BEEN TURNED OFF, DISCONNECTED AND
ELECTRICALLY ISOLATED SO THAT NO ACCIDENTAL CONTACT CAN BE MADE WITH
ENERGIZED PARTS. FOLLOW ALL MANUFACTURER’S WARNING AND

INSTRUCTIONS.

WARNING: OPERATION OF BUSWAY WHICH HAS BEEN WATER OR MOISTURE DAMAGED

CAN CAUSE PROPERTY DAMAGE, SEVRE PERSONAL INJURY. OBSERVE THE
PRECAUTIONS IN SECTION 6 AND 7 TO ASSURE ADEQUATE INSULATION
2. UNPACKING
2.1. Care must be taken while unpacking. Strip cutters should be used on all metal strips securing the
package.

2.2. Nail pullers should be used for unpacking wooden crates to avoid damage.
2.3. Remove any support blocks which may have been used for shipping.
2.4. DO NOT REMOVE THE PLASTIC WRAPPING ON THE BUSDUCT AT THE LOAD AND SUPPLY
ENDS TILL THE BUSDUCT IT TAKEN UP FOR INSTALLATION, AS DUST, MOISTURE AND
ANY OTHER CONTAMINATION CAN OCCUR WHICH MIGHT RESULT IN THE FAILURE OF THE
BUSDUCT AFTER INSTALLATION.

2.5. Check the material received as against the packing list of the package.

3. HANDLING
These guidelines are provided to help avoid personal injury, and equipment damage during handling and
to facilitate moving the busduct sections and fittings at the job site.

3.1. Handle busduct with care to avoid damage to internal components and the enclosure or its finish.

Avoid subjecting busduct to twisting, denting, and impact and in general, rough handling.
3.2. Do not use busduct ends for lifting busduct sections or fittings.
3.3. When the busduct is received, unpack it sufficiently to inspect it for concealed damage and to
determine that the shipment is complete and correct.
 3.4. If busduct is to be stored prior to installation, restore the packing for protection during that period
(see section 4.). When conditions permit, leave the packing intact until the section or fittings are at
their final installation location.

3.5. Verify that the weights of any busduct sections or fittings are within the rated capacity of the handling
equipment to be used.

3.6. A fork lift truck may offer a more convenient

method of handling busduct and has the added
advantage of permitting it to be hoisted between
levels. Balance the load carefully. Fig. 1

Fig. 1

3.7. Platform lifts or elevators, either manually or

power operated, can be used advantageously in
moving loads of busduct between elevations.

Fig. 2
Fig 2.

4. STORAGE
4.1. Busduct sections and fittings which are not to be installed and energized immediately should be
stored in a heated building having adequate air circulation and protection from dirt, fumes, water, and
physical damage.

4.2. It is recommended that busduct should not be stored outdoors. Protect busduct from dust and water
by covering with the waterproof sheet.(Fig. 3)
 Fig. 3

4.3. If it must be stored outdoors, cover it securely to provide protection from weather and dirt. Temporary
electrical heating should be installed beneath the cover to prevent condensation.

4.4. Outdoor busduct is not weather resistant until completely and properly installed and should
be treated exactly the same as indoor busduct until after it is installed.

4.5. Bus duct should always be placed on the floor horizontally and, wooden battens or forms are placed
underneath the busduct.(Fig. 3 & Fig. 4)
 Wrong Method of Storing of the Busducts.

DO NOT REMOVE THE PLASTIC

WRAPPPING UNTIL TAKEN FOR

ASSEMBLY

Correct Method of Storing of the Busducts.

Fig. 4

5. OPERATION

5.1. Provide sufficient horizontal and vertical clearance from walls and ceilings to provide easy access to
joints, both for the original installation and possible removal of a section when required.
 Copper Busduct Aluminum Busduct
Busduct Weight kg/m Width Busduct Weight kg/m Width
Rating Height 3P 3P 3P 3P Rating Height 3P 3P 3P 3P
mm mm
In 400
Amps 115 3W
21 4W
25 3W 4W In 400
Amps 125 3W
18 4W
22 3W 4W
630 125 22 27 630 125 19 24
800 125 24 30 800 140 24 28
1000 140 30 36 1000 165 28 34
1250 165 35 43 1250 205 34 39
1600 205 43 51 1600 250 42 46
2000 240 45 58 2000 305 48 54
2500 305 58 78 2500 405 50 59
3200 405 76 94 3200 475 63 74
3600 475 86 107 3600 495 64 75
4000 495 99 125 4000 605 72 85
4500 605 118 145 4500 710 76 89
5000 710 134 166 105 125 105 125
6300 740 141 177 5000 905 85 100
Table 1
5.2. Table 1 shows the approximate weight of busduct. However, the weight of special busduct (e.g.
flanged end, expansion joint and etc.) should be considered during transporting the units as it is
heavier than the weight calculated.

5.3. Avoid subjecting busduct not only to twisting, denting, and impact and, in general, rough handling.

Especially busduct ends are not to be hit against the structures or equipment and also not allowed to
stand busduct against the wall or other structures.

5.4. Suitable and certified hoisting wire should be used to hoist the busduct for easy installation and also
to avoid damage to the housing.

5.5. Ensure that proper distribution of the busduct weight is applied and careful approach is a must to
avoid any damage to the housing that could pinch the busduct insulation and result in a failure.

5.6. No direct fixing of hoisting wire to the joint cover hole on the housing for of the busduct, but instead,
use lifting jig for both horizontal and vertical busduct installation. (Fig. 5)

5.7. The joint hole should not be used for hoisting as it cannot withstand the weight of the busduct, which
result break on the wielding parts or any damages.
5.8. Do not drag the busduct across the floor.
5.9. When installing vertical riser, it is easier to lower the busduct from the floor above where it will be
installed. Vertical sections are often stored on the floor above their final location to facilitate lowering
them into position.

5.10. While hoisting any feeder ensure that the opposite side of the feeder being hoisted should be rested
on a support in order to prevent any damage to the joint.
5.11. Hang one busduct unit with two hangers in principle.
5.12. Depending on the site condition, preferably flanged end, flange end box, cable feed box shall be
installed first, followed by the sub-sequent unit numbers.(Fig 6)

5.13. While installing the busduct each unit of the busduct to be individually checked for IR value.
5.14. Also the IR to be checked during the various stages of installation.
 It is lowered after proper alignment
Using the lifting fixture the busduct is with the load and supply of the
Perfectly meshed busduct.
raised. corresponding busduct

Fig 5 Fig 6
6. PROTECTION AGAINST INGRESS OF DUST AND WATER
The ingress of dust and water into the busduct will decrease electrical and physical properties and
cause dielectric damage.

6.1. Some common sources of such contaminants are:

6.1.1. During construction – indoor busduct must be protected from moisture during and after
installation. Special attention should be given to riser busduct during construction to protect them
from moisture from uncompleted roofs, walls, etc. Outdoor busduct is not weather resistant,
until completely and properly installed and should be treated exactly the same as
indoor busduct until it is installed.

6.1.2. Floor level liquids – minimum curbs of four inches should be installed around all floor
openings for riser busduct to prevent floor level liquids (water / oil spills) from entering the
openings.

6.1.3. Leaking roof – protect indoor busduct with a temporary sheet metal shield or other
protective cover to prevent water from falling onto the busduct until the roof is repaired.

6.1.4. Pipes – protect indoor busduct with a temporary sheet metal shied or other protective cover
to prevent water from falling onto the busduct until the pipes are repaired. Where pipes
(especially cold water pipes) pass directly above indoor busduct, the busduct should be
protected from dripping condensate by insulating the pipe or permanently shielding the
busduct with sheet metal or plastic.

6.1.5. Sprinklers – protect indoor busduct from direct or indirect spray of sprinklers.

6.2. To prevent this, take precaution against the ingress of dust water during storage and installation.
6.2.1. Install busduct after the general construction works are completed.
6.2.2. Install busduct when possible leaking roof is sealed.
6.2.3. Install extra cover at the busduct end.

7. SUMMARY
7.1. Review erection drawing very carefully.
7.2. Check the bill of material.
7.3. Check description and identification of each piece before installation it.

7.4. Follow instruction on each piece for torque requirement.

7.5. Follow manufacturer’s joint assembly instruction drawing for both indoor and outdoor procedure.
7.6. Conduct an insulation resistance test on each section of busduct before it is installed.
7.7. Conduct an insulation resistance test on the portion of each run already installed on a daily basis.

7.8. Check for possible source of water that may fall on indoor busduct and take corrective action to
prevent this.
8. JOINT ASSEMBLY
The joint section is heart of the busduct during its operation, so proper tightening of
the joint bolt is important to ensure its continuous and satisfactory operation.
8.1. Ensure all contact surfaces are clean and free of contaminants by using dry cloth.

8.2. Align the bus duct ends of adjoining sections, verifying proper phase alignment,

a
n

d
s Fig. 7 (b) Inserting Rod
Fig. 7 (c)
l Fig. 7 (a)
 and slide the sections together as illustrated in Fig. 7. It is done by inserting jointing tool inside the
joining holes.

8.3. For easier connection of “supply” and “load” and less impact on the download of the busduct weight, certain
interval has to be kept. Use joint cover by screwing bolt on the lower part of the joint cover then follow by the
upper part of the joint cover this would enable easy jointing and accurate jointing interval. (Fig. 8.1, 8.2)

Fig. 8.1
Fig. 8.2
8.4. Assembly

8.4.1. Ensure load and supply sides are aligned correctly by placing inserting tool.

8.4.2. Joint the two sections until the joint edge to edge distance is 300mm or to have adequate contact
surfaces of each phase to phase.

8.4.3. Insert joint bolt with the joint support through the joint hole and tighten it with plate spring and MF nut
with the tool.

8.4.4. For IP 65 and IP67, install side cover with gasket and then fix with bolts (M8x16) on both sides.

8.4.5. Install the joint cover with gasket on the top and bottom of the jointing section.

8.4.6. After side cover and joint cover are fixed, apply sealant around the covers to ensure its protection
against water and dust.

8.5. Ensure that all busduct installation is in straight alignment, either in horizontally or vertically in order to have
proper jointing system. Then only tighten the Maintenance Free nut to the required torque

9. HORIZONTAL HANGER INSTALLATION

9.1. Fix Horizontal hanger to the hanger rod M12 fully threaded rod, and adjust it for correct elevation of the busduct
as per site condition.

9.2. Lay the busduct on the horizontal hanger.

9.3. Ensure the busduct is aligned in straight line.

9.4. Install the hanger clamp on both side of the busduct for fixture.

9.5. Additional horizontal hangers shall be placed on elbows, such as vertical / horizontal elbow, offset elbow,
combination elbow and etc.

9.6. Supporting interval of horizontal hanger shall not exceed 1.5 meters for straight length. However each elbows /

bends must be supported separately

 Anchor Fastener

Nut

Threaded Screw Rod

Holding

Clamps

Horizontal Support

Fig. 12
 Dimensions for Horizontal Hanger (Fig. 12)

Width “A” Aluminum

Copper Conductor Conductor
Height “W” Ampere Rating Height “W”
3P 3W 3P 4W
Ampere
400Rating 115 400 125
630 125 630 125
800 125 800 140
1000 140 1000 165
1250 165 1250 205
1600 205 1600 250
2000 240
2500 305 2000 305
3200 405 2500 405
3600 475 3200 475
4000 495 3600 495
4500 605 4000 605
5000 710 105 125 4500 710
6300 740 5000 905

Note: ‐ Horizontal Support Hangers should not be over a Joint Section.

Support Hanger Load

Screw Threading
Ampere Rating Steel Angle Size (mm) on Rod in mm Weight (kg/m)

400 – 1250A 40 x 40 x 5 (Thick) M 12 3.00

1600 – 2500A 50 x 50 x 5 (Thick) M 12 3.80

2500 – 6300A 65 x 65 x 5 (Thick) M 12 4.90

10. VERTICAL FIX HANGER INSTALLATION
Vertical Fix hanger shall be installed to fix the first feeder unit, on the first floor, for firm hold of the busduct.

10.1. Temporarily support the busduct section in place. Fit the C-Channel (customer’s scope) onto the Floor Flange.

Fix on the bolts (customers scope) onto the slab in order to hold the C-Channel firmly to the slab.

10.2. Drill the C-Chanel with opening hole of 14mm dia. To accommodate the fixed support rod. Locate the hole in
line with the centerline of the side of the busduct housing. The distance in between these two holes from center
is 65mm. Then, drill the busduct housing with opening hole of 12mm dia. With the height around 85mm from the
 top of the C-Channel for installing the L-Channel Bracket by using M10 bolts supplied. The distance in between
these two holes from center to center is 60mm.

10.3. Fix the rod to the top of the C-Channel together with the nuts as show. Try to adjust the Top Nut on both sides
until the height from the top of the C-Channel to the base of the “L” Channel is around 50mm and it is aligned
with the opening hole of 12mm dia. On the busduct housing.

10.4. Then fix the “L” Channel together with the nuts as shown (Fig. 13).

10.5. The process of fixing the Vertical fixed hanger is completed.

Vertical Fixed Hanger

Vertical Fixed Hanger (400A – 1000A)

Vertical Fixed Hanger (1250A – 3200A)

Vertical Hanger (3600A – 6300A)
11. VERTICAL SPRING HANGER INSTALLATION
For Vertical Spring Hanger, they are used on subsequent floors to absorb any expansion occurrence from
busduct. Moreover, immediately support shall be provided if the floor-to floor distance exceeds 4 meters.

The following instructions are for fitting of vertical fixed Hanger for Busduct systems.

11.1. Temporarily support the busduct section in place. Fit the C-

Channel (customer’s scope) onto the Floor Flange. Fix on the
bolts (customer’s scope) onto the slab in order to hold the C-
Channel firmly to the slab.

11.2. Drill the C-Chanel with opening hole of 14mm dia. To

accommodate the fixed support rod. Locate the hole in line
with the centerline of the side of the busduct housing. The
distance between these two holes from center is 65mm.

Then, drill the busduct housing with opening hole of 12mm dia.
with the height around 190mm from the top of the C-Channel
for installing the L-Channel Bracket by using M10 bolts
Fig. 15
supplied. The distance in between these two holes from center
to center is 60mm.

11.3. Fix the rod to the top of the C – Channel together with the
nuts.

11.4. Try to adjust the top nut on both sides until the height from the
top of the C – Channel to the base of the L – Channel is
around 155mm, while the height from the bottom of L –
channel to the bracket of the vertical spring hanger is 100mm.
Then, fix the L – Channel together with the nuts as shown in
Fig. 15.

11.5. Unscrew the top nut, 15mm above the top of the L – channel.

The process of installing the vertical spring hanger is

completed.
Vertical Spring Hangers

Vertical Spring Hanger (400A – 1000A)

Vertical Spring Hanger (1250A – 3200A)

Vertical Spring Hanger (3600A – 6300A)

12. INSPECTION OF JOINT BOLT

MARINE ELECTRICAL INDIA PVT LTD S.M.A.R.T. Busduct System use MF (Maintenance Free) nut at the
jointing section which ensures the proper tightening of the bolt.

12.1. Tighten the MF nut using either a ratchet wrench or, a torque wrench (set to 1400kg-cm / 14kg-m).

12.2. Ensure the tightness of the MF nut until the neck of the MF nut is broken. If the MF nut is not tightened properly,
an over-heating of the busduct may occur.

12.3. The torque values of tightening of the nuts are as shown below. Table 2
 NUT SIZE M8 M10 M14
TORQUE VALUE (kg – cm) 90 – 110 180 – 230 1400 – 1500
TORQUE VALUE (kg – m) 0.9 – 1.10 1.80 – 2.30 14 –
159

Table 2
13. FIXING TAP-OFF-BOX

13.1. This work shall only be carried out by competent and

suitably qualified persons.

13.2. Ensure that one end of the cable is terminated to the

plug-in box isolator and the other end is terminated and
isolated in the equipment to be connected.

13.3. Remove the plug-in hole cover.

13.4. Do not remove the plug-in hole insulation plate as

removal could expose live busbars.

13.5. The orientation of the plug-in hole base plate can be

verified by visual inspection.

13.6. Ensure that the Tap-Off-Box isolator is switched off.

13.7. Align the Tap-Off-Box connection stabs with the plug-in

hole plate and push in fully.

13.8. Secure the Tap-Off-Box in position with the four fixing

clamps located on the back of the box. Note that
incoming side of the isolator may be live and care should
be taken not to displace any internal screens or shrouds.

13.9. When the box is secured in place, verify the phasing of

the plug-in box before energizing equipment.
14. ENERGIZING
Before Energizing

14.1. Recheck all joint connections for tightness by following on the recommended torque value given as section

13.3. Table 2. Ensure that outer head of MF nut is broken. If not, then retighten the nut until it is broken, before installing side cover.

14.2. Ensure that upper nuts are of the spring hangers are unscrewed 15mm above the upper part of spring hanger.

14.3. Isolate the busduct run by disconnecting all connections to transformers, switchboards, meters and so forth.

14.4. Conduct an insulation resistance test on the whole busduct connection after installation. The insulation resistance value cannot be specified due to the length of the route and the environmental
factors. In a dried atmosphere, it would give a value of approximately 100 MΩ, it has to be checked due to some factors that can reduce the insulation and the other factors can be as follows;

14.4.1. Whether the busduct is damaged.

14.4.2. Whether the connecting parts are fixed precisely.

14.4.3. Whether the bolts for connecting the equipment are securely fastened.

14.4.4. Whether the hangers are supporting the busduct securely.

14.4.5. Whether the vertical spring hanger is properly.

14.4.6. Busduct kept idle without charging for a very long period of time in humid atmosphere / conditions.

After energizing

When the equipment is energized for the first time, competent and qualified electrical personal should be present. If short circuits and ground faults caused by damage or poor installation
practices have not been detected in the check-out procedure, serious damage can result when the power is turned on.

14.5. There should be no electrical load on the busduct when it is energized. Since busduct typically extends through several rooms and floor levels, care should be taken to see that all devices fed
from the busduct are in the “OFF” position.

14.6. The equipment should be energized in sequence by starting at the source end of the system and working towards the load end. In other words, energize the main devices, then the feeder
devices and then the branch- circuit devices. Turn the devices to the “ON” position with a firm positive motion.
14.7. After all over-current devices have been turned on, loads such as lighting circuits, contractors, heaters, and motors may be turned “ON”.

14.8. Busduct, when operating properly, will have a moderate hum. Excessive noise may be an indication of hardware that has not been tightened or of metal parts that have been improperly
assembled.

14.9. Occurrence of sparking at any point along the busduct is not a normal condition. The busduct must be de- energized immediately, and remain de-energized until the sparking condition has
been corrected.

15. CARE AND MAINTENANCE

15.1. OUTDOOR BUSDUCT

15.1.1. Inspect busduct once each year or after any severe electrical short circuit or ground fault.

15.1.2. Perform an infra-red temperature scan on all electrical connections and busduct enclosure while busduct is energized and operating under maximum load conditions. A permanent
record should be kept. If readings change with time, deterioration may be taking place and must be corrected.

15.1.3. Turn off power to the busduct.

15.1.4. If there is appreciable accumulation of dust and dirt, clean it off by using a brush, vacuum cleaner, or clean lint-free rags. In order to avoid blowing dust into busduct joint, circuit
breakers, or other equipment, do not use a blower or compressed air. Ensure that all drain holes are operating properly.

15.1.5. Check the insulation resistance prior to re-energizing the busduct. A permanent record should be kept of resistance readings. If readings decrease appreciably with time, deterioration
is taking place and must be corrected (contact the manufacturer).
Busway Installation
Schneider Electric, Mumbai

1
Agenda

1. Material receiving and storage

2. Preparation before installation

3. Installation - Horizontal application

4. Installation - Vertical application

5. Installation - Tap off unit
Material receiving and storage

3
• Check the packing list against the equipment received to ensure the order and
shipment are complete with local Schneider engineer.

• Check for any damage that may have occurred in transit. If any problem be found,
notify local Schneider office immediately.
4
• Match No. of crates in the packing list with shipping mark .
5
• Self-protection with well packing (plastic wrap)

• Storage in a dry and clean environment

• Apply “rain coat” to protect unfinished run after installation each time
Self-protection Storage Environment Rain Coat

6
• Water/ dust will provide alternative path / heating point

• Damage insulation

• Latent hazard of short circuit

7

8
Preparation before installation

9
• Open crates

• Packing List & Bom List & Brass should be corresponding.

Packing list

Brass drawing
Run No.

10
Bom list from Brass
• Assembly tools and accessories

• Bolts and assembly tool are supplied along with busway.

Bolts for IP plate

Remarks: read carefully Busway Instruction Bulletin before installation. AT2

11
• Insulation test

• Conduct an insulation test at 1000V on each device before installation. The megohm
reading should not be less than 10MΩ.
12
Installation- Horizontal application

13
 Hanger

Elbow

Straight length
Flange end

L
14
Hanger
15
• Fix hanger according to specific base point. For horizontal application, the maximum distance
between two supporting poles is 3 meters for indoor, and 1.5 meters for outdoor.
16
• Two kinds of hanger for horizontal installation.

Drop rod
 Horizontal flatwise hanger Horizontal edgewise hanger

Remark :drop rod should be provided by customer. Flatwise hanger requires 2 pcs rods while edgewise is 1 pcs.
Test alignment when installing.
17
Straight length
18
• Remove tie channel from busway before installation.

Tie channel
19
• Orient the busways straight lengths with “TOP” sides facing the same way.

• Raise the busways to the desired height.

• Be sure the busways are aligned properly before attempting to join them.
1. 20
• Hook the joint assembly tool in the surge clamp, insert the rod through the hole and wedge it

on the opposite busway.

• Avoid the wrong connection between earth bar and phase bar.


Attention

21
• Pull to slide the busways together until distance between two holes is 340mm.
22
• Place the top cover plate on the top side of the joint.

• Tighten joint bolts until outer head breaks off, mount the bottom cover using the same
procedure used to install the top cover.
Remarks: CFD has no top & bottom plate. 23
• Tighten the rubber plug in the center hole of the bottom cover plate.

• Install tie channel, eight protruding pins are all need to be tighten.

• Make insulation test after finishing installation

Attention

24
Elbow
25
• Remove the protective paper from the sealants which appear on the duct sides on fitting only.

Protective paper
Attention

26
 Attention

Washer 27
Flange end
28
• Same connection way as elbow Installation at joint pak.

• Distance between flange end and conductors of terminal is normally 500mm.

Flange end box
29
• Except top entry, side entry is allowed when top room is not enough.

Top entry Side entry

31
Installation- Vertical application

32
Straight length
Spring hanger

Channel

33
• Make sure horizontal alignment.
 Channel

Remark :keep hole position same to keep vertical alignment.

34
• Built concrete curd around channel to prevent water ingress.
35
Spring hanger

36
• Pre-adjust the length of spring

• Install spring hanger on horizontal channel

Compress length
of spring hanger
 Remark: for vertical application, it requires two nos/pairs of spring hanger if spacing is more than 4.8 meters. 37

.
• Tighten the top nuts to the proper spring compression dimension.
For example:CFD2516GM54

1) Busway width 2) Spacing between floors

3) Spring hanger type 4) Compressed dimension 38

• Lift the busways to final installation location

• Fasten the hanger clamps to the busway duct sides and tighten the nuts.

Hanger clamps
39
• Note
• At design stage, distance between bottom of spring hanger and center of connection is at least
530mm.
40
• Spring hanger installation

• Back off the top nuts to the top of the rod after complete run is installed.
Attention 
41


• Spring hanger installation
 42


Straight length
43
• Check vertical alignment

• Conduct insulation test for busway before installation.

IF NOT
Attention

44
• Raise the busway to the final installation location to connect the existing busway, same procedure
as horizontal application.
1 2 3 4 5
45
• Keep N phase face left all the time.
 Attention

46
N L3 L2 L1
Installation- Tap off unit

47
5. Installation - Tap off unit

• Normally, PIU can be installed in a Plug–in type installation way.

• For above 630A (includes 630A), installation way is Bolt-on type. Especially for horizontal and
vertical, they have different mounting.
Plug-in type Bolt-on type

48
 ©2014 Schneider Electric. All Rights Reserved.

All trademarks are owned by Schneider Electric Industries SAS or its affiliated companies or their respective
owners.

15.2. INDOOR BUSDUCT

15.2.1. Inspect busduct once each year or after any severe electrical short circuit or ground fault.
 15.2.2. Perform an infra-red temperature scan on all electrical connections and busduct enclosure while
busduct is energized and operating under maximum load conditions. A permanent record should be
kept. If readings change with time, deterioration that may be taking place and must be corrected.

15.2.3. Turn off power to busduct.

15.2.4. Look for any moisture or signs of previous wetness or dripping onto the busduct or onto connection
boxes from leaky roofs, pipes, sprinklers or other sources moisture. Look for any recent changes in
sprinklers or other plumbing that might now be a source of trouble to busduct.

15.2.5. Seal off any cracks or openings which have allowed moisture to enter the busduct or its connection
boxes. Eliminate source of any dripping onto the busduct and any other sources of moisture see
SECTION 6 or more details on preventing liquid from getting onto the busduct.

15.2.6. Replace or thoroughly dry and clean any insulating material which is damp or wet or shows
accumulation of deposited material from previous wettings.

15.2.7. If there is appreciable accumulation of dust, clean it off by using a brush, vacuum cleaner, or clean
lint-free rags. In order to avoid blowing dust in the busduct joints, circuit breakers, or other equipment,
do not use a blower or compressed air.

15.2.8. Carefully inspect all visible electrical joints and terminals.

15.2.9. Visually check connections to be certain that they are clean and secure. Loose and/or contaminated
connections increase electrical resistance which can cause overheating. Such overheating is indicated
by discoloration or flaking of insulation and/or metal parts. Pitting or melting of connecting surfaces is
a sign of arcing due to a loose or otherwise poor connection. Parts which shows evidence of
overheating or looseness should be cleaned or replaced if damaged, contact manufacturer before
opening joint bolts.

15.2.10. Check the insulation resistance prior to re-energizing the busduct. A permanent record should be kept
of resistance readings. If readings decrease appreciably with time, deterioration is taking place and

must be corrected also, refer to section 14.4

Verification of Insulation Resistance (Refer IEC 60439 – 1:1999, page # 72)

For PTTA (Partially Type Tested Assemblies) which have not been subjected to a dielectric test according to

8.2.2 or 8.3.2 (clause numbers 8.2.2 page # 61 or 8.3.2 page# 71 of IEC 60439 – 1), an insulation measurement
using an insulation measuring device at a voltage of at least 500V shall be carried out.

In this case, the test is deemed satisfactory if the insulation resistance between circuits and exposed
conductive parts is at least 1000ષ/V per circuit referred to the nominal voltage to earth of these circuits.
By exception, items which, according to their specific requirements, are current‐consuming apparatus (e.g.
windings, measuring instruments) at the application of the test voltage or are not designed for the full test
voltage shall be disconnected as appropriate.
16. Process Flow Chart for Installation.

Study the Busduct Layout drawing.

Proceed with the marking and the drilling

of the supports as per drawing.

Fix the Horizontal / Vertical

supports as per drawing.

Starting from one end of the equipment or panel and, start

connecting from the flanged end in Sequential order.

Check for Vertical Plumb / Horizontal Level

of the busduct during installation.

Check IR value of the connected busducts before the start and at the end of the shift during the installation process

on a daily basis. Also cover the end portion of the busduct to prevent any water or dust seepage or contamination.

Shear the Maintenance Free Nuts at 14kg‐m

torque with a torque wrench.

 Carry out the final Inspection as per

the checklist in this manual.

Do the IR Test of the

whole installed system.

Not OK

OK

Energize the Busduct System

17. Appendix

Pre Installation Checklist

Sr. No. Location / Status

Inspection Check Line No.

1 Check Electrical Shaft size as per drawing. Ok Not Ok N. A.

2 Wet riser and sprinkler should not be in the same shaft. Ok Not Ok N. A.
Electrical Shaft Clearance for no Water seepage. Proper
plastering / white wash / tiling to avoid any seepage of
3 Paint / Cement on the busduct. Ok Not Ok N. A.

Installed supports are as per approved drawing and the

4 supports are not at jointing section. Ok Not Ok N. A.
Check whether all electrical equipment like transformer
5 Ok Not Ok N. A.
/DG /Panels are positioned and as per approved drawing.
Check the Detailed packing list with part number(s)
received, along with consignment and verify, the same
with approved drawing whether all the bus duct sections
are received. And all busduct, and its accessories are
6 received as per approved drawing and there is no Ok Not Ok N. A.
shortfall on accessories and hardware.
If any shortfall of accessories or hardware are reported
the same is inform to manufacturer/supplier on the same
7 day. Ok Not Ok N. A.

Busduct consignment to be stored in dry place and

covered with proper plastic. (Do not remove the plastic
wrapped on the load / supply ends of the busduct till
8 taken for installation) Ok Not Ok N. A.
Check whether all required tools and tackles mentioned in
the installation manual are available before starting the
9 installation. Ok Not Ok N. A.

IR value check for every bus duct feeder before

10 Ok Not Ok N. A.
Installation
Client's Competent Personnel should take training on the
method of installation of the bus duct / Rising main /
11 Lighting Trunking from MARINE ELECTRICAL INDIA PVT Ok Not Ok N. A.
LTD before start of installation.
Outdoor busduct is not weather resistant, until
completely and properly installed. Should be treated
exactly the same as indoor busduct, until it is
12 installed. Ok Not Ok N. A.

Note: - To put the Check mark for compliance.

Checked at site by:-

Name Signature Date

Verified by Client’s site engineer:-

Name Signature Date

PROJECT NAME:‐ Date:‐

Insulation Resistance Test (In Mega – Ohms)

Test Equipment Used:‐ Insulation Resistance Tester (Meggar)

Make:‐ Range:‐ Serial Number:‐

Calibrated:‐ Yes / No Current Rating:‐

Reference Between Before shearing After shearing Remarks

1 R Phase ‐ Neutral

2 Y Phase ‐ Neutral

3 B Phase ‐ Neutral

4 R Phase ‐ Earth

5 Y Phase ‐ Earth

6 B Phase ‐ Earth

7 Neutral ‐ Earth

8 R Phase ‐ Y Phase

9 R Phase ‐ B Phase

10 B Phase ‐ Y Phase
For Client For Commissioning
 Instruction / Check list for Pre-Commissioning of the Busduct System

Sr.
Description Status
No.
Client's Competent Personnel should take training on the method of installation of the bus
1 duct / Rising main / lighting Trunking from MARINE ELECTRICAL INDIA PVT LTD before start Ok Not Ok N. A.
of
All installation.
the busduct lines are aligned in plumb in case of riser & at zero level in case of horizontal
2 run of busduct. Ok Not Ok N. A.
Check whether all the joint bolts are sheared @14-15 kg-m. and tightening of joint bolt is
3 Ok Not Ok N. A.
100% responsibility of installation contractor / Clients.
Take insulation resistance at 500V. Check the IR before and after Shearing of joint Bolts. As
per IEC 60439-1, clause 8.3.4 insulation resistance should be at least 1000 ષ/V i.e. 0.5 M ષ.
4 (To maintain stringent quality standards MARINE ELECTRICAL INDIA PVT LTD Ok Not Ok N. A.
recommends
Check whether1M allષthe
) spring Hangers top Nuts are loosen and spring should be loaded in
5 Ok Not Ok N. A.
case of Riser as per installation manual.
Check whether earthing run along with Bus duct is physically connected to both the ends of
6 the busduct flanged & equipment. Ok Not Ok N. A.

7 Check whether all the bolts at Flanged end are tightened. Ok Not Ok N. A.
Check tightening of all the bolts of flexible links to equipment side like Panel ,Transformer,
8 DG Ok Not Ok N. A.
Check whether all the supports to the risers and bus duct line are installed properly to carry
9 the required weight of Busduct Ok Not Ok N. A.

10 Check whether all the holding clips on the horizontal supports are tighten Ok Not Ok N. A.

11 Check whether all the holding clips on Tap off box are tighten Ok Not Ok N. A.

12 Relay Setting of all the MCCB / ACB. Ok Not Ok N. A.

13 Check for chance of water seepage on Busduct / Rising Main from other utilities Ok Not Ok N. A.

14 Wet Riser & Sprinkler should not be in same shaft. Ok Not Ok N. A.

Check whether the entire name plates on Tap Off Box & panels indicating outgoing location
15 of supply. Ok Not Ok N. A.
Check whether caution / danger stickers displayed on all the Tap Off Boxes and Electrical
16 Ok Not Ok N. A.
Panels.

17 Check whether earthing wire is connected to Tap Off Box door & bus duct housing. Ok Not Ok N. A.

Check Phase sequence of Rising Main (R, Y, B, and N) in line with Tap off box incoming and
18 outgoing. Ok Not Ok N. A.

Check Whether Outdoor Installation Bus duct is properly filled up with sealant/compound at
19 the joints in case of IP/65/68 Ok Not Ok N. A.

Bus Duct / Rising Mains should not be energized without checking of all above instructions
20 and installation Contractor / Client to ensure all above points Ok Not Ok N. A.

Note: - To put the Check mark for compliance.

Checked at site by:-

Name Signature Date

Verified by Client’s site engineer:-

Name Signature Date

NOTES:
Website: - www.MARINE ELECTRICAL INDIA PVT
LTD.com