5600CT9101

I-Line Installation, Special Features, and Services

Installation Recommendations

To make the busway installation proceed as quickly and efficiently as possible, a few preliminary steps should be taken.

  1. Familiarize yourself with the busway routing. If record drawings were supplied by the factory, have a copy accessible to the installers.

  2. Inspect busway for damage when received. Store busway in a clean, dry location.

  3. Have the following tools available for the busway installation:

    • 1/2-in. (13 mm) nut driver or socket and rachet

    • Torque wrench or breaker bar with 5/8-inch (16 mm) head

    • 3/4-in. (19 mm) socket for torque wrench or breaker bar

    • Busway assembly tool (AT-2) for 800–5000 A (provided by Schneider Electric)

    • Level

    • 6 ft. tape measure or wooden ruler

    • Busway insulation tester (“megger,” 1000 V recommended)

  4. Carefully read the installation instructions for all devices and NEMA Publication BU 1.1 provided with the busway before installing any of the equipment. This will help ensure proper installation and operation procedures are followed for the busway system being installed. Note the instructions call for the busway to be “megger” tested before and after installation.

  5. Install busway hangers and supports. The most common method of supporting the busway hangers is threaded drop rods (or all thread), which the installer must supply.

  6. Anticipate the weight of the objects being installed so the necessary lifting devices and manpower are available.

  7. If any problems are encountered or questions arise, contact your local Schneider Electric representative.

  8. Once the installation of the busway is complete, NEMA Publication BU 1.1 should be delivered to the facility owner for his or her use in operating and maintaining the busway system.

Painting Installed Busway Systems

A busway system that includes plug-in units can be painted after installation. However, all precautions must be taken to prevent the paint from coming in contact with conductors and insulation. All nameplates and labels (safety labels, serial number labels, UL labels, etc.) must remain visible and legible.

Hanger Spacing

Normally, the support for outdoor busway is in the form of a customer-supplied
T-stand type device. However, hangers are available from Schneider Electric when drop rods can be used.

Maximum support intervals include:

  • Vertical mounting

    • indoor–16 ft (488 cm)

    • outdoor–10 ft (305 cm)

  • Horizontal mounting

    • indoor–10 ft (305 cm)

    • outdoor–5 ft (152 cm)

Maintenance Recommendations

General Danger Safety Label

DANGER
hazard of electric shock, explosion, or arc flash
  • Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E, NOM-029-STPS-2011, and CSA Z462.
  • This equipment must be installed and serviced only by qualified personnel.
  • Perform such work only after reading and understanding all of the instructions contained in this bulletin.
  • Turn off all power supplying this equipment before working on or inside equipment.
  • Before performing visual inspections, tests, or maintenance on this equipment, disconnect all sources of electric power. Assume all circuits are live until they are completely de-energized, tested, and tagged. Pay particular attention to the design of the power system. Consider all sources of power, including the possibility of backfeeding.
  • Always use a properly rated voltage sensing device to confirm power is off.
  • Handle this equipment carefully and install, operate, and maintain it correctly in order for it to function properly. Neglecting fundamental installation and maintenance requirements may lead to personal injury, as well as damage to equipment or other property.
  • Disconnect the neutral connection at any Surge Protective Device (SPD) or other electronic device prior to performing electrical insulation resistance tests; reconnect to the device after testing.
  • Carefully inspect your work area and remove any tools and objects left inside the equipment.
  • Replace all devices, doors, and covers before turning on power to this equipment.
  • All instructions in this bulletin assume that the customer has taken these measures before performing maintenance or testing.
Failure to follow these instructions will result in death or serious injury.

NEMA Publication BU 1.1 is provided with each busway project as a guide for proper installation, operation, and maintenance of busway products. This publication addresses such areas as inspection of all electrical joints and terminals for tightness, preventing the entry of water and contaminants into the busway, instructions for what to do if water and contaminants do enter the busway, and other maintenance topics. This publication is also available upon request by contacting your local Schneider Electric representative.

Other publications Schneider Electric recommends to help ensure the highest quality of product performance are as follows:

  • NFPA 70–National Electrical Code (U.S.)

  • NFPA 70B–Maintenance of Electrical Equipment

  • NEMA BU 1–Busway Standard published by the National Electrical Manufacturers Association

CSA C22.1–Canadian Electrical Code, Part 1

Special Busway Construction

This section outlines requirements for busways with features other than our standard.

Special Paint

I-Line busway can be provided in colors other than ANSI 49 gray for an additional fee. The special color requested should be specified by an ANSI color code at the time of order entry. With typically lengthened lead times for special color parts, it is imperative to provide this information as early as possible in the order process so delivery commitments can be met.

Low Current Density Busway

Some customers require a lower current density busway than our standard for rigorous duty in their installation. Schneider Electric has developed a range of busway for the most commonly requested current density of 1000 A per square inch for copper busway and 750 A per square inch for aluminum busway. If you require this current density for your installation, specify it, and we can meet your need. If you have requests for another specific current density, contact your local Schneider Electric representative.

Riser Plug-In Busway

Schneider Electric also offers an I-Line II plug-in busway specifically designed for installation in riser closets of high-rise buildings. This plug-in busway has a plug-in door on the front side that faces out into the room. The back of the busway, which faces the wall, is blanked off with a feeder bus side rail.

This design provides a plug-in busway ideally suited for riser cabinets and gives the customer only the necessary plug-in openings. The catalog number for this device is the same as our plug-in busway, except an R is substituted for the P. (Example: if the standard plug-in busway prefix is AP2512G, the riser busway prefix is AR2512G.)

Splash Resistant Busway

Some indoor busway is subject to occasional water exposure, such as roof leaks or sprinklers. While this application does not require the full protection of outdoor busway, additional protection is needed for the indoor busway. The splash resistant feature is tested to the International IEC 60529 standard and is rated as IP54. This rating specifies protection from dust (“limited ingress permitted with no harmful deposits”) and water (“splashed from all directions with limited ingress permitted”).

This feature is available as an option with indoor plug-in and feeder busway. It is identified by the addition of “M54” at the end of the standard catalog number.

Harmonic Busway

To properly allow for the impact of total harmonic distortion (THD), a busway solution must address both the current capacity of the neutral and the ability to dissipate the heat generated with the maximum anticipated load. The increased neutral currents will result in additional heating of all phase conductor bars, therefore de-rating of the busway is necessary.

With the Schneider Electric harmonic busway solutions, the neutral is sized to carry the full current of the expected harmonic load, while the increased cross section of the phase conductors dissipates the added heat generated within the busway.

There are two harmonic busway offers available:

  • 15%<THD<35% rating (letter X in the catalog number)

  • THD>35% rating (letter Y in the catalog number)

For example, if the standard busway prefix is AP2512G, the THD>35% harmonic busway prefix is APY2512G.

Seismically Qualified Busway

I-Line busway has been seismically qualified to meet the seismic provisions of
the International Building Code (IBC), California Building Code (CBC), and
ASCE/SEI 7 based on triaxial shake table testing following the code recognized test protocol ICC ES AC156. All qualification shake table testing was conducted by an independent test facility to verify compliance to an Ip = 1.5 by verifying post test equipment functionality as required by ASCE 7 for equipment that is part of a seismic designated system.

The shake table earthquake simulation subjected the busway test specimens to dynamic demands that can be more severe than the earthquake codes for most locations. A certificate of self certification is available on request from your local sales office and is based on site-specific, code-defined, seismic demand requirements for the installed location information supplied to Schneider Electric.

The qualified busway equipment must be installed, anchored, and restrained in accordance with Schneider Electric installation guidelines. For the purpose of seismic restraint design, the center of gravity is centrally located for all outside linear dimensions for each section or device (as listed along with their respective weights). Anchorage of equipment to the primary building structure is required to validate seismic certification of the equipment. The structural engineer or design engineer of record is responsible for design of the code compliant seismic restraint system for the building equipment. Schneider Electric is not responsible for the specification and performance of seismic restraint and anchorage systems.

Services

Schneider Electric offers a wide range of services to make the use of I-Line busway as simple as possible. A summary of these services follows:

Busway Measuring and Layout Service

Schneider Electric can provide full-site measuring and coordination of a busway installation. This service is ideal for large complicated projects requiring close coordination with other services. This service must be requested at the time of specification and order entry. Refer requests for this service to your local Schneider Electric representative.

Emergency Service

Trained and qualified busway personnel are on call 24 hours a day to assist in your emergency busway needs. Call Schneider Electric at 1-888-778-2733.

“Missing Link” Program

The “Missing Link” program is designed specifically to help a customer correct last minute changes to a project using busway. Those changes could include an unplanned obstruction requiring the busway to be rerouted, incorrect measurement of the busway run, or the need to order additional pieces to supplement busway previously ordered. The program applies to the United States, Canada, and Mexico, and guarantees shipment of factory-built busway in five to seven working days, or Schneider Electric pays for the premium freight. For complete details of the program, contact Schneider Electric at 1-888-778-2733.

How To Properly Measure Your Missing Link Dimensions

All missing link dimensions should be measured to the nearest whole inch from centerline of joint to centerline of joint, or centerline of joint to centerline of busway.

As shown in Missing Link Dimensions, diagram “A–Straight Lengths,” the centerline of the joint is located at the joint bolt on the end with a joint pack installed. If the joint pack is not installed, the centerline of the joint is one inch
(25 mm) from the end of the bus bars.

If it is necessary to measure an elbow, the dimensions X and Y (shown in Missing Link Dimensions, diagram “B–Elbows”) are all that’s needed. Be sure to measure from centerline of joint (as described above) to centerline of busway housing. You must also specify whether an edgewise or flatwise elbow is required. Flatwise Elbows–Application Data lists the standard minimum elbow dimensions for each amperage.

Missing Link Dimensions

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