The document provides installation and maintenance instructions for busway. It defines qualified personnel and labels used in the manual. It describes preparing for installation, including inspecting components, checking the route, and determining installation order. The document explains joint assembly, supporting horizontal and vertical runs, and performing maintenance checks.

1. Installation & Maintenance Manual

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

3. 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.
XX
Preparing forInstallation
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.
OK

4. 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.
Phase sequence
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”.
C
A
B
G
3Phase, 4Wire
+Housing Ground,
+50%, 100% Ground bus
N
WARNING
Lifting busway without the use of proper lifting devices may result in
busway damage, serious injury or death.
WARNING
WARNING: The embossed arrows on the joint covers must point in the
same direction as the arrows on the joint supports.

5. 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
3-W AND
4W
4-W AND
4W
P1
P2
P3
110
150
190
135
175
215
130
180
230

6. Jointing Method
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.
Housing mold Double head Joint Bolt
Bus bar
Bus bar
Integral housing Ground
Integral Ground
(End ramp)
A phase
B phase
C phase
N phase
Insulating plate
Joint bolt nut
Threaded
hole
Housing mold Joint stack
Housing side ground plate
(End ramp)

7. 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.
CAUTION
Ensure that the bus bars and housing end ramps engage properly
between the joint stack and insulator plates as shown in the figure.
WARNING

8. 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.
Joint Assembly Instructions
Using a torque wrench, tighten
the outer bolt head of the joint
bolt until it breaks off (shear
torque = 800 kgf·cm)
Joint kit
Bar end
1
2

9. 4
Attach the joint cover
components over the
assembled joint using the
supplied fasteners.
3
Check that there are no gaps
between the joint cover and
housing to ensure the
environmental integrity of the
joint.

10. R
S
T
N
16/31
Plug in Box
Plug in Feeder
Plug In Box - Horizontal
Support

11. Tap off Box
Plug in Box - Vertical

12. Horizontal Support
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.
1. Trapeze Hanger Installation
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.

13. Vertical Support
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.
Spring hanger
Rigid hanger
Hanger bolt
Base channel
Jam nut
Second
adjusting
nut
First
adjusting
nut (take off)
Hanger
clamp
H

14. 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
Case 2.
Case 1.
L + 42
21 21
L - 250
L + 250

15. Maintenance and Inspection
The following maintenance and inspections are recommended for
ensuring the safe operation and extended life of the busway.
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.
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.
WARNING
1. External Appearance
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.

16. 1. Was there any shipping damage? Report any minor damage or
missing parts 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, or
concrete materials? Yes/No
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
concrete 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? (Individual
pieces should megohm test as infinite resistance. Consult the factory if
you 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 support 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. Joints
should 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/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
seal between the bus 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
Busway Installation Checklist
Project Name : Identification :