Suite 003, 8, Sino Plaza 255-257 Gloucester Road, ° Causeway Bay, Hong Kong Tel: (852) 2838 6808 Fax: (852) 2898 0689 ‘Macau Office: . Est, Ponte de Pas On, SIN, Bul Ind. San Ném, +1 Andar, Taipa, Macau ‘ol: (889) 28850125 Faxc (869) 28850131 e ® . Installation Manual e BICC-MM BUSWAY ® MMIM-004A AUG2007Table of Contents Page 1, Busway Installation-Summary of Importance .... 2. Standard Modules 3. Support Systems-Spring Hanger ... 4, Support Systems-Fixed Hanger .... 5. Support Systems — Supports horizontal installations . 2 . Support Systems — Supports vertical installations . . x . Installation of vertical spring supports ..... . Installation of vertical fixed supports .... 2 Installation of busway . 10.Installation of Plug in box .. 11.Check List for Installed Busway ... 12.Installation Instruction ...pup wity uiptauauuM — summary vs smpyr ase Note: The plastic covers should be left intact until the joints are due to be assembled. 1, Support (Page 4-14) (a) A fixed support must be installed at the base of each riser. (b)A spring support is required to support 2 to 9 meters of busway riser. The top nut of the spring support must be removed after installation. (©)? and ‘C’ cleats must be fitted on the busway at intervals of 1.5 to 2.5, meters with a minimum of one support per busway section. 2. The vertical, horizontal and joint cover plates must be. aligned after installation. 3. The bolts at each joint should be tightened to the required torque. (M16: 120Nm or 90 Ib-ft, M12: 60Nm or 45 Ib-ft) 4, All the nuts/bolts at the joint casing must be tightened and the earth strap linking every two sections is securely fastened. 5. “Installation Guide Bar” should be used to slide the joint together allowing approximately 4 mm clearance between the insulating tube and spade end. Ensure separators are in tact (Page 17). Belleville washers found in each joint are in the right direction, For IP66 protection, silicone must be applied to all joint areas and Belleville washers (Page 18-21). 8. Itis necessary to ensure the two bolts inside and four fixing brackets outside of each plug-in box are securely fastened to the busway body (Page 23). 9. Sections of busway should undergo an insulation resistance test (1000V) to ensure their integrity. 10.Maintenance is recommended’'to bé carried out once every 24 months. Please refer to MM Powerplus Busway Limited product catalogue.Standard modules t Straight Lengths Straight Lengths ° Bolt ~ Spade Configuration Bolt -Bolt Configuration. | Straight Lengths Elbow Bend Spade — Spade Configuration | | Flat Bend Elbow OffsetFlat Bend Offset End Closure Flange Ends Standard modules T Section Expansion Unit Plug in unitew 215 aaasya IV 2H yes ~ caninsty axons nats FL tht . “S4NNIO? dYDONS- =—teh ee set = : | (SOLE TIVASNI ERLAY aA0HRD SN ZEN = poe onus: : | EF , a os : x Zl ed. voces a8 SES so8uegy Supdg-suiaysig yr0ddng 5 : |For horizontal installations, sliding ‘H’ and ‘C’ cleats are available for mounting on customer supplied channels or angles. Supports are required for at least every 1.5 metres with a minimum of one support per busway-section. Supports-vertical installations For verticals risers, fixed vertical supports (vertical hangers) and spring supports (vertical spring hangers) are available. In a typical riser, a fixed support is installed iat the base of the riser and the spring supports are installed at every floor above the fixed support. The spring supports are designed to support between 2 and 9 metres of busway. The span should be set by adjusting the spring length (see Page 7 & 8). When floor to floor level exceeds 4 metres or more than one section, sliding cleats as used in a horizontal installation are installed to restrict any lateral movement of the busway.‘Setup length of springs ‘Setup length of springs Attachment Copper Conductors ‘3 bar systems 140 130] == 4] | 120 SSS oon fun Se no aE 10r 3 3 7 3 iT ‘Distance between Spring Supports (m) Aluminium Conductors 3 bar systems 140) » SSeS =e | 0 SSS Se 135! pa wa ba us! 3 5 7 9 ‘Distance between Spring Supports (mm) 1i | i Copper Conductors | 4 bar systems « 140) e! — | a a | i | }——t 4 Se See 04 120] lak |usca 4 oe | fom @| 3 110 | lo | 100 fr | ¥ 3 5 7 9 uw Distance betwen Spring Supports (m) ° Aorinium Conductors 4 bar systems | 140) J ——— a ° | : a SS 8 Ss aa PSS 120] eae | 3 10 [y= e| r 3 i 7 3 it Distance between Spring Supports (rn) : oe Coppet Conductors e| rm 5 bacsystems | t Se 1 130 | S Sonn 1 % 120 ooo 6 a ee g 110 SSH an 100 1 3 5 7 9 UW Distance between Spring Supports (m)AnsuAMUUN usu UCHUM iyi _reLusar oping vuppune vs ees Powerplus Busway (see Page 10 & 11) . Bofore installation, temporarily support the busway sections in place. Drill the base support channels(customer supplied) to accommodate support rods, The hole size required is 12mm, Locate holes in line with the centerline of the channel side of the busway. 3. Fit the aluminum fixing pads to the channel side of the busway. Fixing pads should be about 275mm above the top of base support channel, Drill four holes (8mm) on the busway enclosure for mounting the fixing pad. |. Fit the spring support components to the fixing pads. . Fix the rods to the base channel. Tighten the nuts at the bottom of the springs temporarily. Remove the temporary supports from the busway. Adjust the springs to appropriate lengths to ensure busway is vertical. Remove the top nuts from the spring rods above the springs. be Bane Adjustment of Springs 1. Adjustment of the springs should take place only when all vertical spring supports and busway are installed. 2. Start the spring adjustment at the topmost spring support. 3, Loosen the lock nut at the bottom of the spring. From the appended graph (Page 7 & 8) find out the correct length to adjust the springs. Tighten the adjusting nut so that the spring is compressed to the recommended length. Then tighten the lock nut. -croone-v00) ‘vorat000) (omorsno £4 ponins) if (@amoysn9 £q ponddns) ‘Hoddns oumeys ovogt, sodas ouweye 25, Zs waLAV aAOWRULANGOL » VRE} yee outs atieal ts ‘yopesa Sods (OMY THVASNI Bx @ T 24 9PIAN O9T-00T ¥o0z -vooct 1 TEQ-SPIAK E9-OF ‘vooo! -voor LIOVUA SAO 40 ON. NotLanIosaa qovaaany SLMOddNS ONTAdS(eo00s-o0sed ~ (woooe-o0sz) S| (aomoysno Xq paddng) roddns jouneyp 265 (@oeuoysno £a ponds). ~ eveupens pa popnsa | ame © meni oof 08% -voo0s -voose | z se 1a 002 ‘vo00¢ -voost | Tepvudsaows0 ON NOTARIOSEC sovaanYInstallation Instruction for Vertical Fixed Supports of. “BICC-MM” Powerplus Busway (see Page 13 & 14) . Before installation, temporarily support the busway sections in place. "Drill the base support channels (customer supplied) to suit the support type. The hole size required is 16mm. Spacing of holes should be the same as the top support bracket (i, 100mm). Locate holes equally around the centerline of the finned side of the busway. . Fit the aluminum fixing pads to the channel side of the busway. Fixing pads, should be about 275mm above. the top of base support channel. Drill four holes (Smm) on the busway enclosure for mounting the fixing pad. .- Fit the support components to the fixing pads. . Fix the rods to the base channel. ;. To prevent lateral movement of the busway, it is recommended to fit sliding cleats adjacent to the fixed supports. Remove the temporary supports from the busway. aoe » pe 2'20005-008e! BUSA OOF 097 -vo00s -YOOsE | 384 2pith 000 “voooe -¥00sT amDVuasdowsOON NOLAN wovERaW. | Sodas TAXInstallation of Busway Note: The plastic covers should be left intact until the joints are due to be assembled. Joint Assembly: 1. Remove the plastic protection at the joint. 2. Remove all 4 pieces of aluminium covers.(Refer to Figure 2) 3. Inspect busway bars to ensure that no damage to the surfaces has occurred and that the surfaces must be smooth. . 4, Using the “Installation Guide Bar” as a guide, slide joint together allowing approximately 4mm clearance between insulating tube and spade end. Ensure separators are intact. (Refer to Figure 3) 5. Apply two continuous beads of silicone sealant to the black sponge rubber for protection against moisture, which is only required for IP66 application. (Refer to Figure 4) 6. Replace the finned side plates, making sure the nylon insulators fit into the ‘4mm gap on the spade end. 7. Apply a bead of silicone sealant under washers, which is only required for 1P66 application. (Refer to Figure 5) 8, Tighten the bolts. Torque settings are: Busway fitted with M12 bolts-6ONm or 45Lb-ft. Busway fitted with M16 bolts-120Nm or 90Lb-ft. . Apply two beads of silicone sealant along the edges of the top and bottom cover plates, which is only required for IP66 application, re-install and tighten. (Refer to Figure 6) 10.Re-install the earth strap. (Refer to Figure 7) 11.Sections of busway should undergo an insulation resistance test (1000V) to ensure their integrity. eFIGURE 3 Approximately 4mm clearance required on assembly 7FIGURE 4 sy to bead of stone Pear EPDM. | rubber seal e e! i Apply two beads of silicone sealant all around “Approximately ‘gm gap oe ‘| | | @|FIGURE 5 FOR IP66 ONLY Apply a bead of silicone sealant under washers Apply two beads of silicone sealant 19® j ' e FOR TP66 ONLY i FIGURE 6 | 8) Apply two beads of Apply abead of sifgone silicone sealant sealant under wash | : 20plone 7 FOR IP66 ONLY Apply silicone sealant solid each joint endsusuaursuUM UL cig un vUA 1. Remove cover on plug-in point by undoing two screws. 2. In the plug-in point, there is a mould with one hole and two inserts with M10 thread. (Refer to Figure 8) 3. Open the door of the plug-in box and also remove the plate on the side of e the box. : 4, At the back of the box are the contacts and also a guide pin which fits into the hole in the mould when the box is pushed on. 5. Inside the box, there are two holes in the phase mould, one on the top left ‘ide of the MCCB and one accessed through the side plate, Two M10 X 40 ° brass setscrews (supplied) are screwed through the holes in the phase mould into the threaded holes in the plug in point mould. (Refer to Figure 9) 6. Four brackets (supplied) are fitted to each comer at the back of the box to secure the plug-in box to the busway. (Refer to Figure 10) 2FIGURE 9BICC-MM Busway Checklist for Installed Busway Upon completion of busway system instalation, it is recommended to check up on the installation ‘work to ensure systom integrity and the system has been properly installed in good condition for energization, ‘The following isa checklist drawn wp for the purpose: Yes__No @ Sumvort 1, Isevery horizontal section supported by at Ieastone palrofcleets? =] 2. Is there proper support under the joints for horizontal runs? og 3, Tsusway fitted with cleats at intervals of 1.5-2.5M? oa ‘Ar the cleats fted comely? 4, Is vertical section supported by prope “supports? a0 {it inludes fixed supports or spring supports or cleats) \ 5. Aretho fixed supports o spring supports installed according othe =F] proper method and location? 6. Arethe top nuts ofthe spring supports removed or loosened the {op of threaded rods? ®) Alignment 1. Are he horizontal sestions aligned in a staight line? o.o 2, Arothe vertical setons aligned? o.0 3, Atecover plate fins and bustuct fin aligned? ooo © Assembly 1. Arethe bolts ateac jin tightened to the required torque? oo (M6: 120m or 9ob-, M2: 6ONm or 4SIb-R) 2, AretheMB bolts & nuts tightened? oa 3, _Arethe remaining bolts at the joint casings all tightened? o-oo 4, athe earth strap linking every two seotions seeurely fastened? o06 | | () Insulation 1 © ws 1 2 3. Is the result of insulation fet along the whote length of busway (ell foad should be removed before measurement satisfactory? Is insulating tube broken? 1s separator of insulation sheet damaged? Ifthe fish plate i taken off, the separator should be 12.5mm longer ‘and wider than the copper conductor? Is a separation of 4mm left at the joint? Ate the Belleville washers found in each joint and they are inthe right direction? For IP66, is our silicone sealant applied to every joint? For IP66, if joints ae dismantled, is rubber being replaced on the fish plate? Is silicone sealant adequately applied to al oint areas and tothe Belleville washers? @ Plugsin (Bolt-on Boxes 1. 2 ‘Are the plugein boxes / bolton boxes securely fastened fo the body of the busway? (itis necessary to check ifthe bolts inside each box are securely fastened to the busway body) ‘Ate all plugein boxes / bolt-on boxes earthed? © Site Testing 1 Ts moga test being performed on each run? 0 a a o Q O a 25