GE Industrial Solutions Spectra II Series Plug-in and Feeder Busway with BlueCoat Epoxy Insulation System User Manual
GE Energy
Industrial Solutions
Spectra and Spectra II Series™
Plug-in and Feeder Busway
With BlueCoat® Epoxy Insulation System
DEH-40087
Installation and Maintenance Instructions
i
WARNINGS, CAUTIONS AND NOTES AS USED IN THIS PUBLICATION
WARNINGS
Warning notices are used in this publication to emphasize that hazardous voltages, currents, or other
conditions that could cause personal injury are present in this equipment or may be associated with its
use.
Warning notices are also used for situations in which inattention or lack of equipment knowledge could
cause either personal injury or damage to equipment.
CAUTIONS
Caution notices are used for situations in which equipment might be damaged if care is not taken.
NOTES
Notes call attention to information that is especially significant to understanding and operating the
equipment.
This document is based on information available at the time of its publication. While efforts have been
made to ensure accuracy, the information contained herein does not cover all details or variations in
hardware, nor does it provide for every possible contingency in connection with installation, operation,
and maintenance. Features may be described herein that are not present in all busway systems. GE
Consumer & Industrial assumes no obligation of notice to holders of this document with respect to
changes subsequently made.
GE Energy makes no representation or warranty, expressed, implied, or statutory, with respect to, and
assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information
contained herein. No warrantees of merchantability or fitness for purpose shall apply.
To request a busway installation video or to ask questions about your installation, contact the GE
factory at (731) 645-6121.
The following are trademarks of GE Company: Spectra Series™, Spectra RMS™, BlueCoat®, Weathershield™, Joint-Guard™,
Spectra II™
© 2007 GE Company
All Rights Reserved
ii
Spectra and Spectra II Series™ Plug-In and Feeder Busway
Table of Contents
Contents
Installing Spectra Series Busway ............................................................... 3
Storage Precautions ......................................................................... 3
Pre-Installation Procedure ............................................................. 3
Installation of Spectra Series Busway ....................................... 3
Installing Indoor Busway ............................................................................... 5
Horizontal Mounting ......................................................................... 5
Vertical Mounting ............................................................................... 5
Joining Lengths ................................................................................... 8
Expansion Lengths ............................................................................ 9
Busway Field Check Pieces and Replacement Pieces ..... 10
Installing an End Box ...................................................................... 10
Installing and Removing Busway Plugs ................................................ 11
Installing a Plug Not Equiped with Plug-Assist.................... 12
Installing a Plug Equipped with Plug-Assist .......................... 12
Removing a Plug ............................................................................... 12
Installing Dripproof, Splashproof, and Outdoor Busway ............... 14
Installation Tips ................................................................................. 15
Installing an End Box ...................................................................... 18
Installing Spectra II Series Busway .......................................................... 21
Horizontal Mounting ....................................................................... 21
Vertical Mounting ............................................................................. 21
Installing an End Box ...................................................................... 22
Joining Lengths ................................................................................. 22
Remove the Joint or Captive Piece of Busway.................... 23
Busway Plugs ..................................................................................... 25
Busway Maintenance Procedures ........................................................... 26
Protecting the Busway from Contamination ....................... 26
Maintenance Procedures ............................................................. 26
Inspecting the Busway .................................................................. 26
Inspecting Current-Carrying Components ........................... 26
Busway Installation Checklist .................................................................... 28
1
Spectra and Spectra II Series™ Plug-In and Feeder Busway
List of Figures and Tables
Figures
1. The bar end and joint end of the busway .................................................................................................................. 3
2. Minimum clearances to be maintained in various installations. ..................................................................... 4
3. Dimensions between drop rods for dual-hanger installations. ........................................................................ 5
4. Single-rod hanger with one stack (a) (standard) mounted flat and (b) mounted edgewise. ............... 5
5. Rigid riser hanger installation. ......................................................................................................................................... 6
6. Spring riser hanger installation ....................................................................................................................................... 6
6A. Seismic spring riser hanger installation………………………………………………………………………………….…………………..….6
7. Bus plugs with door hinges at the left end ................................................................................................................ 7
8. Bus plugs with door hinges at the top. ........................................................................................................................ 7
9. Indoor joint cap. ..................................................................................................................................................................... 8
10. Outdoor joint cap. ................................................................................................................................................................. 8
11. Busway joint at the standard distance ....................................................................................................................... 8
12. Busway joint at the minimum distance. ..................................................................................................................... 9
13. Busway joint at the maximum distance. .................................................................................................................... 9
14. Installing an expansion length. .................................................................................................................................... 10
15. Measuring Spectra busway for a field check ........................................................................................................ 10
16. Installing an end box. ....................................................................................................................................................... 10
17. Plug handle positions. ...................................................................................................................................................... 12
18. Mounting a bus plug on Spectra Series busway .................................................................................................. 13
19. Assembly of a typical dripproof, splashproof, or outdoor busway joint. ................................................... 16
20. Assembly shown without joint caps, wireform springs connected. ............................................................ 16
21. View of completed joint assembly with joint caps installed. .......................................................................... 17
22. View of completed joint assembly showing joint caps. .................................................................................... 17
23. End box installed on the end of a run. ...................................................................................................................... 18
24. Edge wise outdoor Elbow Joint .................................................................................................................................... 19
25 Edge wise outdoor Elbow Joint asm instructions ................................................................................................ 19
26 Edge wise outdoor Elbow Joint .................................................................................................................................... 20
27 Edge wise outdoor Elbow Joint asm instructions ................................................................................................ 20
28. Minimum clearances Spectra II ................................................................................................................................... 21
29. Lowamp busplug data ..................................................................................................................................................... 21
30. Spectra II flatwise hanger .............................................................................................................................................. 22
31. Spectra II edgewise hanger ........................................................................................................................................... 22
32. Spectra II trapeze edgewise hanger .......................................................................................................................... 22
33. Spectra II trapeze flatwise hanger ............................................................................................................................. 22
34. Spectra II cross section.................................................................................................................................................... 22
35. Spectra II end box .............................................................................................................................................................. 22
36. Spectra II busway joint at minimum .......................................................................................................................... 23
37. Spectra II busway joint at standard ........................................................................................................................... 23
38. Spectra II busway joint at maximum ........................................................................................................................ 24
39. Joint cap ................................................................................................................................................................................ 24
40. Bus plug mounting ............................................................................................................................................................ 24
Tables
1. Selection of spring hanger based on Seismic load……………………………………………………………………………………..5
2. Selection of spring hanger based on Seismic load……………………………………………………………………………………..5
3. Dimensions for Spectra RMS™ circuit breaker bus plugs ................................................................................... 7
4. Dimensions for Types QMR and QMW fusible switch bus plugs ...................................................................... 7
5. Dimensions for molded-case circuit breaker bus plugs. ..................................................................................... 7
6. Busway and hanger mounting dimensions .............................................................................................................. 7
7. Number of busway springs required per busway weight .................................................................................. 7
8. Busway weights ..................................................................................................................................................................... 7
9. Busway torque requirements ....................................................................................................................................... 10
10. Lowamp plug sizes ............................................................................................................................................................ 21
11. Spectra II busway cross section .................................................................................................................................. 22
12. Lowamp plug weight ........................................................................................................................................................ 22
13. Spectra II busway weight ............................................................................................................................................... 22
2
Spectra and Spectra II Series™ Plug-In and Feeder Busway
NOTE: No busway, including outdoor rated, is
weatherproof until completely and properly
installed.
NOTE: Aucune canalisation pour barres omnibus,
incluant celles classées pour l'extérieur, n'est à
l'épreuve de l'eau jusqu'à ce qu'elle soit installée
complètement et correctement.
Installing Spectra Series Busway
Installing Spectra Series™ Busway
Storage Precautions
Before storing, unpack sufficiently to make a
check of the busway for possible concealed
damage resulting from shipping and handling. If
damage has occurred, notify the shipper
immediately. If the busway is free of damage,
restore the packing until ready for installation.
Store indoors in a clean, dry area, preferably close
to the installation points.
Protect the busway from mechanical damage and
any contact with or exposure to corrosive fumes,
Installation of Spectra Series Busway
Establish the bus bar phase sequence (Ø side is
labeled) to determine how the busway is to be
installed, so that correct phasing is maintained
throughout the system. Note that phase
transposition lengths, when furnished, may
relocate the Ø to the opposite side of a busway
run.
Each busway piece has a ―bar end‖ and a ―joint
end,‖ as illustrated in Figure 1. Normally the
busway is oriented end for end with bar ends
pointing away from the source. Also, the ø side
should be oriented down for horizontal plug-in
applications.
liquids, salts, or concrete.
Failure to store and protect the busway properly
can cause serious damage and will void the
warranty.
Pre-Installation Procedure
When possible, deliver the busway to its
installation location before unpacking. Large
labels on each shipping carton or crate designate
the items contained. Additionally, each busway
piece is identified with an item number label.
Inspect each busway piece for possible damage
or contamination. Contact surfaces must be clean.
However, do not attempt to polish tarnished
contact surfaces.
Check to ensure that joint insulators are not
damaged or cracked and are firmly in place.
Megohm test each piece before installation.
Figure 1. The bar end and joint end of the busway.
In vertical riser installations, it is easier to lower
the busway into place than it is to raise it.
If installation drawings have been furnished,
information regarding the orientation of the
busway and location of the ø side, as well as other
pertinent data, will be furnished. These drawings
should be followed carefully to ensure a proper
busway system.
Where to Start
Start the installation, if at all possible, at the most
critical point, such as a main feed box,
switchboard or switchgear, elbow, or other critical
fitting or termination.
3
Spectra and Spectra II Series™ Plug-In and Feeder Busway
Installing Spectra Series Busway
Obstructions
Where a busway run must pass through a wall or
floor, an opening one inch larger than the busway
cross-section should be provided. Joints may not
occur inside walls or floors per the NEC. A flange is
available to mask the opening after the busway is
installed.
Minimum Clearances
Figure 2 illustrates the minimum clearances that
must be maintained in various installation
situations.
4‖ minimum provides clearance for 30–100 A fusible plugs. 7‖ minimum for 200
A fusible plugs. 8‖ minimum for all other plugs. See Tables 1, 2, and 3.
Figure 2. Minimum clearances to be maintained in various
installations.
4
Spectra and Spectra II Series™ Plug-In and Feeder Busway
NOTE: Check that the initial height is 8 inches, as
shown in Figure 6.
NOTE: Veuillez vous assurer que la hauteur
initiale est de 8 pouces, tel que montré à la Figure
6.
Installing and Removing Spectra Busway Plugs
Installing Indoor Busway
Horizontal Mounting
Overhead Support
For overhead-supported busway, 1/2-inch drop
rods are recommended with a maximum 10-foot
spacing. Drop rods and other hardware must be
furnished by the installer. Figure 3 illustrates
mounting dimensions for typical installations.
• Maintain good alignment of the drop rods
along the busway run.
• Do not support busway at the joints.
• After the busway is secured in the hangers,
adjust the hangers on the rods for the correct
elevation.
• Sway braces (furnished by the installer) may be
required to keep the run straight or to prevent
rotation.
Wall or Column Support
Table 4, Table 5 and Table 8. Select the spring
hanger based on the seismic load; amperage and
Vertical support spacing mentioned in table 1 & 2.
Table 1: Selection of spring hanger based on Seismic load and
amperage.
Table 2: Selection of spring hanger based on Seismic load.
Single-rod hangers, as shown in Figure 4, may be
used for mounting busway on walls or columns
with the addition of an angle support supplied by
the installer.
the floor, follow this procedure to assemble
hangers to the busway, as illustrated in Figure 5
Figure 6 & 6A. For convenience in assembly, step 8
may be completed before the hangers are
attached to the busway.
After placing the length of busway through
Figure 3. Dimensions between drop rods for dual-hanger
installations.
Figure 4. Single-rod hanger with one stack (a) (standard) mounted
flat and (b) mounted edgewise.
Vertical Mounting
Support Busway on maximum 16-foot centers.
Use Table 7 to determine the number of springs
required based on busway weight, as listed in
1. Loosen the hanger bolt A, shown in Figure 5.
2. Assemble the hangers to each side of the
busway.
3. Position the hangers on the busway so that
the base channel (B) rests on the floor or other
support. A floor flange (C) may be placed under
the hanger, but it will not support the busway
weight.
4. Fit the hanger clamps (G) to the busway
housing and hand tighten the hanger bolts (A).
5. Anchor the base channels to their supports.
6. Tighten the hanger bolts (A).
5
Spectra and Spectra II Series™ Plug-In and Feeder Busway
H = 5
585
8 –
W
150
W =
Busway wt /ft ft/floor + devices on floor
Total number of springs/floor
Installing and Removing Spectra Busway Plugs
7. Install the next length and make the joint
assembly (see the instructions for joining
lengths below).
8. If springs are furnished, they must be adjusted
as shown in Figure 6 at this time. Determine
the required dimension H of the hanger
springs, found on the layout drawing or by
using the formula,
Using the final adjusting nuts (E), set the
springs on the hangers to the dimension H.
With the springs adjusted, hold nut (E) in
position and tighten jam nut (F) against nut (E)
Figure 5. Rigid riser hanger installation.
to retain the spring setting. Tighten all jam
nuts (F) using this procedure.
Note that when you are calculating the
dimension H for the bottom floor of a riser with
an elbow and busway directly below the floor,
the following must be included in the footage
calculation:
• Busway below the floor to the elbow,
• The elbow,
• 8 feet of horizontal busway.
For the riser to function as a free end, the last
horizontal hanger must be 8 feet from the
bottom elbow.
9. After the busway run is installed and all ―H‖
dimensions are set to the required settings,
starting at the top hanger raise the initial
Figure 6. Spring riser hanger installation
adjusting nuts (D) of all hangers to the top of
the spring studs. The studs are crimped to hold
the nuts in the uppermost position.
NOTE: Failure to properly adjust the spring
hangers could damage the bus and void the
warranty.
Figure 6A. Seismic Spring riser hanger installation (Cat No:
SBSR”X”)
6
Spectra and Spectra II Series™ Plug-In and Feeder Busway
Frame
Dimensions, in.
Handle
Ht.
Wt.,
lb.
Outlets
Fig.
W L D
SED, SEH, SEL, SEP
11.00
13.00
8.00
11.00
25 1 7
SFH, SFL, SFP
11.00
21.25
9.00
12.00
41 1 7
SGH, SGL, SGP
16.75
26.50
12.50
20.50
91 2 8
SKH. SKL, SKP
16.75
36.50
12.50
20.50
160 2 8
Rating,
Volts
Amps
Dimensions, in.
Wt.,
lb
Fig.
W L D
Handle
Ht.
Std
Gutter
Ext
Gutter
240 &
600
30
11.25
13.00
18.63
8.75
11.00
24 7 60
11.25
13.00
18.63
8.75
11.00
25 7 100
11.25
18.75
NA
8.75
11.00
28 7 200
16.00
18.75
24.50
8.75
11.00
46 7 400
20.50
18.75
NA
18.75
24.00
135 8 600
20.50
24.50
NA
18.75
28.00
160
8
Frame
Dimensions, in.
Wt.,
lb
Outlets
Fig.
W L D
Handle
Height
TEB, TED, THED
11.00
13.00
8.00
11.00
24 1 7
TFJ, TFK, THFK
11.00
18.50
9.50
12.00
44 1 7
TJJ, TJK4, TJK6,
THJK4, THJK6
16.75
24.50
12.50
20.50
95 2 8
TKM8, THKM8,
THK
16.75
36.50
12.50
20.50
160 2 8
TB1 (fused)
11.00
18.50
8.00
11.00
29 1 7
TB4 (fused)
16.75
30.50
12.50
20.50
65 2 8
TB6 (fused)
16.75
45.25
12.50
20.50
175 2 8
TB8 (fused)
16.75
45.25
12.50
20.50
185 2 8
Bars per
Phase
Ampere Rating
Dimensions, in.
Copper
Aluminum
Busway A
Hanger B
1
225–800
225–600
43/8
101/4
1000 — 5
1200
800
55/8
1350
1000
61/8
1600
1200
7
2000
1350
81/2
14
—
1600
91/4
2500
—
101/4
—
2000
11
181/2
2
3000 — 15
—
2500
151/2
4000
3000
18
221/2
5000
—
211/2
26
—
4000
23
Busway
Weight, lb
No. of Springs
Required per Floor
0–600
2
601–1200
4
Over 1200
6
Amperes
Busway Weight, lb/ft
Copper
Aluminum
3 Wire
4 Wire
3 Wire
4 Wire
225 8 9 5 6
400 8 9 5 6
600 8 9 5 6
800 8 9 6 7
1000
10
12 7 8
1200
12
15 8 9
1350
14
17 9 10
1600
16
20
10
12
2000
21
26
12
15
2500
26
33
17
20
3000
32
40
19
23
4000
42
52
25
30
5000
52
66 — —
Installing and Removing Spectra Busway Plugs
Table 3. Dimensions for Spectra RMS™ circuit breaker bus plug.
Table 7. Number of busway springs required per busway weight.
Maximum distance from the busway housing to the handle tip.
For ground fault option, increase width by 2.125 inches and length by 6.00
inches.
Table 4. Dimensions for Types QMR and QMW fusible switch bus
plugs, as illustrated in Figure and Figure 8.
Table 5. Dimensions for molded-case circuit breaker bus plugs.
Table 8. Busway weights.
Table 6. Busway and hanger mounting dimensions, as illustrated in
Figure 2 and Figure 3.
The door hinges at the left end. The L and W dimensions are shown over
the largest part of the plug.
Figure 7. Bus plugs with door hinges at the left end.
Important Note:
On vertical riser applications use a Minimun of 18‖ of
un-supported flexible conduit connecting to bus plugs.
7
Spectra and Spectra II Series™ Plug-In and Feeder Busway
WARNING: The housing-ground side plates must pass
between the outside insulators and the joint-ground side
plates to avoid a phase-to-ground short circuit.
AVERTISSEMENT: Les plaques de côté reliant le boîtier à
la mise à la terre doivent passer entre les isolateurs
extérieurs et les plaques de côté du joint à la terre pour
éviter un court -circuit de phase à la terre.
NOTE: If any adjustments are made in Step 5, remove
the shipping screws and center the joint between the
two housings.
NOTE: Retirer les vis d'expédition et centrer le raccord
entre les deux habitacles sitout ajustement est
apporté à la fiche-boîtier à l'étape 5.
Installing and Removing Spectra Busway Plugs
Joining Lengths
Use the following procedure to join two lengths of
busway.
1. Remove at least one joint cap, shown in Figure
9 and Figure 10, from the two pieces to be
joined, retaining the bolts.
2. Align the sections to be joined by matching up
the Ø SIDE labels attached to the ends of each
section.
3. If necessary, loosen the joint bolt slightly.
The door hinges at the top. The L and W dimensions are shown over the
largest part of the plug.
Figure 8. Bus plugs with door hinges at the top.
4. Slide the sections together. Ensure that the
busbars interweave the insulators, as shown in
Figure 11, Figure 12, and Figure 13.
5. In nominal position, the standard distance
between the joint cap bolt holes is 10 1/4
inches for outdoor busway, as shown in Figure
11. On indoor busway, the standard distance
between the two housings is 8 3/8 inches, in
nominal position, as shown in Figure 11. An
alignment line marked ―N‖ on the joint cap
window should line up with the edge of the
housing at nominal position. However, the joint
is also adjustable, as shown in Figure 12 and
Figure 13. Simply move the sections in or out
to the desired length, as shown, and remove
the twist-outs in both joint caps (outdoor only)
if needed, as shown in Figure 10.
6. If the joint caps are not already in place,
reattach them and hand-tighten the mounting
screws.
7. When joining old-style indoor to new-style
indoor busway, use a 3/8" x 1/2" bolt to attach
8
Spectra and Spectra II Series™ Plug-In and Feeder Busway
Installing and Removing Spectra Busway Plugs
the joint cap to the housing spacer of old-style
indoor and the 5/16" x 2" bolt provided on the
new-style indoor and attach to the U clip.
8. When joining Spectra Series Busway to
Spectra II Plug-in Busway, a combination joint
cap will be provided, use the 5/16‖ X 2‖ bolt to
attach this joint cap to the Spectra Series
Busway and the M10 X 16 bolts to attach the
cap to the Spectra II Busway.
Figure 9. Indoor joint cap.
Figure 10. Outdoor joint cap.
Figure 11. Busway joint at the standard distance.
Figure 12. Busway joint at the minimum distance.
Figure 13. Busway joint at the maximum distance.
9. When joining Style II outdoor to new-style
indoor busway, use the existing 3/8" x 1/2" bolt
to attach the joint cap to the housing spacer of
Style II outdoor and the 5/16" x 2" bolt
provided on the new-style indoor and attach
to the U clip.
10. Inspect the busway run for straightness in all
planes and make any adjustments necessary
for good alignment.
11. Grease has been applied to the joint bolt head
and threads to reduce friction. Do not remove
this grease.
12. Tighten the joint bolt with a 5/8‖ or 16-mm
socket wrench until the smaller, top head
breaks off. When the Belleville washers on
both sides are flattened, the bolt is fully
tightened. If the optional Joint-Guard™
9
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