BUSWAY SYSTEM MOUNTING ������������������������������������������������������������������������������������������������������������������������������������������������������������ 8
MOUNTING THE END FEED ���������������������������������������������������������������������������������������������������������������������������������������������������������������� 9
VERTICAL END FEED SUPPORT������������������������������������������������������������������������������������������������������������������������������������������������� 9
HORIZONTAL END FEED SUPPORT ������������������������������������������������������������������������������������������������������������������������������������������ 9
MOUNTING THE BUSRAIL ����������������������������������������������������������������������������������������������������������������������������������������������������������������� 10
SUPPORT �������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 10
INSTALLATION OF THE SPLICE CONNECTOR – 160 - 250 AMP �����������������������������������������������������������������������������������������������11
INSTALLATION OF OPTIONAL "C-CLIPS" FOR 35kAIC RATED 400A BUSWAY ����������������������������������������������������������������������15
END FEED C-CLIP INSTALLATION �������������������������������������������������������������������������������������������������������������������������������������������15
BUSRAIL AND SPLICE JOINT C-CLIP INSTALLATION ���������������������������������������������������������������������������������������������������������15
INSTALLATION OF THE SPLICE CONNECTOR – 400 AMP ����������������������������������������������������������������������������������������������������������17
INSTALLATION OF THE END CAP CLOSURE PLATE ���������������������������������������������������������������������������������������������������������������������20
CABLE TERMINATIONS TO THE END FEED BOX ���������������������������������������������������������������������������������������������������������������������������21
TAP OFF BOX INSTALLATION ������������������������������������������������������������������������������������������������������������������������������������������������������������23
TAP OFF BOX MOUNTING ��������������������������������������������������������������������������������������������������������������������������������������������������������24
Before Energizing The Busway Checklist ....................................................................................................25
Energizing The Busway System ......................................................................................................................26
System Description ...............................................................................................................................................32
Power Monitoring System Overview .............................................................................................................32
Option 1 - TAP OFF BOX MONITORING ONLY ������������������������������������������������������������������������������������������������������������������������������ 33
POWER INSERTER PCB ������������������������������������������������������������������������������������������������������������������������������������������������������������� 34
TAP OFF BOX MONITORING COMPONENTS ������������������������������������������������������������������������������������������������������������������������ 35
Option 2 - END FEED MONITORING ONLY ������������������������������������������������������������������������������������������������������������������������������������ 36
POWER INSERTER PCB ������������������������������������������������������������������������������������������������������������������������������������������������������������� 37
POWER INSERTER PCB ������������������������������������������������������������������������������������������������������������������������������������������������������������� 40
TAP OFF BOX MONITORING COMPONENTS ������������������������������������������������������������������������������������������������������������������������ 41
REQUIRED MATERIAL ����������������������������������������������������������������������������������������������������������������������������������������������������������������47
USING THE ACCUMULATOR SETUP PROGRAM ������������������������������������������������������������������������������������������������������������������48
COMMON PROCEDURES ���������������������������������������������������������������������������������������������������������������������������������������������������������� 50
DATA TAB �������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 51
CUSTOMER CONNECTIONS TO 7" LOCAL DISPLAY �������������������������������������������������������������������������������������������������������������������� 53
POWER CONNECTIONS ������������������������������������������������������������������������������������������������������������������������������������������������������������ 56
GENERAL ����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 86
Appendix G: Service ..............................................................................................................................................88
STANDARD WARRANTY ��������������������������������������������������������������������������������������������������������������������������������������������������������������������� 88
START UP ����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 88
TRAINING ���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 88
TIME AND MATERIALS ������������������������������������������������������������������������������������������������������������������������������������������������������������������������88
SPARE PARTS ���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 89
TAP OFF BOX QUICK INSTALL SHEET ��������������������������������������������������������������������������������������������������������������������������������������������� 92
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Figure 54 - Connections on IX Display Interface Board ��������������������������������������������������������������������58
Figure 55 - Modbus to 7" Local Display Wiring Schematic ���������������������������������������������������������������59
Figure 56 - Branch Circuit Monitoring System Board Interconnection �����������������������������������������68
Figure 57 - Input Power Monitor Board to End Feed Current Transformers Schematic ����������69
Figure 59 - End Feed Current Transformer (CT) Orientation ������������������������������������������������������������70
Figure 58 - End Feed Input Power Monitor Board �������������������������������������������������������������������������������70
Installation & Operation Manual, GE Series DPB Busway
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INSTALLATION GUIDE
160, 225, 250, 400 AMP
Installation & Operation Manual, GE Series DPB Busway
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Series DPB Busway Installation & Operation Manual
INTRODUCTION
This manual details the fundamental instructions required for the proper handling, storage, installation and maintenance of
the Series DPB Busway manufactured by GE Critical Power.
Installers shall familiarize themselves with this document and become familiar with the design and specific characteristics of
each Series DPB Busway component and run. Proper planning and coordination between trades is important for an efficient
installation.
Every component shall be tested, inspected and packaged at the assembly plant. Manufacturing details are checked and
tested regarding the mechanical and electrical specification of the system. After factory inspection, the busway is boxed and
crated for shipment to the job site. The catalogue number and job number will be clearly marked on each shipping package
and individual item.
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SAFETY WARNING
DANGER
HAZARD OF ELECTRIC SHOCK, BURN, OR EXPLOSION
Only qualied electrical maintenance personnel should install, operate, service and maintain
this busway system and associated equipment. This document should not be viewed as
sufcient for those who are not otherwise qualied to operate, service, or maintain the
equipment discussed.
Turn off power to the busway before installing, removing, or working on this equipment.
CONFIRM THAT ALL POWER IS OFF
Always use a properly rated voltage sensing device to conrm that all power is off. Always
wear proper protection.
The accurate operation of this equipment depends upon proper handling, installation,
operation, and maintenance.
Failure to follow these instructions may result in serious injury or death
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RECEIVING, HANDLING, & STORAGE
WARNING
HAZARD OF ELECTRIC SHOCK, BURN, OR EXPLOSION
Protect this equipment from containments such as water, salt, concrete dust and other corrosive
environments before and during installation.
Equipment and packing are not weather resistant and shall not be stored outside or exposed to
the environment
Do not sit, walk or stand on this equipment.
RECEIVING
HANDLING
Failure to follow these instructions may result in equipment damage, serious
injury or death.
Upon receipt, check the packing list against the equipment received to ensure the order and shipment are
complete. Claims for shortages or other errors must be made in writing to GE Corp within 30 days after the
receipt of your shipment.
Upon receipt, inspect the busway packaging components and sections for any damage that may have
occurred during shipping. If damage is found, immediately make a claim with the carrier and notify
GE Critical Power.
Cut the banding that secures the package with band cutters.
Exercise care when unpacking.
Handle these products with care, avoid damage to the components, do not drop, bend, pierce or mishandle in
any manner the system as this may lead to a faulty installation
Avoid denting or mishandling that may cause damage. Ensure the handling personnel and equipment at the
job site is adequate for handling the busway.
Use the correct tools to remove the packing at each busway end. Take care not to damage the housing,
which could result in a failure of the busway. Avoid using objects with sharp edges to lift the busway.
STORAGE
Most packaging is recyclable dispose of all packing appropriately.
If the busway is not installed and energized immediately, store the busway in its original packaging in a clean,
dry space.
Busway should not be stored outdoors.
Busway should not be stored in a moist environment.
Protect against moisture.
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INSTALLATION
PRE-INSTALLATION REVIEW
PROPER INSTALLATION OF THE SERIES DPB BUSWAY IS
ESSENTIAL TO THE BUSWAY OPERATION.
Before installing the busway:
1) Conduct an insulation resistance test on each busway device to check for possible
damage during shipment or storage. Ensure the phase-to-phase, phase-to-neutral,
and phase-to-ground isolation.
2) Confirm that the ambient temperature range is within acceptable limits –10°C through +40°C.
If not, please consult the factory for possible de-rating.
3) Ensure that there is sufficient clearance from the walls, ceilings, and load devices.
4) Ensure that the factory-manufactured mounting supports will conform to the recommended
spacing guidelines as detailed in the section titled "Mounting the Busrail".
5) Ensure that all splice connections, end feed units, and tap off boxes will be accessible after
installation.
6) After determining the clearances and the mounting method (vertical or horizontal) for the busway
system, level and align the end feeds and busrails before the final tightening and alignment of all
supporting members.
7) Align the busbar ends of adjoining sections, verifying proper busbar alignment, phasing,
and spacing.
8) Verify that the incoming system phasing, and voltage match the busway system phasing and
rated voltage.
Installation & Operation Manual, GE Series DPB Busway
March 25, 2013, Rev 0
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INSTALLATION HAZARD
Depending on the installation orientation of the busways, the following WARNING should always be considered.
CAUTION
HAZARD OF EQUIPMENT DAMAGE
Always maintain the minimum required clearance distance as shown below.
Failure to follow these instructions may result in equipment damage or personal
injury.
VERTICAL BUSWAY INSTALLATION
See Figure 1. For busways installed vertically with channel opening down,
always maintain:
A minimum clearance distance of 6 inches (153 mm) from the top of the
busways to the ceiling and 1 inch (26mm) from the wall.
Parallel runs for two systems mounted in the same area shall have the following
clearances between the systems.
A minimum clearance distance of 6 inches (153 mm) from the center-point of
busway run A to the next run B.
ceiling
6"
wall
1"
2.5"
bus rail A
underside of busway
bus rail B
18" minimum
Top of Server Cabinet
or Equipment
5"
underside of busway
6"
Figure 1 - Vertical Busway Installation
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HORIZONTAL BUSWAY INSTALLATION
See Figure 2. For busways installed flat wise or horizontally, maintain the following clearances.
A minimum clearance of 6 inches (153mm) from top of bus to ceiling.
A minimum clearance distance of 1 inch (26 mm) from the back of the busways to the edge of the wall.
A minimum clearance distance of 6 inches (153 mm) from the center-point of one busway run to
the next when mounted in a stacked configuration, one above the other.
ceiling
6"
1.0"
underside of busway
wall
bus rail A
Tap Off box insertion
6"
bus rail B
Figure 2 - Horizontal Busway Installation
Example A/B Horizontal Busway Installation
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BUSWAY SYSTEM MOUNTING
SPECIFIED AND SAFE OPERATION OF THE SERIES DPB BUSWAY IS DEPENDENT ON ITS
PROPER INSTALLATION. MISALIGNMENT OF THE BUSWAY COMPONENTS, (END FEEDS,
BUS RAILS, AND SPLICES) WILL COMPROMISE ITS PERFORMANCE.
1) End Feed enclosures must be securely mounted so that they are completely level (side-to-side and front-to-back).
2) Bus Rails must be securely installed so that they are level and completely aligned to the End Feed enclosures and with
adjoining Bus Rail sections.
3) When each Busway run is properly supported / mounted, leveled , and aligned, all Splices must be verified to be
"un-cammed" (not actuated with Cam Actuator Tool).
4) The Splice units must be able to move freely and fully into both sections of adjoining sections of bus before the Splices can
be "cammed" (actuated).
5) Once the free movement of the Splice units is verified, the Splice can be actuated. The installation of Dowel Pins completes
the correct installation of the Splices.
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MOUNTING THE END FEED
VERTICAL END FEED SUPPORT
Series DPB End Feed enclosures can be mounted in a number of ways. The recommended method for mounting Series DPB
End Feed enclosures is as shown in Figure 3. Four 3/8" threaded rods (see Figure 3A) secure the enclosure to the ceiling or to
UnistrutTM, and a standard busway hanger supports the Splice Extension. These need to be aligned and leveled to each other
so that the End Feed is completely level after installation.
UNISTRUT
TM
Figure 3A
THREADED ROD
END FEED
VERTICAL BUSRAIL HANGER
END FEED OR
CEILING / UNISTRUT
TM
OPTIONAL BCMS
MONITORING MODULE
Figure 3 - Vertical End Feed Support
HORIZONTAL END FEED SUPPORT
Series DPB End Feed enclosures can be horizontally mounted. The recommended method is similar to the vertical mounting
method and is shown in Figure 4 below. The enclosure is supported by four 3/8" threaded rods (see Figure 4A) secure the
enclosure to the ceiling or to UnistrutTM, and a standard busway hanger supports the Splice Extension. These need to be
aligned and leveled to each other so that the End Feed is completely level after installation.
UNISTRUT
TM
HORIZONTAL BUSRAIL HANGER
THREADED ROD
END FEED
OPTIONAL BCMS
MONITORING MODULE
ON BOTTOM OF END FEED
Figure 4 - Horizontal End Feed Support
Installation & Operation Manual, GE Series DPB Busway
March 25, 2013, Rev 0
Figure 4A
END FEED OR
CEILING / UNISTRUT
GE Confidential
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Series DPB Busway Installation & Operation Manual
MOUNTING THE BUSRAIL
SUPPORT
When mounting the bus rail please use the supplied hangers that are designed to fit into the top and or side channels found
on each section of bus rail. Each section of bus rail should have at least one hanger and threaded rod assembly with the
maximum span being 5' on centers. 10' and 12' bus rail sections should have a minimum of two hanger and threaded rod
assemblies. Bus Rail lengths longer than 12' should have a minimum of three hangers and threaded rod assemblies. The
span of the hanger and threaded support at a Splice point should be a maximum of 6' on center. Each section of bus rail
needs to be aligned and level. See Figure 5.
Threaded Rod and
Hanger Assembly
6'
X
Figure 5 - Busrail Mounting Support around Splice Point
NEUTRALS ALIGNMENT
Our busway system is designed so that it is NOT possible to mount the busways if the neutral conductor is not in phase with
one another from section to section. The neutral conductor of each element MUST be aligned on the same side of the system. Clear markings are also made on the busway system to ensure proper phasing. See Figure 6.
Threaded Rod and
Hanger Assembly
X
X = 10' to 12'
neutral to neutral
neutral
NA
Figure 6 - Busrail Neutrals Alignment
Installation & Operation Manual, GE Series DPB Busway
March 25, 2013, Rev 0
A
C
CB
neutral
N
B
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Series DPB Busway Installation & Operation Manual
INSTALLATION OF THE SPLICE CONNECTOR – 160 - 250 AMP
All busway sections are shipped from the factory with one splice pack assembly. As each busway section is
mounted on its hanger supports, the abutting end of the splice section can be installed to
the adjoining busway section.
Connection of Busway Sections and Fittings: (See Figure 7)
1) Each section of busway will come with one Splice Pack assembly (D) and two "E" Clips (E) one at each
end of the bus section. Make sure the “E” Clips are always installed on each end of each rail.
2) Bus sections are phase-keyed to maintain proper circuit phasing of the run.
3) Section 2 (with the splice) and Section 1 (without splice) will be aligned on their respective supports. Slide
Section 1 forward on the splice pack.
4) Slide Splice Joint Covers (B & C) and "E" Clip (E) into place positioning them equally across the bus.
5) Slide Grounding Plate (A) into place and secure the four grounding screws to the busway.
Torque values for the set screws is 60 in-lbs minimum and a maximum of 85 in-lbs.
6) Slide the Splice Pack Assembly so that it is positioned equally on either side of the bus section joint.
Allen-head screws
12
A Top Grounding Plate with set screws
EE
7) Starting from one end of the Splice Pack (Figure 8), only use the steel cam-actuator tools supplied to
expand the splice joint contact assemblies into contact with bus sections bus bars.
i) Insert one tool into the first cam port #1; the second cam-actuator tool into the adjacent cam port
#2. Rotate each tool ¼ turn to expand the contact plates.
ii) Rotate the adjacent, non-metallic cam spacers (a & b), ¼ turn to hold the expanded contact plate
in place. DO NOT ATTEMPT TO USE THE NON-METALLIC CAMSPACERS TO EXPAND THE CONTACT
PLATE ASSEMBLIES.
iii) Rotate and remove the cam actuator tool in cam port #1, and insert it into cam port #3. Rotate the
steel tool in cam port #3, 1/4 turn clockwise to expand the contact plates.
iv) Rotate the adjacent, non-metallic cam spacers (c & d), 1/4 turn clockwise.
v) Rotate and remove the cam actuator tool in cam port #2, and insert it into cam port #4. Rotate the
steel tool in cam port #4 to expand the contact plates.
vi) Rotate the adjacent, non-metallic cam spacers (e & f), 1/4 turn clockwise.
vii) Rotate and remove the cam actuator tools.
B Side Cover Support Plate
C Side Cover Support Plate
D Splice Pack Assembly
E “E” clip
cam spacer position - splice installation complete as seen from bottom
bcde f
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8.) CAUTION: DO NOT proceed to 9) Installation of the Dowel Pin Devices until the Cam Spacers are
verified to be in the locked position. A properly installed Splice, when viewed from the bottom (open
channel) of the joined bus sections will show the Cam Spacers in the Locked Position as show in
Figure 8.1 below.
Cam SpacerCam Actuator Tool Port
Cams in Locked Position
Figure 8.1 - Cam Spacers in Locked Position
9.) Installation Of The Dowel Pin Devices
The Dowel Pins are used to secure open Cam Actuator Tool ports and add Cam Spacer functionality.
Material Required for Initial Installation (before busway is energized*):
Four Dowel Pin Devices
10) Inspect the busway, and verify that the splice connections of the busway have been installed correctly
per INSTALLATION OF THE SPLICE CONNECTOR – 160 to 250 AMP.
1. Verify no gaps between the bus connections
2. Verify the E-clips are positioned properly.
3. Verify the Cam Spacers (white-tipped, slotted lock pins) are positioned properly.
*please contact factory service for dowel pin installation procedure when working on an energized
busway (800-225-4838)
11.) Each Dowel Pin has an O-ring set into a small groove on the insertion end of the dowel pin.
(See Figure 8.2).
O-Ring
Figure 8.2 - Dowel Pin
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12.) Position the Dowel Pin into the round port between the first pair (viewed left-to-right, or right-to-left) of
installed white-tipped, slotted Cam Spacers. The conical pointed end is inserted first, and the end with
the O-ring inserted last. (See Figure 8.3)
Figure 8.3 - Positioning of Dowel Pins
13.) Using pressure push the Dowel Pin so that it is inserted completely into the Cam Actuator Tool Hole.
(See Figure 8.4)
Figure 8.4 - Insertion of Dowel Pin
14.) Make sure that the O-ring on the dowel is inside the E-clip. (See Figure 8.5)
E Clip
Before
Before
After
Figure 8.5 - Dowel Pin O-Ring Inside "E" Clip
15.) Repeat Step 13 until all four (4) vacant Cam-Actuator Tool Ports have Dowel Pins in them.
16.) Repeat the process for each splice in the bus run until complete.
E Clip
After
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INSTALLATION OF OPTIONAL "C-CLIPS" FOR 35kAIC RATED 400A BUSWAY
The 35 kAIC rated 400A Busway utilizes a C-Clip to control tolerances in the busrail channel opening. Detailed below are the
modified installation instructions to install these C-Clips on End Feeds and Busrails.
END FEED C-CLIP INSTALLATION
See Figure 9 - End Feed C-Clip Installation - 400 Amp
1.) Locate the C-clip
2.) Remove E-clip by sliding it off the bus rail of the End Feed
3.) Install the C-clip by sliding into place between the walls of the open channel.
4.) Reinstall the E-clip.
5.) Position C-clip so that that it butts up against the E-clip.
6.) Tighten screws on C-clip.
NOTE: Loosen, do not remove, the two screws of the C-clip assembly.
Figure 9 - End Feed C-clip Installation - 400 Amp
BUSRAIL AND SPLICE JOINT C-CLIP INSTALLATION
Install C-clips at the prescribed locations on the bus rail. (See Figure 10 - Busrail C-Clip Installation - 400 Amp).
1.) A C-clip should be placed approximately every 31.5" along the busrail or 2 x 31.5" (63") Pitch Location For Clip. If Tap Off
Boxes are installed in the busrail and meet the 31.5" requirement then a C-clip is not required. If a 31.5" opening exists along
the busrail then a C-clip will need to be installed.
NOTE: Loosen, do not remove, the two screws of the C-clip assembly.
2x31.5" (63")
Pitch Location For Clip
Figure 10 - Busrail C-Clip Installation - 400 Amp
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2.) Slide the C-clip into bus rail positioning the C-clip as shown in (Figure 11 - Busrail C-Clip Profile View - 400 Amp). NOTE: Do
not tighten the screws yet.
Figure 11 - Busrail C-Clip Profile View - 400 Amp
3.) Position a Splice Connector into the bus rail that has been properly mounted and supported (leveled, aligned).
NOTE: When the busway is mounted horizontally, make sure the Cam Spacers are flush with the top of the Splice Connector
before positioning the assembly. (See Figure 12 - Cam Spacers)
4.) Bring the ends of busrails to be spliced together, position the Splice Pack equally across the joint, position the E-clips, Side
Support Plates, and Grounding plate ready for Splice cam actuation. (See Figure 13 - Busrail C-Clip Splice and E-Clip Location - 400 Amp).
5.) Install the Splice per section "INSTALLATION OF THE SPLICE CONNECTOR - 400 AMP".
6.) Position and tighten the two screws of each C-clip.
E-clip
Cam Spacer
Figure 12 - Busrail Cam Spacers
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March 25, 2013, Rev 0
All busway sections will come from the factory with one splice connection.
As the busways section is mounted on its hanger supports, the abutting end of the splice section can be
installed to the adjoin busway section.
Connection of Busway Sections and Fittings: (See Figure 14)
1) Each section of busway will come with one Splice Pack assembly (D) and two "E" Clips (E) one at each
end of the bus section. Make sure the “E” Clips are always installed on each end of each rail.
2) Bus sections are phase-keyed to maintain proper circuit phasing of the run.
3) Section 2 (with the splice) and Section 1 (without splice) will be aligned on their respective supports.
Slide Section 1 forward on the splice pack.
4) Slide Splice Joint Covers (B & C) and "E" Clip (E) into place positioning them equally across the bus.
5) Slide Grounding Plate (A) into place and secure the four grounding screws to the busway. Tighten each
nut to a torque value of 85 in-lbs.
6) Slide the Splice Pack Assembly so that it is positioned equally on either side of the bus section joint.
Grounding Stud Nut
diagram 7
A
B
D
Splice Pack
C
A Top Grounding Plate
EE
7) See Figure 8 for Splice Installation reference. Starting from one end of the Splice Pack (Figure 15),
only use the steel cam-actuator tools supplied to expand the splice joint contact assemblies into
contact with bus sections bus bars.
i) Insert one tool into the first cam port #1; the second cam-actuator tool into the adjacent cam port
#2. Rotate each tool ¼ turn to expand the contact plates.
ii) Rotate the adjacent, non-metallic cam spacers (a & b), ¼ turn to hold the expanded contact plate
in place. DO NOT ATTEMPT TO USE THE NON-METALLIC CAMSPACERS TO EXPAND THE CONTACT
PLATE ASSEMBLIES.
iii) Rotate and remove the cam actuator tool in cam port #1, and insert it into cam port #3. Rotate the
steel tool in cam port #3, ¼ turn to expand the contact plates.
iv) Rotate the adjacent, non-metallic cam spacers (c & d), ¼ turn.
v) Rotate and remove the cam actuator tool in cam port #2, and insert it into cam port #4. Rotate
and remove the cam actuator tool in cam port #3, and insert it into cam port #5. Rotate the steel
tools in cam ports #4 and #5 to expand the contact plates.
vi) Rotate the adjacent, non-metallic cam spacers (e & f), ¼ turn.
B Side Cover Support Plate
C Side Cover Support Plate
D Splice Pack Assembly
E “E” clip
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Cam
Cam
Cam
Cam
Cam
Cam
a
Cam
Port #1
Cam Spacers
bottom view
Cam
Port #2
bcdefgh
Cam
Port #3
Cam
Port #4
Cam
Port #5
Cam
Port #6
123456
vii) Rotate and remove the cam actuator tool in cam port #4, and insert it into cam port #6. Rotate the
steel tool in cam port #6 to expand the contact plates.
viii) Rotate the adjacent, non-metallic cam spacers (g & h), ¼ turn.
ix) Rotate and remove the cam actuator tools.
Port #1
123456
a
bottom view
Cam
Port #1
123456
a
Port #2
Port #3
Port #4
Port #5
Port #6
bcdefgh
cam spacer alignment before installation
Cam
Port #2
Cam
Port #3
Cam
Port #4
Cam
Port #5
Cam
Port #6
bcdefgh
cam spacer position - splice installation complete as seen from bottom
Figure 15 - Splice Installation Detail 400 Amp
8.) CAUTION: DO NOT proceed to 9) Installation of the Dowel Pin Devices until the Cam Spacers are
verified to be in the locked position. A properly installed Splice, when viewed from the bottom (open
channel) of the joined bus sections will show the Cam Spacers in the Locked Position as show in Figure
15.1 below.
Cam SpacerCam Actuator Tool Hole
Cams in Locked Position
Figure 15.1 - Cam Spacers in Locked Position
9.) Installation Of The Dowel Pin Devices
The Dowel Pins are used to secure open Cam Actuator Tool ports and add Cam Spacer functionality.
Material Required for Initial Installation (before busway is energized*):
10) Inspect the busway, and verify that the splice connections of the busway have been installed correctly
Six Dowel Pin Devices
per INSTALLATION OF THE SPLICE CONNECTOR – 400 AMP.
1. Verify no gaps between the bus connections
2. Verify the E-clips are positioned properly.
3. Verify the Cam Spacers (white-tipped, slotted lock pins) are positioned properly.
* please contact factory service for dowel pin installation procedure when working on an energized
busway (800-225-4838)
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11.) Each Dowel Pin has an O-ring set into a small groove on the insertion end of the dowel pin.
(See Figure 15.2).
O-Ring
Figure 15.2 - Dowel Pin
12.) Position the Dowel Pin into the round port between the first pair (viewed left-to-right, or right-to-left) of
installed white-tipped, slotted Cam Spacers. The conical pointed end is inserted first, and the end with
the O-ring inserted last. (See Figure 15.3)
Figure 15.3 - Positioning of Dowel Pins
13.) Using pressure push the Dowel Pin so that it is inserted completely into the Cam Actuator Tool Hole.
(See Figure 15.4)
Figure 15.4 - Insertion of Dowel Pin
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14.) Insert another Dowel into the next empty port on the splice. (Six empty tool ports per 400A splice
connection). Make sure that the O-ring on the dowel is inside the black bracket (E-clip) (See Figure 15.5)
E Clip
Before
Before
After
Figure 15.5 - Dowel Pin O-Ring Inside "E" Clip
15.) Repeat Step 13 until all the vacant Cam-Actuator Tool ports have Dowel Pins in them.
16.) Repeat the process for each splice in the bus run until complete.
16) Repeat the process for each splice in the bus run until complete.
INSTALLATION OF THE END CAP CLOSURE PLATE
Always terminate each busway run with an end cap in order to prevent any contact with live
conductors or internal components inside the extruded aluminum busrail housing. See Figure 16.
E Clip
After
To install, align side and top tabs with channels on busrail and tap in using a rubber mallet until flush.
The method of installation of the end caps is common for all mounting positions.
Figure 16 - Busrail End Cap Installation
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March 25, 2013, Rev 0
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CABLE TERMINATIONS TO THE END FEED BOX
STANDARD END FEED
Run all conduit fittings and supports;
attach cable to the listed lugs on the
termination pad.
Ensure that phasing is correct
(see Figure 17).
Once complete, torque all connections
with a torque wrench to the values
specified on the label located inside the
End Feed Box.
ØC
N
ØA
ØB
GROUND
Figure 17 - Standard End Feed Cable Terminations
BRANCH CIRCUIT MONITORING (BCMS)
END FEED
Run all conduit fittings and supports;
attach cable to the listed lugs on the
termination pad.
Ensure that phasing is correct (see Figure
18) and that Current Transformers (CT)
are facing in the correct direction (see
Figure 19). The H1 notation on the CT
should be facing the input power source.
Once complete, torque all connections
with a torque wrench to the values
specified on the label on the End Feed Box.