TBC Cast Resin Busway Manual

Transcription

1 TBC Cast Resin Busway Manual No : SA3001 Pub. Date: Reversion:1.0. CONTENTS Forward. 1 Busway Knowledge..2 Receipt Check... 3 Storage... 4 Handling 5 Installation. 6 Final Check... 7 Operation Conditions 8 Care and Maintenance... 9 Getting Rid of Failure. 10 Contact Us... 11

2 Forward 1 This manual is a guide of practical information for installation, test, operation and maintenance of TBC cast resin busway system (indoor only). A successful busway service depends on as well as proper handling, precise measurement, layout, design and engineering fitting installation, testing, commissioning, maintenance. Neglecting or failing one of the fundamental requirements may lead to personal injury and damage to electric equipment or others. Through planning and sufficient coordination among manufacture, civil contractor, electrical contractor, busway installer and project administrator are necessary for excellent busway installation and service. For specific information not covered by the instructions in this manual, please contact directly Taiwan Busway Corporation for technical support and services thru tbc@msa.hinet.net, or dial Contents as follows: Forward Busway Knowledge Site Receiving Check Storage Handling Installation Final Check Operation Condition Care and maintenance Trouble shooting Contact us Introduction of scope and each chapter Construction and features of busway Counting and checking on the arrival of the parts Storage in the job site Lifting and transportation Basic knowledge in installation Checking, testing, and records after practical completion Routine maintenance and scheduling Procedure of trouble shooting Contacting information Prior to activation of busway system, be sure to read this busway technical information to avoid an injury or damage from improper installation

3 Busway Knowledge Overview of busway components Side wall Busway straight Conductor Fixed torque screw Vectoring cover plate/ Directional cover plate Upper covering Flanged gasket Joint stack 2.2 Elbow type information, please refer to section 1-20, 2-1~2-13 LV Vertical Edgewise Elbow NV Vertical Edgewise Elbow TV Edge Tee LH Horizontal Flatwise Elbow NH Horizontal Flatwise Elbow TH Flat Tee - 2 -

4 Receipt Check 3 Site Receiving: 3.1 When delivered at project site, please check if the items have been exposed to moisture or physical impact, the fixed steel ribbon is loosen or not, shall the ribbon is loosen, please refix it to avoid the danger occurring when unloading the goods. 3.2 It requires applicable forklift to unload the items to the floor in according to the total weight marked on each pallet. 3.3 Please check if there is any damage during unloading and transportation in packaging materials and busway body. Shall there is any damage found, please call the attentions of the transporter and take photo (if possible) and contact TBC. 3.4 Do not expose busway items to direct sunshine, rains, moisture or other possible contaminants. 3.5 Handling on job site must be done per the instructions on this manual. 3.6 Upon receiving the busway sections and fittings, count and check with the delivery note to tally the delivery is complete without missing. Storage Busway shall be stored in the project site or assigned locations for some time repeat the receiving checks and restore the packaging materials from time to time. 4.2 The busway sections and fittings should be stored in a dry place, protected from dirt or water. Such locations can not be the passages where chance of physical stress is inevitable. 4.3 Busway can not be put on the floor directly. Busway should be cushioned by a wooden batten ( / 100mm 100mm 1000mm) and should be kept horizontally and stacked securely, shown as illustration below

5 4.4 To avoid the joints of busway from contamination and physical stress, the packaging materials of both ends should remain intact w/o opening until the busway items are ready for installation. 4.5 Busway shall be stored in a clean dry space having a uniform temperature to prevent moisture condensation. Shall the storage period be longer, the busway must be covered by plastics sheets. 4.6 It is recommended that busway not be stored outdoors. However, if it must be kept outdoors, cover it securely to provide protection and avoid exposed to direct sunshine. 4.7 Outdoor busway should be treated exactly the same as indoor busway to ensure the quality for busway is not weather resistant until completely installed. Handling 5 Cast resin busway is heavy electrical equipment; the following guidelines must be obeyed to avoid personal injury. 5.1 Handle with Care is the basic rule to avoid freefalling, such impact may cause damage to internal and busway system structural integrity and performance. 5.2 Do not use busway either end or both ends for lifting busway section(s) or fitting(s). 5.3 Verify the weight of busway is within the rated capacity of the handling equipment at all time. 5.4 Foamed rubber or soft materials to apply on the trolley to avoid direct contact between busway and trolley, the resin may be damaged. 5.5 When a platform dolly is used, balance the load carefully with well-fixed package.(nylon rope is used to fix busway. 5.6 A forklift is a good tool in handling busway movement, balance the load carefully in the process due to the smooth and slippery cast resin surface of busway. 5.7 Elevators, (manual or power operated) can be used in moving loads of busway between levels, busway joints must be protected carefully to avoid impact, and must note if there is enough space vertically accommodate such handling requirement. 5.8 If a crane is used to unpack the pallet, use nylon straps only, steel wire or sling is not allowed. Balance the load with care and check if the fastening steel straps are loosened to make sure lifting safety all the time

6 Installation Preparation Proceed the necessary works in according to the busway diagrams Check and clear the routes and path before transferring the busway items from storage place(s) to each final installation location Check the project site and plan for the installation sequence Check if there is any barrier in the busway route; clear all possible obstacles, obstruction in the busway system route, such as unexpected pipes, poles. And check the space dimension and positions of equipments where busway will be installed The route and path provide busway from storage place to the final installation location must give sufficient space in handling Wood batten is necessary and useful, which can serve as cushion material when busway is temporarily stored prior to installation, to avoid direct contact between busway and floor, or dolly or carrier, the resin may be damaged Nylon strap or Nylon rope is the best option in lifting, shall sling is applied, a soft protective wrapping material gasket must be added to keep busway surface resin from damage by hard sling wires Provide sufficient in working lighting When busway joints need to be dissembled, new fixed forgue bolts are needed, or apply parts, torque wrench to desired torque requirement Before busway installation, check the bill of material to verify all the necessary accessories and screws are complete, the description and identification of each piece are correct Before mounting procedure, check if the installation drawings are complete and the routes of hanger and support are clear. 6.2 Sorting and arrangement of busway items Make planning for installation and check if the installation route is unobstructed in according to the layout Check with the layout plan and bill of material to position the feeder busway items from the pallets, moving to the installation site in sequence as coded ready for installation lifting

7 6.2.3 While sorting busway items, follow layout and special attention should give to busway joints, profile plates and direction of nameplates to avoid phase interchange during installation that may cause unexpected damage and delay of project. 6.3 Hanging & supporting Installation of busway hangers according to layout drawings Check the installation sequence and route as per layout planing Construction of hangers: - 6 -

8 6.3.4 Construction measures of hangers are agreed by busway and the hangers applied. Threaded rod Table 1 Double nut Copper C Channel C2000(4.1x4.1cm) distance for hanger: 150cm Length=30[cm] Length=50[cm] Length=100[cm] Length=30[cm] W. Rated flex flex flex moment/stress 150cm [A] δ MAX [cm] δ MAX [cm] δ MAX [cm] M MAX σ MAX [kg] [cm-kg] [kg/cm 2 ] Length=50[cm] Length=100[cm] moment/stress moment/stress M MAX σ MAX M MAX σ MAX [cm-kg] [kg/cm 2 ] [cm-kg] [kg/cm 2 ] C Channel: C2000 (International standard e.g. ASTM, 2007) Dimension: 41 41, Thickness: 2m/m (min.) Allowable stress: 1160 [kg/cm 2 ] Break down stress/load 1160Kg/cm 2 Ex. 2000A Busway distance for hanger: 150cm moment L: 50cm From Table 1 Flex max: cm Stress max: kg/cm 2 Actual load 428 kg/cm 2 < hanger allowable stress 1160 kg/cm 2-7 -

9 6.3.5 Installation of hangers (optional) H Channel: RC Configuration: 6.4 Lifting and Protection Two supporting points are recommended when crane is used to keep balance and avoid twisting Nylon strap or nylon rope is the best option in lifting, shall sling is applied, a soft protective wrapping material must be added to protect busway surface resin from damage by hard sling wires When using forklift during installation, balance the load carefully in the lifting due to the slippery smooth surface of cast resin busway

10 6.4.4 As busway is hoisted to position and supported by hangers, adjust the vertical height and horizontal position properly and fasten by screw nuts In vertical mounting, lift the busway section to the higher position then lay downwards, that will make installation easier After busways sections and joints are installed, the busway sections must be covered properly to protect them from moisture and dirt. 6.5 Installations in joints assembly and cleaning and joints installation Before joints assembling, the conductors contact surface of joints and busway conductors must be dry and cleaned Prepare fixed torque bolts and insulation tubes on joints. Ready to be plugged into side plates Pull busway conductors and joint stack holes aligned. Both insert insulation tubes fasten joint stack by fixed torque bolts and nuts Space between busway conductors is 10m/m Adjust the horizontal and leveling of busway sections to exact position, tighten fixed torque bolts and nuts continuously torque value about 65-70lb-ft Shall busway must be water proofed; the protection shielding must be fixed in proper position on both ends In case busway joints need to be reassembled in any reason, knowing the fixed torque bolts has broken, retighten the bolts w/torque wrench by 65-70lb-ft torque Tighten the bolts of the cover plante of the joint closure after assembly of the joints or cover the assembled joint w/pvc film to prevent dust or moisture contamination. Test insulation resistance value right after joint assembly record Tighten joint enclosure covering plates bolts w/ water proofing gaskets to achieve water roof feature. (The busway system is water and dust proof once enclosures - 9 -

11 Shall the joints can not be assembled w/in the same working day. The joints enclosures must be covered and protected by PVC film from dust and moisture contamination. 6.6 Space intervals between busway installations Min. interval between vertical arrayal Min. interval between horizontal arrayal Min. space between joint and wall Min.space between plug in units opening and wall Min. space between vertical channels Min. space between joint and ceiling, floor floor floor

12 6.7 Wall flange and grouting with fire resistance mud Opening size of wall flange Rated Cu Al [A] type A B type A B WF WF WF WF WF WF WF WF WF WF WF WF WF WF WF WF WF WF Wall flange Where a busway protrudes through wall or floor, to grout with fire resistance mud to align with the wall and fix the flange frame on the wall. grouting flange frame(iron) 11

13 6.8 Mounting of floor steel channel spring hanger Fix the floor steel channel on the floor Tighten the nuts of spring hanger on the floor steel channel Two spring hangers are locked tightly in opposite by full threaded rods Calculate burden weight load according to busway weight list, installation layout and busway length on each floor, adjust the spring tension nut to the accommodate load bearing value 彈簧架型式及配合 Rated Cu Al Full width [A] type A B type A B SH SH SH SH SH SH SH SH SH Rod length 2000 SH SH SH SH SH SH SH SH SH Screw reference list 0 max.. loading 500KG/set Spring hanger load/weight bearing terms:contain weight bearing a. SH150 Spring hanger can max. 500kg. b.sh150 weight bearing is subject to the floors height to calculate busway 12

14 Floor Clearance 樓層間距 (max:5000mm) length and weight, the supporting of spring hanger depends on this weight. Ex: Floor height 3.5m capacity: 4000A weight: 132kg/m Spring hanger supporting= 3.5 x 132kg= 462kg height of spring shall be adjusted to 120mm Distances between spring hangers must comply with the terms (a, b): a. Weight bearing of each floor must be less than 500kg (as 6.8.5). b. Installation interval is listed in Table 2. c. Installation interval is decided by flex. And stress. Ex: Floor height 5M capacity: 4000 earthquake: class 5 Max. Flex. δ= cm Max. Stress σ = 16 kg/cm2 busway allowable stress σallow = 660 kg/cm2 Allowable stress 660 kg/cm2 > max. Stress 16 kg/cm2 d. Installation interval of spring hangers and weight bearing. (Table 2.) e. Installation interval of spring hangers (Table 3.) Copper Table 2. Distance for vertical installation Distance Rated [A] Distance 3[M] W./Floor [kg] 4[M] W./Floor [kg] Distance 5[M] W./Floor [kg] Table 3. Distance for installation for SH Copper Distance for installation busway for SH Capacity[A] [M] 800~ ~

15 6.9 Installation of Plug in Unit Installation of Plug in Unit (lower than 630A) Check if the PIU is of the correct dimension before mounting Allow sufficient space and clearances to install, remove plug in units and open covers All plug-in provisions that are not in use must be covered with the covers plates provided by the manufacturer All tap off and plug in units should be in the OFF position during mounting on busway and be aware that they are set in the correct position Installation of Plug in Unit Check if the PIU is of the correct dimension before mounting Allow sufficient space and clearances to install, remove PIU and open covers All plug-in provisions that are not in use should be covered with the covers plates provided by the manufacturer All branching and plug in units should be in the OFF position during mounting on busway and be aware that if they are set in the correct position. 14

16 PE R S T N MCCB NFB primary plate door handle copper plate PIU socket torque screw(65ft-lbs) busway PIU plate PIU opening figure 3. components pin plated screws PIU plate Step 1. Loosen torque bolt (1~2circles) Step 2. Fix PIU plate on busway. Step 3. Align the PIU box bracket hole to the fixed hole on busway, insert the pin into the hole. Step 4. Clamp the PIU unit into busway opening provision. Step 5. Lock the side joint plate on busway plate. Step 6. Lock the torque screw tightly after the bolting, check if all the joints are locked tightly. 15

17 6.10 Allocation of PIU loading The following condition must be considered about the Load Distribution of PIU load distribution of PIU. a. The total loading capacity of PIU can not exceed the max. busway loading capacity. b. Busway Capacity 4000A & 5000A are dual bridged design, PIU loading capacity can not exceed 50% of. busway loading capacity, this factor must be considered when designing load distribution. Ex. 4000A busway system is composed of 2lines 2000A busway, the total PIM loading capacity each line of can not system exceed than 2000A max. busway loading capacity. Dual connected Dual connected 6.11 Water proofing barrier As the floor opening is prepared, a barrier should be provided to restrict the flow of rain into the opening The dimension of the barrier is 10 10cm square Before the water proofing barrier is built, the floor must be roughly finished and rebar gronted to ensure structural strength and fully water proofed. 16

18 Final check 7 All TBC cast resin busway has passed the required tests in factory to keep premium quality. Incase the busway is stored in poor environment for long period, appearance check must be applied and the parts must be cleaned thoroughly. Before energizing, conduct an insulation resistance between phases and ground with a tester. Special attention must be given to the spastic energy discharge of the hi-resistance tester accumulating energy after test for safety purpose. 7.1 Steps to be taken before energizing: Recheck all joint connections for tightness. Follow the manufacturer s torque instructions Ensure that all tap-off or plug in units are in the OFF position, and the insertion clip is connected properly Verify that the system phases comply with the installation drawings Check if the grounding is properly installed Measure insulation resistance with an insulation resistance tester rated higher than 500V between phases and ground and record. (Must conform to IEC, CNS procedures and standards) 17

19 7.1 Punch list item Checking contents busway joint PIU 1 Marks of phases and circuits Braided flexible Copper conductor and ground 2 bolts are tightly locked 3 Each Busway section is supported by hangers 4 Busway section installed straightly and aligned 5 Spring hangers nuts are tightly locked 6 Adjustment of nuts of spring tension sets 7 Scratches and patches on busway system 8 Busway surface is clean End cover is locked tightly and fully water proofed Torque bolts are tightened properly tightly (random examed) Each connector is correctly installed according to drawings 12 Clean on joint closures 13 test 19 Screw on cover locked tightly (gasket expands slightly) 14 Confirm Torque ready on PIU joint screws 15 PIU enclosure position and tightened properly. 16 PIU switch on OFF position 17 Correct markings Enough space for door opening & wiring 18 connection Measure insulation resistance value with Hi-resistance tester at DC500V location location 2F 3F 4F 5F 6F 7F 2F 3F 4F 5F 6F 7F No.SA Authorized: 18 Inspector:

20 7.2 PIU (plug-in unit) Final check list Taiwan Busway Co., Ltd. PIU Final Check List 1. Job Name: 2. Subcontractor: 3. Inspect date: 4. Punch List item Checking contents Location Location PIU Test 1 Confirmations of torque value of PIU joints bolts and screws. 2 PIU enclosure tightened properly 3 PIU switch OFF position 4 Correct markings 5 Enough space for door opening & wiring 6 Measure insulation resistance value with Hi resistance tester at DC 500V 2F 3F 4F 5F 6F 7F 2F 3F 4F 5F 6F 7F No.:SA Authorized: Inspector: 19

21 Operating conditions TBC cast resin busway is designed and manufactured according to IEC standard. It can be operated in ambient temperature up to 40. The temperature rise of any part of the busway system should not exceed 55K by full loading, when average ambient temperature is limited to 35. Please confirm such ambient temperature limitation before energizing the busway system. 8.2 After the busway is energized, the surface temperature can rise to 90, therefore, please provide well ventilated environment. Keep unexpected tubing materials and equipment away from busway system. Prevent accident or wound from overheating subjects. 8.3 After the busway is energized, do not remove any components of busway system. (Joint covering plate, spring hangers ) Please disengage live line power before scheduled and unscheduled maintenance. Live line maintenance is absolutely prohibited. Care and Maintenance For maintenance personnel safety please confirm grounding system has been properly installed, and connected. Disengage or switch off busway power line before conduction scheduled or unscheduled maintenance service. 9.2 First scheduled inspection and maintenance after energizing busway system. Conduct first inspection and maintenance to confirm each and every joint bolts and nuts are tightened properly according to manufacturer s recommended torque value. Such scheduled inspection maintenance program should be conducted within 6 months from initial energizing of the busway system. 9.3 Periodical inspection and maintenance TBC busway System is nearly maintenance free product. Nevertheless, periodical inspection and maintenance program(s) will improve its service quality and life span for many years more. The inspection and maintenance program(s) scheduling depends on installation environment conditions. Generally speaking, when the TBC busway system is installed in clean and cool air environment, we recommend a once every 2 years schedule will be applied, when TBC Busway System is installed in dusty and warm air environment, we strongly recommend once every 3-6 months scheduling will be applied. Unscheduled inspection and maintenance program(s) can be conducted by experienced electrical supervisor(s) or administrator of each building or plant. 20

22 Recommendation periodical inspection and maintenance guideline and detailed service scope(s). Site Condition Schedule Scopes Clean & Cool 3 years 1. Turn off power switch or disengage power line entirely. 2. Conduct insulation resistance test in each circuit or phase. 3. Apply brush to remove dusts on the TBC Busway surface. 4. Dusty Every 1 year 1. Turn off power switch or disengage power Line entirely. 2. Conduct insulation resistance test in each circuit or phase. 3. Apply brush to remove dusts on TBC busway surface. 4. Heavily Dusty Eevery 6 months 1. Turn off power switch or disengage power line or below entirely. 2. Conduct insulation resistance test in each circuit or phase. 3. Apply brush to remove dusts on TBC busway surface. 2. Use a brush to clean dust off 3. Extract some sections and perform test 21

23 TBC Busway Trouble Shooting Trouble Shooting Abnormality Possible Reason(s) Trouble Shooting Procedures ACB protection switch 1. Busway overloading 1.1 Please check if PIU switch trips-off, tripped-off if yes, we suggest the load side may short circuited. 1.2 Please check if TBC Busway has been overloaded or actual load condition has exceeded the busway rated capacity. 1.3 Please conduct busway insulation resistance testing (no less than 5MΩ) to confirm the TBC Busway is in its normal service condition. 1.4 After eradicating overcurrent issue and confirm the TBC Busway System is in normal service condition (insulation resistance value is higher than 5MΩ), you may reenergize the system with care. 2. Busway Short Circuited 2.1 Please perform insulation resistance test and confirm TBC Busway has short-circuited. 2.2 Contact local technical service and support unit or local distributor of TBC or call up TBC technical suppot. 2.3 Ocular inspection along TBC Busway route(s) to find any abnormality in PIUs Busway joint(s) or Busway section(s). Such as Busway section(s) decoloration enclosure cover plate(s) deformations, busway deformation, burnt odor or mark etc. 2.4 After all verification and confirmation of failure, presence and witness by local distributor, representative(s) or TBC personnel 22

24 at site. Disassemble component(s) or part(s), replace new component(s) or part(s) will follow according to the recommendation of TBC technical representative or personnel. PIU tripped-off 1. Overloading 1.1 Please measure PIU secondary loading current to verify if there is possible overloading. 1.2 To eradicate the overloading trouble before re-switch on the PIU switch. 2.Secondary side short 2.1 Please measure resistance at circuited secondary side and find out if it is short circuited. 2.2 To eradicate said short circuited abnormality before re-switch on PIU switch. Busway overheating 1. Busway Overloading 1.1 Please verify loading records to check if actual load profile exceeds busway rated capacity. 1.2 Please reduce load current within busway rated capacity to eradicate busway overheat problem. 2. Abnormal temperature 2.1 Conduct infra-red thermal scanning rise due to Joint(s) bolt(s) and Nut(s) loosened on all joints to find out the possible abnormal not joint(s). Mark the abnormal joint(s), open up joint enclosure(s) and re-tighten the joint bolts and nuts to desired 65-70lb-ft torque. 23

25 Contact us 11 Taiwan Busway Co., Ltd. No. 23, 9 th Road., Lin Kou 2 nd Ind. Park, 244, Lin Kou Hsiang, Taipei Hsien, Taiwan, R.O.C TEL: FAX: Web site: address: tbc.busway@msa.hinet.net 24