12/11/2017 Ensuring a Good Bus Duct Installation

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Ensuring a Good Bus Duct Installation

Paying attention to certain details of bus duct projects will ensure trouble-free service.Abus duct system is an
e ective method of distributing power to your switchgear and various loads. Yet, bus duct problems lead to
catastrophic damage and extensive downtime. Let's look at how you properly order and install your system.
Ampacity. You may know the basic bus duct selection requirements already

John Paschal | Oct 01, 2000

Paying attention to certain details of bus duct projects will ensure trouble-free service.

Abus duct system is an effective method of distributing power to your switchgear and various loads. Yet, bus duct
problems lead to catastrophic damage and extensive downtime. Let's look at how you properly order and install your
system.

Ampacity. You may know the basic bus duct selection requirements already (see sidebar below). One of those
requirements is ampacity. Rather than establish ampacity based on a standard chart's temperature assumptions, account
for your actual operating environment. Bus typically occupies the high-temperature area near the ceiling.

Once you've determined that area's maximum ambient temperature, factor in the specified temperature rise from no load
to full load. For example, it's common for industrial bus duct specifications to limit ampacity to 1000A per sq in. of copper
conductor. However, many brands of bus duct have current ratings based on 1800A per sq in. of copper; thus the
temperature rise (from no load to full load) increases. If your bus duct run is long and operates at 1800A per sq in., you
must accommodate voltage drop within the bus duct.

L ti M b d t i t ll d i i d t i l d i l f iliti i di t l d t f th
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Location. Many bus ducts installed in industrial and commercial facilities are immediately downstream of the
transformers, but upstream of the main overcurrent device. Thus, transformer protection devices often inadequately
protect the bus duct zone from fault. So, consider the value of extra protection with service conductor bus ducts. The extra
up-front cost is nothing compared to the savings in downtime.

Allow for the space requirements and weight of the bus duct. You may need to change other components or select a
different style of bus duct for your installation. One place to pay particular attention is at the transformer. Since torque
forces can easily induce transformer-bushing seal leaks, you want to prevent vertical loading on transformer bushings. To
do so, ensure proper support for the vertical sections of the bus bars within the bus duct enclosure. Also, the air terminal
chamber at the transformer must be of adequate structural design to assume the weight of the vertical bus duct as it
terminates at the transformer end. Otherwise, the weight of the bus duct may bend the air terminal chamber - sometimes
immediately, sometimes after several weeks. Contact the transformer manufacturer for assistance with determining the
suitability of this chamber for the intended bus duct.

If you are installing bus duct outside, select a housing type that sheds rainwater - rather than pooling it on top of the
housing. Don't rely on sealants to make up for poor housing selection. Even the best sealants age and crack - especially
when exposed to sunlight. Even microscopic cracks can admit sufficient water for a violent electrical explosion. Don't
forget those bus duct breather openings. Order them with factory-installed screens to prevent insect penetration.

In humid climates, bus ducts installed outdoors need protection from internal and external rust. You can provide this
protection by choosing a housing made of a rust-resistant metal - such as stainless steel. Or you can coat the housing
metal to prevent oxidation. You can assure coatings will last a long time by starting with a two-part epoxy primer or
chromate vinyl wash primer and finishing with either a two-part polyurethane or catalyst-cured polyester paint. Specify
such finishes only if you can't get the rust-resistant metal to begin with. The finishes are expensive and have
environmental consequences.

If you are going to install any part of the bus duct outdoors, use factory-installed pre-wired space heaters with integral
thermostats to prevent condensation problems. These are not expensive. Where the bus duct enters through an outside
wall, use flame-retardant, waterproof, and vapor-resistant wall entrance fittings. It's likely you'll need to support the bus
duct system at the wall. In such a case, the wall flange must be able to carry the structural load of the bus duct weight.
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Finally, don't forget the assembly hardware. Again, outside service is more demanding - don't settle for anything less than
stainless steel. Cost reduction from using cadmium-plated hardware can be economically false due to problems resulting
from rust.

Working with the manufacturer. The degree to which you must interact with the factory depends on the size and lead
time of your order - as well as your project deadlines. What sets the stage for problems more than anything else is a
specification problem. Specifications are often incomplete, incorrect, or poorly communicated. Avoid changes in
specification midway through the manufacturing process by carefully planning upfront. Pay special attention to
dimensions. This is arguably the biggest problem area in bus duct orders.

When you place your order, work with your sales representative to ensure the manufacturer understands and approves of
your specifications. In some cases, the manufacturer will recommend specific changes that will improve performance,
reliability, or lead time. Consider such recommendations as advice from an expert, but be sure to review them against the
particulars of your installation.

To help assure longevity of your bus duct system, ask the manufacturer to wrap (or power dip) the individual bus bars
(within a given bus duct) with non-hygroscopic insulation (it doesn't absorb moisture). When you add insulating boots at
joints (during installation), you end up with a second insulation measure.

Always do an acceptance test before beginning the actual installation process. The first step is to make sure the
dimensions are correct. Then, check for completeness of your order.

Do you have all the required transitions, wall flanges, transformer flanges, and switchboard flanges? Do you have the
copper braids that serve to connect the bus duct bars to the transformer bushings? Are these the correct size and quantity
for the ampacity and physical characteristics? Check these braids for the right bar and pad size.

Ensure the bolt-hole sizes, bolt-hole relative locations, and bolt-hole diameters match at each end of each factory-
assembled braid. On a large order, it makes sense to visit the factory and do the acceptance testing there. On smaller
orders, do this testing as soon as the order arrives - know ahead of time when that will be, and schedule someone to do the
testing.

Installation tips. Your bus duct joints and terminations should be silver-plated when made of copper, and tin-plated when
made of aluminum. Make every effort to use copper bars when bolting to copper switchgear bars, and to use aluminum
bus when bolting to aluminum terminals. When mixing the two metals is unavoidable, liberally apply a manufacturer-
approved antioxidant compound to the dry aluminum bars immediately prior to assembly. Ensure no moisture is present
in the joint.

Bus manufacturers often provide assembly hardware kits that include bolts, nuts, flat washers, locking devices, and
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Belleville washers. You'll save yourself considerable design work and project administration headaches by using these kits
instead of third-party hardware. If you're not using such a kit, use the bolt material, type, and size the manufacturer
recommends for that particular bus duct. If using Belleville washers, use the recommended size and type.

With all assembly hardware, follow instructions precisely so you prevent high-resistance connections or permanent
damage to the bus system. While most Belleville washers do not require a torque wrench for proper assembly, nuts and
bolts do. Don't use generic torque charts. These assume a bolt composition that probably won't match what you're using.
Use torque specifications from the manufacturer of the bolts you are using. Be sure to note the composition (which may
include more than the metal content of the bolt), lubrication, hardness, thread pitch, and size when obtaining the torque
specification.
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Assign someone other than the assembler to test each joint after assembly - because it's easy to miss something. Testing
should include visual checks, torque checks (except for Belleville washers), and resistance measurements. Belleville
washers are usually at the correct torque, if tightened just until they look flat.

After joints pass the testing, protect them with insulating boots. These should encapsulate the entire array of bolt heads
and nuts, since bolts often come very close to other bolts in opposite phases or to the bus duct case.

As a final test, energize the bus with no load. Wait an hour or so, and then give it an infrared scan. You shouldn't have any
hot spots - if you do, repair them and scan again. Once you complete this step, you are ready to put the bus into service.
Then get ready for a life of trouble-free operation.

Sidebar: Standard Requirements for Bus Duct Selection

Has the correct voltage rating

Has sufficient current rating

Has right quantity of conductors (phase, neutral, and ground)

Carries UL label or equivalent

Has adequate short circuit bracing

Is totally enclosed

Carries NEMA 1 rating for indoor or NEMA 3R for outdoor use

TAGS: CONSTRUCTION

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The Evolution of Maintenance Part 2 The Big Just Get Bigger

Petmal/iStock/Thinkstock

MAINTENANCE, REPAIR & OPERATIONS > ENERGY MANAGEMENT

N.Y. Governor Announces $12 Million to Increase Industrial and Multifamily Building Energy Efficiency

Funding helps buildings adopt clean energy technology to monitor energy use and lower costs

Dec 08, 2017

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New York Governor Andrew M. Cuomo has announced $12 million to enhance energy efficiency in industrial and
multifamily buildings. This expands the Real Time Energy Management (RTEM) initiative launched last year to improve
efficiency in commercial buildings, including office buildings, hotels, universities, hospitals and retail stores. RTEM
systems continuously monitor real-time data of a building's energy use and transform it into actionable information, by
using sensors, meters, and other equipment. The data can pinpoint a building's operational inefficiencies to help identify
conservation measures and help justify capital improvements. Approximately 60% of greenhouse gas emissions in New
York come from buildings.

By reducing energy use in commercial buildings, multifamily and industrial buildings, this program advances Governor
Cuomo's efforts to reduce greenhouse gas emissions 40% by 2030 and the Reforming the Energy Vision strategy to build a
clean, resilient and affordable energy system for all New Yorkers.

Related: New York Governor Announces Immediate Actions to Improve Subway System Power Service

The current expansion brings the total RTEM program to more than $40 million in investments supported by the state's
Clean Energy Fund. The additional funding for the expanded RTEM initiative includes:

$5.7 million in direct incentives for RTEM projects in the industrial sector;

$830,000 for multifamily RTEM projects;

$6 million for commercial RTEM projects that include cloud-based controls.

More information on RTEM funding is available at NYSERDA's website.

TAGS: CONSTRUCTION INTELLIGENT BUILDINGS DESIGN

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SAFETY

ACBMA Study Says AFCI Circuit Breakers Provide Better Protection in Homes than AFCI Receptacles

American Circuit Breaker Manufacturers Association says new research shows advantages of AFCI circuit
breakers over AFCI receptacles.

Dec 08, 2017

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American Circuit Breaker Manufacturers Association says new research shows advantages of AFCI circuit breakers over
AFCI receptacles.

The American Circuit Breaker Manufacturers Association (ACBMA), a non-profit group whose members include Eaton,
General Electric, Schneider Electric and Siemens, recently announced that following comparison testing between Arc
Fault Circuit Interrupter (AFCI)/Dual Function circuit breakers and AFCI/Dual Function receptacles, AFCI breakers
successfully protected against dangerous parallel arcing throughout the entire home run of wiring in new home building,
while AFCI receptacles did not. AFCI receptacles also required additional encasement costs either in metal conduit or
cement to meet National Electrical Code (NEC) standards.

As manufacturers of these important safety devices, we all share the common goals of protecting new homes from
electrical fires and protecting people from the risk of electrocution. It is critical that the electrical community fully
understand the differences between arc fault technologies and their options in the marketplace, said Alan Manche, Vice
President external affairs for Schneider Electric and ACBMA member, in the press release.

A good example of these differences is that while AFCI receptacles do offer protection at the outlet, they repeatedly failed
beyond that point as demonstrated in a recent ACBMA test against UL 1699 standards regarding parallel arcing faults on
the branch circuit home run wiring in the home. AFCI circuit breakers, however, successfully passed this test not only
detecting, but stopping that deadly form of arcing that can lead to electrical fires.

The results of these tests prove that if AFCI receptacles are used instead of AFCI circuit breakers, up to 30 percent of
wiring in every new home built could be at risk from dangerous parallel arcing because AFCI receptacles will not detect
that condition, added Kevin Lippert, Manager Codes and Standards, Eaton Corporation and ACBMA member. That
creates a very real risk that should be of significant concern for every electrician, inspector and ultimately the
homeowner.

The 2014 and 2017 NEC codes also require that AFCI receptacles can be used in new home construction only if their
home run wiring is enclosed in two inches of concrete or steel-armored type cable. In contrast, AFCI circuit breakers do
not require these additional efforts or costs and are UL approved as a means of protecting against electrical fires, and have
met the NEC requirements for nearly 18 years.

Our greatest concern is that electrical contractors and inspectors nationwide are not being made fully aware of the
important differences in arc fault protection technologies and the associated requirements, said Randy Dollar, Director,
Codes and Standards, Siemens and ACBMA member. While some claim AFCI receptacles are cheaper at around $30 and
work just as well as AFCI circuit breakers at around a $40 cost, the facts and testing prove otherwise. The AFCI
receptacles failed critical testing regarding protection against parallel arcing and also require additional costs in the
form of labor and materials to comply with code requirements. AFCI circuit breakers protect a homes entire electrical
system - including the home run - from parallel arcing without those additional costs.

AFCI circuit breakers have been an NEC requirement since 1999. Each year the National Fire Protection Association
indicates there are more than 45,000 electrical house fires in the U.S. For more information on the testing visit
www.acbma.org. Electrical contractors and inspectors can also download additional factual information on the website.

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General Electric (GE), Boston, said it will eliminate 12,000 jobs in its Power Division in response to changing market
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