I-LINE D BUSWAY INSTALLATION INSTRUCTION

76521-030-02
 Follow the safety label instructions on this
equipment and inside this bulletin.

DANGER
HAZARD OF ELECTRIC SHOCK, BURN, OR EXPLOSION
Only qualified electrical maintenance personnel should install,
operate, service, or maintain this equipment. This document
should not be viewed as sufficient for those who are not
otherwise qualified to operate, service, or maintain this
equipment discussed.
Turn off power to busway before installing, removing, or working on this equipment.
Always use a properly rated voltage sensing device to confirm power is off.
The successful operation of this equipment depends upon proper handing,
installation, operation, and maintenance.
Failure to follow these instructions will result in death or serious injury

WARNING
HAZARD OF ELECTRIC SHOCK, BURN, OR EXPLOSION
Protect this equipment from contaminants such as water, salts, concrete and
other foreign matter and other corrosive environments before and during installation.
Outdoor equipment is not weather resistant until completely and properly installed.
Do not sit, walk, or stand on this equipment.
Failure to follow these instructions can result in death, serious injury,
or equipment damage.

CAUTION
HAZARD OF EQUIPMENT DAMAGE
Hydrocarbon spray propellants and hydrocarbon-based sprays or compounds
will cause degradation of certain plastics. Before using products to clean, dry,
or lubricate components during installation or maintenance, contact your local
Schneider Electric sales office.

76521-030-02
CONTENTS

INTRODUCTION 1

RECEIVING HANDING STORAGE 2

INSTALLATION NOTE 5

HANGER INSTALLATION 8

BUSWAY INSTALLATION 13

END CLOSURE ASSEMBLY 15

WALL/FLOOR FLANGE 16

STEPS TO TAKE BEFORE ENERGIZING 17

ENERGIZING THE EQUIPMENT 19

APPENDIX 1 20

76521-030-02
INTRODUCTION

This manual contains instructions for the handling, storage, installation, operation, and
maintenance of I-LINE D busway equipment manufactured by Schneider Electric. The
purchasers, engineering, installation, and operating staff supervisors should familiarize
themselves with this manual and become acquainted with the appearance and characteristics
of each piece of the busway.

Every I-LINE D busway device is carefully inspected and packaged at the assembly plant.
Construction is checked, both structurally and electrically. After a complete inspection, the
busway is prepared for shipment. Each section is packaged for easy handling before
installation.

The catalog number is plainly marked on each shipping section.

1 76521-030-02
RECEIVING, HANDLING & STORAGE
Receiving

Upon receipt, check the packing list against the

equipment received to ensure the order and shipment
are completed. Claims for shortages or other errors
must be made immediately.

Handling
1
2

1
2

3
×

76521-030-02 2
 Using nylon straps to distribute the
weight of the section

Do not drag the busway on the Avoid using objects with

floor. sharp edges to lift the busway.

Do not use busbar ends for lifting Do not use busbar ends for
busway sections or fittings. lifting busway sections or
fittings.

padding

3 76521-030-02
 Storage
Waterproof，anti-theft，dustproof Control temperature and humidity

+40
RH≤50% when T=40°C,
RH≤90% when T≤20°C,

-5

Stored indoor

76521-030-02 4
INSTALLATION NOTE
Environment NOT Outdoor installation
Indoor installation

40

-5

RH≤50% when T=40°C,

RH≤90% when T≤20°C,

Protection
Use “Installation Protection Bag” at the end of unfinished run

Installation Protection Bag

Installation
Protection Bag

Installation Protection Bag #: 77134-001-XX(Need to puchase)

Recommended bus w idth(W)

Installation Protection Bag Catalog
mm inch
77134-001-01 W<240 W<9.4
77134-001-02 240”W<450 9.4”W<17.7
77134-001-03 W•450 W•17.7

5 76521-030-02
 Clearance
Required clearance for busway installation(without plug-in units)

100
100 100 100

100
100
100

149
149

100
100

1. “100” is minimum dimension

2. “A” : maintenance dimension requires a minimum A
dimension equal or greater than busway width. busway width
3. Uint: mm

A waterproof curbing should be set up if the

busway pass through a floor slab.

>650mm

Avoid joint through floor, and reserve position

mounting bracket（>650mm)

When the joint is at the bottom of the floor

or on either side of the wall (Joint cannot
pass through the position of the wall) , the
end of the busbar should be more than
300mm away from the wall. >300mm

76521-030-02 6
 Required clearance for Plug-in mounting

NCBA(PE)

Keep N phase on left hand side when raise the

plug-in type busway.
IMPORTANT:
Essential for proper mounting of plug-in units.The busbar
trunking must be positioned as shown above so that the
top marking is to the right and the neutral position to the
left.

Circuit Breaker Plug-in Unit:

Circuit breaker plug-in unit may be installed on both sides
of a riser.

Plug-in Unit with Schneider Electric MCCB

Trip Rating(A) A(mm) F(mm) H(mm)
NSD 16-100 651 60 260
NSXF,NSXN,NSXH,NSEN,NSES,NSEH 16-250 651 60 280
NSXF,NSXN,NSXH,NSEN,NSES,NSEH 252-500 910 145 380
NSN,NSH,NSEN,NSES,NSEH 630-1000 932 160 406

(Check these dimensions carefully before installing straight length)

7 76521-030-02
HANGER INSTALLATION
1
Vertical mounting
Fixed Hanger mounting

”16FT(4.88M)
x4 M14

2
Spring Hanger adjust

Pre-adjust the length of spring shown in table.

”16FT(4.88M)

Compress
length of spring
hanger.

Channels
furnished by
customer .

76521-030-02 8
3
Spring Hanger mounting

2 1

14~17 N m

4 Back off the top nuts to the top of the rod after
complete run is installed.

x4

9 76521-030-02
76521-030-02
Spring
F =G

Housing Width

Vertical Spring Hangers

10
 Flatwise mounting
“TOP”Label

5M)
FT(3.0
B us way”10 FT(1.5M)
Indoor or Busway” 5
Outdo
“TOP”Label

Rod provided by customer

1 2
Place nut, washer and Place busway
hanger channel, raise
on the desired height
x2
Hanger is not allowed to be installed
1 in areas with cover plates.

3
Place the retaining clip and secure nut

x2

11 76521-030-02
 Edgewise mounting

5 M)
0FT(3.0 )
usway”1 5M
Indoor B usway”5FT(1.
B
Outdoor

Rod provided by customer

1 Suspend the hanger and 2 Raise the busway into position

adjust the hanger to the
correct elevation

Hanger is not allowed to be installed

in areas with cover plates.

3
Install the bottom bolts

1 1

M14

22

76521-050-01 12
BUSWAY INSTALLATION
1 Joint assembly

Be sure the busway are aligned

properly before connection.

Surge clamps

Rob
Joint assembly tool
catalog no. AT22
P
TO

P
TO

9.4in
240mm
13.4in
340mm

2
Cover plates assembly

x4

9.5~10.8N·M

x4

13 76521-030-02
3
Tighten the joint bolt(s)

60~80lb-ft 1
“1Â0

CLACK
2

Outer head of VISI-TITE bolt is broken off and red label is gone

76521-030-02 14
END CLOSURE ASSEMBLY
1 2
Install insulator onto each busbar Push U cover onto busway
Make these two lines approximate
align when assemble U cover.
TOP

3 4
Install metal tie channel

1
2

1
10-32 self-threading fastener ×4
5/16-18×3/4 bolt ×4

3
Fasten top and bottom screw
10-32 self-threading
fastener ×4

15 76521-030-02
WALL/FLOOR FLANGE

2
1 6
4

Note:These accessory do not have

any waterproof and fire protection
functions.

Assembly in sequence

76521-030-02 16
STEPS TO TAKE BEFORE ENERGIZING
1
Tighten bolts
Check if all the outer head of VISI-TITE bolt is broken off and the red label is gone.

2
Insulation resistance test
1 Conduct an insulation resistance test on each
busway before installation.
2 Conduct an insulation resistance test on the
whole run.
3 Keep above record of each busway
and each run as “Appendix 1”.

Off
PE The load and line ends
A
M B disconnected, and no over
C
N current devices installed.

Insulation resistance tester

rated at 1000 volts

The megohm reading should not be less than the

value calculated from the following formula, neither
less than 5 Megohms.

Megohms = 100/length of run (in feet)

or
Megohms = 30.5/length of run (in meters)

17 76521-030-02
3
Check all points before energizing

Items Check Points Methods Judging Standards Page

1.Check if all the VISI-TITE bolts are Visual confirmation The outer head of VISI-TITE P17
bolt is broken off and the red
tightened to a correct torque. label is gone.

2.If the outer head of VISI-TITE bolt is

broken off，check for the bolt if re-tighted Torque wrench 60~80 lb-ft or 95±14N M.
to a correct torque

3.Check the earth connection of Flange Earth wire is connected to the

end/Feed unit/ PIU and the phase Visual confirmation earth terminal.
Busway sequence Correct the phase sequence.

4.Check if there’s any damage, No damage, deformation or

deformation or water stain on busway Visual confirmation water stain.
or other parts.

The resistance is more than

Insulation resistance the formula provieded (use
5.Measure the insulation resistance. tester P17
insulation resistance tester
with 1000V range).

6.Fix the joint covers, tie channels and Visual confirmation Torque Tie channel:
rubbers, tighten all the screws 7~8 lb-ft or 9.5~10.8N M P13
Torque wrench

7.Make sure the alignment of busway for Spirit level or plumb Horizontal or vertical P13
horizontal or vertical application. alignment.

1.Check if the nuts on top of spring Visual confirmation The nuts are loosened to the P9
hangers are loosened. top.
Spring Hanger
Please refer to the instruction
2.Check the compressed length of spring Caliper manual for the prescribed P10
hanger. compressed length.

* This table also applies to maintenance

76521-030-02 18
ENERGIZING THE EQUIPMENT

When the equipment is energized for the first time, qualified electrical personnel should
be present. If short circuits and ground faults caused by damage or poor installation
practices have not been detected in the checkout procedure, serious damage can result
when the power is turned on.

The busway should have no electrical load on it when it is energized. Because busway
typically extends through several rooms and floor levels, ensure that all devices fed from
the busway are in the off position.

Energize the equipment in sequence by starting at the source end of the system and
working toward the load end. In other words, energize the main devices, then the feeder
devices, and then the branch-circuit devices. Turn the devices to the ‘ON’ position with a
firm positive motion.

After all over current devices have been turned on, loads such as lighting circuits,
contactors, heaters, and motors may be turned on.

Busway, when operating properly, will have a moderate hum. Excessive noise may be
an indication of hardware that has not been tightened or of metal parts that have been
improperly assembled.

Occurrence of sparking at any point along the busway is not a normal condition.
De-energize the busway immediately. Correct the cause of the sparking condition. Then
conduct an insulation resistance test according to page 17 before attempting to energize
again.

19 76521-030-02
 Appendix 1: Insulation Resistance Readings
* For Daily Report by Contractor

DATE: DATE: DATE: DATE:

RUN NAME: RUN NAME: RUN NAME: RUN NAME:
Phase M Phase M Phase M Phase M
A PE A PE A PE A PE
B PE B PE B PE B PE
C PE C PE C PE C PE
N PE N PE N PE N PE
A B A B A B A B
A C A C A C A C
A N A N A N A N
B C B C B C B C
B N B N B N B N
C N C N C N C N

DATE: DATE: DATE: DATE:

RUN NAME: RUN NAME: RUN NAME: RUN NAME:
Phase M Phase M Phase M Phase M
A PE A PE A PE A PE
B PE B PE B PE B PE
C PE C PE C PE C PE
N PE N PE N PE N PE
A B A B A B A B
A C A C A C A C
A N A N A N A N
B C B C B C B C
B N B N B N B N
C N C N C N C N

DATE: DATE: DATE: DATE:

RUN NAME: RUN NAME: RUN NAME: RUN NAME:
Phase M Phase M Phase M Phase M
A PE A PE A PE A PE
B PE B PE B PE B PE
C PE C PE C PE C PE
N PE N PE N PE N PE
A B A B A B A B
A C A C A C A C
A N A N A N A N
B C B C B C B C
B N B N B N B N
C N C N C N C N

Note: the insulation resistance reading should not be less than 100÷length of run (in feet)
Or
30.5÷length or run (in meters).
Neither less than 5 megohms.

76521-030-02 20
85 JunYe Road, Eastern Section of
Economic & Technological
Development Zone, Guangzhou
510530, PR China
Tel: (86)20 2820 2828
Fax: (86)20 2820 2888
Service hotline:400 810 1315
Electrical equipment should be serviced only by qualified
electrical maintenance personnel. No responsibility is
assumed by Schneider for any consequences arising out
of the use of this manual.
Bulletin No: 76521-030-02(SB)
Publish day: 08/2018
Schneider Electric All Right Reserved