PowerWave 2 TM Bus System

Transcription

1 PowerWave 2 TM Bus System 250A 800A Installation and Operation Ctrl Nr: PM Revision: 001

2 PowerWave 2 Bus System Installation and Operation Thank you for your recent purchase of a PowerWave 2 Bus System from Power Distribution, Inc. For safety reasons as well as to ensure optimal performance of your PowerWave 2 Bus System, please carefully read the instructions before trying to install, operate, service or maintain the system. For any questions regarding the installation, operation, service or maintenance of your PowerWave 2 Bus System, please contact us: Power Distribution, Inc Oakleys Court Richmond, VA pdiservice@pdicorp.com PowerWave 2 Bus System 250A 800A Installation and Operation Ctl Number: PM Rev 001 Power Distribution, Inc All rights reserved. DynaCool On-demand Cooling System, JCOMM, PDI, PDIQ, Powercube, Quad-Wye, QuikSwitch, ToughRail Technology, and WaveStar are registered trademarks of Power Distribution Inc. All other trademarks are held by their respective owners. Power Distribution, Inc. (PDI) Power Distribution, Inc. (PDI) designs, manufactures, and services mission critical power distribution, static switching, and power monitoring equipment for corporate data centers, alternative energy, industrial and commercial customers around the world. For over 30 years, PDI has served the data center and alternative energy markets providing flexible solutions with the widest range of products in the industry. 2

3 Contents Contents Safety Introduction Specification Environmental Specification Electrical Specification: Busway Electrical Specification: Tap-Off Box Grounding Standards and Certifications Parts Catalog: Bus Run Structure Parts List End Feeds Modular End Feed Compact End Feed (250A) Standard End Feed (250A, 400A) Bus Rails Bus Rail (250A-400A) Bus Rail (800A) Elbows Neutral Positions Vertical Elbow (250A-400A) Horizontal Elbow (250A-400A) Vertical Elbow (800A) Couplings Bus Rail Coupling (250, 400A) Bus Rail Coupling (800A) End Feed Couplings (250A Bus Systems) Hangers Vertical Hangers Horizontal Hangers (250A-400A) End Caps Parts Catalog: Tap-Off Boxes Tap-Off Box Components Tap-Off Box Ground and Isolated Ground Standard Tap-Off Box Offerings Vertical Tap-Off Box 10.25" 20A/30A/50A

4 PowerWave 2 Bus System Installation and Operation Vertical Tap-Off Box 12" 20A/30A/50A with Monitoring Vertical Tap-Off Box 10.25" 60A Vertical Tap-Off Box 14" 60A with Monitoring Horizontal Tap-Off Box 14" 20/30/50/60A Horizontal Tap-Off Box 14" 20A/30A/50A/60A with Monitoring Horizontal Tap-Off Box 14" 20A/30A/50A without Monitoring Horizontal Tap-Off Box 14-in 20/30A/50A with Monitoring Custom Tap-Off Boxes Branch Circuit Monitoring System Installation Planning Planning Electrical Requirements Source Voltage and Frequency Neutral Size Current Loads Upstream Circuit Breakers End Feed Disconnects Dual Bus Runs Grounding Planning Monitoring Requirements Physical Layout and Parts Selection Horizontal or Vertical Orientation Bus Run Length and Capacity Keep-Out Areas for Tap-Off Boxes Using Older Tap-Off Boxes Small Corrections to Bus Run Length (250A/400A) A Bus System Keep-Out Areas Overhead Support Structure PDI Application Engineering Conclusion Installation Receive and Inspect Unloading, Unpacking, and Handling Installation Sequence Create Overhead Support Structure Create Starter Rail for Compact End Feed (250A) Compact End Feed Starter Rail Attach Starter Rail to End Feed Create Starter Rail for the Standard End Feed (250A)

5 Contents 6.7 Installing Bus Rails Hanging Vertical Bus Rails Hanging Horizontal Bus Rails Hanging Elbows Installing a Coupling (250A-400A) Installing and Removing Tap-Off Boxes Adjust Bus Rail C-Clips A Bus System Installation A Installation Outline Tools Required for Installation Prepare the 800A Modular End Feed Installing the 800A Modular End-feed Steps to Install 800A Coupling Power and Ground Connections Lugs, Wires, and Torque Compact End Feed: Ground Connections Compact End Feed: Power Connections Standard End Feed: Power and Ground Connections Modular End Feed: Power and Ground Connections Start Up Procedure Power Up Checklist Power Up Maintenance Annual Inspection Procedure After Short Circuit or Ground Fault Acronym Glossary

6 PowerWave 2 Bus System Installation and Operation Figures Figure 1 PowerWave 2 Bus Systems 250A, 400A, and 800A Figure 2 Dual Horizontal Busways in 300 mm of Overhead Space (250A Bus System) Figure 3 Busway Structural Parts Figure 4 Modular End Feed (250A-800A) with Factory-Created Starter Rail Figure 5 Compact End Feed (250A): Limited Overhead Space Applications (horizontal) Figure 6 Standard End Feed (250A, 400A): Standard Applications (Vertical or Horizontal) Figure 7 Modular End Feed Starter Rail Figure 8 Modular End Feed Dimensions (250A, 400A) Figure 9 Modular End Feed Dimensions (800A) Figure 10 Compact End Feed: T1 and T2 Orientation Figure 11 Compact End Feed: Base and BCMS Extension Figure 12 Compact End Feed Base: Covers Slide Off Figure 13 Standard End Feed (covers removed) Figure 14 Standard End Feed with BCMS Extension Figure 15 Standard End Feed Dimensions (250A, 400A) Figure 16 Bus Rail ( A) Figure 17 Bus Rail Channels Figure 18 Bus Rail Dimensions (250A-400A) Figure 19 Bus Rail Dimensions (800A) Figure 20 Elbow Nomenclature: A, B Rails, Neutral Positions Figure 21 Vertical Elbow Dimensions (250A-400A) Figure 22 Horizontal Elbow Standard Dimensions (250A-400A) Figure A Elbow Figure 24 Bus Rail Coupling Figure A Bus Rail Coupling Parts Explosion Figure A Bus Rail Coupling with Bus Rails, Parts Explosion Figure 27 End Feed Coupling Figure 28 End Feed Coupling (250A) Dimensions Figure 29 Vertical Hanger Spacing Figure 30 Vertical Hanger (slide on) (250A-400A) Figure 31 Vertical Hanger (twist-on) (250A-400A) Figure 32 Vertical Hanger (800A) Figure 33 Horizontal Bus Rail Hanger Figure 34 Sliding Horizontal Hangers onto Bus Rail Figure 35 Horizontal Hanger Placement for Standard Bus Rail (12 ft./3.66 m) Figure 36 End Caps ( A, 800A) Figure 37 Tap-Off Box Components Figure 38 Tap-Off Box Ground, Isolated Ground, and Orientation to Bus Rail Figure 39 Standard Receptacles Figure 40 Sample IEC309 Receptacle Coding Figure 41 Vertical Tap-Off Box in 20A/30A/50A without BCMS Monitoring Figure 42 Vertical Tap-Off Box 12-in 20A/30A/50A with BCMS Monitoring Figure 43 Vertical Tap-Off Box in 60A without BCMS Monitoring Figure 44 Vertical Tap-Off Box 14-in 60A with BCMS Monitoring Figure 45 Horizontal Tap-Off Box 14-in 20A/30A/50A/60A without Monitoring Figure 46 Horizontal Tap-Off Box 14-in 20A/30A/50A/60A with Monitoring Figure 47 Horizontal Tap-Off Box 14-in 20A/30A/50A without Monitoring Figure 48 Horizontal Tap-Off Box, 14-in 20A/30A/50A with Monitoring

7 Contents Figure 49 Tap-Off Boxes Can Overlap Couplings Figure in Tap-Off Boxes Overlapping Coupling Figure 51 End Feed Keep-out Area Figure 52 Tap-Off Box Placement in Elbows Figure 53 Horizontal Busway with Perpendicular Unistruts Figure 54 Horizontal Busway with Parallel Unistrut Support Structure Figure 55 Compact End Feed Starter Rail Step1: Hangers Figure 56 Compact End Feed Starter Rail Step 2: Flange Plate Figure 57 Compact End Feed Starter Rail Step 3: End Feed Coupling Figure 58 Compact End Feed Starter Rail Step 4: Coupling Cover Figure 59 Compact End Feed Starter Rail Step 5: Attach Starter Rail Figure 60 Creating Starter Rail for Standard End Feed Figure 61 Horizontal Hanger Spacing Figure 62 Positioning Elbow Hangers on Legs (250A-400A) Figure 63 Installing Coupling Step 1: Bus Rails Figure 64 Installing Coupling Step 2: Divider Figure 65 Installing Coupling Step 3: Coupling Halves Figure 66 Installing Coupling Step 4: Ground Jumper Plate Figure 67 Installing Coupling Step 5: Bolt Coupling Halves Together Figure 68 Installing Coupling Step 6: Ground Jumper and Side Plates Figure 69 Installing Coupling Step 7A, 7B: Monitoring and Isolated Ground Options Figure 70 Installing Coupling Step 8: Connect Bottom Cover Figure 71 Installing Coupling: Completed View Figure 72 Inserting Tap-Off Box into Bus Rail Figure 73 Adjust Bus Rail C-Clips to Make Room for Tap-Off Boxes Figure 74 Attach Starter Rail to Modular End Feed Figure 75 Prepare 800A Modular End Feed for Installation Figure A Bus Rail Coupling Parts Explosion Figure 77 Install 800A Coupling: Steps Figure 78 Install 800A Coupling, Steps Figure 79 Install 800A Coupling, Steps Figure 80 Install 800A Coupling, Step Figure 81 Install 800A Coupling, Step 11: Support U-Channel Figure 82 Sample End Feed Torque Specification Label Figure 83 Compact End Feed Ground Connections Figure 84 Compact End Feed T1 Power Connections Figure 85 Compact End Feed T2 Power Connections Figure 86 Standard End Feed: Ground Connections Figure 87 Standard End Feed Power Connections Figure 88 Standard End Feed: Power Connections Torque Figure 89 Modular End Feed: Power and Ground Connections Tables Table 1 Parts List Table 2 Parts Applicability by Amperage Table 3 Vertical Tap-Off Box in 20/30/50A Options (208V L-L/120V L-N) Table 4 Vertical Tap-Off Box 12-in 20/30/50A Options with Monitoring (208V L-L/120V L-N) Table 5 Vertical Tap-Off Box in 60A Options (208V L-L/120V L-N) Table 6 Vertical Tap-Off Box 14-in 60A Options with Monitoring (208V L-L/120V L-N)

8 PowerWave 2 Bus System Installation and Operation Table 7 Horizontal Tap-Off Box 14-in 20/30/50/60A Options (208V L-L/120V L-N) Table 8 Horizontal Tap-Off Box 14-in 20/30/50/60A Options with Monitoring (208V L-L/120V L-N) Table 9 Horizontal Tap-Off Box 14-in 20/30A/50A Options without Monitoring (208V L-L/120V L-N). 55 Table 10 Horizontal Tap-Off Box 14-in 20/30A/50A Options with Monitoring (208V L-L/120V L-N) Table 11 Power and Ground Wire Size Table

9 PowerWave 2 Bus System Installation and Operation Safety Please pay special attention to the use of Danger symbols throughout this manual indicating electrical or other safety hazards. Following these safety instructions is extremely important to avoid possible injury or death. DANGER! This symbol is used throughout this manual to indicate the presence of high voltages, representing a hazard for electric shock, burn or explosion. Follow the instructions carefully to avoid serious or fatal injury. Follow safe electrical work practices: Disconnect and lock-out all power supplying equipment before working on or installing PowerWave 2 Bus System components. Use a properly rated voltage sensing device to confirm power is OFF. Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel and in accordance with all local safety codes. Power Distribution, Inc. assumes no responsibility for any consequences arising out of the use of this manual. This document should not be viewed as sufficient by otherwise non-qualified personnel to operate, service, or maintain the equipment discussed. Read, understand, and follow the instructions before installing this product. Install device in an appropriate electrical environment per local regulations. ESD sensitive equipment. Ground yourself, discharge any static charge and ensure that the device is effectively grounded before handling the unit. 9

10 PowerWave 2 Bus System Installation and Operation 1 Introduction PowerWave 2 Bus Systems are compact, lightweight busways that can be deployed quickly using easy-to-assemble kits. PowerWave 2 Bus Systems allow any voltage 600V and are available in 250A, 400A, and 800A systems. 600A PowerWave 2 Bus Systems are under development using similar technology. 800A PowerWave 2 Bus System with Modular End Feed 250A or 400A PowerWave 2 Bus System with Standard End Feed Figure 1 PowerWave 2 Bus Systems 250A, 400A, and 800A PowerWave 2 Bus Systems provide compact power distribution systems to server racks: PowerWave 2 is installed completely overhead, requiring no server room floor space. Power and communications for monitoring are integrated in a single bus run, reducing space required for multiple cable and conduit runs. The 250A PowerWave 2 Bus System has special adaptations for horizontal busways and can be installed where there is little space above server racks. Single or dual horizontal bus runs can be installed in less than 300 mm (< 11.82") of overhead space (Figure 2). PowerWave 2 Bus Systems are designed for demanding data center power environments: Neutral options are available up to 150% on all busways. Dual bus runs provide redundancy even with limited overhead space (Figure 2). Through Tap-Offs, the exact circuit breaker capacity and receptacle type can be specified at any location along the rail, simply by inserting the correct Tap-Off Box into the busway: Tap-Off Boxes are highly configurable to meet load demands and specific requirements, including monitoring. Tap-Off Boxes are available for horizontal and vertical orientations. Up to (6) circuits (poles) can be monitored for current only or current and voltage, such as (2) x (3)-phase circuits or (3) x (2)-phase circuits. 10

11 Introduction Front View Overhead View Figure 2 Dual Horizontal Busways in 300 mm of Overhead Space (250A Bus System) Busway space is very efficiently used with design latitude to place Tap-Off Boxes nearly anywhere to power servers: Continuous rail design allows Tap-Off Boxes to be inserted nearly anywhere along the rail. On 250A and 400A systems, TOB enclosures can overlap a Coupling (splice), resulting in little or no lost bus rail space at the Coupling. Because Tap-Off Boxes can overlap Couplings, Couplings can be placed directly above servers without displacing Tap-Off Boxes. Tap-Off Box installation is safe for live systems. PowerWave 2 Bus Systems have an IP2X finger-safe rating (IEC 60529). Tap-Off Boxes have a two-stage insertion into the bus rail: ground connections are made automatically before contact is made with conductors. Covers over the Tap-Off Box mast channels are available as an option in 6-inch lengths. Installation planning and parts ordering are rationalized: Couplings, Bus Rails, and Elbows have been newly designed for 250A and 400A systems to provide a busway that is lightweight, easy to design, configure and reconfigure, and easy to install. Because Tap-Off Boxes can overlap Couplings on 250A and 400A, customers do not have to use custom length bus rails to position the coupling away from servers. Consequently, customers can use more standard length bus rails with fewer couplings than with other busways. Installation planning is simplified and initial system costs are reduced. Two new end feeds are available: the Compact End Feed (250A) and the Standard End Feed (250A-400A). These new end feeds are symmetrical and can be installed in either 11

12 PowerWave 2 Bus Systems Installation and Operation right-hand or left-hand orientations. Any bus rail can be used as a starter rail so that these busways can be reconfigured using different bus rails at different lengths without reordering new starter rails. The Modular End Feed, used on the PowerWave Bus System, is also available for PowerWave 2 Bus Systems in all amperages. PowerWave 2 Bus System installation is easier and faster than for other busways: Rugged yet lightweight Toughrail Technology design reduces time and labor up to 30% over current PowerWave Bus Systems. Lightweight parts reduce handling difficulty. The extruded aluminum bus rail one-piece housing has no bolts or welds, reducing weight. The Bus Rail Coupling for 250A and 400A Bus Systems installs in less than two (2) minutes and requires no special tools. The End Feed Coupling for 250A and 400A Bus Systems lets you quickly create starter rails. PowerWave 2 has diagnostic and monitoring capabilities: Overhead bus run circuits are easily traceable, unlike underfloor cables. The optional Branch Circuit Monitoring System (BCMS) can monitor the power source to each busway at the end feed and at up to (31) Tap-Off Boxes or, if input power is not monitored, up to (32) Tap-Off Boxes per end feed. BCMS offers monitoring for current only or both current and voltage. Power monitoring can be aggregated in several ways: o Building Management System (BMS). o PowerWave 2 7" Local Display monitoring up to (6) bus runs, each with (15) Tap- Off Boxes, or (96) devices in total. o BCMS Hub, monitoring up to (240) devices. o Modbus or SNMP protocols. 12

13 Specification 2 Specification 2.1 Environmental Specification Operating Environment: 40⁰C maximum ambient temperature 55 C rise over 40 C / 104 F with no de-rating Storage Environment: Store equipment in a clean, dry environment in its original packaging. 2.2 Electrical Specification: Busway Amperage PowerWave 2 Bus Systems are available in these amperages: 250A, 400A, and 800A. 600A Bus Systems are under development using similar technology. PowerWave 2 Bus Systems are 100% rated at their specified amperages. Voltage PowerWave 2 Bus Systems are rated for any voltage 600VAC, including these standard voltages: (208/120), (380/220), (400/230), (415/240), (480/277), (575/332). Voltage drop-off along the bus run per 100' of installed system is approximately 2V. Operating frequency: 50/60Hz Neutral Options: 100% neutral standard, 150% neutral optional Conductor Materials: copper conductors and neutral Short Circuit Withstand Ratings 250A Bus Systems: o 42 kaic up to 208VAC o 35 kaic up to 480VAC o 22 kaic up to 600VAC 400A Bus Systems: o 42kAIC up to 208VAC o 35kAIC up to 480VAC o 22kAIC up to 600VAC 800A Bus Systems: o 42kAIC up to 600V Busway Orientation: 100% rated for any orientation. For example, there is no derating for horizontal vs. vertical orientation. 13

14 PowerWave 2 Bus Systems Installation and Operation 2.3 Electrical Specification: Tap-Off Box Amperages Tap-Off Boxes (TOBs) available for all amperage busways. TOBs that can be used with any amperage Bus System are available upon request. Maximum TOB amperage: 128A Poles TOBs are ETL-listed for up to (12) poles. Up to (6) poles can be monitored with the Branch Circuit Monitoring Option o (2) x (3) poles (2 x 3-phase circuits) o (3) x (2) poles (3 x 2-phase circuits) Maximum (6) poles per TOB are recommended, if monitoring used. If customers switch neutrals, maximum (8) poles per TOB are recommended, (6) monitored phase poles and (2) non-monitored neutral poles. Voltages TOBs are available for 3-phase, 2-phase, and 1-phase voltages. 3-phase voltages available, requiring 3-pole circuit breakers: o 3-phase voltages: (208), (380), (400), (415), (480), (575), and (600) o (IEC: L1-L2-L3) o (NEC: A-B-C) o If neutral is switched, a 4-pole circuit breaker is required. 2-phase (phase-phase) voltages available, requiring 2-pole circuit breakers: o 2-phase voltages: (208), (380), (400), (415), (480), (575), (600) o (IEC phase-phase: L1-L2, L2-L3, L3-L1) o (NEC phase-phase: A-B, B-C, C-A) o If neutral is switched a, 3-pole circuit breaker is required. 1-phase (phase-neutral) voltages available, requiring 1-pole circuit breakers: o 1-phase voltages: (120), (220), (230), (240), (277), (332), (347) o (IEC: L1-N, L2-N, L3-N) o (NEC: A-N, B-N, C-N) o If neutral is switched, a 2-pole circuit breaker is required. Circuit Breakers and Receptacles Circuit breakers and receptacles offered at these amperages: (IEC) 16A, 32A, and 63A (UL) 15A, 20A, 30A, 50A, 60A kaic ratings vary by circuit breaker, up to 22 kaic available. 2.4 Grounding Busway Ground Integral ground in one-piece extruded aluminum Bus Rail housing with ground connected across Couplings. Connection to customer single-point ground is at the end feed. 14

15 Specification Tap-Off Box Ground (4) Ground connections per Tap-Off Box, automatically grounded when TOB is inserted into the Bus Rail Left and right side grounds are connected, ensuring that the TOB can be completely grounded from the ground connection on either side. Consequently, the TOB is grounded even when the TOB overlaps a Coupling. TOBs can overlap Couplings on A Bus Systems. (Optional) Isolated ground connection to Bus Rail: TOBs using isolated ground can overlap Couplings on the left side of the TOB on 250A-400A systems. 2.5 Standards and Certifications Certifications and Standards PowerWave 2 Bus Systems are certified to the following standards: Underwriters Laboratory Standard UL 857, the common UL, CSA, and ANSI standard for busways. IEC IEC standard for busway systems. C-Tick (Australia). Underwriters Laboratories of Canada (CUL listing). China Compulsory Certification (CCC) (pending). PowerWave 2 Bus Systems also meet the following standards: IEC Standard, use of the busway housing assembly as the protective ground conductor. Low Voltage Directive (73/23/EEC) including Amendment (93/68/EEC). Low Voltage Switchgear and Control Assemblies, Part 1: Type Tested and partially typetested Assemblies, IEC : Part 2: Particular requirements for Bus Bar Trunking Systems (Busways), IEC : IEC Standard, requiring that tap-off units instantly connect loads or secondary runs. National Electrical Code (NEC) Article 364 Busways 19. NEMA AB1, Molded Case Circuit Breakers and Molded Case Switches. NEMA KS-1, Enclosed and Miscellaneous Distribution Equipment Switches. National Fire Protection Agency (NFPA)

16 PowerWave 2 Bus Systems Installation and Operation 3 Parts Catalog: Bus Run Structure PowerWave 2 Bus Systems enable customers to easily design and install a busway using kitted parts. This chapter surveys PowerWave 2 Bus System parts and part options. The customer selects PowerWave 2 Bus System structural parts and Tap-Off Boxes to match their own requirements. The busway structural parts those used to construct the busway without Tap-Off Boxes are shown in an example in Figure 3. Tap-Off Boxes are described later in Chapter 4 Parts Catalog: Tap-Off Boxes. Hangers Elbow(s) Hangers Couplings Bus Rail End Cap End Feed Coupling Bus Rail Standard End Feed Figure 3 Busway Structural Parts Some part options must be identically specified throughout the entire busway structure: Bus system amperage Neutral size Source voltage as connected at the end feed (required for Tap-Off Box specification) Horizontal or vertical orientation BCMS options (Tap-Off Box monitoring requires a communications cable that is run throughout the bus run.) Isolated ground (uses a Bus Rail channel to provide isolated ground to each Tap-Office Box) The following sections describe PowerWave 2 Bus System parts and customer options. 16

17 Parts Catalog: Bus Run Structure 3.1 Parts List Table 1 Parts List End Feeds Compact End Feed (250A) Compact End Feed BCMS Extensions (250A) Standard End Feed (250A, 400A) Standard End Feed BCMS Extension (250A, 400A) Modular End Feed (250A, 400A or 800A) Modular End Feed BCMS Extension (250A, 400A or 800A) Bus Rails Bus Rail (250A, 400A, or 800A) Standard Length 12' (3.66 m) Bus Rail (250A, 400A,or 800A) Custom Length 3-12' ( m) in 1 ft. (30.5 cm) increments Starter Rail, Modular End Feed (250A, 400A), ' Starter Rail, Modular End Feed (800A), 3-11' Elbows Elbow, Horizontal (250A) Elbow, Vertical (250A, 400A) Elbow, Vertical (800A) Couplings Coupling, Bus Rail (250A, 400A) Coupling, Bus Rail (800A) Coupling, Compact End Feed (250A) Coupling, Standard End Feed (250A) Hangers Hanger, Horizontal, 2-bolt Hanger, Vertical (slide-on) Hanger, Vertical (twist-on) Hanger, Vertical (800A) Other Parts End Cap (250A, 400A or 800A) BCMS Modbus cable (length per Bus Rail) Applicability of above parts by amperage and orientations of the bus system is shown in Table 2. Standard and custom Tap-Off Boxes are described in Chapter 4 Parts Catalog: Tap-Off Boxes. 17

18 PowerWave 2 Bus Systems Installation and Operation Table 2 Parts Applicability by Amperage Parts Bus Rail (size and conductors vary by amperage) - Standard rails = 12' - Custom rails = 3'-12' in 1' increments 250A Bus System Bus Rails 400A Bus System 800A Bus System X X X Hangers Hanger, Vertical (slide-on) X X Hanger, Vertical (twist-on) X X Hanger, Vertical (800A) X Hanger, Horizontal, 2-bolt X X End Feeds and Starter Rails Modular End Feed (MEF) X X X - Factory-created starter rail X X X Standard End Feed (vertical or horizontal applications) - Customer-built starter rail using Standard End Feed Coupling Compact End Feed (horizontal, limitedspace applications) - Customer-built starter rail using Compact End Feed Coupling X X X X X X Couplings Coupling 6 1/2" (Bus Rail-to-Bus Rail or Bus-Rail to Elbow) (250A/400A) X X Coupling 9 1/4" (Bus Rail-to-Bus Rail or Bus Rail-to-Elbow) (800A) X Standard End Feed Coupling X X Compact End Feed Coupling X Elbows Vertical Elbow 250A, 400A X X Vertical Elbow 800A X Horizontal Elbow 250A X End Caps End Cap 250A, 400A X X - End Cap 800A X 18

19 Parts Catalog: Bus Run Structure 3.2 End Feeds PowerWave 2 Bus Systems have three kinds of end feeds: 1. Modular End Feed ( A) is available for all PowerWave 2 Bus Systems of any amperage. The Modular End Feed comes with a starter rail created at the factory. The starter rail can be shipped installed on the end feed or shipped separately. (Figure 4). 2. Compact End Feed (250A) is intended principally for horizontally oriented applications in confined overhead space. Any Bus Rail can be turned into a starter rail. (Figure 5). 3. Standard End Feed (250A, 400A), for applications where overhead space is not limited, is intended principally for use with vertically oriented Bus Rails. Any Bus Rail can be turned into a starter rail. Any Bus Rail can be turned into a starter rail. (Figure 6) All end feeds are hung from the customer s overhead support structure using customer provided hardware, such as all-thread. End feeds have no knockouts or predrilled holes for external cabling or overhead support. Customers must drill holes and execute cut-outs in end feeds for all-thread, bolts, and cabling. Each type of end feed has a different layout for power and ground connections. The size of an end feed varies by amperage. Modular End Feed (Covers Removed) Starter Rail Power Connections Modular End Feed is available for busways of any amperage. Figure 4 Modular End Feed (250A-800A) with Factory-Created Starter Rail Compact End Feed Base with power connections Horizontal Bus Rail Compact End BCMS Extension with Branch Circuit Monitoring System (BCMS) connections and components Figure 5 Compact End Feed (250A): Limited Overhead Space Applications (horizontal) 19

20 PowerWave 2 Bus Systems Installation and Operation Standard End Feed BCMS Extension Standard End Feed Base Figure 6 Standard End Feed (250A, 400A): Standard Applications (Vertical or Horizontal) Modular End Feed Modular End Feed (250A, 400A or 800A) Starter Rail, Modular End Feed (250A, 400A, or 800A), ordered with Modular End Feed Modular End Feed BCMS Extension (250A, 400A or 800A) The Modular End Feed ( A) used on PowerWave Bus Systems is also available for PowerWave 2 Bus Systems of any amperage. The Modular End Feed has a factory-created starter rail (Figure 7), which can only be used with the Modular End Feed (Figure 8). The starter rail is a standard PowerWave 2 Bus Rail (see 3.3 Bus Rails), but power connections and the flange plate are unique to the Modular End Feed. The starter rail can be shipped attached to the Modular End Feed or separately. The Modular End Feed must be ordered as Right-Hand or Left-Hand orientation. See orientations in Figure 9, 800A Modular End Feed Layout and Dimensions. Beyond the Flange Plate, all options and connections are the same for as for other PowerWave Silver Bus Systems. Flange Plate and power connectors are unique to the Modular End Feed. The customer specifies the starter Bus Rail in the same way as all other PowerWave Silver Bus Rails. This starter rail cannot be with any other end feed. The starter rail can be shipped attached to the Modular End Fee or unattached. Figure 7 Modular End Feed Starter Rail 20

21 Parts Catalog: Bus Run Structure 250A Modular End Feed 250A weight without BCMS: 10 lbs. 250A weight with BCMS Extension: 16 lbs. 400A Modular End Feed 3'-11.5' Figure 8 Modular End Feed Dimensions (250A, 400A) 21

22 PowerWave 2 Bus Systems Installation and Operation Left Hand Orientation 3' 11' 800A Modular End Feed Dimensions: 27.00"H x 30.00"W x 17.15"D Starter Rail standard length = 11', customizable 3' to 11' Left Hand Orientation Right Hand Orientation Figure 9 Modular End Feed Dimensions (800A) 22

23 Parts Catalog: Bus Run Structure Customer specifies the following for the Modular End Feed: Modular End Feed, Right Hand or Left Hand Amperage: 250A, 400A, or 800A Neutral: 250A-800A: 100% or 150% neutral Starter Rail length: o Custom rail lengths (250A-400A): ' in 1' increments o Custom rail lengths (800A): 3-11' in 1' increments o Starter rail can be shipped attached to end feed or unattached. Options: o Branch Circuit Monitoring System (BCMS) option: Source power monitoring at end feed (current and voltage) Tap-Off Box monitoring (current and voltage) Tap-Off Boxes can be individually selected for monitoring. If any BCMS option is selected, the BCMS Extension is required for the end feed. If Tap-Off Box monitoring is selected, a communications cable is provided throughout the bus run. o Isolated Ground option requires copper strip in a Bus Rail channel. o End feed disconnect options: 4MCB8- (4-pole Main CB 80% rated) 4MCB10- (4-pole Main CB 100%rated) 4MSW- (4-pole Main Switch/Isolator) 3MCB8- (3-pole Main CB 80% rated) 3-pole Main CB 100% rated 3MSW- (3-pole Main Switch/Isolator) 3FD- (3-pole Fuse-Disconnect) Compact End Feed (250A) Compact End Feed (Base) Type 1 (250A) Compact End Feed (Base) Type 2 (250A) BCMS Extension (250A) The Compact End Feed is intended principally for horizontal busway applications where overhead space is limited. Using this end feed a dual bus run can be installed in 300 mm (11.81") of server rack overhead space (see Figure 2). The Compact End Feed has two orientations, T1 and T2. Both can function as a left-hand or righthand end feed. The T1 and T2 orientations provide customers with flexibility in positioning power connections (Figure 10). 23

24 PowerWave 2 Bus Systems Installation and Operation T1 Bus Bars for Coupling power connections are left-justified. T2 Bus Bars for Coupling power connections are right-justified. Rotate end feed 180⁰ to change LH-RH position. Overhead View Overhead View T1 in LH and RH Bus Rail orientations T2 in LH and RH Bus Rail orientations Figure 10 Compact End Feed: T1 and T2 Orientation End Feed Coupling BCMS Extension Ground BCMS PCBs Power Connections BCMS Fuses Compact End Feed: BCMS Extension Compact End Feed: Base Single-Point Ground Connection Figure 11 Compact End Feed: Base and BCMS Extension 24

25 Parts Catalog: Bus Run Structure The Compact End Feed has two sections (Figure 11): Base, providing source power and ground connections to the busway BCMS Extension (optional), an add-on box providing Branch Circuit Monitoring System connections and PCBs for power source monitoring and Tap-Off Box monitoring. The Base section covers slide off for access to both power connections and the End Feed Coupling. Each covers attaches to the Base with two screws (Figure 12). Figure 12 Compact End Feed Base: Covers Slide Off Customer specifies the following for the Compact End Feed: Compact End Feed, choose an orientation: o T1 o T2 Amperage: 250A Neutral: 100% or 150% neutral Options: o Branch Circuit Monitoring System (BCMS) option: Source power monitoring at end feed (current and voltage) Tap-Off Box monitoring (current and voltage) Tap-Off Boxes can be individually selected for monitoring. If any BCMS option is selected, the BCMS Extension is required for the end feed. If Tap-Off Box monitoring is selected, a communications cable is provided throughout the bus run. o Isolated Ground option requires copper strip in a Bus Rail channel o Note: There is no disconnect option for the Compact End Feed. 25

26 PowerWave 2 Bus Systems Installation and Operation Standard End Feed (250A, 400A) Standard End Feed (250A, 400A) Standard End Feed BCMS Extension (250A, 400A) Power Connections End Feed Coupling Enclosure BCMS Fuses Single Point Ground Connection Figure 13 Standard End Feed (covers removed) The Standard End Feed (Figures 13, 14, 15) can be used in both vertical and horizontal orientations. The Standard End Feed has a special enclosure with power connections that covers the End Feed Coupling. Customer specifies the following for the Standard End Feed: Standard End Feed Amperage: 250A or 400A Neutral: 100% or 150% neutral Options: o Branch Circuit Monitoring System (BCMS) option: Source power monitoring at end feed (current and voltage) Tap-Off Box monitoring (current and voltage) Tap-Off Boxes can be individually selected for monitoring. If any BCMS option is selected, the BCMS Extension is required for the end feed. If Tap-Off Box monitoring is selected, a communications cable is provided throughout the bus run. o Isolated Ground option requires copper strip in a Bus Rail channel o End Feed Disconnect options: 4MCB8- (4-pole Main CB 80% rated) 26

27 Parts Catalog: Bus Run Structure 4MCB10- (4-pole Main CB 100%rated) 4MSW- (4-pole Main Switch/Isolator) 3MCB8- (3-pole Main CB 80% rated) 3-pole Main CB 100% rated 3MSW- (3-pole Main Switch/Isolator) 3FD- (3-pole Fuse-Disconnect) Flange Plate BCMS Extension for Standard End Feed Starter Rail is customer-built from Bus Rail and End Feed Coupling. BCMS Fuses Figure 14 Standard End Feed with BCMS Extension Standard End Feed 250A: 16"W x 16"H x 8.64"D Standard End Feed 400A: 22"W x 18"H x 9.9"D 250A Weight without BCMS: 10 lbs. 250A Weight with BCMS Extension: 16 lbs. BCMS Extension Standard End Feed is symmetric and can be used in RH and LH orientations. Figure 15 Standard End Feed Dimensions (250A, 400A) 27

28 PowerWave 2 Bus Systems Installation and Operation 3.3 Bus Rails Bus Rail (250A, 400A, or 800A) Standard Length 12' (3.66 m) Bus Rail (250A, 400A, or 800A) Custom Length 3-12' ( m) in 1 ft. (30.5 cm) increments Part Construction Toughrail Technology o Extruded aluminum housing, 1-piece design without welds or bolts o Provides bus run strength and stability o Ground path integrated into housing, providing ensured path to ground o Minimizes electromagnetic interference o Continuous plug-in style bus rail allows Tap-Off Box insertion at any point along rail except for 1/2" (1.3 cm) exclusion zone for TOB mast next to a Coupling (250A-400A). o Oversize bus bars o Nickel under-plating with silver over-plating o Superior voltage drop characteristics: See Chapter 2 Specification for conductor and neutral materials. Three channels for TOB masts, monitoring communications cable, and isolated ground (Figure 17). Customer specifies the following for Bus Rails: Amperage: 250A, 400A, or 800A Neutral: 100% or 150% neutral for all amperages Bus rail length: o Standard rail length: 12' (3.66 m) o Custom rail lengths: 3-12' ( m) in 1 ft. (30.5 cm) increments Options: o o Branch Circuit Monitoring System (BCMS) option: Source power monitoring at end feed (current and voltage) Tap-Off Box monitoring (current and voltage) Tap-Off Boxes can be individually selected for monitoring. If any BCMS option is selected, the BCMS Extension is required for the end feed. If Tap-Off Box monitoring is selected, a communications cable is provided throughout the bus run. Isolated Ground Option provides copper strip in a Bus Rail channel. 28

29 Parts Catalog: Bus Run Structure Bus Rail (250A-400A) Ground Jumper Plate Slides over Coupling to connect ground across Coupling (remove screws to slide over Coupling) Glastic Insulation (2) Side Plate(s) Slides over Coupling on each side to provide Coupling cover (remove screws to slide over Coupling) Conductors Neutral Figure 16 Bus Rail ( A) Part Kit, Bus Rail Parts included with all A Bus Rails (see Figure 16): o Bus Rail at customer specified length, amperage, and neutral sizing o (1) Ground jumper plate for connecting single-point ground over Coupling o (2) Side Plates (each side) for sliding over the Coupling. (See 6.10 Installing a Coupling (250A-400A).) o Note: Ground Jumper Plate and Side Plates can slide off Bus Rail for positioning hangers. 29

30 PowerWave 2 Bus Systems Installation and Operation Tap-Off Box Monitoring Option provides a communications cable integrated into a Bus Rail channel with sockets for connecting cables to Tap-Off Boxes at 13" (33 cm) intervals (see Figure 17). Isolated Ground Option provides a copper grounding strip in its own Bus Rail channel. Monitoring connections to Tap -Off Boxes are located in the Monitoring Channel spaced at 13" / 33 cm. Monitoring Channel (Communications) 13" Monitoring / 33 cm connections 13" / 33 cm Tap-Off Box Mast Channel Channel for Isolated Ground Channel for Isolated Ground or Cabled Chassis Ground (mutually exclusive options) Monitoring Channel (Communications) shown unused Tap-Off Box Mast Channel Isolated Ground Channel with Connection across Coupling Figure 17 Bus Rail Channels Standard 12' (3.66 m) Bus Rail Dimensions Dimensions: o Length = 12' (3.66m), length of housing = " ( cm) o Height (horizontal orientation) = 2.53" (6.43 cm) o Width (horizontal orientation) = 5.25" (13.34 cm) 30

31 Parts Catalog: Bus Run Structure Figure 18 Bus Rail Dimensions (250A-400A) Bus Rail (800A) Figure 19 Bus Rail Dimensions (800A) 31

32 PowerWave 2 Bus Systems Installation and Operation 3.4 Elbows Elbow, Horizontal, 250A-400A Elbow, Vertical, 250A-400A Elbow, Vertical, 800A An Elbow turns the bus run at a 90⁰ angle. Different Elbows are used for horizontal and vertical busways. Both the Horizontal Elbow and the Vertical Elbow are standard parts, each with standard leg lengths. Leg lengths cannot be customized. Leg lengths and dimensions differ for horizontal and vertical orientation. See the following sections for part dimensions. Elbows use same hangers as Bus Rails of the same orientation (horizontal or vertical). Phase conductors and neutrals must be the same size or larger than the Bus Rails in the same busway. Elbow part nomenclature is shown in Figure 20. Neutral placement and cross-over options are different for horizontal and vertical Elbows. See the following sections for options. O-Outer I-Inner A- Rail leg Elbow Neutral positions L- Left R- Right B- Rail leg ELLO H = Horizontal V = Vertical EL - Elbow ELRI ELRO ELLI Examples: HELLO = Horizontal ELbow Left & Outer VELRO = Vertical ELbow Right & Outer Figure 20 Elbow Nomenclature: A, B Rails, Neutral Positions Neutral Positions Neutral positions on both legs must match those of the adjacent Bus Rails. Horizontal Elbows have a single neutral placement option HELLO. Neutral crossover options for Horizontal Elbows are restricted to reduce the height of the part so that it can fit in a confined space. Vertical Elbows have several neutral position options, which customers can specify. See Figure 20 and Vertical Elbow (250A-400A) Vertical Elbow (250A-400A) Dimensions for the Vertical Elbow are shown in Figure

33 Parts Catalog: Bus Run Structure Dimensions are shown in inches. Figure 21 Vertical Elbow Dimensions (250A-400A) Vertical Elbows can have the following neutral configurations (see Figure 20, Elbow Nomenclature): VELLO- Vertical Elbow Left - Outer (shown in Figure 21) VELRI- Vertical Elbow Right - Inner Neutral (shown in Figure 21) VELLI- Vertical Elbow Left - Inner Neutral (see Figure 20) VELRO- Vertical Elbow Right - Outer Neutral (see Figure 20) Customer specifies the following for Elbows: Vertical or horizontal orientation Amperage: 250A or 400A Neutral size: 100% or 150% neutral Neutral positions, as shown in Figure 20. The Elbow leg length is different for horizontal and vertical elbows: o Horizontal Elbow leg length from centerline (Figure 22): in (40.6 cm) o Vertical Elbow leg length from centerline (Figure 21): in (47.8 cm) The following options must be specified the same as Bus Rail options on the same bus run: o Branch Circuit Monitoring System (BCMS) option for Tap-Off Boxes: This option determines if a communications cable is provided in the Bus Rail monitoring channel. o Isolated Ground option requires a copper strip in a Bus Rail channel. 33

34 PowerWave 2 Bus Systems Installation and Operation Horizontal Elbow (250A-400A) Horizontal Elbow dimensions are shown in Figure 22. Horizontal Elbow shown with neutrals in left outer positions (or HELLO neutral positions, see nomenclature in Figure 18.) HELLO is the only neutral positioning option available for the Horizontal Elbow. Dimensions are shown in inches. Figure 22 Horizontal Elbow Standard Dimensions (250A-400A) Horizontal Elbow allows these neutral positions (see Figure 20, Elbow Nomenclature ): HELLO: Horizontal Elbow Left - Outer Vertical Elbow (800A) 22" Leg lengths cannot be customized. Two neutral crosses are available: - VELRI (shown at left) - VELLO 22" Figure A Elbow 34

35 Parts Catalog: Bus Run Structure The 800A Bus System has a vertical Elbow only, which allows two neutral position crosses: VELRI- Vertical Elbow Right - Inner Neutral (Figure 23) VELLO- Vertical Elbow Left - Outer (shown in Figure 20) The 800A Elbow has the dimensions shown in Figure Couplings End Feeds, Bus Rails, and Elbows are joined together into a bus run using Couplings. The Couplings used in PowerWave 2 Bus Systems install quickly and require no special tools. A Coupling is held in place with a bolt, nut, and washers. There are two Couplings: Bus Rail Coupling, for joining Bus Rail to Bus Rail or Bus Rail to Elbow. The same Coupling is used for 250A and 400A systems. Bus Rail Coupling (800A) End Feed Coupling, for joining Bus Rail to End Feed, 250A Compact End Feed or Standard End Feed only. There is no end feed coupling for Modular End Feeds, because they have starter rails built at the factory. A Bus Rail Coupling (Figure 21) joins two Bus Rails or a Bus Rail and an Elbow. Customer specifies the following for a Bus Rail Coupling: Bus Rail Coupling Amperage: 250A, 400A, or 800A Part Kit, Bus Rail Coupling (1) Disassembled Bus Rail Coupling as shown in Figure 24. Measurements (250A) Dimensions: 6.50" L x 3.00" W x 4.17" H (16.5 cm x 7.6 cm x 10.6 cm) Weight: 5 lbs. (2.3 kg) Measurements (800A) Dimensions: Coupling 9.25"L (width of divider=coupling+1/8 conductor gap) x 3.83" W x 5.9" H (both halves) Coupling Drip Cover: 16.98"L x 4.55"W "H Part Construction Housing construction: plastic Channel Conductors: copper 35

36 PowerWave 2 Bus Systems Installation and Operation Bus Rail Coupling (250, 400A) Coupling, Bus Rail (250A, 400A) Bus Rail Side Plates and Ground Jumper Plate slide over the Bus Rail Coupling. Cutaway view of installed Coupling, joining two Bus Rails. Bus Rail Conductors are shown inside the Coupling. Figure 24 Bus Rail Coupling Bus Rail Coupling (800A) The Bus Rail Coupling for the 800A Bus System (Figure 26) is larger (9.125" long vs 6.5") and heavier than the 250A-400A Coupling. Its structure is similar to the A Coupling. Differences include Grounding strap installed instead of Sliding Ground Plate Drip cover over Coupling Support U-Channel See installation instructions for assembly of the Coupling onto the Bus Rail. 36

37 Parts Catalog: Bus Run Structure Ground Strap Drip Cover Divider Coupling Side Plates (2) Coupling Bottom Section Coupling Top Section Bus Rail Coupling Bottom Cover Support U- Channel Figure A Bus Rail Coupling Parts Explosion 3.6 End Feed Couplings (250A Bus Systems) Coupling, Compact End Feed (250A) Coupling, Standard End Feed (250A, 400A) The 250A End Feed Couplings for the Compact and Standard End Feeds are similar to a Bus Rail Coupling, but with power conductors to make End Feed power connections. An End Feed Coupling can be attached to any 250A Bus Rail creating a starter rail that can be connected to the Compact or Standard End Feed (Figure 27). The starter rail attaches to the End Feed with an End Feed Flange Plate and inserts directly into an End Feed. Customer specifies the following for an End Feed Coupling: Amperage: 250A Part Kit, End Feed Coupling (1) Disassembled End Feed Coupling Coupling Cover plates 37

38 PowerWave 2 Bus Systems Installation and Operation Measurements (250A Compact End Feed, Standard End Feed Coupling is similar) Dimensions: 6.50" L x 3.00" W x 5.90" H (16.5 cm x 7.62 cm x 15.0 cm) For dimensions on Orthographic part projection, see Figure 28. Weight: 5 lbs. (2.3 kg) Completed Starter Rail End Feed Flange Plate Coupling Cover Coupling End Feed Coupling is assembled on a Bus Rail to create a starter rail that inserts directly into an end feed End Feed Coupling has power conductors to connect to end feed power conductors. Figure 27 End Feed Coupling Figure 28 End Feed Coupling (250A) Dimensions 38

39 Parts Catalog: Bus Run Structure 3.7 Hangers Hanger, Vertical (slide-on) Hanger, Vertical (twist-on) Hanger, Vertical (800A) Hanger, Horizontal, 2-bolt Bus Rails and Elbows are hung with hangers from the ceiling or other structure. There are separate hangers for horizontally and vertically-oriented bus runs Vertical Hangers Vertical Bus Rails are hung using the Vertical Hangers shown in Figures 30 and 31. Slide-on Vertical Hangers are installed from the end of the rail and are recommended. Twist-on Vertical Hangers are inserted as two separate pieces under the top lips of the Bus Rail, twisted into place, and screwed together. Vertical hangers support bus rails with vertical orientation. PDI recommends three (3) vertical hangers per 12' (3.66 m) of bus rail (Figure 29). One (1) hanger is recommended within 12" (30.5 cm) of each Coupling and one (1) hanger should be centered between them. Maximum hanger spacing should be 5' (152 cm) or less. Note: Customers supply bolts or all-thread to attach vertical hangers to overhead Unistruts or other support structure. ~5' (152 cm) hanger spacing ~5' (152 cm) hanger spacing Install hanger 1 ft. (30.5 cm) from Coupling Install (1) hanger so that hangers are spaced no more than 5' (30.5 cm) from each other. Install hanger 1 ft. (30.5 cm) from Coupling Figure 29 Vertical Hanger Spacing 39

40 PowerWave 2 Bus Systems Installation and Operation Note: Customer provides the means of attaching the hanger (bolt, all-thread, etc.) to the customer s busway support structure. Use standard Unistrut nuts with hangers. Vertical Hanger (slide on) Kit Vertical Hanger slides onto Bus Rail. Figure 30 Vertical Hanger (slide on) (250A-400A) Figure 31 Vertical Hanger (twist-on) (250A-400A) The hanger for the 800A Bus System is a 2-piece hanger that inserts into the top channel of the busway (Figure 32). 40

41 Parts Catalog: Bus Run Structure Figure 32 Vertical Hanger (800A) Horizontal Hangers (250A-400A) Figure 33 shows the Horizontal Hanger for horizontally oriented Bus Rails and Elbows. Hangers slide onto the Bus Rail from the end (Figure 34). The Horizontal Hanger Kit contains: (1) x Hanger (2) x Retainer Clips The customer chooses the busway support structure and provides the means of attaching the hanger to the support structure. The support structure can be Unistrut, grid, or other ceiling support. Hanger spacing and quantity Bus Rails: PDI recommends (4) four horizontal hangers per 12' (3.66 m) bus rail (Figure 35): o Place a hanger within 1' of each bus rail end. o Place two (2) hangers evenly spaced between the end hangers or about 3.33' spacing (101.5 cm). o Hangers should be spaced no more than 3.5' (1.07 m) from each other. Elbows: o Place a hanger on each side of the elbow joint. End Feeds: hangers are not used; customer provides hardware to hang end feeds from Unistruts or other overhead support structure. 41

42 PowerWave 2 Bus Systems Installation and Operation Note: Customer provides the means of attaching the hanger (bolt, all-thread, etc.) to the customer s busway support structure. Horizontal Hanger Kit Use standard Unistrut nuts with hangers. Figure 33 Horizontal Bus Rail Hanger Slide Horizontal Hangers over the end of the Bus Rail and into place. Horizontal Hanger and Bus Rail shown in profile Figure 34 Sliding Horizontal Hangers onto Bus Rail 42

43 Parts Catalog: Bus Run Structure 3.33' (101.5 cm) 3.33' (101.5 cm) 3.33' (101.5 cm) Install (1) hanger 1 ft. (30.5 cm) from Coupling Install (2) hangers so that all hangers are spaced about 3.33' (101.5 cm) from each other. Install (1) hanger 1 ft. (30.5 cm) from Coupling Figure 35 Horizontal Hanger Placement for Standard Bus Rail (12 ft./3.66 m) 3.8 End Caps End Cap (250A-400A) End Cap (800A) The end of a bus run has exposed high voltage, high amperage conductors. An End Cap (Figure 36) provides an insulating cover over these conductors, preventing contact with the conductors. An End Cap also provides insulation between conductors. DANGER! High voltages and amperages! Risk of electrical shock and electrocution causing injury or death! The exposed terminal conductors on every busway must be covered by an End Cap! All conductors are separately insulated in the End Cap. Attach End Cap to Bus Rail with 3/8" screw (250A-400A). Attach 800A End Cap to Bus Rail with a single grounding lug. End Cap Back View Figure 36 End Caps ( A, 800A) The End Cap for 800A Bus Systems is larger and is secured to the Bus Rail with a single grounding lug. The lug must be tight so that the End Cap cannot be pulled off. 43

44 Parts Catalog: Tap-Off Boxes 4 Parts Catalog: Tap-Off Boxes Tap-Off Boxes (TOBs) are inserted into Bus Rails, providing power to server racks. A TOB is a user-installable part. Each TOB can be unique along the busway. TOBs are available that are specialized for horizontal or vertical Bus Rails as determined by the accessibility of circuit breakers on the TOB. Limitations of Number of TOBs per Bus Run The number is limited by the total amperage load of the TOBs compared to the amperage rating of the busway. Monitoring limitations: o Maximum (32) devices per end feed or bus run can be monitored by BCMS (optional): (1) input power source + up to (31) TOBs Up to (32) TOBs if the input power source is not monitored. Important! Connecting more than (32) devices for monitoring on a single bus run may render the monitoring PCBs inoperable. o Maximum (15) TOBs per busway can be monitored by the optional 7" display along with the busway s End Feed, regardless of whether input source power is monitored. Placement Restrictions TOBs can be placed side-by-side on the busway with no clearance between them. The total number of TOBs that can be physically placed per busway is limited only by the width of the TOBs and small keep-out areas. (The number of TOBs that can be used per busway is limited by the amperage capacity of the busway.) For 250A-400A Bus Systems: o The keep-out area around Couplings is 1/2" from the edge of the Coupling to the edge of the TOB mast. In most cases, the TOB enclosure body can overlap the Coupling. TOBs with isolated ground can only overlap the Coupling on the left side. o Only a 10.25" TOB can be inserted into the short leg of an Elbow. For 800A Bus Systems, TOB enclosures cannot overlap the Coupling. Electrical Characteristics TOBs are available in 3-phase, 2-phase, and 1-phase for standard source voltages. Maximum amperage per TOB (specifically, per TOB mast) is 128A. Poles: o TOBs are ETL-listed for up to (12) poles (phases) or ((4) x 3-phase receptacles). o Up to (6) poles can be monitored with the Branch Circuit Monitoring Option (2) x (3) poles (2 x 3-phase circuits) (3) x (2) poles (3 x 2-phase circuits) (6) x (1) pole (6 x 1-phase circuits, vertical Tap-Off Boxes only) o Maximum (6) poles are recommended, if monitoring used. If customers switch the neutral pole in a TOB circuit, maximum (8) poles are recommended per TOB ((6) monitored phase poles and (2) neutral poles that are not monitored.) 44

45 Parts Catalog: Tap-Off Boxes Orientation PowerWave 2 Bus Systems are 100% rated for any orientation. There is no de-rating for a horizontal orientation compared to a vertical orientation. Enclosure Sizes Enclosure sizes are largely based on: Size and number of receptacles Number of circuit breakers BCMS monitoring option Vertical or horizontal or orientation of the busway: o Vertical TOBs have receptacles on the bottom of the TOB and circuit breakers on the operator-facing panel. o Horizontal TOBs have both receptacles and circuit breakers on the operatorfacing panel for access to the circuit breakers; consequently horizontal TOBs are usually wider than vertical TOBs. o TOBs are available in the following enclosure widths: 10.25", 12", 14" 17" PDI offers standard TOBs and, at extra cost, custom-designed TOBs. 4.1 Tap-Off Box Components Figure 37 and 38 show Tap-Off Box components. Mast: inserts into Bus Rail, making power connections. Mast conductor contact fingers lock onto Bus Rail conductors (on both sides of mast) BCMS Tap-Off Box Monitoring connection to Bus Rail. U-Channel attaches to Tap-Off Box enclosure, providing a standard interface to the Bus Rail Cam Slide locks Tap- Off Box onto conductors and Bus Rail. Circuit Breakers (1) per receptacle Enclosures available in these widths: 10.25" 12.0" 14.0" 17.0" Receptacles for connecting server power cords Figure 37 Tap-Off Box Components 45

46 PowerWave 2 Bus Systems Installation and Operation Mast (2) Ground Clips Each Side Conductor Contact Fingers Isolated Ground (Optional) (2) Ground Clips Each Side Bus Rail Monitoring Communications Channel Isolated Ground Channel Tap-Off Box Ground Slots Cam Slide Engagement Mechanism is ALWAYS on neutral side of the Bus Rail. Tap-Off Box Ground Clips Tap-Off Box Isolated Ground Tap-Off Box Ground Clips Inserted into Bus Rail Ground Slots Tap-Off Box Isolated Ground Inserted into Bus Rail Isolated Ground Channel Figure 38 Tap-Off Box Ground, Isolated Ground, and Orientation to Bus Rail 46

47 Parts Catalog: Tap-Off Boxes 4.2 Tap-Off Box Ground and Isolated Ground Tap-Off Boxes are grounded automatically when inserted into a Bus Rail in a two-step process. Ground clips insert into the rail ground slots before contact is made with conductors (Figure 38). Four (4) ground contacts are usually made when a Tap-Off Box is inserted into a Bus Rail. The grounds on both sides of a TOB are jumpered together, so that a TOB need only be grounded to the Bus Rail on one side. Because one side need not be directly grounded to the Bus Rail, that TOB side can overlap a Coupling. (Note: Older Tap-Off Boxes used in PowerWave 2 applications cannot overlap Couplings. TOBs used on 800A Bus Systems also cannot overlap the Couplings.) The optional Isolated Ground makes a Tap-Off Box connection to the Isolated Ground Channel in the Bus Rail. 4.3 Standard Tap-Off Box Offerings PDI offers a standard selection of TOBs for PowerWave 2 Bus Systems, based on most common TOBs used by PDI customers in the international (IEC) market: Four (4) TOBs for vertical bus run applications (Vertical applications are far more common than horizontal.) Four (4) TOBs for horizontal bus run applications Parameters for Standard Tap-Off Boxes: 208V 3-phase or 120V 1-phase (208V L-L/120V L-N) (1) or (2) NEMA, California Standard, or IEC309 receptacles Number of wires: o 3-wire = 1P+N+G or 2P+G o 4-wire = 3P+G o 5-wire = 3P+N+G Circuit breaker and receptacle amperage: o 20A 1-phase, 2-phase, or 3-phase o 30A 1-phase, 2-phase, or 3-phase o 50A 1-phase or 3-phase o 60A 1-phase or 3-phase Short circuit withstand rating for circuit breakers: o 10 kaic standard o 22 kaic available as an optional upgrade up to 30A BCMS monitoring option for TOBs: o BCMS (current and voltage monitoring) o No monitoring Standard receptacles used in Tap-Off Boxes (Figure 39): o NEMA receptacles 30A o California Standard 50A o IEC 60A For IEC309 receptacles, consult the server plug encoding and IEC 309 tables to match plug to receptacle. (See sample IEC309 receptacle coding, Figure 40.) o Receptacle ground pin location (4H or 9H) o Drop cords are not offered, but can be specified as optional upgrade. 47

48 PowerWave 2 Bus Systems Installation and Operation Standard Receptacles 20A L POLE 3-WIRE L POLE 3-WIRE L POLE 4-WIRE L POLE 5-WIRE 30A L POLE 3-WIRE L POLE 3-WIRE L POLE 4-WIRE L POLE 5-WIRE 50A CS POLE 3-WIRE CS POLE 4-WIRE 60A 360R4 1 or 2 POLE 3-WIRE 460R9 3-POLE 4-WIRE 560R9 3-POLE 5-WIRE Figure 39 Standard Receptacles N = Number of wires (3, 4, or 5) AA = Amperage of receptacle, plug, or connector R/C/P: R=Receptacle, C=Connector, P=Plug V=Voltage number (consult IEC 309 tables) Example: 3 20 R 4 or 3-wire 20A 120V L-N. Figure 40 Sample IEC309 Receptacle Coding 48

49 Parts Catalog: Tap-Off Boxes Vertical Tap-Off Box 10.25" 20A/30A/50A 30A 2-receptacles, 2-circuit breakers 20A 1-receptacle, 1-circuit breaker (NEMA) Figure 41 Vertical Tap-Off Box in 20A/30A/50A without BCMS Monitoring Some configurations require a longer or taller Tap-Off Box. Table 3 Vertical Tap-Off Box in 20/30/50A Options (208V L-L/120V L-N) Number Receptacles and Circuit Breakers Wires 2 Amps kaic Rating 1 Receptacle Code 1 3 (1P+N+G) 20A 10 NEMA L5-20 No 2 3 (1P+N+G) 20A 10 NEMA L5-20 No 1 3 (2P+G) 20A 10 NEMA L6-20 No 2 3 (2P+G) 20A 10 NEMA L6-20 No 1 3 (1P+N+G) 30A 10 NEMA L5-30 No 2 3 (1P+N+G) 30A 10 NEMA L5-30 No 1 3 (2P+G) 30A 10 NEMA L6-30 No 2 3 (2P+G) 30A 10 NEMA L6-30 No 1 4 (3P+G) 30A 10 NEMA L15-30 No 2 4 (3P+G) 30A 10 NEMA L15-30 No 1 5 (3P+N+G) 30A 10 NEMA L21-30 No 2 5 (3P+N+G) 30A 10 NEMA L21-30 No 1 3 (2P+G) 50A 10 CaStd CS8269 No 2 3 (2P+G) 50A 10 CaStd CS8269 No 1 4 (3P+G) 50A 10 CaStd CS8369 No 2 4 (3P+G) 50A 10 CaStd CS8369 No 1 22 kaic circuit breakers are available as an optional upgrade. 2 Isolated Ground available as an option. BCMS 49

50 PowerWave 2 Bus Systems Installation and Operation Vertical Tap-Off Box 12" 20A/30A/50A with Monitoring 30A, 2-receptacles, 2-circuit breakers (NEMA shown) with BCMS monitoring option. 20A, 1-receptacle, 1-circuit breaker (NEMA shown) with BCMS monitoring Figure 42 Vertical Tap-Off Box 12-in 20A/30A/50A with BCMS Monitoring This vertical 12" (30.5 cm) 20A/30A/50A Tap-Off Box has the same options as the 10.25" (26 cm) vertical 20A/30A/50A Tap-Off Box except that it has BCMS Monitoring. The BCMS option requires a larger enclosure to contain the monitoring components. Some configurations also require a longer or taller Tap-Off Box to accommodate larger circuit breakers, for example. Table 4 Vertical Tap-Off Box 12-in 20/30/50A Options with Monitoring (208V L-L/120V L-N) Number Receptacles and Circuit Breakers Wires 2 Amps kaic Rating 1 Receptacle Code 1 3 (1P+N+G) 20A 10 NEMA L5-20 Yes 2 3 (1P+N+G) 20A 10 NEMA L5-20 Yes 1 3 (2P+G) 20A 10 NEMA L6-20 Yes 2 3 (2P+G) 20A 10 NEMA L6-20 Yes 1 4 (3P+G) 20A 10 NEMA L15-20 Yes 2 4 (3P+G) 20A 10 NEMA L15-20 Yes 1 5 (3P+N+G) 20A 10 NEMA L21-20 Yes 2 5 (3P+N+G) 20A 10 NEMA L21-20 Yes 1 3 (1P+N+G) 30A 10 NEMA L5-30 Yes 2 3 (1P+N+G) 30A 10 NEMA L5-30 Yes 1 3 (2P+G) 30A 10 NEMA L6-30 Yes 2 3 (2P+G) 30A 10 NEMA L6-30 Yes 1 4 (3P+G) 30A 10 NEMA L15-30 Yes 2 4 (3P+G) 30A 10 NEMA L15-30 Yes 1 5 (3P+N+G) 30A 10 NEMA Yes 2 5 (3P+N+G) 30A 10 NEMA Yes 1 3 (2P+G) 50A 10 CaStd CS8269 Yes 2 3 (2P+G) 50A 10 CaStd CS8269 Yes 1 4 (3P+G) 50A 10 CaStd CS8369 Yes 2 4 (3P+G) 50A 10 CaStd CS8369 Yes 1 22 kaic circuit breakers are available as an optional upgrade. 2 Isolated Ground available as an option. BCMS 50

51 Parts Catalog: Tap-Off Boxes Vertical Tap-Off Box 10.25" 60A 60A 2 receptacles (IEC), 2 circuit breakers 60A 1 receptacle (IEC), 1 x 3-pole circuit breaker Figure 43 Vertical Tap-Off Box in 60A without BCMS Monitoring Table 5 Vertical Tap-Off Box in 60A Options (208V L-L/120V L-N) Number Receptacles and Circuit Breakers Wires 2 Amps kaic Rating 1 Receptacle Code 1 3 (1P+N+G) 60A 10 IEC R4 No 2 3 (1P+N+G) 60A 10 IEC R4 No 1 4 (3P+G) 60A 10 IEC R9 No 2 4 (3P+G) 60A 10 IEC R9 No 1 5 (3P+N+G) 60A 10 IEC R9 No 2 5 (3P+N+G) 60A 10 IEC R9 No 1 22 kaic circuit breakers are available as an optional upgrade. 2 Isolated Ground available as an option. BCMS 51

52 PowerWave 2 Bus Systems Installation and Operation Vertical Tap-Off Box 14" 60A with Monitoring 60A 1 receptacle 1 x 3-pole circuit breaker 4-wire Figure 44 Vertical Tap-Off Box 14-in 60A with BCMS Monitoring This vertical 14" 60A Tap-Off Box has the same options as the 10.25" vertical 60A Tap-Off Box except that it has BCMS Monitoring. The BCMS option requires a larger enclosure to contain the monitoring components. Table 6 Vertical Tap-Off Box 14-in 60A Options with Monitoring (208V L-L/120V L-N) Number Receptacles and Circuit Breakers Wires 2 Amps kaic Rating 1 Receptacle Code BCMS 1 3 (1P+N+G) 60A 10 IEC R4 Yes 2 3 (1P+N+G) 60A 10 IEC R4 Yes 1 4 (3P+G) 60A 10 IEC R9 Yes 2 4 (3P+G) 60A 10 IEC R9 Yes 1 5 (3P+N+G) 60A 10 IEC R9 Yes 2 5 (3P+N+G) 60A 10 IEC R9 Yes 1 22 kaic circuit breakers are available as an optional upgrade. 2 Isolated Ground available as an option. 52

53 Parts Catalog: Tap-Off Boxes Horizontal Tap-Off Box 14" 20/30/50/60A 20A, 30A, 50A, or 60A, 1 receptacle, (California Standard 50A receptacle is shown), 1 circuit breaker 60A, 1 receptacle, 1 circuit breaker Figure 45 Horizontal Tap-Off Box 14-in 20A/30A/50A/60A without Monitoring On horizontal Tap-Off Boxes circuit breakers and receptacles are mounted on the same panel so that they are both accessible to operators when inserted into the Bus Rail in a horizontal orientation. Table 7 Horizontal Tap-Off Box 14-in 20/30/50/60A Options (208V L-L/120V L-N) Number Receptacles and Circuit Breakers Wires 2 Amps kaic Rating 1 Receptacle Code 1 3 (1P+N+G) 20A 10 NEMA L5-20 No 1 3 (2P+ G) 20A 10 NEMA L6-20 No 1 3 (1P+N+G) 30A 10 NEMA L5-30 No 1 3 (2P+G) 30A 10 NEMA L6-30 No 1 4 (3P+G) 30A 10 NEMA L15-30 No 1 5 (3P+N+G) 30A 10 NEMA L21-30 No 1 3 (2P+G) 50A 10 CaStd CS8269 No 1 4 (3P+G) 50A 10 CaStd CS8369 No 1 3 (1P+N+G) 60A 10 IEC R4 No 1 4 (3P+G 60A 10 IEC R9 No 1 5 (3P+N+G) 60A 10 IEC R9 No 1 22 kaic circuit breakers are available as an optional upgrade. 2 Isolated Ground available as an option. BCMS 53

54 PowerWave 2 Bus Systems Installation and Operation Horizontal Tap-Off Box 14" 20A/30A/50A/60A with Monitoring 20A, 30A, 50A, or 60A, 1 circuit breaker, 1 receptacle (IEC shown), with BCMS Monitoring Figure 46 Horizontal Tap-Off Box 14-in 20A/30A/50A/60A with Monitoring On horizontal Tap-Off Boxes circuit breakers and receptacles are mounted on the same panel so that they are both accessible to operators when inserted into the Bus Rail in a horizontal orientation. Table 8 Horizontal Tap-Off Box 14-in 20/30/50/60A Options with Monitoring (208V L-L/120V L-N) Number Receptacles and Circuit Breakers Wires 2 Amps kaic Rating 1 Receptacle Code BCMS 1 3 (1P+N+G) 20A 10 NEMA L5-20 Yes 1 3 (2P+G) 20A 10 NEMA L6-20 Yes 1 3 (1P+N+G) 30A 10 NEMA L5-30 Yes 1 3 (2P+G) 30A 10 NEMA L6-30 Yes 1 4 (3P+G) 30A 10 NEMA L15-30 Yes 1 5 (3P+N+G) 30A 10 NEMA L21-30 Yes 1 3 (2P+G) 50A 10 CaStd CS8269 Yes 1 4 (3P+G) 50A 10 CaStd CS8369 Yes 1 3 (1P+N+G) 60A 10 IEC R4 Yes 1 4 (3P+G) 60A 10 IEC R9 Yes 1 5 (3P+N+G) 60A 10 IEC R9 Yes 1 22 kaic circuit breakers are available as an optional upgrade. 2 Isolated Ground available as an option. 54

55 Parts Catalog: Tap-Off Boxes Horizontal Tap-Off Box 14" 20A/30A/50A without Monitoring 20A/30A/50A, 2 circuit breakers, 2 receptacles (California Standard shown) Figure 47 Horizontal Tap-Off Box 14-in 20A/30A/50A without Monitoring Table 9 Horizontal Tap-Off Box 14-in 20/30A/50A Options without Monitoring (208V L-L/120V L-N) Number Receptacles and Circuit Breakers Wires 2 Amps kaic Rating 1 Receptacle Code 2 3 (2P+G) 20A 10 NEMA L6-20 No 2 3 (2P+G) 30A 10 NEMA L6-30 No 2 4 (3P+G) 30A 10 NEMA L15-30 No 2 5 (3P+N+G) 30A 10 NEMA L21-30 No 2 3 (2P+G) 50A 10 CaStd CS8269 No 2 4 (3P+G) 50A 10 CaStd CS8369 No 1 22 kaic circuit breakers are available as an optional upgrade. 2 Isolated Ground available as an option. BCMS 55

56 PowerWave 2 Bus Systems Installation and Operation Horizontal Tap-Off Box 14-in 20/30A/50A with Monitoring 20A, 30A, 50A (2) circuit breakers (2) receptacles (NEMA shown) Figure 48 Horizontal Tap-Off Box, 14-in 20A/30A/50A with Monitoring Table 10 Horizontal Tap-Off Box 14-in 20/30A/50A Options with Monitoring (208V L-L/120V L-N) Number Receptacles and Circuit Breakers Wires 2 Amps kaic Rating 1 Receptacle Code 2 3 (2P+G) 20A 10 NEMA L6-20 Yes 2 3 (2P+G) 30A 10 NEMA L6-30 Yes 2 4 (3P+G) 30A 10 NEMA L15-30 Yes 2 5 (3P+N+G) 30A 10 NEMA L21-30 Yes 2 3 (2P+G) 50A 10 CaStd CS8269 Yes 2 4 (3P+G) 50A 10 CaStd CS8369 Yes 1 22 kaic circuit breakers are available as an optional upgrade. 2 Isolated Ground available as an option. BCMS 56

57 Parts Catalog: Tap-Off Boxes 4.4 Custom Tap-Off Boxes Custom Tap-Off Boxes (TOBs) are available at extra cost. PDI application engineers will work with customers to design TOBs meeting customer requirements. Customers should specify the following: Voltage Phases (3-, 2-, 1-phase) Neutral switching (yes/no) Circuit breakers: o Amperage for circuit breakers and receptacle o Short circuit withstand rating (kaic) of circuit breakers o IEC or UL certification for circuit breakers and receptacles/connectors o Circuit breaker frame NEMA, California Standard, or IEC309 receptacle or connector o Drop cord length if connector is used instead of receptacle *Isolated Ground Option (yes/no) *BCMS Plus (current and voltage monitoring) monitoring for TOBs (yes/no): BCMS, up to (6) circuits * These options must also be specified on Bus Rail, Elbow, and End Feed orders to provide the compatible supporting structure for these TOB options (such as monitoring cable and isolated ground strip in Bus Rails). Voltages TOBs are available for 3-phase, 2-pase, and 1-phase voltages: 3-phase voltages available, requiring 3-pole circuit breakers: o 3-phase voltages: (208), (380), (400), (415), (480), (575), and (600) o (IEC: L1-L2-L3) o (NEC: A-B-C) o Note: If the neutral wire is switched, a 4-pole circuit breaker is required. 2-phase (phase-phase) voltages available, requiring 2-pole circuit breakers: o 2-phase voltages: (208), (380), (400), (415), (480), (575), (600) o (IEC phase-phase: L1-L2, L2-L3, L3-L1) o (NEC phase-phase: A-B, B-C, C-A) o Note: If the neutral wire is switched, a 3-pole circuit breaker is required. 1-phase (phase-neutral) voltages available, requiring 1-pole circuit breakers: o 1-phase voltages: (120), (220), (230), (240), (277), (332), (347) o (IEC: L1-N, L2-N, L3-N) o (NEC: A-N, B-N, C-N) o Note: If the neutral wire is switched, a 2-pole circuit breaker is required. Circuit Breakers and Receptacles Circuit breakers and receptacles are available at these amperages: (IEC) 16A, 32A, 63A, and 125A 57

58 PowerWave 2 Bus Systems Installation and Operation (UL) 15A, 20A, 30A, 50A, 60A Short circuit withstand ratings vary; up to 22 kaic can be specified. 4.5 Branch Circuit Monitoring System BCMS Modbus cable, per foot Power Monitoring is an optional feature using PDI s Branch Circuit Monitoring System (BCMS). Monitoring is available for source power at the end feed and/or power delivered to Tap-Off Boxes. For each bus run, specify BCMS Monitoring options: BCMS for Source Power (input power measurements at the End Feed) o BCMS (Current and Voltage Monitoring) o If BCMS is implemented, end feeds will have BCMS Extensions to house PCBs. BCMS for Tap-Off Boxes (specified for each Tap-Off Box) o BCMS (Current and Voltage Monitoring) o If BCMS is implemented for Tap-Off Boxes, Tap-Off Boxes will have PCBs for monitoring. Communications cable is run through the length of the bus run through the monitoring (communications) channel on the Bus Rail and other parts. Length of communications (Modbus) cable is specified as orderable option. See related manual, PowerWave 2 Bus System, Branch Circuit Monitoring System, Setup and Operation PM

59 Installation Planning 5 Installation Planning To plan a PowerWave 2 Bus System installation, select contiguous groups of servers as bus run candidates, determine their electrical and monitoring requirements, and translate these into physical bus run layouts with parts selections. 5.1 Planning Electrical Requirements Determine the electrical requirements of a bus run before designing the physical layout Source Voltage and Frequency Source voltage at end feed: PowerWave 2 allows any voltage 600V. Voltage is uniform throughout the bus run (except for voltage drop characteristics see the Specification). The source voltage and frequency are necessary parameters for TOBs and circuit breakers Neutral Size Select neutral size. Neutral size must be the same for the entire bus run. See Specification for available sizes Current Loads Server rack current load translates to load for a TOB receptacle. TOB circuit breakers must exceed expected load. Determine if bus run reserve capacity is needed for load spikes or expansion. Based on the sum of TOB loads, select the amperage capacity of the bus run (150A or 250A). The sum of TOB loads must not exceed the rated amperage of the bus run: Load(TOB1) + Load(TOB2) + + Load(TOBN) + (reserve capacity) Bus Run Rating. If the sum of loads and reserve capacity exceeds the amperage rating of the bus run, then select the next higher rated product (e.g., 250A -> 400A), or divide the server group into multiple bus runs Upstream Circuit Breakers Upstream circuit breakers are recommended to be rated at 100% of the bus run amperage rating to avoid stranding bus run capacity. For dual bus runs, upstream circuit breakers should also be rated at 100% of a single bus run, or the dual run will not be suitable as a fully redundant system. 59

60 PowerWave 2 Bus Systems Installation and Operation End Feed Disconnects Disconnects are optionally available in the Standard and Modular End Feeds and are typically used for these purposes: End feed circuit breakers let the bus run be isolated for maintenance. End feed circuit breakers provide a locally visible and accessible disconnect when the main power disconnect to the bus run is remote. End feed fuse disconnects can provide a higher kaic than is typically available through circuit breakers, providing additional protection for the bus run. The Compact End Feed does not allow disconnects Dual Bus Runs Determine whether you will use single or dual bus runs. (This is not a parameter on any part.) Dual bus runs are recommended in areas with unreliable utility power. Most servers can be dualcorded allowing redundant power source access. Each end feed in a dual bus run should be powered from a separate independent power source. Preferably, the end feed for one side of the dual bus run should be physically positioned at the opposite end as the end feed on the other side. This reduces risk that accidentally cut cables will bring down the entire bus run. Both bus runs should be balanced at 50% total load of the dual bus run, and the total load on both bus runs must not exceed the amperage rating of either bus run Grounding The customer must provide a single-point ground connection to the ground lug in each end feed. See Table 11, Power and Ground Wire Size Table. BCMS Extension (optional) to an end feed requires 18 AWG (0.82 mm 2 ) ground wire for control wiring, connected to the single-point ground lug in the end feed, wired at the factory. 5.2 Planning Monitoring Requirements Monitoring is recommended to track loads and to assess whether you are approaching the bus run s limits. The PowerWave 2 Branch Circuit Monitoring System (BCMS) integrates monitoring and communications into the same bus run as power distribution. BCMS is available with these options: Source monitoring (input power connected at end feed): current and voltage Tap-Off Box monitoring: current and voltage Monitoring limitations per end feed: o (1) input power source + (31) TOBs o (0) input power source + (32) TOBs 60

61 Installation Planning o o WARNING: Monitoring more than (32) devices (input power source + TOBs) per end feed or on a single bus run may render the monitoring PCBs inoperable! Maximum (15) TOBs per end feed can be monitored by the optional 7" display, regardless of whether the input power source is monitored. 5.3 Physical Layout and Parts Selection You should have a Plan View of your server room layout. (Some customers develop a 3D CAD software layout of the room.) Overhead obstructions, such as posts, CRAC units, fire detection and suppression equipment, should be noted on the Plan View or on an Elevation View. Using the Plan View and your electrical and monitoring requirements, develop your physical bus run layouts. Make maximum use of floor space and long continuous bus runs Horizontal or Vertical Orientation Determine horizontal or vertical orientation. Horizontal orientation is best for applications where there is limited overhead space. Some horizontal parts have restricted features to minimize the part height for installation in 300 mm of overhead space. Vertical orientation should be used for most applications. It is easier to install and has the most options, such as end feed choices and elbow neutral cross-overs. Part orientations: Bus Rails, Couplings, End Feed Couplings, and End Caps are the same for horizontal or vertical orientation. Elbows and Hangers can be used in only one orientation; there are different parts for horizontal and vertical orientation. Other parts have a preferred orientation but can be used in either orientation: o All end feeds can be used in either orientation but the Compact End Feed (250A) is the best for limited overhead space with a horizontally oriented bus run. o All Tap-Off Boxes can be inserted into a Bus Rail at either orientation, but horizontal Tap-Off Boxes have both circuit breakers and receptacles on the bottom panel for operator visibility and easy access. o Note: The 800A Bus System does not have horizontal hangers Bus Run Length and Capacity PowerWave 2 bus runs have no physical length limitation. However, voltage delivered along a bus run drops off with bus run length. The voltage drop off for PowerWave 2 Bus Systems is among the lowest in the industry. See 2.2 Electrical Specification: Busway. The number of Tap-Off Boxes that can be inserted into a bus run is limited by the number and widths of the Tap-Off Boxes compared to the length of the bus run. the sum total amperage load of the Tap-Off Boxes compared to the amperage capacity of the bus run. 61

62 PowerWave 2 Bus Systems Installation and Operation small keep-out areas where Tap-Off Boxes cannot be inserted. See Keep-Out Areas for Tap-Off Boxes. the number of Tap-Off Boxes that can be monitored on a bus run (see 5.2 Monitoring Requirements.) Keep-Out Areas for Tap-Off Boxes PowerWave 2 Bus Systems are continuous rail installations, letting you insert Tap-Off Boxes anywhere along the Bus Rail. However, there are small keep-out areas, where TOBs cannot be placed. Tap-Off Box Placement next to Couplings (250A-400A) Customers usually want TOBs placed directly above servers to make the shortest run for power cords from the server rack to the associated TOB. Having a TOB directly above its server rack also makes it easier for operators to associate the TOB with its servers. In bus systems, the Coupling (or splice in other systems) can displace TOBs to either side. Consequently customers have sometimes designed the bus run to position the splice away from the servers. The design usually required truncated bus rails to get the splice in a position so that it did not interfere with TOB placement. However, in PowerWave 2 bus runs, TOBs can overlap Couplings, leaving little or no unused rail space (Figures 49 and 50). Left and right side grounds on TOBs are jumpered together so that the ground connections directly under the Coupling are grounded through the ground connected outside the Coupling. ½-inch (1.27 cm) keep-out area between TOB mast and Coupling. TOB Mast COUPLING TOB Mast TOB Enclosure TOB Enclosure TOB Enclosures can overlap Coupling. Overlap area is larger with larger TOBs. Figure 49 Tap-Off Boxes Can Overlap Couplings Consequently, TOBs can be positioned directly above servers, even if a coupling is also positioned there. More bus run can be profitably used. There is no need to use shorter rails to position the coupling. Customers can use more full length 12' (3.66 m) Bus Rails. With full length rails, customers need fewer Couplings in the bus run. 62

63 Installation Planning (2) x in (26 cm) Tap-Off Boxes (smallest Tap-Off Box) leave only 4" of unused rail space. Large Tap-Off Boxes leave no unused rail space. Figure in Tap-Off Boxes Overlapping Coupling End Feed Keep-Out Areas (250A only) End feeds have a small keep out area, shown in Figure 51. TOB masts can come up to end feed bracket. Clearance between end feeds and TOB enclosures must be at least 1.5" (3.8 cm). Figure 51 End Feed Keep-out Area 63

64 PowerWave 2 Bus Systems Installation and Operation Tap-Off Box Placement in Elbows (250A-400A) Elbows have two legs: Figure 52 shows placement of TOB masts and enclosures around Elbows. A 10.25" (26 cm) TOB can be inserted into an Elbow leg. On horizontal Elbows, if TOBs face inward, only one leg can have a TOB, as shown in Figure 52. TOB enclosure can come to this point. TOB mast can come to this point. A 10.25" (26 cm) TOB can be inserted into an Elbow leg. If TOBs face inward, only one leg can have a TOB. Figure 52 Tap-Off Box Placement in Elbows Using Older Tap-Off Boxes Older Tap-Off Boxes can be used in PowerWave 2 bus runs. However, they cannot overlap Couplings and or take advantage of the smaller keep-out areas. They are best used in the middle of Bus Rails and away from joins Small Corrections to Bus Run Length (250A/400A) For precise layout, be aware of these minor corrections to the bus run length: Standard Bus Rails are 12' (3.66 m) from the end of one conductor to the other. However, at the Coupling, there is a 1/8 (.3175 cm) gap between conductors. An End Cap adds 0.313" (0.8 cm) to the end of the bus run. Consequently, a bus run with (3) Bus Rails with (2) couplings, the total length is 64

65 Installation Planning o (3) Bus Rails + 2 Conductor Gaps at Couplings + End Cap, OR o 36' (3 x 12') + (2 x 1/8") " = 36' 0.56" = m A Bus Rail inserts into an end feed 3.188" or 8.1 cm. Subtract this number from total length of the bus run A Bus System Keep-Out Areas Tap-Off Boxes cannot overlap Couplings or Elbows on 800A Bus Systems. 5.4 Overhead Support Structure PowerWave 2 Bus Systems are hung from an overhead support structure, such as a Unistrut or grid structure. It is the customer s responsibility to evaluate, select, and install the overhead support structure and to provide the connecting hardware, such as bolts or all-thread, to connect Silver Bus System hangers to the selected structure. All seismic calculations must be done prior to hanging bus run by civil engineer. 5.5 PDI Application Engineering PDI Application Engineering can provide you assistance with installation planning. You should provide PDI with the following at minimum: A Plan View (overhead view) of the server room or area being served by the bus run(s). An Elevation View of the server room. Show Interferences posts, air handlers, etc. that can impede the bus run(s). KW density of the server racks or equipment served by the bus run(s). 5.6 Conclusion Thorough planning for your PowerWave 2 installation will ensure that your installation goes smoothly, that your installation environment is prepared, that all parts kits are ordered, and that the parts kits integrate well to match your requirements. Your next step should be to prepare an installation plan with installation sequences and assigned personnel. 65

66 PowerWave 2 Bus Systems Installation and Operation 6 Installation DANGER! This product must be installed and inspected by licensed electricians or by PDIauthorized technicians. This document should not be viewed as sufficient by otherwise non-qualified personnel to operate, service, or maintain this equipment. Severe or fatal injury can result from electrical shock during contact with high voltage conductors, monitoring PCBs, or similar equipment! Disconnect power before drilling holes, making cutouts, attaching conduit, or connecting to PDUs, RPPs, or other power distribution equipment. Use Lock Out/Tag Out procedures. Wear suitable personal protective clothing and use protective equipment for performing mechanical and electrical installations. Leave ample space for attaching and routing wires. 6.1 Receive and Inspect Parts are shipped as kits. Upon delivery, verify that you have received all kits and parts: 1. Compare the actual shipment with the bill of lading. Report any missing items to the carrier and PDI immediately. 2. Also compare the bill of lading with your order. Report discrepancies to PDI immediately. 3. Inspect the shipping packaging and the shipping skids, if applicable, for signs of damage. Report damage to the shipping company and to PDI immediately. 4. Store the kits or parts in a dry environment before installation. 6.2 Unloading, Unpacking, and Handling 1. Plan your route for moving the equipment. Ensure that all passages are large enough. Check for any non-negotiable corners or offsets in hallways. 12' bus rails can be difficult to move through stairwells and corners. 2. Use a forklift or pallet jack to move the kits or parts on their shipping skid as close as possible to the final installation position. Do not exceed a 10-degree tilt if moving with a forklift. 3. If kits and parts are shipped on pallets, carefully cut the bands holding the kits or parts to the pallets. Use caution: bands are under tension and can cause personal injury. Use caution! Bands holding kits to pallets are under tension and can cause personal injury when cut. 66

67 Installation 4. Lift the units off the skids with a forklift capable of handling the weight of the unit. Ensure that the pallet is located on a level floor with room to maneuver around it. 5. When opening the shipping package, use care not to puncture the packaging with sharp objects. Remove all plastic wrapping and packing material from the unit. 6.3 Installation Sequence PDI recommends that you have an Installation Plan with an installation sequence, such as the following: 1. Create the overhead busway support structure. 2. Install the end feed. 3. Build a complete bus run structure of Bus Rails Elbows, Couplings, and End Cap. Installation Sequence: Install Bus Rails and Elbows, joining sections with Couplings as the bus run structure is built. For example: Install two Bus Rails, then the Coupling that joins them. 4. Connect ground and power. 5. Execute startup checklist. 6. Power up and test the bus run. 7. Install Tap-Off Boxes. 8. Connect server power strip whips. 9. Test Tap-Off Boxes. 10. Power up servers. 11. Test BCMS, if BCMS options have been selected. 6.4 Create Overhead Support Structure PowerWave 2 Bus Systems are hung from an overhead support structure, such as a Unistrut or grid structure. It is the customer s responsibility to evaluate, select, and install the overhead support structure and to provide the connecting hardware, such as bolts or all-thread, to connect PowerWave 2 Bus System hangers to the selected structure. The installation examples that follow assume overhead Unistruts. Recommended: Install overhead Unistruts perpendicular to busways (Figure 53). This is the most common Unistrut setup. Unistruts must be laid out to match correct hanger spacing on the Bus Rails and Elbows. Hanger spacing varies according to horizontal or vertical spacing. It allows the busway to be repositioned to correct positioning of Tap-Off Boxes for better operator access. If using a ceiling drop grid, to prepare for hanging busway, place all thread in a straight line according to your hanger layout. If hanging from a concrete ceiling, use a laser to line up the bus run, drill concrete anchors, and install all-thread. 67

68 PowerWave 2 Bus Systems Installation and Operation On right: Overhead Unistruts installed perpendicular to horizontal busway (with Compact End Feed) The Unistruts must be installed to match hanger spacing; the spacing cannot be adjusted once installed. Figure 53 Horizontal Busway with Perpendicular Unistruts Horizontal hangers have two bolt attachments, also allowing Unistruts to run parallel to the busway (Figure 54). This setup allows the hangers to be repositioned easily, but does not allow you to reposition the busway for easier Tap-Off Box access. Make sure that the rear busway is close enough to the front of the server racks to allow easy access to circuit breakers. Vertical busways have one overhead bolt and can be positioned with the Unistruts perpendicular or parallel to the busway. Unistruts Two Unistruts overhead parallel to each bus run. Horizontal Hanger and Bolts Horizontal Bus Rail, channel opening to front Figure 54 Horizontal Busway with Parallel Unistrut Support Structure There are no hangers for end feeds. End feeds are attached to customer s overhead support system using customer hardware. There are no pre-punched knock-outs for external wiring. Installers must make their own cutouts for wiring. Cutouts should have grommets installed. 6.5 Create Starter Rail for Compact End Feed (250A) A starter rail is the Bus Rail that is attached to the end feed. For the Compact End Feed and Standard End Feed, you can create a starter rail from any length Bus Rail and End Feed Coupling. Create the starter rail before hanging the rail. (This step does not apply to the Modular End Feed, which has a starter rail built at the factory.) 68

69 Installation Compact End Feed Starter Rail Step 1: Slide Hangers onto Bus Rail at appropriate spacing before hanging the rail or attaching it to an end feed. Horizontally oriented Bus Rails require more hangers than vertically oriented. See Horizontal Hangers for spacing information. Figure 55 Compact End Feed Starter Rail Step1: Hangers Step 2A: Attach End Feed Flange Plate to the selected Bus Rail using (4) enclosed screws. End Feed Flange Plate Ground Wire Attached to Flange Step 2B: Slide Bus Rail through its hangers away from the end feed to allow space for adding the End Feed Coupling. Figure 56 Compact End Feed Starter Rail Step 2: Flange Plate 69

70 PowerWave 2 Bus Systems Installation and Operation Step 3: Attach End Feed Coupling over conductors. Step 3A: Insert Divider between Conductors as shown. Step 3B: Clamp both halves of the End Feed Coupling over the conductor, snug against End Feed Flange Plate. Match (6) slots on each half to (6) tabs on each side of the Divider. Step 3C: Insert enclosed bolt through both halves of the End Feed Coupling and the Divider. Attach hex nut and screw down with enclosed Allen wrench until the nut is in the recessed hex nut hole and tightly screwed on. Divider Bolt Figure 57 Compact End Feed Starter Rail Step 3: End Feed Coupling Step 4: Attach End Feed Coupling Cover over End Feed Coupling. Remove (4) nuts (top and bottom) to attach End Feed Coupling Cover to End Feed Flange Plate. Step 4A: Remove (4) nuts from End Feed Flange Plate and install End Feed Coupling Cover over (4) flange bolts. Step 4B: Screw nuts back on and tighten. End Feed Flange Plate End Feed Coupling Cover Figure 58 Compact End Feed Starter Rail Step 4: Coupling Cover Attach Starter Rail to End Feed This step does not apply to the Modular End Feed, which has the starter rail built in and attached to the end feed at the factory. 70

71 Installation Step 5A: Remove Compact End Feed covers. Step 5B: Insert starter rail into Compact End Feed and attach to end feed with (4) bolts and (4) nuts (enclosed). Step 5C: Replace end feed covers. Figure 59 Compact End Feed Starter Rail Step 5: Attach Starter Rail 6.6 Create Starter Rail for the Standard End Feed (250A) Creating a starter rail for the Standard End Feed is similar to creating one for the Compact End Feed. Step numbers below refer to Figure 60: 1. Remove end feed covers. Hang Standard End Feed, using customer-supplied support system and hardware. Customers must drill their own all-thread holes and create their own cutouts. 2. Install Bus Rail. a. Slide or insert vertical hangers onto Bus Rail. See Vertical Hangers for spacing. b. Hang Bus Rail: Connect Hangers to overhead Unistruts. c. Slide Bus Rail on its hangers away from end feed to create room to connect flange plate and End Feed Coupling. 3. Connect Bus Rail to Standard End Feed Flange Plate. (Similar to Figure 56, Compact End Feed Starter Rail Step 2: Flange Plate. ) 4. Attach End Feed Coupling to Bus Rail, using the same procedure as for a Compact End Feed, but with a different flange (Similar to Figure 57, Compact End Feed Starter Rail Step 3: End Feed Coupling. ) 5. Connect starter rail and end feed. a. Insert assembled starter rail into end feed. b. Connect Flange Plate to Standard End Feed using (4) attached bolts and nuts. c. Insert Standard End Feed Coupling Cover over End Feed Coupling. 6. Attach Coupling Cover to End Feed Flange Plate using screws on Flange Plate. 71

72 PowerWave 2 Bus Systems Installation and Operation 7. Completed. Adjust Bus Rail hanger spacing. OR Figure 60 Creating Starter Rail for Standard End Feed 6.7 Installing Bus Rails Attach Bus Rails to the overhead support structure using customer supplied hardware and the number of hangers appropriate to the vertical or horizontal orientation of the rail. (See following sections.) Check that Bus Rails are level and that the conductors on adjacent rails are aligned and nearly touch. Install two (2) adjacent Bus Rails, then join with a Coupling. Extend the busway with another Bus Rail or Elbow, then join with another Coupling. Continue until the busway structure is complete except for the end feed. The final section of Bus Rail must have an End Cap installed (see Figure 36, End Caps ). 72

73 Installation DANGER! High voltages and amperages! Risk of electrical shock and electrocution causing injury or death! The exposed terminal conductors on every busway must be covered by an End Cap! Hanging Vertical Bus Rails Install vertically oriented Bus Rails with Vertical Hangers. Slide-on Vertical Hangers are recommended. Install slide-on Vertical Hangers by sliding each hanger onto the end of the Bus Rail and sliding it into position (Figure 30, Vertical Hanger (slide-on) (250A-400A) ). Insert twist-on Vertical Hangers as two separate pieces under the top lips of a Bus Rail, twist into place, and screw the two pieces together using the enclosed screws (Figure 31, Vertical Hanger (twist-on) (250A-400A ). PDI recommends three (3) vertical hangers per 12' (3.66 m) of Bus Rail. One (1) hanger is recommended within 12" (30.5 cm) of each Bus Rail end and one (1) hanger should be centered between them. Maximum hanger spacing should be 5' (152.4 cm) or less Hanging Horizontal Bus Rails Bus Rails: PDI recommends (4) four horizontal hangers per 12' (3.66 m) bus rail: Place a hanger within 1' of each bus rail end. Place two (2) hangers evenly spaced between the end hangers or about 3.33' spacing (101.5 cm). Hangers should be spaced no more than 3.5' (1.07 m) from each other (Figure 61). See Figure 34, Sliding Horizontal Hangers onto Bus Rail. Install a hanger 1 ft. from each Bus Rail end. Install (4) hangers per 12' (30.5 cm) Bus Rail. 4 4 Space hangers no more than 3.5' (107 cm) apart. Figure 61 Horizontal Hanger Spacing 73

74 PowerWave 2 Bus Systems Installation and Operation 6.8 Hanging Elbows 2. On short Elbow legs, install hangers within (1) ft. (30.5 cm) of Coupling center. 1. Install hangers outside, but close to Elbow brackets. Figure 62 Positioning Elbow Hangers on Legs (250A-400A) Elbows should be hung with two (2) hangers, positioned according the following rules (Figure 62): 1. Both hangers should be outside, but close to the Elbow bracket. 2. On Elbow legs, hangers should each be within 1 ft. (30.5 cm) of the center of each Coupling. 6.9 Installing a Coupling (250A-400A) This section illustrates joining two Bus Rails with a Coupling or an Elbow. Reference Bus Rail Coupling (250A-400A). Coupling installation is simple and requires no special tools, only an Allen wrench, included in the Coupling kit. A Coupling can be installed at least (10) ten times while maintaining conductivity. 74

75 Installation Step 1: Hang (2) Bus Rails so that both rails are level and aligned with each other and the conductors nearly touch. (1) Ground Jumper Plate Each Bus Rail has (1) Ground Jumper Plate and (2) Side Plates that slide along the rail. Slide them to one side of the Coupling or join area. (2) Side Plates (one on each side) Figure 63 Installing Coupling Step 1: Bus Rails Step 2A: From the Coupling kit, insert the Divider between the conductors, perpendicular to them. 6.5" (16.5 cm) 1/8" (3.175 mm) gap between conductors 6.5" (16.5 cm) Step 2B: Important! Slide Bus Rails together until the fit between the Bus Rails and Divider is snug. Note: The Divider maintains the correct spacing for the Coupling. Space between the aluminum shells of the Bus Rails should be 6.5" (16.5 cm), the width of the Divider. There should be a 1/8" (3.175 mm) gap between conductors. Figure 64 Installing Coupling Step 2: Divider 75

76 PowerWave 2 Bus Systems Installation and Operation Step 3: Clamp the top and bottom halves of the Coupling over the top and bottom conductors. Mate the Coupling halves with the (6) tabs on each side of the Divider. Figure 65 Installing Coupling Step 3: Coupling Halves Step 4: Remove screws from top of Bus Rail. Slide the Ground Jumper Plate over the Coupling and center. Reinsert (2) outside screws and tighten. Ground Jumper Plate must be securely attached to the Bus Rails on both sides. This is essential to the grounding of the bus run! Figure 66 Installing Coupling Step 4: Ground Jumper Plate 76

77 Installation Step 5A: Insert the enclosed bolt into the top hole of the Coupling all the way through both Coupling halves. Step 5B: Screw the nut onto the bottom of the bolt so that the nut rests in the recessed hole. Step 5C: Screw the bolt and nut tightly using the enclosed Allen wrench. The bolt protrudes allowing the bottom cover to be attached in Step 7. Figure 67 Installing Coupling Step 5: Bolt Coupling Halves Together Step 5: Slide the (2) Side Plates over the Coupling and center. Ground Jumper Plate (2) Side Plates (one on each side) Figure 68 Installing Coupling Step 6: Ground Jumper and Side Plates The following optional features, if installed, require connections across the Coupling: BCMS Monitoring for Tap-Off Boxes: a communications cable in the Bus Rail Monitoring Channel (which extends through Elbows) must be connected. Isolated Ground Option: a copper ground strip in the Isolated Ground Channel must be connected. 77

78 PowerWave 2 Bus Systems Installation and Operation Step 7: Connect Optional Features Step 7A: If the customer has selected BCMS Monitoring for Tap-Off Boxes, communications cables will be installed in the Bus Rails and Elbows. Snap together the communications cables from each side of the Coupling. Step 7B: If you have selected the Isolated Ground Option, a copper grounding strip will be installed in the Bus Rails or Elbows being connected by the Coupling. Attach the enclosed copper connecting strip to the isolated ground strips on both sides of the Coupling using (4) enclosed screws. Tighten with the Allen wrench. Figure 69 Installing Coupling Step 7A, 7B: Monitoring and Isolated Ground Options Step 8A: Insert the Bottom Cover under the Coupling. Make sure that the communications cable is not pinched, if installed. Communications cable channel and isolated ground channel are connected across Coupling. Bus Rail channels are empty. Step 8B: The tabs on the Bottom Cover lock into the tab openings on the Side Plates. Screw the cap nut onto the bolt to secure. Tighten with the Allen wrench. Figure 70 Installing Coupling Step 8: Connect Bottom Cover 78

79 Installation Completed Coupling Installation should look like these illustrations. Figure 71 Installing Coupling: Completed View 6.10 Installing and Removing Tap-Off Boxes Tap-Off Boxes have cam-actuated connections to the busway (Figure 66). Top View Cam-knob opened to left (OFF) to insert or remove Tap-Off Box from rail. Finger contacts engage conductors when cam-knob is closed to the right (ON). Figure 72 Inserting Tap-Off Box into Bus Rail To insert Tap-Off Boxes into a Bus Rail or Elbow (Figure 72): 1. Position the Tap-Off Box so that the cam-knob is on the neutral side of the rail. (Neutral is always labeled on the Bus Rail.) 2. Insert the Tap-Off Box mast into the rail. The ground connection will be made and the phasing will be aligned when the Tap-Off Box is fully seated against the Bus Rail. The ground connection is always made first. 3. Screw in the hold-down screws over top of the Bus Rail lip. Do not tighten the hold-down screws so tightly that they penetrate the Bus Rail. 79

80 PowerWave 2 Bus Systems Installation and Operation 4. To energize the Tap-Off Box, slide the cam knob right to the ON position engaging the Finger Contacts to the phase and neutral bus bars. TOBs have several safety features that prevent incorrect insertion into or removal from the rail: Tap-Off Boxes and Bus Rails have physical barriers that prevent inserting the Tap-Off Box backwards, that is, not on the neutral side. A Tap-Off Box cannot be inserted into the Bus Rail if the cam knob is in the ON position and the Tap-Off Box finger contacts are extended. A Tap-Off Box cannot be removed from the busway system while the cam-knob is in the ON position. The finger contacts will not pass through the opening until fully retracted and the bus insulation will keep the contacts from passing through the bus until they are fully disengaged and closed. The finger contacts are spring-activated to the OFF position to ensure that they fully retract. The ground connection is always made first before power connections. The PowerWave 2 Bus System has an IP2X finger-safe rating. To remove a Tap-Off Box from the rail, make sure Tap-Off Box circuit breakers are opened (OFF), slide the cam-knob left completely to the OFF position, and slide the Tap-Off Box out of the rail Adjust Bus Rail C-Clips Bus Rails have C-clips to stiffen the mast channel. The C-clips can be moved to allow Tap-Off Box insertion, but do not move the C-clips at the ends of the rail. Slide the C-clips only enough to make room for Tap-Off Boxes; maintain a generally even spacing (Figure 73). Do not move the C-clips at ends of the rail. You can slide C-clips along the mast channel to make room for Tap- Off Box insertion. Adjust the C-clip position only enough to make room to insert a Tap-Off Box. C-clips should be evenly spaced along a Bus Rail. Figure 73 Adjust Bus Rail C-Clips to Make Room for Tap-Off Boxes 80

81 Installation A Bus System Installation A Installation Outline Installation of the 800A PowerWave 2 Bus System requires the user to properly plan the installation while using the appropriate hardware and connection points to install the busway. Below is a step-bystep list of actions required for installation. 1. Consult submittal drawing and ensure that all parts on submittal are present and accounted for. 2. Layout busway in the appropriate configuration keeping a special note of neutral location, bus length, and end-feed positioning. 3. Raise and hang the end-feed starter rail of the Busway System. 4. Raise and hang subsequent bus rails ensuring to line up neutrals and maintain a level bus run. 5. Install Coupling connections throughout the bus run. 6. Install an endcap to the end of the busway run. 7. Identify the conduit entry point within the end-feed box and punch sheet metal entry point. 8. Install end-feed box to end-feed starter rail and support with all thread support rod and appropriate hardware. 9. Land conduit to end-feed box and run cable to lug connection points. 10. Connect cable runs using appropriate lugs to each phase and neutral of the PowerWave 2 Bus System. 11. Commission the bus run: load Tap-off Boxes with a load bank and thermal scan the Coupling and lug points. 12. For installation of power monitoring using PDI s BCMS, consult the PowerWave 2 Bus System, Branch Circuit Monitoring System, Setup and Operation PM Tools Required for Installation You will need the following tools in good condition: 5/16 Open-end Wrench #2 Phillips-Head screwdriver Sheet Metal Punch- (specific to conduit size) Lug Connection Point Tools- (specific to lug desired) Scissor Lift (or appropriate manpower) Read the installation instructions before using tools to install the busway Prepare the 800A Modular End Feed Identify where conduit will enter the end feed. Conduit cannot enter the end feed through the left or right panels. 81

82 PowerWave 2 Bus Systems Installation and Operation Conduit must not interfere with the (2) ground terminals (on inside bottom of unit) or, if installed, the optional isolated ground terminal (on inside top of unit) Installing the 800A Modular End-feed 1. Hang the starter rail using the appropriate number of hangers and anchor points. Recommended hangers for vertical busway are (3) hangers per 12' run spaced maximum 5' apart, (1) at 1' maximum from each end. See Figure 29, Vertical Hanger Spacing. 2. If the starter rail is not already installed, secure the prepared Modular End Feed to the starter rail using the (8) supplied screws on the Bus Rail flange. (8) Connection holes for attaching Starter Rail Flange. (2) Ground Wires Isolated Ground Channel BCMS Compartment Modular End Feed 800A Left-Hand Orientation Figure 74 Attach Starter Rail to Modular End Feed 3. Connect two (2) ground wires into (2) ground lugs inside Modular End-Feed. 82

83 Installation All-thread rod support points Cut-outs or knockouts can be made on top, bottom, or rear (green areas). DO NOT execute knockouts on side panels. DO NOT interfere with - Ground terminals (bottom of unit) - Isolated ground terminal (top of unit) (2) Ground Lugs installed on bottom of end feed (2) Ground Wires from Starter Rail Flange 800A has (2) 2-hole ground lugs on the bottom of the unit. Connect a ground wire into each lug. Figure 75 Prepare 800A Modular End Feed for Installation 4. Support Modular End-Feed box with all-thread rod secured into universal-strut or concrete. 5. Run electrical conduit and electrical wire to the end-feed. 6. Make conduit holes. Do not interfere with ground or isolated ground terminals or cut holes in side panels. 7. Connect conduit and lug each wire to appropriate phases, neutral, and ground. Neutral position varies by left-hand or right-hand orientation of the end feed (see Figure 9). 8. There are (3) double-lug positions for each power connection (ABCN). See wire recommendations in Table There are (2) ground wires from the starter rail flange Steps to Install 800A Coupling The steps to install the 800A Coupling are similar to those for the 250A-400A Coupling. The parts used for the 800A Coupling are shown in the parts explosion in Figure

84 PowerWave 2 Bus Systems Installation and Operation Ground Strap Drip Cover Divider Coupling Side Plates (2) Coupling Bottom Section Coupling Top Section Bus Rail Cable Harness Protector Support U- Channel 5. Figure Secure 76 four 800A (4) Bus Philipps Rail Coupling head screws Parts on Explosion the side of the Coupling. 1. Slide both side plates onto the left or right bus bar away from the Coupling area. 2. Insert glastic divider between the top two and bottom two phases of the system. 2. Insert the Divider between the top and bottom conductors. 1. Slide the Side Plates onto Bus Rail, if necessary, and away from the Coupling area. Inserted Divider should be snug against Bus Rails. Divider controls spacing of the Coupling. Figure 77 Install 800A Coupling: Steps

85 Installation 3. Insert bottom Coupling section onto bottom two busbar conductors and use a rocking motion to slide it onto the busbars. (Note: the action of securing the Coupling may be difficult because of the strong contact needed to ensure a good connection.) 4. Insert the top Coupling section onto top two busbar conductors using similar rocking motion. 5. Secure the Coupling top and bottom halves with (4) Phillips head screws. 4. Install top half of Coupling with rocking motion. 5. Secure top and bottom halves of Coupling with (4) 8-16 x 3/4" Phillips panhead plastic thread forming screws 3. Install bottom half of Coupling with rocking motion. Figure 78 Install 800A Coupling, Steps Connect the grounding strap across the top of the Coupling using the 5/16 wrench to secure the four connection points (two on each side). 7. Attach Drip Cover to top of Coupling using four (4) pop-screws. (Note: to remove Drip Cover, popout the screws rather than unscrew them.) 7. Attach Drip Cover over Ground Strap using (4) pop-screws. (To remove Drip Cover, pop out the screws rather than unscrew them.) 6. Install Ground Strap over Bus Rails with (4) bolts and (4) nuts. Figure 79 Install 800A Coupling, Steps If BCMS (monitoring) is installed for Tap-Off Boxes, a communications cable is installed in each Bus Rail or Elbow. Connect the cables as shown in Figure 69 for 250A-400A Couplings. Similarly, if 85

86 PowerWave 2 Bus Systems Installation and Operation the Isolated Ground option is selected, connect the isolated ground channels with the copper grounding strip as shown in Figure Attach the cable harness protector to the bottom half of the Coupling using four (4) pop-screws 10. Slide the (2) Side-plates across the Coupling and line up hole with the center line of Coupling. Install 800A Cable Harness Protection with (4) pop-screws. Slide (2) Side Plates over Coupling and line up hole with Coupling center. Figure 80 Install 800A Coupling, Step Slide support U-Channel over Side Plates and secure using (2) Philips head screws on either side of the busway. PEM screw hole. Slide support U-Channel over Side Plates and secure using (2) Philips head screws on either side of the busway. Figure 81 Install 800A Coupling, Step 11: Support U-Channel 86

87 Power and Ground Connections 7 Power and Ground Connections Customers provide their own wiring and conduit to end feeds. End feeds do not have knock-outs or pre-drilled holes. Customers must create their own cable entry or landing holes. All cable entry holes should have grommets. 7.1 Lugs, Wires, and Torque Customer power connection lugs by end feed type: Compact End Feed (250A): 1-hole lugs (1/4-in), single wire connections only Standard End Feed (250A): 2-hole lugs (3/8-in), one wire or two parallel wire connections Modular End Feed (250A-400A): 2-hole lugs (3/8-in), one wire or two parallel wire connections Modular End Feed (800A): 2-hole lugs (1/2-in), one wire, or two parallel wire connections Power conductor connections from End Feed Coupling to Coupling Conductors: Compact End Feed: 1-hole lugs (1/4-in), single wire connections only Standard End Feed: 1-hole lugs (5/16-in), single wire connection only Modular End Feed: Connections made at factory Table 11 Power and Ground Wire Size Table Busway Amperage Phase Wiring, Single Wire Phase Wire, Two (2) or (3) Parallel Neutral Wire, Single Wire Neutral Wire, Two (2) Parallel Ground Wire, Single Wire 250A 250 MCM (2) x 1 AWG 250 MCM (N=100%) 500 MCM (N=150%) 400A 600MCM (2) x 3/0 AWG 600MCM (N=100%) N/A 1 (N=150%) 1 AWG (N=100%) (2) x 3/0 AWG (N=150%) (2) x 350MCM (150%) (2) x 3/0 AWG (N=100%) 6 AWG 2 AWG 800A N/A 1 (4) x 3/0 AWG (3) x 300MCM N/A 1 (3) x 300MCM (N=100%) (4) x 350MCM (N=150%) 1/0 2 1 Single wire not recommended A Modular End Feed has (2) 1/0 ground wires connected separately to (2) ground lugs. Isolated Ground: Use Ground Wire, Single Wire size from above table. BCMS Control Wiring Ground: Use 18 AWG wire for control (BCMS) ground connections from BCMS Extension to single-point ground lug. Torque power connections as follows: Compact End Feed (250A): 1/4"-20 screws; torque 85-in.-lbs, tolerance (-10) in-lbs.: o Coupling conductors to power conductors o Power connections to customer input power cables Standard End Feed (250A): 5/16"-18 screws; torque 200 in-lbs, tolerance (-10)-in.-lbs.: o Coupling conductors to power conductors 87

88 PowerWave 2 Bus Systems Installation and Operation o Power connections to customer input power cables Modular End Feed ( A): 3/8"-16 screws; torque 350 in-lbs, tolerance (-15)-in.-lbs.: o Power connections to customer input power cables Modular End Feed (800A): 1/2"-13 screws; torque 875 in-lbs, tolerance (-30)-in-lbs o Power connections to customer input power cables Torque specifications are given on a label in each end feed (Figure 82). Figure 82 Sample End Feed Torque Specification Label 7.2 Compact End Feed: Ground Connections Figure 83 shows single-point ground, isolated ground, and BCMS ground for the Compact End Feed. See Table 11, Power and Ground Wire Size Table, for ground wire sizes by busway amperage. Connect ground wires before power wires. Single Point Ground Connection Isolated Ground Connection (with standoff) BCMS Extension is grounded to the single point ground lug with 18 AWG (0.82 mm 2 ) wire. Figure 83 Compact End Feed Ground Connections 88

89 Power and Ground Connections 7.3 Compact End Feed: Power Connections Compact End Feeds T1 (Figure 84) and T2 (Figure 85) both can be used in right-hand or left-hand orientations. The layout of power connection is the same, whether the end feed is deployed in a righthand or left hand orientation, as shown in the following illustrations. T1: NCAB (N-L3-L1-L2) T2: CNBA (L3-N-L2-L1) Compact End Feed T1 Left Hand Orientation NCAB Power Connections Power Connections Single-Hole Lugs ¼"-20 hex-head screws (included, hand-tightened on connections) Torque: 85 in-lbs, tolerance (-10) inlbs N C A B N C A B Use same torque on - Customer power cable connections - Coupling to EF power conductors Compact End Feed T1 Right Hand Orientation NCAB Power Connections Figure 84 Compact End Feed T1 Power Connections 89

90 PowerWave 2 Bus Systems Installation and Operation Compact End Feed T2 Left Hand Orientation Power Connections Single-Hole Lugs ¼"-20 hex-head screws (included, handtightened on connections) Torque: 85 in-lbs, tolerance (-10) in-lbs. C N B A C N B A Use same torque on - Customer power cable connections - Coupling to EF power conductors Compact End Feed T2 Right Hand Orientation Figure 85 Compact End Feed T2 Power Connections 7.4 Standard End Feed: Power and Ground Connections Isolated Ground Connection Single Point Ground Connection Figure 86 Standard End Feed: Ground Connections 90

91 Power and Ground Connections Power connection layout Right hand orientation neutral (as shown) Power connections on End Feed Coupling Cover align exactly with Bus Rail neutral and phases. Left Hand orientation (below) reverses connections across center axis. Power Connections Double-Hole Lugs 3/8"-16 hex-head screws (included, hand-tightened on connections) Torque: 175 in-lbs, tolerance 15 inlbs Figure 87 Standard End Feed Power Connections Customer power cable connections (double-hole lugs): 3/8"-16 screws: 350 in-lbs, tolerance (-15) in-lbs End Feed Coupling to Coupling Cover power conductor connections: 516"-18 screws: 350 in-lbs, tolerance (-15) in-lbs Customer power cable connections (double-hole lugs): 3/8"-16 screws: 350 in-lbs, tolerance (-15) in-lbs Figure 88 Standard End Feed: Power Connections Torque 91

92 PowerWave 2 Bus Systems Installation and Operation 7.5 Modular End Feed: Power and Ground Connections Left-hand orientation (neutral on right) Power connections reverse across vertical axis to match bus rail layout. Right Hand orientation (neutral on left) Power connections directly align with bus rail: N-N, A-A, B-B, C-C. Isolated Ground Connection Single Point Ground Connection Customer Power Connections (NABC) Double-Hole Lugs 250A-400A: 3/8"-16 hex-head screws (included, hand-tightened on connections) Torque: 350 in-lbs, tolerance (-15) in-lbs A MEFs have (1) ground connection lug. 800A MEF has (2) ground wires and (2) double-hole ground connection lugs. 800A: 1/2"-13 hex-head screws (included, hand-tightened on connections) Torque: 875 in-lbs, tolerance (-30)-in-lbs Figure 89 Modular End Feed: Power and Ground Connections 92