ABB WavePro LT Manual

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Installation and Maintenance Manual

WavePro LT Aluminium Busway

• Unparalleled safety and protection

measures

• Wide range of designs meeting cus-

tomer’s stringent requirements

• Lower installation and maintenance

costs

—

WavePro LT Busway System provides

safe and reliable electrical distribution in

commercial and industrial applications.

WavePro LT Busway System reduces

installation cost while providing

superior performance for electrical

contractors and end users.

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Table of Contents

005-007 System overview

005 Service Condition

005-007 Major parameter and configuration

008-020 Installation

008-012 Busway Installation

013-014 Installation of bus plug

014 Installation of end box

015 Installation of the joint

016-019 Installation of the Spring Hanger

020 Installing IP54, IP65 busway

021 Commissioning

022 Maintenance

023-024 Busway installation checklist

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WARNINGS, CAUTIONS AND NOTES AS USED IN THIS

PUBLICATION

This document is based on information available at the time of its publication. While efforts have been made to ensure

accuracy, the information contained herein does not cover all details or variations in hardware, nor does it provide for every

possible contingency in connection with installation, operation, and maintenance. Features may be described herein that are

not present in all busway systems. GE Consumer & Industrial assumes no obligation of notice to holders of this document

with respect to changes subsequently made.

ABB Consumer & Industrial makes no representation or warranty, expressed, implied, or statutory, with respect to, and

assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. No

warrantees of merchantability or fitness for purpose shall apply.

To ask questions about your installation, contact the ABB company at (86) 800 820 8206.

Warning

Warning notices are used in this publication to emphasize that hazardous voltages, currents, or other

conditions that could cause personal injury are present in this equipment or may be associated with its use.

Warning notices are also used for situations in which lack of equipment knowledge could cause either

personal injury or damage to equipment.

Caution

Caution notices are used for situations in which equipment might be damaged if care is not taken.

Note

Notes call attention to information that is especially significant to understanding and operating the

equipment.

WavePro LT Aluminium Busway Installation and Maintenance Manual 5

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System overview

Service Condition & Major parameter and configuration

Storage Notice:

Please check whether there is any damage in the transportation. If any, please inform the carrier

immediately. If no damage, please store it with the package on until installation. Keep the storage

environment clean, tidy, dry and preferable near to the installation place.

Please prevent the busway from impinge against, prevent contact the caustic liquid, gas, dust , salts, or

concrete. The unsuitable storage and convey can bring on serious damage and make the expiration date

invalid.

Service Condition

• The altitude should not be higher than 2000m;

• The ambient temperature should not be lower than -5℃ and greater than +40℃, the average

temperature within 24 hours should not be greater than 35℃;

• There is no obviously shaking and impact vibration at this site;

• The air should be free from explosive risk, metal corrosion, insulation damage due to gas or dust;

• There should be no rain or snow invading in site.

Major parameter and configuration

Storage Notice:

• Rated working voltage：690V/415V

• Rated insulation voltage：1000V/690V

• Rated working current：

100A、160A、200A、250A、400A、500A、630A、800A、1000A、1250A、1350A、1600A、2000A、250

0A、3150A、3800A、4000A

• Rated working frequency：50/60Hz

• Insulation resistance：

Within the ambient temperature of +20℃ and the relative humidity of 60%, the resistance of each

busway should be more than 20MΩ before installation. However, it is allowed be less than 20MΩ due to

higher humidity or dewing.

• Dielectric strength Each bus bar has to go through a Hi-pot test 3750V/ 5S before leaving factory.

• Short circuit capacity

Note

No busway, including outdoor rated, is waterproof until completely and properly

installed.

6WavePro LT Aluminium Busway Installation and Maintenance Manual

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System overview

Major parameter and configuration

Aluminium conductor

Rated current

（A）

Rated short-time withstand current

（kA）

Rated peak withstand current

（kA）

100~250 10 17

400~500 20 40

630~800 30 63

1000~2500 50 105

3150~4000 80 176

Configuration：

• Busway is composed of bus bars, insulation material and closed housing. The section is shown below.

four wires five wires

Fig. 1.1

WavePro LT Aluminium Busway Installation and Maintenance Manual 7

Aluminium busbar

current

(A)

Width W

(mm)

Height H

(mm)

Weight of busbar

Housing ground (kg)

100%N

Internal ground (kg)

100%N, 50%Pe

100~250 128 88 8.8 9.2

400 128 98 9.9 10.3

500 128 108 11.0 11.5

630 128 118 12.0 12.7

800 128 138 14.1 15.0

1000 128 153 15.8 16.8

1250 128 183 18.9 20.1

1350 128 198 20.5 22.0

1600 128 218 22.7 24.3

2000 128 258 26.9 29.0

2500 128 316 32.2 34.9

3150 128 460 48.0 51.9

3800 128 550 57.9 62.8

4000 128 590 62.3 67.6

Current Weight (Kg)

Only with switch

Physical data of plug

(L×W×H) mm

Manual operating

mechanism

100~160A 25 450×240×260

250A 30 550×260×280

400A 40 650×300×300

1000A** 85 1200×550×400

Rotary operating

mechanism

100A~160A 25 430×240×(275+70)**

250A 30 550×260×(320+70)**

400A 40 650×300×(340+70)**

1000A** 85 1200×550×(400+70)**

Table 1

Fig. 1.2

Physical data of plug (L×W×H) mm

Note

*1000A is PTO design

**The added 70 mm is for the Rotary handle installation space.

8WavePro LT Aluminium Busway Installation and Maintenance Manual

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Installation

Busway Installation

Horizontal Installation

• Horizontal through-the-wall installation

For dimensions of through-the –wall installation, please refer to the following figure.

Pre-Installation Procedure

• When possible, deliver busway to its installation location before unpacking.

• Large labels on each hipping carton or crate designate the items contained.

• Additionally, each busway piece is identified with an item number label. Make sure to install all the

busways according the blueprint unless the engineer instructs locally.

• All the screw down moment should according to below form, excepting the bolt in the joint.

Caution

Inspect each busway piece for possible damage or contamination. Contact surfaces must

be clean. However, do not attempt to polish tarnished contact surfaces. Check to ensure

that joint insulators are not damaged or cracked and are firmly in place.

Note

Make insulation resistance test for each piece before installation.

M10 M12 M14 M16 M20

Screw Down Strength 17 .7～2 2 . 6 31.4～39.2 51.0～60.8 78.5～98.1 156.9 ～196.2

Fig. 2.1

500 500

Wall

Floor

≥400

W+100

H+100

W+100

≥500

WavePro LT Aluminium Busway Installation and Maintenance Manual 9

• Horizontal installation-trapeze hangers overhead support

Holes shall be first drilled in the floor so as to inlay steel expansion bolts (holes may also be drilled on the spot

for flexible installation) or pre-bury steel object for welding with hangers. The distance between two adjacent

hangers shall not exceed 2m. Please specify your special requirements in order. There are two forms of

horizontal installation. Please refer to the following figure.

Fig. 2.2

Edgewise

Flatwise

10 WavePro LT Aluminium Busway Installation and Maintenance Manual

There are vertical and horizontal installation styles in this method.

Rated Current of Plugs (A) 100 250 400 1000

L (mm) 150 195 210 300

• Horizontal installation-wall support

Pay attention to linearity of the installation hole (i.e. the entire run of supports shall be installed at the

same level at the same level). For installation types, refer to the graphic representation.

Horizontal installation along the wall may also contain vertical and horizontal installation.

Key points in horizontal installation

• When busway is placed horizontally, its distance from ground should be more than 2.2m, except for

those in electricity-dedicated rooms (e.g. distribution room, electromotor room, electric shaft room,

interlayer etc).

• The distance from wall should be more than 0.1m, and that from upper floor, ceiling floor and beam

bottom should not be less than 0.1m.

• Center distance between two neighboring parallel busways should not be less than 0.35m and it should

not be less than 0.1m from board.

• Joint should be outside of the wall.

Fig. 2.3

Busway

Wall

Bracket Arm

Edgewise

Busway

Wall

Bracket Arm

Flatwise

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Installation

Busway Installation

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