ABB WavePro LT Manual
—
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.
—
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
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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