IB-DU1000 Metal-Enclosed Bus

Maintenance and Installation for Low and Medium Voltage Metal-Enclosed Bus

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Metal-Enclosed Bus

Contact Information
Powell Electrical Systems, Inc.
www.powellind.com
Delta/Unibus
E-mail: Info@deltaunibus.com
515 N. Railroad Avenue
Northlake, IL 60164
Tel: 708.409.1200
Fax: 708.409.1211

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IB-DU1000

Metal-Enclosed Bus

IB-DU1000

Contents
I. Introduction................................................................................................................................................................................................ 4
II. Description.................................................................................................................................................................................................. 4
A. General.................................................................................................................................................................................................. 4
B. Conductors........................................................................................................................................................................................... 4
C. Insulation System............................................................................................................................................................................... 4
D. Enclosure.............................................................................................................................................................................................. 4
E. Bus Supports........................................................................................................................................................................................ 5
III. Receiving and Storage......................................................................................................................................................................... 5
A. Shipping................................................................................................................................................................................................ 5
B. Receiving............................................................................................................................................................................................... 5
C. Unloading............................................................................................................................................................................................. 5
D. Storage.................................................................................................................................................................................................. 7
IV. Installation................................................................................................................................................................................................. 8
A. Installation Drawings....................................................................................................................................................................... 8
B. Erection.................................................................................................................................................................................................. 8
C. Alignment............................................................................................................................................................................................. 9
D. Assembly.............................................................................................................................................................................................. 9
E. Field Testing.......................................................................................................................................................................................10
V. Operation and Maintenance............................................................................................................................................................11
A. Operation...........................................................................................................................................................................................11
B. Maintenance......................................................................................................................................................................................11
C. Spare Parts..........................................................................................................................................................................................11
D. Field Service.......................................................................................................................................................................................11

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IB-DU1000

Caution

Before any adjustment, servicing, parts replacement, or any other act is performed
requiring physical contact with the electrical working components or wiring of this
equipment, the power supply must be disconnected.

I. Introduction
This manual provides general instruction and information
related to Delta/Unibus metal-enclosed bus systems.
Refer to the drawings and information included with
each order for specific instructions. All the relevant
information provided should be read thoroughly
before proceeding with any activity to the installation,
maintenance, or operation of the bus system.
All work must be performed and supervised by
responsible personnel who are thoroughly trained and
knowledgable in all aspects related to the installation,
maintenance, and operation of bus systems. These
instructions are intended to provide only general
information related specifically to the installation of
metal-enclosed bus systems and do not include all the
procedures and precautions that must be followed to
insure the safety of both personnel and equipment.

II. Description
A. General
Delta/Unibus metal-enclosed bus systems are custom
designed for each specific application. Segregated,
non-segregated, or isolated phase constructions are
available. A complete line of terminations, horzontal
and vertical elbows, horizontal and vertical tee taps,
phase transpositions, expansion joints, earthquake
and misalignment joints, wall penetration assemblies,
smoke and fire barriers, etc. are utilized to optimize
the design of each bus system.

and power losses. Bus conductors may be full

round edge bars, square or round tubes, channels,
or tohter configurations. Standard construction
is in compliance with ANSI C37.20 which specifies
an allowable hottest-spot conductor and splice
temperature rise of 65C in a 40C ambient. All
contact surfaces at joints or terminations are
plated. Contatct surfaces of copper conductors are
electrically silver-plated and aluminum conductors
are electrically tin-plated over bronze strike by the
Alstan-80A process. Bolted joints in aluminum
conductors are equipped with conical washers which
ensure maintenance of contact pressure.
C. Insulation System
Conductor supports may be track-resistant glass
reinforced polyester blocks, cycloaliphatic epoxy
blocks, or wet process porcelain post insulators.
Molded support blocks are ribbed to maximize both
creepage distance and mechanical strength. Corona
control devices are used to mount the conductors
in the support blocks. These devices also improve
short circuit performance by functioning as shock
absorbers for the impact forces encountered during
high fault currents.
Insulated conductors are normally used on systems
rated 5KV and above. Conductor insulation is
available for low voltage bus systems. The primary
conductor insulation used is epoxy bonded directly
to the conductor. Conductor splices are usually
insulated with molded PVC boots. Terminations may
be insulated with tape or PVC boots.

B. Conductors

D. Enclosure

Copper or aluminum conductors are selected based

on desired continuous and short circuit current
capabilities, maximum operating temperatures,

Aluminum, painted and/or galvanized steel, and

stainless steel housings are available to meet the
environmental requirements of the installation.

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Highly corrosive resistant aluminum enclosures

which minimize power losses associated with both
magnetic and resistance heating are standard.
Non-magnetic housings are suggested for most
applications.
Outdoor enclosures are non-ventilated. Screened
breathers and electric space heaters are used for
condensation control. The electric space heaters may
be either manually or thermostatically controlled.
Covers are sloped to shed water and gasketed to
insure water-tightness.
Indoor enclosures may be either ventilated or nonventilated. Both the top and bottom covers of
ventilated enclosures are Iouvered.
The interior surfaces are prepared and protected with
one coat of primer. This primer coat also enhances
the radiation cooling which results in lower operating
temperatures. All exterior surfaces are prepared,
primed, and given a top and final finish coat of indoor
ANSI-61, outdoor ANSI-70, or outdoor ANSI-24. Other
colors are available upon request.
E. Bus Supports
A complete line of steel or aluminum structural
supports is available. Indoor trapeze type, outdoor
single or double column, wall mounted knee brace,
and lattice type trusses are the most frequently used.
Outdoor structural steel supports are hot-dipped
galvanized after fabrication or primed and painted
after fabrication. Indoor supports are primed and
painted to match the bus housing color.

III. Receiving and Storage

IB-DU1000

Auxiliary items such as splice kits, termination kits,

insulating materials, bolting hardware, etc. are packed
in kits which are clearly identified by purpose and
installation location. A complete set of installation
drawings, bill of material, and installation manual is
shipped with each bus system.
B. Receiving
Prior to acceptance of a shipment a complete
visual inspection should be performed for any
indications of possible shipping damage. Any such
indications must be noted on the shipping papers
when accepting delivery. The equipment should be
inspected for concealed shipping damage as soon
as practicable. If any indication of damage is found,
notify the carrier immediately and arrange for his
inspection. The damaged equipment should remain
in its crate as received until the carriers inspection is
complete. Photographs should be taken to support
the claim. Contact your Delta/Unibus representative
immediately so that corrective action can be initiated.
If the terms of the shipment are F.O.B. plant, it is the
buyers responsibility to file a claim with the carrier.
If the terms are F.O.B. destination, then Delta/Unibus
will file a claim with the carrier. In all cases it is the
buyers responsibility to follow proper receiving
procedures.
Incoming materials should be carefully checked
against the shipping manifest to verify that no
shipping losses have occurred and against the bills
of material to verify that all items have been received.
Shortages should immediately be reported to the
carrier and your Delta/Unibus representative.
C. Unloading

A. Shipping
The bus is shipped in the largest possible factory
assembled sections to facilitate and minimize field
handling and assembly. Crating suitable for shipment
via common carrier motor freight and indoor storage
is standard. Special crating suitable for export
shipments or outdoor storage is available. Observe
markings on the crate which may indicate special
procedures.

Bus systems can be unloaded utilizing fork-lift trucks

or other devices. Lifting slings with a spreader
bar are suggested for safe handling (see Figures
1 & 2). Shipping crates must not be stacked. The
equipment must be protected from the weather at all
times. Tarpaulins can be used to provide temporary
protection.

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Figure 1 Bus Unloading

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IB-DU1000

Metal-Enclosed Bus

IB-DU1000

D. Storage
Bus systems as shipped must be protected from the
weather at all times. For storage periods longer than
90 days the bus shall be placed in a weathertight, well
ventilated building and protected against vandalism.
The floor shall be well drained. The area shall be
provided with uniform heating and temperature
control or its equivalent to prevent condensation and
corrosion.
For storage periods of 90 days or less the bus, with
proper protection, may be stored in outdoor areas
that are marked and designated for storage. This area
is to be well-drained, gravel covered or paved, and
reasonably removed from construction areas and
traffic. Items shall be placed on pallets or shoring
to allow for air circulation and to avoid trapping
water. A weatherproof covering shall be applied in
such a manner that it protects the equipment yet
allow for air-circulation to minimize condensation.
The equipment shall be inspected bi-monthly and
corrective action taken as required.
The high potential test as described under Maintanence
should be performed on each section of bus before
installation. This test should also be performed
before putting the bus into storage if the storage
period will exceed 90 days. The internal surfaces of
the bus must be clean and free of condensation or
moisture before attempting a high potential test.

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IV. Installation
A. Installation Drawings
A set of specific, detailed installation drawings is provided for each bus system. An understanding of the
organization of these drawings is the key to insuring a fast, trouble-free installation. The bus layout drawings and
bills of material are the primary drawings which reference and coordinate all the other drawings and procedures.
Each section of bus is uniquely identified on the layout drawing by a section number. This identification is marked
on each bus section, and the corresponding layout drawings provided with the project can be used to determine
the method of installation of the bus equipment in the field.
B. Erection
Typical methods of lifting individual bus sections are illustrated in Figure 2. The use of nylon lifting slings attached
to a spreader bar is a method that enables safe handling and minimizes marring of the paint finish.
Figure 2 Lifting and Maneuvering Bus Section

The conductor support system used with insulated conductors is designed to eliminate stresses from thermal
expansion. This is accomplished by not restraining the longitudinal movement of the conductor within the conductor support. The conductor in a straight section of bus can be removed by sliding it along the section. Straight
sections are supplied with shipping fixtures that retain the conductors in position. CAUTION: THESE FIXTURES
MUST NOT BE REMOVED UNTIL INSTALLATION IS COMPLETE OR THE CONDUCTORS HAVE BEEN SAFELY SECURED!!!

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C. Alignment
The entire run of bus duct should be installed and
adjusted at all terminal equipment BEFORE final
torquing and insulation of bus conductor joints.
Adjustments to obtain proper alignment should be
distributed evenly throughout the bus system at
every splice. Normally it is not required but a small
amount of additional adjustment can be obtained by
repositioning end flanges.
D. Assembly
Installation drawings contain the construction and
assembly details of standard components.
It is important that assemblies be correct in all
respects. Small details such as the position and
orientation of spacers and bolting hardware must be
observed. Proper torque procedures help insure a
trouble free installation and service life.
The contact surfaces of all electrical joints are
either silver or tin plated. The use of electrical joint
compounds is neither required nor recommended.
Contact surfaces should be cleaned before assembly.
A mild non-metallic abrasive may be used to loosen
dirt or other contaminants.
Each assembly should be cleaned and inspected
as it is completed. Any shipping fixtures must be
removed. SEE THE CAUTION REGARDING STRAIGHT
SECTIONS UNDER THE SECTION ON ERECTION. The
shipping fixture used on misalignment and vibration
collars should not be removed until these sections are
installed or protected from damage.
The components necessary to complete the
installation at each bus end (or splice) have been
shipped in separate identified packages.

IB-DU1000

The bus housings must be properly grounded.

Since the type and number of facilities required to
establish adequate grounding can vary considerably
for different situations, the responsibility for the
design, installation, & verification of the ground can
not be assumed by Delta/Unibus. Ground pads, with
or without cable lugs, can be provided on the bus
housings at convenient locations for connection
to station ground. The bus housing can be used to
establish ground continuity in many applications. It
is important that the housing splice plates which
are designed to provide a low resistance connection
between adjacent bus sections be properly installed.
A continuous insulated or multigrounded copper
or aluminum ground bar is also an available option.
Flexible ground continuity connections which are
provided at bus expansion joints should be inspected
for tightness or damage.
After the installation is complete, the bus insulation
should be checked from phase-to-phase and phaseto-ground using a 1000 volt megger.
Control wiring, such as instrument transformer
secondary circuits, space heater wiring, thermostat
circuits, etc. are subjected to a factory overpotential
test to ground of 1500 volts, 60 HZ, for one (1) minute.
This test should be repeated on the completed
installation.
Perform the AC high potential test as described under
Field Testing.
The entire bus system should be carefully examined
for any indication of physical damage. Touch up paint
should be applied to any finish surfaces which have
been damaged. Avoid excessive accumulation of
touch up paint on breathers. Verify that painting has
not clogged any breathers.

It is important that during installation all the

necessary actions are taken to protect the bus from
the weather and the abnormal entry of dirt or other
contaminants. The space heaters should be put into
operation as soon as practicable.

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E. Field Testing
A one minute AC high potential test can be performed at 75% of the factory test voltage indicated on the test tag
shipped attached to each section of bus. This test is in accordance with ANSI C37.23. See Table 1. The test voltage
is applied phase-to-phase and phase-to-ground. If an AC test set is not available, a one minute DC test may be
used. All internal components of the bus must be CLEAN and DRY before performing the high potential test.
Operation of the bus heaters a minimum of 72 hours before performing a high potential test is recommended.

Voltage and Insulation Levels

Bus Rating
Insulation Level (kV)

10

Field Test
One Minute Withstand

Rated Maximum
kV (RMS)

Power Frequency Withstand

(RMS) Dry One Minute

Impulse
Withstand

AC
kV-RMS

DC
kV

0.635

2.2

NA

1.65

2.3

4.76

19.0

60

14.25

20.25

15.00

36.0

95

27.00

37.50

15.50

50.0

110

37.50

52.50

25.80

60.0

125

45.00

63.75

38.00

80.0

150

60.00

84.00

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V. Operation and Maintenance

A. Operation
The metal enclosed bus systems described in this
manual are self cooled systems which have no
moving components. A long reliable service life is
assured by carefully following the simple installation
and maintenance procedures outlined in this manual.
The bus should never be energized with the presence
of moisture or heavy contamination on the interior
surfaces of the bus. The bus heaters should be
operated a minimum of 72 hours as noted under
MAINTENANCE before energizing a bus that has been
out of service for a period of time. The bus heaters
must remain operational any time the bus is in service
and the possibility of condensation exists.
All covers must be securely in position at all times
during the operation of the bus. Any dented or
damaged housings must be carefully inspected and
corrective action taken before energizing the bus.
The bus system is not intended to be a walkway and
this type of activity must be avoided.
B. Maintenance
The Delta/Unibus metal enclosed bus system
has been designed to eliminate any components
that might require periodic routine lubrication,
maintenance, or replacement. An annual inspection
of the bus is recommended. This should include a
complete visual check for damage or deterioration
and an operational test of the space heater system.
CAUTION: THE BUS SYSTEM MUST BE DE-ENERGIZED
DURING THE REMOVAL OR INSTALLATION OF
HEATERS. Screened or filtered breathers should
be inspected and cleaned at periodic intervals
determined by existing site conditions. The
insulation should be inspected and cleaned as
required. Isopropyl alcohol is a suitable solvent that
is recommended. Particular care should be taken
to avoid the application of any harsh solvents. The
inside surfaces of the housing should be wiped to
remove any loose contamination. A vacuum cleaner
may be used to facilitate the removal of loose
particles.

IB-DU1000

Field experience has verified that re-torquing of

properly installed conductor connecting hardware
is not required on a routine basis. Connections that
are suspect should be inspected and re-torqued as
required.
New gasketing is recommended when reinstalling
covers that have been removed.
C. Spare Parts
The Delta/Unibus metal enclosed bus system has
been designed to eliminate any components that
might require periodic routine replacement. There
are no moving parts. Accordingly it is not necessary
for users to maintain a stock of spare parts.
The procedures described under MAINTENANCE
may result in the need for some miscellaneous
materials such as gasketing, cover mounting
hardware, insulating materials, and touch up paint.
The availability of these materials can facilitate the
completion of preventative maintenance inspections.
D. Field Service
Contact either your Delta/Unibus sales representative
or the Delta/Unibus plant for further assistance.
Trained field service engineers are available to
provide on-site assistance when desired.
Delta/Unibus cannot be responsible for any
modifications made to any bus system without its
express written authorization.

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IB-DU1000
Metal-Enclosed Bus

July, 2006

Powell Electrical Systems, Inc.

Delta/Unibus
515 N. Railroad Ave. Northlake, Il 60164

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2005 Powell Industries, Inc. All rights reserved.

Tel: 709.409.1200 Fax: 709.409.1211

www.powellind.com
info@deltaunibus.com