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Vertiv High PowerBar UL 857 Installer/User Manual
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Vertiv High PowerBar UL 857 Installer/User Manual

Vertiv High PowerBar UL 857 Installer/User Manual

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High PowerBar (HPB) UL 857
Installer/User Guide

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Summary of Contents for Vertiv High PowerBar UL 857

  • Page 1 High PowerBar (HPB) UL 857 Installer/User Guide...
  • Page 2 The products covered by this instruction manual are manufactured and/or sold by Vertiv. This document is the property of Vertiv and contains confidential and proprietary information owned by Vertiv. Any copying, use, or disclosure of it without the written permission of Vertiv is strictly prohibited.
  • Page 3 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide TABLE OF CONTENTS 1 Important Safety Instruction 2 Introduction 3 Handling 3.1 Manual Lifting 3.2 Mechanical Lifting 3.3 Receiving and Inspection 3.4 Storage Instructions 4 Preparing for Installation 4.1 Required Tools 5 Busway Information 5.1 Common Terms...
  • Page 4 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide 9 Maintenance of Busplug Module Appendices Appendix A: Technical Support and Contacts Proprietary and Confidential ©2024 Vertiv Group Corp.
  • Page 5 Proper installation, operation, and maintenance are critical to the performance of the equipment. Correct operating conditions in terms of input voltage, current, and the fault capacities must be ensured at the time of installing the Vertiv™ High PowerBar (HPB) UL 857. Refer ANSI C37.20.1 for abnormal operational conditions.
  • Page 6 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide WARNING! Only Vertiv approved installation personnel may install this product. If training is required, contact Vertiv Technical Support and Contacts page 61. Training is provided on site or at our manufacturing facility. CAUTION: Do not use impact or power tools on any HPB hardware.
  • Page 7 2 Introduction The Vertiv™ High PowerBar (HPB) UL 857 installation manual is designed to assist in the safe handling and installation of the High Powerbar (HPB) UL system. These instructions are in addition to normal safe working practices as required by the local health and safety regulations.
  • Page 8 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide This page intentionally left blank Proprietary and Confidential ©2024 Vertiv Group Corp. 2 Introduction...
  • Page 9 3.4 Storage Instructions The Vertiv™ High PowerBar (HPB) UL 857 must be stored in a covered, clean, dry space which is climate controlled to prevent condensation. Prevent the busway from coming into contact with corrosive fumes, liquids, salts, or any other substances that can cause corrosion.
  • Page 10 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide NOTE: The busway is protected from minor water ingress by means of an overall outer polythene wrap. The stretch wrap must be left in position until the bar is mounted, and joint pack fitted.
  • Page 11 Transport the busway to the installation site before unpacking. Each pallet will have a packing slip with a list of the parts. Unpack the pallet and check for any damage to the Vertiv™ PowerBar Busway. Each busway component is identifiable by a part number on the nameplate, corresponding to the part number on the busway installation drawings.
  • Page 12 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide 4.1 Required Tools Figure 4.1 Tools Needed NOTE: Ensure all tools are on site a week prior to installation training. Item Description T-handle 8 mm ball end hex Metric Machinist Ruler (300mm) or measuring tape 19 mm deepwell socket and 13 mm socket Dewalt (or equivalent) 600lb Clamps/Spreaders (Use 24”...
  • Page 13 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Installation tool kit is comprised of the following installation tools for Vertiv™ PowerBar Busway installation. NOTE: To order additional tool kit for installation use Part No. HPB-JP-INST-KIT. NOTE: Ensure that personnel adhere to safety protocols by wearing the designated PPE during the busway installation process.
  • Page 14 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide This page intentionally left blank Proprietary and Confidential ©2024 Vertiv Group Corp. 4 Preparing for Installation...
  • Page 15 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide 5 Busway Information NOTE: Apply a plumb line or laser level from the start of the run to the end of the run as a guide for the installation of the busway run.
  • Page 16 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide 5.2 Identification Figure 5.1 Typical Part Code Layout Table 5.2 Model Description 5 and 6 Table 5.3 Model Number Digit Description Digit Description Product line • P - PowerBar Conductor material •...
  • Page 17 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide 5.3 Phase Sequence There are six different types of system configurations: Figure 5.3 Three-phase with Isolated Ground (TPE) Figure 5.2 Three-phase (TP) Configuration Configuration Figure 5.5 Three-phase with Neutral (TPN) Figure 5.4 Three-phase with Bare Ground (TPBE)
  • Page 18 6 in. (152.4 mm) from a ceiling. • 4 in. (101.6 mm) from a wall. • 6 in. (152.4 mm) between busway sections. Typical clearances shown. For clearances for specific busway/busplug arrangements, contact Vertiv. Proprietary and Confidential ©2024 Vertiv Group Corp. 5 Busway Information...
  • Page 19 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide 5.5.1 Busway Clearances NOTE: Other obstructions (conduits, water pipes, HVAC, building structures and facilities, other electrical equipment) shall be located using the same clearances. Otherwise follow local rules for clearances (NEMA BU 1.1-2010).
  • Page 20 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide 5.5.2 Busplug Clearances Figure 5.10 Top View of Horizontal Flat Mounted Distribution Busway Typical Busplug door swing dimensions shown, installer must ensure their product (which may differ from these standard dimensions) has sufficient clearance for the door to open 90 degrees, per NEC requirements.
  • Page 21 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide 5.6.2 Fire Barriers When installing a busway section with a fire barrier, ensure that the fire barrier protrudes 2 in. (50 mm) to 4 in. (100 mm) from both sides of the wall. The final sealing between a fire barrier and a wall is to be completed by site builder, NEC and local regulations are followed.
  • Page 22 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 5.14 Fire Block Indoor settings require minimum 8 in. (203 mm) of clearance from joint pack to wall. See Figure 5.15 below. Figure 5.15 Minimum Clearance of Joint Pack Cover Proprietary and Confidential ©2024 Vertiv Group Corp.
  • Page 23 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 5.16 Minimum Clearance of Joint Pack Cover in Floor Penetrations Minimum 8 in. (203.2 mm) from spring hanger bracket to bottom of joint pack in vertical mounting/floor penetrations. Minimum 12 in. (304.8 mm) to concrete from bottom of joint pack cover.
  • Page 24 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide 5.7 Mounting Methods 5.7.1 Horizontal Orientation The busway sections are secured to a framing system, such as strut channel, using the fixing brackets. The bar can be secured both on its flat and on its edge. When installed in flatwise orientation the busway must always have neutral on top.
  • Page 25 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 5.18 Horizontal Edgewise Item Description Triple body Double body Single body Components: Hanging brackets/strut channel and drop rods (provided by others). NOTE: Vertiv does not provide hardware for installation. 5 Busway Information...
  • Page 26 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide This page intentionally left blank Proprietary and Confidential ©2024 Vertiv Group Corp. 5 Busway Information...
  • Page 27 6.1.1 Horizontal Hanging Vertiv recommends that the fixing brackets for the Vertiv™ High PowerBar (HPB) UL 857 must be mounted with support no more than 2.5 ft (762 mm) from the center of each bus joint and with no more than 5 ft (1524 mm) between supports. Tighten the fixing brackets to 10 Nm (7.4 ft-lbs).
  • Page 28 NOTE: It is the responsibility of the support system supplier to ensure their system can safely support the weight of our product. CAUTION: Vertiv™ High PowerBar (HPB) UL 857 fixing brackets must be used. Drilling or cutting the busway on site is prohibited. If threaded rod length exceeds more than 8.2 ft. (2500 mm), there must be a rigid support every 20 ft (6096 mm).
  • Page 29 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.3 Spring Hanger Alternate Installation After Busway is Installed Item Description Unistrut M10 x 150 mm bolt (fully threaded) Support bar Unistrut (not in PBG scope) HPB fixing bracket Spring Hanger Alternate Installation After Busway is Installed: •...
  • Page 30 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide 6.2 Joining Busway Sections NOTE: Tolerances will vary according to the standards used (UL Standard or UL13). 6.2.1 End to End Installation (Method A) Ensure all components are properly and consistently oriented, with the joint block arrows pointing in the same direction on adjoining busway segments.
  • Page 31 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.5 Splaying Joint Pack Item Description Loosen NOTE: Do not remove. Spread plates to facilitate installation 6. Insert plastic combs into the Busway side of the joint pack, the fingers of the comb must be inserted between the joint pack connector plates.
  • Page 32 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.7 Inserting Joint Pack Guide Comb Item Description Plastic comb NOTE: Plastic combs are provided with 5 fingers, fingers can be removed to match busway configuration, see Figure 6.8 below. Figure 6.8 Modifying Guide Comb Based on Busway Configuration 7.
  • Page 33 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.9 Placing Joint Spacer Block on Busway A Item Description Spacer block 8. Insert joint pack into Busway A up to the spacer block. Ensure all busbars and ground flanges are correctly aligned with the joint pack connector plates.
  • Page 34 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide NOTE: Start joint pack on one corner on the side where the comb is located. Ensure all bus bars are aligned in the correct segments of the joint pack. Once the bus bars are aligned with the joint pack, remove the comb tool, and rotate and press the joint pack into place.
  • Page 35 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.12 Applying Clamps to Pull Busways into Joint Pack 15. Inspect Joint Pack and busway sections for proper alignment of all components. Ensure plastic tabs on sides of Joint Pack are not broken due to shipping or mishandling NOTE: The installer can initially tighten the joint pack primary nut 10 NM (14.8 ft-lbs) allowing for adjustment and...
  • Page 36 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.13 UL Standard and UL13 Busway to Busway Distance Item Description HPB-JPJ-0001 NOTE: For UL13 joints, ensure the space for the spacer blocks does not vary by more than 3mm and the ESP fins do not ride up under the JSP nibs.
  • Page 37 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.14 ESP plate JSP plate Item Description Location of ESP plate and JSP plate Figure 6.15 Ensure Plastic Tabs on Joint Pack are not Broken Item Description Ensure plastic tabs on sides are not broken 19.
  • Page 38 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide NOTE: It is important that the M12 joint bolts are sufficiently tightened (not torqued at this step) to ensure the joint pack does not move out of alignment prior to tightening joint cover bolts.
  • Page 39 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.16 Assembled Joint Pack Item Description Busbar A Joint Busbar B Joint cover 6.2.2 Side Installation (Method B) Repeat step 1 through step 5 from End to End Installation (Method A) on page 26.
  • Page 40 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.17 HPB-00000-00569 Plate Applied to Busways Item Description Busway B Busway A Joint pack pusher plate 1 (HPB-00000-00569) 3. Verify the spacing between busway A and B as shown in Figure 6.18 below.
  • Page 41 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.19 Placing Spacer Blocks on Busways Item Description Spacer block (HPB-JPJ-0001) Busway B Busway A 5. Insert guide combs into joint pack, align Joint Pack between spacer blocks, and insert into the space between the Busway Sections, ensuring busway conductors fit between joint pack conductor plates.
  • Page 42 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.20 Orienting Joint Pack to Busway Item Description Spacer block (HPB-JPJ-0001) Busway B Guide comb Joint pack Busway A 6. Securely place HPB-00000-00568 pusher plate over the outer end of the joint pack. See Figure 6.21 on the facing page.
  • Page 43 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.21 Placing HPB-00000-00568 Pusher Plate and Applying Clamps Item Description 600 lb Clamp (Length depends on busway width) Pusher plate 2 (HPB-00000-00568) 7. Position the installer provided compression clamps as shown Figure 6.22 on the next page.
  • Page 44 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.22 Applying Clamps to Both Pusher Plates Item Description Pusher plate 1 (HPB-00000-00569) 8. Tighten the compression clamps uniformly to bring the Joint Pack fully installed between Busway A and B.
  • Page 45 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide NOTE: A M8 T handle ball end hex wrench can be used to assist alignment and fit of the joint cover to the busway before fastening. NOTE: It is important that the M12 joint bolts are sufficiently tightened (not torqued at this step) to ensure the joint pack does not move out of alignment prior to tightening joint cover bolts.
  • Page 46 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide 2. Flare open aluminum cover approximately ½ in. and affix onto end of busway as shown Figure 6.24 below. NOTE: Take care not to damage the gasket. NOTE: Compression clamps can also be used to fit the end cap to the busway before fastening.
  • Page 47 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.25 Cable End Box Item Description Hanging brackets (specific to application) 2. Apply a plumb line or laser level from the start of the run to the end of the run as a guide for the installation of the busway run.
  • Page 48 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide 7. Punch out (remove) the appropriate Cable Conduit fitting holes. 8. Add the necessary conduit glands to the gland plates. 9. Identify lug landing points and NEMA hole pattern for compression or mechanical lugs. See Figure 6.27 below.
  • Page 49 Review the engineered design for supporting, securing, and anchoring the expansion unit. 2. Install the framing structure (channel strut) according to the engineering drawing. CAUTION: Fixing points are to be agreed upon with the Vertiv Engineering team to ensure effective operation of the expansion unit.
  • Page 50 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide CAUTION: Expansion units are fitted with transport brackets needed for shipping and installation. Remove these transport brackets only after the entire bus run is installed and all components have been secured in place.
  • Page 51 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.30 Typical Expansion Module Brace 6.6 Busplug Slot Cover A cover is required over unused busplug positions to increase the ingress protection level to the required standard. NOTE: Screw is torqued only to finger-tight, ensuring slight compression of the gasket.
  • Page 52 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.31 Busplug Slot Cover 6.7 Busplug NOTE: For specific instruction, refer to the busplug installation instructions provided inside the busplug. In accordance with isolation procedures and risk assessments to be carried out by the installer. The installer must isolate the electric busway and ensure that it is not energized.
  • Page 53 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.32 Busplug C-Clamps Item Description C-Clamps 5. Unscrew both C-Clamps as shown in Figure 6.32 above. 6. To open the door rotate the latch 90 degrees in counter clockwise direction with a flat screwdriver.
  • Page 54 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.33 Busplug Earth Contacts and Busway Earth Slots Item Description Earth contact Busway earth slot for busplug NOTE: The Earth contact is the first feature to make contact with the busway housing.
  • Page 55 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.34 Busplug J-hooks 12. Using a T-bar or 6 mm hex Allen wrench and calibrated torque wrench, torque the interlock screws to 4 Nm. See Figure 6.35 on the next page.
  • Page 56 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.35 Busplug Clamping Mechanism Interlock Screws Item Description Interlock screw 13. Close the door and tighten the latch ¼ turn Clockwise. 14. Re-affix the C-Clamps to the back of the busplug and tighten hardware to 15 Nm (11 ft-lbs).
  • Page 57 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Figure 6.36 Reattach C-Clamp Installation Item Description Re-attach and properly torque C -Clamps to 15 Nm (11 ft-lbs). NOTE: Additional brackets for drop rod hangers are provided for larger busplugs. 15. Perform an overall check for any debris, dust, or misalignment.
  • Page 58 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide This page intentionally left blank Proprietary and Confidential ©2024 Vertiv Group Corp. 6 Installation...
  • Page 59 3. Verify that all joints have been torqued according to the recommended setting and have not been subsequently loosened. Ensure all joint covers are firmly secured. 4. The testing procedure must be performed and documented as per Vertiv™ High PowerBar (HPB) UL 857 standard testing. (Refer to NEMA BU 1.1-2010, Section 7).
  • Page 60 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide This page intentionally left blank Proprietary and Confidential ©2024 Vertiv Group Corp. 7 Pre-Energization...
  • Page 61 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide 8 Energizing When reconnecting the system prior to energization, ensure correct phasing and rotation is achieved by testing prior to energizing the supply. 2. Verify all busplugs are turned off prior to energizing.
  • Page 62 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Table 8.1 Prior to Energizing (continued) Prior to Energizing Insulation resistance test completed. Ready to make final connections and checks prior to energizing. Prior to energizing, verify isolation of loads. Proprietary and Confidential ©2024 Vertiv Group Corp.
  • Page 63 If discoloration has occurred on the contact surfaces due to overheating, ensure the gap between contacts are • consistent and have not been damaged during transport. If the contacts have been damaged, contact Vertiv. • If the joint pack components or busbars show signs of discoloration, degradation, or arcing, the cause must be determined.
  • Page 64 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide This page intentionally left blank Proprietary and Confidential ©2024 Vertiv Group Corp. 9 Maintenance of Busplug Module...
  • Page 65 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide Appendices Appendix A: Technical Support and Contacts A.1 Technical Support/Service in the United States Vertiv Group Corporation 24x7 dispatch of technicians for all products. 1-800-543-2378 Vertiv™ PowerBar Products Europe - +44(0) 2835 3030...
  • Page 66 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide This page intentionally left blank Proprietary and Confidential ©2024 Vertiv Group Corp. Appendices...
  • Page 67 Vertiv™ High PowerBar (HPB) UL 857 Installer/User Guide...
  • Page 68 Vertiv.com | Vertiv Headquarters, 505 N Cleveland Ave, Westerville, OH 43082 USA ©2024 Vertiv Group Corp. All rights reserved. Vertiv™ and the Vertiv logo are trademarks or registered trademarks of Vertiv Group Corp. All other names and logos referred to are trade names, trademarks or registered trademarks of their respective owners. While every precaution has been taken to ensure accuracy and completeness here, Vertiv Group Corp.

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