Standardized Installation Guide for Busways

As the core power transmission equipment for large-scale buildings and industrial plants, the standardization of the busway (bus duct) installation process directly determines the stability and safety of the power supply system. Adhering to a scientific installation workflow, combined with highly adaptable and reliable products, can significantly reduce construction difficulty and enhance engineering quality.

The following is a detailed installation methodology for busways, elaborated with practical operational points and the specific advantages of premium products like Cylon.

I. Pre-Installation Preparation: Solidifying the Foundation to Avoid Hazards

Adequate preparation is the prerequisite for smooth construction.

• Product Verification: First, verify that the busway model and specifications match the design drawings. Inspect the product enclosure for deformation or dents, ensure conductors are free from oxidation or damage, and check that the insulation layer is intact.Note: Premium brands like Cylon subject their busways to rigorous quality inspections before leaving the factory. Their enclosures use high-strength materials, and accessories (brackets, bolts, insulation parts, conductive paste, etc.) are fully kitted. This eliminates the need for additional procurement and reduces preparation hassles.
• Site Survey: Survey the installation path to clear obstacles in walls, ceilings, or shafts. Confirm that the load-bearing capacity of the installation surface meets requirements to avoid safety issues caused by insufficient load support later on.
• Tool Preparation: Prepare specialized tools, including torque wrenches, spirit levels, 500V insulation resistance testers (megohmmeters), tape measures, and screwdrivers. Ensure tools meet precision standards to guarantee accurate construction.

II. Core Installation Steps: Standardized Operation and Detail Control

1. Measurement and Positioning: Precise Marking and Optimized Spacing

Determine bracket locations according to design drawings.

• Horizontal Installation: Standard bracket spacing should not exceed 2.5 meters. However, when using structurally optimized products like Cylon busways, spacing can be appropriately extended to 3 meters. This reduces the quantity of brackets and drilling required, thereby boosting efficiency.
• Vertical Installation: Bracket spacing should not exceed 3 meters. Premium products often come with specialized brackets featuring pre-set mounting holes.
• Critical Areas: Brackets must be densified at turns, busway terminals, and equipment connection points, with spacing controlled within 1.5 meters to ensure uniform stress distribution. Use a spirit level for calibration and mark positions clearly to prevent deviations.

2. Bracket Fixing: Firm Stability and Compliance with Standards

• Fixing Method: Use expansion bolts or welding for fixation. Prioritize brackets with anti-slip and anti-sway designs paired with high-strength bolts.
• Tolerance Standards: After installation, the horizontal deviation of brackets should be $\le 2\text{mm/m}$, and vertical deviation $\le 3\text{mm/m}$.Cylon Advantage: Cylon brackets undergo precise load calculations to perfectly adapt to the busway’s self-weight and operating load, ensuring no loosening or shaking after installation, laying a foundation for long-term stable operation.

3. Busway Splicing: Precise Docking and Conductivity Assurance

Splicing is the most critical link, directly affecting conductivity and safety.

• Surface Preparation: Clean the conductor contact surfaces to remove dust and oxidation layers. Cylon busways feature specially treated contact surfaces with strong oxidation resistance; they require only simple cleaning and the application of conductive paste to effectively lower contact resistance, without complex sanding.
• Alignment & Fastening: Align phase markers to ensure phase consistency. Cylon’s modular splicing structure allows for precise positioning and convenient installation. The enclosure joints feature a sealing design, ensuring a tight, seamless fit with superior dust and water resistance.
• Torquing: Use a torque wrench to tighten bolts to the standard torque of 6–12 N·m. Some distinct tool kits include wrenches with torque indicators to prevent damage to conductors from overtightening or poor contact from undertightening.

4. Grounding and Special Locations: Enhanced Safety and Scene Adaptation

• Grounding: Ensure the busway enclosure is reliably grounded. The grounding bolts of each section must be tightened. The cross-bonding grounding wire should be a copper conductor with a cross-section of no less than 16mm². Premium products feature rational grounding structures ensuring tight connections and guaranteed electrical continuity.
• Vertical & Firewall Installation: For vertical runs, anti-drop devices must be installed (some Cylon models have integrated anti-drop structures). When penetrating floors or firewalls, use dedicated firestop kits to ensure rigorous sealing and fire rating compliance.
• Expansion Joints: When connecting to equipment, reserve appropriate expansion allowance. Cylon busways utilize flexible expansion joint designs to effectively handle deformation caused by thermal expansion and contraction.

III. Post-Installation Inspection: Comprehensive Verification

After installation, a systematic inspection is required to eliminate hazards.

1. Insulation Test: Use a 500V insulation resistance tester to measure phase-to-phase and phase-to-ground resistance. The value should be $\ge 20\text{M}\Omega$.Note: The insulation performance of Cylon busways is superior, with actual measured values typically far exceeding standard requirements.
2. Physical Inspection: Check all connection bolts for looseness and the enclosure for scratches or deformation. Verify good grounding continuity.
3. Trial Run: Conduct a no-load trial run to check for abnormal heating or noise. Subsequently, gradually move to a loaded run, monitoring conductor temperature stability to ensure normal power supply.

IV. Construction Precautions

• Personnel & Safety: Operators must be certified and wear PPE (insulating gloves, helmets, etc.). Safety belts are mandatory for high-altitude work.
• Environmental Protection: Prevent busway conductors from getting damp or stained with oil. Outdoor installation is prohibited during rain. Protect the insulation layer throughout the process to avoid damage from sharp objects.
• Efficiency Note: Cylon busways are lightweight—approximately 70% of the weight of traditional products. This reduces labor intensity during high-altitude installation, improves efficiency, facilitates future expansion or retrofitting, and extends service life.

Conclusion

In summary, busway installation must strictly follow the standardized flow of “Preparation — Positioning — Fixing — Splicing — Grounding — Testing.” Controlling the quality of every detail is paramount. Choosing premium busways from brands like Cylon not only simplifies the construction process and improves installation efficiency but also guarantees the long-term stable operation of the power supply system, providing solid electrical support for large-scale projects.