Testing Metal Enclosed Bus Duct

By
Robert E. Fuhr, P.E.

Commissioning and testing today’s modern electrical equipment is essential. There are many benefits in
performing electrical commissioning including cost savings. The equipment manufacturer or contractor
can correct problems or replace equipment easier when they are discovered during startup, while the
equipment is under warrantee, and before the owner moves in. Other benefits may include increased
personnel safety and equipment protection, reduced downtime, and reduced insurance premiums.

There are many code requirements that mandate some electrical testing and commissioning. Some of these
codes include the National Electric Code (NEC) and National Fire Protection Association (NFPA). Local
electrical inspectors or “authorities having jurisdiction” (AHJ) may have additional testing requirements.

Like all electrical distribution equipment, metal enclosed bus duct (MEBD) should be inspected and tested
before placing it in service. MEBD is a combination of conductors and raceway. The bus bars (copper or
aluminum) are insulated and sandwiched together. The physical clearance between phases can be as little
as a half an inch. A metal coving to form the raceway encloses the phases, neutral, and ground buses. The
bus duct sections come in lengths of 10 feet or less and are bolted together to form a compact reliable
conductor and raceway. The voltage range is from 208 volts to 15 kV and from 400 amperes to 5,000
amperes.

Bus Duct

Picture 1 – Low Voltage Bus Duct (Entering top of Switchboard)

 Picture 2 – Bus Duct Connectors and Short Sections

It is extremely important to test and inspect MEBD due to the close physical proximity between the phases.
The insulation between these phases is essential. Manufacturing defects, physical abuse, or moisture and
greatly impact the quality of this insulation.

The following are the mechanical and visual checks and inspections that must be performed:

A) Compare equipment nameplate data with drawings and specifications.

B) Inspect physical, electrical, and mechanical condition. (Look for signs of moisture penetration)
C) Inspect bus for physical damage and proper connection in accordance with single-line diagram.
D) Inspect for proper bracing, suspension alignment, and enclosure ground. (Verify that the bus duct is
properly braced between floors and horizontal runs.)
E) Verify tightness of accessible bolted electrical connections by calibrated torque wrench method in
accordance with manufacturer’s published data.
F) Mark the head of the bolt with a permanent marking pen. (Lose connections will cause heating and
damage to connection.)
G) Check for proper physical orientation per manufacturer’s labels to ensure proper cooling. (prevents
bus duct from heat damage when at full load)
H) Perform continuity tests on each conductor to verify a proper phase relationship exists. (This is
especially important when transition sections are used.)
I) Check outdoor busway for removal of “weep-hole” plugs, if applicable, and the proper installation of
joint shield. (Failure to remove plugs will cause moisture build up and bus duct failure.)
J) Check for proper fire blocking material and installation between floors.

The following are the electrical inspections and tests that must be performed:
A) Insulation Resistance Test (non destructive test Units – Mega-Ohms)
B) Overpotential Test (higher voltage applied than insulation test. Defective bus insulation will break
down. Units – micro-amps)
C) Low Resistance Test (tests joint/connection resistance Units – Micro-Ohms)
D) Phasing Test

Case Study

We recently proved the value of commissioning bus duct on one of our projects. As commissioning agents
for a new high tech multi-story commercial building, we specified that the testing contractor perform the
tests listed above. The building had 16 runs of bus duct. Some of the bus duct ran the entire height of the
building ( 7 floors). Some of the runs had very complex transition sections.
Our tests and inspections revealed the following:
A) Although each section of bus duct was tested individually by the contractor before installation, our
final insulation resistance and overpotential tests found 3 sections of defective bus. The manufacturer
supplied new sections and the contractor replaced the defective sections.
B) 5 runs were found to have incorrect transition sections that resulted in the following:
A phase and neutral being swapped. (the voltage to ground for the neutral bus on vertical section of
bus duct was 277 Volts (the value should have been zero volts).

Summary

As with all power distribution components, metal enclosed bus duct must be inspected and tested prior to
placing it in service. Mechanical, visual, and electrical inspections and tests must be performed. Failure to
perform these inspections and tests can result in severe equipment damage, construction delays, and loss of
production.

About the Author:

Bob Fuhr graduated with a B.S.E.E. from the University of Wisconsin in 1980. Before graduating, Mr.
Fuhr worked for Madison Gas and Electric in Madison, WI and Tennessee Valley Authority in Knoxville,
TN.

After graduation, he worked for General Electric Company from 1980 to 1986 as a Field Engineer
performing commissioning and start up tests on a multitude of power distribution equipment. From 1986 to
1989 he worked as a Senior Facilities Engineer at the University of Washington. There he re-
commissioned the electrical power distribution system for University Hospital.

In 1986, he established Power Systems Engineering, a consulting firm that specializes in power systems
studies, power quality services, and commissioning services. He also teaches classes in electrical safety,
power factor correction, harmonics and filter design. He has written numerous articles on power system
studies, testing, commissioning, and power quality.

Mr. Fuhr is a Professional Engineer registered in Washington, Oregon, California, and Alaska. Bob has
been involved in IEEE and the Industrial Applications Society since 1986. He has served as an officer for
IAS from 1988 to 1992. He was the 1991-92 Chairperson of IAS. He was a Member-at-large for the
Seattle Section of IEEE for 1992-93. He is an IEEE Senior Member. He is also member of the Electric
League of the Pacific Northwest and the Building Commissioning Association (BCA).