The ABCs of Planning and Installing Bus Duct

The ABCsof Planningand InstallingPow-R-Way IIIBus Duct

Instruction Manual

Supersedes File 30-500,pages 1 – 72 dated 1974

ABC_frontandback_covers.fm Page 1 Monday, December 16, 2002 6:36 PM

Effective: December 2002 IM01701002E

Page 1

Description Page

Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Pow-R-Way

III

Layout

. . . . . . . . . . . . . . . . . . .

4

Walk-through & On-site Measurements. . . .

4

Feeder Runs. . . . . . . . . . . . . . . . . . . . . . . . .

4

Connecting PRW

III

toSwitchboards and Switchgear . . . . . . .

12

Connecting PRW

III

toMotor Control Centers . . . . . . . . . . . . .

13

Connecting PRW

III

to Transformers . . . .

13

Installation Tips . . . . . . . . . . . . . . . . . . . .

15

Multiple Feeder Bus Runs . . . . . . . .

15

Busway Joint Clearances . . . . . . . . .

15

Wall and Floor Penetrations . . . . . . .

16

Outdoor Considerations . . . . . . . . . .

17

Plug-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

Floor Height Measurements . . . . . . . . .

19

Installation Tips . . . . . . . . . . . . . . . . . . . .

21

Maximum Height . . . . . . . . . . . . . . .

21

Other Equipment or Walls in CloseProximity to the Busway Riser. . . . .

21

T Location. . . . . . . . . . . . . . . . . . . . . . . .

21

Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Elbows . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Flanges. . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Tees . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Cable Tap Boxes . . . . . . . . . . . . . . . . . . .

23

Weatherheads . . . . . . . . . . . . . . . . . . . . .

24

Expansion Joints. . . . . . . . . . . . . . . . . . .

24

Bus Plugs

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

Plug-in Units . . . . . . . . . . . . . . . . . . . . . . . .

25

Bolt-on Units . . . . . . . . . . . . . . . . . . . . . . . .

26

Built-in Power Takeoff Devices . . . . . . .

26

Bridge Joint Power Takeoff Devices . . . .

26

Installation Tips . . . . . . . . . . . . . . . . . . . . . .

28

Coordination

. . . . . . . . . . . . . . . . . . . . . . . . . . .

29

Drawings

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

Customer Approval Drawings . . . . . . . . . .

31

Customer Layout Drawings . . . . . . . . . . . .

33

Construction Drawings . . . . . . . . . . . . . . . .

33

Installation Guide

. . . . . . . . . . . . . . . . . . . . . . .

35

Indoor Joint Assembly Instructions . . . . .

35

Final Field Fits . . . . . . . . . . . . . . . . . . . . . . .

37

How to Remove a Section of Busway . . . .

37

Outdoor Busway Supports . . . . . . . . . . . . .

40

Accessories

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

Hangers . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

Wall/Floor Flanges. . . . . . . . . . . . . . . . . . . .

45

End Closers . . . . . . . . . . . . . . . . . . . . . . . . .

45

Busway Handling

. . . . . . . . . . . . . . . . . . . . . . .

46

Shipping. . . . . . . . . . . . . . . . . . . . . . . . . . . .

46

Busway Labels. . . . . . . . . . . . . . . . . . . . . . .

46

Dimensional Data

. . . . . . . . . . . . . . . . . . . . . . .

47

ABC_BusDuct_prf4.fm Page 1 Friday, December 13, 2002 4:06 PM

Page 2

IM01701002E Effective: December 2002

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Page 3

Introduction

Eaton’s Cutler-Hammer Pow-R-Way

III

(PRW

III

) is a 600 volt, totally enclosed, non-ventilated, sandwich busway design available with either copper bus bars rated from 225 to 5000 amperes or with aluminum bus bars rated from 225 to 4000 amperes. PRW

III

is available in outdoor feeder, indoor feeder, indoor plug-in and indoor sprinkler proof plug-in configurations. All four types can be connected together without adapters or special splice plates provided they are of the same current and system rating. The short circuit withstand ratings for plug-in busway are equal to those of indoor and outdoor feeder busway of the same current and system rating.

PRW

III

busway can be utilized in applications such as simple, straight runs of plug-in fed from a cable tap box, or complex runs with multiple feeders. However simple or complex, the system must be planned in advance.

The purpose of this handbook is to help you plan, lay out, and install PRW

III

busway with an easy, step-by-step approach. The handbook describes a number of examples and details of how the product is applied, as well as specific details on how to coordinate the installation of PRW

III

with other products manufactured by Eaton’s Cutler-Hammer business.

1. This handbook should be used as a refer-ence guide only. Other useful references are NEMA

T

document BU 1.1-2001, Technical Data TD01701001E,

Consulting Application Guide

,

13th Edition

CA08104001E, and Selling Policy 25-000. Customer approval and the particular details of the application must dictate the final decision on any system.


Page 4


Pow-R-Way

III

Layout

Walk-through and On-site Measurements

Before deciding the layout of a PRW

III

busway job, we suggest you have these basic materials: a sketch pad, measuring tape – 25 and 100 foot (7.6 and 30.4 m), 6-foot (1.8 m) folding wood rule, chalk line, plumb bob, and a marker.

First, it’s always a good idea to walk through the entire facility to get an idea of general routing. While walking through, make note of obstructions to the busway routing. At the same time, establish one elevation to minimize the need for offsets. Elevations between rooms or various parts of the building must be checked. Otherwise, busway installed at a specific elevation in one part of the building may be too high or too low at another point.

After the initial walk-through, you are ready to begin measuring the layout. For reference points, use structures already available in the building, such as walls or columns.

Do not attempt to divide the run into specific sections of duct. This is the responsibility of the Busway Division.

Feeder Runs

The following pages contain samples of floor plans that range from a simple service application to a multi-story building. The combination of sketches will, in all probability, cover most of the situations you will encounter. The sketches can also serve as a guide to help you look for, identify, and measure the most important site dimensions that must be submitted with each order.

Having complete layout information when the order is entered will save time and expedite the release for manufacture.

The sketches include:

Figure 2

Basic Site Dimensions(using walls as reference points)

Figure 3

Site Measurements Required for Service Entrance from Pad Mounted Transformer and Service Entrance from Weatherhead

Figure 4

Horizontal Offset

Figure 5

Vertical Offset

Figure 6

Single-Run Distribution System

Figure 7

Double-Run Distribution System

Figure 8

Using Columns as Reference Points

Figure 9

Multi-Floor



Page 5

Figure 1. Enlarged Plan View of Switchboard Room

Figure 2. Basic Site Dimensions — Required Before Starting PRW

III

Busway Layout

?

?

Switchboard

Front

?

?

?

?

?

?

?

?

?


Page 6


Figure 3. Site Measurements Required for Service Entrance from Pad Mounted Transformer and Service Entrance from Weatherhead

Transformer

FrontSwitchboard

?

??

?

?

?

LV

?

?

?

Check Local Codes For Correct Height

FrontSwitchboard

Front

Section AA

FrontSwitchboard

?

?

?

A A

?



Page 7

Figure 4. Horizontal Offset

Front

?

?

??

??


Page 8


Figure 5. Vertical Offset

Front

A

A

AA

Section AA

? ?

?

?

?



Page 9

Figure 6. Single-Run Distribution System

Front

?

?

? ?

?

?

?

?

?


Page 10


Figure 7. Double-Run Distribution System

Figure 8. Using Columns as Reference Points

Front

?

? ?

?

?

?

? ?

?

? ?

Front

?

A B C D E

2

3

4

5

6

??

?

?

? ?

?

?

?

?

?

?

1



Page 11

Figure 9. Multi-Floor

Actual measurements should start in the area where the switchboard, switchgear or MCC is located. If the gear has not been installed, chalk in the specified location and the point of entry for the busway. For transformer connections, transformer taps and weatherhead information, see

Pages 50

,

51

and

64

–

67

.

One of the most important steps in planning a large PRW

III

busway layout is coordination between the trades. This is a good time for the electrical contractor to meet with plumbing, heat-ing, lighting and sprinkler system contractors to establish a definite right-of-way throughout the construction area. Once established, hours of frustrating re-routing can be saved. Many times, immediately after the right-of-way has been deter-mined, electrical contractors will install busway hanger drop rods to claim and identify their areas.

The next step is to establish the busway elevation, then start horizontal measurements using the following examples as a guide. The examples indicate the dimensions required.

FinishedFloor

1st Floor

2ndFloor

FinishedFloor

Roof

MCCFront

?

??

??

??

?

?


Page 12


Connecting Pow-R-Way

III

to Switchboardsand Switchgear

The Cutler-Hammer Sales Office should specifyall Divisions that must coordinate activities. After release of busway with complete information, the Busway Division will send flange reference drawings and coordination to the other Division/Satellite Plant/OEM.

When equipment of other manufacturers is involved, the customer and the Cutler-Hammer Sales Office have the responsibility for obtaining flange references and dimensions (see

Figure 10

). Wherever possible, standard flanges will be used. This is easier to accomplish if coordination is completed as soon as possible. Otherwise, special flanges will be used, and special prices will apply.

The switchgear manufacturer determines the loca-tion of the bus entrance on the switchgear. The Busway Division will define the phasing, once the bus layout is released with complete information.

Note:

When busway enters the top of switchgear, pay close attention to obstructions on the top of the gear (i.e. — roof ventilation or breaker lifting devices).

Note:

Special flanges are required when connecting to outdoor DS

II

and Magnum

E

switchgear for bus ratings of 3200 A – 5000 A copper and 2500 A – 4000 A aluminum.

Figure 10. Busway Connection to Switchboard

FrontSwitchboard

?

?

? ?

?

?

??

?



Page 13


III

to Motor Control Centers

Busway connection to Cutler-Hammer motor control centers is relatively simple (see

Figure 11

). Keep in mind that the MCC is normally supplied with a sheet metal cubicle (i.e. top hat, pull box) on top of the standard enclosure to accept the busway flange. This is due to the close proximity of the internal horizontal bus to the top of the structure. This pull box can vary in height and must be determined to establish proper busway elevation. Busway connections can be established on any side of the top hat. However, top connectors are the most common.


III

to Transformers

Throat Connections

For throat connections, complete transformer information must be provided. The bus connection will then be designed to fit accordingly (see

Figure 12A

). The Busway Division provides the busway and flexible connections to connect to transformer low voltage spades.

Top Entry Connections

For connections to transformers with top entry, complete transformer information must be pro-vided. The Busway Division will design and supply a flange connection with flexible connectors (see

Figure 12B

).

Figure 11. Busway Connection to Motor Control Center

MCC

Top Hat ? ? ?

?

?

? ?


Page 14


Figure 12A. Busway Connection to Transformer Throat

Figure 12B. Busway Flange Connection to Transformer

?

TransformerLV Studs

TransformerThroat

Flexible Braid

suctroat

Obstruction

?

?

LC

?

CL

?20.00

(508.0)

FlexibleBraid



Page 15

Installation Tips

Multiple Feeder Bus Runs

For multiple runs of busway, thought must be given to horizontal and vertical clearances between runs. Clearances shown in

Figure 13

must be maintained for assembly purposes.

Figure 13. Horizontal Runs

Note:

The joint bolt-head is on the T-opposite side of the busway. The contractor and owner should be consulted to be sure that there is adequate room for installation and maintenance.

Busway Joint Clearances

Per NEMA

T

standards, busway may penetrate a wall or floor if in unbroken lengths. It therefore follows that busway joints cannot fall in walls or floors. The example in

Figure 14

illustrates the minimum distance that the centerline of a PRW

III

busway joint can be located from a wall. Outdoor busway must penetrate the building wall and extend into the building at least 1 foot (305 mm) before indoor busway can be used.

Figure 14. Required Minimum Distance from Wall

Wall

Ceiling6.00

(152.4) Min.

6.00 (152.4)

Min.

6.00 (152.4)

Min.

6.00 (152.4)

Min.

JointCL

10.00 (254.0) Min.


Page 16


Wall and Floor PenetrationsWall and floor openings for busway should be at least 1-inch (25.4 mm) larger than outside dimensions of busway (see Figure 15). When an elbow or flange must be installed through a wall or floor, the opening must be large enough to accom-modate proper installation.

Curbs around floor openings are highly recom-mended. A curb prevents water from flowing down through floor openings. Many times damage occurs to the busway because the busway is not properly protected.

Figure 15. Minimum Clearances for Wall andFloor Openings

2.00(50.8)

Wall/FloorFlange

Wall/FloorOpeningBus

Duct

All 4 Sides

Wall/Floor

1.00(25.4)



Page 17

Outdoor ConsiderationsOutdoor PRWIII is rated for NEMA 3S application only after the busway is completely installed(see Figures 16 and 17), the T marking is on top, and the system carries a constant minimum 50 percent load.

Figure 16. Wall Penetration with Outdoor Busway

10.00(254.0)

Indoor

Outdoor

Outdoor

IndoorT

T

T


Page 18


Figure 17. Outdoor Pow-R-Bridge Detail

NOTIC

ENO

TICE

DANG

ERDA

NGER

DANGERDANGER NOTICENOTICE

Floor

Floor

Floor

Remove These Plugs Only

1 Bar/Phase

1 Bar/Phase

2 Bars/Phase

2 Bars/Phase

Side View

T

After Joints are Completely Assembled,Caulk the Areas Indicated with Dow Corning795 Silicone Caulking Compound or Dap Inc.Dynaflex 230 Latex Sealant.

After Joints are Completely Assembled,Caulk the Areas Indicated with Dow Corning795 Silicone Caulking Compound or Dap Inc.Dynaflex 230 Latex Sealant.

Horizontal



Page 19

Plug-in

Floor HeightThe basic dimensions (height from finished floor to finished floor including floor thickness) required for every busway riser are shown in Figure 18. Do not assume that all floors are the same height or thickness.

Note: If a curb is to be supplied around the floor opening, specify height of curb.

When planning the riser layout, joint clearance above the floor must be maintained to install joint cover plates and vertical spring hangers. A mini-mum distance of 18 inches (457.2 mm) above the floor or curb to centerline of the joint is required.

PRWIII Plug-in busway comes in straight lengthsof 2, 4, 6, 8 and 10 feet (.6, 1.2, 1.8, 2.4 and 3.0 m) only. Therefore, the floor height will dictate the maximum length of a plug-in section that can be installed on that floor. For an example of a typical riser layout, see Figure 19.

Example: If the floor height is less than 12 foot 10 inches (3.9 m) and floor thickness is 6 inches (152.4 mm), it is not possible to use a 10 foot (3 m) straight length of plug-in duct. Instead, a shorter 8, 6, 4, 2 foot (2.4, 1.8, 1.2, .6 mm) straight length would be used.

When planning to install a plug in the bottom most plug-in opening, verify the dimensions of the plug to ensure clearance above the vertical hanger.

Using the example in Figure 19, you can experiment with plugs to be supplied and determine the number that can fit on each floor. Refer to Pages 68 – 70 for the dimensions of the plug-in units.


Page 20


Figure 18. Basic Height Measurement Required for Risers

Figure 19. Typical Floor for Plug-in Duct

Curb WhereRequired

Floor

Bus Duct

Floor

?

?

?

?

CLCLC Plug-in opening

LCLCL Plug-in opening




14'-0" (4.3 m)

LCLCL Joint

JointLCLCL

Floor 1

Floor

6" (457.2 mm)

(254.0 mm)

(609.6 mm)

(609.6 mm)

(609.6 mm)

(609.6 mm)

6" (457.2 mm)4" Curb



Page 21

Installation Tips

Maximum HeightAs a guide, the maximum height of a plug-in unit with an operating handle or fuses should not be more than 6 feet 6 inches (2.0 m) above the floor when mounted on a vertical riser. Check local codes to determine if this restriction applies. This is a very limiting factor where the size and quantity of the plugs on each floor exceed the 6-feet 6-inches (2.0 m) rule.

Other Equipment or Walls in Close Proximity to the Busway RiserInstalling busway with plug-in or bolt-on units in a vertical riser requires pre-planning. See Figure 21 for examples of busway risers in an electrical closet. The busway with plug-in or bolt-on units must be arranged to clear other equipment and walls in the electrical closet. In particular, see that the plug-in or bolt-on hinged cover can be opened fully for maintenance.

T LocationOn a vertical riser of PRWIII plug-in busway, the load direction of the plugs will be pointed down when T is to the left of the plug.

Figure 20. Preferred Unit Orientation

ON

T

OFF

Line

Load


Page 22


Figure 21. Preferred Arrangements for Wiring Closets

Plug-in/BoltOn Unit

Opened Hinged Cover

Wall

Duct

Plug-inUnit

CL

F

T

C

A

B

Wall

4.00(101.6)Min.

Operating Handle

DuctCL

T

C

F



Page 23

FittingsThe PRWIII product offering includes a varietyof fittings that facilitate complex routing of busway systems.

ElbowsPRWIII includes two elbow designs.

Traditional ElbowThe traditional elbow is used to make 90º turns in the busway run. The four types that are available are forward, rearward, upward and downward. See Pages 56 and 57 for minimum leg lengths.

Corner-Joint ElbowThe corner-joint elbow is a feature unique to PRWIII. This special elbow is a hybrid of a traditional elbow and a bridge joint. Because the corner-joint elbow is more compact, it can be installed in areas where a traditional 90º elbow can not be installed. The leg lengths for corner-joint elbows are listed on Pages 58 and 59.

Note: Corner-joint elbows are suitable for indoor use only.

OffsetsAn offset is two elbows fabricated into a single fitting for use where space restrictions prohibit the use of two separate traditional elbows. The minimum leg lengths are listed on Pages 60 and 61.

FlangesFlanges provide a direct connection to low voltage switchgear, switchboards, motor control centers, and other equipment. PRWIII offers three types of flanges: standard, elbow and flush. The type of flange required will be determined by the busway layout. See Pages 52 – 54 for minimum leg lengths for each type of flange.

TeesA tee is a busway fitting suitable for connectionin three directions. See Pages 62 and 63 for minimum dimensions.

Cable Tap BoxesA cable tap box is used when a busway run is being fed by cable and conduit, or where loads served by busway are connected without the need for overcurrent protection. PRWIII offers end, center and plug-in cable tap boxes. For further information on plug-in cable tap boxes see Technical Data TD01701001E. Dimensions of end and center cable tap boxes can be found on Pages 50 and 51.


Page 24


WeatherheadsA weatherhead is used for service entrance connections to busway. See Pages 50 and 51 for dimensions.

Expansion JointsExpansion joints accommodate the expansion and contraction of bus bars with respect to the enclo-sure. The Busway Division recommends using an expansion joint under the following conditions:

1. When crossing a building expansion.

2. On vertical risers over 100 feet (30.4 m) where adequate bracing may not be possible in the basement run adjacent to the vertical riser.

3. On horizontal runs of 150 feet (45.7 m) that are fixed at both ends, unless the footage is broken up with elbows.

4. For long straight runs of 300 feet (91.4 m) where the ends are not fixed, use one expansion joint. From 300 to 600 feet (91.4 to 182.9 m), use two expansion joints, unless the load taken off the bus by plug-in units is great enough to reduce the current at equal intervals along the length of the entire run.



Page 25

Bus PlugsThe Pow-R-Way III busway product offers a com-plete family of bus plugs. Traditional plug-in units are available up to 800 amperes, and bolt-on units are available for up to 1200 ampere applications. Plug-in units install at the openings provided on plug-in type busway, while bolt-on units are used with power takeoff devices.

Plug-in UnitsStandard plug-in units include circuit breaker and fusible plugs with overcurrent protection, as well as plug-in cable tap boxes without overcurrent protection. Advanced plug-in units are available including Clipper TVSS surge suppression, com-municating IQ Energy SentinelE and OPTIME circuit breakers, and AdvantageE combination contactors and starters.

Plug-in units feature mechanical interlocks which prevent their installation or removal while the switch is in the ON position, and to prevent accidental closing of the switch when the cover is open. In addition, the plugs are provided with a means of padlocking the cover closed and padlocking the devices in the OFF position.

A polarizing alignment pin is located on the line side of each plug-in enclosure. The alignment pin is inserted into the guide port in the busway housing for proper installation.

Fusible plug-in units are available in 30A to 800A ratings. Fusible type plugs include the quick-make, quick-break disconnect switch and positive pres-sure fuse clips. These plugs are shipped fully assembled with neutral and ground stabs as required. See Table 15 on Page 70 for detailed information.

Breaker plug-in units are available for “FD” through “ND” (800A only) frame Cutler-Hammer Series CT 3-pole circuit breakers only. These plugs are shipped fully assembled with breaker, trip unit, rating plug, terminals, neutral and ground as required. See Table 14 on Page 69 for detailed information.

Fusible and circuit breaker bus plugs may be ordered on Vista under suffix “QAP” using an assembled catalog number. See Cutler-Hammer Distribution Products Catalog CA08101001E for details.

Plug-in Cable Tap Boxes are available in 200A, 400A, 600A and 800A ratings. They may be ordered with mechanical or compression lugs. See Table 3 on Page 51 for detailed information.


Page 26


Plug-in Units (Continued)Front covers are hinged on the load end of theenclosure. Clearance required in front of the unit is equal to “A” dimension in Tables 14 and 15 on Pages 69 and 70. All plugs shown on Page 68 are quick-make, quick-break. “F” and “B” dimensions are included in tables.

Operating handles are shipped assembled for plugs rated 200A and below, as shown in Figure 22. Handles can easily be moved to the end of the plug in the field.

Bolt-on UnitsA power takeoff is used to tap off power up to 1200 amperes. Where power is required in excess of the current carry capabilities of the plug-in stabs (800 amperes), a power takeoff must be used. The power takeoff bolts directly to the contact surfaces of the bus bars. A bolt-on fusible switch or circuit breaker unit is then installed on the power takeoff. Power takeoff devices are available as built-in or bridge joint types.

Built-in Power Takeoff Devices (Figure 22)A built-in power takeoff is a special piece of feeder busway that allows for the attachment of a bolt-on unit. Built-in power takeoffs are used where space restrictions dictate that the wide dimension of the busway be flat against the wall, ceiling or other obstruction. In this application, power takeoffs and bolt-on plug units are used instead of plug-in units.

Bolt-on (fusible switch, circuit breaker or panelboard) units bolt either below or above the power takeoff box. When laying out run, F and T markings must be as shown. A built-in PTO may be oriented on any surface of the busway.

Bridge Joint Power Takeoff Devices (Figure 23)A bridge joint power takeoff is a special connection that allows for the attachment of a bolt-on unit at the bridge joint. The bridge joint power takeoff and a bolt-on unit can be used to tap off power where plug-in busway is not available. Bridge joint power takeoff devices install on the “F” or “F-opposite” side of the busway at bridge joint locations.



Page 27

Figure 22. Built-in Power Takeoff

Figure 23. Bridge Power Takeoff

P.T.O.

Pow-R-Bridge

6.94(176.3)

Pow-R-Bridge

P.T.O.

Edgewise MountedSingle Bar Per Phase Only

Flatwise Mounted — Available in Single and Double Bars Per Phase

9.00(228.6)

15.00(381.0)

17.00(431.8)Min.

9.00(228.6)

15.00(381.0)

17.00(431.8)Min.

6.94(176.3)

CL

CL

T

F

Line

Load

CL

CL

FT

T

Line

Load

FF

DANGER

DANGER

Load

Line


Page 28


Installation TipsWhen planning a plug-in bus run, be sure toconsider the following:

Door ClearanceAllow the clearance in front of a plug-in device to be greater than “A” for 30 – 100 ampere plugs and “B” for 200 ampere and above to allow the door to swing to a full 90º. (See Tables 14 and 15 on Pages 69 and 70.)

Additional SupportOn horizontal bus runs, larger plugs (200A and above) require additional supports independent of bus.

Balance PlugsOn horizontal bus runs, care should be taken to balance the number and size of plugs on each side of the bus to prevent the bus from twisting.

Handle ClearanceAllow a minimum clearance of 4 inches (101.6 mm) for operation of the handle (extends 1-3/16 inches (30.2 mm) beyond the bus plug).



Page 29

CoordinationPRWIII busway sections have T and F markings. When assembling the system, T and F markings of adjacent sections must be aligned. The T and F markings on a busway run are necessary for two reasons:

1. To ensure proper alignment and orientation of the phases during installation; and

2. For coordinating purposes when connectingto switchboards, switchgear, motor control centers, etc., because the busway neutral is opposite the T marking.

There are several conditions that must be taken into consideration when T and F are determined:

1. If the busway has a portion of the run requir-ing plug-in units in a vertical riser, the T and F are then determined by the position of the plug-in units on the riser and its relationship to the wiring closet wall, and whether the load end of the plug must be toward the floor or ceiling.

2. As shown in Figure 24, the load end of the plug will face down when the T marking is to the left of the plug. This orientation will ensure that the operating handle will be ON in the up position. (Plugs on the opposite side will have the load end facing up and the handle will be ON in the down position.)

3. For correct operation of horizontal plug-in runs, the T marking of the bus must face up, as shown in Figure 24.

Responsibility of determining T and F locations, rests on the factory. The contractor provides the desired location of plugs on the riser.


Page 30


Figure 24. Plug-in Device Mounting

ON

OFF

Handle

Load

Load

Handle

ON

OFFLoad

OFF

ON

Handle

ON

OFF

Handle

ON

OFFOFF

ON

OFF

ONON

OFF

Handle

Handle

HandleHandle

Load

Load

Load

Load

T

T

T

F

F

F

F

T



Page 31

Drawings

Customer Approval DrawingsWhen required, customer approval drawings can be supplied by several different methods:

1. On smaller jobs, the Cutler-Hammer Sales Office can prepare sketches or get approved drawings from the customer without a formal approval drawing from the Busway Division.

2. The Sales Office can send hand sketches or the customer’s electrical and architectural drawings to the Busway Division for preparation of formal prints.

3. Approval packages can be prepared using the Bid ManagerE Busway drawing software.

Detailed approval drawings, as shown in Figure 25, expedite the release for manufacture. Therefore, it is important that the information sent to the Division be as complete as possible. If incomplete, a great deal of time can be wasted obtaining missing information.

Information required to plan a busway layout includes:

1. Front location of switchgear, switchboards, transformers or other cubicles.

2. Floor heights and floor/curb thickness onrisers.

3. Location of bus risers in relation to closet walls.

4. Location of plugs on a riser in relation to closet walls.

5. Location and thickness of walls.

6. Pad heights.

7. Location of other obstructions.

The approval drawing that is sent back to the field for approval may require additional dimensions to complete the busway layout. The electrical contractor will fill in these dimensions after field measuring the job, approve the drawing for manufacture, and submit it to the Divisionfor manufacture.


Page 32


Figure 25. Sample Approval Drawings

2-.25 x 5.50 (6.4 x 139.7) Aluminum/Phase2-.25 x 5.50 (6.4 x 139.7) Aluminum/Neutral

Duct Weight = 24 lbs/ftColor = ANSI 61 Gray

Run Indoor/Outdoor1600 A. 3-Phase Aluminum, 277/480 Volts

4 Wire, Housing Ground, 100% Neutral


Duct Weight = 13 lbs/ftColor = ANSI 61 Gray

0

0

0

0

0

0

0

00

T

F

0

0

Outdoor

T

4.38(111.3)

18.64(473.5)

G

G

AB

N

4.38(111.3)

9.40(238.8)

Customer Please Note:

- Verify T & F Markings

May Penetrate & Supply Thickness- Verify or Indicate Label & Front of Switchboard- Verify or Indicate Label & Front of Transformer

Transformer

Front Switchboard

2500 A. 3-Phase, 4W 1600 A. 3-Phase, 4W

PluUn

Run Indoor/Outdoor2500 A. 3-Phase Aluminum, 277/480 Volts


T

00 0



Page 33

Customer Layout DrawingsIn some instances a customer will enter an order and release it for manufacturing based on prepared drawings. In this type of order the Sales Office can expedite the manufacture of the busway by reviewing the customer drawing to ensure that complete information is provided.

Construction DrawingsPrior to shipment of busway from the factory, the Cutler-Hammer business will send the installer a customer layout drawing. A sample appears in Figure 26.

This drawing contains a complete layout of the entire installation and a bill of material (BOM).

The BOM includes item numbers which can be correlated with the drawing, description of each piece, and style number and quantity of each piece.

The installer should review this drawing prior to and during the installation process.

Note: Plug-in units are generally not shown on a construction drawing.

Included in the construction drawing package is the following:

■ As-built drawings.■ Final field fit form (if required).■ Cut sheets for the terminations.■ Hanger instructions.■ Joint puller instructions.■ Joint assembly instructions.■ Maintenance manual.


Page 34


Figure 26. Sample Installation Drawing

Same Elevation

4

See DrawingBVC1004 Line 15

See DrawingBVC1012 Line 5

7

2500 A.3-phase 4W.

1600 A. 3-Phase 4W.12

All Floors

11

13

Plug-in Unit

12

13

15

12

10

12'-6"

12'-6"

3'

1'

-1"

24'-5"

1'-3"

2'-1"

1'-5"

6"

10'-0" Length

2'-6" Length

10'-0" Length

2'-5" Length

Hanger

Hanger

A17

A16

End CloserA15

A13

A12

Elbow

Elbow

A09

A10

A08

A07

BVD0301G15

BVD0300G12

4

3

PSW1589A14

PSW1589A13

PSW1589A10

5687D01G30

PSW1589A08

PSW1589A07

BVD0299G06

BVD0156G08

PSW1589A11

3

1

1

2

3

2

1

1

1

Elbow-Flange

Flange-Elbow

1'-3"

A02 Elbow

HangerA05

A04

DESCRIPTION

A01

ITEM

2'-6"

10'

PSW1589A06

PSW1589A04

PSW1589A02

BVD0301G12

BVD0299G11

PSW1589A01

OR S.O. #STYLE #

1

1

2

1

1

1

Req.

RUN 1Indoor Pow-R-Way III


0.25 x 6.25 (6.4 x 158.8) Aluminum/Phase0.25 x 6.25 (6.4 x 158.8) Aluminum/Neutral

Duct Weight: 13 lbs/ftColor - ANSI 61 Gray

West RiserIndoor Pow-R-Way III



Duct Weight: 24 lbs/ftColor - ANSI 61 Gray

7/16"

8'

10'

FrontSwitchboard

Transformer

OutdoorIndoor

2'-1-5/8"

4.38

G

B C N

4.38(111.3)

A

9.40(238.8)

(473.5



Page 35

Installation GuideEvery piece of PRWIII busway comes with a T and an F label. The T label indicates the phasing of the busway and the F label is used for orientation. PRWIII busway is phased G, A, B, C, N from the T label. It is imperative for all busway to be installed with all of the labels consistent throughout the run, and per Eaton supplied customer drawings. It is necessary to have T on the top of all runs of busway that are installed outdoors.

Indoor Joint Assembly InstructionsWhen connecting sections of PRWIII together, the following guidelines must be followed. Contact surfaces must be clean and free of all contami-nants. Next, align the left end of one section to the right end of the adjoining section with T and F labels matching. Then slide two sections of duct together until the edge of the aluminum housing is 4-1/2 inch (114.3 mm) from the center-line of the joint bolt. (Joint puller, catalog number JP-1, avail-able if required. See Figure 27.)

Install the joint covers. Finally, align busway and tighten insulated joint bolt until the top head of the bolt breaks off.

Note: PRWIII Busway with 6-1/4-inch and 8-inch (152.4, 158.8 and 203.2 mm) bus bars uses 2 bolts per joint. This maintains constant contact pressure over the entire width of the bus bar.

Before making connections to the line and load ends, and without plug-in devices installed, megger the complete busway run and check phase sequence. For 100 foot (3 m) runs or less, the megger value should be a minimum of 1 megohm. The value for longer runs may be proportionately lower.

Note: For complete assembly instructions, please refer to drawing BVD1050 for indoor installations and BVD1082 for outdoor or sprinkler proof installations as well as the latest publication of NEMA Bulletin BU 1.1.


Page 36


Figure 27. Joint Puller

1. Bolt Joint Puller to End Blocks at BuswayJoints as Shown Using .375 (9.5)-16 Hardware Supplied In Cloth Bag.

Puller May Be Used with Wider Bus Bars.

End Block

Note:

End Block

Optional Joint Puller(See Note 2)

Joint Puller

End Block

End Block

Joint Puller

Joint Puller

F

T

T

T

F

T

T F

F

T

T

F



Page 37

Final Field FitsA final field fit section of busway is typically an elbow or short section of feeder that is intention-ally left out of a run for later shipment. It is most often a mutually agreed upon section between the customer and the plant. Once the initial shipment of bus is installed, the contractor is to measure for the final field fit piece (being careful to follow the instructions on the final field fit form supplied with the construction drawings). This completed form is then faxed to Greenwood for release. The final field fit will ship 5 – 10 working days from release.

How to Remove a Section of BuswayWhen the need arises to remove a section from the middle of an existing run of PRWIII busway, the following steps must be taken:

1. Refer to Figures 28 and 29.

2. De-energize the busway.

3. Remove joint covers (and splice covers for outdoor busway) of the joints to be loosened.

4. Remove .190 (4.8)-32 retainer screws from top and bottom pressure plates (if not already removed).Note: At this point the bridge joint is no longer securely fastened to the busway.

5. Loosen the insulated joint bolt on both ends of the busway section to be removed.

6. Carefully remove busway section.

7. To install new section, use reverse procedure.


Page 38


Figure 28. Indoor Joint Assembly

DANGER NOTICE

Bridge JointPressure Plate(top & bottom)

Double HeadedTorque IndicatingBolt (bottom)

BellevilleWasher

Ground Path Plate

Bridge JointRetainer Screw(must be removed for 1-inch (25.4 mm)adjustment)

Ground PathEnd Block

130∞ EpoxyInsulation on Bars

.375 (9.5)-16 flg.Head Hex Bolt

Joint Cover

Ground Path Label

Captive NutRetainer


High StrengthGlass PolyesterInsulators

Ground PathContact Surface

1/4-20 flg.Head Hex Bolt(4 per cover)

(4 per cover)

FT

T

TF



Page 39

Figure 29. Outdoor Joint Assembly

Gasketed TopAccess Cover

Drain Hole Plug

Gasketed Torque- Bolt Access Cap(Top & Bottom)

Closed CellNeoprene GasketWater Barrier

Captive NutRetainer

Pressure Plate(Top & Bottom)

BellevilleWasher

Bridge Joint Retainer Screw (Must be Removed for .08 (2.03) Adjustment)

Water Barrier


Pow-R-BridgeJoint

Gasketed BottomAccess Cover

Torque BoltAccess Opening

DANGER NOTICE

Ground PathLabel

Gasketed FrontJoint Cover

DrainHole Plug

GasketedCover Plate


Ground PathContact Surface

GasketedCover Plate

Gasketed RearJoint Cover

F

T

T

FT


Page 40


Outdoor Bus SupportsBusway connected to outdoor transformers, switchgear, etc., must be supported by some means. This is the responsibility of the contractor or owner. The transformer throat, see Figure 30, is not designed to carry the busway weight.

In Figure 30, if dimension “A” is less than 10 feet (3 m), a knee brace should be sufficient to carry the weight of the busway outside the building. This brace must be supplied by the owner or contractor and may vary in design as dictated by specific job conditions.

Note: If the overall weight of the vertical portion of the busway extending from the transformer throat exceeds 225 lbs (102 kg), then an additional support must be placed a maximum of 12 inches (304.8 mm) from the center-line of the elbow bend.

Figure 30. Outdoor Run

If dimension “A” is greater than 10 feet (3 m) long as in Figure 30, the busway should have:

1. Pipe supports under it;

2. Knee brace under transformer throat; and

3. Drop rods and channel hangers underbusway indoor.

Note: All bracing is to be supplied by the owner or contractor except the hangers on the indoor portion. Cutler-Hammer busway is listed with Underwriters LaboratoriesT for mounting on 10-foot (3 m) centers.

KneeBrace

Sealing Ring

12.00(304.8) Min.

OutdoorIndoor

LV

HV

IndoorSwitchboard

AdditionalSupport

A



Page 41

Accessories

Hangers

Horizontal Hangers (Hook and Angle) One hanger is supplied for every 10 feet (3.0 m)of horizontally mounted PRWIII busway. The type of hanger is determined by the customer’s specific requirements for installation. Care should be given when locating the drop rods, in order to avoid placing hangers at joint locations. If the horizontal busway run is plug-in type, adequate ceiling clearance must be allowed for the largest plug to be mounted on the bus. Hanger types are shown in Figure 31.

Note: Drop rods are provided by others.

Note: Standard hangers require 1/2-inch (12.7 mm) drop rods and Seismic hangers require 3/4-inch (19.1 mm) drop rods.

Vertical HangersWhen busway is to be installed vertically, a spring suspension type vertical hanger is used. Vertical hangers are not provided unless specified. A vertical hanger must be used on each floor. The maximum span permitted by UL on vertical hangers is 16 feet (4.9 m). Intermediate hangers are required for floor heights exceeding 16 feet (4.9 m). See Figure 32.

Seismic HangersFor Seismic applications, see drawing BVC 1104. Seismic hangers are also equipped to handle a 3/4-inch (19.1 mm) drop rod.


Page 42


Figure 31. Horizontal Hangers

DuctWidth

FlatwiseHook Hanger

EdgewiseHook Hanger

Flatwise Angle Hanger1 Bar Per Phase

Flatwise Angle Hanger2 Bars Per Phase

Edgewise Angle Hanger1 Bar Per Phase

Edgewise Angle Hanger2 Bars Per Phase

DuctWidth

DuctHeight

DuctWidth

DuctWidth

DuctHeight

DuctHeight



Page 43

Figure 32A. Vertical Hangers

F

T F

3 1/2"3 1/2"

4"4"

3"3"

3 1/2"3 1/2" 3 1/2"3 1/2"

3"3"

4"4" 4"4"

3"3"

3 1/2"3 1/2"

3"3"

4"4"

3 1/2"3 1/2"

3"3"

4"4" 4"4"

3"3"

3 1/2"3 1/2"

Floor

Floor

1-Inch (25.4)Minimum

Lap AroundFloor Opening

(Typical)

Duct Width

Center SpringFor 6.25 and 8.00(158.7 and 203.2)

Bar Widths

.31 (7.9) - 18Hardware

Drill .34 (8.6) Holesin Busway Housing

Using Hanger asa Template

A

DuctHeight

For 1 or 2 bars per Phase(4 Springs)

"F" & "F-OPPOSITE" Mounting

T F

Floor

Mounting Support(By Others)Floor Flange

(Optional)

.63 (15.9) DiameterStud

A 5.75(146.1)

VerticalHanger

For 1 Bar per Phase Busway(4 or 6 Springs)

"T" & "T-OPPOSITE" Mounting


Page 44


Figure 32B. Vertical Hangers

T T

F

3 1/2"3 1/2"

4"4"

3"3"

3 1/2"3 1/2"

3"3"

4"4" 4"4"

3"3"

3 1/2"3 1/2" 3 1/2"3 1/2"

3"3"

4"4"

3 1/2"3 1/2"

3"3"

4"4" 4"4"

3"3"

3 1/2"3 1/2"

.31 (7.9) - 18Hardware

Busway Width

A

Busway

1-Inch (25.4)MinimumLap AroundFloor Opening(Typical)

Drill .34 (8.63) Holesin Busway HousingUsing Hanger asa Template

Floor

For 2 bars per Phase Busway(6 Springs)

"F" & "F-OPPOSITE" Mounting

T F

A 5.75(146.1)

Floor

Floor Flange(Optional)

Mounting Support(By Others)

.63 (15.9)Diameter Stud

VerticalHanger



Page 45

Wall/Floor FlangesFor wall/floor flange dimensions, see Figure 33. Wall/floor flanges are required when busway penetrates a wall or floor. This device offers no fire protection or weatherproofing. It is for cosmetic purposes only. Two wall flanges are required for each wall penetration (one for each side). One floor flange is required for each floor penetration (floor side only).

Figure 33. Wall/Floor Flange

End ClosersEnd closures terminate a bus run.

Typical Wall/Floor Flange Detail1 Bar Per Phase

(Wall Opening Should Be 1-inch (25.4)Wider Than Bus On All Sides)

Wall/Floor

Typical Wall/Floor Flange Detail2 Bar Per Phase

(Wall Opening Should Be 1-inch (25.4)Wider Than Bus On All Sides)

Wall/Floor

BuswayHeight

BuswayWidth

BuswayHeight

BuswayWidth

2.00(508.0)

2.00(508.0)

2.00(508.0)

2.00(508.0)


Page 46


Busway Handling

ShippingAll busway shipments are made from Greenwood, South Carolina, and are shipped F.O.B. first desti-nation, freight prepaid if total weight is over 300 lbs. (136 kg.) Should the receiver notice any short-age versus the shipping notice, the receiver should file a claim with the carrier immediately. The same procedure should be followed for damaged freight. All hangers are shipped in separate cartons and should be accounted for per the bill of material.

DO NOT REMOVE BUSWAY FROM ORIGINAL SHIPPING CONTAINER UNTIL READY FOR INSTALLATION.

This will help prevent the problem of mechanical damage, dirt, dust, plaster or paint on the individual pieces.

Busway LabelsBusway items have a nameplate which indicates the General Order number (GO#), item number, and specific rating information (see Figure 34). All busway fittings are clearly marked with T and F labels. When installing the busway sections the T and F markings of adjacent sections must match and must be installed in the proper orientation as shown on the customer drawing.

Figure 34. Busway Label

POW-R-WAY POW-R-WAY IIIIII

STYLE NO.

RMS SYM A

SHORT CIRCUIT CURRENT RATING

RATING OF SYSTEM IS LIMITED TO LOWEST SHORT CIRCUIT RATING OF ANY BUSWAY OR FITTING INSTALLED.MAX. SUPPORT SPACING: 10 FT. (305 cm) HORIZONTAL RUN: 16 FT. (488 cm) VERTICAL RISER. SHORT CIRCUIT

DC A

MFG. DATE:

Material

BVA1000H01

When protected by a ampere maximum class

fuse or a CUTLER-HAMMER type

circuit breaker rated for not more than amperes,

this busway is rated for use on a circuit capable ofdelivering not more than RMS symmetrical

amperes volts maximum. ~

V

% GRD.

PHASE

NEUT A

A

WIRE

~

REV. 4

BEFORE INSTALLING, REMOVING OR WORKING ON THIS EQUIPTMENT. HAZARD OF ELECTRICAL SHOCK OR BURN. TURN OFF POWER TO BUSWAY

CUTLER-HAMMERCUTLER-HAMMERCUTLER-HAMMERCUTLER-HAMMER

DANGER

1200

125,000 100%

277/480

3 4

50% HSG.

PYW03125-A01

1200

L

1200

200,000

600

ALUMINUM



Page 47

Dimensional Data

Figure 35. Pow-R-Way III Cross-Section Dimensions

Width

Height

Width

Height

Figure B

Figure A

2500 to 4000 Ampere Aluminum3200 to 5000 Ampere Copper

225 to 2000 Ampere Aluminum225 to 2500 Ampere Copper


Page 48

IM01701002E

Effective: December 2002

Table 1. Bus Bar and Housing — Dimensions in Inches (mm)Ampere

Rating

Phase Bar Size

(Depth and Width)

Bar

Per

Ph

ase

3-Wire with No Neutral and 4-Wire with 100% Neutral 4-Wire with 200% Neutral

Fig

ure

Conductor Configuration and Housing Size (Width x Height)

Cu Al 50% Integral Housing

Ground 3WH

50% Integral

Ground Bus 3WHG

50% Integral

Isolated Ground 3WI

50% Integral Housing

Ground 4WNH

50% Integral

Ground Bus 4WNG

50% Integral

Isolated Ground 4WNI

225 400 600

225 400—

.25 x 1.62 (6.35 x 41)

.25 x 1.62 (6.35 x 41)

.25 x 1.62 (6.35 x 41)

111

4.75 x 4.38 (121 x 111) 4.75 x 4.38 (121 x 111) 4.75 x 4.38 (121 x 111)

4.75 x 4.50 (121 x 114) 4.75 x 4.50 (121 x 114) 4.75 x 4.50 (121 x 114)

4.75 x 4.55 (121 x 116) 4.75 x 4.55 (121 x 116) 4.75 x 4.55 (121 x 116)

4.75 x 4.92 (121 x 125) 4.75 x 4.92 (121 x 125) 4.75 x 4.92 (121 x 125)

4.75 x 5.05 (121 x 128) 4.75 x 5.05 (121 x 128) 4.75 x 5.05 (121 x 128)

4.75 x 5.10 (121 x 130) 4.75 x 5.10 (121 x 130) 4.75 x 5.10 (121 x 130)

AAA

80010001200

600— 800

.25 x 1.62 (6.35 x 41)

.25 x 2.25 (6.35 x 57)

.25 x 2.75 (6.35 x 70)

111

4.75 x 4.38 (121 x 111) 5.38 x 4.38 (137 x 111) 5.88 x 4.38 (149 x 111)

4.75 x 4.50 (121 x 114) 5.38 x 4.50 (137 x 114) 5.88 x 4.50 (149 x 114)

4.75 x 4.55 (121 x 116) 5.38 x 4.55 (137 x 116) 5.88 x 4.55 (149 x 116)

4.75 x 4.92 (121 x 125) 5.38 x 4.92 (137 x 125) 5.88 x 4.92 (149 x 125)

4.75 x 5.05 (121 x 128) 5.38 x 5.05 (137 x 128) 5.88 x 5.05 (149 x 128)

4.75 x 5.10 (121 x 130) 5.38 x 5.10 (137 x 130) 5.88 x 5.10 (149 x 130)

AAA

135016002000

100012001350

.25 x 3.25 (6.35 x 83)

.25 x 4.25 (6.35 x 108)

.25 x 5.50 (6.35 x 140)

111

6.38 x 4.38 (162 x 111) 7.38 x 4.38 (187 x 111) 8.64 x 4.38 (219 x 111)

6.38 x 4.50 (162 x 114) 7.38 x 4.50 (187 x 114) 8.64 x 4.50 (219 x 114)

6.38 x 4.55 (162 x 116) 7.38 x 4.55 (187 x 116) 8.64 x 4.55 (219 x 116)

6.38 x 4.92 (162 x 125) 7.38 x 4.92 (187 x 125) 8.64 x 4.92 (219 x 125)

6.38 x 5.05 (162 x 128) 7.38 x 5.05 (187 x 128) 8.64 x 5.05 (219 x 128)

6.38 x 5.10 (162 x 130) 7.38 x 5.10 (187 x 130) 8.64 x 5.10 (219 x 130)

AAA

—25003200

16002000—

.25 x 6.25 (6.35 x 159)

.25 x 8.00 (6.35 x 203)

.25 x 4.25 (6.35 x 108)

112

9.40 x 4.38 (239 x 111)11.17 x 4.38 (284 x 111)16.14 x 4.38 (410 x 111)

9.40 x 4.50 (239 x 114)11.17 x 4.50 (284 x 114)16.14 x 4.50 (410 x 114)

9.40 x 4.55 (239 x 116)11.17 x 4.55 (284 x 116)16.14 x 4.55 (410 x 116)

9.40 x 4.92 (239 x 125)11.17 x 4.92 (284 x 125)16.14 x 4.92 (410 x 125)

9.40 x 5.05 (239 x 128)11.17 x 5.05 (284 x 128)16.14 x 5.05 (410 x 128)

9.40 x 5.10 (239 x 130)11.17 x 5.10 (284 x 130)16.14 x 5.10 (410 x 130)

AAB

4000—5000

250032004000

.25 x 5.50 (6.35 x 140)

.25 x 6.25 (6.35 x 159)

.25 x 8.00 (6.35 x 203)

222

18.64 x 4.38 (473 x 111)20.16 x 4.38 (512 x 111)23.70 x 4.38 (602 x 111)

18.64 x 4.50 (473 x 114)20.16 x 4.50 (512 x 114)23.70 x 4.50 (602 x 114)

18.64 x 4.55 (473 x 116)20.16 x 4.55 (512 x 116)23.70 x 4.55 (602 x 116)

18.64 x 4.92 (473 x 125)20.16 x 4.92 (512 x 125)23.70 x 4.92 (602 x 125)

18.64 x 5.05 (473 x 128)20.16 x 5.05 (512 x 128)23.70 x 5.05 (602 x 128)

18.64 x 5.10 (473 x 130)20.16 x 5.10 (512 x 130)23.70 x 5.10 (602 x 130)

BBB

AB

C_B

usDuct_prf4.fm

Page 48 Friday, Decem

ber 13, 2002 4:06 PM


Page 49

Tabl

e 2.

Wei

ght a

nd C

urre

nt D

ensi

tyA

mp

ere

Rati

ng

Weig

ht

(Lb

s./

Ft.

) an

d C

urr

en

t D

en

sit

y (

Am

pere

s/i

n2)

Metr

ic W

eig

ht

(kg

/M)

an

d C

urr

en

t D

en

sit

y (

Am

pere

s/c

m2)

Cu

rren

t D

en

sit

yA

mp

ere

s/i

n2

Weig

ht

— In

clu

din

g In

teg

ral H

ou

sin

g G

rou

nd

(Lb

s./

Ft.

)C

urr

en

t D

en

sit

yA

mp

ere

s/c

m2

Weig

ht

— In

clu

din

g In

teg

ral H

ou

sin

g G

rou

nd

(kg

/M)

3-W

ire

4-W

ire

100%

Neu

tral

4-W

ire

200%

Neu

tral

Ad

d f

or

Inte

rnal

Gro

un

d

3-W

ire

4-W

ire

100%

Neu

tral

4-W

ire

200%

Neu

tral

Ad

d f

or

Inte

rnal

Gro

un

d

Cu

Al

Cu

Al

Cu

Al

Cu

Al

Cu

Al

Cu

Al

Cu

Al

Cu

Al

Cu

Al

Cu

Al

Cu

Al

225

400

600

225

400

—

554

985

1477

554

985

—

8 8 8

5 5 —

10 10 10

6 6 —

11 11 11

7 7 —

0.78

0.78

0.78

0.23

0.23

—

86

153

229

86

153

—

12 12 12

7 7 —

15

15

15

9 9 —

17

17

17

11 11 —

1.1

7 1

.17

1.1

7

0.35

0.35

—

800

1000

1200

600

— 800

1969

1778

1745

1477

— 1164

8 10 12

5 — 6

10 12 15

6 — 7

11 14 17

7 — 8

0.78

1.08

1.33

0.23

— 0.40

305

276

270

229

— 180

12 15 18

7 — 9

15

18

22

9 — 11

17

21

26

11 — 12

1.1

7 1

.62

1.9

8

0.35

— 0.60

1350

1600

2000

1000

1200

1350

1662

1506

1455

1231

1129

982

14 17 23

7 8 11

17 21 28

8 10 12

20 25 33

9 11 13

1.57

2.05

2.66

0.47

0.62

0.80

258

233

226

191

175

152

21 25 34

11 12 16

25

32

42

12 15 18

30

37

49

14 16 20

2.3

4 3

.06

3.9

6

0.71

0.92

1.20

— 2500

3200

1600

2000

—

— 1250

1505

1024

1000

—

— 29 34

12 14 —

— 36 42

13 16 —

— 42 49

15 18 —

— 3.87

4.11

0.91

1.17

—

— 194

233

159

155

—

— 43 51

18 21 —

— 54

63

20 24 —

— 63

73

22 27 —

— 5.7

6 6

.12

1.36

1.75

—

4000

— 5000

2500

3200

4000

1455

— 1250

909

960

1000

45 — 63

21 23 28

56 — 72

24 26 32

66 — 85

27 29 36

5.32

— 7.74

1.61

1.83

2.35

226

— 194

140

149

155

67 — 94

32 34 42

83

— 108

36 39 48

98

— 126

40 43 54

7.9

2— 11

.53

2.40

2.73

3.50


Page 50


Cable Tap Boxes

Figure 36. Cable Tap Boxes

“T” SideRemovableIndoor

11.62(295.1)

17.50(444.5)

Side Opposite “T”Removable Indoor

17.50(444.5)

15.00(381.0)

of Duct of Box

of Busway

CL

Gasketed AccessCover on Frontand Back of Boxfor Outdoor TapBoxes Only

32.50(825.5)

Side Opposite “T”Removable Indoor

15.00(381.0)

Gasketed Access Coveron Front and Back of Boxfor Outdoor Tap Boxes Only

of BoxLC

11.62(295.1)

LC

“T”SideRemovableIndoor

of DuctLC

F

C

of BuswayLC

EndRemovableIndoor

F Dimension isthe MinimumGutter Space

30.00(762.0)

32.50(825.5)

CL

11.62(295.1)

17.50(444.5)

15.00(381.0) Removable Barrier

of DuctCL

of BuswayLC

1.00(25.4)Compression andMechanical Lugs

24.00(609.6)

38.00(965.2)

DMin.

Gutter

Space

A

A

40.00(1016.0)

B

of BoxCL

A

End Cable Tap Box

Center Cable Tap Box

Weatherhead

CLCL CL

30.00(762.0)

BuswayHeight

BuswayWidth

BuswayHeight

BuswayWidth

BuswayWidth

BuswayHeight


Effective: December 2002

IM01701002E

Page 51

Table 3. Cable Tap Box — Dimensions in Inches (mm)AmpereRating

End Cable Tap Box Center Cable Tap Box Quantity of Mechanical Terminals,Range — (1) #4 – 600 kcmil or(2) 1/0 – 250 kcmil Cu/AlCopper Aluminum Copper Aluminum Weatherhead

Dimension Dimension Dimension Dimension Dimension Dimension Dimension Dimension Dimension Copper Aluminum

(A) (A) (A) (B) (C) (A) (B) (C) (A) G P N G P N

225 400 600

12.00 (304.8)12.00 (304.8)12.00 (304.8)

12.00 (304.8)12.00 (304.8)12.00 (304.8)

16.50 (419.1)16.50 (419.1)16.50 (419.1)

40.00 (1016.0)40.00 (1016.0)40.00 (1016.0)

3.63 (92.2) 3.63 (92.2) 3.63 (92.2)

16.50 (419.1)16.50 (419.1)16.50 (419.1)

40.00 (1016.0)40.00 (1016.0)40.00 (1016.0)

3.63 (92.2) 3.63 (92.2) 3.63 (92.2)

16.50 (419.1)16.50 (419.1)16.50 (419.1)

111

2 2 2

4 4 4

111

222

4 4 4

80010001200

12.00 (304.8)12.00 (304.8)12.00 (304.8)

12.00 (304.8)12.00 (304.8)12.00 (304.8)

16.50 (419.1)16.50 (419.1)16.50 (419.1)

40.00 (1016.0)40.00 (1016.0)40.00 (1016.0)

3.63 (92.2) 3.63 (92.2) 3.63 (92.2)

16.50 (419.1)16.50 (419.1)20.50 (520.7)

40.00 (1016.0)40.00 (1016.0)42.50 (1079.5)

3.63 (92.2) 3.63 (92.2) 4.75 (120.7)

16.50 (419.1)16.50 (419.1)16.50 (419.1)

222

3 3 4

5 6 8

222

334

5 6 8

135016002000

12.00 (304.8)20.50 (520.7)20.50 (520.7)

20.50 (520.7)24.50 (622.3)24.50 (622.3)

16.50 (419.1)20.50 (520.7)20.50 (520.7)

40.00 (1016.0)42.50 (1079.5)42.50 (1079.5)

3.63 (92.2) 4.75 (120.7) 4.75 (120.7)

20.50 (520.7)24.50 (622.3)24.50 (622.3)

42.50 (1079.5)45.00 (1143.0)45.00 (1143.0)

4.75 (120.7) 6.00 (152.4) 6.00 (152.4)

16.50 (419.1)16.50 (419.1)16.50 (419.1)

233

4 5 6

8 912

233

456

8 912

2500320040005000

24.50 (622.3)30.50 (774.5)45.00 (1143.0)45.00 (1143.0)

30.50 (774.5)30.50 (774.5)45.00 (1143.)—

24.50 (622.3)30.38 (774.5)45.00 (1143.0)45.00 (1143.0)

42.50 (1079.5)58.00 (1473.2)60.50 (1536.7)60.50 (1536.7)

6.00 (152.4)10.75 (273.1)12.25 (311.2)12.25 (311.2)

30.38 (771.7)30.38 (771.7)45.00 (1143.0)—

58.00 (1473.0)58.00 (1473.0)60.50 (1536.7)—

10.75 (273.1)10.75 (273.1)12.25 (311.2)—

16.50 (419.1)30.00 (762.0)30.00 (762.0)30.00 (762.0)

4567

8 91215

16182430

456—

8912—

161824—

AB

C_B

usDuct_prf4.fm

Page 51 Friday, Decem

ber 13, 2002 4:06 PM

Page 52


Elbow Flanges

Figure 37. Elbow Flanges

Table 4. Forward and Rearward Elbow FlangesAmpere Rating Minimum Dimensions in Inches (mm)

Cu Al Joint Let (X) Flange Leg (Y)

225 400 600

225 400—

13.00 (330.2)13.00 (330.2)13.00 (330.2)

8.75 (222.3) 8.75 (222.3) 8.75 (222.3)

80010001200

600— 800

13.00 (330.2)13.00 (330.2)13.50 (342.9)

8.75 (222.3) 8.75 (222.3) 9.25 (235.0)

135016002000

100012001350

13.50 (342.9)14.00 (355.6)14.50 (368.3)

9.25 (235.0) 9.75 (247.7)10.25 (260.4)

—25003200

16002000—

15.00 (381.0)16.00 (406.4)18.50 (469.9)

10.75 (273.1)11.75 (298.5)14.00 (355.6)

4000—5000

250032004000

19.50 (495.3)20.50 (520.7)22.50 (571.5)

15.25 (387.4)16.00 (406.4)17.75 (450.9)

Forward ElbowRight Flange

Rearward ElbowRight Flange

CL

T

T

T

T

F

F

CL CL

CL

CL

CL



Page 53

Figure 38. Elbow Flanges

Table 5. Upward and Downward Elbow FlangesAmpere

Rating

Minimum Dimension in Inches (mm)

Joint Let (X) Flange Leg (Y)

Cu Al Up Down Up Down

225 400 600

225 400—

10.00 (254.0)10.00 (254.0)10.00 (254.0)

13.00 (330.2)13.00 (330.2)13.00 (330.2)

5.75 (146.1)5.75 (146.1)5.75 (146.1)

8.75 (222.3)8.75 (222.3)8.75 (222.3)

80010001200

600— 800

10.00 (254.0)10.00 (254.0)10.00 (254.0)

13.00 (330.2)13.00 (330.2)13.00 (330.2)

5.75 (146.1)5.75 (146.1)5.75 (146.1)

8.75 (222.3)8.75 (222.3)8.75 (222.3)

135016002000

100012001350

10.00 (254.0)10.00 (254.0)10.00 (254.0)

13.00 (330.2)13.00 (330.2)13.00 (330.2)

5.75 (146.1)5.75 (146.1)5.75 (146.1)

8.75 (222.3)8.75 (222.3)8.75 (222.3)

—25003200

16002000—

10.00 (254.0)10.00 (254.0)12.00 (304.8)

13.00 (330.2)13.00 (330.2)13.00 (330.2)

5.75 (146.1)5.75 (146.1)7.75 (196.9)

8.75 (222.3)8.75 (222.3)8.75 (222.3)

4000—5000

250032004000

12.00 (304.8)12.00 (304.8)12.00 (304.8)

13.00 (330.2)13.00 (330.2)13.00 (330.2)

7.75 (196.9)7.75 (196.9)7.75 (196.9)

8.75 (222.3)8.75 (222.3)8.75 (222.3)

Downward ElbowRight Flange

L

Upward ElbowRight Flange

LCLC

LC

CL

CT

T

F

LC

T

TF


Page 54


Standard/Flush Flanges

Figure 39. Standard/Flush Flanges

Table 6. Standard/Flush FlangesAmpereRating

Minimum Leg Length (X)in Inches (mm)

Cu Al Flush Flange Standard Flange

225 400 600

225 400 600

15.00 (381.0)15.00 (381.0)15.00 (381.0)

11.62 (295.16)11.62 (295.16)11.62 (295.16)

80010001200

80010001200

15.00 (381.0)15.00 (381.0)15.00 (381.0)

11.62 (295.16)11.62 (295.16)11.62 (295.16)

135016002000

135016002000

15.00 (381.0)15.00 (381.0)15.00 (381.0)

11.62 (295.16)11.62 (295.16)11.62 (295.16)

2500320040005000

250032004000—

15.00 (381.0)15.00 (381.0)15.00 (381.0)15.00 (381.0)

11.62 (295.16)11.62 (295.16)11.62 (295.16)11.62 (295.16)

Flush Flange

Standard Flange

15.00(381.0)Min.

Bridge

LC

1.25

LC

F

T

T

11.62(295.2)Min.

Bridge

LC

LC

F

T

T



Page 55



Page 56


Elbows

Figure 40. Elbow Types

Forward

Rearward

Upward

LC

CL

X X

X X

X

Downward

X

X

X

CL

T

T

F

CL

LC

LC LC

LC

T

TF

LC

LC

T

TF

T

TF

LC

LC

LC



Page 57

Table 7. Elbows — Dimensions in Inches (mm)AmpereRating

MinimumLeg Length

MinimumLeg Lengths (X)

Cu Al Upward Downward Forward/Rearward

225 400 600

225 400—

10.00 (254.0)10.00 (254.0)10.00 (254.0)

13.00 (330.2)13.00 (330.2)13.00 (330.2)

13.00 (330.2)13.00 (330.2)13.00 (330.2)

80010001200

600— 800

10.00 (254.0)10.00 (254.0)10.00 (254.0)

13.00 (330.2)13.00 (330.2)13.00 (330.2)

13.00 (330.2)13.00 (330.2)13.50 (342.9)

135016002000

100012001350

10.00 (254.0)10.00 (254.0)10.00 (254.0)

13.00 (330.2)13.00 (330.2)13.00 (330.2)

13.50 (342.9)14.00 (355.6)14.50 (368.3)

—25003200

16002000—

10.00 (254.0)10.00 (254.0)12.00 (304.8)

13.00 (330.2)13.00 (330.2)13.00 (330.2)

12.00 (381.0)16.00 (406.4)18.50 (469.9)

4000—5000

250032004000

12.00 (304.8)12.00 (304.8)12.00 (304.8)

13.00 (330.2)13.00 (330.2)13.00 (330.2)

19.50 (495.3)20.50 (520.7)22.50 (571.5)


Page 58


Corner Joint Elbows

Figure 41. Corner Joint Elbows

Forward

Rearward

Downward

Upward

LC

LC LC

LCX

X Y

Y

T

F

T

F

T

F

T

F

LC

LC LC

LC

LC

LC

LC

Y

Y

X

X

LC



Page 59

Table 8. Corner JointsAmpereRating

Dimensions in Inches (mm)

Forward/Rearward Upward/Downward

Cu Al (X) (Y) (X) (Y)

225 400 600

225 400—

0.94 (23.9) 0.94 (23.9) 0.94 (23.9)

5.38 (136.7) 5.38 (136.7) 5.38 (136.7)

4.71 (119.6)4.71 (119.6)4.71 (119.6)

4.35 (110.5)4.35 (110.5)4.35 (110.5)

80010001200

600— 800

0.94 (23.9) 1.25 (31.8) 1.50 (38.1)

5.38 (136.7) 5.69 (144.5) 5.94 (150.9)

4.71 (119.6)4.71 (119.6)4.71 (119.6)

4.35 (110.5)4.35 (110.5)4.35 (110.5)

135016002000

100012001350

1.75 (44.5) 2.25 (57.2) 2.88 (73.2)

6.19 (157.2) 6.69 (169.9) 7.31 (185.7)

4.71 (119.6)4.71 (119.6)4.71 (119.6)

4.35 (110.5)4.35 (110.5)4.35 (110.5)

—25003200

16002000—

3.25 (82.6) 4.12 (104.7) 6.64 (168.7)

7.70 (195.6) 8.57 (217.7)11.07 (281.2)

4.71 (119.6)4.71 (119.6)4.71 (119.6)

4.35 (110.5)4.35 (110.5)4.35 (110.5)

4000—5000

250032004000

7.89 (200.4) 8.65 (219.7)10.42 (264.7)

12.32 (312.9)13.08 (332.2)14.85 (377.2)

4.71 (119.6)4.71 (119.6)4.71 (119.6)

4.35 (110.5)4.35 (110.5)4.35 (110.5)


Page 60


Offsets

Figure 42. Offsets

Forward

Rearward

Upward

Downward

3.00(76.2) Min.

LCY

Y

T

LC

LC

TF

LC

LC

LC

LC3.00(76.2) Min.

T

TF

LC

LC

LC

Y

Y

3.00(76.2) Min.LC

LC

LC

LC

LC

TF

Y

Z

LC

LC

LC

LC

LC

3.00(76.2) Min.

Z

YT

T

F



Page 61

Tabl

e 9.

Offs

ets

Am

pere

Rati

ng

Min

imu

m D

imen

sio

ns in

In

ch

es (

mm

)

Up

ward

Do

wn

ward

Fo

rward

/Rearw

ard

Cu

Al

(Y)

(Z)

(Y)

(Z)

(Y)

225

400

600

225

400

—

10.0

0 (2

54.0

)10

.00

(254

.0)

10.0

0 (2

54.0

)

13.0

0 (3

30.2

)13

.00

(330

.2)

13.0

0 (3

30.2

)

13.0

0 (3

30.2

)13

.00

(330

.2)

13.0

0 (3

30.2

)

10.0

0 (2

54.0

)10

.00

(254

.0)

10.0

0 (2

54.0

)

13.0

0 (3

30.2

)13

.00

(330

.2)

13.0

0 (3

30.2

)

800

1000

1200

600

— 800

10.0

0 (2

54.0

)10

.00

(254

.0)

10.0

0 (2

54.0

)

13.0

0 (3

30.2

)13

.00

(330

.2)

13.0

0 (3

30.2

)

13.0

0 (3

30.2

)13

.00

(330

.2)

13.0

0 (3

30.2

)

10.0

0 (2

54.0

)10

.00

(254

.0)

10.0

0 (2

54.0

)

13.0

0 (3

30.2

)13

.00

(330

.2)

13.5

0 (3

42.9

)

1350

1600

2000

1000

1200

1350

10.0

0 (2

54.0

)10

.00

(254

.0)

10.0

0 (2

54.0

)

13.0

0 (3

30.2

)13

.00

(330

.2)

13.0

0 (3

30.2

)

13.0

0 (3

30.2

)13

.00

(330

.2)

13.0

0 (3

30.2

)

10.0

0 (2

54.0

)10

.00

(254

.0)

10.0

0 (2

54.0

)

13.5

0 (3

42.9

)14

.00

(355

.6)

14.5

0 (3

68.3

)

— 2500

3200

1600

2000

—

10.0

0 (2

54.0

)10

.00

(254

.0)

12.0

0 (3

04.8

)

13.0

0 (3

30.2

)13

.00

(330

.2)

13.0

0 (3

30.2

)

13.0

0 (3

30.2

)13

.00

(330

.2)

13.0

0 (3

30.2

)

10.0

0 (2

54.0

)10

.00

(254

.0)

12.0

0 (3

04.8

)

15.0

0 (3

81.0

)16

.00

(406

.4)

18.5

0 (4

69.9

)

4000

— 5000

2500

3200

4000

12.0

0 (3

04.8

)12

.00

(304

.8)

12.0

0 (3

04.8

)

13.0

0 (3

30.2

)13

.00

(330

.2)

13.0

0 (3

30.2

)

13.0

0 (3

30.2

)13

.00

(330

.2)

13.0

0 (3

30.2

)

12.0

0 (3

04.8

)12

.00

(304

.8)

12.0

0 (3

04.8

)

19.5

0 (4

95.3

)20

.50

(520

.7)

22.5

0 (5

71.5

)


Page 62


Tees

Figure 43. Tees

Forward

Rearward

LCX

T

T

LCX

F

LC

T

TF

LC

Y

LCF

T

T

LC

LC

LC

LC

LC

Y

X

XT

TF

TT

F

T

TF

LC

LC

LC

LC

LC

LC

Y

X

X

T

T F

T

TF

TT

F

Upward

Downward

LC

LC

LC

LC

T

TF

FT

T

T

TF

X

X

Y



Page 63

Table 10. TeesAmpere

Rating

Minimum Leg Dimensions in Inches (mm)

Forward/Rearward Upward/Downward

Cu Al (X) (Y) (X) (Y)

225 400 600

225 400—

13.00 (330.2)13.00 (330.2)13.00 (330.2)

13.00 (330.2)13.00 (330.2)13.00 (330.2)

21.25 (539.8)21.25 (539.8)21.25 (539.8)

25.50 (647.7)25.50 (647.7)25.50 (647.7)

80010001200

600— 800

13.00 (330.2)13.00 (330.2)13.50 (342.9)

13.00 (330.2)13.00 (330.2)13.50 (342.9)

21.25 (539.8)21.88 (555.8)22.38 (568.5)

25.50 (647.7)25.50 (647.7)25.50 (647.7)

135016002000

100012001350

13.50 (342.9)14.00 (355.6)14.50 (368.3)

13.50 (342.9)14.00 (355.6)14.50 (368.3)

22.88 (581.2)23.88 (606.6)25.12 (638.1)

25.50 (647.7)25.50 (647.7)25.50 (647.7)

—25003200

16002000—

15.00 (381.0)16.00 (406.4)27.25 (692.2)

15.00 (381.0)16.00 (406.4)26.38 (670.1)

25.88 (657.4)27.62 (701.6)23.88 (606.6)

25.50 (647.7)25.50 (647.7)25.50 (647.7)

4000—5000

250032004000

28.50 (723.9)29.25 (793.0)31.00 (787.4)

27.62 (701.6)28.38 (720.9)30.12 (765.1)

25.12 (638.1)25.88 (637.4)27.62 (701.6)

25.50 (647.7)25.50 (647.7)25.50 (647.7)


Page 64


Single-Phase Transformer Tap

Figure 44. Single-Phase Transformer Tap

Table 11. Single-Phase Transformer TapAmpereRating

Minimum Dimensionsin Inches (mm)

Cu Al (X) (Y)

225 400 600

225 400—

4.00 (101.6) 4.00 (101.6) 4.00 (101.6)

7.00 (177.8) 7.00 (177.8) 7.00 (177.8)

80010001200

600— 800

4.00 (101.6) 4.50 (114.3) 5.00 (127.0)

— 9.75 (247.7)10.75 (273.1)

135016002000

100012001350

5.50 (139.7) 6.50 (165.1) 7.75 (196.9)

11.75 (298.5)13.75 (349.3)16.25 (412.8)

—25003200

16002000—

8.50 (215.9)10.25 (260.4) 6.50 (165.1)

17.50 (444.5)21.25 (539.8)13.75 (349.3)

4000—5000

250032004000

7.75 (196.9) 8.50 (215.9)10.25 (260.4)

16.25 (412.8)17.50 (444.5)21.25 (539.8)

POW-R-BRIDGE

8.50 + X(215.9) + X

POW-R-BRIDGE

LC

8.50 + X(215.9) + X

TAPS

17.00 + 2X(431.8) + 2X

C Phase or Neutral

8.50 + X(215.9) + X

8.50 + X(215.9) + X

17.00 + 2X(431.8) + 2X

8.50 + X(215.9) + X

8.50 + Y(215.9) + Y

GroundWhenRequired

LCLC

TAPSLC

POW-R-BRIDGELC

POW-R-BRIDGELCTAPSLC

T

F

C

B

A Phase or Neutral

B Phase or Neutral

T

F

A

C

G

T

F

B

A



Page 65

Three-Phase Transformer Tap

Figure 45. Three-Phase Transformer Tap

Table 12. Three-Phase Transformer Tap —Dimensions in Inches (mm)(A) Minimum Dimensions

Wire Designation

3W/3WH 3WG/3WHG/3WI

4W/4WH 4WG/4WHG/4WI/4WNG/4WNHG/4WNI

16.5 (419.1) 16.5 (419.1) 19.5 (495.3) 19.5 (495.3)

(B) Minimum Dimensions

Wire Designation

3W/3WH 3WG/3WHG/3WI

4W/4WH4WN/4WNH

4WG/4WHG/4WI/4WNG/4WNHG/4WNI

6.25 (158.8) 12.12 (307.8) 9.25 (235.0) 15.12 (384.0)

(C) Minimum Dimensions

Wire Designation

50% HousingGround

50% Internal Groundand 100% Ground

3.00 (76.2) 6.00 (152.4)

C

6.00(152.4)

A

L

Taps CLB

15.00(381.0)

Support Pad

6.00 (152.4) (1-Phase)7.50 (191.0) (2-Phase)

NC

BA

G

C

T

T

F


Page 66


Transformer Throat Connections

Figure 46. Transformer Throat Connections

1.75 (44.5) Plus1/2 (12.7) Duct Width

Sealing Ring

A

CL

TransformerThroat

Transformer

Transformer

9.50 (241.3)

Sealing Ring

Sealing Ring

Felt Gasket

Screw

Sealing Ring

Edge ofTransformerThroat

T

TransformerThroat

T

CL

A

Edge ofTransformerThroat



Page 67

Table 13. Transformer ThroatsAmpereRating

Bars perPhase

Minimum Dimensionsin Inches (mm)

(A)

Aluminum 225 – 13501600 – 20002500 – 4000

112

26.00 (660.4)28.50 (723.9)31.50 (800.1)

Copper 225 – 200025003200 – 5000

112

26.00 (660.4)28.50 (723.9)31.50 (800.1)


Page 68


Bus Plugs

Figure 47. Bus PlugsNote: The clamp and guide mechanism adds 2.50 inches (63.5 mm) to the overall length of the unit.

Clamp and Guide

ON

OFF

ON

E

DHandle C

A

F Plug-in Openingand B Phase

C

B

Guide Pin

LCLC

CLCLC

CLCLC



Page 69

Tabl

e 14

. Cir

cuit

Bre

aker

Plu

g-in

Uni

ts

1T

he

clam

p a

nd

gu

ide

mec

han

ism

ad

ds

2.50

inch

es (

63.5

mm

) to

th

e o

vera

ll le

ng

th o

f th

e u

nit

.

Plu

g-i

nU

nit

Maxim

um

Am

pere

sM

axim

um

ac V

olt

sD

imen

sio

ns in

In

ch

es (

mm

)M

ech

an

ical Term

inal

Wir

e R

an

ge P

er

Ph

ase (

mm

2)

Ap

pro

x.

Weig

ht

Lb

s. (k

g)

(A)

1(B

)(C

)(D

)(E

)(F

)

P3B

FD(E

- & F

-Fra

me

Bre

aker

s)22

560

019

.26

(489

)12

.36

(314

)5.

43(1

38)

6.25

(159

)4.

00(1

02)

6.05

(154

)10

0 A

— (1

) #14

– 1

/0 (2

.5 –

50)

150

A —

(1) #

4 –

4/0

(25

– 95

)25 (1

1.33

)

P3B

JD(J

-Fra

me

Bre

aker

s)25

060

021

.33

(542

)12

.36

(314

)6.

97(1

77)

10.4

4(2

65)

4.00

(102

)6.

06(1

54)

250

A —

(1) #

14 –

350

kcm

il (2

5 –

185)

225

A —

(1) 3

– 3

50 k

cmil

(35

– 18

5)47 (2

1.31

)

P3B

KD

(K-F

ram

e B

reak

ers)

400

600

32.5

0(8

26)

13.2

9(3

38)

7.79

(198

)12

.56

(319

)4.

00(1

02)

6.64

(169

)35

0 A

— (1

) 250

– 5

00 k

cmil

(120

– 2

40)

400

A —

(2) 3

/0 –

250

kcm

il (4

5 –

120)

53 (24.

04)

P3B

LD(L

-Fra

me

Bre

aker

s)60

060

044

.03

(111

8)19

.65

(499

)10

.15

(258

)17

.38

(441

)4.

00(1

02)

9.83

(250

)40

0 A

— (1

) 4/0

– 6

00 k

cmil

(120

– 3

00)

600

A —

(2) 4

00 –

500

kcm

il (1

85 –

240

)75 (3

4.01

)

P3B

MD

(M-F

ram

e B

reak

ers)

800

600

44.0

3(1

118)

19.6

5(4

99)

10.1

5(2

58)

17.3

8(4

41)

4.00

(102

)9.

83(2

50)

600

A —

(2) #

1 –

500

kcm

il (5

0 –

240)

800

A —

(2) 5

00 –

750

kcm

il (3

00 –

400

)13

6(6

1.68

)

P3B

ND

(N-F

ram

e B

reak

ers)

800

600

44.0

3(1

118)

19.6

5(4

99)

10.1

5(2

58)

17.3

8(4

41)

4.00

(102

)9.

83(2

50)

700

A —

(2) #

1 –

500

kcm

il (5

0 –

240)

800

A —

(3) 3

/0 –

400

kcm

il (9

5 –

185)

138

(62.

59)

P3B

LAP

(TR

I-PA

C)

400

600

44.0

3(1

118)

19.6

5(4

99)

10.1

5(2

58)

13.8

0(3

57)

4.00

(102

)9.

83(2

50)

225

A —

(1) #

6 –

350

kcm

il (1

6 –

185)

400

A —

(1) #

4 –

250

kcm

il an

d (1

) 3/0

–60

0 kc

mil

(25

– 12

0 an

d 9

5 –

300)

96 (43.

54)

P3B

LCl

400

600

40.0

0(1

016)

19.6

5(4

99)

10.1

5(2

58)

13.8

0(3

51)

4.00

(102

)9.

83(2

50)

(1) #

4 –

250

kcm

il (2

5 –

120)

an

d(1

) 3/0

– 6

00 k

cmil

(95

– 30

0)88 (3

9.91

)


Page 70


Tabl

e 15

. Fus

ible

Plu

g-in

Uni

ts

1T

he

clam

p a

nd

gu

ide

mec

han

ism

ad

ds

2.50

inch

es (

63.5

mm

) to

th

e o

vera

ll le

ng

th o

f th

e u

nit

.

Plu

g-i

nU

nit

Maxim

um

Am

pere

sM

axim

um

ac V

olt

sD

imen

sio

ns in

In

ch

es (

mm

)M

ech

an

ical Term

inal

Wir

e R

an

ge P

er

Ph

ase (

mm

2)

Ap

pro

x. W

eig

ht

Lb

s. (k

g)

(A)

1(B

)(C

)(D

)(E

)(F

)

P3F

321R

an

dP

3F36

1R30

240

20.8

5(5

29.6

)12

.36

(313

.9)

5.4

3(1

37.9

) 7

.88

(200

.2)

4.00

(101

.6)

6.0

6(1

53.9

)C

u —

(1) #

14 –

#3

(2.5

– 3

5)A

l — (1

) #12

– #

2 (3

.2 –

35)

22

(9.9

8)60

0

P3F

322R

an

dP

3F36

2R60

240

20.8

5(5

29.6

)12

.36

(313

.9)

5.4

3(1

37.9

) 7

.88

(200

.2)

4.00

(101

.6)

6.0

6(1

53.9

)

Cu

— (1

) #14

– #

3 1/

0 (2

.5 –

35)

Al —

(1) #

12 –

#2

(3.2

– 3

8) 2

4 (1

0.88

)60

0C

u —

(1) #

14 –

1/0

(2.5

– 5

0)A

l — (1

) #12

– 1

/0 (3

.2 –

50)

P3F

323R

an

dP

3F36

3R10

024

020

.85

(529

.6)

12.3

6(3

13.9

) 5

.43

(137

.9)

7.8

8(2

00.2

)4.

00(1

01.6

) 6

.06

(153

.9)

Cu

— (1

) #14

– 1

/0, (

2.5

– 5.

0)A

l — (1

) #12

– 1

/0 (3

.2 –

50)

24

(10.

88)

600

(1) #

4 –

250

kcm

il C

u/A

l (25

– 1

20)

P3F

324R

an

dP

3F36

4R20

024

021

.75

(552

.5)

15.5

7(3

95.5

) 9

.66

(245

.4)

8.2

0(2

08.3

)4.

00(1

01.6

) 7

.63

(193

.8)

(1) #

4 –

250

kcm

il C

u/A

l (25

– 1

20)

47

(21.

31)

(1) #

4 –

600

kcm

il C

u/A

l (25

– 3

00)

or

(2) 2

50 k

cmil

(120

)60

0

P3F

325R

an

dP

3F36

5R40

024

060

046

.94

(119

2.3)

21.2

2(5

39.0

)10

.07

(255

.8)

12.6

7(3

21.8

)4.

00(1

01.6

)10

.69

(271

.5)

(2) #

2 –

600

kcm

il C

u/A

l (35

– 3

00)

77

(34.

74)

P3F

365H

400

600

23.4

7(5

96.1

)21

.22

(539

.0)

21.0

0(5

33.4

)12

.67

(321

.8)

4.00

(101

.6)

10.6

9(2

71.5

)(2

) #2

– 60

0 kc

mil

Cu

/Al (

35 –

300

) 8

1 (3

6.74

)

P3F

326R

an

dP

3F36

6R60

024

046

.94

(119

2.3)

26.3

1(6

68.3

)10

.59

(270

.0)

14.2

6(3

62.2

)4.

00(1

01.6

)13

.16

(334

.3)

(2) #

2 –

600

kcm

il C

u/A

l (35

– 3

00)

82

(37.

19)

600

(3) #

4 –

600

kcm

il (2

5 –

300)

P3F

327R

an

dP

3F36

7R80

024

046

.94

(119

2.3)

26.3

1(6

68.3

)10

.59

(270

.0)

14.2

6(3

62.2

)4.

00(1

01.6

)13

.16

(334

.3)

(3) #

4 –

600

kcm

il C

u/ A

l (25

– 3

00)

108

(48.

98)

600



Page 71

NEMA is the registered trademark and service mark of the National Electrical Manufacturers Association. UL is a federally registered trademark of Underwriters Laboratories Inc.


Page 72




Eaton Corporation is a global $7.3 billion

diversified industrial manufacturer that is

a leader in fluid power systems; electrical

power quality, distribution and control;

automotive engine air management and

fuel economy; and intelligent truck systems

for fuel economy and safety. Eaton has 48,000

employees and sells products in more than

50 countries. For more information, visit

www.eaton.com.

Eaton CorporationCutler-Hammer business unit1000 Cherrington ParkwayMoon Township, PA 15108-4312USAtel: 1-800-525-2000www.cutler-hammer.eaton.com

© 2002 Eaton CorporationAll Rights ReservedPrinted in USAPublication No. IM01701002EDecember 2002

ABC_frontandback_covers.fm Page 2 Monday, December 16, 2002 6:36 PM

Documents

The ABCs of Planning and Installing Bus Duct