pow-r-way iiit low voltage busway · eaton corporation pow-r-way iii low voltage busway 5 inside of...

Pow-R-Way IIIT Low Voltage Busway

Product Focus

Pow-R-Way III Offers a Full Line of

Low Voltage Busway to Meet the

Needs of a Global Marketplace

Product Offerings

Plug-in Busway

• 225 to 5000 amperes copper.

• 225 to 4000 amperes aluminum.

• Straight sections of plug-inbusway are available in 24-inch (609.6 mm) incrementallengths from a 2-foot (.6 m)minimum to a 10-foot (3.0m) maximum. Sprinkler-proofplug-in busway is an avail-able option.

Feeder Busway

• 225 to 5000 amperes copper.

• 225 to 4000 amperes aluminum.

• Straight sections of indoorand outdoor feeder buswayare available in any length in1/8-inch (3.2 mm) incre-ments from a 16-inch (406.4mm) minimum to a 10-foot(3.0 m) maximum. A widerange of fittings are availablefor indoor and outdoor feeder busway.

Plug-in Units

• A full family of busway plug-in units is available. Standardplug-in units include fusibleor circuit breaker protection.Advanced plug-in units

include TVSS surge suppres-sion, and communicating IQEnergy SentinelsE,OPTIME circuit breakers,and AdvantageE combina-tion contactors and starters.

Product Features and Benefits

• The aluminum two-piecehousing provides durabilityand product integrity.

• The lightweight and com-pact design provides foreasy installation.

• The housing is combinedwith a true sandwich designin both plug-in and feederbusway, contributing to improved coordination andhigh short circuit ratings.

• An epoxy insulation process ensures optimum conductorand system protection.

• Silver-plated joint and con-tact surfaces provide high-quality connections.

• Highly automated manufac-turing processes result in asuperior product withreduced cycle times.

• The Pow-R-Bridge jointpackage and torque-indicat-ing bolt gives a rugged, yetflexible and easy-to-install,connection.

2 EATON CORPORATION Pow-R-Way III Low Voltage Busway

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1. Pow-R-Way III Installation

Pow-R-Way III provides a busway systemthat can be utilized over a broad spectrum ofindustrial, commercial and institutional appli-cations worldwide. A typical example is thisinstalled run of 1600 ampere aluminum plug-in busway.

Pow-R-Way IIILow VoltageBusway

Eaton’s electrical business has combined the require-ments of NEMAT, ULT and CSAT into one design — the Cutler-HammerT Pow-R-Way III busway system. It can be utilized over a broad spectrum of industrial,commercial and institutional applications worldwide.Standard features include a two-piece all-aluminumhousing, finger-safe plug-in outlets, an integralground path, and the highest 6-cycle short circuitwithstand ratings available in the industry today.

• The Eaton Final Field Fit program ensures accuratelayout and allows for minorlast-minute modificationsduring installation.

• Advanced system toolsincluding Bid ManagerE,ProDesignE, and AutoCADdrawings, provide quick andaccurate information.

Product Support

Busway product and applicationsupport is available from a professional team of Eatonemployees that include fieldsales engineers, applicationengineers, engineering services and systems, and the Greenwood busway product engineers.

Additional Pow-R-WayIII Information

• Technical DataTD01701001E

• Distribution EquipmentCatalog CA08101001E

Superior HousingDesign

Pow-R-Way III is constructedwith a lightweight and rugged,two-piece, all-aluminum extrud-ed housing. The nonventilated

• Corner joint elbows contribute to successful layouts and minimize space limitations.

• High 6-cycle short circuit ratings optimize coordinationbetween busway and power equipment.

• This world-class productdesign and manufacturingmeets requirements ofNEMA, UL, CSA and ISOT.

• Flexible ground and neutral options provide solutions forany application problem.

• A full family of plug-in units is available for everypower need.

• Advanced bus plugs provideprotection, communicationand coordination capabilities.

Busway Capabilities

• Plug-in units are available forimmediate shipment inselect ampere ratings andsystem configurations.

• The busway manufacturingplant in Greenwood, SC, isable to meet your emer-gency or quick ship lead-times from one day to two weeks.

• Customer approval drawingscan be available in twoweeks or less to meet yourproject requirements.

EATON CORPORATION Pow-R-Way III Low Voltage Busway 3

housing design excludes potential points of entry bymoisture or dust. There are noseams or welds across the topor bottom of the housing. Thereare no fastening bolts orscrews that penetrate the housing to enter the bus bars.The two-piece housing is boltedtogether along the bottomsides only, below the bus barswith high tensile strength, zinc-plated hardware. This design forms a tight,secure housing with a highdegree of rigidity and bracing.The nonmagnetic aluminumhousing provides for excellentheat dissipation and a signifi-cant reduction in reactance andmagnetic flux leakage as com-pared to a steel, or steel andaluminum combination housing.With this housing design, Pow-R-Way III achieves a minimum6-cycle short circuit rating of 85kA for 225 to 600 amperebusway, and a maximum of 200kA for 3000 to 5000 amperebusway (plug-in or feeder).

True Sandwich Design

Bus bars for plug-in applicationshave full-sized conductor tabswelded to their side edges to form the plug-in contact surfaces. The tabs are of thesame exact thickness as the

conductor bars and are weldedin place by a fully automated,state-of-the-art weldingprocess. This process also mills and cleans the weldedsurface to ensure a smooth and uniform contact surface. This design extends the contactsurfaces outside of the buswayhousing and into the plug-inoutlet. This eliminates the needto separate or flare the bars inorder to create contact pointsfor the stab assemblies of plug-in devices. This enables Pow-R-Way III plug-in busway to bebuilt with the same seamlesshousing as feeder busway. Thebenefits of maintaining thesandwich design through plug-in and feeder are improved heatdissipation and improved brac-ing. The high short circuit with-stand ratings of feeder bus cannow be equaled by plug-inbusway. This results in com-plete coordination on bus runsthat utilize a mix of plug-in andfeeder busway.Maintaining a true sandwichdesign also eliminates potentialpathways for the propagation offlame, smoke or gas throughthe busway housing which ismore commonly referred to asthe “chimney effect.”

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2. Housing Process

The extruded aluminum housing channels arecut to size by an automated process.

3. Housing Features

Potential points of entry for moisture anddust are eliminated from the Pow-R-Way IIIdesign. There are no seams, spot welds or penetrations through the housing top or bottom.

4. Welding Process

Full-sized conductor tabs are welded to theside edges of plug-in bus bars by a state-of-the-art welding process.

5. Plug-In Outlet

The plug-in contact surfaces of Pow-R-WayIII extend into the outlet, allowing for a con-tinuous sandwich design to be maintainedthrough plug-in and feeder busway.

With the release of a retainerscrew, the Pow-R-Bridge canprovide an adjustment in sec-tion length of up to ±0.5 inch(12.7 mm) at each joint. Overadjustment is preventedby the joint covers, which willonly allow the ±0.5 inch (12.7mm) maximum adjustment, and by stopping lances on theconductor bars of the Pow-R-Bridge. Due to a single bolt nonrotatingdesign, the Pow-R-Bridge maintains its configurationintegrity when it is removedfrom a section of busway. The conductor plates and insulators do not displace orswivel, making reinstallationquick and easy.The insulators of the Pow-R-Bridge are made of highstrength, molded glass polyester and they are rated as Class B, 130ºC, insulating material.Joint connections for outdoorfeeder busway are made with a completely weatherized version of the Pow-R-Bridge.Aluminum water barriers are provided across the top andbottom sides of both joint endson each section of outdoorbusway. Closed cell, neoprenegaskets are applied to the top of each water barrier and to the

Epoxy InsulationProvides ExceptionalPerformance

Bus bars are fabricated fromhigh strength, 98% conductivitycopper or 55% conductivity aluminum. The phase and neutral bars are insulated withClass B, 130ºC, epoxy insulationapplied by an automated fluidized bed process. This application insulates the conduc-tors in a precisely defined andcontrolled manner to ensure asmooth, continuous and uniform thickness.The bus bars undergo a seriesof pretreatment processes toclean them, which enhances the bonding of the epoxy powder. The pretreatment stage also helps to prevent anycontamination of the powder.After pretreatment, the bars are submerged in a two-stationwater bath to remove the chemicals used in the pretreat-ment process. After the cleaning is complete, the busbars are preheated uniformly inan air-circulating oven to enablethe epoxy powder to melt andfuse to the bus bar. The epoxy powder is appliedover the full length of the pre-heated bar except for the jointand contact surfaces. After the

The Pow-R-BridgePackage

Pow-R-Way III joint connectionsare made with the rugged Pow-R-Bridge joint package. A Pow-R-Bridge is installed oneach section of busway prior to shipment. Torque-indicatingbolts of a double-headed designare provided as standard toensure that proper installationtorque is achieved. A standardwrench or socket with a 14-inch (355.6 mm) minimumhandle should be used to complete the joint connectionbetween two sections. Fall-away instruction tags are also furnished on thetorque-indicating bolts to allow for visual inspection from a distance. Torque should be applied to theouter bolt head only. As theproper value is achieved, thatbolt head will shear off andallow the instruction tag to fallto the floor. Any Pow-R-Bridgethat is improperly torqued willretain the highly visible cautionyellow tag and should beretightened. The inner bolt headremains intact for future workand a label with the propertorque information is providedon the Pow-R-Bridge.


epoxy is allowed to gel andfuse to the bus bars, they entera cure oven. This ensures thatall the epoxy cross links andhardens to the bars. The consistent thickness and smooth surface of theepoxy provides a high-qualityinsulation with a 50-year lifecycle. The fluidized bed processalso provides excellent edgecoverage to the bars. Epoxyprovides optimum resistance to water absorption and chemi-cal erosion. It has excellentdielectric strength, is flameretardant, and resists impactsthat other Class B insulatingmaterial cannot withstand.Epoxy has outstanding heattransfer characteristics and isideally suited for sandwich bus applications.

Highly Durable Silver Plating

Silver-plating is applied to alljoint and contact surfaces.Aluminum bars are silver-platedby the ALSTAN 88C process.Copper bars are silver-plated bya flashing process. Silver-platingprovides an extremely durablecontact surface for the spring-loaded connections of plug-in device stab assemblies.


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1. Epoxy Process

The preheated copper bars are shown priorto immersion in the epoxy powder.

2. Insulation

All phase and neutral bars receive a coatingof Class B, 130ºC, epoxy insulation appliedby a fluidized bed process. The copper feederbars are shown being withdrawn from thebed and sent to a cure oven.

3. Plating Process

Feeder bus bars are loaded onto racks prior to beginning the ALSTAN 88C silver-plating process.


inside of the aluminum side-access joint covers. The gas-kets are manufactured as a single-piece design to obtainmaximum water resistance. The aluminum top and bottomaccess covers bolt directly tothe water barriers and are over-lapped by the side-access jointcovers to form a water-resistantenclosure around the joint.The outdoor Pow-R-Bridge hasthe same 0.5 inch (12.7 mm)adjustability and features as theindoor unit, and is UL listed.

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4. Pow-R-Bridge

The robust Pow-R-Bridge joint package pro-vides a solid and safe connection along with1-inch (25.4 mm) adjustability in sectionlength at each joint. The photo shows thePow-R-Bridge in 2000 ampere (foreground),2500 ampere (center) and 5000 ampere cop-per configurations.

5. Joint Installation

The photo is of a 3000 ampere copper Pow-R-Bridge connecting two short sections offeeder busway. (Shown with the top-, bot-tom- and side-access covers removed.)

6. Joint Orientation

A 1200 ampere copper Pow-R-Bridge withjoint covers removed, showing the properorientation of the double-headed, torque-indicating bolt (bottom) and the heavy-dutycaptive nut retainer (top). The fall-away taghas been removed in this picture.

A Space-SavingInnovation…TheCorner Joint Elbow

When it comes to bends andturns in a bus run, specifiersoften face serious limitations.The leg length of a traditional90-degree elbow is limited bythe amount of space needed to weld or bend bus bars, toprovide an enclosure around the bars, and to create a con-nection to the adjacent section.In most applications, especially

in the higher ampere ratings, asignificant amount of area maybe required. Given the complexity of today’sindustrial and commercial distri-bution systems and the need tocoordinate layouts with HVAC,plumbing and lighting require-ments, space quickly becomes a critical factor. The Pow-R-Way III corner jointelbow can be installed in areaswhere a traditional 90-degreeturn could never have beenaccomplished before.

With a leg length of 4.71 inches(119.6 mm) for an upward or4.35 inches (110.5 mm) for adownward elbow, the cornerjoint can solve any serious path-way problem and contribute tosuccessful layouts with minimalspace requirements. The corner joint is as reliable as it is original. It is seismic certified and exceeds therequirements of both theUniform Building Code (UBCT)and California Building Code(CBC) (Zone 4). The corner joint is also UL listed for indoor applications. Due to its compact design, the corner joint also allows for

layouts that provide optimumutilization of space. Critical section length that would nor-mally be required for a tradition-al elbow leg length can now bededicated to maximizing usableplug-in section length.

High 6-Cycle and 1-Second Short CircuitWithstand Ratings

Pow-R-Way III offers the high-est 6-cycle short circuit ratingsin the industry. Six-cycle ratingsexceed NEMA and UL 3-cycle requirements, and ensure maximum withstand capability.



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1. Corner Joint Elbow

The minimum leg lengths of the corner jointallow for optimum utilization of the plug-insection length. The picture above shows a2000 ampere forward corner joint connect-ing two sections of plug-in busway.

2. Torque-Indicating Bolts

The Pow-R-Bridge and corner joint elbowsare provided with torque-indicating bolts asstandard. The only tool that is required tocomplete a connection properly is a stan-dard wrench or socket with a 14-inch (355.6mm) minimum handle.

3. Fall-Away Tags

Fall-away instruction tags are furnished on the torque-indicating bolts to allow for visual inspection from a distance. Any Pow-R-Bridge or corner joint that is improperlytorqued will retain the highly visible tag.

4. Corner Joints

The exclusive Pow-R-Way III corner jointelbow can solve any difficult pathway prob-lem with leg lengths as small as 4.71 inches(119.6 mm) for an upward or 4.35 inches(110.5 mm) for a downward elbow. The cor-ner joint is provided with torque-indicatingbolts, fall-away instruction tags, and theheavy-duty captive nut retainer. The photo-graph depicts a 1000 ampere (front fore-ground), two 2500 ampere (foreground), a 5000 ampere upward (center background)and two 5000 ampere forward.

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CORNER JOINT ELBOW LEG LENGTHS

Ampere Rating Forward Backward Upward Downward (X) (Y) (X) (Y) Cu Al Inches mm Inches mm Inches mm Inches mm

225 225 0.94 23.9 5.38 136.7 4.71 119.6 4.35 110.5400 400 0.94 23.9 5.38 136.7 4.71 119.6 4.35 110.5600 – 0.94 23.9 5.38 136.7 4.71 119.6 4.35 110.5800 600 0.94 23.9 5.38 136.7 4.71 119.6 4.35 110.51000 – 1.25 31.8 5.69 144.5 4.71 119.6 4.35 110.51200 800 1.50 38.1 5.94 150.9 4.71 119.6 4.35 110.51350 1000 1.75 44.5 6.19 157.2 4.71 119.6 4.35 110.51600 1200 2.25 57.2 6.69 169.9 4.71 119.6 4.35 110.52000 1350 2.88 73.2 7.31 185.7 4.71 119.6 4.35 110.5– 1600 3.25 82.6 7.70 195.6 4.71 119.6 4.35 110.52500 2000 4.12 104.6 8.57 217.7 4.71 119.6 4.35 110.53200 – 6.64 168.7 11.07 281.2 4.71 119.6 4.35 110.54000 2500 7.89 200.4 12.32 312.9 4.71 119.6 4.35 110.5– 3200 8.65 219.7 13.08 332.2 4.71 119.6 4.35 110.55000 4000 10.42 264.7 14.85 377.2 4.71 119.6 4.35 110.5

The 6-cycle ratings allow forsafer coordination withswitchgear having 4-cycle ratedbus system. All ampere ratingsof Pow-R-Way III have beentested to 6-cycle standards andhave achieved a minimum rat-ing of 85 kA rms symmetricaland a maximum rating of 200kA rms symmetrical (see shortcircuit rating table). Pow-R-Way III provides optimum coordination in a distribution system as the short circuit ratings of plug-inare equal to the ratings ofindoor and outdoor feederbusway. The integrity andstrength of the two-pieceextruded aluminum housingdesign ensures specifiers andusers of a safe and durableinstallation for industrial, commercial and institutionalapplications.Pow-R-Way III meets therequirements of NEMA, UL857, CSA C22.2 No. 27-94, and ANSI. The design is alsoavailable as an outdoor feeder,indoor feeder (for use withindoor sprinkler-proof applica-tions), indoor plug-in, and in an indoor sprinkler-proof configuration for both plug-in and feeder. All four types of busway can be used interchangeably without the use of adapters


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5. Pow-R-Way III Busway

Pow-R-Way III offers the highest 6-cycleshort circuit withstand ratings available inthe industry today. It is available in outdoorand indoor feeder configurations, indoorplug-in, and indoor sprinkler-proof design forboth feeder and plug-in.

or special splice plates, provid-ed they are of the same currentand system rating. Pow-R-WayIII is also certified for seismicwithstand capability in accor-dance with the earthquakerequirements as specified inboth the UBC and the CBC. The seismic capability of Pow-R-Way III exceeds theZone 4 requirements.Pow-R-Way III is available in rat-ings from 225 to 4000 amperesaluminum and from 225 to5000 amperes copper in bothplug-in and feeder designs.

SHORT CIRCUIT WITHSTAND AND RATINGS RMS SYMMETRICAL AMPERES FOR PLUG-IN AND FEEDER BUSWAY

Ampere Rating 6-Cycle Cu Al 225 85,000 85,000400 85,000 85,000600 85,000 85,000800 85,000 100,0001000 100,000 100,0001200 100,000 125,0001350 100,000 150,0001600 125,000 150,0002000 150,000 150,0002500 150,000 200,0003200 200,000 200,0004000 200,000 200,0005000 200,000 –


A “Safety-First” Plug-inBusway Design

All Pow-R-Way III plug-inbusway and plug-in devices aredesigned with the safety of theinstaller and user as a key criteria. Plug-in outlets protectagainst accidental contact with live parts by an operator by not allowing a 0.47-inch (12 mm) or larger probe to enter the plug-in outlet.The bus plug ground stabmakes a positive connectionwith the busway ground (inte-gral or internal) before the phase or neutral stabs contactthe bus bars.As a countermeasure to theeffects of thermal expansionand mechanical vibration, theplug-in outlet is secured to thebusway housing with high-ten-sile strength locking hardware. A bus plug alignment port isprovided in the busway housingto facilitate unit alignment andprevent a bus plug from beinginstalled 180 degrees out ofrotation. A polarizing alignmentpin is attached to the line side end of each bus plug enclosure. The alignment pinmust be inserted into the portfor proper installation. The alignment pin and port pro-vide polarization and ensure

positive positioning of the plug-in stabs onto the bus bars.The plug-in outlet and cover are made from a durable, high strength, polycarbonatematerial which is rated as Class B, 130ºC, insulation. The outlet cover is designed toprevent the entry of dirt, dustand moisture into the buswayhousing. To limit access byunauthorized personnel, thecover has a standard positivescrew close feature that pro-hibits the opening of the coverwithout the use of a tool. Thecover can also be sealed with autility “lead lock.” Both the out-let and cover have an ultravioletinhibitor in their composition toensure long life.

Pow-R-Way III Offers Grounding Options toMeet Every CustomerPreference and Need

The two-piece extruded alu-minum housing is UL listed as a 50% integral ground path(integral earth) and is fully faultrated. The system ground continuity is maintained througheach joint by ground path collector blocks, ground pathpressure plates (both are furnished at each end of a section), and the aluminum joint

covers. The joint covers areprovided with ground path contact surfaces on the insideof each end. When the coversare installed, the contact sur-faces are bolted directly to theground path collector blockswith four 3/8-inch hex bolts per cover. The ground path pressureplates contribute to systemground continuity by makingpositive contact with the Pow-R-Bridge. This contact is maxi-mized and maintained when the torque-indicating bolt heads of the Pow-R-Bridge aresheared off during installation.A highly visible label will be furnished on each joint cover to alert the installer that thecovers must be properlyinstalled in order to maintainthe ground path. The result is a50% ground path that ensuresground continuity with very lowresistance characteristics.If the customer prefers a tradi-tional 50% internal ground bus,it can be provided as an optionwith the Pow-R-Way III design.

Pow-R-Way IIIProvides Solutions toSpecific Problems thatare Inherent in Today’sElectrical DistributionSystems

100% Ground Option

In certain industrial applications,a ground path greater than 50%may be required. In the past, aspecifier would have to over-rate the busway in order toobtain a 75% or 100% groundpath. In many applications, thisproves to be cost-prohibitive as


1Ground Alignment Port

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1. Plug-In Outlet

Barriers are provided across the openings of the Pow-R-Way III plug-in outlet to protect an operator or installer against accidental contact with a “live” part. A busplug alignment port (to the top right of theoutlet) is furnished in the busway housingas a positive mechanical guide to facilitateunit alignment and prevent the installationof a bus plug 180 degrees out of rotation.The ground (top right) makes a positive connection before the conductor stabs contact the bus bars.

2. Integral Ground

The two-piece extruded aluminum housingof Pow-R-Way III is UL listed for use as a50% integral ground path (integral earth).The system ground continuity is maintainedthrough each joint by the ground path col-lector blocks, ground path pressure plates,and the aluminum joint covers. This providesa ground path that ensures continuity andhas very low resistance characteristics.

RESISTANCE VALUES FOR PLUG-IN ORFEEDER BUSWAY WITH INTEGRAL HOUSING GROUND(Milliohms per 100 feet or 30.5 m)

Ampere Rating Phase Bars Al Cu 225 4.38 2.30400 4.38 2.30600 4.38 2.30800 2.67 2.301000 2.29 1.671200 1.76 1.391350 1.39 1.201600 1.25 0.942000 1.01 0.762500 0.71 0.553200 0.62 0.474000 0.50 0.385000 – 0.27


the ampere rating of thebusway would have to be doubled in order to achieve a100% ground path. Pow-R-WayIII can solve this problem in acost-efficient manner by provid-ing a fully rated 100% groundpath by combining the 50%integral housing ground with a50% internal ground busoption. The two ground pathsare mechanically and electricallytied together at the terminationpoints and at the plug-in outletto deliver a 100% groundedsystem without the need forcostly overrating.

Isolated Ground Option

To meet the growing demandfor grounding isolation, Pow-R-Way III offers a 50% isolatedground bus. The ground bus is insulated with the sameClass B, 130ºC, epoxy as thephase and neutral bars. Thisoption is available for facilitieswith large amounts of micro-processor-based loads. The isolated ground option is alsobeneficial when busway is usedto feed a portion of a facilitythat houses large banks of personal computers.

200% Neutral Option

Power system harmonics aregenerated by various types ofnonlinear loads. Examples of

nonlinear loads are personalcomputers, UPS systems, variable frequency motor controllers, electronic lightingballasts, medical test equip-ment, and many other micro-processor-based apparatuses.On 208 volt wye systems, certain nonlinear loads causeodd triplen harmonics which are additive and will not canceleach other in the neutral. Theneutral current can be as highas 1.73 times the phase current. This can lead to a deterioration of equipment performance and a shortenedlife cycle. Pow-R-Way III offersa solution to this problem witha fully rated 200% neutral busoption. The additional neutralcapacity prevents the overheat-ing caused by high harmonicneutral currents.

3. Neutral Options

The Pow-R-Way III 200% neutral option isunique in that Eaton is the only manufactur-er that provides this option with a fullyrated 1/2-inch (12.7 mm) thick neutral bar.The additional neutral capacity prevents theoverheating caused by high harmonic neu-tral currents. This photograph also shows aninternal aluminum ground bus option (shownwith ground path pressure plates removed).

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4 4. Bus Plugs

Bus plug enclosures feature added wiring space, a line side barrier, and extended ground and neutral terminations to increase installation efficiency and safety. Pictured is a 100 ampere circuit breaker bus plug.

Internal Ground Option

200% Neutral Option


customer personal computer, to collect the information.

TVSS Bus Plugs

Transient Voltage SurgeSuppression (TVSS) is availablefor Pow-R-Way III bus plugswith the Cutler-Hammer Clipper Power System familyof products. The Clipper PowerSystem not only protectsagainst externally-created highenergy transients, such as lightning, but also providesneeded protection against internal transients. Sources ofinternally-generated transientsare arc welders, adjustable frequency controllers, and theswitching on and off of electri-cal distribution equipment. It isestimated that over 80% ofsurge disturbances are actuallycaused by internal transients.The Clipper Power Systemcombines Metal Oxide Varistors (MOVs) for suppres-sion and filtering capacitors toeliminate electrical line noiseand ringing transients.Other Cutler-Hammer productswith communication and/orcoordination capabilities thathave been incorporated intobus plug designs includeAdvantage motor control and DigitripE OPTIM trip unit system.

Enhanced Bus Plug DesignFacilitates Installation andImproves Safety

Pow-R-Way III plug-in protectivedevices are available from 30 to800 amperes in circuit breakerand fusible switch designs. The standard features of both types include:• Oversized Enclosures

Ample wiring space is provided in Pow-R-Way IIIbus plug enclosures, asmany sizes exceed theNEMA requirements for wire bending.

• Extended Ground andNeutral BarsPow-R-Way III bus plugshave extended ground andneutral bars which place the terminals down into the cable entry area makingfor a safer, easier connec-tion. Installers will haveample space to make these terminations.

• Line Side Barriers A barrier is provided over theline side connections of thebus plug stab assembly tothe protective device to pre-vent accidental contact witha live part.

• Bus Plug Alignment PinA bus plug guide port is pro-vided in the busway housingand a polarizing alignment

the plug-in outlet during instal-lation. As the installer tightensthe clamp and guide assem-blies, the stab base is drawnin to overlap the seating ridgeand form a tight seal againstmoisture and dust.

IQ Energy Sentinel™

The Pow-R-Way III family ofbus plugs includes the IQEnergy Sentinel, a UL listedmicroprocessor-based subme-tering device capable of communicating energy usageand demand values over theCutler-Hammer PowerNetEpower monitoring network. This innovative device offers a centralized alternative to individually mountedwattmeters, watthour meters,and watt demand meters. Application examples for the IQ Energy Sentinel bus pluginclude energy monitoring and demand management,energy cost analysis, energyallocation, and tenant or interdepartmental billing. To install the communicationsystem, the customer mustonly provide a twisted pair com-munication cable (run through1/2-inch, 12.7 mm, conduit)connecting the IQ EnergySentinel to a Cutler-HammerCentral Energy Display, or a

1. Alignment Pin

The bus plug alignment pin prevents theinstallation of a plug-in device 180 degreesout of rotation. It also serves as a guide toease installation. The clamp and guides drawthe bus plug tight onto the busway housingas the installer tightens the clamps.

2. Plug Stabs

Rear view of a bus plug showing ground andphase plug-in stabs.

pin is welded to the lineside end of each bus plugenclosure. The alignmentpin must be inserted intothe port for proper installa-tion. This prevents a busplug from being installed180 degrees out of rotation.

• Clamp and GuidesThe clamping mechanismwill draw the unit tight ontothe busway housing as theinstaller tightens the clamps.

• Busway InterlockThe plug-in unit and the bus-way are interlocked to ensurethat the device is in the OFFposition prior to the installa-tion or removal of the unit.

• Dual Purpose InterlockPlug-in units have a dualpurpose interlock which pre-vents the cover from beingopened while the device isin the ON position, and toprevent accidental closing of the device when thecover is open.

• Two-Position HandleBus plugs are shipped withthe handle mounted on theside as standard. The handlecan be quickly relocated to the line side end for horizontal runs in the field.

• Outlet Seating RidgeThe bus plug stab baseengages a seating ridge on

3. IQ Energy Sentinel

The IQ Energy Sentinel is capable of meter-ing and communicating energy usage anddemand values over the PowerNet powermonitoring network or directly to a customerPC for energy monitoring, demand manage-ment, and tenant billing. The IQ EnergySentinel is shown installed on the load side of the 100 ampere circuit breaker.


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Alignment Pin Guide Port

4. TVSS Bus Plug

Pow-R-Way III offers TVSS for buswayapplications with the Clipper Power System.The Clipper bus plug is available in eightdifferent ratings which provide protectionagainst externally created and internallygenerated impulse transients and electricalline noise.

A Complete Line ofFittings for Indoor andOutdoor Applications

Pow-R-Way III offers an exten-sive range of fittings to meetevery application need. Flanges,elbows, end cable tap boxes,and end closures are some ofthe basic fittings that are includ-ed in the Pow-R-Way III design. For more complex layouts,combination elbows and offsetscan be utilized along with trans-former throats, weather-heads,power takeoff sections, reduc-ers, expansion joints, vaultflanges, flush switchboardflanges, crosses and tees.For more detailed informationon Pow-R-Way III, consultTechnical Data TD01701001E.This publication includes allminimum dimensions, weights,application tables, protectivedevice selection charts, a typi-cal Pow-R-Way III specification,and all the technical datarequired for accurate and suc-cessful layout design. Contact your local Eaton salesoffice to make arrangementsfor a Pow-R-Way III capabilitiespresentation at your facility or for assistance with any applica-tion questions you might have.

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5. Elbow

A traditional elbow is available for outdoorapplications and for situations that requirelonger leg lengths than the corner joint.

9. Assembly Process

Straight sections of plug-in and feederbusway are assembled by a fully automated final assembly process. Pow-R-Way III is manufactured at the Eaton plant in Greenwood, SC, an ISO 9002 certified facility.


6. Tee

An upward tee.

7. Flange

A 3000 ampere, 3-wire switchboard flange.

8. Tap Box

A 1200 ampere end cable tap box.

© 2004 Eaton CorporationAll Rights ReservedPrinted in USAPublication No. BR01701001E / Z2934December 2004

Eaton Electrical Inc.1000 Cherrington ParkwayMoon Township, PA 15108United Statestel: 1-800-525-2000www.EatonElectrical.com

Eaton’s electrical business is a global leader in electrical control, power distribution, and industrial automation products and services. Through advanced product development, world-class manufacturing methods, and global engineering services and support, Eaton’s electrical business provides customer-driven solutions under brand names such as Cutler-HammerT, PowerwareT, DurantT, HeinemannT, HolecT and MEMT, which globally serve the changing needs of the industrial, utility, light commercial, residential, and OEM markets. For more information, visit www.EatonElectrical.com.

Eaton Corporation is a diversified industrial manufacturer with 2003 sales of $8.1 billion. Eaton is a global leader in fluid power systems and services for industrial, mobile and aircraft equip-ment; electrical systems and components for power quality, distribution and control; automotive engine air management systems and powertrain controls for fuel economy; and intelli-gent drivetrain systems for fuel economy and safety in trucks. Eaton has 55,000 employees and sells products to customers in more than 100 countries. For more information, visit www.eaton.com.

NEMA is the registered trademark and service mark of the National ElectricalManufacturers Association. UL is a federallyregistered trademark of UnderwritersLaboratories Inc. CSA is a registered trademark of the Canadian StandardsAssociation. Cutler-Hammer is a federally registered trademark of Eaton Corporation.ISO is the registered trademark and soleproperty of the International Organization forStandardization. Uniform Building Code (UBC)is a trademark of the International Conferenceof Building Officials (ICBO).

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