the abcs of planning and installing bus duct
TRANSCRIPT
The ABCsof Planningand InstallingPow-R-Way IIIBus Duct
Instruction Manual
Supersedes File 30-500,pages 1 – 72 dated 1974
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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
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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.
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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
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Figure 1. Enlarged Plan View of Switchboard Room
Figure 2. Basic Site Dimensions — Required Before Starting PRW
III
Busway Layout
?
?
Switchboard
Front
?
?
?
?
?
?
?
?
?
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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
?
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Figure 4. Horizontal Offset
Front
?
?
??
??
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Figure 5. Vertical Offset
Front
A
A
AA
Section AA
? ?
?
?
?
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Figure 6. Single-Run Distribution System
Front
?
?
? ?
?
?
?
?
?
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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
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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
?
??
??
??
?
?
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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
?
?
? ?
?
?
??
?
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Connecting Pow-R-Way
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.
Connecting Pow-R-Way
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 ? ? ?
?
?
? ?
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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
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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.
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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)
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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
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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
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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.
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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
LCLCL Plug-in opening
LCLCL 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
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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
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IM01701002E Effective: December 2002
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
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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.
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IM01701002E Effective: December 2002
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.
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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.
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IM01701002E Effective: December 2002
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.
ABC_BusDuct_prf4.fm Page 26 Friday, December 13, 2002 4:06 PM
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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
ABC_BusDuct_prf4.fm Page 27 Friday, December 13, 2002 4:06 PM
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IM01701002E Effective: December 2002
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).
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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.
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IM01701002E Effective: December 2002
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
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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.
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Page 32
IM01701002E Effective: December 2002
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
1-.25 x 6.25 (6.4 x 158.8) Aluminum/Phase1-.25 x 6.25 (6.4 x 158.8) Aluminum/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
4 Wire, Housing Ground, 100% Neutral
T
00 0
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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.
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IM01701002E Effective: December 2002
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
4 Wire, Housing Ground, 100% Neutral
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
4 Wire, Housing Ground, 100% Neutral
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
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
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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.
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IM01701002E Effective: December 2002
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
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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.
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IM01701002E Effective: December 2002
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
Ground PathEnd Block
High StrengthGlass PolyesterInsulators
Ground PathContact Surface
1/4-20 flg.Head Hex Bolt(4 per cover)
(4 per cover)
FT
T
TF
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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
Ground PathEnd Block
Pow-R-BridgeJoint
Gasketed BottomAccess Cover
Torque BoltAccess Opening
DANGER NOTICE
Ground PathLabel
Gasketed FrontJoint Cover
DrainHole Plug
GasketedCover Plate
Ground PathEnd Block
Ground PathContact Surface
GasketedCover Plate
Gasketed RearJoint Cover
F
T
T
FT
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Page 40
IM01701002E Effective: December 2002
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
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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.
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IM01701002E Effective: December 2002
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
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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
ABC_BusDuct_prf4.fm Page 43 Friday, December 13, 2002 4:06 PM
Page 44
IM01701002E Effective: December 2002
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
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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)
ABC_BusDuct_prf4.fm Page 45 Friday, December 13, 2002 4:06 PM
Page 46
IM01701002E Effective: December 2002
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
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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
ABC_BusDuct_prf4.fm Page 47 Friday, December 13, 2002 4:06 PM
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
Effective: December 2002 IM01701002E
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
ABC_BusDuct_prf4.fm Page 49 Friday, December 13, 2002 4:06 PM
Page 50
IM01701002E Effective: December 2002
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
ABC_BusDuct_prf4.fm Page 50 Friday, December 13, 2002 4:06 PM
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
IM01701002E Effective: December 2002
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
ABC_BusDuct_prf4.fm Page 52 Friday, December 13, 2002 4:06 PM
Effective: December 2002 IM01701002E
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
ABC_BusDuct_prf4.fm Page 53 Friday, December 13, 2002 4:06 PM
Page 54
IM01701002E Effective: December 2002
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
ABC_BusDuct_prf4.fm Page 54 Friday, December 13, 2002 4:06 PM
Effective: December 2002 IM01701002E
Page 55
This page intentionally left blank.
ABC_BusDuct_prf4.fm Page 55 Friday, December 13, 2002 4:06 PM
Page 56
IM01701002E Effective: December 2002
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
ABC_BusDuct_prf4.fm Page 56 Friday, December 13, 2002 4:06 PM
Effective: December 2002 IM01701002E
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)
ABC_BusDuct_prf4.fm Page 57 Friday, December 13, 2002 4:06 PM
Page 58
IM01701002E Effective: December 2002
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
ABC_BusDuct_prf4.fm Page 58 Friday, December 13, 2002 4:06 PM
Effective: December 2002 IM01701002E
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)
ABC_BusDuct_prf4.fm Page 59 Friday, December 13, 2002 4:06 PM
Page 60
IM01701002E Effective: December 2002
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
ABC_BusDuct_prf4.fm Page 60 Friday, December 13, 2002 4:06 PM
Effective: December 2002 IM01701002E
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
)
ABC_BusDuct_prf4.fm Page 61 Friday, December 13, 2002 4:06 PM
Page 62
IM01701002E Effective: December 2002
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
ABC_BusDuct_prf4.fm Page 62 Friday, December 13, 2002 4:06 PM
Effective: December 2002 IM01701002E
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)
ABC_BusDuct_prf4.fm Page 63 Friday, December 13, 2002 4:06 PM
Page 64
IM01701002E Effective: December 2002
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
ABC_BusDuct_prf4.fm Page 64 Friday, December 13, 2002 4:06 PM
Effective: December 2002 IM01701002E
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
ABC_BusDuct_prf4.fm Page 65 Friday, December 13, 2002 4:06 PM
Page 66
IM01701002E Effective: December 2002
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
ABC_BusDuct_prf4.fm Page 66 Friday, December 13, 2002 4:06 PM
Effective: December 2002 IM01701002E
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)
ABC_BusDuct_prf4.fm Page 67 Friday, December 13, 2002 4:06 PM
Page 68
IM01701002E Effective: December 2002
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
ABC_BusDuct_prf4.fm Page 68 Friday, December 13, 2002 4:06 PM
Effective: December 2002 IM01701002E
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
)
ABC_BusDuct_prf4.fm Page 69 Friday, December 13, 2002 4:06 PM
Page 70
IM01701002E Effective: December 2002
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
ABC_BusDuct_prf4.fm Page 70 Friday, December 13, 2002 4:06 PM
Effective: December 2002 IM01701002E
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.
ABC_BusDuct_prf4.fm Page 71 Friday, December 13, 2002 4:06 PM
Page 72
IM01701002E Effective: December 2002
This page intentionally left blank.
ABC_BusDuct_prf4.fm Page 72 Friday, December 13, 2002 4:06 PM
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
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