The ABCs of Planning and Installing Pow-R-Way III Bus Duct

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

Page 1

Description
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . Pow-R-Way III Layout . . . . . . . . . . . . . . . . . . . Walk-through & On-site Measurements. . . . Feeder Runs. . . . . . . . . . . . . . . . . . . . . . . . . Connecting PRWIII to Switchboards and Switchgear . . . . . . . Connecting PRWIII to Motor Control Centers . . . . . . . . . . . . . Connecting PRWIII to Transformers . . . . Installation Tips . . . . . . . . . . . . . . . . . . . . Multiple Feeder Bus Runs . . . . . . . . Busway Joint Clearances . . . . . . . . . Wall and Floor Penetrations . . . . . . . Outdoor Considerations . . . . . . . . . . Plug-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Floor Height Measurements . . . . . . . . . Installation Tips . . . . . . . . . . . . . . . . . . . . Maximum Height . . . . . . . . . . . . . . . Other Equipment or Walls in Close Proximity to the Busway Riser . . . . . T Location. . . . . . . . . . . . . . . . . . . . . . . . Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . Flanges. . . . . . . . . . . . . . . . . . . . . . . . . . . Tees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Tap Boxes . . . . . . . . . . . . . . . . . . . Weatherheads . . . . . . . . . . . . . . . . . . . . . Expansion Joints. . . . . . . . . . . . . . . . . . . Bus Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug-in Units . . . . . . . . . . . . . . . . . . . . . . . . Bolt-on Units . . . . . . . . . . . . . . . . . . . . . . . . Built-in Power Takeoff Devices . . . . . . . Bridge Joint Power Takeoff Devices . . . . Installation Tips . . . . . . . . . . . . . . . . . . . . . . Coordination . . . . . . . . . . . . . . . . . . . . . . . . . . . Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Customer Approval Drawings . . . . . . . . . . Customer Layout Drawings . . . . . . . . . . . . Construction Drawings . . . . . . . . . . . . . . . . Installation Guide . . . . . . . . . . . . . . . . . . . . . . . Indoor Joint Assembly Instructions . . . . . Final Field Fits . . . . . . . . . . . . . . . . . . . . . . . How to Remove a Section of Busway . . . . Outdoor Busway Supports . . . . . . . . . . . . . Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wall/Floor Flanges. . . . . . . . . . . . . . . . . . . . End Closers . . . . . . . . . . . . . . . . . . . . . . . . . Busway Handling . . . . . . . . . . . . . . . . . . . . . . . Shipping. . . . . . . . . . . . . . . . . . . . . . . . . . . . Busway Labels. . . . . . . . . . . . . . . . . . . . . . . Dimensional Data . . . . . . . . . . . . . . . . . . . . . . .
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3 4 4 4 12 13 13 15 15 15 16 17 19 19 21 21 21 21 23 23 23 23 23 23 24 24 25 25 26 26 26 28 29 31 31 33 33 35 35 37 37 40 41 41 45 45 46 46 46 47

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Introduction
Eaton’s Cutler-Hammer Pow-R-Way III (PRWIII) 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. PRWIII 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. PRWIII 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 PRWIII 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 PRWIII with other products manufactured by Eaton’s Cutler-Hammer business. 1. This handbook should be used as a reference guide only. Other useful references are NEMA 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 PRWIII 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 Figure 3 Basic Site Dimensions (using walls as reference points) Site Measurements Required for Service Entrance from Pad Mounted Transformer and Service Entrance from Weatherhead Horizontal Offset Vertical Offset Single-Run Distribution System Double-Run Distribution System Using Columns as Reference Points Multi-Floor

Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9

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Page 5

?

Switchboard

?

? ? ?

Front

Figure 1. Enlarged Plan View of Switchboard Room

?

?

? ?

?

?

Figure 2. Basic Site Dimensions — Required Before Starting PRWIII Busway Layout

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Check Local Codes For Correct Height ? ?

Front Switchboard ? ? LV ? ? ? ? Front Switchboard ? Transformer

? ?

Front Switchboard

Section AA

?

? Front

A

A

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

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? ? ? ? ?

?

Front

Figure 4. Horizontal Offset

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?

?

Section AA

?

A AA

? A

?

Front

Figure 5. Vertical Offset

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? ? ?

?

? ?

?

?

?

Front

Figure 6. Single-Run Distribution System

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? ?

? ?

? ? ? ?

? ? ? Front

Figure 7. Double-Run Distribution System
A B C D E 1

?

?

? ?

?

?

2

?

?

3

? ? ? ?
5 4

?
6

Front

Figure 8. Using Columns as Reference Points

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?

? ? MCC Front

Finished Floor

Roof ? 2nd Floor ? ? 1st Floor ? ?

?

Finished Floor

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 PRWIII busway layout is coordination between the trades. This is a good time for the electrical contractor to meet with plumbing, heating, 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 determined, 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.

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Connecting Pow-R-Way III to Switchboards and Switchgear
The Cutler-Hammer Sales Office should specify all 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 CutlerHammer 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 location 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 DSII and Magnum switchgear for bus ratings of 3200 A – 5000 A copper and 2500 A – 4000 A aluminum.

? ? ? ? Front Switchboard ? ?

? ? ?

Figure 10. Busway Connection to Switchboard

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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 provided. The Busway Division will design and supply a flange connection with flexible connectors (see Figure 12B).

Top Hat

?

?

?

? ? ?

MCC

?

Figure 11. Busway Connection to Motor Control Center

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Transformer

LV Studs s uct roat

Transformer Throat

Flexible Braid ? Obstruction

Figure 12A. Busway Connection to Transformer Throat
C L ? 20.00 (508.0)

? C L Flexible Braid

?

?

Figure 12B. Busway Flange Connection to Transformer

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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.

6.00 (152.4) Min. 6.00 (152.4) Min. 6.00 (152.4) Min. Wall

6.00 (152.4) Ceiling Min.

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 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 PRWIII 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.

10.00 (254.0) Min. C L Joint

Figure 14. Required Minimum Distance from Wall
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Wall and Floor Penetrations
Wall 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 accommodate proper installation. Curbs around floor openings are highly recommended. A curb prevents water from flowing down through floor openings. Many times damage occurs to the busway because the busway is not properly protected.

Wall/Floor All 4 Sides 2.00 (50.8) 1.00 (25.4) Bus Duct Wall/Floor Opening

Wall/Floor Flange

Figure 15. Minimum Clearances for Wall and Floor Openings

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Outdoor Considerations
Outdoor 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.

Outdoor Indoor

10.00 (254.0)

T

Outdoor

T
Indoor

T

Figure 16. Wall Penetration with Outdoor Busway

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Floor

2 Bars/Phase

After Joints are Completely Assembled, Caulk the Areas Indicated with Dow Corning 795 Silicone Caulking Compound or Dap Inc. Dynaflex 230 Latex Sealant.

Floor

DANGER

NOTICE

Side View
T
DANGER NOTICE

1 Bar/Phase

After Joints are Completely Assembled, Caulk the Areas Indicated with Dow Corning 795 Silicone Caulking Compound or Dap Inc. Dynaflex 230 Latex Sealant.

Remove These Plugs Only 1 Bar/Phase 2 Bars/Phase Floor

Horizontal

Figure 17. Outdoor Pow-R-Bridge Detail
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Plug-in
Floor Height
The 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 minimum 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 lengths of 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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Floor

? ? Bus Duct

? Floor ?

Curb Where Required

Figure 18. Basic Height Measurement Required for Risers

Floor

6" (457.2 mm) C Joint L C Plug-in L opening (609.6 mm) C Plug-in L opening (609.6 mm) 14'-0" (4.3 m) (609.6 mm) C Plug-in L opening (609.6 mm) C Plug-in L opening C Joint L 6" (457.2 mm) C Plug-in L opening

(254.0 mm) 4" Curb Floor 1

Figure 19. Typical Floor for Plug-in Duct

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Installation Tips

Maximum Height
As 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 Riser
Installing 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 Location
On 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.

T

Line

ON

OFF Load

Figure 20. Preferred Unit Orientation
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C L Duct F Wall

T

Plug-in/Bolt On Unit Opened Hinged Cover

C

A

B

Wall

T

4.00 (101.6) Min. Plug-in Unit

C

F C L Duct Operating Handle

Figure 21. Preferred Arrangements for Wiring Closets

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Fittings
The PRWIII product offering includes a variety of fittings that facilitate complex routing of busway systems.

Elbows
PRWIII includes two elbow designs.

Traditional Elbow
The 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 Elbow
The 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.

Offsets
An 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.

Flanges
Flanges 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.

Tees
A tee is a busway fitting suitable for connection in three directions. See Pages 62 and 63 for minimum dimensions.

Cable Tap Boxes
A 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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Weatherheads
A weatherhead is used for service entrance connections to busway. See Pages 50 and 51 for dimensions.

Expansion Joints
Expansion joints accommodate the expansion and contraction of bus bars with respect to the enclosure. 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 Plugs
The Pow-R-Way III busway product offers a complete 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 Units
Standard 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, communicating IQ Energy Sentinel and OPTIM circuit breakers, and Advantage 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 pressure 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 C 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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Plug-in Units (Continued)
Front covers are hinged on the load end of the enclosure. 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 Units
A 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.

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C Pow-R-Bridge L 17.00 (431.8) Min. F C P.T.O. L

6.94 (176.3) 9.00 (228.6)

T

Line 15.00 (381.0) Load

Edgewise Mounted Single Bar Per Phase Only C Pow-R-Bridge L 17.00 (431.8) Min. C P.T.O. L

6.94 (176.3) 9.00 (228.6)

F T T

Line 15.00 (381.0) Load

Flatwise Mounted — Available in Single and Double Bars Per Phase

Figure 22. Built-in Power Takeoff

Line

Figure 23. Bridge Power Takeoff
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DAN GER

Load
F
DAN GER

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Installation Tips
When planning a plug-in bus run, be sure to consider the following:

Door Clearance
Allow 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 Support
On horizontal bus runs, larger plugs (200A and above) require additional supports independent of bus.

Balance Plugs
On 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 Clearance
Allow 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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Coordination
PRWIII 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 connecting to 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 requiring 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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ON Handle OFF F T Load Handle

ON OFF

OFF Handle ON

Load

OFF F T Load Handle ON

Handle ON OFF T F Load Handle OFF ON OFF Load Load Handle ON T F

Load Handle OFF ON

Figure 24. Plug-in Device Mounting

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Drawings
Customer Approval Drawings
When 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 Manager 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 on risers. 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 Division for manufacture.

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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 Plu Un

00

0

0 0 0

2500 A. 3-Phase, 4W Outdoor

1600 A. 3-Phase, 4W

T T 0 0 F 0 0 0

0 0 Transformer

0

Front Switchboard

Run Indoor/Outdoor 2500 A. 3-Phase Aluminum, 277/480 Volts 4 Wire, Housing Ground, 100% Neutral

G

4.38 (111.3) T

18.64 (473.5) 2-.25 x 5.50 (6.4 x 139.7) Aluminum/Phase 2-.25 x 5.50 (6.4 x 139.7) Aluminum/Neutral Duct Weight = 24 lbs/ft Color = ANSI 61 Gray

Run Indoor/Outdoor 1600 A. 3-Phase Aluminum, 277/480 Volts 4 Wire, Housing Ground, 100% Neutral
G

4.38 (111.3)

A B N

9.40 (238.8) 1-.25 x 6.25 (6.4 x 158.8) Aluminum/Phase 1-.25 x 6.25 (6.4 x 158.8) Aluminum/Neutral Duct Weight = 13 lbs/ft Color = ANSI 61 Gray

Figure 25. Sample Approval Drawings

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Effective: December 2002

Page 33

Customer Layout Drawings
In 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 Drawings
Prior 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:
s s s s s s s

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

Effective: December 2002

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Page 34

7/16"

15

8'

All Floors
12

10'
13

12'-6"

Plug-in Unit
12

Outdoor Indoor

10' 12'-6"

2500 A. 3-phase 4W.
1600 A. 3-Phase 4W. 2'-1" 2'-1-5/8"

13

2'-6" 1'-3"

6"
12 11

1'-5"
4

10

-1" 24'-5" 1' 3'
7

1'-3" See Drawing BVC1004 Line 15

Same Elevation Transformer Front Switchboard

See Drawing BVC1012 Line 5

RUN 1 Indoor Pow-R-Way III 4 Wire, Housing Ground, 100% Neutral

West Riser Indoor Pow-R-Way III 4 Wire, Housing Ground, 100% Neutral

G 4.38 B C N

A 4.38 (111.3)

9.40 (238.8)
0.25 x 6.25 (6.4 x 158.8) Aluminum/Phase 0.25 x 6.25 (6.4 x 158.8) Aluminum/Neutral Duct Weight: 13 lbs/ft Color - ANSI 61 Gray

(473.5
2-.25 x 5.50 (6.4 x 139.7) Aluminum/Phase 2-.25 x 5.50 (6.4 x 139.7) Aluminum/Neutral Duct Weight: 24 lbs/ft Color - ANSI 61 Gray

ITEM A01 A02

DESCRIPTION Flange-Elbow Elbow

STYLE # OR S.O. # PSW1589A01 PSW1589A02 BVD0299G11

Req. 1 1 1 1 2 1 1 1 2 1 3 3 2 1 1 3 4

A04 A05

Elbow-Flange Hanger

PSW1589A04 BVD0301G12 PSW1589A06

A07 A08 A09 A10

Elbow 2'-5" Length 10'-0" Length Elbow

PSW1589A07 PSW1589A08 5687D01G30 PSW1589A10 BVD0299G06

A12 A13

2'-6" Length 10'-0" Length

PSW1589A11 PSW1589A13 PSW1589A14

A15 A16 A17

End Closer Hanger Hanger

BVD0156G08 BVD0300G12 BVD0301G15

Figure 26. Sample Installation Drawing

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Effective: December 2002

Page 35

Installation Guide
Every 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 Instructions
When connecting sections of PRWIII together, the following guidelines must be followed. Contact surfaces must be clean and free of all contaminants. 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, available 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.

Effective: December 2002

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Page 36

Optional Joint Puller (See Note 2) Joint Puller T F

End Block T

F T

End Block

Joint Puller F T Joint Puller T F

End Block

T T F

End Block

Note: 1. Bolt Joint Puller to End Blocks at Busway Joints as Shown Using .375 (9.5)-16 Hardware Supplied In Cloth Bag. Puller May Be Used with Wider Bus Bars.

Figure 27. Joint Puller

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Effective: December 2002

Page 37

Final Field Fits
A final field fit section of busway is typically an elbow or short section of feeder that is intentionally 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 Busway
When 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.

Effective: December 2002

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Page 38

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

Ground Path Contact Surface

DA

ER NG

TIC NO

E

.375 (9.5)-16 flg. Head Hex Bolt (4 per cover) Joint Cover Ground Path Label

T

F

Ground Path Plate

Ground Path End Block 130∞ Epoxy Insulation on Bars Bridge Joint Pressure Plate (top & bottom)

Double Headed Torque Indicating Bolt (bottom)

Belleville Washer

Bridge Joint Retainer Screw (must be removed for 1-inch (25.4 mm) adjustment) T

Captive Nut Retainer

T F

Ground Path End Block

High Strength Glass Polyester Insulators

Figure 28. Indoor Joint Assembly

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Effective: December 2002

Page 39

Drain Hole Plug Gasketed TorqueBolt Access Cap (Top & Bottom)

Gasketed Top Access Cover

Gasketed Cover Plate

Gasketed Front Joint Cover

Ground Path Label
N DA GE R NO E TIC

Gasketed Rear Joint Cover Ground Path Contact Surface Drain Hole Plug

Gasketed Cover Plate

Belleville Washer Pressure Plate (Top & Bottom) Captive Nut Retainer

Bridge Joint Retainer Screw (Must be Removed for .08 (2.03) Adjustment) Water Barrier T F

Ground Path End Block T Pow-R-Bridge Joint

Closed Cell Neoprene Gasket Water Barrier

Ground Path End Block T F

Torque Bolt Access Opening

Gasketed Bottom Access Cover

Figure 29. Outdoor Joint Assembly

Effective: December 2002

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Page 40

Outdoor Bus Supports
Busway 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.

A 12.00 (304.8) Min.
Indoor Outdoor

Additional Support
Indoor Switchboard

Sealing Ring HV LV Knee Brace

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 under busway 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 Laboratories for mounting on 10-foot (3 m) centers.

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Page 41

Accessories
Hangers
Horizontal Hangers (Hook and Angle)
One hanger is supplied for every 10 feet (3.0 m) of horizontally mounted PRWIII busway. The type of hanger is determined by the customer’s specific requirements for installation. Care should be given when locating the drop rods, in order to avoid placing hangers at joint locations. If the horizontal busway run is plug-in type, adequate ceiling clearance must be allowed for the largest plug to be mounted on the bus. Hanger types are shown in Figure 31.
Note: Drop rods are provided by others. Note: Standard hangers require 1/2-inch (12.7 mm) drop rods and Seismic hangers require 3/4-inch (19.1 mm) drop rods.

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

Effective: December 2002

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Duct Width Duct Width Flatwise Hook Hanger Duct Height Edgewise Hook Hanger Duct Width

Flatwise Angle Hanger 1 Bar Per Phase Duct Width

Flatwise Angle Hanger 2 Bars Per Phase

Duct Height

Duct Height

Edgewise Angle Hanger 1 Bar Per Phase

Edgewise Angle Hanger 2 Bars Per Phase

Figure 31. Horizontal Hangers
IM01701002E Effective: December 2002

Page 43

.31 (7.9) - 18 Hardware Drill .34 (8.6) Holes in Busway Housing Using Hanger as a Template

F

Floor 1-Inch (25.4) Minimum Lap Around Floor Opening (Typical)

Duct Height

For 1 or 2 bars per Phase (4 Springs) "F" & "F-OPPOSITE" Mounting

T

F

A
3" 3" 3" 3" 3" 3" 3 1/2" 3 1/2" 3 1/2" 3 1/2" 3 1/2" 3 1/2" 4" 4" 4" 4" 4" 4"

Floor Center Spring For 6.25 and 8.00 (158.7 and 203.2) Bar Widths

Duct Width Vertical Hanger

T

F

A

5.75 (146.1)

Floor .63 (15.9) Diameter Stud Floor Flange (Optional) Mounting Support (By Others)

For 1 Bar per Phase Busway (4 or 6 Springs) "T" & "T-OPPOSITE" Mounting

Figure 32A. Vertical Hangers

Effective: December 2002

IM01701002E

Page 44

T

F

Vertical Hanger

A

5.75 (146.1)

Floor

.63 (15.9) Diameter Stud

Floor Flange (Optional) Busway .31 (7.9) - 18 Hardware

Mounting Support (By Others)

F T T

A
3" 3" 3" 3" 3" 3" 3 1/2" 3 1/2" 3 1/2" 3 1/2" 3 1/2" 3 1/2" 4" 4" 4" 4" 4" 4"

Floor Busway Width 1-Inch (25.4) Minimum Lap Around Floor Opening (Typical) Drill .34 (8.63) Holes in Busway Housing Using Hanger as a Template

For 2 bars per Phase Busway (6 Springs) "F" & "F-OPPOSITE" Mounting

Figure 32B. Vertical Hangers

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Page 45

Wall/Floor Flanges
For 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).
2.00 (508.0) 2.00 (508.0)

Busway Height

Wall/ Floor

Busway Width Typical Wall/Floor Flange Detail 1 Bar Per Phase (Wall Opening Should Be 1-inch (25.4) Wider Than Bus On All Sides)

2.00 (508.0) 2.00 (508.0)

Busway Height

Wall/ Floor Busway Width

Typical Wall/Floor Flange Detail 2 Bar Per Phase (Wall Opening Should Be 1-inch (25.4) Wider Than Bus On All Sides)

Figure 33. Wall/Floor Flange

End Closers
End closures terminate a bus run.

Effective: December 2002

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Page 46

Busway Handling
Shipping
All busway shipments are made from Greenwood, South Carolina, and are shipped F.O.B. first destination, freight prepaid if total weight is over 300 lbs. (136 kg.) Should the receiver notice any shortage 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 Labels
Busway 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.

CUTLER-HAMMER
DANGER

POW-R-WAY III

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

SHORT CIRCUIT CURRENT RATING

A

1200 100% 277/480 3
WIRE 4

When protected by a

1200 ampere maximum class

L fuse or a CUTLER-HAMMER type
RMS SYM A DC A STYLE NO.

125,000

NEUT A V ~

circuit breaker rated for not more than

amperes,

1200

PYW03125-A01

PHASE % GRD.

this busway is rated for use on a circuit capable of 200,000 delivering not more than RMS symmetrical amperes Material volts maximum. ~ 600
ALUMINUM

50% HSG.

MAX. SUPPORT SPACING: 10 FT. (305 cm) HORIZONTAL RUN: 16 FT. (488 cm) VERTICAL RISER. SHORT CIRCUIT RATING OF SYSTEM IS LIMITED TO LOWEST SHORT CIRCUIT RATING OF ANY BUSWAY OR FITTING INSTALLED.
MFG. DATE: BVA1000H01 REV. 4

Figure 34. Busway Label

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Effective: December 2002

Page 47

Dimensional Data
Width

Height

Figure A 225 to 2000 Ampere Aluminum 225 to 2500 Ampere Copper

Width

Height

Figure B 2500 to 4000 Ampere Aluminum 3200 to 5000 Ampere Copper

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

Effective: December 2002

IM01701002E

r and Housing — Dimensions in Inches (mm)
3-Wire with No Neutral and 4-Wire with 100% Neutral Bar Per Phase Conductor Configuration and Housing Size (Width x Height) 50% Integral Housing Ground 3WH 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 4.38 (121 x 111) 5.38 x 4.38 (137 x 111) 5.88 x 4.38 (149 x 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) 50% Integral Ground Bus 3WHG 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 4.50 (121 x 114) 5.38 x 4.50 (137 x 114) 5.88 x 4.50 (149 x 114) 6.38 x 4.50 (162 x 114) 7.38 x 4.50 (187 x 114) 8.64 x 4.50 (219 x 114) 50% Integral Isolated Ground 3WI 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 4.55 (121 x 116) 5.38 x 4.55 (137 x 116) 5.88 x 4.55 (149 x 116) 6.38 x 4.55 (162 x 116) 7.38 x 4.55 (187 x 116) 8.64 x 4.55 (219 x 116) 50% Integral Housing Ground 4WNH 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 4.92 (121 x 125) 5.38 x 4.92 (137 x 125) 5.88 x 4.92 (149 x 125) 6.38 x 4.92 (162 x 125) 7.38 x 4.92 (187 x 125) 8.64 x 4.92 (219 x 125) 50% Integral Ground Bus 4WNG 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 5.05 (121 x 128) 5.38 x 5.05 (137 x 128) 5.88 x 5.05 (149 x 128) 6.38 x 5.05 (162 x 128) 7.38 x 5.05 (187 x 128) 8.64 x 5.05 (219 x 128) 4-Wire with 200% Neutral

e Bar Size h and Width)

50% Integr Isolated Gr

1.62 (6.35 x 41) 1.62 (6.35 x 41) 1.62 (6.35 x 41)

1 1 1 1 1 1

4.75 x 5.10 4.75 x 5.10 4.75 x 5.10

1.62 (6.35 x 41) 2.25 (6.35 x 57) 2.75 (6.35 x 70)

4.75 x 5.10 5.38 x 5.10 5.88 x 5.10

3.25 (6.35 x 83) 1 4.25 (6.35 x 108) 1 5.50 (6.35 x 140) 1

6.38 x 5.10 7.38 x 5.10 8.64 x 5.10

6.25 (6.35 x 159) 1 8.00 (6.35 x 203) 1 4.25 (6.35 x 108) 2

9.40 x 4.38 (239 x 111) 9.40 x 4.50 (239 x 114) 9.40 x 4.55 (239 x 116) 9.40 x 4.92 (239 x 125) 9.40 x 5.05 (239 x 128) 9.40 x 5.10 11.17 x 4.38 (284 x 111) 11.17 x 4.50 (284 x 114) 11.17 x 4.55 (284 x 116) 11.17 x 4.92 (284 x 125) 11.17 x 5.05 (284 x 128) 11.17 x 5.10 16.14 x 4.38 (410 x 111) 16.14 x 4.50 (410 x 114) 16.14 x 4.55 (410 x 116) 16.14 x 4.92 (410 x 125) 16.14 x 5.05 (410 x 128) 16.14 x 5.10

5.50 (6.35 x 140) 2 6.25 (6.35 x 159) 2 8.00 (6.35 x 203) 2

18.64 x 4.38 (473 x 111) 18.64 x 4.50 (473 x 114) 18.64 x 4.55 (473 x 116) 18.64 x 4.92 (473 x 125) 18.64 x 5.05 (473 x 128) 18.64 x 5.10 20.16 x 4.38 (512 x 111) 20.16 x 4.50 (512 x 114) 20.16 x 4.55 (512 x 116) 20.16 x 4.92 (512 x 125) 20.16 x 5.05 (512 x 128) 20.16 x 5.10 23.70 x 4.38 (602 x 111) 23.70 x 4.50 (602 x 114) 23.70 x 4.55 (602 x 116) 23.70 x 4.92 (602 x 125) 23.70 x 5.05 (602 x 128) 23.70 x 5.10

Page 49

Table 2. Weight and Current Density

Ampere Rating

Effective: December 2002
86 153 — 229 — 180 191 175 152 159 155 — 140 149 155 12 12 12 12 15 18 21 25 34 — 43 51 67 — 94 7 7 — 7 — 9 11 12 16 18 21 — 32 34 42 15 15 15 15 18 22 25 32 42 — 54 63 83 — 108 9 9 — 9 — 11 12 15 18 20 24 — 36 39 48 17 17 17 17 21 26 30 37 49 — 63 73 98 — 126 11 11 — 11 — 12 14 16 20 22 27 — 40 43 54 1.17 1.17 1.17 1.17 1.62 1.98 2.34 3.06 3.96 — 5.76 6.12 7.92 — 11.53 0.35 0.35 — 0.35 — 0.60 0.71 0.92 1.20 1.36 1.75 — 2.40 2.73 3.50

Cu

Al

Weight (Lbs./Ft.) and Current Density (Amperes/in2) Current Weight — Including Integral Housing Ground (Lbs./Ft.) Density 3-Wire 4-Wire 4-Wire Add for Amperes/in2 100% Neutral 200% Neutral Internal Ground Cu Al Cu Al Cu Al Cu Al Cu Al

Metric Weight (kg/M) and Current Density (Amperes/cm2) Current Weight — Including Integral Housing Ground (kg/M) Density 3-Wire 4-Wire 4-Wire Add for Amperes/cm2 100% Neutral 200% Neutral Internal Ground Cu Al Cu Al Cu Al Cu Al Cu Al

225 400 600 800 1000 1200 1350 1600 2000 — 2500 3200 4000 — 5000

225 400 — 600 — 800 1000 1200 1350 1600 2000 — 2500 3200 4000

554 985 1477 1969 1778 1745 1662 1506 1455 — 1250 1505 1455 — 1250

554 985 — 1477 — 1164 1231 1129 982 1024 1000 — 909 960 1000

8 8 8 8 10 12 14 17 23 — 29 34 45 — 63

5 5 — 5 — 6 7 8 11 12 14 — 21 23 28

10 10 10 10 12 15 17 21 28 — 36 42 56 — 72

6 6 — 6 — 7 8 10 12 13 16 — 24 26 32

11 11 11 11 14 17 20 25 33 — 42 49 66 — 85

7 7 — 7 — 8 9 11 13 15 18 — 27 29 36

0.78 0.78 0.78 0.78 1.08 1.33 1.57 2.05 2.66 — 3.87 4.11 5.32 — 7.74

0.23 0.23 — 0.23 — 0.40 0.47 0.62 0.80 0.91 1.17 — 1.61 1.83 2.35

86 153 229 305 276 270 258 233 226 — 194 233 226 — 194

IM01701002E

Page 50

Cable Tap Boxes
38.00 (965.2) “T” Side Removable Indoor 11.62 (295.1) C L A D in. r M te C of L Busway
t Gupace S

30.00 (762.0) 32.50 (825.5)

C of Duct C of Box L L Gasketed Access Cover on Front and Back of Box for Outdoor Tap Boxes Only 17.50 (444.5)

Busway Width Busway Height

15.00 (381.0) Side Opposite “T” Removable Indoor

End Cable Tap Box

A “T”Side Removable Indoor 11.62 (295.1) C C of Busway L C of Duct L

B

30.00 (762.0) 32.50 (825.5)

C L

Busway Width Busway Height Side Opposite “T” Removable Indoor

C of Box L

End Removable Indoor F Dimension is the Minimum 15.00 Gutter Space (381.0) 17.50 (444.5)

F

Gasketed Access Cover on Front and Back of Box for Outdoor Tap Boxes Only

Center Cable Tap Box

40.00 (1016.0) C of Box L

A

11.62 (295.1) C L

C of Busway L C of Duct L

24.00 (609.6)

Busway Width Busway Height

1.00 (25.4) Compression and Mechanical Lugs 15.00 (381.0) Removable Barrier 17.50 (444.5)

Weatherhead

Figure 36. Cable Tap Boxes

IM01701002E

Effective: December 2002

ap Box — Dimensions in Inches (mm)
Center Cable Tap Box Copper Dimension (A) Dimension (B) 40.00 (1016.0) 40.00 (1016.0) 40.00 (1016.0) 40.00 (1016.0) 40.00 (1016.0) 40.00 (1016.0) 40.00 (1016.0) 42.50 (1079.5) 42.50 (1079.5) Dimension (C) 3.63 (92.2) 3.63 (92.2) 3.63 (92.2) 3.63 (92.2) 3.63 (92.2) 3.63 (92.2) Aluminum Dimension (A) 16.50 (419.1) 16.50 (419.1) 16.50 (419.1) 16.50 (419.1) 16.50 (419.1) 20.50 (520.7) Dimension (B) 40.00 (1016.0) 40.00 (1016.0) 40.00 (1016.0) 40.00 (1016.0) 40.00 (1016.0) 42.50 (1079.5) 42.50 (1079.5) 45.00 (1143.0) 45.00 (1143.0) 58.00 (1473.0) 58.00 (1473.0) 60.50 (1536.7) — Dimension (C) 3.63 (92.2) 3.63 (92.2) 3.63 (92.2)

ble Tap Box Aluminum Dimension (A)

r

Quantity of Mechan Range — (1) #4 – 60 Weatherhead (2) 1/0 – 250 kcmil C Dimension (A) 16.50 (419.1) 16.50 (419.1) 16.50 (419.1) Copper G 1 1 1 2 2 2 2 3 3 4 5 6 7 P 2 2 2 3 3 4 4 5 6 8 9 12 15 N 4 4 4 5 6 8 8 9 12 16 18 24 30

sion

A

G

304.8) 304.8) 304.8)

12.00 (304.8) 16.50 (419.1) 12.00 (304.8) 16.50 (419.1) 12.00 (304.8) 16.50 (419.1) 12.00 (304.8) 16.50 (419.1) 12.00 (304.8) 16.50 (419.1) 12.00 (304.8) 16.50 (419.1) 20.50 (520.7) 16.50 (419.1) 24.50 (622.3) 20.50 (520.7) 24.50 (622.3) 20.50 (520.7) 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)

1 1 1

304.8) 304.8) 304.8)

3.63 (92.2) 16.50 (419.1) 3.63 (92.2) 16.50 (419.1) 4.75 (120.7) 16.50 (419.1) 4.75 (120.7) 16.50 (419.1) 6.00 (152.4) 16.50 (419.1) 6.00 (152.4) 16.50 (419.1) 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)

2 2 2

304.8) 520.7) 520.7)

3.63 (92.2) 20.50 (520.7) 4.75 (120.7) 24.50 (622.3) 4.75 (120.7) 24.50 (622.3)

2 3 3

622.3) 774.5) 1143.0) 1143.0)

42.50 (1079.5) 6.00 (152.4) 30.38 (771.7) 58.00 (1473.2) 10.75 (273.1) 30.38 (771.7) 60.50 (1536.7) 12.25 (311.2) 45.00 (1143.0) 60.50 (1536.7) 12.25 (311.2) —

4 5 6 —

Page 52

Elbow Flanges
C L C L

C L

T T F

Forward Elbow Right Flange

T

C L

F

T

C L
Rearward Elbow Right Flange

C L

Figure 37. Elbow Flanges Table 4. Forward and Rearward Elbow Flanges
Ampere Rating Cu 225 400 600 800 1000 1200 1350 1600 2000 — 2500 3200 4000 — 5000 Al 225 400 — 600 — 800 1000 1200 1350 1600 2000 — 2500 3200 4000 Minimum Dimensions in Inches (mm) Joint Let (X) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.50 (342.9) 13.50 (342.9) 14.00 (355.6) 14.50 (368.3) 15.00 (381.0) 16.00 (406.4) 18.50 (469.9) 19.50 (495.3) 20.50 (520.7) 22.50 (571.5) Flange Leg (Y) 8.75 (222.3) 8.75 (222.3) 8.75 (222.3) 8.75 (222.3) 8.75 (222.3) 9.25 (235.0) 9.25 (235.0) 9.75 (247.7) 10.25 (260.4) 10.75 (273.1) 11.75 (298.5) 14.00 (355.6) 15.25 (387.4) 16.00 (406.4) 17.75 (450.9)

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Page 53

T T F

C L

Upward Elbow Right Flange C L C L

C L

C L T T F

C L

Downward Elbow Right Flange

Figure 38. Elbow Flanges Table 5. Upward and Downward Elbow Flanges
Ampere Rating Cu Al Minimum Dimension in Inches (mm) Joint Let (X) Up Down Flange Leg (Y) Up Down

225 225 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3) 400 400 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3) 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3) 600 — 800 600 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3) 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3) 1000 — 1200 800 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3) 1350 1000 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3) 1600 1200 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3) 2000 1350 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3) 1600 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3) — 2500 2000 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3) 12.00 (304.8) 13.00 (330.2) 7.75 (196.9) 8.75 (222.3) 3200 — 4000 2500 12.00 (304.8) 13.00 (330.2) 7.75 (196.9) 8.75 (222.3) 3200 12.00 (304.8) 13.00 (330.2) 7.75 (196.9) 8.75 (222.3) — 5000 4000 12.00 (304.8) 13.00 (330.2) 7.75 (196.9) 8.75 (222.3)

Effective: December 2002

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Page 54

Standard/Flush Flanges

T T F 1.25 15.00 Bridge (381.0) C L Min. Flush Flange C L

T T F 11.62 (295.2) Min. C L Standard Flange Bridge C L

Figure 39. Standard/Flush Flanges Table 6. Standard/Flush Flanges
Ampere Rating Cu 225 400 600 800 1000 1200 1350 1600 2000 2500 3200 4000 5000 Al 225 400 600 800 1000 1200 1350 1600 2000 2500 3200 4000 — Minimum Leg Length (X) in Inches (mm) Flush Flange 15.00 (381.0) 15.00 (381.0) 15.00 (381.0) 15.00 (381.0) 15.00 (381.0) 15.00 (381.0) 15.00 (381.0) 15.00 (381.0) 15.00 (381.0) 15.00 (381.0) 15.00 (381.0) 15.00 (381.0) 15.00 (381.0) Standard Flange 11.62 (295.16) 11.62 (295.16) 11.62 (295.16) 11.62 (295.16) 11.62 (295.16) 11.62 (295.16) 11.62 (295.16) 11.62 (295.16) 11.62 (295.16) 11.62 (295.16) 11.62 (295.16) 11.62 (295.16) 11.62 (295.16)

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Effective: December 2002

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Elbows
C L X C L T T F C L X C L

Forward

T C L X C L Rearward C L T F C L X

X T T F X C L C L Upward

T C L F X C L X T

C L

Downward

Figure 40. Elbow Types

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Page 57

Table 7. Elbows — Dimensions in Inches (mm)
Ampere Rating Cu Al Minimum Leg Length Upward Downward 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) Minimum Leg Lengths (X) Forward/Rearward 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.50 (342.9) 13.50 (342.9) 14.00 (355.6) 14.50 (368.3) 12.00 (381.0) 16.00 (406.4) 18.50 (469.9) 19.50 (495.3) 20.50 (520.7) 22.50 (571.5)

225 225 10.00 (254.0) 400 400 10.00 (254.0) 600 — 10.00 (254.0) 800 600 10.00 (254.0) 1000 — 10.00 (254.0) 1200 800 10.00 (254.0) 1350 1000 10.00 (254.0) 1600 1200 10.00 (254.0) 2000 1350 10.00 (254.0) — 1600 10.00 (254.0) 2500 2000 10.00 (254.0) 3200 — 12.00 (304.8) 4000 2500 12.00 (304.8) — 3200 12.00 (304.8) 5000 4000 12.00 (304.8)

Effective: December 2002

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Page 58

Corner Joint Elbows
C L C L X T C L Y C L

F Forward

T F C L X C L Rearward Y C L C L

T F C L Y C L Y

C L Downward

T X F X C L Upward

Figure 41. Corner Joint Elbows

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Effective: December 2002

Page 59

Table 8. Corner Joints
Ampere Rating Cu Al Dimensions in Inches (mm) Forward/Rearward (X) 0.94 (23.9) 0.94 (23.9) 0.94 (23.9) 0.94 (23.9) 1.25 (31.8) 1.50 (38.1) 1.75 (44.5) 2.25 (57.2) 2.88 (73.2) (Y) Upward/Downward (X) (Y)

225 225 400 400 600 — 800 600 1000 — 1200 800 1350 1000 1600 1200 2000 1350 — 1600 2500 2000 3200 —

5.38 (136.7) 4.71 (119.6) 4.35 (110.5) 5.38 (136.7) 4.71 (119.6) 4.35 (110.5) 5.38 (136.7) 4.71 (119.6) 4.35 (110.5) 5.38 (136.7) 4.71 (119.6) 4.35 (110.5) 5.69 (144.5) 4.71 (119.6) 4.35 (110.5) 5.94 (150.9) 4.71 (119.6) 4.35 (110.5) 6.19 (157.2) 4.71 (119.6) 4.35 (110.5) 6.69 (169.9) 4.71 (119.6) 4.35 (110.5) 7.31 (185.7) 4.71 (119.6) 4.35 (110.5)

3.25 (82.6) 7.70 (195.6) 4.71 (119.6) 4.35 (110.5) 4.12 (104.7) 8.57 (217.7) 4.71 (119.6) 4.35 (110.5) 6.64 (168.7) 11.07 (281.2) 4.71 (119.6) 4.35 (110.5)

4000 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 (110.5) 5000 4000 10.42 (264.7) 14.85 (377.2) 4.71 (119.6) 4.35 (110.5)

Effective: December 2002

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Page 60

Offsets
C L Y C L Y C L T T F Forward C L 3.00 (76.2) Min.

C L

C L

3.00 (76.2) Min.

C L

C L Y C L Y T C L T

F

Rearward

T F C L 3.00 (76.2) Min. C L Z C L C L

C L

Y

Upward

C L 3.00 (76.2) Min. C L C L Y C L F Z C L T T

Downward

Figure 42. Offsets

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Effective: December 2002

Page 61

Table 9. Offsets
Forward/Rearward (Z) 10.00 (254.0) 10.00 (254.0) 10.00 (254.0) 10.00 (254.0) 10.00 (254.0) 10.00 (254.0) 10.00 (254.0) 10.00 (254.0) 10.00 (254.0) 10.00 (254.0) 10.00 (254.0) 12.00 (304.8) 12.00 (304.8) 12.00 (304.8) 12.00 (304.8) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.00 (330.2) 13.50 (342.9) 13.50 (342.9) 14.00 (355.6) 14.50 (368.3) 15.00 (381.0) 16.00 (406.4) 18.50 (469.9) 19.50 (495.3) 20.50 (520.7) 22.50 (571.5) (Y)

Ampere Rating

Minimum Dimensions in Inches (mm)

Upward

Downward

Cu

Al

(Y)

(Z)

(Y)

Effective: December 2002

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)

800 1000 1200

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) 13.00 (330.2)

1350 1600 2000

1000 1200 1350

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)

— 2500 3200

1600 2000 —

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

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

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

IM01701002E

4000 — 5000

2500 3200 4000

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

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

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

Page 62

Tees
C L X C L X C L T T F F T T T T F C L Y C L

Forward

C L Y C L T
F

T T F C L

T

T T F X C L Rearward C L Y T T FT T F C L C L

X

T T F X X C L C L C L

Upward C L T T F Y C L T F X X C L Downward C L

T T F T

C L

Figure 43. Tees

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Effective: December 2002

Page 63

Table 10. Tees
Ampere Rating Cu Al Minimum Leg Dimensions in Inches (mm) Forward/Rearward (X) (Y) Upward/Downward (X) (Y)

225 225 13.00 (330.2) 13.00 (330.2) 21.25 (539.8) 25.50 (647.7) 400 400 13.00 (330.2) 13.00 (330.2) 21.25 (539.8) 25.50 (647.7) 13.00 (330.2) 13.00 (330.2) 21.25 (539.8) 25.50 (647.7) 600 — 800 600 13.00 (330.2) 13.00 (330.2) 21.25 (539.8) 25.50 (647.7) 13.00 (330.2) 13.00 (330.2) 21.88 (555.8) 25.50 (647.7) 1000 — 1200 800 13.50 (342.9) 13.50 (342.9) 22.38 (568.5) 25.50 (647.7) 1350 1000 13.50 (342.9) 13.50 (342.9) 22.88 (581.2) 25.50 (647.7) 1600 1200 14.00 (355.6) 14.00 (355.6) 23.88 (606.6) 25.50 (647.7) 2000 1350 14.50 (368.3) 14.50 (368.3) 25.12 (638.1) 25.50 (647.7) 1600 15.00 (381.0) 15.00 (381.0) 25.88 (657.4) 25.50 (647.7) — 2500 2000 16.00 (406.4) 16.00 (406.4) 27.62 (701.6) 25.50 (647.7) 27.25 (692.2) 26.38 (670.1) 23.88 (606.6) 25.50 (647.7) 3200 — 4000 2500 28.50 (723.9) 27.62 (701.6) 25.12 (638.1) 25.50 (647.7) 3200 29.25 (793.0) 28.38 (720.9) 25.88 (637.4) 25.50 (647.7) — 5000 4000 31.00 (787.4) 30.12 (765.1) 27.62 (701.6) 25.50 (647.7)

Effective: December 2002

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Page 64

Single-Phase Transformer Tap
TAPS C L C POW-R-BRIDGE L

17.00 + 2X (431.8) + 2X TAPS C L C POW-R-BRIDGE L 8.50 + X (215.9) + X

8.50 + Y (215.9) + Y

T F

17.00 + 2X (431.8) + 2X TAPS C L C POW-R-BRIDGE L 8.50 + X (215.9) + X

8.50 + X (215.9) + X

A G C

Ground When Required

A Phase or Neutral

T F

8.50 + X (215.9) + X POW-R-BRIDGE C L 8.50 + X (215.9) + X T F

C B

C Phase or Neutral

B A

B Phase or Neutral

Figure 44. Single-Phase Transformer Tap Table 11. Single-Phase Transformer Tap
Ampere Rating Cu 225 400 600 800 1000 1200 1350 1600 2000 — 2500 3200 4000 — 5000 Al 225 400 — 600 — 800 1000 1200 1350 1600 2000 — 2500 3200 4000 Minimum Dimensions in Inches (mm) (X) 4.00 (101.6) 4.00 (101.6) 4.00 (101.6) 4.00 (101.6) 4.50 (114.3) 5.00 (127.0) 5.50 (139.7) 6.50 (165.1) 7.75 (196.9) 8.50 (215.9) 10.25 (260.4) 6.50 (165.1) 7.75 (196.9) 8.50 (215.9) 10.25 (260.4) (Y) 7.00 (177.8) 7.00 (177.8) 7.00 (177.8) — 9.75 (247.7) 10.75 (273.1) 11.75 (298.5) 13.75 (349.3) 16.25 (412.8) 17.50 (444.5) 21.25 (539.8) 13.75 (349.3) 16.25 (412.8) 17.50 (444.5) 21.25 (539.8)

IM01701002E

Effective: December 2002

Page 65

Three-Phase Transformer Tap
15.00 (381.0) Taps C L A C L T T F N C A B C G B Support Pad

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

6.00 (152.4)

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 19.5 (495.3)

16.5 (419.1)

16.5 (419.1)

19.5 (495.3)

(B) Minimum Dimensions Wire Designation 3W/3WH 3WG/3WHG/ 3WI 4W/4WH 4WN/4WNH 4WG/4WHG/ 4WI/4WNG/ 4WNHG/ 4WNI 15.12 (384.0)

6.25 (158.8)

12.12 (307.8)

9.25 (235.0)

(C) Minimum Dimensions Wire Designation 50% Housing Ground 3.00 (76.2) 50% Internal Ground and 100% Ground 6.00 (152.4)

Effective: December 2002

IM01701002E

Page 66

Transformer Throat Connections
Transformer

Transformer Throat Sealing Ring

T

Edge of Transformer Throat

C L A

1.75 (44.5) Plus 1/2 (12.7) Duct Width

Transformer

Transformer Throat Sealing Ring

T C L A

Edge of Transformer Throat

9.50 (241.3)

Sealing Ring

Screw

Felt Gasket

Sealing Ring

Figure 46. Transformer Throat Connections
IM01701002E Effective: December 2002

Page 67

Table 13. Transformer Throats
Ampere Rating Bars per Phase Minimum Dimensions in Inches (mm) (A)

Aluminum
225 – 1350 1600 – 2000 2500 – 4000 1 1 2 1 1 2 26.00 (660.4) 28.50 (723.9) 31.50 (800.1) 26.00 (660.4) 28.50 (723.9) 31.50 (800.1)

Copper
225 – 2000 2500 3200 – 5000

Effective: December 2002

IM01701002E

Page 68

Bus Plugs
A

Handle C L B

F

C Plug-in Opening L and B Phase

ON

OFF

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

IM01701002E

ON
C L
D E C Guide Pin Clamp and Guide

Effective: December 2002

Table 14. Circuit Breaker Plug-in Units
(F) 6.05 (154) 6.06 (154) 6.64 (169) 9.83 (250) 9.83 (250) 9.83 (250) 9.83 (250) 9.83 (250) 350 A — (1) 250 – 500 kcmil (120 – 240) 400 A — (2) 3/0 – 250 kcmil (45 – 120) 400 A — (1) 4/0 – 600 kcmil (120 – 300) 600 A — (2) 400 – 500 kcmil (185 – 240) 600 A — (2) #1 – 500 kcmil (50 – 240) 800 A — (2) 500 – 750 kcmil (300 – 400) 700 A — (2) #1 – 500 kcmil (50 – 240) 800 A — (3) 3/0 – 400 kcmil (95 – 185) 225 A — (1) #6 – 350 kcmil (16 – 185) 400 A — (1) #4 – 250 kcmil and (1) 3/0 – 600 kcmil (25 – 120 and 95 – 300) (1) #4 – 250 kcmil (25 – 120) and (1) 3/0 – 600 kcmil (95 – 300) 250 A — (1) #14 – 350 kcmil (25 – 185) 225 A — (1) 3 – 350 kcmil (35 – 185) 100 A — (1) #14 – 1/0 (2.5 – 50) 150 A — (1) #4 – 4/0 (25 – 95) 25 (11.33) 47 (21.31) 53 (24.04) 75 (34.01) 136 (61.68) 138 (62.59) 96 (43.54) 88 (39.91) Mechanical Terminal Wire Range Per Phase (mm2) Approx. Weight Lbs. (kg)

Page 69

Plug-in Unit

Maximum Amperes

Maximum ac Volts

Dimensions in Inches (mm)

(A)

(B)

(C)

(D)

(E)

P3BFD (E- & F-Frame Breakers)

225

600

19.26 (489)

12.36 (314)

5.43 (138)

6.25 (159)

4.00 (102)

Effective: December 2002

P3BJD (J-Frame Breakers)

250

600

21.33 (542)

12.36 (314)

6.97 (177)

10.44 (265)

4.00 (102)

P3BKD (K-Frame Breakers)

400

600

32.50 (826)

13.29 (338)

7.79 (198)

12.56 (319)

4.00 (102)

P3BLD (L-Frame Breakers)

600

600

44.03 (1118)

19.65 (499)

10.15 (258)

17.38 (441)

4.00 (102)

P3BMD (M-Frame Breakers)

800

600

44.03 (1118)

19.65 (499)

10.15 (258)

17.38 (441)

4.00 (102)

P3BND (N-Frame Breakers)

800

600

44.03 (1118)

19.65 (499)

10.15 (258)

17.38 (441)

4.00 (102)

P3BLAP (TRI-PAC)

400

600

44.03 (1118)

19.65 (499)

10.15 (258)

13.80 (357)

4.00 (102)

P3BLCl

400

600

40.00 (1016)

19.65 (499)

10.15 (258)

13.80 (351)

4.00 (102)

IM01701002E

The clamp and guide mechanism adds 2.50 inches (63.5 mm) to the overall length of the unit.

Table 15. Fusible Plug-in Units
Mechanical Terminal Wire Range Per Phase (mm 2) 22 (9.98) Approx. Weight Lbs. (kg)

IM01701002E
24 (10.88) 24 (10.88) Cu — (1) #14 – #3 (2.5 – 35) Al — (1) #12 – #2 (3.2 – 35) Cu — (1) #14 – #3 1/0 (2.5 – 35) Al — (1) #12 – #2 (3.2 – 38) Cu — (1) #14 – 1/0 (2.5 – 50) Al — (1) #12 – 1/0 (3.2 – 50) Cu — (1) #14 – 1/0, (2.5 – 5.0) Al — (1) #12 – 1/0 (3.2 – 50) (1) #4 – 250 kcmil Cu/Al (25 – 120) (1) #4 – 250 kcmil Cu/Al (25 – 120) (1) #4 – 600 kcmil Cu/Al (25 – 300) or (2) 250 kcmil (120) 47 (21.31) 77 (34.74) 81 (36.74) 82 (37.19) (2) #2 – 600 kcmil Cu/Al (35 – 300) (2) #2 – 600 kcmil Cu/Al (35 – 300) (2) #2 – 600 kcmil Cu/Al (35 – 300) (3) #4 – 600 kcmil (25 – 300) (3) #4 – 600 kcmil Cu/ Al (25 – 300) 108 (48.98)

Plug-in Unit

Maximum Amperes

Maximum ac Volts

Dimensions in Inches (mm) (B) (C) (D) (A)

(E)

(F)

P3F321R and P3F361R

30

240 600

20.85 (529.6)

12.36 (313.9)

5.43 (137.9)

7.88 (200.2)

4.00 (101.6)

6.06 (153.9)

P3F322R and P3F362R

60

240 600

20.85 (529.6)

12.36 (313.9)

5.43 (137.9)

7.88 (200.2)

4.00 (101.6)

6.06 (153.9)

P3F323R and P3F363R

100

240

20.85 (529.6)

12.36 (313.9)

5.43 (137.9)

7.88 (200.2)

4.00 (101.6)

6.06 (153.9)

P3F324R and P3F364R

200

600 240 600

21.75 (552.5)

15.57 (395.5)

9.66 (245.4)

8.20 (208.3)

4.00 (101.6)

7.63 (193.8)

P3F325R and P3F365R

400

240 600

P3F365H

400

600

Effective: December 2002

240 600 600 240 P3F327R and 46.94 26.31 10.59 14.26 4.00 13.16 800 P3F367R (1192.3) (668.3) (270.0) (362.2) (101.6) (334.3) 600 The clamp and guide mechanism adds 2.50 inches (63.5 mm) to the overall length of the unit.

P3F326R and P3F366R

46.94 (1192.3) 23.47 (596.1) 46.94 (1192.3)

21.22 (539.0) 21.22 (539.0) 26.31 (668.3)

10.07 (255.8) 21.00 (533.4) 10.59 (270.0)

12.67 (321.8) 12.67 (321.8) 14.26 (362.2)

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

10.69 (271.5) 10.69 (271.5) 13.16 (334.3)

Page 70

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.

Effective: December 2002

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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 Corporation Cutler-Hammer business unit 1000 Cherrington Parkway Moon Township, PA 15108-4312 USA tel: 1-800-525-2000 www.cutler-hammer.eaton.com
© 2002 Eaton Corporation All Rights Reserved Printed in USA Publication No. IM01701002E December 2002

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