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B RO CH U R E

ReliaGear® High Power Busway

UL857 copper and aluminum
2 RELIAGEAR HIGH POWER BUSWAY
RELIAGEAR HIGH POWER BUSWAY 3

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Table of contents

004 Introduction

005 Standards

006–007 Technical features

008 Straight lengths

009–010 Elbows

011–012 Off-sets

013–014 Combinations

015 Flanges

016–017 Combination flanges

018 Specials

019 Miscellaneous

020 Splice

021 Installation

022–025 Technical data

026 Quick reference guide

4 RELIAGEAR HIGH POWER BUSWAY

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Introduction

ABB’s new ReliaGear High Power Busway can be utilized in building and industrial
applications to deliver power to electrical loads. Available in copper and aluminum,
the ReliaGear High Power Busway serves as an alternative to traditional cabling.

ABB’s ReliaGear High Power Busway range is a 600 V, totally
encased, non-ventilated, low impedance sandwich construction
with epoxy resin coated copper and aluminum conductors.
The range is available from 800A to 4000A in aluminum and up
to 5000A in copper with a maximum 6 cycle RMS symmetrical
short circuit rating of 200KA. It is available with multiple bar
configurations to suit project requirements, including neutral,
double neutral, ground and half ground.
The bar is housed in aluminum casing which also acts as a
ground and is available with a choice of ingress protection
ratings from IP40 to IP55 and IP 67 on request. It is available as
Indoor feeder, indoor plug-in and sprinkler proof configura-
tions. The busway is painted in grey (RAL 7035). Other colors
can be accommodated on request.
The product offering is complete with elbows, offsets, flanges,
tees, end and center feed units, expansion units and splices
commonly required for a busway installation. Installation hangers
are also available to order.
Bus plugs with fusible switches or circuit breakers are available
from 15 through 800 amps.
Features
• Copper and aluminum conductors available in tin or silver
coated-finish.
• Joint pack construction with double headed shear nuts, for
quick installation.
• Up to five bus plug points per side on a 12-ft length.
• All bus plugs have mechanical/electrical interlocks with a
ground first, break last safety feature.
• Pressed out tags for bus plug connections.
 RELIAGEAR HIGH POWER BUSWAY 5

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Standards

Standards
ReliaGear High Power Busway is UL857 listed and manufactured in a certified management system environment where Quality ISO
9001, Safety OHSAS 18001 and Environmental ISO 14001 standards are applied to all aspects of the manufacturing and installation
processes. We meet the requirements of NEMA, CSA (cUL), IEEE, ANSI, IEC & CE.

UL Listed
ABB completed extensive testing at UL accredited laboratories to ensure the product we supply meets UL requirements.

UL 857
Sub-clauses Description
8.2.1 Verification of Temperature Rise Limits
8.2.2 Verification of Dielectric Voltage Withstand Test
8.2.2.2 Clamped Joint Test
8.2.2.3 Reduced Insulation Thickness Test
8.2.3 Verification of Short Circuit Withstand
8.2.3.1.1.2 Dielectric Test Withstand Tests
8.2.6 Verification of Insulation Resistance and Dielectric Withstand After Exposure to Rain
8.2.7.1 Verification of Bending Resistance
8.2.7.2 Verification of Impact Strength
8.2.7.3 Verification of Crushing Resistance
8.2.7.4 Verification of Resistance to Bus Bar Pull Out
8.2.8 Verification of Overload and Endurance of Non-Switching Plug-in Devices
8.2.9 Verification of Resistance to Aging
8.2.10 Verification of Metallic Coating Thickness
8.2.11 Verification of Insulation Base and Support Strength
8.2.12 Gasket Tests
Ref to ANSI/UL 50 Type Rating Tests (Ingress Protection Tests) for the 2 series

Seismic compliance
The product range is certified for Seismic withstand capability and has a qualification level - high (Zone-5) in accordance to IEEE
standard 693-2005.

All certificates available on request.

OHSAS 18001:2007 ISO 9001:2008 ISO 14001:2004

OHS 533652 FM 12680 No: EMS 566536
6 RELIAGEAR HIGH POWER BUSWAY
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Technical features
Conductor/insulation system
ReliaGear High Power Busway is constructed from high purity
99.99% conductivity copper and high density 55% conductivity
aluminum. The conductors are insulated with a Class B
(130 °C/266 °F) epoxy insulation applied uniformly by our
automated electrostatic coating process. The epoxy coating is
non-hygroscopic, chemical resistant and has outstanding heat
transfer characteristics making it ideal for sandwich construction
applications. Epoxy has excellent dielectric strength, is flame
retardant and is impact resistant. The copper busbar is either
tin or silver plated at the contact areas. Class F (155 °C/311 °F)
is also available on request.
The low impedance sandwich design:
• Improves heat dissipation.
• Improves short circuit rating.
• Reduces voltage drop/ impedance compared to cable.
• Removes potential pathways for the propagation of flame,
smoke and gas through the busway system.
The plug-in busway lengths have tabs pressed into the conductor
to allow busplug units to be connected. This patented method
for creating the tabs does not require any welding process,
meaning the integrity of the conductor is not compromised.
Housing details
The ReliaGear High Power Busway UL857 range is constructed
with a rugged extruded all-aluminum housing with powder
coated paint finish. Aluminum offers numerous advantages
when compared to steel housings.
• Aluminum is a very light metal, about a third the weight of
steel on a per foot basis. This reduces transportation costs
and makes the product much easier to install.
• Aluminum is non-magnetic and has a significant reduction in
reactance and magnetic flux leakage when compared to steel.
• Unlike steel which rusts, aluminum naturally produces a
protective oxide coating which makes it highly corrosion
resistant. This means the product is more durable and
requires less maintenance.
• Aluminum is excellent at conducting heat and electricity
which means that the housing can be used as a ground along
the length of the busway.
Isolated ground bar (50% or 100%)
ABB offers a 50% or 100% fully isolated ground for systems
where ground isolation is required such as systems with heavy
microprocessors, based loads or large computer based
installations. The continuity is maintained through the joint pack.
Double neutral (200% option)
ABB offers a fully rated 200% neutral option for busway systems
with non-linear loads.
Note: Consult factory for UL 200% neutral option.
 RELIAGEAR HIGH POWER BUSWAY 7

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Technical features

Vertical spring hanger

Floor Firestop material

UL1479 listed

UL fire stop system Phase configurations

ReliaGear High Power Busway may be used in UL listed Configuration Phases Neutral Ground
through-penetration fire stop systems. Systems applicable to TP 100% 0% Case
busway (i.e. system number C-AJ-6002) are listed in UL Fire TP/N 100% 100% Case
Resistance Directory under Through-Penetration Fire Stop TP/E 100% 0% 100% or 50%
Systems and have met the ASTEM E814 (UL 1479) criteria. TP/NE 100% 100% 100% or 50%
TP/DN 100% 200%1 Case
For typical installations shown in the illustration above, the 1
Consult factory for UL 200% neutral offering.
contractor uses mineral wool batt and fire stop sealant. In
riser applications, the system is used in combination with Note: Case refers to the aluminum casing being used as an integral
ReliaGear High Power Busway UL standard vertical spring ground. 100% or 50% ground bar can either be supplied as an isolated
ground (ISO) or uninsulated internal ground (INT).
hangers and a floor flange. In horizontal applications, the system
is used in combination with two wall flanges, on one side of the
wall, and sealant.
8 RELIAGEAR HIGH POWER BUSWAY

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Straight lengths

Feeder length Straight lengths

Straight lengths include feeder lengths and plug-in lengths
with busplug slots.

Busplug slots allow busplug units to be plugged into the busway

run. The busplug slot outlet and cover are made from a durable,
high strength, Class B, 130 °C insulation material.

The busplug slot cover is designed to prevent access to the

contacts behind the cover and prevent the entry of dirt, dust
or moisture. With a standard busplug unit or fitted cover the
Ingress Protection (IP) levels are at IP40 to IP55. IP67 for
feeder lengths are available upon request.
Plug-in length
Straight lengths can be supplied from a minimum of 2 ft and
up to a maximum of 10 slots can be provided on a 12 ft length
(5 on the front and 5 on the back). The table below illustrates
the different types of build arrangement used depending on
Busplug cover the rating of busway required for the application.

Busplug shutter

Copper Aluminum
Busway Construction Busway size Busway Construction Busway size
rating type rating type
(amps) (amps)
Width Height Width Height
in mm in mm in mm in mm
800A Single 3.74" 95mm 5.83" 148mm 800A Single 4.72" 120mm 5.83" 145mm
1000A Single 4.33" 110mm 5.83" 148mm 1000A Single 5.51" 140mm 5.83" 145mm
1200A Single 4.72" 120mm 5.83" 148mm 1200A Single 6.30" 160mm 5.83" 145mm
1350A Single 5.32" 135mm 5.83" 148mm
1350A Single 6.89" 175mm 5.83" 145mm
1600A Single 6.30" 160mm 5.83" 148mm
1600A Single 8.07" 205mm 5.83" 145mm
2000A Single 7.87" 200mm 5.83" 148mm
2000A Single 10.24" 260mm 5.83" 145mm
2500A Single 9.84" 250mm 5.83" 148mm
3000A Double 13.58" 345mm 5.83" 148mm 2500A Double 14.76" 375mm 5.83" 145mm

4000A Triple 19.69" 500mm 5.83" 148mm 3000A Double 17.13" 435mm 5.83" 145mm
5000A Triple 23.82" 605mm 5.83" 148mm 4000A Triple 23.82" 605mm 5.83" 145mm

Note: The maximum and minimum sizes are not the extent of our offerings, but are a guildeline to help you choose the correct product. Dimensions are
taken from the center of the joint.
 RELIAGEAR HIGH POWER BUSWAY 9

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Elbows

Flatwise elbows
y Flatwise elbows are typically used to make 90° changes in the
direction of the busway system. There are two main types:
y flatwise up and flatwise down.
y

These can be used to turn the busway route up or down if it is

running on its edge, or to turn the busway left and right if it is
running on its flat.
x
x x Edgewise elbows
Edgewise elbows are typically used to make 90° changes in
Flatwise elbow Edgewise elbow Custom elbow
the direction of the busway system.

There are two main types: edgewise right and edgewise left.
These can be used to turn the busway route up or down if it is
running on its flat, or to turn the busway left and right if it is
running on its edge.

Custom elbows
While elbows are typically 90°, ABB can manufacture special angle
elbows if necessary for both flatwise and edgewise products.
Copper
Flatwise elbow (up or down)
Ratings (amps) Minimum leg size Standard leg size Maximum leg size
X Y X Y X Y
in mm in mm in mm in mm in mm in mm
800A 9.06" 230mm 9.06" 230mm 14" 355mm 14" 355mm 30" 762mm 30" 762mm
1000A 9.37" 238mm 9.37" 238mm 14" 355mm 14" 355mm 30" 762mm 30" 762mm
1200A 9.57" 243mm 9.57" 243mm 14" 355mm 14" 355mm 30" 762mm 30" 762mm
1350A 9.84" 250mm 9.84" 250mm 14" 355mm 14" 355mm 30" 762mm 30" 762mm
1600A 10.35" 263mm 10.35" 263mm 14" 355mm 14" 355mm 30" 762mm 30" 762mm
2000A 11.14" 283mm 11.14" 283mm 14" 355mm 14" 355mm 30" 762mm 30" 762mm
2500A 12.13 " 308mm 12.13" 308mm 14" 355mm 14" 355mm 30" 762mm 30" 762mm
3000A 13.98" 355mm 13.98" 355mm 20" 508mm 20" 508mm 30" 762mm 30" 762mm
4000A 17.05" 433mm 17.05" 433mm 20" 508mm 20" 508mm 30" 762mm 30" 762mm
5000A 19.13" 486mm 19.13" 486mm 20" 508mm 20" 508mm 30" 762mm 30" 762mm

Edgewise elbow (left or right)

Ratings (amps) Minimum leg size Standard leg size Maximum leg size
X Y X Y X Y
in mm in mm in mm in mm in mm in mm
800A 10" 230mm 9.06" 230mm 14" 355mm 14" 355mm 30" 762mm 30" 762mm
1000A 9.37" 238mm 9.37" 238mm 14" 355mm 14" 355mm 30" 762mm 30" 762mm
1200A 9.57" 243mm 9.57" 243mm 14" 355mm 14" 355mm 30" 762mm 30" 762mm
1350A 9.84" 250mm 9.84" 250mm 14" 355mm 14" 355mm 30" 762mm 30" 762mm
1600A 10.35" 263mm 10.35" 263mm 14" 355mm 14" 355mm 30" 762mm 30" 762mm
2000A 11.14" 283mm 11.14" 283mm 14" 355mm 14" 355mm 30" 762mm 30" 762mm
2500A 12.13" 308mm 12.13" 308mm 14" 355mm 14" 355mm 30" 762mm 30" 762mm
3000A 13.98" 355mm 13.98" 355mm 20" 508mm 20" 508mm 30" 762mm 30" 762mm
4000A 17.05" 433mm 17.05" 433mm 20" 508mm 20" 508mm 30" 762mm 30" 762mm
5000A 19.13" 486mm 19.13" 486mm 20" 508mm 20" 508mm 30" 762mm 30" 762mm
10 RELIAGEAR HIGH POWER BUSWAY

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Elbows

Aluminum
Flatwise elbow (up or down)
Ratings (amps) Minimum leg size Standard leg size Maximum leg size
X Y X Y X Y
in mm in mm in mm in mm in mm in mm
800A 9.763" 248mm 9.763" 248mm 13.779" 350mm 13.779" 350mm 29.527" 750mm 29.527" 750mm
1000A 9.960" 253mm 9.960" 253mm 13.779" 350mm 13.779" 350mm 29.527" 750mm 29.527" 750mm
1200A 10.551" 268mm 10.551" 268mm 13.779" 350mm 13.779" 350mm 29.527" 750mm 29.527" 750mm
1350A 10.826" 275mm 10.826" 275mm 13.779" 350mm 13.779" 350mm 29.527" 750mm 29.527" 750mm
1600A 11.220" 285mm 11.220" 285mm 13.779" 350mm 13.779" 350mm 29.527" 750mm 29.527" 750mm
2000A 12.322" 313mm 12.322" 313mm 13.779" 350mm 13.779" 350mm 29.527" 750mm 29.527" 750mm
2500A 14.330" 364mm 14.330" 364 mm 13.779" 350mm 13.779" 350mm 29.527" 750mm 29.527" 750mm
3000A 15.708" 399mm 15.708" 399mm 19.685" 500mm 19.685" 500mm 29.527" 750mm 29.527" 750mm
4000A 17.874" 454mm 17.874" 454mm 19.685" 500mm 19.685" 500mm 29.527" 750mm 29.527" 750mm

Edgewise elbow (left or right)

Ratings (amps) Minimum leg size Standard leg size Maximum leg size
X Y X Y X Y
in mm in mm in mm in mm in mm in mm
800A 10" 254mm 10" 254mm 14" 355mm 14" 355mm 24" 610mm 24" 610mm
1000A 10" 254mm 10" 254mm 14" 355mm 14" 355mm 24" 610mm 24" 610mm
1200A 10" 254mm 10" 254mm 14" 355mm 14" 355mm 24" 610mm 24" 610mm
1350A 10" 254mm 10" 254mm 14" 355mm 14" 355mm 24" 610mm 24" 610mm
1600A 10" 254mm 10" 254mm 14" 355mm 14" 355mm 24" 610mm 24" 610mm
2000A 10" 254mm 10" 254mm 14" 355mm 14" 355mm 24" 610mm 24" 610mm
2500A 10" 254mm 10" 254mm 14" 355mm 14" 355mm 24" 610mm 24" 610mm
3000A 10" 254mm 10" 254mm 14" 355mm 14" 355mm 24" 610mm 24" 610mm
4000A 10" 254mm 10" 254mm 14" 355mm 14" 355mm 24" 610mm 24" 610mm
 RELIAGEAR HIGH POWER BUSWAY 11

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Offsets

Combination possibilities
x Flatwise offset up
x
Flatwise offset down
Edgewise offset right
Edgewise offset left

Offset sections
y y An offset is used to avoid obstacles such as pipes or steel
columns and to conform to the structure of the building. It is
basically two elbows fabricated into one single piece.
x x
There are four types of offset sections: flatwise offset up and
down, and edgewise offset left and right.
Flatwise offset Edgewise offset

Copper
Flatwise offset (up or down)
Ratings (amps) Minimum leg size Maximum leg size
X Y X Y
in mm in mm in mm in mm
800A 9.06" 230mm 2" 51mm 26" 660mm 18.11" 460mm
1000A 9.37" 238mm 2" 51mm 26" 660mm 18.74" 476mm
1200A 9.57" 243mm 2" 51mm 26" 660mm 19.13" 486mm
1350A 9.84" 250mm 2" 51mm 26" 660mm 19.69" 500mm
1600A 10.35" 263mm 2" 51mm 26" 660mm 20.71" 526mm
2000A 11.14" 283mm 2" 51mm 26" 660mm 22.28" 566mm
2500A 12.13" 308mm 2" 51mm 26" 660mm 24.25" 616mm
3000A 13.98" 355mm 2" 51mm 26" 660mm 27.95" 710mm
4000A 17.05" 433mm 2" 51mm 26" 660mm 34.10" 866mm
5000A 19.13" 486mm 2" 51mm 26" 660mm 38.26" 972mm

Edgewise offset (left or right)

Ratings (amps) Minimum leg size Maximum leg size
X Y X Y
in mm in mm in mm in mm
800A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
1000A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
1200A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
1350A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
1600A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
2000A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
2500A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
3000A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
4000A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
5000A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
12 RELIAGEAR HIGH POWER BUSWAY

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Offsets

Aluminum
Flatwise offset (up or down)
Ratings (amps) Minimum leg size Maximum leg size
X Y X Y
in mm in mm in mm in mm
800A 9.763" 248mm 2" 51mm 26" 660mm 19.527" 496mm
1000A 9.960" 253mm 2" 51mm 26" 660mm 19.921" 506mm
1200A 10.551" 268mm 2" 51mm 26" 660mm 21.102" 536mm
1350A 10.826" 275mm 2" 51mm 26" 660mm 20.866" 550mm
1600A 11.220" 285mm 2" 51mm 26" 660mm 22.440" 570mm
2000A 12.322" 313mm 2" 51mm 26" 660mm 24.645" 626mm
2500A 14.330" 364mm 2" 51mm 26" 660mm 28.661" 728mm
3000A 15.708" 399mm 2" 51mm 26" 660mm 31.417" 798mm
4000A 17.874" 454mm 2" 51mm 26" 660mm 35.748" 908mm

Edgewise offset (left or right)

Ratings (amps) Minimum leg size Maximum leg size
X Y X Y
in mm in mm in mm in mm
800A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
1000A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
1200A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
1350A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
1600A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
2000A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
2500A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
3000A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
4000A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
5000A 10" 254mm 3" 76mm 20" 508mm 24" 610mm
 RELIAGEAR HIGH POWER BUSWAY 13

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Combinations

Combination possibilities
Edgewise right/flatwise up
y
z
Edgewise right/flatwise down
Edgewise left/flatwise up
Edgewise left/flatwise down
x
Flatwise up/edgewise left
Flatwise up/edgewise right
y Flatwise down/edgewise left
Flatwise down/edgewise right

x z Combination elbows
Combination elbows are used to conform to the buildings'
Edge right flatwise up Flatwise up edgewise structure and to utilize a small amount of space to change
direction by combining both flatwise and edgewise elbows.

Copper
Combination elbows
Ratings (amps) Minimum leg size
X (edgewise side) Y Z (flatwise side)
in mm in mm in mm
800A 10" 254mm 6.77" 172mm 9.06" 230mm
1000A 10" 254mm 7.05" 179mm 9.37" 238mm
1200A 10" 254mm 7.24" 184mm 9.57" 243mm
1350A 10" 254mm 7.56" 192mm 9.84" 250mm
1600A 10" 254mm 8.03" 204mm 10.35" 263mm
2000A 10" 254mm 8.82" 224mm 11.24" 283mm
2500A 10" 254mm 9.80" 249mm 12.13" 308mm
3000A 10" 254mm 11.36" 297mm 13.98" 355mm
4000A 10" 254mm 14.69" 373mm 17.05" 433mm
5000A 10" 254mm 16.73" 425mm 19.13" 486mm

Combination elbows
Ratings (amps) Maximum leg size
X (edgewise side) Y Z (flatwise side)
in mm in mm in mm
800A 24" 610mm 19.06" 484mm 30" 762mm
1000A 24" 610mm 19.37" 492mm 30" 762mm
1200A 24" 610mm 19.57" 497mm 30" 762mm
1350A 24" 610mm 19.84" 504mm 30" 762mm
1600A 24" 610mm 20.35" 517mm 30" 762mm
2000A 24" 610mm 21.14" 537mm 30" 762mm
2500A 24" 610mm 22.13" 562mm 30" 762mm
3000A 24" 610mm 23.98" 609mm 30" 762mm
4000A 24" 610mm 27.05" 687mm 30" 762mm
5000A 24" 610mm 29.13" 740mm 30" 762mm
14 RELIAGEAR HIGH POWER BUSWAY

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Combinations

Aluminum
Combination elbows
Ratings (amps) Minimum leg size
X (edgewise side) Y Z (flatwise side)
in mm in mm in mm
800A 10" 254mm 7.181" 182.4mm 9.763" 248mm
1000A 10" 254mm 7.574" 192.4mm 9.960" 253mm
1200A 10" 254mm 7.968" 202.4mm 10.551" 268mm
1350A 10" 254mm 8.263" 209.9mm 10.826" 275mm
1600A 10" 254mm 8.854" 224.9mm 11.220" 285mm
2000A 10" 254mm 9.937" 252.4mm 12.322" 313mm
2500A 10" 254mm 12.200" 309.9mm 14.330" 364mm
3000A 10" 254mm 13.381" 339.9mm 15.708" 399mm
4000A 10" 254mm 16.728" 424.9mm 17.874" 454mm

Combination elbows
Ratings (amps) Maximum leg size
X (edgewise side) Y Z (flatwise side)
in mm in mm in mm
800A 24" 610mm 19.763" 502mm 30" 762mm
1000A 24" 610mm 19.960" 507mm 30" 762mm
1200A 24" 610mm 20.551" 522mm 30" 762mm
1350A 24" 610mm 20.826" 529mm 30" 762mm
1600A 24" 610mm 21.220" 539mm 30" 762mm
2000A 24" 610mm 22.322" 567mm 30" 762mm
2500A 24" 610mm 24.330" 618mm 30" 762mm
3000A 24" 610mm 25.708" 653mm 30" 762mm
4000A 24" 610mm 27.874" 708mm 30" 762mm
 RELIAGEAR HIGH POWER BUSWAY 15

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Flanges

Flange connections
Flange connections provide a direct connection to low voltage
switchgear, transformer enclosures and other electrical
equipment. Cut out details, dimensions and drilling plans are
provided with the customer drawings and it is the responsibility
of the switchgear manufacturer to provide the opening, drill
fixing holes, connecting hardware and busway risers in their
equipment.

Switchgear can be provided upon request. For more information,

x contact ABB.

For proper coordination between the busway system and the

Panel flange Parallel flange
equipment, detailed drawings, including switchgear phase
rotation, must accompany the order. Standard flanges can be
offset to the left or right of the section as required.

Copper
Panel flange
Ratings (amps) Minimum Maximum
X X
in mm in mm
800A  9" 229mm 33" 838mm
1000A 9" 229mm 33" 838mm
1200A 9" 229mm 33" 838mm
1350A 9" 229mm 33" 838mm
1600A 9" 229mm 33" 838mm
2000A 9" 229mm 33" 838mm
2500A 9" 229mm 33" 838mm
3000A 9" 229mm 33" 838mm
4000A 9" 229mm 33" 838mm
5000A 9" 229mm 33" 838mm

Aluminum
Panel flange
Ratings (amps) Minimum Maximum
X X
in mm in mm
800A  9" 229mm 33" 838mm
1000A 9" 229mm 33" 838mm
1200A 9" 229mm 33" 838mm
1350A 9" 229mm 33" 838mm
1600A 9" 229mm 33" 838mm
2000A 9" 229mm 33" 838mm
2500A 9" 229mm 33" 838mm
3000A 9" 229mm 33" 838mm
4000A 9" 229mm 33" 838mm
16 RELIAGEAR HIGH POWER BUSWAY

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Combination flanges

Combination possibilities
x Panel flange/edgewise left
Panel flange/edgewise right
x
Panel flange/edgewise up
Panel flange/edgewise down
Edgewise left/panel flange
Edgewise right/panel flange
Flatwise up/panel flange
Flatwise down/panel flange

Combination flanges
A flange combination elbow is a combination of a standard
elbow and a standard flange. Flange combination elbows are
typically used when the minimum leg lengths for either the
standard elbow or the standard flange cannot be maintained.
y y

For example: when the busway must lay close to the top of the
Flatwise elbow flange Edgewise elbow flange
switchgear to avoid other services or when there is reduced
head height above the switchgear.

Copper
Flange/elbows (flatwise)
Ratings (amps) Minimum leg size Maximum leg size
X Y X Y
in mm in mm in mm in mm
800A 9.06" 230mm 3.85" 98mm 30" 762mm 18.11" 460mm
1000A 9.37" 238mm 4.13" 105mm 30" 762mm 18.74" 476mm
1200A 9.57" 243mm 4.33" 110mm 30" 762mm 19.13" 486mm
1350A 9.84" 250mm 4.65" 118mm 30" 762mm 19.69" 500mm
1600A 10.35" 263mm 5.12" 130mm 30" 762mm 20.70" 526mm
2000A 11.14" 283mm 5.91" 150mm 30" 762mm 22.28" 566mm
2500A 12.13" 308mm 6.89" 175mm 30" 762mm 24.25“ 616mm
3000A 13.98" 355mm 8.78" 223mm 30" 762mm 27.95" 710mm
4000A 17.05" 433mm 11.81" 300mm 30" 762mm 34.09" 866mm
5000A 19.13" 486mm 13.90" 353mm 30" 762mm 38.27" 972mm

Flange/elbows (edgewise)
Ratings (amps) Minimum leg size Maximum leg size
X Y X Y
in mm in mm in mm in mm
800A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
1000A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
1200A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
1350A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
1600A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
2000A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
2500A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
3000A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
4000A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
5000A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
 RELIAGEAR HIGH POWER BUSWAY 17

Aluminum
Flange/elbows (flatwise)
Ratings (amps) Minimum leg size Maximum leg size
X Y X Y
in mm in mm in mm in mm
800A 9.763" 248mm 3.149" 80mm 30" 762mm 19.527" 496mm
1000A 9.960" 253mm 3.543" 90mm 30" 762mm 19.921" 506mm
1200A 10.551" 268mm 3.937" 100mm 30" 762mm 21.102" 536mm
1350A 10.826" 275mm 4.232" 107.5mm 30" 762mm 21.653" 550mm
1600A 11.220" 285mm 4.822" 122.5mm 30" 762mm 22.440" 570mm
2000A 12.322" 313mm 5.905" 150mm 30" 762mm 24.645" 626mm
2500A 14.330" 364mm 6.496" 165mm 30" 762mm 28.661" 728mm
3000A 15.708" 399mm 7.677" 195mm 30" 762mm 31.417" 798mm
4000A 17.874" 454mm 12.677" 322mm 30" 762mm 35.748" 908mm

Flange/elbows (edgewise)
Ratings (amps) Minimum leg size Maximum leg size
X Y X Y
in mm in mm in mm in mm
800A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
1000A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
1200A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
1350A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
1600A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
2000A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
2500A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
3000A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
4000A 10" 254mm 5" 127mm 24" 610mm 20" 508mm
18 RELIAGEAR HIGH POWER BUSWAY

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Specials

Flatwise tees
Flatwise tees are used to split one busway run into two runs
x going in different directions. This can be very useful in utilizing a
small amount of space and supplying two different areas of a
building with power. Flatwise tees are a combination of a feeder
length and a flatwise elbow.

Copper
Flatwise tee
Ratings (amps) Minimum leg size Standard leg size Maximum leg size
X Y X Y X Y
in mm in mm in mm in mm in mm in mm
800A 18.11" 460mm 9.06" 230mm 28" 711mm 14" 356mm 60" 1524mm 26" 660mm
1000A 18.39" 476mm 9.37" 238mm 28" 711mm 14" 356mm 60" 1524mm 26" 660mm
1200A 19.13" 486mm 9.57" 243mm 28" 711mm 14" 356mm 60" 1524mm 26" 660mm
1350A 19.69" 500mm 9.84" 250mm 28" 711mm 14" 356mm 60" 1524mm 26" 660mm
1600A 20.71" 526mm 10.35" 263mm 28" 711mm 14" 356mm 60" 1524mm 26" 660mm
2000A 22.28" 566mm 11.14" 283mm 28" 711mm 14" 356mm 60" 1524mm 26" 660mm
2500A 24.25“ 616mm 12.13" 308mm 28" 711mm 14" 356mm 60" 1524mm 26" 660mm
3000A 27.95" 710mm 13.98" 355mm 40" 1016mm 20" 508mm 60" 1524mm 26" 660mm
4000A 34.09" 866mm 17.05" 433mm 40" 1016mm 20" 508mm 60" 1524mm 26" 660mm
5000A 38.27" 972mm 19.13" 486mm 40" 1016mm 20" 508mm 60" 1524mm 26" 660mm

Aluminum
Flatwise tee
Ratings (amps) Minimum leg size Standard leg size Maximum leg size
X Y X Y X Y
in mm in mm in mm in mm in mm in mm
800A 19.527" 496mm 9.763" 248mm 28" 711mm 28" 356mm 60" 1524mm 26" 660mm
1000A 19.921" 506mm 9.960" 253mm 28" 711mm 28" 356mm 60" 1524mm 26" 660mm
1200A 21.102" 536mm 10.551" 268mm 28" 711mm 28" 356mm 60" 1524mm 26" 660mm
1350A 21.653" 550mm 10.826" 275mm 28" 711mm 28" 356mm 60" 1524mm 26" 660mm
1600A 22.440" 570mm 11.220" 285mm 28" 711mm 28" 356mm 60" 1524mm 26" 660mm
2000A 24.645" 626mm 12.322" 313mm 28" 711mm 28" 356mm 60" 1524mm 26" 660mm
2500A 28.661" 728mm 14.330" 364mm 28" 711mm 28" 356mm 60" 1524mm 26" 660mm
3000A 31.417" 798mm 15.708" 399mm 28" 711mm 28" 356mm 60" 1524mm 26" 660mm
4000A 35.748" 908mm 17.874" 454mm 28" 711mm 28" 356mm 60" 1524mm 26" 660mm
 RELIAGEAR HIGH POWER BUSWAY 19

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Miscellaneous

End feed units End caps Spring hanger

Cable end feed units are used on the
ends of busway risers which are cable
fed. They can be on the top of the busway,
feeding down through the building, or
they can be located at the bottom of
the busway riser, feeding up through
the building.
The size of the cable end feed unit
depends on a number of factors:
• Rating of busway
• Size of cable
• Number of cables
• Whether a protective device or an
isolator is required
End caps are used to safely cap off the
end of a busway run. The end cap units
are factory fitted but they can be easily
removed on site to allow for the extension
of a busway system. If the busway run is
bottom fed, the end cap would be located
at the top end of the busway. If the system
is top fed, then the end cap would be
located at the bottom. In the case of a
center fed system, an end cap must be
used at both ends of the system, at the
top and bottom.
Center feed units are used in the middle
of busway risers which are cable fed.
The size of a center feed unit depends
on a number of factors:
• Rating of busway
• Size of cable
• Number of cables
• Whether a protective device or an
isolator is required

Expansion units
Expansion units are fittings used to accommodate the expansion and contraction of
a busway system and building movement. Expansion units are typically installed in
the center of long busway runs, and might also be used at the beginning of riser runs
to minimize the stress on the lower section of the busway run. Another common use
is where a busway crosses an expansion joint of a building.

Expansion units are recommended when a straight busway run exceeds 60m.

Expansion units allow for a 40mm movement along the length of the busway.
20 RELIAGEAR HIGH POWER BUSWAY

—
Splice

Splice Flatwise elbow splice

ReliaGear High Power Busway is a compression joint design
which utilizes a specially designed Belleville washer to distribute
the pressure evenly over the joint pack.
The splice can provide a field adjustment of +/-0.5" in length
of two joint packs to allow for installation variation.
Flatwise elbow joint packs are typically used to make 90°
changes in the direction of the busway system.
These can be used to turn the busway route up or down if it is
running on its edge, or to turn the busway left and right if it is
running on its flat.

Joint packs are used to connect all the components in a busway

system together, from feeder lengths to flatwise tees.

The ground is maintained through the joint, both by the joint

pack cover and by the ground side plate. The joint pack is
supplied in specific sizes depending on the rating of busway
required.

During installation, when the joint is torqued properly, the

first head of the nut will break off and the red indicator disk
will fall away.

If any red disks are still present after installation, the joints
have not been properly secured.
 RELIAGEAR HIGH POWER BUSWAY 21

—
Installation

Edge installation Flat installation Spring hanger

This is the preferred method of installation
for smaller rated busway systems. It is
also the main method used to install
distribution busway in building risers as
it ensures busplug units can be connected
easily.
This is the preferred method of installation
for higher rated, multistack busway
systems. When coordinated through the
building on its flat, any busway rating
only has a height of 148mm/5.83".
Spring hangers are used to support
vertical busway runs. They are used to
support the weight of the busway system
on each floor and also compensate for
minimal building movement and thermal
expansion.

The standard spring bracket is designed

to suit our single stack busway system;
for multistack arrangements, please
contact our engineering team for details.

Installation
Busway can either be installed to run on its “flat" or on its “edge." This installation decision is governed by a number of factors:

• Busway route • Type of installation • Available space • Size of busway

Special sections
We manufacture a variety of more specialized units and components to meet unique system requirements ranging from edgewise
tees, flatwise crosses, step up/step down reducers, phase rotation units, in-line disconnect cubicles, in-line busplug units, custom
built busway connection units.

ABB has the ability to manufacture a wide range of specialize busway for various and unique applications.

Please contact ABB with your specialized application, our engineering team will work with you to customize a solution.
22 RELIAGEAR HIGH POWER BUSWAY

—
Technical data—copper

Rated Current (A) 800 1000 1200 1350 1600

Rated Operational Voltage (V) 600 600 600 600 600
Rated Insulation Voltage (V) 600 600 600 600 600
Short Circuit
6 Cycle RMS Symmetrical Short
Circuit rating (KA) 75 100 100 100 150
Phase Conductor Cross Sectional Area
Inches² 0.31 0.47 0.56 0.70 0.93
Milimeters² 202 300 360 450 600
Neutral Conductor Cross Sectional Area
Inches² 0.31 0.47 0.56 0.70 0.93
Milimeters² 202 300 360 450 600
Isolated 100% Ground Conductor Cross Sectional Area
Inches² 0.31 0.47 0.56 0.70 0.93
Milimeters² 202 300 360 450 600
50% Ground Cross Sectional Area
Inches² 0.16 0.23 0.28 0.35 0.46
Milimeters² 105 150 180 225 300
Housing Ground Path Cross Sectional Area
Inches² 2.68 2.82 2.92 3.06 3.30
Milimeters² 1730 1820 1880 1970 2120
Overall Dimensions
Height x Width (in) 3.74 x 5.83 4.33 x 5.83 4.72 x 5.83 5.32 x 5.83 6.30 x 5.83
Height x Width (mm) 95 x 148 110 x 148 120 x 148 135 x 148 160 x 148
Weight
Weight of 4 Bar System (lbs/ft) 10.43 12.89 14.57 17.09 21.29
Weight of 5 Bar System (lbs/ft) 11.77 14.80 16.87 20.33 25.12
Resistance
Resistance (mΩ/100ft) at 68.5 °F 2.591 1.450 1.098 0.838 0.561
Resistance (mΩ/100ft) at 176 °F 3.201 1.785 1.385 1.042 0.732
Reactance
Reactance (mΩ/100ft) at 60Hz 1.189 0.558 0.497 0.406 0.293
Impedance
Impedance (mΩ/m) at 176 °F 3.354 1.840 1.437 1.092 0.756
Voltage Drop Full Load 60Hz per 100ft
Power Factor = 0.7 (V/100ft) at 176 °F 4.299 2.853 2.752 2.384 1.998
Power Factor = 0.8 (V/100ft) at 176 °F 4.573 3.052 2.922 2.519 2.109
Power Factor = 0.9 (V/100ft) at 176 °F 4.756 3.203 3.041 2.606 2.179
Power Factor = 1.0 (V/100ft) at 176 °F 4.482 3.091 2.879 2.436 2.018
 RELIAGEAR HIGH POWER BUSWAY 23

Rated Current (A) 2000 2500 3000 4000 5000

Rated Operational Voltage (V) 600 600 600 600 600
Rated Insulation Voltage (V) 600 600 600 600 600
Short Circuit
6 Cycle RMS Symmetrical Short circuit rating (KA) 150 150 200 200 200
Phase Conductor Cross Sectional Area
Inches² 1.30 1.77 1.86 2.51 3.49
Milimeters² 840 1140 1200 1620 2250
Neutral Conductor Cross Sectional Area
Inches² 1.30 1.77 1.86 2.51 3.49
Milimeters² 840 1140 1200 1620 2250
Isolated 100% Ground Conductor Cross Sectional Area
Inches² 1.30 1.77 1.86 2.51 3.49
Milimeters² 840 1140 1200 1620 2250
50% Ground Cross Sectional Area
Inches² 0.65 0.88 0.93 1.25 1.74
Milimeters² 420 570 600 810 1125
Housing Ground Path Cross Sectional Area
Inches² 3.66 4.14 6.60 9.60 10.56
Milimeters² 2360 2660 4238 6179 6809
Overall Dimensions
Height x Width (in) 7.87 x 5.83 9.84 x 5.83 13.58 x 5.83 19.69 x 5.83 23.82 x 5.83
Height x Width (mm) 200 x 148 250 x 148 345 x 148 500 x 148 605 x 148
Weight
Weight of 4 Bar System (lbs/ft) 28.01 36.42 43.17 58.37 59.95
Weight of 5 Bar System (lbs/ft) 33.37 43.69 50.97 68.59 70.17
Resistance
Resistance (mΩ/100ft) at 68 °F 0.480 0.327 0.293 0.232 0.149
Resistance (mΩ/100ft) at 176 °F 0.587 0.403 0.341 0.283 0.199
Reactance
Reactance (mΩ/100ft) at 60Hz 0.267 0.176 0.146 0.129 0.075
Impedance
Impedance (mΩ/m) at 176 °F 0.640 0.428 0.366 0.309 0.199
Voltage Drop Full Load 60Hz
Power Factor = 0.7 (V/100ft) at 176 °F 2.083 1.766 1.785 2.008 1.666
Power Factor = 0.8 (V/100ft) at 176 °F 2.181 1.854 1.876 2.103 1.765
Power Factor = 0.9 (V/100ft) at 176 °F 2.233 1.903 1.928 2.153 1.831
Power Factor = 1.0 (V/100ft) at 176 °F 2.033 1.745 1.774 1.960 1.722
24 RELIAGEAR HIGH POWER BUSWAY

—
Technical data—aluminum

Rated Current (A) 800 1000 1200 1350 1600

Rated Operational Voltage (V) 1000 1000 1000 1000 1000
Rated Insulation Voltage (V) 1000 1000 1000 1000 1000
Short Circuit
6 Cycle RMS Symmetrical Short circuit rating (KA) 75 100 100 100 150
Phase Conductor Cross Sectional Area
Inches² 0.59 0.74 0.93 1.07 1.35
Neutral Conductor Cross Sectional Area
Inches² 0.59 0.74 0.93 1.07 1.35
Millimeters² 360 480 600 690 870
Isolated 100% Ground Conductor
Inches² 0.59 0.74 0.93 1.07 1.35
Millimeters² 360 480 600 690 870
50% Ground Cross Sectional Area
Inches² 0.28 0.37 0.47 0.53 0.67
Millimeters² 180 240 300 345 435
Housing Ground Path
Inches² 2.92 3.10 3.30 3.44 3.74
180millimeters² 1880 2000 2120 2210 2390
Overall Dimensions
Height x Width (in) 4.72 x 5.83 5.51 x 5.83 6.30 x 5.83 6.89 x 5.83 8.07 x 5.83
Height x Width (mm) 120 x 148 140 x 148 160 x 148 175 x 148 205 x 148
Weight
Weight of 4 Bar System (lbs/ft) 8.26 9.52 10.78 11.73 13.59
Weight of 5 Bar System (lbs/ft) 8.98 10.48 11.98 13.10 15.32
Resistance
Resistance (mΩ/100ft) at 68 °F 2.092 2.009 1.397 1.245 1.165
Resistance (mΩ/100ft) at 176 °F 2.628 2.527 1.754 1.562 1.466
Reactance
Reactance (mΩ/100ft) at 60Hz 0.436 0.430 0.308 0.278 0.265
Impedance
Impedance (mΩ/m) at 176 °F 2.139 2.058 1.427 1.285 1.195
Voltage Drop Full Load 60Hz per 100ft
Power Factor = 0.7 (V/100ft) at 176 °F 2.980 3.596 3.009 3.021 3.369
Power Factor = 0.8 (V/100ft) at 176 °F 3.275 3.949 4.085 3.312 3.692
Power Factor = 0.9 (V/100ft) at 176 °F 3.540 4.264 3.560 3.571 3.978
Power Factor = 1.0 (V/100ft) at 176 °F 3.641 4.377 3.646 3.653 4.064
 RELIAGEAR HIGH POWER BUSWAY 25

Rated Current (A) 2000 2500 3000 4000

Rated Operational Voltage (V) 1000 1000 1000 1000
Rated Insulation Voltage (V) 1000 1000 1000 1000
Short Circuit
6 Cycle RMS Symmetrical Short circuit rating (KA) 150 200 200 200
Phase Conductor Cross Sectional Area
Inches² 1.86 2.14 2.70 3.49
Millimeters² 1200 1380 1740 2250
Neutral Conductor Cross Sectional Area
Inches² 1.86 2.14 2.70 3.49
Millimeters² 1200 1380 1740 2250
Isolated 100% Ground Conductor
Cross Sectional Area
Inches² 1.86 2.14 2.70 3.49
Millimeters² 1200 1380 1740 2250
50% Ground Cross Sectional Area
Inches² 0.93 1.07 1.35 1.74
Millimeters² 600 690 870 1125
Housing Ground Path
Inches² 4.22 6.88 7.44 10.56
Millimeters² 2720 4419 4779 6809
Overall Dimensions
Height x Width (in) 10.24 x 5.83 14.76 x 5.83 17.13 x 5.83 23.82 x 5.83
Height x Width (mm) 260 x 148 375 x 148 435 x 148 605 x 148
Weight
Weight of 4 Bar System (lbs/ft) 17.08 23.63 27.35 37.26
Weight of 5 Bar System (lbs/ft) 19.48 26.43 30.87 41.80
Resistance
Resistance (mΩ/100ft) at 20 °F 0.844 0.741 0.582 0.397
Resistance (mΩ/100ft) at 80 °F 1.061 0.930 0.732 0.497
Reactance
Reactance (mΩ/100ft) at 60Hz 0.201 0.160 0.134 0.094
Impedance
Impedance (mΩ/m) at 176 °F 0.866 0.758 0.598 0.406
Voltage Drop Full Load 60Hz per 100ft
Power Factor = 0.7 (V/100ft) at 176 °F 3.070 3.315 3.159 2.878
Power Factor = 0.8 (V/100ft) at 176 °F 3.358 3.639 3.460 3.148
Power Factor = 0.9 (V/100ft) at 176 °F 3.612 3.928 3.726 3.386
Power Factor = 1.0 (V/100ft) at 176 °F 3.675 4.028 3.802 3.445
26 RELIAGEAR HIGH POWER BUSWAY

—
Quick reference guide

Critical dimensions: Operating conditions:

Busway passing through a wall, ceiling or floor:
• From the center-line of a joint to the wall, ceiling or floor
allow a minimum of 7 in.
• Joints cannot be positioned inside a wall, ceiling or floor.
Joints must be accessible for maintenance.
Busway clearances:
• From the top of the busway to a wall, ceiling, floor or another
busway allow a minimum of 50mm.
• From the side of the busway to a wall, ceiling, floor or other
busway minimum of 2 in.
• Derating for higher ambient temperature
• Relative humidity: 95% or below.
• Product designed for indoor use.
• Ambient temp : -22 °F to 131 °F
ReliaGear High Power Busway may be operated continuously
at its assigned ratings, without exceeding the maximum hot
spot temperature rise of 131 °F, provided the ambient temperature
does not exceed 131 °F. For higher ambient temperatures, the
ratings should be reduced by applying the appropriate multiplier
shown in the table below.

Busplug clearances:
• Ensure adequate space is given to allow the busplug unit to
be operated both easily and safely. Ambient temperature (°F) Multiplier
131 1
Feeder busway length: 140 0.95
• Minimum length – 2 ft 149 0.9
• Maximum length – 12 ft 158 0.85
167 0.8
Plug-in busway length: 176 0.74
• Minimum length – 2 ft
185 0.68
• Maximum length – 12 ft

Flatwise elbow section:

• Minimum leg length – varies depending on the busway.
• Maximum leg length – 2.5 ft

Edgewise elbow section:

• Minimum leg length – 10 in
• Maximum leg length – 2 ft

Critical details
• Busway drawing must have all relevant dimensions.
• Center-line dimensions are standard, please highlight any
dimensions that are not center-line dimensions.
• Walls and floors must be located, shown and dimensioned.
• The front of all switchboards must be given and the phasing
for any existing boards provided.
• Transformer connections require full details.
• When using rising busway, please note the phase orientation
of the plug-in sections.
• Horizontal plug-in busway positioned on its flat must always
be oriented with the neutral phase to the top.
RELIAGEAR HIGH POWER BUSWAY 27
—
ABB Inc.
Electrification Products
8155 T&B Boulevard
Memphis, TN 38125
abb.com/lowvoltage
Technical Support: 888-385-1221
7:00 a.m. - 5:00 p.m., CST, Monday-Friday

ABB
Electrification Products
800 Hymus Boulevard
Saint-Laurent, Quebec, Canada
H4S 0B5
abb.ca/lowvoltage
Phone: 514-856-6266
Toll Free: 888-856-6266
ep.support@ca.abb.com

—
We reserve the right to make technical
changes or modify the contents of this
document without prior notice. With regard
to purchase orders and/or contracts, the
agreed particulars shall prevail. ABB Inc.
does not accept any responsibility what-
soever for potential errors or possible lack
of information in this document.

We reserve all rights in this document and in

1SXU900202B0201, July 2017

the subject matter and illustrations contained

therein. Any reproduction, disclosure to third
parties or utilization of its contents - in whole
or in parts - is forbidden without prior written
consent of ABB Inc.

© Copyright 2017 ABB. All rights reserved.