Cutler-Hammer
C2-1
May 2001
Pow-R-Way III Joint Design
General
Cutler-Hammer Pow-R-Way III is a 600 volt,
totally enclosed, non-ventilated, sandwich
bus design available with copper bus bars in
ratings from 225 to 5000 amperes or with alu-
minum bus bars from 225 to 4000 amperes.
Pow-R-Way III is available in outdoor feeder,
indoor feeder, indoor plug-in and indoor
sprinkler-proof configurations. All four types
can be used interchangeably without adapt-
ers 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.
Figure 1: Conductor Configurations
Pow-R-Way III Designations for Available Conductor Configurations Including Grounding and Neutral Options (see Figure 1)
3WG 3-Phase, 3-Wire, 50% Internal Ground
3WI 3-Phase, 3-Wire, 50% Isolated Internal Ground
3WH 3-Phase, 3-Wire, 50% Integral Housing Ground
3WHG 3-Phase, 3-Wire, 100% Ground➀
➀ 100% Ground consists of the 50% integral hous-
ing ground combined with a 50% internal ground
bus.
Busway
Low-Voltage Busway – Pow-R-Way III
General Description
Standards
Pow-R-Way III meets the requirements of fied in both the Uniform Building Code and
NEMA, UL 857, CSA C22.2 NO. 27-94, IEC 439- California Building Code. The seismic capa-
1, 2 and 4, IEC 529 and IEC 947-1, IEEE, ANSI bility of Pow-R-Way III exceeds the worst-
and is manufactured in an ISO 9002 certified case Zone 4 required levels.
facility. Pow-R-Way III complies with British
Standard 5490 for protection against ingress
of foreign bodies, 12 mm or larger, at the
plug-in opening (Finger Safe) and is rated as
IP2X. Pow-R-Way III complies with IEC 529,
and is self certified to IP40, IP43 and IP54 for
plug-in bus and IP40, IP43, IP54 and IP56 for
feeder bus. Pow-R-Way III is also certified for
Seismic Withstand Capability in accordance
with the earthquake requirements as speci-
4WG 3-Phase, 4-Wire, 50% Internal Ground, 100% Neutral
4WI 3-Phase, 4-Wire, 50% Isolated Internal Ground, 100% Neutral
4WH 3-Phase, 4-Wire, 50% Integral Housing Ground, 100% Neutral
4WHG 3-Phase, 4-Wire, 100% Ground➀, 100% Neutral
4WNG 3-Phase, 4-Wire, 50% Internal Ground, 200% Neutral
4WNI 3-Phase, 4-Wire, Isolated Internal Ground, 200% Neutral
4WNH 3-Phase, 4-Wire, 50% Integral Housing Ground, 200% Neutral
4WNHG 3-Phase, 4-Wire, 100% Ground➀, 200% Neutral
 Busway
C2-2 Low-Voltage Busway – Pow-R-Way III
General Description
Pow-R-Bridge (Figure 2)
Pow-R-Way III joint connections are made
with the Pow-R-Bridge joint package which is
installed on each section of busway prior to
shipment. A double headed, torque indicating
bolt is provided to ensure that proper installa-
tion torque is achieved. Fall-away instruction
tags are furnished on the torque indicating
bolt heads to allow for visual inspection from
a distance. When the proper torque value is
achieved, the top bolt head will shear off and
allow the tag to fall to the floor. Any joint that
is improperly torqued will retain the highly
visible (caution yellow) tag at the bolt head.
Figure 2: Pow-R-Bridge Features
Figure 2a: Outdoor Bridge Joint Features
By releasing the bridge joint retainer screw, the
Pow-R-Bridge can provide an adjustment of
1-inch (25.4 mm) at each joint. Over adjustment
is prevented by the joint covers, which will only
allow a 1-inch adjustment to be made and by
stopping lances on the conductor bars of the
Pow-R-Bridge. The non-rotating design of
the Pow-R-Bridge maintains its configuration
integrity when it has been removed from a sec-
tion of busway. The conductors and insulators
will not displace or swivel, making reinstalla-
tion of the Pow-R-Bridge quick and easy.
Cutler-Hammer
May 2001
Outdoor Pow-R-Bridge (Figure 2a)
Joint connections for outdoor feeder busway
are made with a weatherized version of the
Pow-R-Bridge joint. Aluminum water barriers,
1/16-inch thick, are provided across the “T” and
“T opposite” sides of both joint ends on each
section of outdoor busway. Closed cell, neo-
prene gaskets are applied to the top of each
water barrier and to the inside of the aluminum
side access covers. The aluminum side access
covers overlap the top and bottom access cov-
ers and bolt directly onto the end blocks. Thus,
the completed outdoor joint has a water-resis-
tant enclosure assembled around it. The out-
door Pow-R-Bridge has the same 1-inch (25.4
mm) adjustibility and features as the indoor
unit, is CSA and UL listed, and meets the IEC re-
quirements for IP56 applications. No field gas-
keting or caulking is required.
Cutler-Hammer Busway
C2-3
May 2001 Low-Voltage Busway – Pow-R-Way III
General Description

Construction Details (Figure 3)

Conductor/Insulation System
Bus bars are fabricated from high strength,
98% conductivity copper or 55% conductivity
aluminum. The joint edge of each busway con-
ductor bar is beveled while the Pow-R-Bridge
conductor bars have full rounded edges. This
makes for a smooth and easy connection be-
tween the busway and Pow-R-Bridge joint. The
phase and neutral bars are insulated with Class
B 130°C epoxy insulation. The epoxy powder is
applied by an automated fluidized bed process
to ensure uniform thickness. The epoxy pow-
der is applied over the full length of the pre-
heated bar except for the joint and plug-in
contact surfaces. After the powder has been
fused to the bus bar, the bars enter an oven to
cure. This process ensures that all of the epoxy
powder cross links and hardens to the bus bar.

Fluidized bed applied epoxy is non-hygroscop-

ic and chemical resistant. Epoxy has outstand-
ing heat transfer characteristics and is ideally
suited for sandwich bus applications. The uni-
form thickness and smooth surface provided
by epoxy ensures that the insulation will have
no cavities or voids and also provides excellent
edge coverage to the bars. Epoxy has excellent
dielectric strength, is flame retardant and
resists impacts that other Class B insulating
material could not withstand. Figure 3: Housing Assembly

Bus bars for plug-in applications have full
sized welded conductor tabs at the contact
location points of the plug-in outlet. The tabs
are of the same exact thickness as the con-
ductor bars. The plug-in conductor tabs
extend into the plug-in outlet, maintaining
a true sandwich design throughout the entire
busway length.
The result is improved heat dissipation,
better bracing and elimination of the need to
separate, or flare, the conductor bars at the
plug-in opening. Maintaining a true sandwich
design also eliminates potential pathways for
the propagation of flame, smoke and gas
through the busway housing, commonly
referred to as “chimney effect.”
Silver plating is applied to all joint and con-
tact surfaces after the fluidized bed epoxy is
applied. Aluminum bus bars are silver plated
by the ALSTAN 88C process. Copper bus bars
are plated with silver by a flashing process.
The silver plating of the conductor tabs pro-
vides an extremely durable contact surface
for the spring loaded connections of bus plug
stab assemblies.
Housing Details (Figure 3)
Pow-R-Way III is constructed with a rugged
two-piece extruded aluminum housing. Pow-
R-Way III is designed to prohibit the entry of
dirt and moisture. There are no seams or
welds across the top or bottom sides of the
housing. The housing is bolted along the
bottom sides only, below the bus bars with
high tensile strength zinc plated hardware.
No fastening bolts or screws penetrate the
housing or enter the bus bar package.
Pow-R-Way III achieves the highest 6-cycle
short circuit withstand ratings available in
the industry today. The non-magnetic, all-
aluminum housing provides for excellent
heat dissipation and a significant reduction
in reactance and magnetic flux leakage as
compared to a steel or steel and aluminum
combination housing. The integrity and
strength of the housing assures specifiers
and users of a safe and durable installation
over a broad spectrum of industrial and
commercial applications.
A protective finish of ANSI 61, epoxy powder
paint is applied to the inside and outside sur-
faces by an automated electrostatic process.
Internal Ground
Pow-R-Way III offers a 50% ground bus
(copper or aluminum) that is internal to the
busway.
Integral Ground
The two-piece, extruded aluminum housing
is designed, manufactured and UL listed as a
50% integral ground path (integral earth) and
is fully fault rated. The system ground conti-
nuity is maintained through each joint by the
ground path end blocks, ground path plates
and joint covers. The aluminum joint covers
are furnished with ground path contact s
urfaces on the inside of each end. When the
covers are installed, the contact surfaces are
bolted directly to the ground path end blocks
with four 3/8-16 1/2-inch hex bolts per cover.
A highly visible label is furnished on each
joint cover to alert the installer that the
covers must be properly installed to maintain
the ground path. The result is a 50% ground
path that assures ground continuity with very
low resistance characteristics.
200% Neutral Option
Pow-R-Way III offers a fully rated, 200%
neutral bus option for busway fed distribution
systems with non-linear loads. The additional
neutral capacity prevents the overheating
caused by zero sequence harmonic currents.
The Pow-R-Way III 200% neutral is manufac-
tured with a single 1/2-inch thick bus bar
which receives the same silver plating and
Class B, 130°C Epoxy insulation as the phase
bars.
Isolated Ground Option
To meet the growing demand for grounding
isolation, Pow-R-Way III offers a 50% isolated
ground bus that is insulated and internal to
the busway. This option is available for
application to operations with heavy micro-
processor-based loads or large computer
installations where grounding isolation is
essential.
 Busway Cutler-Hammer
C2-4 Low-Voltage Busway – Pow-R-Way III May 2001

General Description

Plug-in Protective Devices

All Pow-R-Way III plug-in units are designed
with the safety of the installer and user as the
key criteria. The following features are stan-
dard for both fusible and circuit breaker type
plug-in units:

Pow-R-Way III bus plugs have extended

ground and neutral bars which bring the
termination points down into the cable entry
area making for a safer, easier connection.

A barrier is provided over the line side

connections from the bus plug stab assembly
to the fusible switch or circuit breaker.

The bus plug ground stab makes positive

contact with the busway ground (integral or
internal) before the phase or neutral stabs
contact the bus bars.

A bus plug guide port is provided in the

busway housing, to the right of each plug-in
outlet. A polarizing alignment pin is located
at the line side end of each bus plug enclo-
sure. The alignment pin must be inserted into Figure 4: Typical Circuit Breaker Plug-in Unit
the guide port for proper installation. The
plug-in unit and the busway are interlocked
to ensure that the device is in the “OFF”
position prior to installation or removal of
the unit.

To ensure that the bus plug is seated onto the

busway, the clamping mechanism will draw
the unit tight onto the busway housing as the
installer tightens the clamps.

Plug-in units have an interference bracket

which prevents the cover from being opened
while the device is in the “ON” position and
to prevent accidental closing of the device
while the cover is open.

There are two locations available for field

positioning of the bus plug operating handle.
On vertical bus run applications the handle
can be mounted on the side of the plug and
for horizontal runs the handle can be mount- Figure 5: Plug-in Stab Details
ed on the (line side) end of the unit. Bus plugs
are shipped with the handle mounted on
the side as standard. Mounting positions
are illustrated in Figure 7.

Plug-in outlets are rated for finger safety to

British Standard 5490-IP2X and IEC 529.
These are internationally recognized safety
standards that certify the degree of protec-
tion from accidental contact with a “live” part
by an installer or operator.

As a countermeasure to the effects of thermal

expansion and vibration, the plug-in outlet is
secured to the busway housing with high ten-
sile strength, locking hardware.

When a plug-in unit is installed, the bus plug

stab base assembly engages a seating ridge
provided on the plug-in outlet. The stab base
is drawn in to overlap the ridge and form a
tight seal against moisture and dust.
Figure 6: Plug-in Outlet Details
Cutler-Hammer Busway
C2-5
May 2001 Low-Voltage Busway – Pow-R-Way III
General Description

Plug-in Device Mounting

The load end of a plug-in unit varies with the
orientation of the busway as determined by
the “F” and “T” markings. See illustrations
below.
Preferred Arrangements for Wiring Closets➀➁

CL Plug-in T
F
Plug-in Unit
Opening

B
13⁄16

End View

Wall

4 in.
Minimum

T
Plug-in
C Unit

F
Operating
Plan View Handle

Wall

Two Per ¯ Duct

F Plug-in T
Unit
F
CL

Power Take Off

Bolt-on Unit

Typical Bolt-on with Operating Handle

Power Take Off

Figure 7: Plug-in Device Mounting

➀ See page C2-22 for dimensions of plug-in units.

➁ Clearance in front of plug-in device must be greater
than “A” (page C2-22) to allow 90° door swing.
 Busway
C2-6 Low-Voltage Busway – Pow-R-Way III
General Description
Advanced Bus Plugs
Clipper Power Systems TVSS Bus Plug
The Pow-R-Way III plug-in device product
offering includes Transient Voltage Surge
Suppression (TVSS) which is ideal for
busway fed distribution systems. A transient
voltage surge can disrupt, damage or destroy
sensitive microprocessor-based equipment.
Cutler-Hammer has developed the Clipper
Power System (CPS) family of products to
ensure that quality power is supplied to com-
mercial, industrial, medical and institutional
facilities.
The suppression of AC transients is accom-
plished through the utilization of Metal Oxide
Varistors (MOVs) which provide a low
impedance path to divert surges away from
loads. TVSS and filtering reduce MOV stress
resulting in a longer life cycle, lower let
through voltage, better noise attenuation
levels and increased reliability. Electrical line
noise and ringing transients are eliminated
by adding filtering capacitors to the suppres-
sion device.
Since the TVSS unit is directly connected to the
busway it is able to minimize let-through volt-
age to loads which are fed from a protected
busway run. The integrated design of the CPS
bus plug saves the user needed wall space and
greatly reduces installed project cost. The CPS
bus plug is furnished with a fusible disconnect.
Cutler-Hammer
May 2001
IQ Energy Sentinel Bus Plugs Ground Detector/Neutralizer Plug
The IQ Energy Sentinel is a UL listed micro- In rare cases, bus bars in a busway system
processor-based metering module capable of pick up static electricity. In order to discharge
communicating energy usage and demand this potential, a neutralizer and ground detec-
values over the Cutler-Hammer IMPACC/ tor bus plug is available. The unit has three
PowerNet power monitoring network. These 18,000 ohm resistors connected between the
innovative submetering devices are designed bus bars and the ground. Static electricity is
to mount directly to Series C molded case discharged through these resistors. A neon
breakers through 400 amperes and are avail- lamp is wired in series with the bus bar and
able for universal mounting through 2500 part of the resistor and burns continuously. If
amperes. there is a ground anywhere on the system of
a lower resistance than the path through the
Digitrip OPTIM Bus Plugs lamp, the lamp will go out, indicating that
Digitrip OPTIM is a new programmable, there is a short in the system.
communicating, microprocessor-based elec-
tronic trip unit system for Cutler-Hammer
Series C Circuit Breakers. OPTIM is available for
Pow-R-Way III bus plugs on the L-Frame (70 to
600 ampere) circuit breakers. Digitrip OPTIM
provides superior programmable protection
and coordination, and state-of-the-art monitor-
ing and communications.
Combination Starter Bus Plugs
Plug-in combination starters or contactors
are mounted in enclosures identical to the cir-
cuit breaker and fusible switch type bus plugs
including the clamp and guides, safety inter-
locks and guide pin. They are available from
size 0 through 5 with a circuit breaker, motor
circuit protector or fusible disconnect. For
specific applications and outline dimensions
refer to Cutler-Hammer.
Cutler-Hammer Busway
C2-7
May 2001 Low-Voltage Busway – Pow-R-Way III
Layout Dimensions

Pow-R-Way III Plug-in Busway

Figure 8, Tables A and B
225 to 5000 amperes Copper
225 to 4000 amperes Aluminum

Straight sections of plug-in are made only in

24-inch (609.6 mm.) incremental lengths with
a maximum length of 10 feet (3048 mm). Fig-
ure 8 depicts the configuration of plug-in
busway and Pow-R Bridge for the available
ampere ratings. See Table A for reference to
the proper configuration.

Table A. Configurations
Ampere Rating Figure
Cu Al
225 225 A
400 400 A
600 600 A
800 800 A
1000 1000 A
1200 1200 A
1350 1350 A
1600 — A
2000 — A
— 1600 B
2500 2000 B
3200 — C
4000 2500 C
— 3200 D
5000 4000 D

Table B illustrates the quantity of plug-in

openings per side that are available per stan-
dard section.

Table B. Number of Plug-in Openings

Duct Length Number of Plug-in Openings
Inches mm Front Back
24 610 1 1
48 1219 2 2
72 1829 3 3
96 2438 4 4
120 3048 5 5

Each section will include one, factory installed,

Pow-R-Bridge mounted to the left end of the
busway (with the Top “T” label to the top,
when viewing the bus from the “F” front side).
Each Pow-R-Bridge will have a “T” label which
must always match the “T” orientation of the
busway.

Plug-in Outlet
The plug-in outlets are rated for finger safety
to IP2X in accordance with IEC 529 and British
Standard 5490. These are internationally rec-
ognized safety standards that ensure the de-
gree of protection from accidental contact of
live parts by an operator or installer. The
plug-in outlet and cover are made from a
durable, high strength, polycarbonate mate-
rial which is rated as Class B, 130º C, insula-
Figure 8: Plug-in Busway
tion. The plug-in cover is designed to protect As a countermeasure to the effects of thermal
the contact surfaces and prevent the entry of expansion and mechanical vibration, the plug-
dirt, dust or moisture. The cover has a posi- in outlet is secured to the busway housing
tive screw close feature that prohibits the with high tensile strength locking hardware.
opening of the cover without the use of a tool.
The cover is also Utility “lead lock” sealable.
 Busway Cutler-Hammer
C2-8 Low-Voltage Busway – Pow-R-Way III May 2001

Layout Dimensions

Pow-R-Way III Feeder Busway

Figure 9 and Table A
225 to 5000 amperes Copper
225 to 4000 amperes Aluminum

Straight sections of feeder busway can be

supplied in any length, at 1/8-inch (3.18 mm)
increments, from a 21-inch (533.4 mm.)
minimum to a 10-foot (3048 mm.) maximum.
Figure 9 illustrates the configuration of
feeder busway and Pow-R-Bridge for the
available ampere ratings. See Table A for
reference to the proper configuration.

Table A. Configurations
Ampere Rating Figure
Cu Al
225 225 A
400 400 A
600 600 A
800 800 A
1000 1000 A
1200 1200 A
1350 1350 A
1600 — A
2000 — A
— 1600 B
2500 2000 B
3200 — C
4000 2500 C
— 3200 D
5000 4000 D

Each section will include one, factory in-

stalled, Pow-R-Bridge mounted to the left end
of the busway (with the Top “T” to the top,
when viewing the bus from the “F” front side).
Each Pow-R-Bridge will have a “T” label which
must always match the “T”orientation of the
busway.

Figure 9: Feeder Busway

Cutler-Hammer Busway
C2-9
May 2001 Low-Voltage Busway – Pow-R-Way III
Layout Dimensions

Dimensions – Bus Bar and Housing

3-Wire with No Neutral
Ampere Rating Phase Bar Size Bar Conductor Configuration and Housing Size (Width x Height) Inches (mm) Figure
Cu Al (Depth and Width) Per 50% Integral Housing 50% Internal Ground Bus 50% Internal Isolated ➀
Inches (mm) Phase Ground 3WH 3WHG Ground 3WI
225 225 .25 x 1.62 (6.35 x 41) 1 4.75 x 4.38 (121 x 111) 4.75 x 4.50 (121 x 114) 4.75 x 4.55 (121 x 116) A
400 400 .25 x 1.62 (6.35 x 41) 1 4.75 x 4.38 (121 x 111) 4.75 x 4.50 (121 x 114) 4.75 x 4.55 (121 x 116) A
600 – .25 x 1.62 (6.35 x 41) 1 4.75 x 4.38 (121 x 111) 4.75 x 4.50 (121 x 114) 4.75 x 4.55 (121 x 116) A
800 600 .25 x 1.62 (6.35 x 41) 1 4.75 x 4.38 (121 x 111) 4.75 x 4.50 (121 x 114) 4.75 x 4.55 (121 x 116) A
1000 – .25 x 2.25 (6.35 x 57) 1 5.38 x 4.38 (137 x 111) 5.38 x 4.50 (137 x 114) 5.38 x 4.55 (137 x 116) A
1200 800 .25 x 2.75 (6.35 x 70) 1 5.88 x 4.38 (149 x 111) 5.88 x 4.50 (149 x 114) 5.88 x 4.55 (149 x 116) A
1350 1000 .25 x 3.25 (6.35 x 83) 1 6.38 x 4.38 (162 x 111) 6.38 x 4.50 (162 x 114) 6.38 x 4.55 (162 x 116) A
1600 1200 .25 x 4.25 (6.35 x 108) 1 7.38 x 4.38 (187 x 111) 7.38 x 4.50 (187 x 114) 7.38 x 4.55 (187 x 116) A
2000 1350 .25 x 5.50 (6.35 x 140) 1 8.64 x 4.38 (219 x 111) 8.64 x 4.50 (219 x 114) 8.64 x 4.55 (219 x 116) A
– 1600 .25 x 6.25 (6.35 x 159) 1 9.40 x 4.38 (239 x 111) 9.40 x 4.50 (239 x 114) 9.40 x 4.55 (239 x 116) A
2500 2000 .25 x 8.00 (6.35 x 203) 1 11.17 x 4.38 (284 x 111) 11.17 x 4.50 (284 x 114) 11.17 x 4.55 (284 x 116) A
3200 – .25 x 4.25 (6.35 x 108) 2 16.14 x 4.38 (410 x 111) 16.14 x 4.50 (410 x 114) 16.14 x 4.55 (410 x 116) B
4000 2500 .25 x 5.50 (6.35 x 140) 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) B
– 3200 .25 x 6.25 (6.35 x 159) 2 20.16 x 4.38 (512 x 111) 20.16 x 4.50 (512 x 114) 20.16 x 4.55 (512 x 116) B
5000 4000 .25 x 8.00 (6.35 x 203) 2 23.70 x 4.38 (602 x 111) 23.70 x 4.50 (602 x 114) 23.70 x 4.55 (602 x 116) B

4-Wire with 100% Neutral

Ampere Rating Phase and Neutral Bar Bar Conductor Configuration and Housing Size (Width x Height) Inches (mm) Figure
Cu Al Size (Depth and Width) Per 50% Integral Housing 50% Internal Ground Bus 50% Internal Isolated ➀
Inches (mm) Phase Ground 4WH 4WHG Ground 4WI
225 225 .25 x 1.62 (6.35 x 41) 1 4.75 x 4.38 (121 x 111) 4.75 x 4.50 (121 x 114) 4.75 x 4.55 (121 x 116) A
400 400 .25 x 1.62 (6.35 x 41) 1 4.75 x 4.38 (121 x 111) 4.75 x 4.50 (121 x 114) 4.75 x 4.55 (121 x 116) A
600 – .25 x 1.62 (6.35 x 41) 1 4.75 x 4.38 (121 x 111) 4.75 x 4.50 (121 x 114) 4.75 x 4.55 (121 x 116) A
800 600 .25 x 1.62 (6.35 x 41) 1 4.75 x 4.38 (121 x 111) 4.75 x 4.50 (121 x 114) 4.75 x 4.55 (121 x 116) A
1000 – .25 x 2.25 (6.35 x 57) 1 5.38 x 4.38 (137 x 111) 5.38 x 4.50 (137 x 114) 5.38 x 4.55 (137 x 116) A
1200 800 .25 x 2.75 (6.35 x 70) 1 5.88 x 4.38 (149 x 111) 5.88 x 4.50 (149 x 114) 5.88 x 4.55 (149 x 116) A
1350 1000 .25 x 3.25 (6.35 x 83) 1 6.38 x 4.38 (162 x 111) 6.38 x 4.50 (162 x 114) 6.38 x 4.55 (162 x 116) A
1600 1200 .25 x 4.25 (6.35 x 108) 1 7.38 x 4.38 (187 x 111) 7.38 x 4.50 (187 x 114) 7.38 x 4.55 (187 x 116) A
2000 1350 .25 x 5.50 (6.35 x 140) 1 8.64 x 4.38 (219 x 111) 8.64 x 4.50 (219 x 114) 8.64 x 4.55 (219 x 116) A
– 1600 .25 x 6.25 (6.35 x 159) 1 9.40 x 4.38 (239 x 111) 9.40 x 4.50 (239 x 114) 9.40 x 4.55 (239 x 116) A
2500 2000 .25 x 8.00 (6.35 x 203) 1 11.17 x 4.38 (284 x 111) 11.17 x 4.50 (284 x 114) 11.17 x 4.55 (284 x 116) A
3200 – .25 x 4.25 (6.35 x 108) 2 16.14 x 4.38 (410 x 111) 16.14 x 4.50 (410 x 114) 16.14 x 4.55 (410 x 116) B
4000 2500 .25 x 5.50 (6.35 x 140) 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) B
– 3200 .25 x 6.25 (6.35 x 159) 2 20.16 x 4.38 (512 x 111) 20.16 x 4.50 (512 x 114) 20.16 x 4.55 (512 x 116) B
5000 4000 .25 x 8.00 (6.35 x 203) 2 23.70 x 4.38 (602 x 111) 23.70 x 4.50 (602 x 114) 23.70 x 4.55 (602 x 116) B

➀ Refer to Figure 10 on page C2-10 for Figures A

and B.
 Busway Cutler-Hammer
C2-10 Low-Voltage Busway – Pow-R-Way III May 2001

Layout Dimensions

Dimensions – Bus Bar and Housing, Continued

4-Wire with 200% Neutral
Ampere Rating Phase Bar Size Bar Conductor Configuration and Housing Size (Width x Height) Inches (mm) Figure
Cu Al (Depth and Width) Per 50% Integral Housing 50% Internal Ground Bus 50% Internal Isolated ➀
Inches (mm)➁ Phase Ground 4WNH 4WNG➂ Ground 4WNI
225 225 .25 x 1.62 (6.35 x 41) 1 4.75 x 4.92 (121 x 125) 4.75 x 5.05 (121 x 128) 4.75 x 5.10 (121 x 130) A
400 400 .25 x 1.62 (6.35 x 41) 1 4.75 x 4.92 (121 x 125) 4.75 x 5.05 (121 x 128) 4.75 x 5.10 (121 x 130) A
600 – .25 x 1.62 (6.35 x 41) 1 4.75 x 4.92 (121 x 125) 4.75 x 5.05 (121 x 128) 4.75 x 5.10 (121 x 130) A
800 600 .25 x 1.62 (6.35 x 41) 1 4.75 x 4.92 (121 x 125) 4.75 x 5.05 (121 x 128) 4.75 x 5.10 (121 x 130) A
1000 – .25 x 2.25 (6.35 x 57) 1 5.38 x 4.92 (137 x 125) 5.38 x 5.05 (137 x 128) 5.38 x 5.10 (137 x 130) A
1200 800 .25 x 2.75 (6.35 x 70) 1 5.88 x 4.92 (149 x 125) 5.88 x 5.05 (149 x 128) 5.88 x 5.10 (149 x 130) A
1350 1000 .25 x 3.25 (6.35 x 83) 1 6.38 x 4.92 (162 x 125) 6.38 x 5.05 (162 x 128) 6.38 x 5.10 (162 x 130) A
1600 1200 .25 x 4.25 (6.35 x 108) 1 7.38 x 4.92 (187 x 125) 7.38 x 5.05 (187 x 128) 7.38 x 5.10 (187 x 130) A
2000 1350 .25 x 5.50 (6.35 x 140) 1 8.64 x 4.92 (219 x 125) 8.64 x 5.05 (219 x 128) 8.64 x 5.10 (219 x 130) A
– 1600 .25 x 6.25 (6.35 x 159) 1 9.40 x 4.92 (239 x 125) 9.40 x 5.05 (239 x 128) 9.40 x 5.10 (239 x 130) A
2500 2000 .25 x 8.00 (6.35 x 203) 1 11.17 x 4.92 (284 x 125) 11.17 x 5.05 (284 x 128) 11.17 x 5.10 (284 x 130) A
3200 – .25 x 4.25 (6.35 x 108) 2 16.14 x 4.92 (410 x 125) 16.14 x 5.05 (410 x 128) 16.14 x 5.10 (410 x 130) B
4000 2500 .25 x 5.50 (6.35 x 140) 2 18.64 x 4.92 (473 x 125) 18.64 x 5.05 (473 x 128) 18.64 x 5.10 (473 x 130) B
– 3200 .25 x 6.25 (6.35 x 159) 2 20.16 x 4.92 (512 x 125) 20.16 x 5.05 (512 x 128) 20.16 x 5.10 (512 x 130) B
5000 4000 .25 x 8.00 (6.35 x 203) 2 23.70 x 4.92 (602 x 125) 23.70 x 5.05 (602 x 128) 23.70 x 5.10 (602 x 130) B

Figure 10

➀ Refer to Figure 10 for Figures A and B.

➁ Neutral bar is 0.5 (12.7) x width shown.
➂ 100% ground available with same dimensions,
which utilizes 50% internal ground and 50%
integral housing ground.
Cutler-Hammer
May 2001
Fittings
There is a fitting to meet every application
need: flanges, elbows, offsets, tees, cable tap
boxes, weatherheads, transformer connec-
tions, power take-off sections, reducers,
adapter cubicles, expansion joints and end
closures.
These fittings, along with standard and
minimum dimensions, are described on the
following pages.
Figure 11: Top (T) and Front (F) Orientation for Fittings
Busway
Low-Voltage Busway – Pow-R-Way III
Layout Dimensions
When making field measurements and
layouts, it should be remembered that the
dimensions are given from the centerline
of the Pow-R-Bridge.
The relationship of fittings to straight lengths
(forward, rearward, upward and downward)
is illustrated in Figure 11.
C2-11
All straight lengths and fittings are marked
with a “T” label for TOP and an “F” label for
FRONT. The “T” and “F” locations will also
be noted on the construction, or as-built,
drawings furnished by Cutler-Hammer.
When installing the busway, the “T” and “F”
markings of each section must match. Fail-
ure to do so will result in an improper instal-
lation with the phase bars out of sequence.
 Busway Cutler-Hammer
C2-12 Low-Voltage Busway – Pow-R-Way III May 2001

Layout Dimensions

Traditional Indoor and Outdoor Elbows

Elbows are used to make 90° changes in the Upward and Downward Elbows
direction of busway runs. The four types that Ampere Rating Minimum Leg Lengths (X)
are available are forward, rearward, upward
and downward. See minimum leg lengths Upward Downward
listed for each type in the tables below. All Cu Al Inches mm Inches mm
dimensions are to the centerline of the 225 225 10.00 254.00 13.00 330.20
Pow-R-Bridge.
400 400 10.00 254.00 13.00 330.20
Forward and Rearward Elbows 600 — 10.00 254.00 13.00 330.20
Ampere Rating Minimum Leg Lengths (X) 800 600 10.00 254.00 13.00 330.20
Cu Al Inches mm 1000 — 10.00 254.00 13.00 330.20
225 225 13.00 330.20 1200 800 10.00 254.00 13.00 330.20
400 400 13.00 330.20 1350 1000 10.00 254.00 13.00 330.20
600 — 13.00 330.20 1600 1200 10.00 254.00 13.00 330.20
800 600 13.00 330.20 2000 1350 10.00 254.00 13.00 330.20
1000 — 13.00 330.20 — 1600 10.00 254.00 13.00 330.20
1200 800 13.50 342.90 2500 2000 10.00 254.00 13.00 330.20
1350 1000 13.50 342.90 3200 — 12.00 304.80 13.00 330.20
1600 1200 14.00 355.60 4000 2500 12.00 304.80 13.00 330.20
2000 1350 14.50 368.30 — 3200 12.00 304.80 13.00 330.20
— 1600 15.00 381.00 5000 4000 12.00 304.80 13.00 330.20
2500 2000 16.00 406.40
3200 — 18.50 469.90
4000 2500 19.50 495.30
— 3200 20.50 520.70
5000 4000 22.50 571.50

Figure 12: Traditional Elbows

Cutler-Hammer Busway
C2-13
May 2001 Low-Voltage Busway – Pow-R-Way III
Layout Dimensions

Corner Joint Elbows Given the complexity of today’s industrial Pow-R-Way III Corner Joint Elbows can solve
When it comes to bends and turns in a bus and commercial distribution systems and the any serious pathway problem and contribute
run, specifiers often face serious limitations. need to coordinate layouts with the HVAC, to successful layouts with minimal space
The leg length of a traditional 90° elbow is plumbing and lighting requirements, space requirements. The Corner Joint Elbow is CSA
limited by the amount of space needed to quickly becomes a critical factor. and UL listed for indoor applications and is
weld or bend bus bars, provide an enclosure also certified for Seismic Withstand Capabili-
around the bars and create a connection to The Pow-R-Way III Corner Joint Elbow can be ty to worst-case, Zone 4 levels.
the adjacent section. In most applications, installed in areas where a traditional 90° turn All dimensions are to the centerline of the
especially with higher ampere ratings, a could never have been accomplished before. Corner Joint Connection.
significant area may be required. It enables plug-in openings to be maximized.
Forward/Rearward
Ampere Dimensions
Rating (X) (Y)
Cu Al Inches mm Inches mm
225 225 .94 23.88 5.38 136.65
400 400 .94 23.88 5.38 136.65
600 — .94 23.88 5.38 136.65
800 600 .94 23.88 5.38 136.65
1000 — 1.25 31.75 5.69 144.53
1200 800 1.50 38.10 5.94 150.88
1350 1000 1.75 44.45 6.19 157.23
1600 1200 2.25 57.15 6.69 169.93
2000 1350 2.88 73.15 7.31 185.67
— 1600 3.25 82.55 7.70 195.58
2500 2000 4.12 104.65 8.57 217.68
3200 — 6.64 168.66 11.07 281.18
4000 2500 7.89 200.41 12.32 312.93
— 3200 8.65 219.71 13.08 332.23
5000 4000 10.42 264.67 14.85 377.19

Ampere Upward Downward

Rating (X) (Y)
Cu Al Inches mm Inches mm
225 225 4.71 119.63 4.35 110.49
400 400 4.71 119.63 4.35 110.49
600 — 4.71 119.63 4.35 110.49
800 600 4.71 119.63 4.35 110.49
1000 — 4.71 119.63 4.35 110.49
Figure 13: Corner Joint Elbows
1200 800 4.71 119.63 4.35 110.49
1350 1000 4.71 119.63 4.35 110.49
1600 1200 4.71 119.63 4.35 110.49
2000 1350 4.71 119.63 4.35 110.49
— 1600 4.71 119.63 4.35 110.49
2500 2000 4.71 119.63 4.35 110.49
3200 — 4.71 119.63 4.35 110.49
4000 2500 4.71 119.63 4.35 110.49
— 3200 4.71 119.63 4.35 110.49
5000 4000 4.71 119.63 4.35 110.49
 Busway Cutler-Hammer
C2-14 Low-Voltage Busway – Pow-R-Way III May 2001

Layout Dimensions

Elbow Flanges
Flanges can be supplied on the end of the
right or left leg as required. Minimum leg
lengths are listed in the table below. Typical
uses are for busway entrance into low-
voltage switchgear, low-voltage switch-
boards and molded case circuit breakers.
All dimensions are to the centerline of the
Pow-R-Bridge.
Upward and Downward Elbow Flanges
Forward and Rearward Elbow Flanges Ampere Rating Minimum Dimensions
Ampere Minimum Dimensions Joint Leg, (X) Flange Leg, (Y)
Rating Cu Al Up Down Up Down
Joint Leg, (X) Flange Leg, (Y)
Cu Al Inches mm Inches mm Inches mm Inches mm Inches mm Inches mm
225 225 13.00 330.20 8.75 222.25 225 225 10.00 254.00 13.00 330.20 5.75 146.05 8.75 222.25
400 400 13.00 330.20 8.75 222.25 400 400 10.00 254.00 13.00 330.20 5.75 146.05 8.75 222.25
600 — 13.00 330.20 8.75 222.25 600 — 10.00 254.00 13.00 330.20 5.75 146.05 8.75 222.25
800 600 13.00 330.20 8.75 222.25 800 600 10.00 254.00 13.00 330.20 5.75 146.05 8.75 222.25
1000 — 13.00 330.20 8.75 222.25 1000 — 10.00 254.00 13.00 330.20 5.75 146.05 8.75 222.25
1200 800 13.50 342.90 9.25 235.00 1200 800 10.00 254.00 13.00 330.20 5.75 146.05 8.75 222.25
1350 1000 13.50 342.90 9.25 235.00 1350 1000 10.00 254.00 13.00 330.20 5.75 146.05 8.75 222.25
1600 1200 14.00 355.60 9.75 247.65 1600 1200 10.00 254.00 13.00 330.20 5.75 146.05 8.75 222.25
2000 1350 14.50 368.30 10.25 260.35 2000 1350 10.00 254.00 13.00 330.20 5.75 146.05 8.75 222.25
— 1600 15.00 381.00 10.75 273.05 — 1600 10.00 254.00 13.00 330.20 5.75 146.05 8.75 222.25
2500 2000 16.00 406.40 11.75 298.45 2500 2000 10.00 254.00 13.00 330.20 5.75 146.05 8.75 222.25
3200 — 18.50 469.90 14.00 355.60 3200 — 12.00 304.80 13.00 330.20 7.75 196.85 8.75 222.25
4000 2500 19.50 495.30 15.25 387.35 4000 2500 12.00 304.80 13.00 330.20 7.75 196.85 8.75 222.25
— 3200 20.50 520.70 16.00 406.40 — 3200 12.00 304.80 13.00 330.20 7.75 196.85 8.75 222.25
5000 4000 22.50 571.50 17.75 450.85 5000 4000 12.00 304.80 13.00 330.20 7.75 196.85 8.75 222.25

Figure 14: Elbow Flanges

Cutler-Hammer Busway
C2-15
May 2001 Low-Voltage Busway – Pow-R-Way III
Layout Dimensions

Offsets
An offset is used to avoid obstacles and
to conform to building structure. It is two
elbows fabricated into a single fitting for
use where space restrictions prohibit the
use of a standard 90° elbow. The minimum
leg lengths are listed in the tables below.
All dimensions are to the centerline of the Upward and Downward Offsets
Pow-R-Bridge.
Ampere Rating Minimum Dimensions
Forward and Rearward Offsets Cu Al Upward Downward
Ampere Rating Minimum Dimensions (Y) (Y) (Z) (Y) (Z)
Cu Al Inches mm Inches mm Inches mm Inches mm Inches mm
225 225 13.00 330.20 225 225 10.00 254.00 13.00 330.20 13.00 330.20 10.00 254.00
400 400 13.00 330.20 400 400 10.00 254.00 13.00 330.20 13.00 330.20 10.00 254.00
600 — 13.00 330.20 600 — 10.00 254.00 13.00 330.20 13.00 330.20 10.00 254.00
800 600 13.00 330.20 800 600 10.00 254.00 13.00 330.20 13.00 330.20 10.00 254.00
1000 — 13.00 330.20 1000 — 10.00 254.00 13.00 330.20 13.00 330.20 10.00 254.00
1200 800 13.50 342.90 1200 800 10.00 254.00 13.00 330.20 13.00 330.20 10.00 254.00
1350 1000 13.50 342.90 1350 1000 10.00 254.00 13.00 330.20 13.00 330.20 10.00 254.00
1600 1200 14.00 355.60 1600 1200 10.00 254.00 13.00 330.20 13.00 330.20 10.00 254.00
2000 1350 14.50 368.30 2000 1350 10.00 254.00 13.00 330.20 13.00 330.20 10.00 254.00
— 1600 15.00 381.00 — 1600 10.00 254.00 13.00 330.20 13.00 330.20 10.00 254.00
2500 2000 16.00 406.40 2500 2000 10.00 254.00 13.00 330.20 13.00 330.20 10.00 254.00
3200 — 18.50 469.90 3200 — 12.00 304.80 13.00 330.20 13.00 330.20 12.00 304.80
4000 2500 19.50 495.30 4000 2500 12.00 304.80 13.00 330.20 13.00 330.20 12.00 304.80
— 3200 20.50 520.70 — 3200 12.00 304.80 13.00 330.20 13.00 330.20 12.00 304.80
5000 4000 22.50 571.50 5000 4000 12.00 304.80 13.00 330.20 13.00 330.20 12.00 304.80

Figure 15: Offsets

 Busway Cutler-Hammer
C2-16 Low-Voltage Busway – Pow-R-Way III May 2001

Layout Dimensions

Tees All dimensions are to the centerline of the Pow-R-Bridge.

A tee is a busway fitting suitable for connection in three directions.
The minimum leg lengths are shown in the following tables.

Forward and Rearward Tees Upward and Downward Tees

Ampere Rating Minimum Leg Dimensions Ampere Rating Minimum Leg Dimensions

Cu Al (X) Inches (X) mm (Y) Inches (Y) mm Cu Al (X) Inches (X) mm (Y) Inches (Y) mm
225 225 13.00 330.20 13.00 330.20 225 225 21.25 539.75 25.50 647.70
400 400 13.00 330.20 13.00 330.20 400 400 21.25 539.75 25.50 647.70
600 — 13.00 330.20 13.00 330.20 600 — 21.25 539.75 25.50 647.70
800 600 13.00 330.20 13.00 330.20 800 600 21.25 539.75 25.50 647.70
1000 — 13.00 330.20 13.00 330.20 1000 — 21.88 555.75 25.50 647.70
1200 800 13.50 342.90 13.50 342.90 1200 800 22.38 568.45 25.50 647.70
1350 1000 13.50 342.90 13.50 342.90 1350 1000 22.88 581.15 25.50 647.70
1600 1200 14.00 355.60 14.00 355.60 1600 1200 23.88 606.55 25.50 647.70
2000 1350 14.50 368.30 14.50 368.30 2000 1350 25.12 638.05 25.50 647.70
— 1600 15.00 381.00 15.00 381.00 — 1600 25.88 657.35 25.50 647.70
2500 2000 16.00 406.40 16.00 406.40 2500 2000 27.62 701.55 25.50 647.70
3200 — 27.25 692.15 26.38 670.05 3200 — 23.88 606.55 25.50 647.70
4000 2500 28.50 723.90 27.62 701.55 4000 2500 25.12 638.05 25.50 647.70
— 3200 29.25 792.95 28.38 720.85 — 3200 25.88 637.35 25.50 647.70
5000 4000 31.00 787.40 30.12 765.05 5000 4000 27.62 701.55 25.50 647.70

Figure 16: Tees

Cutler-Hammer Busway
C2-17
May 2001 Low-Voltage Busway – Pow-R-Way III
Layout Dimensions

End Cable Tap Box

End cable tap boxes are applied to feed a run
of busway with cable and conduit, or where
loads served by busway are connected with-
out the need for overcurrent protection.

Figure 17: End Cable Tap Box

Copper Dimensions Aluminum Dimensions Quantity of Mechanical Terminals, Range – One #4 to

600 kcmil or Two 1/0 to 250 kcmil Cu/Al➁
Copper➂ Aluminum➂
Ampere Rating Dimension Dimension Ampere Rating Dimension Dimension G P N G P N
(A) Inches➀ (A) mm➀ (A) Inches➀ (A) mm➀
225 12.00 304.80 225 12.00 304.80 1 2 4 1 2 4
400 12.00 304.80 400 12.00 304.80 1 2 4 1 2 4
600 12.00 304.80 12.00 304.80 1 2 4 — — —
800 12.00 304.80 600 12.00 304.80 2 3 5 1 2 4
1000 12.00 304.80 — 12.00 304.80 2 3 6 — — —
1200 12.00 304.80 800 12.00 304.80 2 4 8 2 3 5
1350 12.00 304.80 1000 12.00 304.80 2 4 8 2 3 6
1600 20.50 520.70 1200 20.50 520.70 3 5 9 2 4 8
2000 20.50 520.70 1350 20.50 520.70 3 6 12 2 4 8
— — — 1600 24.50 622.30 — — — 3 5 9
2500 24.50 622.30 2000 24.50 622.30 4 8 16 3 6 12
3200 30.50 774.50 — — — 5 9 18 — — —
4000 45.00 1143.00 2500 30.50 774.50 6 12 24 4 8 16
— — — 3200 30.50 774.50 — — — 5 9 18
5000 45.00 1143.00 4000 45.00 1143.00 7 15 30 6 12 24

➀ All dimensions shown in Figure 17 remain con-

stant regardless of system wiring configuration.
➁ Standard 600 kcmil Compression lugs are
available in the same quantities shown for the
mechanical terminals.
➂ G Denotes quantity of terminals per ground bus.
P Denotes quantity of terminals per phase and
100% neutral bus.
N Denotes quantity of terminals per 200% neutral
bus option.
 Busway Cutler-Hammer
C2-18 Low-Voltage Busway – Pow-R-Way III May 2001

Layout Dimensions

Center Cable Tap Box

Center cable tap boxes are applied to center
feed a run of busway with cable and conduit,
or where loads served by the busway are
connected without the need for overcurrent
protection.

Figure 18: Center Cable Tap Box

Copper Aluminum Quantity of Mechanical Terminals,

Ampere Dimension Ampere Dimension Range – One #4 to 600 kcmil or Two
Rating Rating 1/0 to 250 kcmil Cu/Al➁
Copper➂ Aluminum➂
(A) Inches➀ (A) mm➀ (B) Inches➀ (B) mm➀ (A) Inches➀ (A) mm➀ (B) Inches➀ (B) mm➀ G P N G P N
225 16.50 419.10 40.00 1016.0 225 16.50 419.10 40.00 1016.0 1 2 4 1 2 4
400 16.50 419.10 40.00 1016.0 400 16.50 419.10 40.00 1016.0 1 2 4 1 2 4
600 16.50 419.10 40.00 1016.0 — 16.50 — 40.00 1016.0 1 2 4 — — —
800 16.50 419.10 40.00 1016.0 600 16.50 419.10 40.00 1016.0 2 3 5 1 2 4
1000 16.50 419.10 40.00 1016.0 — 16.50 — 40.00 1016.0 2 3 6 — — —
1200 16.50 419.10 40.00 1016.0 800 16.50 419.10 40.00 1016.0 2 4 8 2 3 5
1350 16.50 419.10 40.00 1016.0 1000 16.50 419.10 40.00 1016.0 2 4 8 2 3 6
1600 20.50 520.70 42.50 1079.5 1200 20.50 520.70 42.50 1079.5 3 5 9 2 4 8
2000 20.50 520.70 42.50 1079.5 1350 20.50 520.70 42.50 1079.5 3 6 12 2 4 8
— — — — — 1600 24.50 622.30 45.00 1143.0 — — — 3 5 9
2500 24.50 622.30 45.00 1143.0 2000 24.50 622.30 45.00 1143.0 4 8 16 3 6 12
3200 30.38 774.50 58.00 1473.2 — — — — — 5 9 18 — — —
4000 45.00 1143.0 60.50 1536.7 2500 30.38 771.65 58.00 1473.0 6 12 24 4 8 16
— — — — — 3200 30.38 771.65 58.00 1473.0 — — — 5 9 18
5000 45.00 1143.0 60.50 1536.7 4000 45.00 1143.0 60.50 1536.7 7 15 30 6 12 24

C Dimension
Copper Aluminum
225-1350A 1600-2000A 2500A 3200A 4000-5000A 225-1000A 1200-1350A 1600-2000A 2500-3200A 4000A
3.63 In. 4.75 In. 6.00 In. 10.75 In. 12.25 In. 3.63 In. 4.75 In. 6.00 In. 10.75 In. 12.25 In.
92.20 mm 120.65 mm 152.40 mm 273.05 mm 311.15 mm 92.20 mm 120.65 mm 152.40 mm 273.05 mm 311.15 mm

➀ All dimensions in figure 18 remain constant
regardless of system wiring configuration.
➁ Standard 600 kcmil compression lugs are avail-
able in the same quantities shown for the mechan-
ical terminals.
➂ G Denotes quantity of terminals per ground bus.
P Denotes quantity of terminals per phase and
100% neutral bus.
N Denotes quantity of terminals per 200% neutral
bus option.
Cutler-Hammer Busway
C2-19
May 2001 Low-Voltage Busway – Pow-R-Way III
Layout Dimensions

End Closures
End closures terminate a bus run and can
be used to close either the right or left end.
Refer to page C2-2, Figure 1 for wiring con-
ductor configurations.

Ampere Rating Dimension

Cu Al (A) Inches (A) mm
225 225 5.13 130.30
400 400 5.13 130.30
600 — 5.13 130.30
800 600 5.13 130.30
1000 — 5.75 146.05 Figure 19: End Closure with Pow-R-Bridge Removed.
1200 800 6.25 158.75
1350 1000 6.75 171.45
1600 1200 7.77 197.35
2000 1350 9.02 229.10
— 1600 9.78 248.41
2500 2000 11.55 293.37
3200 — 16.52 419.60
4000 2500 19.02 482.85
— 3200 20.54 521.71
5000 4000 24.08 611.63

Dimension (B)
3WH, 3WG, 3WHG, 4WNH, 4WNG,
3WI, 4WH, 4WG, 4WNI, 4WNHG
4WHG, 4WI
Inches 5.00 5.50
mm 127.00 139.70

Note: End closure extends 0.44 inches

(11.18 mm) beyond the centerline of the
removed Pow-R-Bridge.
 Busway Cutler-Hammer
C2-20 Low-Voltage Busway – Pow-R-Way III May 2001

Layout Dimensions

Horizontal Hangers Flatwise Hook Hanger

One hanger is provided for every 10 feet of
Ampere Rating Duct Width Dimension (A)
horizontally mounted busway. The type of
hanger supplied is determined by the specific Cu Al Inches mm Inches mm
mounting requirements of the busway. Types 225 225 4.75 120.65 5.12 130.04
of hook hangers and angle hangers are 400 400 4.75 120.65 5.12 130.04
shown below.
600 — 4.75 120.65 5.12 130.04
Drop rods (1/2-inch diameter) are not included 800 600 4.75 120.65 5.12 130.04
and must be furnished by the installer. Drop 1000 — 5.38 136.65 5.75 146.05
rods (3/4-inch diameter) are required for seis- 1200 800 5.88 149.35 6.25 158.75
mic applications.
1350 1000 6.38 162.05 6.75 171.45
1600 1200 7.38 187.45 7.75 196.85
2000 1350 8.64 219.45 9.03 229.36
— 1600 9.40 238.76 9.78 248.41
2500 2000 11.17 283.71 11.58 294.13

Edgewise Hook Hanger

Conductor Configuration Duct Height Duct Width (A) Inches (A) mm (B) Inches (B) mm
3WH/4WH/3WG/3WHG 4.38-4.56 In., 4.75-6.38 In., 8.40 213.36 4.81 122.17
4WG/4WHG 111-116 mm 121-162 mm
3WI/4WI 4.38-4.56 In., 7.38-11.17 In., 13.19 335.02 4.81 122.17
111-116 mm 187-284 mm
4WNH/4WNG 4.92-5.10 In., 4.75-6.38 In., 8.40 213.36 5.35 135.89
125-130 mm 121-162 mm
4WNHG/4WNI 4.92-5.10 In., 7.38-11.17 In., 13.19 335.02 5.35 135.89
125-130 mm 187-284 mm
Figure 20: Hook Hangers
Flatwise Angle Hanger
Ampere Rating Conductor Busway Width (A)
Copper Aluminum Bars Per Inches mm Inches mm
Phase
225 225 1 4.75 120.65 9.00 228.60
400 400 1 4.75 120.65 9.00 228.60
600 — 1 4.75 120.65 9.00 228.60
800 600 1 4.75 120.65 9.00 228.60
1000 — 1 5.38 136.65 9.63 244.60
1200 800 1 5.88 149.35 10.12 257.04
1350 1000 1 6.38 162.05 10.63 270.00
1600 1200 1 7.38 187.45 11.63 295.40
2000 1350 1 8.64 219.45 12.88 327.15
— 1600 1 9.40 238.76 13.62 345.94
2500 2000 1 11.17 283.71 15.44 392.17
3200 — 2 16.14 409.95 20.39 577.91
4000 2500 2 18.64 473.45 22.88 581.15
— 3200 2 20.16 512.06 24.39 619.50
5000 4000 2 23.70 601.98 28.00 711.20

Edgewise Angle Hanger

Conductor Configuration Duct Height (A) Inches (A) mm
3WH/4WH/3WG/3WHG/4WG/4WHG 4.38-4.56 In., 111-116 mm 9.00 228.60
3WI/4WI
4WNH/4WNG/4WNHG/4WNI 4.92-5.10 In., 125-130 mm 9.36 237.74

Figure 21: Angle Hangers

Cutler-Hammer Busway
C2-21
May 2001 Low-Voltage Busway – Pow-R-Way III
Layout Dimensions

Vertical Hangers
When busway is to be installed vertically, a
spring suspension type vertical hanger
should be used. Vertical hangers are not
provided unless specified.
This unique hanger equalizes the weight of
vertically mounted busway along all sup-
ports. A vertical hanger must be used on each
floor and at the end of the bus run on the last
floor. The maximum span permitted by CSA
and UL on vertical hangers is 16 feet.
Intermediate hangers are also required for
floor heights exceeding 16 feet.

Conductor Configuration Busway Height Hangers on “F” and “F” Opposite Sides
Inches mm (A) Inches (A) mm (B) Inches (B) mm Illustration Number
3WH/4WH 4.38 111.25 4.72 119.88 4.25 107.95 Figure A & B
3WG/3WHG/4WG/4WHG 4.50 114.30 4.91 124.71 4.44 112.77 Figure A & B
3WI/4WI 4.56 115.82 4.91 124.71 4.44 112.77 Figure A & B
4WHN 4.92 124.96 5.25 133.35 4.79 121.66 Figure A & B
4WNG/4WNHG 5.05 128.27 5.44 138.17 4.97 126.23 Figure A & B
4WNI 5.10 129.54 5.44 138.17 4.97 126.23 Figure A & B

Ampere Rating Busway Width Hangers on “T” and “T” Opposite Sides
Cu Al Inches mm (A) Inches (A) mm Illustration Number
225 225 4.75 120.65 4.62 117.34 Figure C
400 400 4.75 120.65 4.62 117.34 Figure C
600 — 4.75 120.65 4.62 117.34 Figure C
800 600 4.75 120.65 4.62 117.34 Figure C
1000 — 5.38 136.65 5.25 133.35 Figure D
1200 800 5.88 149.35 5.75 146.05 Figure D
1350 1000 6.38 162.05 6.25 158.75 Figure D
1600 1200 7.38 187.45 7.25 184.15 Figure D
2000 1350 8.64 219.45 8.50 215.90 Figure D
— 1600 9.40 238.76 9.25 234.95 Figure E
2500 2000 11.17 283.71 11.06 280.92 Figure E
3200 — 16.14 409.95 16.00 406.40 Figure F
4000 2500 18.64 473.45 18.50 469.90 Figure F
— 3200 20.16 512.06 20.06 510.00 Figure F
5000 4000 23.70 601.98 23.59 600.00 Figure F

Figure 22: Vertical Hangers

 Busway Cutler-Hammer
C2-22 Low-Voltage Busway – Pow-R-Way III May 2001

Layout Dimensions

Dimensions – Plug-in Units

C
L

Figure 24

Plug-in Unit Max. Max. Ac Dimensions, Inches (mm) Mechanical Terminal Approx.
Amps Volts (A) (B) (C) (D) (E) (F) Wire Range Per Phase (mm2) Wghts.
Lbs. (Kgs)

Circuit Breaker Plug-in Units

P3BFD 225 600 19.26 12.36 5.43 6.25 4.00 6.05 100A – (1) #14 to 1/0 (2.5 to 50) 25
(E- & F-Frame (489) (314) (138) (159) (102) (154) 150A – (1) #4 to 4/0 ( (25 to 95) (11.33)
Breakers)
P3BJD 250 600 21.33 12.36 6.97 10.44 4.00 6.06 250A – (1) #14 to 350 kcmil (25 to 185) 47
(J-Frame Breakers) (542) (314) (177) (265) (102) (154) 225A – (1) 3 to 350 kcmil (35 to 185) (21.31)
P3BKD 400 600 32.50 13.29 7.79 12.56 4.00 6.64 350A – (1) 250 to 500 kcmil (120 to 240) 53
(K-Frame Breakers) (826) (338) (198) (319) (102) (169) 400A – (2) 3/0 to 250 kcmil (45 to 120) (24.04)
P3BLD 600 600 44.03 19.65 10.15 17.38 4.00 9.83 400A – (1) 4/0 to 600 kcmil (120 to 300) 75
(L-Frame Breakers) (1118) (499) (258) (441) (102) (250) 600A – (2) 400 to 500 kcmil (185 to 240) (34.01)
P3BMD 800 600 44.03 19.65 10.15 17.38 4.00 9.83 600A – (2) #1 to 500 kcmil (50 to 240) 136
(M-Frame Breakers) (1118) (499) (258) (441) (102) (250) 800A – (2) 500 to 750 kcmil (300 to 400) (61.68)
P3BND 800 600 44.03 19.65 10.15 17.38 4.00 9.83 700A – (2) # 1 to 500 kcmil (50 to 240) 138
(N-Fame Breakers) (1118) (499) (258) (441) (102) (250) 800A – (3) 3/0 to 400 kcmil ( (95 to 185) (62.59)
P3BLAP 400 600 44.03 19.65 10.15 13.80 4.00 9.83 225A – (1) #6 to 350 kcmil (16 to 185) 96
(Tri-Pac) (1118) (499) (258) (357) (102) (249) 400A – (1) #4 to 250 kcmil and (1) 3/0 to (43.54)
600 kcmil (25 to 120 and 95 to 300)
P3BLCL 400 600 40.00 19.65 10.15 13.80 4.00 9.83 (+)#4 to 250 kcmil (25 to 120) plus 88
(1016) (499) (258) (351) (102) (249) (r)3/0 to 600 kcmil (95 to 300) (39.91)

Fusible Plug-in Units

P3F321R and 30 240 20.85 12.36 5.43 7.88 4.00 6.06 Cu – (1) #14 to #3, (2.5 to 35) 22
P3F361R 600 (530) (314) (138) (200) (102) (154) Al – (1) #12 to #2 (3.2 to 35) (9.98)

P3F322R and 60 240 20.85 12.36 5.43 7.88 4.00 6.06 Cu – (1) #14 to #3, (2.5 to 35) 24
(530) (314) (138) (200) (102) (154) Al – (1) #12 to #2 (3.2 to 38) (10.88)
P3F362R 600 Cu – (1) #14 to 1/0 (2.5 to 50)
Al – (1) #12 to 1/0 (3.2 to 50)
P3F323R and 100 240 20.85 12.36 5.43 7.88 4.00 6.06 Cu – (1) #14 to 1/0, (2.5 to 50) 24
P3F363R (530) (314) (138) (200) (102) (154) Al – (1) #12 to 1/0 (3.2 to 50) (10.88)
600 (1) # 4 to 250 kcmil Cu/Al (25 to 120)
P3F324R and 200 240 23.52 15.57 7.19 8.20 4.00 7.63 (1) # 4 to 250 kcmil Cu/Al (25 to 120) 47
(597) (395) (183) (208) (102) (194) (21.31)
P3F364R 600 (1) #4 to 600 kcmil Cu/Al (25 to 300)
or (2) 250 kcmil (120)
P3F325R and 400 240 46.94 21.22 10.07 12.67 4.00 10.69 (2) #2 to 600 kcmil Cu/Al (35 to 300) 77
P3F365R 600 (1192) (539) (256) (322) (102) (272) (34.92)

P3F365H 400 600 23.47 21.22 21.00 12.67 4.00 10.69 (2) #2 to 600 kcmil Cu/Al (35 to 300) 81
(596) (539) (533) (322) (102) (272) (36.74)
P3F326R and 600 240 46.94 26.31 10.59 14.26 4.00 13.16 (2) #2 to 600 kcmil Cu/Al (35 to 300) 82
P3F366R 600 (1192) (669) (270) (362) (102) (334) (3) #4 to 600 kcmil Cu/Al (25 to 300) (37.19)

P3F327R and 800 240 46.94 26.31 10.59 14.26 4.00 13.16 (3) #4 to 600 kcmil Cu/Al (25 to 300) 108
P3F367R 600 (1192) (669) (270) (362) (102) (334) (48.98)
Cutler-Hammer Busway
C2-23
May 2001 Low-Voltage Busway – Pow-R-Way III
Technical Data

Plug-in Protective Devices, Circuit Breaker Selection and Interrupting Ratings Chart
Breaker Frame Ampere Rating 240 Vac 480 Vac 600 Vac
Symmetrical Symmetrical Symmetrical
Amperes Amperes Amperes
ED 100-225 65,000
EDH 100-225 100,000
EDC 100-225 200,000
EHD 15-100 18,000 14,000
FDB 15-100 18,000 14,000 14,000
FD 15-225 65,000 25,000 18,000
HFD 15-225 100,000 65,000 25,000
FDC 15-225 200,000 100,000 35,000
JDB, JD 70-250 65,000 25,000 18,000
HJD 70-250 100,000 65,000 25,000
JDC 70-250 200,000 100,000 35,000
DK 250-400 65,000
KDB 250-400 65,000 35,000 25,000
KD, CKD➀ 250-400 65,000 35,000 25,000
HKD, CHKD➀ 250-400 100,000 65,000 35,000
KDC 250-400 200,000 100,000 50,000
LDB 300-600 65,000 35,000 25,000
LD, CLD➀ 300-600 65,000 35,000 25,000
HLD, CHLD➀ 300-600 100,000 65,000 35,000
LDC, CLDC➀ 300-600 200,000 100,000 50,000
MD 400-800 42,000 35,000 22,000
MDS 400-800 42,000 35,000 22,000
MDSC➁ 400-800 42,000 35,000 22,000
ND➂ 600-1200 65,000 50,000 25,000
HND➂ 600-1200 100,000 65,000 35,000
NDC➂ 600-1200 200,000 100,000 50,000
Current Limiting Breakers
LA Tri-Pac 70-400 200,000 200,000 200,000

Fusible Switch Horsepower and Short Circuit Ratings (based on fuse class)
Ampere 240 Volts 480 Volts 600 Volts
Rating NEC Standard Maximum Max. Sym. NEC Standard Maximum Max. Sym. NEC Standard Maximum Max. Sym.
RMS @ Fuse RMS @ Fuse RMS @ Fuse
Class Class Class
30 3 7.5 200kA - R 5 15 200kA - R 7.5 20 200kA - R
60 7.5 15 200kA - R 15 30 200kA - R 15 50 200kA - R
100 15 30 200kA - R 25 60 200kA - R 30 75 200kA - R
200 25 60 200kA - R 50 125 200kA - R 60 150 200kA - R
400 50 125 200kA - R 100 250 200kA - R 125 350 200kA - J
600 75 200 200kA - R 150 400 200kA - J 200 500 200kA - J
800 100 250 200kA - L 200 500 200kA - L 250 500 200kA - L

➀ Indicates 100% rated breaker. Contact the Product ➂ Plug-in units available up to 800 amperes. Above
Line for application Information. 800 amperes only available in built-in or bridge
➁ Indicates 100% rated breaker available for built-in joint power take-off or bolt-on unit.
or bridge joint Power Take-off/Bolt-on units only,
from 800 amperes and above. Contact the
Product Line for application Information.
 Busway Cutler-Hammer
C2-24 Low-Voltage Busway – Pow-R-Way III May 2001

Technical Data

Short Circuit Rating

Aluminum
Ampere 6-Cycle RMS Symmetrical IEC 439 Short Circuit Maximum Class L Fuse to Achieve
Rating Short Circuit Rating Rating 6-Cycle RMS Series Rating
Plug-in Feeder 1 Second (60 cycles)
Plug-in and Feeder 100 kA 200 kA
225 85,000 85,000 30,000 2000A 1200A
400 85,000 85,000 30,000 2000A 1200A
600 85,000 85,000 30,000 2000A 1200A
800 100,000 100,000 43,000 — 2500A
1000 100,000 100,000 52,000 — 2500A
1200 125,000 125,000 61,000 — 2500A
1350 150,000 150,000 87,000 — 4000A
1600 150,000 150,000 95,000 — 4000A
2000 150,000 150,000 121,000 — 4000A
2500 200,000 200,000 130,000 — —
3200 200,000 200,000 173,000 — —
4000 200,000 200,000 200,000 — —

Copper
Ampere 6-Cycle RMS Symmetrical IEC 439 Short Circuit Class L Fuse Needed to Achieve
Rating Short Circuit Rating Rating 6-Cycle RMS Series Rating
Plug-in Feeder 1 Second (60 cycles)
Plug-in and Feeder 100 kA 200 kA
225 85,000 85,000 43,000 2000 1600
400 85,000 85,000 43,000 2000 1600
600 85,000 85,000 43,000 2000 1600
800 85,000 85,000 43,000 2000 1600
1000 100,000 100,000 55,000 — 3000
1200 100,000 100,000 68,000 — 3000
1350 100,000 100,000 80,000 — 3000
1600 125,000 125,000 97,000 — 3000
2000 150,000 150,000 130,000 — 4000
2500 150,000 150,000 173,000 — 4000
3200 200,000 200,000 182,000 — —
4000 200,000 200,000 200,000 — —
5000 200,000 200,000 200,000 — —

Resistance Values for Integral Housing Ground

(Only) (Milliohms per 100 Feet or 30.5 Meters)
Ampere Aluminum Phase Copper Phase
Rating Conductors Conductors
225 1.04 1.04
400 1.04 1.04
600 1.04 1.04
800 .95 1.04
1000 .92 .99
1200 .85 .95
1350 .72 .92
1600 .68 .85
2000 .61 .72
2500 .36 .61
3200 .34 .43
4000 .30 .36
5000 — .30
Cutler-Hammer Busway
C2-25
May 2001 Low-Voltage Busway – Pow-R-Way III
Technical Data

Line-to-Line Voltage Drop

The tables below give average 3-phase voltage drop per 100 feet (30.48 meters) at rated current and varying power factor. Line-to-neutral
voltage drop is obtained by multiplying the line value by .577.

Copper
Ampere Rating Percent Power Factor
0 10 20 30 40 50 60 70 80 90 100
225 Plug-in .235 .275 .31 .34 .375 .4 .425 .445 .455 .46 .40
Feeder .47 .55 .62 .68 .75 .80 .85 .89 .91 .92 .80
400 Plug-in .415 .485 .55 .615 .67 .72 .765 .80 .825 .825 .725
Feeder .83 .97 1.10 1.23 1.34 1.44 1.53 1.60 1.65 1.65 1.45
600 Plug-in .625 .735 .835 .935 1.025 1.105 1.175 1.235 1.27 1.28 1.13
Feeder 1.25 1.47 1.67 1.87 2.05 2.21 2.35 2.47 2.54 2.56 2.26
800 Plug-in .83 .99 1.13 1.27 1.40 1.52 1.62 1.70 1.76 1.79 1.59
Feeder 1.66 1.97 2.26 2.53 2.79 3.03 3.24 3.40 3.52 3.57 3.18
1000 Plug-in .82 .97 1.10 1.22 1.33 1.44 1.53 1.60 1.65 1.66 1.45
Feeder 1.64 1.93 2.19 2.43 2.66 2.88 3.06 3.19 3.29 3.31 2.90
1200 Plug-in .81 .95 1.08 1.21 1.32 1.43 1.52 1.59 1.64 1.65 1.45
Feeder 1.61 1.90 2.16 2.41 2.64 2.85 3.03 3.17 3.27 3.29 2.90
1350 Plug-in .77 .91 1.04 1.16 1.27 1.37 1.46 1.53 1.58 1.59 1.41
Feeder 1.54 1.81 2.07 2.31 2.53 2.74 2.92 3.06 3.16 3.18 2.81
1600 Plug-in .70 .83 .95 1.06 1.16 1.26 1.34 1.41 1.46 1.48 1.31
Feeder 1.39 1.65 1.89 2.11 2.32 2.52 2.68 2.82 2.91 2.95 2.62
2000 Plug-in .67 .80 .92 1.04 1.14 1.24 1.33 1.40 1.45 1.47 1.31
Feeder 1.34 1.60 1.84 2.07 2.28 2.48 2.65 2.79 2.89 2.93 2.62
2500 Plug-in .58 .70 .81 .91 1.01 1.10 1.18 1.25 1.30 1.32 1.20
Feeder 1.15 1.39 1.61 1.82 2.01 2.20 2.36 2.49 2.59 2.64 2.39
3200 Plug-in .81 .93 1.04 1.14 1.23 1.32 1.38 1.43 1.46 1.45 1.23
Feeder 1.61 1.85 2.07 2.27 2.46 2.63 2.76 2.86 2.92 2.89 2.46
4000 Plug-in .84 .96 1.08 1.19 1.29 1.38 1.46 1.51 1.54 1.54 1.31
Feeder 1.67 1.92 2.16 2.38 2.58 2.76 2.91 3.02 3.08 3.07 2.62
5000 Plug-in .72 .83 .94 1.04 1.14 1.22 1.29 1.35 1.38 1.38 1.20
Feeder 1.43 1.66 1.88 2.08 2.27 2.44 2.58 2.69 2.76 2.76 2.39

Aluminum
Ampere Rating Percent Power Factor
0 10 20 30 40 50 60 70 80 90 100
225 Plug-in .23 .305 .38 .45 .515 .585 .645 .70 .75 .79 .77
Feeder .46 .61 .76 .90 1.03 1.17 1.29 1.40 1.50 1.58 1.54
400 Plug-in .405 .545 .68 .81 .935 1.055 1.17 1.275 1.37 1.44 1.41
Feeder .81 1.09 1.36 1.62 1.87 2.11 2.34 2.55 2.74 2.88 2.81
600 Plug-in .61 .83 1.05 1.26 1.47 1.67 1.85 2.02 2.18 2.31 2.28
Feeder 1.21 1.66 2.10 2.52 2.93 3.33 3.70 4.04 4.35 4.61 4.55
800 Plug-in .69 .87 1.04 1.21 1.37 1.52 1.66 1.78 1.88 1.95 1.85
Feeder 1.37 1.73 2.08 2.41 2.73 3.03 3.31 3.55 3.76 3.90 3.69
1000 Plug-in .73 .92 1.11 1.29 1.46 1.62 1.77 1.90 2.02 2.09 1.99
Feeder 1.45 1.84 2.21 2.57 2.91 3.24 3.54 3.80 4.03 4.18 3.97
1200 Plug-in .67 .85 1.02 1.18 1.84 1.49 1.63 1.75 1.85 1.93 1.83
Feeder 1.33 1.69 2.03 2.36 9.68 2.98 3.25 3.50 3.70 3.85 3.65
1350 Plug-in .58 .74 .89 1.04 1.18 1.31 1.44 1.55 1.64 1.71 1.63
Feeder 1.15 1.47 1.78 2.07 2.36 2.62 2.87 3.09 3.28 3.41 3.25
1600 Plug-in .60 .78 .94 1.10 1.25 1.39 1.52 1.64 1.74 1.82 1.73
Feeder 1.20 1.55 1.87 2.19 2.49 2.78 3.04 3.28 3.48 3.63 3.46
2000 Plug-in .59 .63 .93 1.09 1.24 1.39 1.53 1.65 1.76 1.83 1.76
Feeder 1.18 1.25 1.86 2.18 2.48 2.78 3.05 3.29 3.51 3.66 3.51
2500 Plug-in .60 .75 .89 1.03 1.16 1.29 1.40 1.50 1.58 1.64 1.54
Feeder 1.19 1.49 1.78 2.05 2.32 2.57 2.80 2.99 3.16 3.27 3.07
3200 Plug-in .63 .79 .94 1.09 1.23 1.36 1.48 1.58 1.67 1.73 1.63
Feeder 1.26 1.58 1.88 2.17 2.45 2.71 2.96 3.16 3.34 3.46 3.25
4000 Plug-in .66 .83 1.00 1.15 1.31 1.45 1.58 1.70 1.80 1.86 1.76
Feeder 1.31 1.66 1.99 2.30 2.61 2.89 3.16 3.39 3.59 3.72 3.52
 Busway Cutler-Hammer
C2-26 Low-Voltage Busway – Pow-R-Way III May 2001

Technical Data

Resistance, Reactance and Impedance Derating Chart for Higher Ambient

Aluminum Bars Temperatures
Pow-R-Way III busway may be operated
Milliohms per 100 ft. (30.48 Meters) Line-to-Neutral Aluminum Plug-in and Feeder Busway continuously at its assigned ratings without
Ampere Rating Resistance Reactance Impedance exceeding the maximum hot spot tempera-
225 4.38 1.17 4.54 ture rise of 55° C, provided the ambient tem-
perature does not exceed 40° C. For higher
400 4.38 1.17 4.54
ambient temperatures, the ratings should be
600 4.38 1.17 4.54 reduced by applying the appropriate multi-
800 2.67 1.05 2.84 plier shown in the following chart.
1000 2.29 .84 2.44
Ambient Temp. °C Multiplier
1200 1.76 .64 1.87
40 1.00
1350 1.39 .49 1.47
45 .95
1600 1.25 .43 1.32
50 .90
2000 1.01 .34 1.07
55 .85
2500 .71 .27 .76
60 .80
3200 .62 .24 .67
65 .74
4000 .50 .19 .54
70 .67
Copper Bars
Milliohms per 100 ft. (30.48 Meters) Line-to-Neutral Copper Plug-in and Feeder Busway
Ampere Rating Resistance Reactance Impedance
225 2.30 1.20 2.59
400 2.30 1.20 2.59
600 2.30 1.20 2.59
800 2.30 1.20 2.59
1000 1.67 .95 1.93
1200 1.39 .78 1.60
1350 1.20 .66 1.37
1600 .94 .50 1.07
2000 .76 .39 .85
2500 .55 .26 .61
3200 .47 .31 .51
4000 .38 .24 .45
5000 .27 .16 .32

Weight (Pounds/Ft.) and Current Density (Amperes Per Square Inch)

Ampere Rating Current Density Weight – Including Integral Housing Ground (Pounds/Ft.)
Amperes Per Square
3-Wire 4-Wire 100% Neutral 4-Wire 200% Neutral Add for Internal Ground
Inch
Cu Al Cu Al Cu Al Cu Al Cu Al Cu Al
225 225 554 554 8 5 10 6 11 7 .78 .23
400 400 985 985 8 5 10 6 11 7 .78 .23
600 — 1477 — 8 — 10 — 11 — .78 —
800 600 1969 1477 8 5 10 6 11 7 .78 .23
1000 — 1778 — 10 — 12 — 14 — 1.08 —
1200 800 1745 1164 12 6 15 7 17 8 1.33 .40
1350 1000 1662 1231 14 7 17 8 20 9 1.57 .47
1600 1200 1506 1129 17 8 21 10 25 11 2.05 .62
2000 1350 1455 982 23 11 28 12 33 13 2.66 .80
— 1600 — 1024 — 12 — 13 — 15 — .91
2500 2000 1250 1000 29 14 36 16 42 18 3.87 1.17
3200 — 1505 — 45 — 56 — 66 — 4.11 —
4000 2500 1455 909 34 21 42 24 49 27 5.32 1.61
— 3200 — 960 — 23 — 26 — 29 — 1.83
5000 4000 1250 1000 63 28 72 32 85 36 7.74 2.35
Cutler-Hammer Busway
C2-27
May 2001 Low-Voltage Busway – Pow-R-Way III
Technical Data

Metric Weight (Kg/M) and Current Density (Amperes Per cm2)

Ampere Rating Current Density Weight – Including Integral Housing Ground (kg/M)
Amps/cm2 3-Wire 4-Wire 100% Neutral 4-Wire 200% Neutral Add for Internal Ground
Cu Al Cu Al Cu Al Cu Al Cu Al Cu Al
225 225 86 86 12 7 15 9 17 11 1.17 .35
400 400 153 153 12 7 15 9 17 11 1.17 .35
600 — 229 — 12 — 15 — 17 — 1.17 —
800 600 305 229 12 7 15 9 17 11 1.17 .35
1000 — 276 — 15 — 18 — 21 — 1.62 —
1200 800 270 180 18 9 22 11 26 12 1.98 .60
1350 1000 258 191 21 11 25 12 30 14 2.34 .71
1600 1200 233 175 25 12 32 15 37 16 3.06 .92
2000 1350 226 152 34 16 42 18 49 20 3.96 1.20
— 1600 — 159 — 18 — 20 — 22 — 1.36
2500 2000 194 155 43 21 54 24 63 27 5.76 1.75
3200 — 233 — 67 — 83 — 98 — 6.12 —
4000 2500 226 140 51 32 63 36 73 40 7.92 2.40
— 3200 — 149 — 34 — 39 — 43 — 2.73
5000 4000 194 155 94 42 108 48 126 54 11.53 3.50

TVSS Bus Plugs, Clipper Power Systems Selection Chart

Catalog Number P3F-CPS-M P3F-CPS-H P3F-CPS-S2 P3F-CPS-S P3F-CPS-B
Surge Current Per Phase 400 kA 250 kA 160 kA 120 kA 100 kA
Surge Current Mode
Line-Neutral 200 kA 125 kA 60 kA 60 kA 50 kA
Line-Ground 200 kA 125 kA 60 kA 60 kA 50 kA
Neutral-Ground 200 kA 125 kA 60 kA 60 kA 50 kA
Line-Line (Delta and ungrounded applications only) 200 kA 125 kA 60 kA 60 kA 50 kA
Protection Modes
3-Phase Wye Systems 7 7 7 7 7
3-Phase Delta Systems 6 6 6 6 6
Filter Attenuation 55dB 55dB 55dB 55dB 40dB
(Based on MIL-STD-220A) at 100kHz
IEEE Category B3 Ringwave Suppression <150V <150V <150V <150V <350V
(L-N Mode; 6000V, 500A)
Surge Withstand Capabilities >4000 >3500 >2500 >2500 >1500
IEEE C3 Wave (10 kA)
TVSS TRI-Monitor System
1. Overcurrent Protection Yes Yes Yes Yes Yes
2. Infrared Detection Yes Yes Yes Yes Optional
3. Thermal Detection Yes Yes Yes Yes Optional
 Busway
C2-28 Low-Voltage Busway – Pow-R-Way III
Typical Specifications
1. Ratings
A. The busway shall be Cutler-Hammer type
Pow-R-Way III:
[3-phase, 3-wire with 50% housing ground
and optional 50% internal ground]
[3-phase, 3-wire with 50% housing ground
and optional 50% isolated ground]
[3-phase, 4-wire with 100% neutral,
50% housing and optional 50% internal
ground]
[3-phase, 4-wire with 100% neutral,
50% housing and optional 50% isolated
ground]
[3-phase, 4-wire with 200% neutral]
[3-phase, 4-wire with 200% neutral,
50% housing ground and optional
50% internal ground]
[3-phase, 4-wire with 200% neutral,
50% housing ground and optional
50% isolated ground]
with voltage and current ratings as
indicated on the contract drawings.
B. The busway shall, have a minimum of
6-cycle short-circuit rating of 85 kA RMS
symmetrical for ratings through 800A, 100
kA RMS symmetrical for ratings through
1350A, 125 kA RMS symmetrical for rat-
ings through 1600A, 150 kA RMS symmet-
rical ratings through 2500A, and 200 kA
RMS symmetrical for ratings through
5000A.
2. Construction
A. The busway and associated fittings shall
consist of [aluminum] [copper] conductors
totally enclosed in a 2-piece extruded alumi-
num housing. Outdoor feeder, indoor feeder
and indoor plug-in busway shall be inter-
changeable at the same rating without the
use of adapters or special splice plates.
Where indicated on the drawings, provide
indoor, sprinkler-proof plug-in busway. Out-
door designs requiring addition of caulking
or gasketing in the field are not acceptable.
Fittings such as – elbows, tees, flanges, etc. –
shall be identical for use with both the plug-
in and feeder types of busway. The busway
shall be capable of being mounted flatwise,
edgewise, or vertically without derating. The
busway shall consist of standard 10-foot sec-
tions with special sections and fittings pro-
vided to suit the installation. Horizontal runs
shall be suitable for hanging on 10-foot max-
imum centers. Vertical runs shall be suitable
for mounting on 16-foot maximum centers.
Provide one (1) hanger for every ten (10) feet
of horizontally mounted duct. On vertical
runs provide one adjustable hanger per
floor.
3. Bus
A. Bus bars shall be fabricated from high
strength, [55% conductivity aluminum]
[98% conductivity copper] and suitably
plated at all electrical contact surfaces.
B. Bus bars shall be insulated over their entire
length, except at joints and contact surfaces,
with a CSA and UL listed insulating material
consisting of epoxy applied by fluidized bed
process. Tape or heat-shrink sleeve insula-
tion, or any other method of insulation
which can allow air-gaps or insulation
breakdown, shall not be acceptable.
C. The busway shall be capable of carrying
rated current continuously without exceed-
ing a temperature rise of 55 degrees C
based on a 40 degrees C ambient.
4. Bus Joints
A. Each busway section shall be furnished
complete with joint hardware and covers.
The busway joints shall be a single-bolt,
non-rotating, removable bridge design. All
bridge joints shall be furnished with
torque-indicating double head joint bolts
and Belleville washers. The bridge joint
shall utilize a captive nut retainer on the
opposite side of the torque indicating bolt.
The bridge joint design shall ensure
proper installation without the use of a
torque wrench, and provide visual indica-
tion that the joint is properly torqued. Each
busway joint shall allow for a minimum
length adjustment of +/- 0.5 inches. De-
energization of busway shall not be
required for safe testing of joint tightness.
5. Housing
A. The busway housing shall be a 2-piece
design fabricated from extruded aluminum.
The 2-piece housing shall be bolted
together along the bottom flange using
grade 5, 1/4x20 zinc-plated fasteners on
3-inch centers for maximum mechanical
strength. The busway enclosure finish shall
be ANSI 61 gray baked epoxy powder paint
applied by an electrostatic process.
B. Outdoor feeder busway housing shall be
identical to indoor feeder busway hous-
ings, and shall be UL listed for outdoor
use. Busway shall be completely weather-
ized at the factory, and designed such that
only protective joint covers are required
for outdoor application.
6. Plug-in Busway
A. Where required, busway shall be of the
plug-in type. Plug-in busway shall be avail-
able in standard 2-, 4-, 6-, 8-, and
10-foot lengths, with plug-in openings pro-
vided on both sides of the busway sec-
tions on 24-inch centers. Plug-in
covers shall prohibit dirt and debris from
entering contact plug-in openings in the
busway. The design shall allow for ten (10)
hinged cover outlets per ten (10) feet of
plug-in length, and covers shall be field-
convertible to hinge on either side. Covers
for plug-in openings shall have a positive
screw close feature and provisions for
installation of power company seals. The
contact surfaces for bus plug stabs shall
be silver-plated of the same material, thick-
ness, and rating as the phase bars. The
tabs shall be welded to the busbars. A
standard silver-plated housing ground
connection shall be supplied in each plug-
in opening. Positive mechanical guides for
Cutler-Hammer
May 2001
plug-in units shall be provided at each
plug-in opening to facilitate unit alignment
and prevent improper installation.
B. Where required, plug-in units of the types
and ratings indicated on the plans and
specifications shall be supplied. Plug-in
units shall be mechanically interlocked
with the busway housing to prevent their
installation or removal while the switch is
in the ON position. The enclosure of any
plug-in unit shall make positive ground
connection to the duct housing before the
stabs make contact with the bus bars. All
plug-in units shall be equipped with a
defeatable interlock to prevent the cover
from being opened while the switch is in
the ON position and to prevent accidental
closing of the switch while the cover is
open. The plugs shall be provided with a
means for padlocking the cover closed and
padlocking the disconnect device in the
OFF position. The operating handle and
mechanism shall remain in control of the
disconnect device at all times, permitting
its easy operation from the floor by means
of a hookstick or chain. Plug-in units shall
be equipped with a means for direct posi-
tioning or hanging, so that the weight is
borne by the duct before the stabs make
contact with the bus bars. For safety rea-
sons, no projections shall extend into the
busway housing other than the plug-in
stabs. All plug-in units shall be inter-
changeable without alteration or modifica-
tion of plug-in duct.
C. Fusible-type plugs shall have a quick-
make/quick-break disconnect switch and
positive pressure fuse clips
– OR –
C. Circuit breaker-type plugs shall have an
interrupting rating of not less than ____
symmetrical RMS amperes or be series-
rated as otherwise shown in the contract
document and shall meet all requirements
of UL Standard 489. It shall be possible to
increase the interrupting rating of a
breaker plug-in device having ampere rat-
ings through 400A up to 100 kAIC at 480
Vac and 200 kAIC at 240 Vac by changing
out the circuit breaker only and leaving the
enclosure intact. All breaker plug-in
devices shall be Cutler-Hammer type
Series C.
D. Current-limiting circuit breaker-type plug-
in devices shall be units which provide
integral time delay/thermal trip protection
and current-limiting protection in one
assembly. These breakers shall be UL
rated at 200 kAIC at 240 Vac, and 150 kAIC
at 480 Vac, and shall be series-rated to pro-
tect all molded case breakers downstream
as shown on the drawings.
7. Transient Voltage Surge Suppression
A. Provide transient voltage surge sup-
pression.
B. Refer to the TVSS Bus Plug, Clipper
Power Systems Selection Chart page C2-
27 and select the TVSS as required.