The ABCs of Planning and Installing Bus Duct

The ABCs of Planning and Installing Pow-R-Way III Bus Duct Instruction Manual Supersedes File 30-500, pages 1 – 72 dated 1974

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Description

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . Pow-R-Way III Layout . . . . . . . . . . . . . . . . . . . Walk-through & On-site Measurements. . . . Feeder Runs. . . . . . . . . . . . . . . . . . . . . . . . . Connecting PRWIII to Switchboards and and Switchgear . . . . . . . Connecting PRWIII to Motor Control Centers Centers . . . . . . . . . . . . . Connecting PRWIII to Transfor ransformer mers s .... Installation Tips Tips . . . . . . . . . . . . . . . . . . . . Multiple Multiple Feede Feederr Bus Runs Runs . . . . . . . . Busway Busway Joint Joint Clearan Clearances ces . . . . . . . . . Wall and Floor Floor Penetrations . . . . . . . Outdoor Outdoor Consid Considerati erations ons . . . . . . . . . . Plug-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Floor Floor Height Height Measurem Measurements ents . . . . . . . . . Installation Tips Tips . . . . . . . . . . . . . . . . . . . . Maximum Maximum Height Height . . . . . . . . . . . . . . . Other Equipment or Walls in Close Proximity Proximity to the Busway Busway Riser. Riser . . . . . T Location. . . . . . . . . . . . . . . . . . . . . . . . Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elbows Elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . Flanges. . . . . . . . . . . . . . . . . . . . . . . . . . . Tees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Tap Boxes . . . . . . . . . . . . . . . . . . . Weatherheads . . . . . . . . . . . . . . . . . . . . . Expansion Joints. . . . . . . . . . . . . . . . . . . Bus Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug-in Units . . . . . . . . . . . . . . . . . . . . . . . . Bolt-on Units . . . . . . . . . . . . . . . . . . . . . . . . Built-in Power Power Takeoff Takeoff Devices . . . . . . . Bridge Bridge Joint Joint Power Takeoff Takeoff Devices Devices . . . . Installation Tips Tips . . . . . . . . . . . . . . . . . . . . . . Coordination . . . . . . . . . . . . . . . . . . . . . . . . . . . Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Customer Approval Drawings Drawings . . . . . . . . . . Customer Layout Drawings Drawings . . . . . . . . . . . . Construction Drawings Drawings . . . . . . . . . . . . . . . . Installation Guide . . . . . . . . . . . . . . . . . . . . . . . Indoor Indoor Joint Joint Assembly Assembly Instruc Instructions tions . . . . . Final Field Fits . . . . . . . . . . . . . . . . . . . . . . . How to Remove Remove a Sectio Section n of Busway Busway . . . . Outdoor Busway Supports. . . . . . . . . . . . . Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wall/Floor Flanges. . . . . . . . . . . . . . . . . . . . End Closers . . . . . . . . . . . . . . . . . . . . . . . . . Busway Handling . . . . . . . . . . . . . . . . . . . . . . . Shipping. . . . . . . . . . . . . . . . . . . . . . . . . . . . Busway Labels. . . . . . . . . . . . . . . . . . . . . . . Dimensional Data . . . . . . . . . . . . . . . . . . . . . . .

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Introduction Eaton’s Cutler-Hammer Pow-R-Way III (PRWIII) is a 600 volt, totally enclosed, non-ventilated, sandwich busway design available with either copper bus bars rated from 225 to 5000 amperes or with aluminum bus bars rated from 225 to 4000 amperes. PRWIII is available in outdoor feeder, indoor feeder, indoor plug-in and indoor sprinkler proof plug-in configurations. All four types can be connected together without adapters or special splice plates provided they are of the same current and system rating. The short circuit withstand ratings for plug-in busway are equal to those of indoor and outdoor feeder busway of the same current and system rating. PRWIII busway can be utilized in applications such as simple, straight runs of plug-in fed from a cable tap box, or complex runs with multiple feeders. However simple or complex, the system must be planned in advance. The purpose of this handbook is to help you plan, lay out, and install PRWIII busway with an easy, step-by-step approach. The handbook describes a number of examples and details of how the product is applied, as well as specific details on how to coordinate the installation of PRW III with other products manufactured by Eaton’s Cutler-Hammer business. 1. This This hand handbo book ok shou should ld be used used as a ref refer er-ence guide only. Other useful references are NEMA document BU 1.1-2001, Technical Data TD01701001E, Consulting Application Guide , 13th Edition CA08104001E, and Selling Policy 25-000. Customer approval and the particular details of the application must dictate the final decision on any system.

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Pow-R-Way III Layout  Walk-through and On-site Measurements Before deciding the layout of a PRW III busway job, we suggest you have these basic materials: a sketch pad, measuring tape – 25 and 100 foot (7.6 and 30.4 m), 6-foot (1.8 m) folding wood rule, chalk line, plumb bob, and a marker. First, it’s always a good idea to walk through the entire facility to get an idea of general routing. While walking through, make note of obstructions to the busway routing. At the same time, establish one elevation to minimize the need for offsets. Elevations between rooms or various parts of the building must be checked. Otherwise, busway installed at a specific elevation in one part of the building may be too high or too low at another point. After the initial walk-through, you are ready to begin measuring the layout. For reference points, use structures already available in the building, such as walls or columns. Do not attempt to divide the run into specific sections of duct. This is the responsibility of the Busway Division.

Feeder Runs The following pages contain samples of floor fl oor plans that range from a simple service application to a multi-story building. The combination of sketches will, in all probability, cover most of the situations you will encounter. The sketches can also serve as a guide to help you look for, identify, and measure the most important site dimensions that must be submitted with each order. Having complete layout information when the order is entered will save time and expedite the release for manufacture. The sketches include: Figure 2

Basic Site Dimensions (using walls as reference points)

Figure 3

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

Figure 4

Horizontal Offset

Figure 5

Vertical Offset

Figure 6

Single-Run Distribution System

Figure 7

Double-Run Distribution System

Figure 8

Using Columns as Reference Points

Figure 9

Multi-Floor

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?

Switchboard

?

?

Front

? ?

Figure 1.Enlarged Plan View of Switchboard Room

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

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Check Local Codes For Correct Height ? ?

Front Switchboard ? ? LV

? ?

?

Transformer

? ?

Front Switchboard

? ?

Front Switchboard

Section AA

?

?

Front

A

A

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

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? ?

?

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Front

Figure 4.Horizontal Offset

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Section AA

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A AA

? A

?

Front

Figure 5.Vertical Offset

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Front

Figure 6.Single-Run Distribution System

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?

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Front

Figure 7.Double-Run Distribution System A

C

B

D

E 1

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3

? 4

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? 5

? Front 6

Figure 8.Using Columns as Reference Points

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Finished Floor

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MCC Front

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Roo ooff

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? 2nd

Floor

? ?

? 1st Floor

Finished Floor

Figure 9.Multi-Floor Actual measurements should start in the area where the switchboard, switchgear or MCC is located. If the gear has not been installed, chalk in the specified location and the point of entry for the busway. busway. For transformer connections, transformer taps and weatherhead information, see Pages 50, 51 and 64 – 67. One of the most important steps in planning a large PRWIII busway layout is coordination between the trades. This is a good time for the electrical contractor to meet with plumbing, heating, lighting and sprinkler system contractors to establish a definite right-of-way throughout throughout the construction area. Once established, hours of frustrating re-routing can be saved. Many times, immediately after the right-of-way has been determined, electrical contractors will install busway hanger drop rods to claim and identify their areas. The next step is to establish the busway elevation, then start horizontal measurements using the following examples as a guide. The examples indicate the dimensions required.

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Connecting Pow-R-Way III to Switchboards and Switchgear The Cutler-Hammer Cutler-Hammer Sales Office Offi ce should specify all Divisions that must coordinate activities. After release of busway with complete information, the Busway Division will send flange reference drawings and coordination to the other Division/  Satellite Plant/OEM. When equipment of other manufacturers is involved, the customer and the CutlerHammer Sales Office have the responsibility for obtaining flange references and dimensions (see Figure 10). Wherever possible, standard flanges will be used. This is easier to accomplish if coordination is completed as soon as possible. Otherwise, special flanges will be used, and special prices will apply. The switchgear manufacturer determines the location of the bus entrance on the switchgear. The Busway Division will define the phasing, once the bus layout is released with complete information. Note:When busway enters the top of switchgear, pay close attention to obstructions on the top of the gear (i.e. — roof ventilation or breaker lifting devices). Note:Special flanges are required when connecting to outdoor DSII and Magnum switchgear for bus ratings of 3200 A – 5000 A copper and 2500 A – 4000 A aluminum.

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Front Switchboard

?

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Figure 10.Busway Connection to Switchboard

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Connecting Pow-R-Way III  to Motor Control Centers Busway connection to Cutler-Hammer Cutler-Hammer motor control centers is relatively simple (see Figure 11). Keep in mind that the MCC is normally supplied with a sheet metal cubicle (i.e. top hat, pull box) on top of the standard enclosure to accept the busway flange. This is due to the close proximity of the internal horizontal bus to the top of the structure. This pull box can vary in height and must be determined to establish proper busway elevation. Busway connections can be established on any side of the top hat. However, top connectors are the most common.

Connecting Pow-R-Way Pow-R-Way III to Transformers Throat Connections  For throat connections, complete transformer information must be provided. The bus connection will then be designed to fit accordingly (see Figure 12A). The Busway Division provides the busway and flexible connections to connect to transformer low voltage spades.

Top Entry Connections  For connections to transformers with top entry, complete transformer information must be provided. The Busway Division will design and supply a flange connection with flexible connectors (see Figure 12B).

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Top Hat

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MCC

? ?

?

Figure 11.Busway Connection to Motor Control Center

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LV Studs Transformer s ct roatt roa

Transformer Trans Throa roatt

e Bra raiid Flexibl Fle xible ?

Obst str ruction

Figure 12A.Busway Connection to Transformer Throat C L ?

20.00 (508.0)

?

C L Flexible Braid

?

?

Figure 12B.Busway Flange Connection to Transformer

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Installation Tips Multiple Feeder Bus Runs  For multiple runs of busway, busway, thought must be given to horizontal and vertical clearances between runs. Clearances shown in Figure 13 must be maintained for assembly purposes.

6.00 (152.4) Min.

6.00 (152.4) Ceiling Min.

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

Figure 13.Horizontal Runs Note:The joint bolt-head is on the T-opposite side of the busway. busway. The contractor and owner should be consulted to be sure that there is adequate room for installation and maintenance.

Busway Joint Clearances  Per NEMA standards, busway may penetrate a wall or floor if in unbroken lengths. It therefore follows that busway joints cannot fall in walls or floors. The example in Figure 14 illustrates the minimum distance that the centerline of a PRW III busway joint can be located from a wall. Outdoor busway must penetrate the building wall and extend into the building at least 1 foot (305 mm) before indoor busway can be used.

10.00 (254.0) Min. C L Joint

Figure 14.Required Minimum Distance from Wall Effective: December 2002

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Wall and Floor Penetrations  Wall and floor openings for busway should be at least 1-inch (25.4 mm) larger than outside dimensions of busway (see Figure 15). When an elbow or flange must be installed through a wall or floor, the opening must be large enough to accommodate proper installation. Curbs around floor openings are highly recommended. A curb prevents water from flowing down through floor openings. Many times damage occurs to the busway because the busway is not properly protected.

Wall/Floor All 4 Sides

2.00 (50.8) 1.00

(25.4)

Wall/Floor Opening

Bus Duct

Wall/Floor Flange

Figure 15.Minimum Clearances for Wall and Floor Openings

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Outdoor Considerations  Outdoor PRWIII is rated for NEMA 3S application only after the busway is completely installed (see Figures 16 and 17), the T marking is on top, and the system carries a constant minimum 50 percent load.

Outdoor

T

10.00 (254.0)

Indoor

Outdoor

T Indoor

T

Figure 16.Wall Penetration with Outdoor Busway

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Floor

Phase 2 Bars / Ph

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

         E           C          I          T           O          N

          R          E           G          N           A           D

Floor

Side View

DANGER

Phase 1 Bar / Ph

NOTICE

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

Remove These

Plugs Only

Phase 1 Bar / Ph

Phase 2 Bars / Ph

Floor

Horizontal

Figure 17.Outdoor Pow-R-Bridge Detail IM01701002E

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Plug-in Floor Height The basic dimensions (height from finished fi nished floor to finished floor including floor thickness) required for every busway riser are shown in Figure 18. Do not assume that all floors are the same height or thickness. Note:If a curb is to be supplied around the floor opening, specify height of curb.

When planning the riser layout, joint clearance above the floor must be maintained to install joint cover plates and vertical spring hangers. A minimum distance of 18 inches (457.2 mm) above the floor or curb to centerline of the joint is required. PRWIII Plug-in busway comes in straight lengths of 2, 4, 6, 8 and 10 feet (.6, 1.2, 1.8, 2.4 and 3.0 m) only. Therefore, the floor height will dictate the maximum length of a plug-in section that can be installed on that floor. For an example of a typical riser layout, see Figure 19.

Example: If the floor height is less than 12 foot 10 inches (3.9 m) and floor thickness is 6 inches (152.4 mm), it is not possible to use a 10 foot (3 m) straight length of plug-in duct. Instead, a shorter 8, 6, 4, 2 foot (2.4, 1.8, 1.2, .6 mm) straight length would be used. When planning to install a plug in the bottom most plug-in opening, verify the dimensions of the plug to ensure clearance above the vertical hanger. hanger. Using the example in Figure 19, you can experiment with plugs to be supplied and determine the number that can fit fi t on each floor fl oor.. Refer to Pages 68 – 70 for the dimensions of the plug-in units.

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Floor

? ?

Bus Duct

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Curb Where Required Floor ?

Figure 18.Basic Height Measurement Required for Risers

Floor

" (457.2 mm)

Joint

Plug-in opening (609.6 mm)

Plug-in opening (609.6 mm) 14'-0"

Plug-in opening

(4.3 m) (609.6 mm)

(609.6 mm)

254 4.0 mm) (25 4" Curb

Plug-in opening

Plug-in opening Joint

6" (457.2 mm)

Floor 1

Figure 19.Typical Floor for Plug-in Duct

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Installation Tips Maximum Height  As a guide, the maximum height of a plug-in unit with an operating handle or fuses should not be more than 6 feet 6 inches (2.0 m) above the fl oor when mounted on a vertical riser. riser. Check local codes to determine if this restriction applies. This is a very limiting factor where the size and quantity of the plugs on each floor exceed the 6-feet 6-inches (2.0 m) rule.

Other Equipment or Walls in Close Proximity to the  Busway Riser  Installing busway with plug-in or bolt-on units in a vertical riser requires pre-planning. See Figure 21 for examples of busway risers in an electrical closet. The busway with plug-in or bolt-on units must be arranged to clear other equipment and walls in the electrical closet. In particular, see that the plug-in or bolt-on hinged cover can be opened fully for maintenance.

T Location  On a vertical riser of PRWIII plug-in busway, the load direction of the plugs will be pointed down when T is to the left of the plug.

T

Line

ON

OFF Load

Figure 20.Preferred Unit Orientation Effective: December 2002

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CL Duct F

Wall

T

Plug-in/Bolt On Unit

C

Opened Hinged Cover

A

B

Wall

T

4.00 (101.6) Min.

Plug-in Unit

C

F

CL Duct

Operating Handle

Figure 21.Preferred Arrangements for Wiring Closets

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

Elbows PRWIII includes two elbow designs.

Traditional Elbow  The traditional elbow is used to make 90º turns in the busway run. The four types that are available are forward, rearward, upward and downward. See Pages 56 and 57 for minimum leg lengths.

Corner-Joint Elbow  The corner-joint elbow is a feature unique to PRWIII. This special elbow is a hybrid of a traditional elbow and a bridge joint. Because the corner-joint corner-joint elbow is more compact, it can be installed in areas where a traditional 90º elbow can not be installed. The leg lengths for corner-joint elbows are listed on Pages 58 and 59. Note:Corner-joint elbows are suitable for indoor use only.

Offsets An offset is two elbows fabricated into a single fitting for use where space restrictions prohibit the use of two separate traditional elbows. The minimum leg lengths are listed on Pages 60 and 61.

Flanges Flanges provide a direct connection to low voltage switchgear, switchboards, motor control centers, and other equipment. PRWIII offers three types of flanges: standard, elbow and flush. The type of flange required will be determined by the busway layout. See Pages 52 – 54 for minimum leg lengths for each type of flange.

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

Cable Tap Boxes A cable tap box is used when a busway run is being fed by cable and conduit, or where loads served by busway are connected without the need for overcurrent protection. PRWIII offers end, center and plug-in cable tap boxes. For further information on plug-in cable tap boxes see Technical Data TD01701001E . Dimensions of end and center cable tap boxes can be found on Pages 50 and 51.

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

Expansion Joints Expansion joints accommodate the expansion and contraction of bus bars with respect to the enclosure. The Busway Division recommends using an expansion joint under the following conditions: 1. When When cr cros ossi sing ng a bui build ldin ing g expa expans nsio ion. n. 2. On ver verti tica call rise risers rs ove overr 100 100 feet feet (30 (30.4 .4 m) m) wher where e adequate bracing may not be possible in the basement run adjacent to the vertical riser. 3. On hor horiz izon onta tall run runs s of 150 150 feet feet (45 (45.7 .7 m) tha thatt are fixed at both ends, unless the footage is broken up with elbows. 4. For For lon long g str strai aigh ghtt run runs s of of 300 300 feet feet (91 (91.4 .4 m) where the ends are not fixed, use one expansion joint. From 300 to 600 feet (91.4 to 182.9 m), use two expansion joints, unless the load taken off the bus by plug-in units is great enough to reduce the current at equal intervals along the length of the entire run.

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Bus Plugs The Pow-R-Way III busway product offers a complete family of bus plugs. Traditional plug-in units are available up to 800 amperes, and bolt-on units are available for up to 1200 ampere applications. Plug-in units install at the openings provided on plug-in type busway, while bolt-on units are used with power takeoff devices.

Plug-in Units Standard plug-in units include circuit breaker and fusible plugs with overcurrent protection, as well as plug-in cable tap boxes without overcurrent protection. Advanced plug-in units are available including Clipper TVSS surge suppression, communicating IQ Energy Sentinel  and OPTIM circuit breakers, and Advantage  combination contactors and starters. Plug-in units feature mechanical interlocks which prevent their installation or removal while the switch is in the ON position, and to prevent accidental closing of the switch when the cover is open. In addition, the plugs are provided with a means of padlocking the cover closed and padlocking the devices in the OFF position. A polarizing alignment pin is located on the line side of each plug-in enclosure. The alignment pin is inserted into the guide port in the busway housing for proper installation. Fusible plug-in units are available in 30A to 800A ratings. Fusible type plugs include the quick-make, quick-break disconnect switch and positive pressure fuse clips. These plugs are shipped fully assembled with neutral and ground stabs as required. See Table 15 on Page 70 for detailed information. Breaker plug-in units are available for “FD” through “ND” (800A only) frame Cutler-Hammer Series C 3-pole circuit breakers only. These plugs are shipped fully assembled with breaker, trip unit, rating plug, terminals, neutral and ground as required. See Table 14 on Page 69 for detailed information. Fusible and circuit breaker bus plugs may be ordered on Vista under suffix “QAP” using an assembled catalog number. See Cutler-Hammer  Distribution Products Catalog CA08101001E Catalog  CA08101001E for details. Plug-in Cable Tap Boxes are available in 200A, 400A, 600A and 800A ratings. They may be ordered with mechanical or compression lugs. See Table 3 on Page 51 for detailed information.

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Plug-in Units (Continued) Front covers are hinged on the load end of the enclosure. Clearance required in front of the unit is equal to “A” dimension in Tables 14 and 15 on Pages 69 and 70. All plugs shown on Page 68 are quick-make, quick-break. “F” and “B” dimensions are included in tables. Operating handles are shipped assembled for plugs rated 200A and below, below, as shown in Figure 22. Handles can easily be moved to the end of the plug in the field.

Bolt-on Units A power takeoff is used to tap off power up to 1200 amperes. Where power is required in excess of the current carry capabilities of the plug-in stabs (800 amperes), a power takeoff must be used. The power takeoff bolts directly to the contact surfaces of the bus bars. A bolt-on fusible switch or circuit breaker unit is then installed on the power takeoff. Power takeoff devices are available as built-in or bridge joint types.

Built-in Power Takeoff Takeoff Devices (Figure 22) A built-in power takeoff is a special piece of feeder busway that allows for the attachment of a bolt-on unit. Built-in power takeoffs are used where space restrictions dictate that the wide dimension of the busway be flat against the wall, ceiling or other obstruction. In this application, power takeoffs and bolt-on plug units are used instead of plug-in units. Bolt-on (fusible switch, circuit breaker or panelboard) units bolt either below or above the power takeoff box. When laying out run, F and T markings must be as shown. A built-in PTO may be oriented on any surface of the busway.

Bridge Joint Power Takeoff Devices (Figure 23) A bridge joint power takeoff is a special connection that allows for the attachment of a bolt-on unit at the bridge joint. The bridge joint power takeoff and a bolt-on unit can be used to tap off power where plug-in busway is not available. Bridge joint power takeoff devices install on the “F” or “F-opposite” side of the busway at bridge joint locations.

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C L Pow-R-Bridge

6.94 (176.3)

17.00 (431.8)

T

Min. F

9.00 (228.6)

C L P.T.O.

Line

15.00 (381.0) Load

Edgewise Mounted Single Bar Per Phase Only C L Pow-R-Bridge

6.94 (176.3)

17.00 (431.8)

F T

T

9.00 (228.6)

Min. C L P.T.O.

Line

15.00 (381.0) Load

Flatwise

Mounted — Available in Single and Double Bars Per Phase

Figure 22.Built-in Power Takeoff

     R      E      G       N     A      D

Load   F

Line

     R      E      G       N     A      D

Figure 23.Bridge Power Takeoff Effective: December 2002

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

Door Clearance Allow the clearance in front of a plug-in device to be greater than “A” for 30 – 100 ampere plugs and “B” for 200 ampere and above to allow the door to swing to a full 90º. (See Tables 14 and 15 on Pages 69 and 70.)

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

Balance Plugs On horizontal bus runs, care should be taken to balance the number and size of plugs on each side of the bus to prevent the bus from twisting.

Handle Clearance Allow a minimum clearance of 4 inches (101.6 mm) for operation of the handle (extends 1-3/16 inches (30.2 mm) beyond the bus plug).

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Coordination PRWIII busway sections have T and F markings. When assembling the system, T and F markings of adjacent sections must be aligned. The T and F markings on a busway run are necessary for two reasons: 1. To ensur ensure e prope properr align alignmen mentt and and orien orientat tation ion of the phases during installation; and 2. For For coor coordi dina nati ting ng pur purpo pose ses s when when con conne nect ctin ing g to switchboards, switchgear, motor control centers, etc., because the busway neutral is opposite the T marking. There are several conditions that must be taken into consideration when T and F are determined: 1. If the the bus buswa way y has has a port portio ion n of of the the run run requ requir ir-ing plug-in units in a vertical riser, the T and F are then determined by the position of the plug-in units on the riser and its relationship to the wiring closet wall, and whether the load end of the plug must be toward the floor or ceiling. 2. As shown in Figure 24, the load end of the plug will face down when the T marking is to the left of the plug. This orientation will ensure that the operating handle will be ON in the up position. (Plugs on the opposite side will have the load end facing up and the handle will be ON in the down position.) 3. For For corr correc ectt oper operat atio ion n of hor horiz izon onta tall plug plug-i -in n runs, the T marking of the bus must face up, as shown in Figure 24. Responsibility Responsibility of determining T and F locations, rests on the factory. factory. The contractor provides the desired location of plugs on the riser.

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ON Handle

ON

OFF

T F

Handle

OFF

Load Lo ad

OFF Handle Load Lo ad

ON

OFF F

Load Lo ad T

Handle

ON

Handle ON

Load Lo ad

OFF

T

T

Handle OFF F

ON

F

Load Lo ad

Handle

Load Lo ad Handle

OFF ON ON OFF Load Lo ad

Figure 24.Plug-in Device Mounting

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Drawings Customer Approval Drawings When required, customer approval drawings can be supplied by several different methods: 1. On sma small ller er job jobs, s, the the Cu Cutl tler er-H -Ham amme merr Sal Sales es Office can prepare sketches or get approved drawings from the customer without a formal approval drawing from the Busway Division. 2. The The Sal Sales es Office Office can can sen send d han hand d ske sketc tche hes s or or the customer’s customer’s electrical and architectural drawings to the Busway Division for preparation of formal prints. 3. Appr Approv oval al pac packa kage ges s can can be pre prepa pare red d usin using g the the Bid Manager  Busway drawing software. Detailed approval drawings, as shown in Figure 25, expedite the release for manufacture. Therefore, it is important that the information sent to the Division be as complete as possible. If incomplete, a great deal of time can be wasted obtaining missing information. Information required to plan a busway layout includes: 1. Front Front locati location on of switch switchgea gearr, switch switchboa boards rds,, transformers or other cubicles. 2. Floo Floorr hei heigh ghts ts and and floor floor/c /cur urb b thi thick ckne ness ss on on risers. 3. Loca Locati tion on of bus bus ris riser ers s in rela relati tion on to clo close sett walls. 4. Loca Locati tion on of plu plugs gs on on a ris riser er in in rela relati tion on to closet walls. 5. Loca Locati tion on and and thi thick ckne ness ss of of wal walls ls.. 6. Pad heights. 7. Loca Locati tion on of oth other er obs obstr truc ucti tion ons. s. The approval drawing that is sent back to the field fi eld for approval may require additional dimensions to complete the busway layout. The electrical contractor will fill in these dimensions after field measuring the job, approve the drawing for manufacture, and submit it to the Division for manufacture.

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Customer Please Note:

0 0

- Verify T & F Markings May Penetrate &

Supply Thickness - Verify or Indicate Label & Front of Switchboard - Verify or Indicate Label & Front of Transformer

2500 A. 3-Phase, 4W

0

Pl U

0 0 0

1600 A. 3-Phase, 4

Outdoor T

0

0

T

F

0

0 0

0 0

0

Front

Switchboard Transformer Run Indoor / Outdoor

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

4.38 (111.3) T

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

Run Indoor / Outdoor

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

4.38 (111.3) N

9.40 (238.8) 1-.25 x 6.25 (6.4 x 15 8.8) Aluminum/Phase 1-.25 x 6.25 (6.4 x 15 8.8) Aluminum/ Neutral Duct Weight = 13 lbs/ ft Color = ANSI 61 Gray

Figure 25.Sample Approval Drawings

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Customer Layout Drawings In some instances a customer will enter an order and release it for manufacturing based on prepared drawings. In this type of order the Sales Office can expedite the manufacture of the busway by reviewing the customer drawing to ensure that complete information is provided.

Construction Drawings Prior to shipment of busway from the factory, the Cutler-Hammer business will send the installer a customer layout drawing. A sample appears in Figure 26. This drawing contains a complete layout of the entire installation and a bill of material (BOM). The BOM includes item numbers which can be correlated with the drawing, description of each piece, and style number and quantity of each piece. The installer should review this drawing prior to and during the installation process. Note:Plug-in units are generally not shown on a construction drawing.

Included in the construction drawing package is the following: s s s s s s s

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

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7 / 16

"

'

8

15

All Floors 12

10

'

13

12 -6 '

"

Plug-in Unit 12

Outdoor

10

Indoor

2500 A.

3-phase 4W.

12 -6 '

13 "

2 -1

"

2 -6 '

"

1 -3 '

"

12

2 -1-5 / 8 '

"

1 -5 '

"

6

1600 A. 3-Phase 4W. '

'

"

10 4

1

"

24 -5 '

'

1 -3 '

7

3

'

"

"

See Drawing BVC1004 Line 15

Same Elevation

See Drawing BVC1012 Line 5

Transformer Front

Swit itc chboard

West Riser Indoor Pow-R-Way

RUN 1 IIII Indoor Pow-R-Way II 4

Wire,

4

Housing Ground, 100% Neutral

Wire,

IIII II

Housing Ground, 100% Neutral

G 4.38

4.38

(111.3)

B C N

9.40

(473.5

(238.8) 0.25 x 6.25 (6.4 x 158.8) Aluminum / Phase

2-.25 x 5.50 (6.4 x 13

Phase

0.25 x 6.25 (6.4 x 158.8) Aluminum / Neutral

2-.25 x 5.50 (6.4 x 139.7) Aluminum / Neutral

Duct Weight: 13 lbs / ft Color - ANSI 61 Gray

Duct Weight: 24 lbs / ft Color - ANSI 61 Gray

ITE IT EM

CRIPTION DES ESC

STYLE # OR S.O. #

A01

Flange-Elbow

PSW1589A01

1

A0 2

Elbow

PSW1589A02

1

BVD0299G11

1

Req.

A04

Elbow-Flange

PSW1589A04

1

A05

Hanger

BVD0301G12

2

PSW1589A06

1

A0 7

Elbow

PSW1589A07

1

A0 8

2 -5 Length

PSW1589A08

1

A0 9

10 -0 Length

5687D01G30

2

PSW1589A10

1

BVD0299G06

3

A10

'

"

'

"

Elbow

A1 2

2 -6 Length

PSW1589A11

3

A1 3

10 -0 Length

PSW1589A13

2

PSW1589A14

1

'

"

'

"

A15

End Closer

BVD0156G08

1

A1 6

Hanger

BVD0300G12

3

A1 7

Hanger

BVD0301G15

4

Figure 26.Sample Installation Drawing

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Installation Guide Every piece of PRWIII busway comes with a T and an F label. The T label indicates the phasing of the busway and the F label is used for orientation. PRWIII busway is phased G, A, B, C, N from the T label. It is imperative for all busway to be installed with all of the labels consistent throughout the run, and per Eaton supplied customer drawings. It is necessary to have T on the top of all runs of busway that are installed outdoors.

Indoor Joint Assembly Instructions When connecting sections of PRWIII together, the following guidelines must be followed. Contact surfaces must be clean and free of all contaminants. Next, align the left end of one section to the right end of the adjoining section with T and F labels matching. Then slide two sections of duct together until the edge of the aluminum housing is 4-1/2 inch (114.3 mm) from the center-line center-line of the joint bolt. (Joint puller, catalog number JP-1, available if required. See Figure 27.) Install the joint covers. Finally, Finally, align busway and tighten insulated joint bolt until the top head of the bolt breaks off. Note:PRWIII Busway with 6-1/4-inch and 8-inch (152.4, 158.8 and 203.2 mm) bus bars uses 2 bolts per joint. This maintains constant contact pressure over the entire width of the bus bar.

Before making connections to the line and load ends, and without plug-in devices installed, megger the complete busway run and check phase sequence. For 100 foot (3 m) runs or less, the megger value should be a minimum of 1 megohm. The value for longer runs may be proportionately proportionately lower. Note:For complete assembly instructions, please refer to drawing BVD1050 for indoor installations and BVD1082 BV D1082 for outdoor or sprinkler proof installations as well as the latest publication of NEMA Bulletin BU 1.1.

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Optional

Joint Puller (See Note 2) Joint Puller T F

Block

T

nd Block

F T

Joint Puller F T

Joint Puller T F

End Block

T

End Block T

Note:

F

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

Figure 27.Joint Puller

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Final Field Fits A final field fit section of busway is typically an elbow or short section of feeder that is intentionally left out of a run for later shipment. It is most often a mutually agreed upon section between the customer and the plant. Once the initial shipment of bus is installed, the contractor is to measure for the final field fit piece (being careful to follow the instructions on the final field fit form supplied with the construction drawings). This completed form is then faxed to Greenwood for release. The final field fit will ship 5 – 10 working days from release.

How to Remove a Section of Busway When the need arises to remove a section from the middle of an existing run of PRWIII busway, the following steps must be taken: 1. Refer to Figures 28 and 29. 2. De-e De-en nerg ergize ize th the bu buswa sway. 3. Remo Remove ve joi joint nt cov cover ers s (and (and spl splic ice e cove covers rs for for outdoor busway) of the joints to be loosened. 4. Remo Remove ve .19 .190 0 (4.8 (4.8))-32 32 ret retai aine nerr scre screws ws fro from m top and bottom pressure plates (if not already removed). Note:At this point the bridge joint is no longer securely fastened to the busway.

5. Loos Loosen en the the ins insul ulat ated ed joi joint nt bol boltt on bot both h ends ends of of the busway section to be removed. 6. Care Carefu full lly y remo remove ve bus buswa way y sect sectio ion. n. 7. To inst install all new sectio section, n, use revers reverse e proc procedu edure. re.

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1 / 4-2 4-20 flg. Head Hex Bolt (4 per cover)

Ground Path Contact Surface

  E  R   N G   D A

.375 (9.5 .5))-16 flg. Head Hex Bolt (4 per cover)

  E   T  I  C

N  O

Joint Cover Ground Path Label

T

F

Ground Path Plate

Ground Path End Block

130 Epoxy Insulation on Bars ∞

Bridge Joint Pressure Plate (top & bottom) Double Headed Torque Indicating Bolt (bottom)

Belleville Washer

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

Captive Nut Retainer

T

F

Ground Path End Block

High Strength Glass Polyester Insulators

Figure 28.Indoor Joint Assembly

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Drain Hole Plug

Gasketed Top Access Cover

Gasketed TorqueBolt Access Cap (Top & Bottom)

Gasketed Front Joint Cover

Gasketed Cover Plate

Ground Path Label DA

R GE

N

E T IC NO

Gasketed Cover Plate

Gasketed Rear Joint Cover Ground Path Contact Surface

Drain Hole Plug

Bridge Joint Retainer Screw (Must be 2.03)) Adjustment) Removed for .08 (2.03 Belleville Washer

Water

T

Pressure Plate (Top & Bottom) Captive Nut Retainer

Barrier

F

T

Ground Path End Block

Pow-R-Bridge Joint

Closed Cell Neoprene Gasket Water Barrier

Ground Path End Block T

F

Torque Bolt Access Opening

Gasketed Bottom Access Cover

Figure 29.Outdoor Joint Assembly

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Outdoor Bus Supports Busway connected to outdoor transformers, switchgear, etc., must be supported by some means. This is the responsibility of the contractor or owner. The transformer throat, see Figure 30, is not designed to carry the busway weight. In Figure 30, if dimension “A” is less than 10 feet (3 m), a knee brace should be sufficient to carry the weight of the busway outside the building. This brace must be supplied by the owner or contractor and may vary in design as dictated by specific job conditions. Note:If the overall weight of the vertical portion of the busway extending from the transformer throat exceeds 225 lbs (102 kg), then an additional support must be placed a maximum of 12 inches (304.8 mm) from the center-line center-line of the elbow bend.

A 12.00 (304.8) Min. door r Indoo

Outdoo r

Additional Support Indoor Switchboard

Sealing Ring HV LV

Knee Brace

Figure 30.Outdoor Run If dimension “A” is greater than 10 feet (3 m) long as in Figure 30, the busway should have: 1. Pipe supp suppor orts ts under nder it; 2. Kn Knee ee bra brace ce und under er tran transf sfor orme merr thro throat at;; and and 3. Drop Drop rods rods and and cha chann nnel el hang hanger ers s und under er busway indoor. indoor. Note:All bracing is to be supplied by the owner or contractor except the hangers on the indoor portion. Cutler-Hammer busway is listed with Underwriters Laboratories for mounting on 10-foot (3 m) centers.

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

Vertical Hangers When busway is to be installed vertically, vertically, a spring suspension type vertical hanger is used. Vertical hangers are not provided unless specified. specifi ed. A vertical hanger must be used on each floor fl oor.. The maximum span permitted by UL on vertical hangers is 16 feet (4.9 m). Intermediate hangers are required for floor heights exceeding 16 feet (4.9 m). See Figure 32.

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

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Duct Width Duct Width Duct Height

Flatwise Hook Hanger

Edgewise

Hook Hanger Duct Width

Flatwise Angle Hanger 1 Bar Per Phase Duct Width

Flatwise Angle Hanger 2 Bars Per Phase

Duct Height

Duct Height

Edgewise Angle Hanger 1 Bar Per Phase

Edgewise Angle Hanger 2 Bars Per Phase

Figure 31.Horizontal Hangers IM01701002E

Effective: December 2002

Page 43

F

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

Floor

1-Inch (25.4)

Minimum Lap Around Floor Opening (Typical)

Duct Height

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

F

T

A 3"

3"

3"

3"

3"

3"

3 1/2"

3 1/2"

3 1/2"

3 1/2"

3 1/2"

3 1/2"

4"

4"

4"

4"

4"

4"

Floor

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

Duct Width

T

F

A

Vertical Hanger

5.75 (146.1)

Floor

.63 (15.9) Diameter Stud

Floor Flange (Optional)

Mounting Support (By Others)

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

Figure 32A.Vertical Hangers

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T

F

Vertical

Hanger

A

5.75 (146.1)

.63 (15.9) Diameter Stud

Floor

Mounting Support (By Others)

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

F T

T

A 3"

3 1/2"

4"

3"

3 1/2"

4"

3"

3 1/2"

4"

3"

3"

3 1/2"

3 1/2"

4"

4"

3"

3 1/2"

4"

Floor Busway Width 1-Inch (25.4)

Drill .34 (8.63) Holes

Minimum Lap Around Floor Opening (Typical)

in Busway Housing Using Hanger as a Template

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

Figure 32B.Vertical Hangers

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 Wall/Floor Flanges For wall/floor flange dimensions, see Figure 33. Wall/floor flanges are required when busway penetrates a wall or floor fl oor.. This device offers no fire fi re protection or weatherproofing. It is for cosmetic purposes only. Two wall flanges are required for each wall penetration (one for each side). One floor flange is required for each floor penetration (floor side only). 2.00 (508.0)

Busway Height

2.00 (508.0)

Wall/  Floor

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

Busway Height

2.00 (508.0) 2.00 (508.0)

Wall/  Floor Busway Width

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

Figure 33.Wall/Floor Flange

End Closers End closures terminate a bus run.

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Busway Handling Shipping All busway shipments are made from Greenwood, South Carolina, and are shipped F.O.B. first destination, freight prepaid if total weight is over 300 lbs. (136 kg.) Should the receiver notice any shortage versus the shipping notice, the receiver should file a claim with the carrier immediately. The same procedure should be followed for damaged freight. All hangers are shipped in separate cartons and should be accounted for per the bill of material.

DO NOT REMOVE BUSWAY FROM ORIGINAL SHIPPING CONTAINER CONTAINER UNTIL READY FOR INSTALLATION. This will help prevent the problem of mechanical damage, dirt, dust, plaster or paint on the individual pieces.

Busway Labels Busway items have a nameplate which indicates the General Order number (GO#), item number, and specific rating information (see Figure 34). All busway fittings are clearly marked with T and F labels. When installing the busway sections the T and F markings of adjacent sections must match and must be installed in the proper orientation as shown on the customer drawing.

POW-R-WAY III

CUTLER-HAMMER DANGER

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

SHORT CIRCUIT CURRENT RATING

A

1200

When protected by a

ampere1200 maximum class

fuse L or a CUTLER-HAMMER type RMS SYM A

125,000

NEUT A V ~

DC A STYLE NO.

PYW03125-A01

100% 277/480

PHASE

3

WIRE 4

% GRD.

50% HSG.

circuit breaker rated for not more than

amperes,

1200

this busway is rated for use on a circuit capable of 200,000 delivering not more than RMS symmetrical amperes

volts 600 maximum. ~

Material

ALUMINUM

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

BVA1000H01

REV. 4

Figure 34.Busway Label

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Page 47

Dimensional Data Width

Height

Figure A

225 to 2000 Ampe Amp ere Aluminum er 225 to 2500 Ampe Amp ere Copp Coppe

Width

Height

Figure B

2500 to 4000 Ampe Ampere Aluminum er 3200 to 5000 Ampe Ampere Copp Coppe

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

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Page 49

   5   5    5    0    1   2   0    6   5    0   3   0    l    3  .   7  .   5  .  .   9  .   2  .    3  .   7  .    4  .   3  .    3  .    6  .    7    A    0   0  —   0  —0    0   0   1    1   1  —   2   2   3

  r   l    d   o  a    )    f   n  n   r   u    M    d   e   o    /    d   t   r   u   g    A   I   n    G   C    k    (    d    l   a    )   n   r    2   u    t   o   u    l   r   m   e    A   c    G    N    /   e   s   g    i   r   e   n    %   r    i    0   u   e   s    W     p   u    4   0   o    2    C   m   H    l    A    (    l   a   r   a    t   y   r    t   u    l    i   g   e    A   s    t   e   n   n   e   N   e    I   r   %    D   g    i    0    t   n    W   -   0   u   n    i    4    d    1    C   e   r   u   r    l   c   u   n    C   I    l    d   n   —    A   a    t    )    h   e   r   g    i    M    i    /   e    W   u     g    W    3    C    k    (    t    2    h   m   g    i   c    l   e    /   s    A    W   t   y  e   r   c   n   t    i    i   r   e   s  e   r   p    t   r   n   e   u  e  m   u    M   C   D   A    C

   7   7   7    7   2   8    4   6   6    1  .   0  .   9  .  .   1  .   1  .    1  .   6  .   9  .    3    1   1   1    1   1   1    2   3   3

   6   2    2    3    7  .  .    5  .   1  .    9    5   6    7    1   —   —1

   1   1    1    2    4   6   0    2   7    0   3   4    1   1  —   1  —1    1   1   2    2   2  —   4   4   5    7   7   7    7   1   6    0   7   9    1   1   1    1   2   2    3   3   4

   3   3    8    6    6   7    9    2   —   —1

   9   9    9    1    2   5   8    0   4    6   9   8   —   —1    1   1   1    2   2  —   3   3   4    5   5   5    5   8   2    5   2   2    1   1   1    1   1   2    2   3   4

   4   3    3    8    5   6    8    0   —   —1

   7   7    7    9    1   2   6    8   1    2   4   2   —   —    1   1   1    1   2  —   3   3   4    2   2   2    2   5   8    1   5   4    3   1    7    4    1   1   1    1   1   1    2   2   3   —4   5    6  —9    6   3    9    0    1   5   2    9   5    0   9   5    8   5    2    8    9   7   5    5   5    4   4   5    1  —   2  —1    1   1   1    1   1  —   1   1   1    6   3   9    5   6   0    8   3   6    4   3    6    4    8   5   2    0   7   7    5   3   2    9   3    2    9    1   2    3   2   2    2   2   2   —1   2    2  —1

   3   3    3    0    7   2   0    1   7    1   3   5    l    2  .   8  .   3  .  .    4  .    4  .   6  .   8  .    9  .   1  .    6  .   2  .    2    A    0   0  —   0  —0    0   0   0    0   1  —   1   1   2

   )  .   r   l    d    t   o  a   n    F   n    f   r    /   u  .    8   8    8   8   3    7   5   6    7   1    2    4    d   e   o   u    8   s    d   t   r    7  .    7  .  .   0  .   3  .    5  .   0  .   6  .    8  .   1  .    3  .   7  .   7  .    7    b    A   n    5   —7    1    2    2   —3    4    0    0    0    0    1    1    I    G    C    L    (

Page 49

   5   5    5    0    1   2   0    6   5    0   3   0    l    3  .   7  .   5  .  .   9  .   2  .    3  .   7  .    4  .   3  .    3  .    6  .    7    A    0   0  —   0  —0    0   0   1    1   1  —   2   2   3

  r   l    d   o  a    )    f   n  n   r   u    M    d   e   o   u    /    d   t   r   g    A   I   n   G   C    k    (    d    l   a    )   n   r    2   u    t   o   u    l   m  r   e    A   c    G    N    /   e   s   g    i   r   e   n    %   r    i    0   u   e   s    W     p   u    4   0   o    2    C   m   H    l    A    (    l   a   r   a    t   y   r    t   u    l    i   g   e    A   s    t   e   n   n   e   N   e    I   r   %    D   g    i    0    t   n    W   -   0   u   n    i    4    d    1    C   e   r   u   r    l   c   u   n    C   I    l    d   n   —    A   a    t    )    h   e   r   g    i    M    i    /   e    W   u     g    W    3    C    k    (    t    2    h   m   g    i   c    l   e    /   s    A    W   t   y  e   r   c   n   t    i    i   r   e   s  e   r   p    t   r   n   e   u  e  m   u    M   C   D   A    C

   7   7   7    7   2   8    4   6   6    1  .   0  .   9  .  .   1  .   1  .    1  .   6  .   9  .    3    1   1   1    1   1   1    2   3   3

   6   2    2    3    7  .  .    5  .   1  .    9    5   6    7    1   —   —1

   1   1    1    2    4   6   0    2   7    0   3   4    1   1  —   1  —1    1   1   2    2   2  —   4   4   5    7   7   7    7   1   6    0   7   9    1   1   1    1   2   2    3   3   4

   3   3    8    6    6   7    9    2   —   —1

   9   9    9    1    2   5   8    0   4    6   9   8   —   —1    1   1   1    2   2  —   3   3   4    5   5   5    5   8   2    5   2   2    1   1   1    1   1   2    2   3   4

   4   3    3    8    5   6    8    0   —   —1

   7   7    7    9    1   2   6    8   1    2   4   2   —   —    1   1   1    1   2  —   3   3   4    2   2   2    2   5   8    1   5   4    3   1    7    4    1   1   1    1   1   1    2   2   3   —4   5    6  —9    6   3    9    0    1   5   2    9   5    0   9   5    8   5    2    8    9   7   5    5   5    4   4   5    1  —   2  —1    1   1   1    1   1  —   1   1   1    6   3   9    5   6   0    8   3   6    4   3    6    4    8   5   2    0   7   7    5   3   2    9   3    2    9    1   2    3   2   2    2   2   2   —1   2    2  —1

   3   3    3    0    7   2   0    1   7    1   3   5    l    2  .   8  .   3  .  .    4  .    4  .   6  .   8  .    9  .   1  .    6  .   2  .    2    A    0   0  —   0  —0    0   0   0    0   1  —   1   1   2

   )  .   r   l    d    t   o  a   n    F   n    f   r    /   u  .    d   e   o   u   s    d   t   r    b    A   n   G   C    I    L    (    d    l   n   a   r   u    t   o   u    l   r   e    A    G   e   N    )   r   %    i    2   g   n   n    i    W    0   u    i      0    /   s   s   u    4   2    C   o   e   r    H   e    l    l   p   a   a   r    t   r   m  g   u    l    A   e   e    A    (    t    N   e   n   y    I   r    t    i   g    i   %   s    0   u   n    W   n    i     e    d    4   0    1    C    D   l   u    t   c   n   n   e    I   r    l   r   —    A   u    C   t    h   e   r    d    y    i   g    t    i   n     i   a   e    W    s    )   u      n  .    W   3    C    e    t     D    F  .    2    t    /   s   n    n    b    i    l    e    /    L    r   s    (    A    r    t    t   y  e    u   r   n   t    i     C    h   e   s  e   g   r    i     d   e   r   n  p    n   u  e  m   u    a    W   C   D   A    C    t

    h    g     i    e     W   e  .     2   r   e  g   n    e   p   i     l    t     b   m  a    a    A   R     T

   8   8   8    8   8   3    7   5   6    7   1    2    4    7  .    7  .  .   0  .   3  .    5  .   0  .   6  .    8  .   1  .    3  .   7  .   7  .    7    0   0   0    0   1   1    1   2   2   —3   4    5  —7    7   7    7    8    9   1   3    5   8    7   9   6    1   1    1   1  —   2   2   3   —   —    1   1   1    1   4   7    0   5   3    2   9    6    5    1   1   1    1   1   1    2   2   3   —4   4    6  —8    6   6    6    7    8   0   2    3   6    4   6   2    1   1    1   1  —   2   2   3   —   —    0   0   0    0   2   5    7   1   8    6   2    6    2    1   1   1    1   1   1    1   2   2   —3   4    5  —7    5   5    5    6    7   8   1    2   4    1   3   8    1    1   1  —   2   2   2   —   —    8   8   8    8   0   2    4   7   3    9   4    5    3    1   1    1   1   2   —2   3    4  —6    4   5    7    4    1   9   2    4   0    9   0   0    5   8    7    6    3   2   8    2   0    0   6   0    5   9    4    1    2   1   9    0   0    9   9   0    1   —   1  —1    1   1    1   1  —    4   5   7    9   8   5    2   6   5    0   5    5    0    5   8   7    6   7   4    6   0   5    5   0    5    5    5   9   4    9   7   7    6   5   4    2   5    4    2    1    1   1   1    1   1   1   —1   1    1  —1

   5   0    0    0    0   0   0    0   0    0   0   0    0    0    0    0   0   5    0   0    0   0   0    l    2    2   4    6    8    0   2   3    6   0    5   2   0    A   —   —    1   1   1    1   2  —   2   3   4    5   0   0    0   0   0    0   0   0    0   0    0    0    0   0    0   0   0    5   0   0    0   0    0    0   u    2    2   4   6    8   0   2    3   6   0    5   2    0    0    1   1    1   1   2   —2   3    4  —5    C

Effective: December 2002

IM01701002E

Page 50

Cable Tap Boxes A

38.00 (965.2)

D   n   r   M   i   t  t e .

“T” Side Removable Indoor

  u  e   G  a  c   p   S

C L of Busway

30.00 (762.0) 32.50 (825.5)

11.62 (295.1) C L

C L of Duct

Busway Width

C L of Box

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

15.00 (381.0)

Busway Height

17.50 (444.5)

Side Opposite “T” Removable Indoor

End Cable Tap Box

B

A

C

“T”Side Removable Indoor

C L

C Lof Busway

11.62 (295.1)

30.00 (762.0)

C L of Duct

32.50 (825.5)

F

End

Removable Indoor

C Lof Box

Busway Width Busway Height

15.00 (381.0)

Side Opposite “T” Removable Indoor

F Dimension is the Minimum Gutter Space

17.50 (444.5)

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

Center Cable Tap Box

A

40.00 (1016.0)

C Lof Box

24.00 (609.6) C L of Busway

11.62 (295.1)

C Lof Duct

C L

1.00 (25.4) Compression and Mechanical Lugs

Busway Width

15.00 (381.0)

Busway Height

Removable Barrier

17.50 (444.5)

Weatherhead

Figure 36.Cable Tap Boxes

IM01701002E

Effective: December 2002

p Box — Dimensions in Inches (mm) le Tap Box

ion

Center Cable Tap Box

Quantity of Mecha Range — (1) #4 – 6 Weatherhead (2) 1/0 – 250 kcmil

Aluminum

Copper

Aluminum

Dimension

Dimension

Dimension

Dimension

Dimension

Dimension

Dimension

Dimension

Copper

(A)

(A)

(B (B)

(C)

(A)

(B (B)

(C)

(A)

G

P

N

04.8) 04.8) 04.8)

12.00 (304.8) 16.50 (419.1) 12.00 (304.8) 16.50 (419.1) 12.00 (304.8) 16.50 (419.1)

40.00 (1016.0) 40.00 (1016.0) 40.00 (1016.0)

3.63 (92.2) 3.63 (92.2) 3.63 (92.2)

16.50 (419.1) 16.50 (419.1) 16.50 (419.1)

40.00 (1016.0) 40.00 (1016.0) 40.00 (1016.0)

3.63 (92.2) 3.63 (92.2) 3.63 (92.2)

16.50 (419.1) 16.50 (419.1) 16.50 (419.1)

1 1 1

2 2 2

4 4 4

1 1 1

04.8) 04.8) 04.8)

12.00 (304.8) 16.50 (419.1) 12.00 (304.8) 16.50 (419.1) 12.00 (304.8) 16.50 (419.1)

40.00 (1016.0) 40.00 (1016.0) 40.00 (1016.0)

3.63 (92.2) 3.63 (92.2) 3.63 (92.2)

16.50 (419.1) 16.50 (419.1) 20.50 (520.7)

40.00 (1016.0) 40.00 (1016.0) 42.50 (1079.5)

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

2 2 2

3 3 4

5 6 8

2 2 2

04.8) 20.7) 20.7)

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

40.00 (1016.0) 42.50 (1079.5) 42.50 (1079.5)

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

42.50 (1079.5) 45.00 (1143.0) 45.00 (1143.0)

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

2 3 3

4 5 6

8 9 12

2 3 3

22.3) 74.5) 143.0) 143.0)

30.50 (774.5) 30.50 (774.5) 45.00 (1143.) —

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

4 5 6 7

8 9 12 15

16 18 24 30

5 6

24.50 (622.3) 30.38 (774.5) 45.00 (1143.0) 45.00 (1143.0)

58.00 (1473.0) 58.00 (1473.0) 60.50 (1536.7) —

10.75 (273.1) 10.75 (273.1) 12.25 (311.2) —

16.50 (419.1) 30.00 (762.0) 30.00 (762.0) 30.00 (762.0)

Page 52

Elbow Flanges C L

C L

C L

T T

F

Forward Elbow Right Flange

T

C L

F

T

C L

C L

Rearward Elbow Right Flange

Figure 37.Elbow Flanges Table 4.Forward and Rearward Elbow Flanges

Page 52

Elbow Flanges C L

C L

C L

T T

F

Forward Elbow Right Flange

T

C L

F

T

C L

C L

Rearward Elbow Right Flange

Figure 37.Elbow Flanges Table 4.Forward and Rearward Elbow Flanges Ampere Rating

Minimum Dimensions in Inches (mm)

Cu

Al

Joint Let (X)

Flange Leg (Y)

225 400 600

225 400 —

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

8.75 (222.3) 8.75 (222.3) 8.75 (222.3)

800 1000 1200

600 — 800

13.00 (330.2) 13.00 (330.2) 13.50 (342.9)

8.75 (222.3) 8.75 (222.3) 9.25 (235.0)

1350 1600 2000

1000 1200 1350

13.50 (342.9) 14.00 (355.6) 14.50 (368.3)

9.25 (235.0) 9.75 (247.7) 10.25 (260.4)

— 2500 3200

1600 2000 —

15.00 (381.0) 16.00 (406.4) 18.50 (469.9)

10.75 (273.1) 11.75 (298.5) 14.00 (355.6)

4000 — 5000

2500 3200 4000

19.50 (495.3) 20.50 (520.7) 22.50 (571.5)

15.25 (387.4) 16.00 (406.4) 17.75 (450.9)

IM01701002E

Effective: December 2002

Page 53

C L

T

T

F

Upward Elbow Right Flange C L C L

C L

C L

C L

T T

F

Downward Elbow Right Flange

Figure 38.Elbow Flanges Table 5.Upward and Downward Elbow Flanges Ampere Rating

Joint Let (X)

Cu

Up

Al

Minimum Dimension in Inches (mm) Flange Leg (Y) Down

Up

Down

225 225 10.00 (254.0) 400 400 10.00 (254.0) 10.00 (254.0) 600 —

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

5.75 (146.1) 5.75 (146.1) 5.75 (146.1)

8.75 (222.3) 8.75 (222.3) 8.75 (222.3)

800 600 10.00 (254.0) 1000 — 10.00 (254.0) 1200 800 10.00 (254.0)

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

5.75 (146.1) 5.75 (146.1) 5.75 (146.1)

8.75 (222.3) 8.75 (222.3) 8.75 (222.3)

1350 1000 10.00 (254.0) 1600 1200 10.00 (254.0) 2000 1350 10.00 (254.0)

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

5.75 (146.1) 5.75 (146.1) 5.75 (146.1)

8.75 (222.3) 8.75 (222.3) 8.75 (222.3)

— 1600 10.00 (254.0) 2500 2000 10.00 (254.0) 3200 — 12.00 (304.8)

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

5.75 (146.1) 5.75 (146.1) 7.75 (196.9)

8.75 (222.3) 8.75 (222.3) 8.75 (222.3)

4000 2500 12.00 (304.8) — 3200 12.00 (304.8) 5000 4000 12.00 (304.8)

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

7.75 (196.9) 7.75 (196.9) 7.75 (196.9)

8.75 (222.3) 8.75 (222.3) 8.75 (222.3)

Effective: December 2002

IM01701002E

Page 54

Standard/Flush Flanges

T T

F 1.25

Bridge C L

C L

15.00 (381.0) Min.

Flush Flange

T

T

Bridge

F 11.62 (295.2) Min.

C L

C L Standard

Flange

Figure 39.Standard/Flush Flanges Table 6.Standard/Flush Flanges Ampere Rating Cu

Minimum Leg Length (X) in Inches (mm) Al

Flush Flange

Standard Flange

225 400 600

225 400 600

15.00 (381.0) 15.00 (381.0) 15.00 (381.0)

11.62 (295.16) 11.62 (295.16) 11.62 (295.16)

800 1000 1200

800 1000 1200

15.00 (381.0) 15.00 (381.0) 15.00 (381.0)

11.62 (295.16) 11.62 (295.16) 11.62 (295.16)

1350 1600 2000

1350 1600 2000

15.00 (381.0) 15.00 (381.0) 15.00 (381.0)

11.62 (295.16) 11.62 (295.16) 11.62 (295.16)

2500 3200 4000 5000

2500 3200 4000 —

15.00 (381.0) 15.00 (381.0) 15.00 (381.0) 15.00 (381.0)

11.62 11.62 11.62 11.62

IM01701002E

(295.16) (295.16) (295.16) (295.16)

Effective: December 2002

Page 55

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Effective: December 2002

IM01701002E

Page 56

Elbows C L

C L

X

X

C L

C L

T T

F

Forward

T T

C L

C L

F X

X

C L

C L Rearward Re arward

X T T

F

X

C L

C L

Upward

T

C L

F

T

X

C L X

C L

Downward

Figure 40.Elbow Types

IM01701002E

Effective: December 2002

Page 57

Table 7.Elbows — Dimensions in Inches (mm) Ampere Rating

Minimum Leg Length

Cu

Upward

Al

Minimum Leg Lengths (X) Downward

Forward/Rearward

225 225 225 225 10.00 (254.0) 400 400 400 400 10.00 (254.0) 600 600 — 10.00 (254.0)

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

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

800 800 600 600 10.00 (254.0) 1000 — 10.00 (254.0) 1200 800 800 10.00 (254.0)

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

13.00 (330.2) 13.00 (330.2) 13.50 (342.9)

1350 1000 10.00 (254.0) 1600 1200 10.00 (254.0) 2000 1350 10.00 (254.0)

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

13.50 (342.9) 14.00 (355.6) 14.50 (368.3)

— 1600 10.00 (254.0) 2500 2000 10.00 (254.0) 3200 — 12.00 (304.8)

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

12.00 (381.0) 16.00 (406.4) 18.50 (469.9)

4000 2500 12.00 (304.8) — 3200 12.00 (304.8) 5000 4000 12.00 (304.8)

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

19.50 (495.3) 20.50 (520.7) 22.50 (571.5)

Effective: December 2002

IM01701002E

Page 58

Corner Joint Elbows C L

C L

Y

X

C L

C L

T

F

Forward

T

F

C L

X

Y

C L

C L

C L Rearward Re arward

T

F

C L

Y

C L Y

C L Downward

T X

F X

C L

Upward

Figure 41.Corner Joint Elbows

IM01701002E

Effective: December 2002

Page 59

Table 8.Corner Joints Ampere Rating

Forward/Rearward

Upward/Downward

Cu

(X)

(X)

Al

Dimensions in Inches (mm) (Y)

(Y)

225 225 400 400 600 —

0.94 (23.9) 0.94 (23.9) 0.94 (23.9)

5.38 (136.7) 4.71 (119.6) 4.35 (110.5) 5.38 (136.7) 4.71 (119.6) 4.35 (110.5) 5.38 (136.7) 4.71 (119.6) 4.35 (110.5)

800 600 1000 — 1200 800

0.94 (23.9) 1.25 (31.8) 1.50 (38.1)

5.38 (136.7) 4.71 (119.6) 4.35 (110.5) 5.69 (144.5) 4.71 (119.6) 4.35 (110.5) 5.94 (150.9) 4.71 (119.6) 4.35 (110.5)

1350 1000 1600 1200 2000 1350

1.75 (44.5) 2.25 (57.2) 2.88 (73.2)

6.19 (157.2) 4.71 (119.6) 4.35 (110.5) 6.69 (169.9) 4.71 (119.6) 4.35 (110.5) 7.31 (185.7) 4.71 (119.6) 4.35 (110.5)

— 1600 2500 2000 3200 —

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

4000 2500 7.89 (200.4) 12.32 (312.9) 4.71 (119.6) 4.35 (110.5) — 3200 8.65 (219.7) 13.08 (332.2) 4.71 (119.6) 4.35 (110.5) 5000 4000 10.42 (264.7) 14.85 (377.2) 4.71 (119.6) 4.35 (110.5)

Effective: December 2002

IM01701002E

Page 60

Offsets C L

C L

3.00 (76.2) Min.

Y

C L

C L

Y

C L

T T

F

Forward

C L

C L

C L

3.00 (76.2) Min.

Y

C L Y

C L

T

F

T

Rearward Re arward

F

T

C L C L

3.00 (76.2) Min.

Y

C L

C L

Z

Upward

C L

C L

3.00 (76.2) Min. C L C L

T

F

Y

C L

T

Z

Downward

C L

Figure 42.Offsets

IM01701002E

Effective: December 2002

Page 61

   d   r   a   w   r   a   e    R    /    d   r   a   w   r    )   o    F    Y    (

   )   )   )    )   )   )    )   )   )    )   )   )    )   )   )    2  .   2  .   2  .    2  .   2  .   9  .    9  .   6  .   3  .    0  .   4  .   9  .    3  .   7  .   5  .    0   0   0    0   0   2    2   5   8    1   6   9    5   0   1    3   3   3    3   3   4    4   5   6    8   0   6    9   2   7    3    (   3    (   3    (    3    (   3    (   3    (    3    (   3    (   3    (    3    (   4    (   4    (    4    (   5    (   5    (    0   0   0    0   0   0    0   0   0    0   0   0    0   0   0    0  .   0  .   0  .    0  .   0  .   5  .    5  .   0  .   5  .    0  .   0  .   5  .    5  .   5  .   5  .    3   3   3    3   3   3    3   4   4    5   6   8    9   0   2    1   1   1    1   1   1    1   1   1    1   1   1    1   2   2

   )   )   )    )   )   )    )   )   )    )   )   )    )   )   )    0  .   0  .   0  .    0  .   0  .   0  .    0  .   0  .   0  .    0  .   0  .   8  .    8  .   8  .   8  .    4   4   4    4   4   4    4   4   4    4   4   4    4   4   4    5   5   5    5   5   5    5   5   5    5   5   0    0   0   0    2    (   2    (   2    (    2    (   2    (   2    (    2    (   2    (   2    (    2    (   2    (   3    (    3    (   3    (   3    (    0   0   0    0   0   0    0   0   0    0   0   0    0   0   0  .   0  .   0  .    0  .   0  .   0  .    0  .   0  .   0  .    0  .   0  .   0  .    0  .   0  .   0  .    )    0    0    0    0    0    0    0    0    0    0    0    0    2    2    2    2    Z    (    1   1   1    1   1   1    1   1   1    1   1   1    1   1   1

   )   )   )    )   )   )    )   )   )    )   )   )    )   )   )    2  .   2  .   2  .    2  .   2  .   2  .    2  .   2  .   2  .    2  .   2  .   2  .    2  .   2  .   2  .    d   r    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0   a    3   3   3    3   3   3    3   3   3    3   3   3    3   3   3    3   w    (   3    (   3    (    3    (   3    (   3    (    3    (   3    (   3    (    3    (   3    (   3    (    3    (   3    (   3    (   n    0   0   0    0   0   0    0   0   0    0   0   0    0   0   0    0    0    0    0    0    0    0    0    0    0    0    0    0    0   w   )    0  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .   o    Y    3   3   3    3   3   3    3   3   3    3   3   3    3   3   3    D   (    1   1   1    1   1   1    1   1   1    1   1   1    1   1   1

   )   )   )    )   )   )    )   )   )    )   )   )    )   )   )    2  .   2  .   2  .    2  .   2  .   2  .    2  .   2  .   2  .    2  .   2  .   2  .    2  .   2  .   2  .    0   0   0    0   0   0    0   0   0    0   0   0    0   0   0    3   3   3    3   3   3    3   3   3    3   3   3    3   3   3    3    (   3    (   3    (    3    (   3    (   3    (    3    (   3    (   3    (    3    (   3    (   3    (    3    (   3    (   3    (    0   0   0    0   0   0    0   0   0    0   0   0    0   0   0  .   0  .   0  .    0  .   0  .   0  .    0  .   0  .   0  .    0  .   0  .   0  .    0  .   0  .   0  .    )    0    3    3    3    3    3    3    3    3    3    3    3    3    3    3    3    Z    (    1   1   1    1   1   1    1   1   1    1   1   1    1   1   1

   )   m   m    (   s   e    h   c   n    I   n    i   s   n   o    i   s   n   e   m    i    D   m   d   u   r   m   a    i   n   w    i   p    )    M   U   Y    (

   l    A

   )   )   )    )   )   )    )   )   )    )   )   )    )   )   )    0  .   0  .   0  .    0  .   0  .   0  .    0  .   0  .   0  .    0  .   0  .   8  .    8  .   8  .   8  .    4   4   4    4   4   4    4   4   4    4   4   4    4   4   4    5   5   5    5   5   5    5   5   5    5   5   0    0   0   0    2    (   2    (   2    (    2    (   2    (   2    (    2    (   2    (   2    (    2    (   2    (   3    (    3    (   3    (   3    (    0   0   0    0   0   0    0   0   0    0   0   0    0   0   0    0  .   0  .   0  .    0  .   0  .   0  .    0  .   0  .   0  .    0  .   0  .   0  .    0  .   0  .   0  .    0   0   0    0   0   0    0   0   0    0   0   2    2   2   2    1   1   1    1   1   1    1   1   1    1   1   1    1   1   1

   5   0    2   0    2   4

   0    0    0   0   0    0   0    0   0   0    0    0    0   0   5    0   0    0   0   0    6    8    0   2   3    6   0    5   2   0   —   —    1   1   1    1   2  —   2   3   4

   s    t    e    s     f     f     O   e  .     9   r   e   g   n    e   p   i    5   0   0    0   0   0    0   0   0    0   0    0    0     l    t    0   0    0   0   0    5   0   0    0   0    0    0     b   m  a   u    2    2    4   6    8   0   2    3   6   0    5   2    0    0    a    A    R    C    1   1    1   1   2   —2   3    4   —5     T

Effective: December 2002

IM01701002E

Page 62

Tees C L C L

X

C L

T T

X

Y

C L

F

C L T

T T F

F

T

Forward

C L Y

C L T

T F

T

T

F

C L

T

X

T F

C L X

C L Rearward Re arward

C L

Y T

C L

T FT

T

F

T T

F X

C L

X

C L

C L

Upward C L T T

F

Y

T T

F T

C L T F

X

X

C L

C L

C L Downward

Figure 43.Tees

IM01701002E

Effective: December 2002

Page 63

Table 10.Tees Ampere Rating

Forward/Rearward

Upward/Downward

Cu

(X)

(X)

Al

Minimum Leg Dimensions in Inches (mm) (Y)

(Y)

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

Effective: December 2002

IM01701002E

Page 64

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

TAPS C L

8.50 + Y (215.9) + Y

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

TAPS C L

8.50 + X (215.9) + X

8.50 + X (215.9) + X

17.00 + 2X (431.8) + 2X

8.50 + X (215.9) + X

F

A

C L POW-R-BRIDGE

TAPS C L

T

G C

Ground When Required

A Phase or Neutral

T F

8.50 + X (215.9) + X

C

POW-R-BRIDGE C L

B

8.50 + X (215.9) + X

C Phase or Neutral

T F

B

A

B Phase or Neutral

Figure 44.Single-Phase Transformer Tap Table 11.Single-Phase Transformer Tap Ampere Rating Cu

Minimum Dimensions in Inches (mm) Al

(X)

(Y)

225 400 600

225 400 —

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

7.00 (177.8) 7.00 (177.8) 7.00 (177.8)

800 1000 1200

600 — 800

4.00 (101.6) 4.50 (114.3) 5.00 (127.0)

— 9.75 (247.7) 10.75 (273.1)

1350 1600 2000

1000 1200 1350

5.50 (139.7) 6.50 (165.1) 7.75 (196.9)

11.75 (298.5) 13.75 (349.3) 16.25 (412.8)

— 2500 3200

1600 2000 —

8.50 (215.9) 10.25 (260.4) 6.50 (165.1)

17.50 (444.5) 21.25 (539.8) 13.75 (349.3)

4000 — 5000

2500 3200 4000

7.75 (196.9) 8.50 (215.9) 10.25 (260.4)

16.25 (412.8) 17.50 (444.5) 21.25 (539.8)

IM01701002E

Effective: December 2002

Page 65

Three-Phase Transformer Tap 15.00 (381.0)

Taps C L

Support Pad

B

A

C L

T

G A

T F

B

C

C

N

6.00 (152.4)

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

Figure 45.Three-Phase Transformer Tap Table 12.Three-Phase Transformer Tap — Dimensions in Inches (mm) (A) Minimum Dimensions Wire Designation 3W/3WH

16.5 (419.1)

3WG/3WHG/ 3WII 3W

16.5 (419.1)

4W/4WH

4WG/4WHG/ 4WI/4WNG/ 4WNHG/ 4WNI

19.5 (495.3)

19.5 (495.3)

4W/4WH 4WN/4WNH

4WG/4WHG/ 4WI/4WNG/ 4WNHG/ 4WNI

(B) Minimum Dimensions Wire Designation 3W/3WH

6.25 (158.8)

3WG/3WHG/ 3WII 3W

12.12 (307.8)

9.25 (235.0)

15.12 (384.0)

(C) Minimum Dimensions Wire Designation 50% Housing Ground 3.00 (76.2)

50% Internal Ground and 100% Ground 6.00 (152.4)

Effective: December 2002

IM01701002E

Page 66

Transformer Throat Th roat Connections Conne ctions Transformer

Transformer Throat

Sealing Ring

T

Edge of Transformer Throat

C L

A

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

Transformer

Transformer Throat

Sealing Ring

T

C L

Edge of Transformer

Throat

A

9.50

(241.3)

Sealing Ring

Screw

Felt Gasket

Sealing Ring

Figure 46.Transformer 46.Transformer Throat Connections IM01701002E

Effective: December 2002

Page 67

Table 13.Transformer Throats Ampere Rating

Bars per Phase

Minimum Dimensions in Inches (mm) (A)

Aluminum 225 – 1350 1600 – 2000 2500 – 4000

1 1 2

26.00 (660.4) 28.50 (723.9) 31.50 (800.1)

1 1 2

26.00 (660.4) 28.50 (723.9) 31.50 (800.1)

Copper 225 – 2000 2500 3200 – 5000

Effective: December 2002

IM01701002E

Page 68

Bus Plugs A

    N     O

E

D Handle

B

C

Plu lugg-in in Openin pening g and B Phase

Guide Pin

ON

OFF

Clamp and Guide

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

IM01701002E

Effective: December 2002

Page 69

 .    )   g   x   t   k    )    )    )    )    )    )    )    h   o    3    1    4    1    8    9    4    (   r   i   g    3  .  .    3  .    0  .    0  .    6   6  .    8   5  .    5  .   p  e  s    1    1    4    4    1    2    3   p    b    5   1    7   2    3   2    5   3    3   6    3   6    6   4    A   W    L    2   (    4   (    5   (    7   (    1   (    1   (    9   (

   )   m   m    (    l   e   a  s   a   n    h    i   P   m   r   r   e  e    T   P    l   e   a   c  g    i   n   n  a   a   R    h   e   c   i   e  r    M    W    2

   )    1    9  .    9    8   3    8   (

   )    )   )    )   –    )    0   )    0    0    0    )    0    5    4   0    0   4    )   0    )   5    )   /    8   )    2   2    3   2    0   4    0   8    5   3    1   5   –   1   –  –    4  –    4   1    8   )    )    1   –   8    (   0    0  –    0   5    2    0    2   –    1    1   –   –   –    2   5    2   8    0    5    d   0    d    )    5   –    1    1    0   3    0   9    6  n   3   n    0   )    2    4    1    (    (    (    (   a   )    5    (    (   l    5    (    1    5   5    l   5    l    l   –    (    (    (   a    )    3    i    l   l    0   –   9    i   (    i   l    i    l    i   i    l    i    l    l    0    5    i    i    i    i    0    l    2   m   m   m   m    5   –    9    i    3   m   m   m  .   c   c   c   c    1   m   m   m   m   c   c   c    2    k  m   k   k    k   k   c   k   c   k   c  c   d   –  –    (   5    2   c    0   0    0   0    k   0    k   0    k   k  n    5   5    (    0   k    0    /   0    5    0   5    0   0    0   5    0   0    0   0  a    2   9    1   /    3   0    5   2    6   5    0   7    0   4    5   5   0    (   (    l    5    5    3    2    l    2   –   4   –   5   –   –   –    i   –   –   –   –  –   1    i    3   –   –   –   m    4    4  –    0   0    0   0    0    0   c    1   4    1    5   /    /   0    1   0    1   /    6   4  –   m   c    k    #   #    #   3    2   3    4   4    #   5    #   3    #   #   5    k    )   )    )   )    )   )    )   )    )   )    )   )    )   )   2    (    0   0    1    1    1    1    1    2    1    2    2    2    2    3    1    1    0    (   (    (   (    (   (    (   (    (   (    (   (    (   (   l    i    5    2   6   —  —  —  —  —  —  —  —  —  —  —  —  —  —  m   –  –   c    0    /    A   A   A   A   A   A   A   A   A   A   A   A   A   A   k    4    #    3    0   0    0   5    0   0    0   0    0   0    0   0    5   0   0    )   )    0   5    5   2    5   0    0   0    0   0    0   0    2   0   0    1   1    1   1    2   2    3   4    4   6    6   8    7   8    2   4   6    (   (

   )    F    (

   )    )    )    )    )    )    )    5   4    6   4    4   9    3   0    3   0    3   0    3   0    5    5    6    5    5    5    0    0    6    8    8    8  .   1  .   1  .   1  .   2  .   2  .   2    8  .   5    6   (    6   (    6   (    9   (    9   (    9   (    9   2    (

   )    3   0    8  .   5    9   2    (

   )    E    (

   )    )    )    )    )    )    )    0   2    0   2    0   2    0   2    0   2    0   2    0   2    0    0    0    0    0    0    0    0    0    0    0    0  .   1  .   1  .   1  .   1  .   1  .   1    0  .   0    4   (    4   (    4   (    4   (    4   (    4   (    4   1    (

   )    D    (

   )    4   )    6   )    8   )    8   )    8   )    0   )    5   9    4    5    3    3    3    8  .   5  .   9  .   1  .   1  .   1  .   7    5    6    1    4    4    4    2  .   1    0   2    2   3    7   4    7   4    7   4    3   5    6   (    1   (    1   (    1   (    1   (    1   (    1   3    (

   )    0   2    0  .   0  .    4   1    (    t    i   n   u   e    )    h    0   1    8  .   5    t    3   3    f    1   (   o    h    t   g   n    )    l   e    5   8    1    l  .    l    0   5    2    1   (   a   r   e   v   o   e    )    h    5   9    6  .   9    t    9   4    t    1   (   o    )   m    )   m    0   6    5  .    0  .   1    3    0    0   1    6    4   (    (   s   e    h   c   n    i    0  .    0    5    0    2    6   s    d    d   a   m   s    i   n   a    0    0    h   c    4   e   m   e    d    i   u   g    d   n   a   p   m   a    l    l   c    C   e    L    h    B    3    T    P     

   )   m   m   )    C    (    (   s   e    h   c   n    I   n    )    i    (   s    B   n   o    i   s   n   e        m   )    i    D   A    (   m   u   t   s    l   m  o    i   x   V   a  c    M  a

   s    t     i    n   m     U   u  s   e   r    n   m   e     i   p   -    i    g   x   a  m    u    M     l    A     P    r    e     k    a    e    r     B    t     i    u    c    r     i     C  .     4   n     1    i   -   t    e    i     l   g   u  n     b    l    a    P   U     T

   )    )    )    5   )    5   )    5   )    5   )    3   8    7   7    9   8    1    1    1    1  .   8  .   8  .   8  .   8    3    7    9    5    5    5    4    9    7  .   1  .   1  .   1    0   2    0   2    0   2    0   5    5   (    6   (    7   (    1   (    1   (    1   (    1   2    (    )    6   )    9   )    5   )    5   )    5   )    5   )    6   4    3    2    6    6    6    6  .   1    3  .   4  .   8  .   9  .   9  .   9  .   9    1    3    9    9    9    2   3    2   3    3   3    9   4    9   4    9   4    9   9    1   (    1   (    1   (    1   (    1   (    1   (    1   4    (    )    )    )    )    )    3   )    0   )    3   8    3   8    3   8    3   8    6   9    2    5    0    0    0    0  .   8    3  .   2  .   6  .   1  .   1  .   1  .   1    4    2    1    1    1    9   4    1   5    2   8    4   1    4   1    4   1    4   1    1   (    2   (    3   (    4   (    4   (    4   (    4   1    (

   0    0    6

   0    0    6

   0    0    6

   0    0    6

   0    0    6

   0    0    6

   0    0    6

   5    2    2

   0    5    2

   0    0    4

   0    0    6

   0    0    8

   0    0    8

   0    0    4

   )   s   r   e    )    k    )    )    )   s   a    )   s   s   s   s   r   r   r   e   r   r   e   r   e   e   e    k    k   e    k    k    B    k   a   a   a   a   e   e   a   e   e   e   e   r   r   r   r   r    B   m    B    B    B    B   a   e   r   e    )   e   e   e    C    F     m    P   m   m    D  a    D  a    A   A    D  a    D  m    D   F    D  m   a   a   r    N  r    L   P   r    L  r    M      F   &   J  r    K   F    F    I    F      F    B  -    B   F    B    B    B    B    B   -    3  -    3  -    3    3  -    3   R    3   E    3   J    P   (    P   (    P   K    (    P   L    (    P   M    (    P   N    (    P   T    (

Effective: December 2002

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   )

   2

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   )    8    8  .    0    1    (    4    2

   )    1    3  .    1    2    (    7    4

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   )    6  .    0   1    0  .   0    4   1    (

   )    6  .    0   1    0  .   0    4   1    (

   )    6  .    0   1    0  .   0    4   1    (

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   )    5  .    7   5    5  .    5   9    1   3    (

   )    6  .    5   9    8  .    0   2    2   5    (

   )    6  .    5   9    8  .    0   2    2   5    (

   )    6  .    5   9    8  .    0   2    2   5    (

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   s    t     i    n   s     U   m   u  e    n   m  r     i   e   -    i   p    g   x   a    u   m     l    A     P    M    e     l     b     i    s    u     F  .     5   n     1    i    e     g   t    i     l   u  n     b    l    a    P   U     T

   )    4    7  .    4    3    (    7    7

   0    0   0   0    4    0   4   0    2    6   2   6

   0    3

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   d   n   a    R   R    1   1    2   6    3   3    F   F    3   3    P   P

   d   n   a    R   R    2   2    2   6    3   3    F   F    3   3    P   P

   d   n   a    R   R    3   3    2   6    3   3    F   F    3   3    P   P

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IM01701002E

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   )    8    9  .    8    4    (    8    0    1

   )    )    )    0    0    0    0    0    0    3    3    3   –   –   )   –    5    5   0    5    2    3    (    (    3    (    0    l    l    l    3    A   –    /    A    /    A    /    5   u   u   u    C    C   2    (    C    l    i    l    i    l    i    l    i   m   m   m   m   c   c   c   c    k    k   k    k    0    0   0    0    0    0   0    0    6    6   6    6   –   –   –   –    2    2   4    4    #    #   #    #    )    )    )    )    2    (    2    (    3    (    3    (

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NEMA is the registered trademark and service mark of the National Electrical Manufacturers Association. UL is a federally registered trademark of Underwriters Laboratories Inc.

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Eaton Corporation is a global $7.3 billion diversified industrial manufacturer that is a leader in fluid power systems; electrical electric al power quality, distribution and control; automotive engine air management and fuel economy; and intelligent truck systems for fuel economy and a nd safety. safety. Eaton has 48,000 48,0 00 employees and sells products in more than 50 countries. For more information, visit www.eaton.com.

Eaton Corporation Cutler-Hammer business unit 1000 Cherrington Parkway Moon Townshi Township, p, PA 15108-431 15108-43122 USA  tel: 1-800-525-2000 www.cutler-hammer.eaton.com © 2002 Eaton Corporation All Rights Reserved Printed in USA Publication No. IM01701002E December 2002