The ABCs of Planning and Installing Bus Duct

ABC_frontandback_covers.
fm Page 1 Monday, December 16, 2002 6:36 PM
The ABCs
of Planning
and Installing
Pow-R-Way III
Bus Duct
Instruction Manual
Supersedes File 30-500,
pages 1 – 72 dated 1974
ABC_BusDuct_prf4.fm Page 1 Friday, December 13, 2002 4:06 PM
Page 1
Description Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pow-R-Way III Layout . . . . . . . . . . . . . . . . . . . 4
Walk-through & On-site Measurements. . . . 4
Feeder Runs. . . . . . . . . . . . . . . . . . . . . . . . . 4
Connecting PRWIII to
Switchboards and Switchgear . . . . . . . 12
Connecting PRWIII to
Motor Control Centers . . . . . . . . . . . . . 13
Connecting PRWIII to Transformers . . . . 13
Installation Tips . . . . . . . . . . . . . . . . . . . . 15
Multiple Feeder Bus Runs . . . . . . . . 15
Busway Joint Clearances . . . . . . . . . 15
Wall and Floor Penetrations . . . . . . . 16
Outdoor Considerations . . . . . . . . . . 17
Plug-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Floor Height Measurements . . . . . . . . . 19
Installation Tips . . . . . . . . . . . . . . . . . . . . 21
Maximum Height . . . . . . . . . . . . . . . 21
Other Equipment or Walls in Close
Proximity to the Busway Riser . . . . . 21
T Location. . . . . . . . . . . . . . . . . . . . . . . . 21
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Flanges. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Tees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cable Tap Boxes . . . . . . . . . . . . . . . . . . . 23
Weatherheads . . . . . . . . . . . . . . . . . . . . . 24
Expansion Joints. . . . . . . . . . . . . . . . . . . 24
Bus Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Plug-in Units . . . . . . . . . . . . . . . . . . . . . . . . 25
Bolt-on Units . . . . . . . . . . . . . . . . . . . . . . . . 26
Built-in Power Takeoff Devices . . . . . . . 26
Bridge Joint Power Takeoff Devices . . . . 26
Installation Tips . . . . . . . . . . . . . . . . . . . . . . 28
Coordination . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Customer Approval Drawings . . . . . . . . . . 31
Customer Layout Drawings . . . . . . . . . . . . 33
Construction Drawings . . . . . . . . . . . . . . . . 33
Installation Guide . . . . . . . . . . . . . . . . . . . . . . . 35
Indoor Joint Assembly Instructions . . . . . 35
Final Field Fits . . . . . . . . . . . . . . . . . . . . . . . 37
How to Remove a Section of Busway . . . . 37
Outdoor Busway Supports . . . . . . . . . . . . . 40
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Hangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Wall/Floor Flanges. . . . . . . . . . . . . . . . . . . . 45
End Closers . . . . . . . . . . . . . . . . . . . . . . . . . 45
Busway Handling . . . . . . . . . . . . . . . . . . . . . . . 46
Shipping. . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Busway Labels. . . . . . . . . . . . . . . . . . . . . . . 46
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . 47
Effective: December 2002 IM01701002E

Page 2
This page intentionally left blank.
IM01701002E Effective: December 2002

Page 3
Introduction
Eaton’s Cutler-Hammer Pow-R-Way III (PRWIII)
is a 600 volt, totally enclosed, non-ventilated,
sandwich busway design available with either
copper bus bars rated from 225 to 5000 amperes
or with aluminum bus bars rated from 225 to 4000
amperes. PRWIII is available in outdoor feeder,
indoor feeder, indoor plug-in and indoor sprinkler
proof plug-in configurations. All four types can
be connected together without adapters or special
splice plates provided they are of the same current
and system rating. The short circuit withstand
ratings for plug-in busway are equal to those
of indoor and outdoor feeder busway of the
same current and system rating.
PRWIII busway can be utilized in applications such
as simple, straight runs of plug-in fed from a cable
tap box, or complex runs with multiple feeders.
However simple or complex, the system must
be planned in advance.
The purpose of this handbook is to help you plan,
lay out, and install PRWIII busway with an easy,
step-by-step approach. The handbook describes
a number of examples and details of how the
product is applied, as well as specific details
on how to coordinate the installation of PRWIII
with other products manufactured by Eaton’s
Cutler-Hammer business.
1. This handbook should be used as a refer-
ence guide only. Other useful references
are NEMAT 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.

Page 4
Pow-R-Way III Layout

Walk-through and On-site Measurements
Before deciding the layout of a PRWIII busway
job, we suggest you have these basic materials:
a sketch pad, measuring tape – 25 and 100 foot
(7.6 and 30.4 m), 6-foot (1.8 m) folding wood rule,
chalk line, plumb bob, and a marker.
First, it’s always a good idea to walk through the
entire facility to get an idea of general routing.
While walking through, make note of obstructions
to the busway routing. At the same time, establish
one elevation to minimize the need for offsets.
Elevations between rooms or various parts of
the building must be checked. Otherwise, busway
installed at a specific elevation in one part of
the building may be too high or too low at
another point.
After the initial walk-through, you are ready to
begin measuring the layout. For reference points,
use structures already available in the building,
such as walls or columns.
Do not attempt to divide the run into specific
sections of duct. This is the responsibility of the
Busway Division.
Feeder Runs
The following pages contain samples of floor
plans that range from a simple service application
to a multi-story building. The combination of
sketches will, in all probability, cover most of the
situations you will encounter. The sketches can
also serve as a guide to help you look for, identify,
and measure the most important site dimensions
that must be submitted with each order.
Having complete layout information when
the order is entered will save time and expedite
the release for manufacture.
The sketches include:
Figure 2 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

Page 5
Switchboard ?
? Front
?
Figure 1. Enlarged Plan View of Switchboard Room
Figure 2. Basic Site Dimensions — Required Before

Starting PRWIII Busway Layout

Page 6
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
from Weatherhead

Page 7
?
? ?
?
?
Front
Figure 4. Horizontal Offset

Page 8
? ?
Section AA
A
?
AA
?
A
Front
Figure 5. Vertical Offset

Page 9
? ?
? ? ?
? ?
Front
Figure 6. Single-Run Distribution System

Page 10
? ?
? ?
? ?
?
? ?
Front
Figure 7. Double-Run Distribution System
A B C D E
1
? ? ? ?
?
?
2
?
?
4
?
?
?
5
?
Front
6
Figure 8. Using Columns as Reference Points

Page 11
?
?
MCC
Finished ? Front
Roof ?
Floor
? ?
2nd
Floor ?
?
?
1st
Floor
Finished
Floor
Figure 9. Multi-Floor
Actual measurements should start in the area
where the switchboard, switchgear or MCC is
located. If the gear has not been installed, chalk in
the specified location and the point of entry for the
busway. For transformer connections, transformer
taps and weatherhead information, see Pages 50,
51 and 64 – 67.
One of the most important steps in planning
a large PRWIII busway layout is coordination
between the trades. This is a good time for the
electrical contractor to meet with plumbing, heat-
ing, lighting and sprinkler system contractors
to establish a definite right-of-way throughout
the construction area. Once established, hours
of frustrating re-routing can be saved. Many times,
immediately after the right-of-way has been deter-
mined, electrical contractors will install busway
hanger drop rods to claim and identify their areas.
The next step is to establish the busway elevation,
then start horizontal measurements using the
following examples as a guide. The examples
indicate the dimensions required.

Page 12
Connecting Pow-R-Way III to Switchboards

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

Page 13
Connecting Pow-R-Way III to Motor Control Centers

Busway connection to Cutler-Hammer motor
control centers is relatively simple (see Figure 11).
Keep in mind that the MCC is normally supplied
with a sheet metal cubicle (i.e. top hat, pull box) on
top of the standard enclosure to accept the busway
flange. This is due to the close proximity of the
internal horizontal bus to the top of the structure.
This pull box can vary in height and must be
determined to establish proper busway elevation.
Busway connections can be established on any
side of the top hat. However, top connectors are
the most common.
Connecting Pow-R-Way III to Transformers
Throat Connections
For throat connections, complete transformer
information must be provided. The bus connection
will then be designed to fit accordingly (see Figure
12A). The Busway Division provides the busway
and flexible connections to connect to transformer
low voltage spades.
Top Entry Connections
For connections to transformers with top entry,
complete transformer information must be pro-
vided. The Busway Division will design and supply
a flange connection with flexible connectors
(see Figure 12B).
? ? ?
Top Hat
? MCC
? ?
Figure 11. Busway Connection to Motor Control Center

Page 14
LV Studs
Transformer
s
uct
roat
Transformer Flexible Braid

Throat
?
Obstruction
Figure 12A. Busway Connection to Transformer Throat
CL
?
20.00
(508.0)
?
CL
Flexible
Braid
? ?
Figure 12B. Busway Flange Connection to Transformer

Page 15
Installation Tips
Multiple Feeder Bus Runs
For multiple runs of busway, thought must
be given to horizontal and vertical clearances
between runs. Clearances shown in Figure 13
must be maintained for assembly purposes.
6.00 6.00
(152.4) (152.4) Ceiling
Min. 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. The contractor and owner should be consulted
to be sure that there is adequate room for installation and
maintenance.
Busway Joint Clearances

Per NEMAT standards, busway may penetrate
a wall or floor if in unbroken lengths. It therefore
follows that busway joints cannot fall in walls or
floors. The example in Figure 14 illustrates the
minimum distance that the centerline of a PRWIII
busway joint can be located from a wall. Outdoor
busway must penetrate the building wall and
extend into the building at least 1 foot (305 mm)
before indoor busway can be used.
10.00 (254.0) Min.

CL
Joint
Figure 14. Required Minimum Distance from Wall

Page 16
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 accom-
modate proper installation.
Curbs around floor openings are highly recom-
mended. A curb prevents water from flowing
down through floor openings. Many times
damage occurs to the busway because the
busway is not properly protected.
Wall/Floor
All 4 Sides
2.00
(50.8)
1.00
(25.4)
Wall/Floor
Bus Opening
Duct
Wall/Floor
Flange
Figure 15. Minimum Clearances for Wall and

Floor Openings

Page 17
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
Figure 16. Wall Penetration with Outdoor Busway

Page 18
Floor 2 Bars/Phase
After Joints are Completely Assembled,

Caulk the Areas Indicated with Dow Corning
795 Silicone Caulking Compound or Dap Inc.
Dynaflex 230 Latex Sealant.
NOTICE
DANGER
Floor
Side View 1 Bar/Phase
DANGER NOTICE
After Joints are Completely Assembled,

Caulk the Areas Indicated with Dow Corning
795 Silicone Caulking Compound or Dap Inc.
Dynaflex 230 Latex Sealant.
Remove These Plugs Only
1 Bar/Phase 2 Bars/Phase Floor
Horizontal
Figure 17. Outdoor Pow-R-Bridge Detail

Page 19
Plug-in
Floor Height
The basic dimensions (height from finished floor
to finished floor including floor thickness) required
for every busway riser are shown in Figure 18.
Do not assume that all floors are the same height
or thickness.
Note: If a curb is to be supplied around the floor opening,
specify height of curb.
When planning the riser layout, joint clearance

above the floor must be maintained to install joint
cover plates and vertical spring hangers. A mini-
mum distance of 18 inches (457.2 mm) above the
floor or curb to centerline of the joint is required.
PRWIII Plug-in busway comes in straight lengths
of 2, 4, 6, 8 and 10 feet (.6, 1.2, 1.8, 2.4 and 3.0 m)
only. Therefore, the floor height will dictate the
maximum length of a plug-in section that can be
installed on that floor. For an example of a typical
riser layout, see Figure 19.
Example: If the floor height is less than 12 foot
10 inches (3.9 m) and floor thickness is 6 inches
(152.4 mm), it is not possible to use a 10 foot (3 m)
straight length of plug-in duct. Instead, a shorter
8, 6, 4, 2 foot (2.4, 1.8, 1.2, .6 mm) straight length
would be used.
When planning to install a plug in the bottom most
plug-in opening, verify the dimensions of the plug
to ensure clearance above the vertical hanger.
Using the example in Figure 19, you can
experiment with plugs to be supplied and
determine the number that can fit on each floor.
Refer to Pages 68 – 70 for the dimensions of
the plug-in units.

Page 20
Floor
?
?
Bus Duct
? Curb Where
Required
Floor
?
Figure 18. Basic Height Measurement Required for Risers
Floor
6" (457.2 mm)

CL Joint
CL Plug-in
opening
(609.6 mm)
CL Plug-in
opening
(609.6 mm)
14'-0" CL Plug-in
(4.3 m)
opening
(609.6 mm)
CL Plug-in
opening
(609.6 mm)
CL Plug-in
(254.0 mm) opening
4" Curb CL Joint
6" (457.2 mm)
Floor 1
Figure 19. Typical Floor for Plug-in Duct

Page 21
Installation Tips
Maximum Height
As a guide, the maximum height of a plug-in unit
with an operating handle or fuses should not be
more than 6 feet 6 inches (2.0 m) above the floor
when mounted on a vertical riser. Check local
codes to determine if this restriction applies. This
is a very limiting factor where the size and quantity
of the plugs on each floor exceed the 6-feet
6-inches (2.0 m) rule.
Other Equipment or Walls in Close Proximity to the
Busway Riser
Installing busway with plug-in or bolt-on units in a
vertical riser requires pre-planning. See Figure 21
for examples of busway risers in an electrical
closet. The busway with plug-in or bolt-on units
must be arranged to clear other equipment and
walls in the electrical closet. In particular, see
that the plug-in or bolt-on hinged cover can be
opened fully for maintenance.
T Location
On a vertical riser of PRWIII plug-in busway, the
load direction of the plugs will be pointed down
when T is to the left of the plug.
ON
Line
OFF
Load
Figure 20. Preferred Unit Orientation

Page 22
CL
Duct
F
Wall
Plug-in/Bolt C
On Unit
Opened
Hinged
Cover A
Wall
T 4.00
(101.6)
Min.
Plug-in
C
Unit
F
CL
Duct Operating
Handle
Figure 21. Preferred Arrangements for Wiring Closets

Page 23
Fittings
The PRWIII product offering includes a variety
of fittings that facilitate complex routing of busway
systems.
Elbows
PRWIII includes two elbow designs.
Traditional Elbow
The traditional elbow is used to make 90º turns in
the busway run. The four types that are available
are forward, rearward, upward and downward.
See Pages 56 and 57 for minimum leg lengths.
Corner-Joint Elbow
The corner-joint elbow is a feature unique
to PRWIII. This special elbow is a hybrid of a
traditional elbow and a bridge joint. Because
the corner-joint elbow is more compact, it can be
installed in areas where a traditional 90º elbow can
not be installed. The leg lengths for corner-joint
elbows are listed on Pages 58 and 59.
Note: Corner-joint elbows are suitable for indoor use only.
Offsets
An offset is two elbows fabricated into a single
fitting for use where space restrictions prohibit
the use of two separate traditional elbows.
The minimum leg lengths are listed on Pages 60
and 61.
Flanges
Flanges provide a direct connection to low voltage
switchgear, switchboards, motor control centers,
and other equipment. PRWIII offers three types
of flanges: standard, elbow and flush. The type of
flange required will be determined by the busway
layout. See Pages 52 – 54 for minimum leg lengths
for each type of flange.
Tees
A tee is a busway fitting suitable for connection
in three directions. See Pages 62 and 63 for
minimum dimensions.
Cable Tap Boxes
A cable tap box is used when a busway run is
being fed by cable and conduit, or where loads
served by busway are connected without the
need for overcurrent protection. PRWIII offers end,
center and plug-in cable tap boxes. For further
information on plug-in cable tap boxes see
Technical Data TD01701001E. Dimensions of
end and center cable tap boxes can be found
on Pages 50 and 51.

Page 24
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 enclo-
sure. The Busway Division recommends using an
expansion joint under the following conditions:
1. When crossing a building expansion.
2. On vertical risers over 100 feet (30.4 m) where
adequate bracing may not be possible in the
basement run adjacent to the vertical riser.
3. On horizontal runs of 150 feet (45.7 m) that
are fixed at both ends, unless the footage is
broken up with elbows.
4. For long straight runs of 300 feet (91.4 m)
where the ends are not fixed, use one expansion
joint. From 300 to 600 feet (91.4 to 182.9 m),
use two expansion joints, unless the load
taken off the bus by plug-in units is great
enough to reduce the current at equal intervals
along the length of the entire run.

Page 25
Bus Plugs
The Pow-R-Way III busway product offers a com-
plete family of bus plugs. Traditional plug-in units
are available up to 800 amperes, and bolt-on units
are available for up to 1200 ampere applications.
Plug-in units install at the openings provided on
plug-in type busway, while bolt-on units are used
with power takeoff devices.
Plug-in 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, com-
municating IQ Energy SentinelE and OPTIME
circuit breakers, and AdvantageE combination
contactors and starters.
Plug-in units feature mechanical interlocks
which prevent their installation or removal while
the switch is in the ON position, and to prevent
accidental closing of the switch when the cover
is open. In addition, the plugs are provided with
a means of padlocking the cover closed and
padlocking the devices in the OFF position.
A polarizing alignment pin is located on the line
side of each plug-in enclosure. The alignment
pin is inserted into the guide port in the busway
housing for proper installation.
Fusible plug-in units are available in 30A to 800A
ratings. Fusible type plugs include the quick-make,
quick-break disconnect switch and positive pres-
sure fuse clips. These plugs are shipped fully
assembled with neutral and ground stabs as
required. See Table 15 on Page 70 for detailed
information.
Breaker plug-in units are available for “FD”
through “ND” (800A only) frame Cutler-Hammer
Series CT 3-pole circuit breakers only. These plugs
are shipped fully assembled with breaker, trip unit,
rating plug, terminals, neutral and ground as
required. See Table 14 on Page 69 for detailed
information.
Fusible and circuit breaker bus plugs may be
ordered on Vista under suffix “QAP” using an
assembled catalog number. See Cutler-Hammer
Distribution Products Catalog CA08101001E
for details.
Plug-in Cable Tap Boxes are available in 200A,
400A, 600A and 800A ratings. They may be
ordered with mechanical or compression lugs.
See Table 3 on Page 51 for detailed information.

Page 26
Plug-in Units (Continued)

Front covers are hinged on the load end of the
enclosure. Clearance required in front of the unit
is equal to “A” dimension in Tables 14 and 15 on
Pages 69 and 70. All plugs shown on Page 68 are
quick-make, quick-break. “F” and “B” dimensions
are included in tables.
Operating handles are shipped assembled
for plugs rated 200A and below, as shown in
Figure 22. Handles can easily be moved to the
end of the plug in the field.
Bolt-on Units
A power takeoff is used to tap off power up to
1200 amperes. Where power is required in excess
of the current carry capabilities of the plug-in stabs
(800 amperes), a power takeoff must be used.
The power takeoff bolts directly to the contact
surfaces of the bus bars. A bolt-on fusible switch
or circuit breaker unit is then installed on the
power takeoff. Power takeoff devices are
available as built-in or bridge joint types.
Built-in Power Takeoff Devices (Figure 22)
A built-in power takeoff is a special piece of feeder
busway that allows for the attachment of a bolt-on
unit. Built-in power takeoffs are used where space
restrictions dictate that the wide dimension of the
busway be flat against the wall, ceiling or other
obstruction. In this application, power takeoffs and
bolt-on plug units are used instead of plug-in units.
Bolt-on (fusible switch, circuit breaker or
panelboard) units bolt either below or above the
power takeoff box. When laying out run, F and T
markings must be as shown. A built-in PTO may
be oriented on any surface of the busway.
Bridge Joint Power Takeoff Devices (Figure 23)
A bridge joint power takeoff is a special connection
that allows for the attachment of a bolt-on unit
at the bridge joint. The bridge joint power takeoff
and a bolt-on unit can be used to tap off power
where plug-in busway is not available. Bridge
joint power takeoff devices install on the “F”
or “F-opposite” side of the busway at bridge
joint locations.

Page 27
CL Pow-R-Bridge
17.00
(431.8)
6.94 T
Min.
(176.3)
F
9.00 CL P.T.O.
(228.6)
Line
15.00
(381.0)
Load
Edgewise Mounted
Single Bar Per Phase Only
CL Pow-R-Bridge
17.00
F (431.8)
6.94
T Min.
(176.3) T
9.00 CL P.T.O.
(228.6)
Line
15.00
(381.0)
Load
Flatwise Mounted — Available in

Single and Double Bars Per Phase
Figure 22. Built-in Power Takeoff
Load
GER
DAN
Line
GER
DAN
Figure 23. Bridge Power Takeoff

Page 28
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).

Page 29
Coordination
PRWIII busway sections have T and F markings.
When assembling the system, T and F markings
of adjacent sections must be aligned. The T and
F markings on a busway run are necessary for
two reasons:
1. To ensure proper alignment and orientation of
the phases during installation; and
2. For coordinating purposes when connecting
to switchboards, switchgear, motor control
centers, etc., because the busway neutral is
opposite the T marking.
There are several conditions that must be taken
into consideration when T and F are determined:
1. If the busway has a portion of the run requir-
ing plug-in units in a vertical riser, the T and
F are then determined by the position of the
plug-in units on the riser and its relationship
to the wiring closet wall, and whether the
load end of the plug must be toward the
floor or ceiling.
2. As shown in Figure 24, the load end of the
plug will face down when the T marking is to
the left of the plug. This orientation will ensure
that the operating handle will be ON in the up
position. (Plugs on the opposite side will have
the load end facing up and the handle will be
ON in the down position.)
3. For correct operation of horizontal plug-in
runs, the T marking of the bus must face up,
as shown in Figure 24.
Responsibility of determining T and F locations,
rests on the factory. The contractor provides
the desired location of plugs on the riser.

Page 30
ON Handle ON
OFF OFF
T Handle
F Load
OFF Handle
Load
ON
OFF
F Load
T Handle ON
Handle
ON
Load
OFF Handle OFF
T
T F
ON
F
Load
Handle Load
Handle
OFF
ON
ON
OFF
Load
Figure 24. Plug-in Device Mounting

Page 31
Drawings
Customer Approval Drawings
When required, customer approval drawings
can be supplied by several different methods:
1. On smaller jobs, the Cutler-Hammer Sales
Office can prepare sketches or get approved
drawings from the customer without a formal
approval drawing from the Busway Division.
2. The Sales Office can send hand sketches or
the customer’s electrical and architectural
drawings to the Busway Division for
preparation of formal prints.
3. Approval packages can be prepared using the
Bid ManagerE Busway drawing software.
Detailed approval drawings, as shown in Figure 25,
expedite the release for manufacture. Therefore,
it is important that the information sent to the
Division be as complete as possible. If incomplete,
a great deal of time can be wasted obtaining
missing information.
Information required to plan a busway layout
includes:
1. Front location of switchgear, switchboards,
transformers or other cubicles.
2. Floor heights and floor/curb thickness on
risers.
3. Location of bus risers in relation to closet
walls.
4. Location of plugs on a riser in relation to
closet walls.
5. Location and thickness of walls.
6. Pad heights.
7. Location of other obstructions.
The approval drawing that is sent back to the field
for approval may require additional dimensions
to complete the busway layout. The electrical
contractor will fill in these dimensions after field
measuring the job, approve the drawing for
manufacture, and submit it to the Division
for manufacture.

Page 32
Customer Please Note: 00
- Verify T & F Markings
May Penetrate & Supply Thickness Plu 0

- Verify or Indicate Label & Un
Front of Switchboard
- Verify or Indicate Label & Front 0
of Transformer 0
0
2500 A. 3-Phase, 4W 1600 A. 3-Phase, 4W
Outdoor
T
T 0 0
0 F 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
G
4.38
(111.3)
T
18.64
(473.5)
2-.25 x 5.50 (6.4 x 139.7) Aluminum/Phase

2-.25 x 5.50 (6.4 x 139.7) Aluminum/Neutral
Duct Weight = 24 lbs/ft
Color = ANSI 61 Gray
Run Indoor/Outdoor
1600 A. 3-Phase Aluminum, 277/480 Volts
4 Wire, Housing Ground, 100% Neutral
G
A
4.38 B
(111.3)
N
9.40
(238.8)
1-.25 x 6.25 (6.4 x 158.8) Aluminum/Phase

1-.25 x 6.25 (6.4 x 158.8) Aluminum/Neutral
Duct Weight = 13 lbs/ft
Color = ANSI 61 Gray
Figure 25. Sample Approval Drawings

Page 33
Customer Layout Drawings

In some instances a customer will enter an
order and release it for manufacturing based
on prepared drawings. In this type of order the
Sales Office can expedite the manufacture of the
busway by reviewing the customer drawing to
ensure that complete information is provided.
Construction Drawings
Prior to shipment of busway from the factory,
the Cutler-Hammer business will send the installer
a customer layout drawing. A sample appears
in Figure 26.
This drawing contains a complete layout of the
entire installation and a bill of material (BOM).
The BOM includes item numbers which can
be correlated with the drawing, description of
each piece, and style number and quantity of
each piece.
The installer should review this drawing prior to
and during the installation process.
Note: Plug-in units are generally not shown on a
construction drawing.
Included in the construction drawing package is
the following:
■ As-built drawings.
■ Final field fit form (if required).
■ Cut sheets for the terminations.
■ Hanger instructions.
■ Joint puller instructions.
■ Joint assembly instructions.
■ Maintenance manual.

Page 34
7/16"
15 8'
All Floors
12
10'
13 12'-6"
Plug-in Unit
12
Outdoor
Indoor 10'
2500 A.
3-phase 4W. 12'-6" 2'-6"
13
1600 A. 3-Phase 4W. 6" 1'-3"
2'-1" 12
2'-1-5/8"
11
1'-5"
10
4
-1"
24'-5"
1' 1'-3"
7
3'
See Drawing
BVC1004 Line 15
Same Elevation See Drawing
Transformer BVC1012 Line 5
Front
Switchboard
RUN 1 West Riser

Indoor Pow-R-Way III Indoor Pow-R-Way III
4 Wire, Housing Ground, 100% Neutral 4 Wire, Housing Ground, 100% Neutral
G
4.38 A
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 139.7) Aluminum/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 Duct Weight: 24 lbs/ft
Color - ANSI 61 Gray Color - ANSI 61 Gray
ITEM DESCRIPTION STYLE # Req.

OR S.O. #
A01 Flange-Elbow PSW1589A01 1
A02 Elbow PSW1589A02 1
BVD0299G11 1
A04 Elbow-Flange PSW1589A04 1
A05 Hanger BVD0301G12 2
PSW1589A06 1
A08 2'-5" Length PSW1589A08 1
A09 10'-0" Length 5687D01G30 2
BVD0299G06 3
A12 2'-6" Length PSW1589A11 3
A13 10'-0" Length PSW1589A13 2
PSW1589A14 1
A15 End Closer BVD0156G08 1
Figure 26. Sample Installation Drawing

Page 35
Installation Guide
Every piece of PRWIII busway comes with a T and
an F label. The T label indicates the phasing of
the busway and the F label is used for orientation.
PRWIII busway is phased G, A, B, C, N from the T
label. It is imperative for all busway to be installed
with all of the labels consistent throughout the
run, and per Eaton supplied customer drawings.
It is necessary to have T on the top of all runs
of busway that are installed outdoors.
Indoor Joint Assembly Instructions

When connecting sections of PRWIII together,
the following guidelines must be followed. Contact
surfaces must be clean and free of all contami-
nants. Next, align the left end of one section to
the right end of the adjoining section with T and F
labels matching. Then slide two sections of duct
together until the edge of the aluminum housing is
4-1/2 inch (114.3 mm) from the center-line of the
joint bolt. (Joint puller, catalog number JP-1, avail-
able if required. See Figure 27.)
Install the joint covers. Finally, align busway and
tighten insulated joint bolt until the top head of
the bolt breaks off.
Note: PRWIII Busway with 6-1/4-inch and 8-inch (152.4,
158.8 and 203.2 mm) bus bars uses 2 bolts per joint. This
maintains constant contact pressure over the entire width
of the bus bar.
Before making connections to the line and
load ends, and without plug-in devices installed,
megger the complete busway run and check phase
sequence. For 100 foot (3 m) runs or less, the megger
value should be a minimum of 1 megohm. The
value for longer runs may be proportionately
lower.
Note: For complete assembly instructions, please refer to
drawing BVD1050 for indoor installations and BVD1082
for outdoor or sprinkler proof installations as well as the
latest publication of NEMA Bulletin BU 1.1.

Page 36
Optional Joint Puller

(See Note 2)
Joint Puller
T
F
End Block
T
End Block
F
T
Joint Puller
F
T Joint Puller
T
End Block
T End Block
T F
Note: 1. Bolt Joint Puller to End Blocks at Busway

Joints as Shown Using .375 (9.5)-16 Hardware
Supplied In Cloth Bag.
Puller May Be Used with Wider Bus Bars.

Figure 27. Joint Puller

Page 37
Final Field Fits

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

When the need arises to remove a section from
the middle of an existing run of PRWIII busway,
the following steps must be taken:
1. Refer to Figures 28 and 29.
2. De-energize the busway.
3. Remove joint covers (and splice covers for
outdoor busway) of the joints to be loosened.
4. Remove .190 (4.8)-32 retainer screws from
top and bottom pressure plates (if not
already removed).
Note: At this point the bridge joint is no longer
securely fastened to the busway.
5. Loosen the insulated joint bolt on both ends of

the busway section to be removed.
6. Carefully remove busway section.
7. To install new section, use reverse procedure.

Page 38
1/4-20 flg.
Head Hex Bolt
(4 per cover)
Ground Path TIC

E .375 (9.5)-16 flg.
NO
Contact Surface DA
NG
ER Head Hex Bolt
(4 per cover)
Joint Cover
Ground Path Label
T F
Ground
Path Plate Ground Path
End Block
130∞ Epoxy
Insulation on Bars
Bridge Joint
Pressure Plate
(top & bottom)
Double Headed
Torque Indicating Belleville
Bolt (bottom) Washer Bridge Joint
Retainer Screw
(must be removed
for 1-inch (25.4 mm)
adjustment)
Captive Nut
Retainer
High Strength
T Glass Polyester
F Ground Path Insulators
End Block
Figure 28. Indoor Joint Assembly

Page 39
Drain Hole Plug Gasketed Top

Access Cover
Gasketed Torque-
Bolt Access Cap
(Top & Bottom)
Gasketed Gasketed Front

Cover Plate Joint Cover
Ground Path
Label
E
TIC
NO
ER
NG
DA
Gasketed Rear Gasketed

Joint Cover Cover Plate
Ground Path Drain

Contact Surface Hole Plug
Bridge Joint Retainer Screw (Must be

Removed for .08 (2.03) Adjustment)
Belleville Water Barrier
Washer T
Pressure Plate F
(Top & Bottom)
Captive Nut Ground Path

Retainer End Block
T
Pow-R-Bridge
Joint
Closed Cell
Neoprene Gasket
Water Barrier Ground Path
End Block
T F
Torque Bolt
Access Opening
Gasketed Bottom
Access Cover
Figure 29. Outdoor Joint Assembly

Page 40
Outdoor Bus Supports

Busway connected to outdoor transformers,
switchgear, etc., must be supported by some
means. This is the responsibility of the contractor
or owner. The transformer throat, see Figure 30,
is not designed to carry the busway weight.
In Figure 30, if dimension “A” is less than 10 feet
(3 m), a knee brace should be sufficient to carry the
weight of the busway outside the building. This
brace must be supplied by the owner or contractor
and may vary in design as dictated by specific job
conditions.
Note: If the overall weight of the vertical portion of the
busway extending from the transformer throat exceeds
225 lbs (102 kg), then an additional support must be
placed a maximum of 12 inches (304.8 mm) from the
center-line of the elbow bend.
12.00
(304.8) Min.
Indoor Outdoor
Additional
Support
Indoor Sealing Ring

Switchboard
HV
LV
Knee
Brace
Figure 30. Outdoor Run

If dimension “A” is greater than 10 feet (3 m) long
as in Figure 30, the busway should have:
1. Pipe supports under it;
2. Knee brace under transformer throat; and
3. Drop rods and channel hangers under
busway indoor.
Note: All bracing is to be supplied by the owner or
contractor except the hangers on the indoor portion.
Cutler-Hammer busway is listed with Underwriters
LaboratoriesT for mounting on 10-foot (3 m) centers.

Page 41
Accessories
Hangers
Horizontal Hangers (Hook and Angle)
One hanger is supplied for every 10 feet (3.0 m)
of horizontally mounted PRWIII busway. The type
of hanger is determined by the customer’s specific
requirements for installation. Care should be given
when locating the drop rods, in order to avoid
placing hangers at joint locations. If the horizontal
busway run is plug-in type, adequate ceiling
clearance must be allowed for the largest plug to
be mounted on the bus. Hanger types are shown
in Figure 31.
Note: Drop rods are provided by others.
Note: Standard hangers require 1/2-inch (12.7 mm) drop
rods and Seismic hangers require 3/4-inch (19.1 mm)
drop rods.
Vertical Hangers
When busway is to be installed vertically, a
spring suspension type vertical hanger is used.
Vertical hangers are not provided unless specified.
A vertical hanger must be used on each floor.
The maximum span permitted by UL on vertical
hangers is 16 feet (4.9 m). Intermediate hangers
are required for floor heights exceeding 16 feet
(4.9 m). See Figure 32.
Seismic Hangers
For Seismic applications, see drawing BVC 1104.
Seismic hangers are also equipped to handle a
3/4-inch (19.1 mm) drop rod.

Page 42
Duct
Width
Duct
Width
Duct
Flatwise Height
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 Edgewise Angle Hanger

1 Bar Per Phase 2 Bars Per Phase
Figure 31. Horizontal Hangers

Page 43
.31 (7.9) - 18 F
Hardware
Drill .34 (8.6) Holes
in Busway Housing
Using Hanger as
a Template
Floor
1-Inch (25.4)
Minimum
Lap Around Duct
Floor Opening Height
(Typical)
For 1 or 2 bars per Phase
(4 Springs)
"F" & "F-OPPOSITE" Mounting
T F
A
3" 3" 3" 3" 3" 3"
3 1/2" 3 1/2" 3 1/2" 3 1/2" 3 1/2" 3 1/2"
4" 4" 4" 4" 4" 4"
Floor
Center Spring
For 6.25 and 8.00
(158.7 and 203.2)
Bar Widths Duct Width
Vertical
Hanger
T F
A
5.75
(146.1)
Floor
.63 (15.9) Diameter
Stud
Mounting Support
Floor Flange
(By Others)
(Optional)
For 1 Bar per Phase Busway

(4 or 6 Springs)
"T" & "T-OPPOSITE" Mounting
Figure 32A. Vertical Hangers

Page 44
T F
Vertical
Hanger
A 5.75
(146.1)
.63 (15.9)
Floor Diameter Stud
Mounting Support
(By Others)
Floor Flange
(Optional)
Busway
.31 (7.9) - 18
Hardware
F
T T
A
3" 3" 3" 3" 3" 3"
3 1/2" 3 1/2" 3 1/2" 3 1/2" 3 1/2" 3 1/2"
4" 4" 4" 4" 4" 4"
Floor
Busway Width
1-Inch (25.4) Drill .34 (8.63) Holes
Minimum in Busway Housing
Lap Around Using Hanger as
Floor Opening a Template
(Typical)
For 2 bars per Phase Busway

(6 Springs)
"F" & "F-OPPOSITE" Mounting
Figure 32B. Vertical Hangers

Page 45
Wall/Floor Flanges
For wall/floor flange dimensions, see Figure 33.
Wall/floor flanges are required when busway
penetrates a wall or floor. This device offers no fire
protection or weatherproofing. It is for cosmetic
purposes only. Two wall flanges are required for
each wall penetration (one for each side). One
floor flange is required for each floor penetration
(floor side only).
2.00
(508.0)
2.00 Busway
(508.0) Height
Wall/
Floor
Busway
Width
Typical Wall/Floor Flange Detail

1 Bar Per Phase
(Wall Opening Should Be 1-inch (25.4)
Wider Than Bus On All Sides)
2.00 Busway
(508.0) Height
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.

Page 46
Busway Handling
Shipping
All busway shipments are made from Greenwood,
South Carolina, and are shipped F.O.B. first desti-
nation, freight prepaid if total weight is over 300
lbs. (136 kg.) Should the receiver notice any short-
age versus the shipping notice, the receiver should
file a claim with the carrier immediately. The same
procedure should be followed for damaged
freight. All hangers are shipped in separate
cartons and should be accounted for per the
bill of material.
DO NOT REMOVE BUSWAY FROM ORIGINAL
SHIPPING CONTAINER UNTIL READY FOR
INSTALLATION.
This will help prevent the problem of mechanical
damage, dirt, dust, plaster or paint on the
individual pieces.
Busway Labels
Busway items have a nameplate which indicates
the General Order number (GO#), item number,
and specific rating information (see Figure 34).
All busway fittings are clearly marked with T and F
labels. When installing the busway sections the T
and F markings of adjacent sections must match
and must be installed in the proper orientation
as shown on the customer drawing.
CUTLER-HAMMER POW-R-WAY III

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 100% circuit breaker rated for not more than amperes, 1200
DC A V ~ 277/480 this busway is rated for use on a circuit capable of
STYLE NO. PYW03125-A01 PHASE 3 WIRE 4 delivering not more than 200,000
RMS symmetrical
% GRD. 50% HSG. 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

Page 47
Dimensional Data
Width
Height
Figure A
225 to 2000 Ampere Aluminum

225 to 2500 Ampere Copper
Width
Height
Figure B
2500 to 4000 Ampere Aluminum

3200 to 5000 Ampere Copper
Figure 35. Pow-R-Way III Cross-Section Dimensions

IM01701002E
Table 1. Bus Bar and Housing — Dimensions in Inches (mm)

Ampere Phase Bar Size 3-Wire with No Neutral and 4-Wire with 100% Neutral 4-Wire with 200% Neutral
Rating (Depth and Width) Conductor Configuration and Housing Size (Width x Height)
Bar Per
Figure
Phase
Cu Al 50% Integral Housing 50% Integral 50% Integral 50% Integral Housing 50% Integral 50% Integral
Ground 3WH Ground Bus 3WHG Isolated Ground 3WI Ground 4WNH Ground Bus 4WNG Isolated Ground 4WNI
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) 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 4.38 (121 x 111) 4.75 x 4.50 (121 x 114) 4.75 x 4.55 (121 x 116) 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 4.38 (137 x 111) 5.38 x 4.50 (137 x 114) 5.38 x 4.55 (137 x 116) 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
Effective: December 2002
— 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) 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
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) 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 4.38 (473 x 111) 18.64 x 4.50 (473 x 114) 18.64 x 4.55 (473 x 116) 18.64 x 4.92 (473 x 125) 18.64 x 5.05 (473 x 128) 18.64 x 5.10 (473 x 130) B
Page 48
— 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) 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 4.38 (602 x 111) 23.70 x 4.50 (602 x 114) 23.70 x 4.55 (602 x 116) 23.70 x 4.92 (602 x 125) 23.70 x 5.05 (602 x 128) 23.70 x 5.10 (602 x 130) B
Table 2. Weight and Current Density
Ampere Weight (Lbs./Ft.) and Current Density (Amperes/in2) Metric Weight (kg/M) and Current Density (Amperes/cm2)
Page 49
Rating Current Weight — Including Integral Housing Ground (Lbs./Ft.) Current Weight — Including Integral Housing Ground (kg/M)
Density 3-Wire 4-Wire 4-Wire Add for Density 3-Wire 4-Wire 4-Wire Add for
Amperes/in 2 Amperes/cm 2
100% Neutral 200% Neutral Internal 100% Neutral 200% Neutral Internal
Ground Ground
Cu Al Cu Al Cu Al Cu Al Cu Al Cu Al Cu Al Cu Al Cu Al Cu Al Cu Al
225 225 554 554 8 5 10 6 11 7 0.78 0.23 86 86 12 7 15 9 17 11 1.17 0.35

400 400 985 985 8 5 10 6 11 7 0.78 0.23 153 153 12 7 15 9 17 11 1.17 0.35
600 — 1477 — 8 — 10 — 11 — 0.78 — 229 — 12 — 15 — 17 — 1.17 —
800 600 1969 1477 8 5 10 6 11 7 0.78 0.23 305 229 12 7 15 9 17 11 1.17 0.35
1000 — 1778 — 10 — 12 — 14 — 1.08 — 276 — 15 — 18 — 21 — 1.62 —
1200 800 1745 1164 12 6 15 7 17 8 1.33 0.40 270 180 18 9 22 11 26 12 1.98 0.60
1350 1000 1662 1231 14 7 17 8 20 9 1.57 0.47 258 191 21 11 25 12 30 14 2.34 0.71
1600 1200 1506 1129 17 8 21 10 25 11 2.05 0.62 233 175 25 12 32 15 37 16 3.06 0.92
2000 1350 1455 982 23 11 28 12 33 13 2.66 0.80 226 152 34 16 42 18 49 20 3.96 1.20
— 1600 — 1024 — 12 — 13 — 15 — 0.91 — 159 — 18 — 20 — 22 — 1.36
2500 2000 1250 1000 29 14 36 16 42 18 3.87 1.17 194 155 43 21 54 24 63 27 5.76 1.75
3200 — 1505 — 34 — 42 — 49 — 4.11 — 233 — 51 — 63 — 73 — 6.12 —
4000 2500 1455 909 45 21 56 24 66 27 5.32 1.61 226 140 67 32 83 36 98 40 7.92 2.40
— 3200 — 960 — 23 — 26 — 29 — 1.83 — 149 — 34 — 39 — 43 — 2.73

5000 4000 1250 1000 63 28 72 32 85 36 7.74 2.35 194 155 94 42 108 48 126 54 11.53 3.50
IM01701002E
Page 50
Cable Tap Boxes
38.00 A
(965.2)
D in. r
M tet
Gupace
“T” Side CL of S
Removable 30.00
Busway (762.0)
Indoor
32.50
11.62 (825.5)
(295.1)
CL CL of Duct CL of Box
Gasketed Access
Cover on Front
Busway and Back of Box
Width 15.00 for Outdoor Tap
Busway (381.0) Boxes Only
Height 17.50
(444.5)
Side Opposite “T”
Removable Indoor
End Cable Tap Box
B
A
“T”Side C
Removable
Indoor CLof Busway
11.62 30.00
C
L of Duct (762.0)
(295.1)
CL 32.50
(825.5)
F
End
CLof Box Removable
Busway Indoor
Width
F Dimension is
Busway the Minimum
Height 15.00 Gutter Space
Side Opposite “T” (381.0)
17.50
Removable Indoor (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)
CLof Box
24.00
(609.6)
CL of Busway
11.62
(295.1)
CL CLof Duct
1.00
(25.4)
Compression and
Busway Mechanical Lugs
Width 15.00 Removable Barrier
Busway (381.0)
Height 17.50
(444.5)
Weatherhead
Figure 36. Cable Tap Boxes

Page 51
Table 3. Cable Tap Box — Dimensions in Inches (mm)
Ampere End Cable Tap Box Center Cable Tap Box Quantity of Mechanical Terminals,
Rating Range — (1) #4 – 600 kcmil or
Copper Aluminum Copper Aluminum Weatherhead (2) 1/0 – 250 kcmil Cu/Al
Dimension Dimension Dimension Dimension Dimension Dimension Dimension Dimension Dimension Copper Aluminum
(A) (A) (A) (B) (C) (A) (B) (C) (A) G P N G P N
225 12.00 (304.8) 12.00 (304.8) 16.50 (419.1) 40.00 (1016.0) 3.63 (92.2) 16.50 (419.1) 40.00 (1016.0) 3.63 (92.2) 16.50 (419.1) 1 2 4 1 2 4
400 12.00 (304.8) 12.00 (304.8) 16.50 (419.1) 40.00 (1016.0) 3.63 (92.2) 16.50 (419.1) 40.00 (1016.0) 3.63 (92.2) 16.50 (419.1) 1 2 4 1 2 4
600 12.00 (304.8) 12.00 (304.8) 16.50 (419.1) 40.00 (1016.0) 3.63 (92.2) 16.50 (419.1) 40.00 (1016.0) 3.63 (92.2) 16.50 (419.1) 1 2 4 1 2 4
800 12.00 (304.8) 12.00 (304.8) 16.50 (419.1) 40.00 (1016.0) 3.63 (92.2) 16.50 (419.1) 40.00 (1016.0) 3.63 (92.2) 16.50 (419.1) 2 3 5 2 3 5
1000 12.00 (304.8) 12.00 (304.8) 16.50 (419.1) 40.00 (1016.0) 3.63 (92.2) 16.50 (419.1) 40.00 (1016.0) 3.63 (92.2) 16.50 (419.1) 2 3 6 2 3 6
1200 12.00 (304.8) 12.00 (304.8) 16.50 (419.1) 40.00 (1016.0) 3.63 (92.2) 20.50 (520.7) 42.50 (1079.5) 4.75 (120.7) 16.50 (419.1) 2 4 8 2 4 8
1350 12.00 (304.8) 20.50 (520.7) 16.50 (419.1) 40.00 (1016.0) 3.63 (92.2) 20.50 (520.7) 42.50 (1079.5) 4.75 (120.7) 16.50 (419.1) 2 4 8 2 4 8
1600 20.50 (520.7) 24.50 (622.3) 20.50 (520.7) 42.50 (1079.5) 4.75 (120.7) 24.50 (622.3) 45.00 (1143.0) 6.00 (152.4) 16.50 (419.1) 3 5 9 3 5 9
2000 20.50 (520.7) 24.50 (622.3) 20.50 (520.7) 42.50 (1079.5) 4.75 (120.7) 24.50 (622.3) 45.00 (1143.0) 6.00 (152.4) 16.50 (419.1) 3 6 12 3 6 12
2500 24.50 (622.3) 30.50 (774.5) 24.50 (622.3) 42.50 (1079.5) 6.00 (152.4) 30.38 (771.7) 58.00 (1473.0) 10.75 (273.1) 16.50 (419.1) 4 8 16 4 8 16
IM01701002E
3200 30.50 (774.5) 30.50 (774.5) 30.38 (774.5) 58.00 (1473.2) 10.75 (273.1) 30.38 (771.7) 58.00 (1473.0) 10.75 (273.1) 30.00 (762.0) 5 9 18 5 9 18
4000 45.00 (1143.0) 45.00 (1143.) 45.00 (1143.0) 60.50 (1536.7) 12.25 (311.2) 45.00 (1143.0) 60.50 (1536.7) 12.25 (311.2) 30.00 (762.0) 6 12 24 6 12 24
5000 45.00 (1143.0) — 45.00 (1143.0) 60.50 (1536.7) 12.25 (311.2) — — — 30.00 (762.0) 7 15 30 — — —
Page 52
Elbow Flanges
CL CL
CL
T
T
F
Forward Elbow
Right Flange
CL T
F
CL
CL
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)
225 225 13.00 (330.2) 8.75 (222.3)

400 400 13.00 (330.2) 8.75 (222.3)
600 — 13.00 (330.2) 8.75 (222.3)
800 600 13.00 (330.2) 8.75 (222.3)
1000 — 13.00 (330.2) 8.75 (222.3)
1200 800 13.50 (342.9) 9.25 (235.0)
1350 1000 13.50 (342.9) 9.25 (235.0)
1600 1200 14.00 (355.6) 9.75 (247.7)
2000 1350 14.50 (368.3) 10.25 (260.4)
— 1600 15.00 (381.0) 10.75 (273.1)
2500 2000 16.00 (406.4) 11.75 (298.5)
3200 — 18.50 (469.9) 14.00 (355.6)
4000 2500 19.50 (495.3) 15.25 (387.4)
— 3200 20.50 (520.7) 16.00 (406.4)
5000 4000 22.50 (571.5) 17.75 (450.9)

Page 53
CL
T
T
F Upward Elbow
Right Flange
CL
CL
CL
CL
CL
T
T
F
Downward Elbow
Right Flange
Figure 38. Elbow Flanges
Table 5. Upward and Downward Elbow Flanges

Ampere Minimum Dimension in Inches (mm)
Rating Joint Let (X) Flange Leg (Y)
Cu Al Up Down Up Down
225 225 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3)
400 400 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3)
600 — 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3)
800 600 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3)
1000 — 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3)
1200 800 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3)
1350 1000 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3)
1600 1200 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3)
2000 1350 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3)
— 1600 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3)
2500 2000 10.00 (254.0) 13.00 (330.2) 5.75 (146.1) 8.75 (222.3)
3200 — 12.00 (304.8) 13.00 (330.2) 7.75 (196.9) 8.75 (222.3)
4000 2500 12.00 (304.8) 13.00 (330.2) 7.75 (196.9) 8.75 (222.3)
— 3200 12.00 (304.8) 13.00 (330.2) 7.75 (196.9) 8.75 (222.3)
5000 4000 12.00 (304.8) 13.00 (330.2) 7.75 (196.9) 8.75 (222.3)

Page 54
Standard/Flush Flanges
T
F
1.25
CL
15.00
Bridge
(381.0)
CL Min.
Flush Flange
T
F Bridge
CL
11.62
(295.2)
Min.
CL
Standard Flange
Figure 39. Standard/Flush Flanges
Table 6. Standard/Flush Flanges

Ampere Minimum Leg Length (X)
Rating in Inches (mm)
Cu Al Flush Flange Standard Flange
225 225 15.00 (381.0) 11.62 (295.16)

400 400 15.00 (381.0) 11.62 (295.16)
600 600 15.00 (381.0) 11.62 (295.16)
800 800 15.00 (381.0) 11.62 (295.16)
1000 1000 15.00 (381.0) 11.62 (295.16)
1200 1200 15.00 (381.0) 11.62 (295.16)
1350 1350 15.00 (381.0) 11.62 (295.16)
1600 1600 15.00 (381.0) 11.62 (295.16)
2000 2000 15.00 (381.0) 11.62 (295.16)
2500 2500 15.00 (381.0) 11.62 (295.16)
3200 3200 15.00 (381.0) 11.62 (295.16)
4000 4000 15.00 (381.0) 11.62 (295.16)
5000 — 15.00 (381.0) 11.62 (295.16)

Page 55

Page 56
Elbows
CL CL
X X
CL CL
T
T
F
Forward
CL T
CL
F
X X
CL CL
Rearward
T
T
F
X C
L
CL
Upward
T
T
CL F
X
CL
CL
Downward
Figure 40. Elbow Types

Page 57
Table 7. Elbows — Dimensions in Inches (mm)

Ampere Minimum Minimum
Rating Leg Length Leg Lengths (X)
Cu Al Upward Downward Forward/Rearward
225 225 10.00 (254.0) 13.00 (330.2) 13.00 (330.2)

400 400 10.00 (254.0) 13.00 (330.2) 13.00 (330.2)
600 — 10.00 (254.0) 13.00 (330.2) 13.00 (330.2)
800 600 10.00 (254.0) 13.00 (330.2) 13.00 (330.2)
1000 — 10.00 (254.0) 13.00 (330.2) 13.00 (330.2)
1200 800 10.00 (254.0) 13.00 (330.2) 13.50 (342.9)
1350 1000 10.00 (254.0) 13.00 (330.2) 13.50 (342.9)
1600 1200 10.00 (254.0) 13.00 (330.2) 14.00 (355.6)
2000 1350 10.00 (254.0) 13.00 (330.2) 14.50 (368.3)
— 1600 10.00 (254.0) 13.00 (330.2) 12.00 (381.0)
2500 2000 10.00 (254.0) 13.00 (330.2) 16.00 (406.4)
3200 — 12.00 (304.8) 13.00 (330.2) 18.50 (469.9)
4000 2500 12.00 (304.8) 13.00 (330.2) 19.50 (495.3)
— 3200 12.00 (304.8) 13.00 (330.2) 20.50 (520.7)
5000 4000 12.00 (304.8) 13.00 (330.2) 22.50 (571.5)

Page 58
Corner Joint Elbows
CL CL
X Y CL
CL
Forward
T
F
CL
X Y CL
CL
CL
Rearward
F
CL
Y
CL
CL
Downward
T
X
F
X
CL
Upward
Figure 41. Corner Joint Elbows

Page 59
Table 8. Corner Joints

Ampere Dimensions in Inches (mm)
Rating Forward/Rearward Upward/Downward
Cu Al (X) (Y) (X) (Y)
225 225 0.94 (23.9) 5.38 (136.7) 4.71 (119.6) 4.35 (110.5)
400 400 0.94 (23.9) 5.38 (136.7) 4.71 (119.6) 4.35 (110.5)
600 — 0.94 (23.9) 5.38 (136.7) 4.71 (119.6) 4.35 (110.5)
800 600 0.94 (23.9) 5.38 (136.7) 4.71 (119.6) 4.35 (110.5)
1000 — 1.25 (31.8) 5.69 (144.5) 4.71 (119.6) 4.35 (110.5)
1200 800 1.50 (38.1) 5.94 (150.9) 4.71 (119.6) 4.35 (110.5)
1350 1000 1.75 (44.5) 6.19 (157.2) 4.71 (119.6) 4.35 (110.5)
1600 1200 2.25 (57.2) 6.69 (169.9) 4.71 (119.6) 4.35 (110.5)
2000 1350 2.88 (73.2) 7.31 (185.7) 4.71 (119.6) 4.35 (110.5)
— 1600 3.25 (82.6) 7.70 (195.6) 4.71 (119.6) 4.35 (110.5)
2500 2000 4.12 (104.7) 8.57 (217.7) 4.71 (119.6) 4.35 (110.5)
3200 — 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)

Page 60
Offsets
CL
CL
Y 3.00
CL (76.2) CL
Min.
Y
CL
T
T
F
Forward
CL
CL
3.00
Y
(76.2) CL
CL Min.
Y
T CL
T
F
Rearward
T
F
CL
CL 3.00
Y (76.2) Min.
CL
CL Z
Upward CL
CL
3.00
(76.2) Min.
CL
T
CL T
Y F
CL Z
CL
Downward
Figure 42. Offsets

Table 9. Offsets
Page 61
Ampere Minimum Dimensions in Inches (mm)

Rating Upward Downward Forward/Rearward
Cu Al (Y) (Z) (Y) (Z) (Y)
225 225 10.00 (254.0) 13.00 (330.2) 13.00 (330.2) 10.00 (254.0) 13.00 (330.2)
400 400 10.00 (254.0) 13.00 (330.2) 13.00 (330.2) 10.00 (254.0) 13.00 (330.2)
600 — 10.00 (254.0) 13.00 (330.2) 13.00 (330.2) 10.00 (254.0) 13.00 (330.2)

800 600 10.00 (254.0) 13.00 (330.2) 13.00 (330.2) 10.00 (254.0) 13.00 (330.2)
1000 — 10.00 (254.0) 13.00 (330.2) 13.00 (330.2) 10.00 (254.0) 13.00 (330.2)
1200 800 10.00 (254.0) 13.00 (330.2) 13.00 (330.2) 10.00 (254.0) 13.50 (342.9)
1350 1000 10.00 (254.0) 13.00 (330.2) 13.00 (330.2) 10.00 (254.0) 13.50 (342.9)
1600 1200 10.00 (254.0) 13.00 (330.2) 13.00 (330.2) 10.00 (254.0) 14.00 (355.6)
2000 1350 10.00 (254.0) 13.00 (330.2) 13.00 (330.2) 10.00 (254.0) 14.50 (368.3)
— 1600 10.00 (254.0) 13.00 (330.2) 13.00 (330.2) 10.00 (254.0) 15.00 (381.0)
2500 2000 10.00 (254.0) 13.00 (330.2) 13.00 (330.2) 10.00 (254.0) 16.00 (406.4)
3200 — 12.00 (304.8) 13.00 (330.2) 13.00 (330.2) 12.00 (304.8) 18.50 (469.9)
4000 2500 12.00 (304.8) 13.00 (330.2) 13.00 (330.2) 12.00 (304.8) 19.50 (495.3)
— 3200 12.00 (304.8) 13.00 (330.2) 13.00 (330.2) 12.00 (304.8) 20.50 (520.7)
5000 4000 12.00 (304.8) 13.00 (330.2) 13.00 (330.2) 12.00 (304.8) 22.50 (571.5)
IM01701002E
Page 62
Tees
CL
X CL
CL
T Y
X T CL
F
CL
T T
T T
F F
Forward
CL
Y
CL
T T
F
T T F
CL
T
X
T
F
CL
X
CL
Rearward
CL
Y
T CL
T FT
T
F
T
T
F
X CL
X CL
CL
Upward
CL
T
T
F Y
T
T CL
F
T
T F
CL
X
X CL
CL Downward
Figure 43. Tees

Page 63
Table 10. Tees

Ampere Minimum Leg Dimensions in Inches (mm)
Rating Forward/Rearward Upward/Downward
Cu Al (X) (Y) (X) (Y)
225 225 13.00 (330.2) 13.00 (330.2) 21.25 (539.8) 25.50 (647.7)
400 400 13.00 (330.2) 13.00 (330.2) 21.25 (539.8) 25.50 (647.7)
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)
3200 — 27.25 (692.2) 26.38 (670.1) 23.88 (606.6) 25.50 (647.7)
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)

Page 64
Single-Phase Transformer Tap

TAPS CL POW-R-BRIDGE
CL
8.50 + Y
17.00 + 2X (215.9) + Y
(431.8) + 2X
TAPS CL POW-R-BRIDGE
CL T
8.50 + X
(215.9) + X
F
8.50 + X Ground
17.00 + 2X (215.9) + X A When
(431.8) + 2X G Required
TAPS CL POW-R-BRIDGE C A Phase or Neutral

CL 8.50 + X T
(215.9) + X
F
8.50 + X
(215.9) + X C
POW-R-BRIDGE
CL B C Phase or Neutral
8.50 + X T
(215.9) + X
F
A B Phase or Neutral
Figure 44. Single-Phase Transformer Tap
Table 11. Single-Phase Transformer Tap

Ampere Minimum Dimensions
Rating in Inches (mm)
Cu Al (X) (Y)
225 225 4.00 (101.6) 7.00 (177.8)

400 400 4.00 (101.6) 7.00 (177.8)
600 — 4.00 (101.6) 7.00 (177.8)
800 600 4.00 (101.6) —
1000 — 4.50 (114.3) 9.75 (247.7)
1200 800 5.00 (127.0) 10.75 (273.1)
1350 1000 5.50 (139.7) 11.75 (298.5)
1600 1200 6.50 (165.1) 13.75 (349.3)
2000 1350 7.75 (196.9) 16.25 (412.8)
— 1600 8.50 (215.9) 17.50 (444.5)
2500 2000 10.25 (260.4) 21.25 (539.8)
3200 — 6.50 (165.1) 13.75 (349.3)
4000 2500 7.75 (196.9) 16.25 (412.8)
— 3200 8.50 (215.9) 17.50 (444.5)
5000 4000 10.25 (260.4) 21.25 (539.8)

Page 65
Three-Phase Transformer Tap
15.00
(381.0)
Support Pad
B
Taps CL
C
L T G
A
T
B
F
C C
N
6.00 (152.4) (1-Phase) 6.00

7.50 (191.0) (2-Phase) (152.4)
Figure 45. Three-Phase Transformer Tap
Table 12. Three-Phase Transformer Tap —

Dimensions in Inches (mm)
(A) Minimum Dimensions
Wire Designation
3W/3WH 3WG/3WHG/ 4W/4WH 4WG/4WHG/
3WI 4WI/4WNG/
4WNHG/
4WNI
16.5 (419.1) 16.5 (419.1) 19.5 (495.3) 19.5 (495.3)
(B) Minimum Dimensions

Wire Designation
3W/3WH 3WG/3WHG/ 4W/4WH 4WG/4WHG/
3WI 4WN/4WNH 4WI/4WNG/
4WNHG/
4WNI
6.25 (158.8) 12.12 (307.8) 9.25 (235.0) 15.12 (384.0)
(C) Minimum Dimensions

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

Page 66
Transformer Throat Connections
Transformer
Transformer
Throat
Sealing Ring
Edge of CL
Transformer
Throat
A
1.75 (44.5) Plus

1/2 (12.7) Duct Width
Transformer
Transformer
Throat
Sealing Ring
CL
Edge of
Transformer
Throat
A
9.50
(241.3)
Sealing Ring
Screw
Felt Gasket
Sealing Ring
Figure 46. Transformer Throat Connections

Page 67
Table 13. Transformer Throats

Ampere Bars per Minimum Dimensions
Rating Phase in Inches (mm)
(A)
Aluminum
225 – 1350 1 26.00 (660.4)
1600 – 2000 1 28.50 (723.9)
2500 – 4000 2 31.50 (800.1)
Copper
225 – 2000 1 26.00 (660.4)
2500 1 28.50 (723.9)
3200 – 5000 2 31.50 (800.1)

Page 68
Bus Plugs
ON
E
CL
D
Handle CL
F
CL Plug-in Opening
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.

Table 14. Circuit Breaker Plug-in Units
Plug-in Maximum Maximum Dimensions in Inches (mm) Mechanical Terminal Approx.
Page 69
Unit Amperes ac Volts (A) 1 (B) (C) (D) (E) (F) Wire Range Per Phase (mm2) Weight
Lbs. (kg)
P3BFD 225 600 19.26 12.36 5.43 6.25 4.00 6.05 100 A — (1) #14 – 1/0 (2.5 – 50) 25
(E- & F-Frame Breakers) (489) (314) (138) (159) (102) (154) 150 A — (1) #4 – 4/0 (25 – 95) (11.33)
P3BJD 250 600 21.33 12.36 6.97 10.44 4.00 6.06 250 A — (1) #14 – 350 kcmil (25 – 185) 47
(J-Frame Breakers) (542) (314) (177) (265) (102) (154) 225 A — (1) 3 – 350 kcmil (35 – 185) (21.31)

P3BKD 400 600 32.50 13.29 7.79 12.56 4.00 6.64 350 A — (1) 250 – 500 kcmil (120 – 240) 53
(K-Frame Breakers) (826) (338) (198) (319) (102) (169) 400 A — (2) 3/0 – 250 kcmil (45 – 120) (24.04)
P3BLD 600 600 44.03 19.65 10.15 17.38 4.00 9.83 400 A — (1) 4/0 – 600 kcmil (120 – 300) 75
(L-Frame Breakers) (1118) (499) (258) (441) (102) (250) 600 A — (2) 400 – 500 kcmil (185 – 240) (34.01)
P3BMD 800 600 44.03 19.65 10.15 17.38 4.00 9.83 600 A — (2) #1 – 500 kcmil (50 – 240) 136
(M-Frame Breakers) (1118) (499) (258) (441) (102) (250) 800 A — (2) 500 – 750 kcmil (300 – 400) (61.68)
P3BND 800 600 44.03 19.65 10.15 17.38 4.00 9.83 700 A — (2) #1 – 500 kcmil (50 – 240) 138
(N-Frame Breakers) (1118) (499) (258) (441) (102) (250) 800 A — (3) 3/0 – 400 kcmil (95 – 185) (62.59)
P3BLAP 400 600 44.03 19.65 10.15 13.80 4.00 9.83 225 A — (1) #6 – 350 kcmil (16 – 185) 96
(TRI-PAC) (1118) (499) (258) (357) (102) (250) 400 A — (1) #4 – 250 kcmil and (1) 3/0 – (43.54)
600 kcmil (25 – 120 and 95 – 300)
P3BLCl 400 600 40.00 19.65 10.15 13.80 4.00 9.83 (1) #4 – 250 kcmil (25 – 120) and 88
(1016) (499) (258) (351) (102) (250) (1) 3/0 – 600 kcmil (95 – 300) (39.91)
1 The clamp and guide mechanism adds 2.50 inches (63.5 mm) to the overall length of the unit.
IM01701002E
Table 15. Fusible Plug-in Units
Plug-in Maximum Maximum Dimensions in Inches (mm) Mechanical Terminal Approx. Weight
Unit Amperes ac Volts (A) 1 (B) (C) (D) (E) (F) Wire Range Per Phase (mm 2) Lbs. (kg)
P3F321R and 240 20.85 12.36 5.43 7.88 4.00 6.06 Cu — (1) #14 – #3 (2.5 – 35)
IM01701002E
30 22 (9.98)
P3F361R 600 (529.6) (313.9) (137.9) (200.2) (101.6) (153.9) Al — (1) #12 – #2 (3.2 – 35)
Cu — (1) #14 – #3 1/0 (2.5 – 35)
P3F322R and 240 20.85 12.36 5.43 7.88 4.00 6.06 Al — (1) #12 – #2 (3.2 – 38)
60 24 (10.88)
P3F362R 600 (529.6) (313.9) (137.9) (200.2) (101.6) (153.9) Cu — (1) #14 – 1/0 (2.5 – 50)
Al — (1) #12 – 1/0 (3.2 – 50)
Cu — (1) #14 – 1/0, (2.5 – 5.0)
P3F323R and 240 20.85 12.36 5.43 7.88 4.00 6.06
100 Al — (1) #12 – 1/0 (3.2 – 50) 24 (10.88)
P3F363R (529.6) (313.9) (137.9) (200.2) (101.6) (153.9)
600 (1) #4 – 250 kcmil Cu/Al (25 – 120)
240 (1) #4 – 250 kcmil Cu/Al (25 – 120)
P3F324R and 21.75 15.57 9.66 8.20 4.00 7.63
200 600 (1) #4 – 600 kcmil Cu/Al (25 – 300) 47 (21.31)
P3F364R (552.5) (395.5) (245.4) (208.3) (101.6) (193.8)
or (2) 250 kcmil (120)
P3F325R and 240 46.94 21.22 10.07 12.67 4.00 10.69
400 (2) #2 – 600 kcmil Cu/Al (35 – 300) 77 (34.74)
P3F365R 600 (1192.3) (539.0) (255.8) (321.8) (101.6) (271.5)
23.47 21.22 21.00 12.67 4.00 10.69
P3F365H 400 600 (2) #2 – 600 kcmil Cu/Al (35 – 300) 81 (36.74)
(596.1) (539.0) (533.4) (321.8) (101.6) (271.5)
P3F326R and 240 46.94 26.31 10.59 14.26 4.00 13.16 (2) #2 – 600 kcmil Cu/Al (35 – 300)
600 82 (37.19)
P3F366R 600 (1192.3) (668.3) (270.0) (362.2) (101.6) (334.3) (3) #4 – 600 kcmil (25 – 300)
P3F327R and 240 46.94 26.31 10.59 14.26 4.00 13.16
800 (3) #4 – 600 kcmil Cu/ Al (25 – 300) 108 (48.98)

P3F367R 600 (1192.3) (668.3) (270.0) (362.2) (101.6) (334.3)
Page 70
1 The clamp and guide mechanism adds 2.50 inches (63.5 mm) to the overall length of the unit.

Page 71
NEMA is the registered trademark and service

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

Page 72

ABC_frontandback_covers.fm Page 2 Monday, December 16, 2002 6:36 PM
Eaton Corporation is a global $7.3 billion

diversified industrial manufacturer that is
a leader in fluid power systems; electrical
power quality, distribution and control;
automotive engine air management and
fuel economy; and intelligent truck systems
for fuel economy and safety. Eaton has 48,000
employees and sells products in more than
50 countries. For more information, visit
www.eaton.com.
Eaton Corporation
Cutler-Hammer business unit
1000 Cherrington Parkway
Moon Township, PA 15108-4312
USA
tel: 1-800-525-2000
www.cutler-hammer.eaton.com
© 2002 Eaton Corporation

All Rights Reserved
Printed in USA
Publication No. IM01701002E
December 2002

The ABCs of Planning and Installing Bus Duct

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fm Page 1 Monday, December 16, 2002 6:36 PM

Effective: December 2002 IM01701002E

This page intentionally left blank.

IM01701002E Effective: December 2002

Effective: December 2002 IM01701002E

Pow-R-Way III Layout

IM01701002E Effective: December 2002

Figure 1. Enlarged Plan View of Switchboard Room

Figure 2. Basic Site Dimensions — Required Before

Effective: December 2002 IM01701002E

Check Local Codes

Figure 3. Site Measurements Required for Service Entrance

IM01701002E Effective: December 2002

Figure 4. Horizontal Offset

Effective: December 2002 IM01701002E

Figure 5. Vertical Offset

IM01701002E Effective: December 2002

Figure 6. Single-Run Distribution System

Effective: December 2002 IM01701002E

Figure 7. Double-Run Distribution System

Figure 8. Using Columns as Reference Points

IM01701002E Effective: December 2002

Effective: December 2002 IM01701002E

Connecting Pow-R-Way III to Switchboards

Figure 10. Busway Connection to Switchboard

IM01701002E Effective: December 2002

Connecting Pow-R-Way III to Motor Control Centers

Figure 11. Busway Connection to Motor Control Center

Effective: December 2002 IM01701002E

Transformer Flexible Braid

Figure 12A. Busway Connection to Transformer Throat

Figure 12B. Busway Flange Connection to Transformer

IM01701002E Effective: December 2002

Busway Joint Clearances

10.00 (254.0) Min.

Figure 14. Required Minimum Distance from Wall

Effective: December 2002 IM01701002E

Wall and Floor Penetrations

Figure 15. Minimum Clearances for Wall and

IM01701002E Effective: December 2002

Figure 16. Wall Penetration with Outdoor Busway

Effective: December 2002 IM01701002E

After Joints are Completely Assembled,

Side View 1 Bar/Phase

After Joints are Completely Assembled,

Remove These Plugs Only

1 Bar/Phase 2 Bars/Phase Floor

Figure 17. Outdoor Pow-R-Bridge Detail

IM01701002E Effective: December 2002

When planning the riser layout, joint clearance

Effective: December 2002 IM01701002E

Figure 18. Basic Height Measurement Required for Risers

6" (457.2 mm)

Figure 19. Typical Floor for Plug-in Duct

IM01701002E Effective: December 2002

Figure 20. Preferred Unit Orientation

Effective: December 2002 IM01701002E

Figure 21. Preferred Arrangements for Wiring Closets

IM01701002E Effective: December 2002

Effective: December 2002 IM01701002E

IM01701002E Effective: December 2002