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Pow-R-Way III Busway Design Guide

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Pow-R-Way III Busway Design Guide Design Guide DG017002EN Effective February 2020 Low-voltage power distribution and control systems > Busway > Low-voltage busway—Pow-R-Way III Contents General Description . 24 .1-2 Overview .................................. 24.1-2 Standards .................................. 24.1-2 Construction Details .......................... 24.1-3 Fittings . 24 .1-8 Fittings .................................... 24.1-8 Elbows .................................... 24.1-9 Flanges .................................... 24.1-12 Offsets .................................... 24.1-14 Tees ...................................... 24.1-16 Crosses ................................... 24.1-17 Tap Boxes ................................. 24.1-18 Weatherheads .............................. 24.1-20 Expansion Joints ............................ 24.1-21 Phase Transpositions ......................... 24.1-21 Transformer Taps ............................ 24.1-22 Transformer Throat Connections ................ 24.1-23 Reducers .................................. 24.1-24 Meter Center Power Takeoffs .................. 24.1-25 Busway-Connected Panelboards ................ 24.1-28 Pow-R-Way III Adapters ....................... 24.1-29 Wall/Floor/Roof Flanges and End Closers ......... 24.1-30 Hangers ................................... 24.1-31 Devices . 24 .1-33 Plug-In Protective Devices ..................... 24.1-33 Surge Protective Device (SPD) Plug-In Devices ..... 24.1-35 Power Takeoffs ............................. 24.1-38 Receptacle Plug-In Devices .................... 24.1-39 Layout . 24 .1-40 Construction Drawing ........................ 24.1-40 Installation Data ............................. 24.1-41 Final Field Fit Program ........................ 24.1-42 Application Data . 24 .1-43 Bus Duct Electrical Data ...................... 24.1-43 Plug-In Device Electrical Data .................. 24.1-46 Bus Duct Physical Data ....................... 24.1-48 Plug-In Device Physical Data ................... 24.1-52 More about this product Eaton.com/busway Complete library of design guides Eaton.com/designguides Low-Voltage Busway Design Guide DG017002EN Pow-R-Way III Effective February 2020 General Description 24 .1-2 Overview Table 24.1-1. Pow-R-Way Designations, See Figure 24.1-2 Available Conductor Including Grounding Eaton’s Pow-R-Way III is a 600 V, totally enclosed, non-ventilated, Configurations and Neutral Options sandwich bus design available with copper bus bars in ratings from 225–5000 A or with aluminum bus bars from 225–4000 A. 3WG Three-phase, three-wire, 50% internal ground Pow-R-Way III is available in outdoor feeder, indoor feeder, 3WI Three-phase, three-wire, 50% isolated internal ground 3WH Three-phase, three-wire, 50% integral housing ground indoor plug-in and indoor sprinkler-proof configurations. All four 3WHG Three-phase, three-wire, 100% ground a types can be used interchangeably without adapters or special 4WG Three-phase, four-wire, 50% internal ground, 100% neutral splice plates provided they are of the same current and system 4WI Three-phase, four-wire, 50% isolated internal ground, 100% neutral rating. The short-circuit withstand ratings for plug-in busway are 4WH Three-phase, four-wire, 50% integral housing ground, 100% neutral equal to those of indoor and outdoor feeder busway. 4WHG Three-phase, four-wire, 100% ground a, 100% neutral 4WNG Three-phase, four-wire, 50% internal ground, 200% neutral 4WNI Three-phase, four-wire, isolated internal ground, 200% neutral 4WNH Three-phase, four-wire, 50% integral housing ground, 200% neutral Standards 4WNHG Three-phase, four-wire, 100% ground a, 200% neutral Pow-R-Way III meets the requirements of NEMAT, ULT 857, CSAT a 100% ground consists of the 50% integral housing ground combined with a C22.2 No. 27-94, IEEET, ANSI, IEC, CE and is manufactured in an 50% internal ground bus. ISOT 9001 certified facility. Table 24.1-2. IEC 61439-6 Type Tests IEC Standards IEC 439-6 Description Pow-R-Way III busway is self certified for all ratings and KEMA Subclause certified on select ratings to conform to the following IEC 10.2.2 Resistance to corrosion Standards: EN 60439-1:1999+A1:2004, EN 60439-2:2000-03, 10.2.3.1 Thermal stability EN 60529. 10.2.3.2 Resistance to abnormal heat and fire due to internal electric effects KEMA Certification 10.2.4 Resistance to ultra-violet (UV) radiation 10.2.5 Lifting Pow-R-Way III busway has been certified by KEMA for the 10.2.6 Mechanical impact following IEC 439-2 subclauses: 10.2.7 Marking 10.2.101 Ability to withstand mechanical loads 10.3 Degree of protection of enclosures 10.4 Creepage distances 10.5 Protection against electric shock and integrity 10.9 of protective circuits Dielectric properties 10.10 Temperature-rise limits Figure 24.1-1. Pow-R-Way III Joint Design 10.11 Short-circuit withstand strength 5.101 Phase conductors characteristics / voltage drop A A A Table 24.1-3. IEC 60529 IP Ratings B B B C C C IEC 529 Busway N N IP Rating Type 3-Phase, 3-Wire 3-Phase, 4-Wire 3-Phase, 4-Wire IP2X Pow-R-Way III plug-in busway; plug-in outlet protects against with Housing Ground with Housing Ground with Housing Ground access to live parts 3WH and 100% Neutral 4WH and 200% Neutral 4WNH IP40 Pow-R-Way III indoor plug-in and feeder busway IP54 Pow-R-Way III sprinkler-proof plug-in busway G G G IP55 Pow-R-Way III outdoor feeder busway A A A IP66 Pow-R-Way III severe outdoor feeder busway B B B C C C Note: Outdoor feeder and sprinkler-proof plug-in busway joints require N N field-applied calk to meet above listed IP ratings. 3-Phase, 3-Wire 3-Phase, 4-Wire 3-Phase, 4-Wire with 50% Internal or with 50% Internal or with 50% Internal or Table 24.1-4. IEC 60529 Degrees of Protection Isolated Ground Bus Isolated Ground Isolated Ground 3WG or 3WI Bus and 100% Neutral Bus and 200% Neutral IEC 529 Description 4WG or 4WI 4WNG or 4WNI IP Rating Figure 24.1-2. Conductor Configurations IP40 Protection against access to hazardous parts with a wire or solid foreign object 1 mm diameter. No protection against water. IP54 Protection against access to hazardous parts with a wire and dust shall not penetrate in quantity to interfere with satisfactory operation or impair safety. Protects against splashing water. IP55 Protection against access to hazardous parts with a wire and dust shall not penetrate in quantity to interfere with satisfactory operation or impair safety. Protects against water jets. IP66 Protection against access to hazardous parts with a wire and dust shall not penetrate in quantity to interfere with satisfactory operation or impair safety. Protects against powerful water jets. EATON www.eaton.com Low-Voltage Busway Design Guide DG017002EN Pow-R-Way III Effective February 2020 General Description 24 .1-3 Construction Details Integral Ground The two-piece, extruded aluminum housing is designed, See Figure 24 .1-3 manufactured and UL listed as a 50% integral ground path Bus bars are fabricated from high strength, 99% conductivity (integral earth) and is fully fault rated. The system ground copper or 57% conductivity aluminum. The joint edge of each continuity is maintained through each joint by the ground path busway conductor bar is beveled while the Pow-R-Bridge end blocks, ground path plates and joint covers. The aluminum conductor bars have full rounded edges. This makes for a smooth joint covers are furnished with ground path contact surfaces on and easy connection between the busway and Pow-R-Bridge the inside of each end. When the covers are installed, the contact joint. The phase and neutral bars are insulated with Class B 130 °C surfaces are bolted directly to the ground path end blocks with epoxy insulation. The epoxy powder is applied by an automated four 3/8-16 1/2-inch (12.7 mm) hex bolts per cover. fluidized bed process to ensure uniform thickness. The epoxy A highly visible label is furnished on each joint cover to alert the powder is applied over the full length of the preheated bar except installer that the covers must be properly installed to maintain for the joint and plug-in contact surfaces. After the powder has the ground path. The result is a 50% ground path that ensures been fused to the bus bar, the bars enter an oven to cure. This ground continuity with very low resistance characteristics. process ensures that all of the epoxy powder cross links and hardens to the bus bar. Fluidized bed applied epoxy provides resistance to water Internal Ground Option absorption and chemical erosion. Epoxy has outstanding heat Pow-R-Way III offers a 50% ground bus (copper or aluminum) transfer characteristics and is ideally suited for sandwich bus that is internal to the busway. applications. The uniform thickness and smooth surface provided by epoxy ensures that the insulation will have no cavities or voids and also provides excellent edge coverage to the bars. Isolated Ground Option Epoxy has excellent dielectric strength, is flame retardant and To meet the growing demand for grounding isolation, Pow-R- resists impacts that other Class B insulating material could Way III offers a 50% isolated ground bus that is insulated and not withstand. internal to the busway. This option is available for application to operations with heavy microprocessor-based loads or large Bus bars for plug-in applications have full-sized welded computer installations where grounding isolation is essential. conductor tabs at the contact location points of the plug-in outlet. The tabs are of the same thickness as the conductor bars. The plug-in conductor tabs extend into the plug-in outlet, maintaining a true sandwich design throughout the entire busway length. The result is improved heat dissipation, better bracing and elimination of the need to separate, or flare, the conductor bars at the plug-in opening. Maintaining a true sandwich design also eliminates potential pathways for the propagation of flame, smoke and gas through the busway housing, commonly referred to as the “chimney effect.” Silver-plating is applied to all joint and contact surfaces after the fluidized bed epoxy is applied.
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