YES_Book.book Page 1 Monday, February 27, 2006 10:20 AM Busway (Low Voltage) 9-1 Electrical Aftermarket Products and Services March 2006 Aftermarket Solutions, Ref. No. [175] Contents 1 Description Page Busway (Low Voltage) 2 Product Description . 9-2 Product History. 9-2 3 Product History Time Line . 9-3 Replacement Capabilities . 9-4 4 Vintage Busway Products. 9-4 Plug-in Units . 9-5 5 100-Ampere Busway . 9-6 Standard Plug-in Busway . 9-7 6 Standard and Low Impedance . 9-8 Quick Assembled Plugs, Catalog Numbering System . 9-10 7 Bolt-on Units . 9-11 Plug-in Units — Used with CP2, CP3 or CP4 . 9-12 8 Technology Upgrades . 9-14 Clipper Power Systems, Busway TVSS Protection . 9-14 9 IQ Energy Sentinels. 9-15 Customer Required Information . 9-15 10 Further Information . 9-15 Pricing Information . 9-15 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Circuit Breaker Enclosure Busway (Low Voltage) 25 CA08105001E For more information visit: www.EatonElectrical.com YES_Book.book Page 2 Monday, February 27, 2006 10:20 AM 9-2 Busway (Low Voltage) Electrical Aftermarket Products and Services March 2006 Aftermarket Solutions, Ref. No. [176] 1 Product Description Cutler-Hammerா Low Voltage Busway from Eaton’s electrical business consists 2 of aluminum or copper bars inside a metal housing used for power distribu- Standard Plug-in Electric Utility (dc) 3 tion. Busway is available in ampere ratings of 100 – 5000 amperes. Busway is available as feeder (indoor or outdoor) 4 and plug-in. Feeder busway routes power from point-to-point, whereas plug-in busway allows for power to be 5 tapped off along a run as needed. Busway is typically used in manufac- Low Impedance Feeder H5000 Plug-in 225 – 1000 Amperes turing buildings and high rise office 6 buildings. 7 Product History Westinghouse began marketing low 8 voltage busway in 1938. The first prod- uct offering was Power Distribution H5000 Feeder Low Impedance Plug-in Busway, utilizing a multiple bolt joint 9 that later evolved into Standard Plug- in Busway. Victory Bus Duct was 10 developed during the Second World War to comply with federal limitations placed on usage of materials such as 11 steel and copper which were critical to the war effort. In 1947, Westinghouse began manufacturing busway at the High Frequency Current Limiting 12 newly acquired facility in Beaver, PA with Standard Plug-in and feeder bus in ratings up to 1500 amperes. All of 13 these early designs used separated, uninsulated bus bars inside a totally Typical Pow-R-Way Plug-in Straight Length Typical Pow-R-Way II Plug-in Straight Length 14 enclosed or perforated steel housing. In 1951, Low Impedance Feeder Westinghouse High Frequency In 1958, Westinghouse sold the rights to 15 Busway was introduced as the first Busway was introduced in 1958 to the Life Line Unibus product line to EDP design to utilize heat shrinkable tubing address the inherent problems of of Allentown, PA which marketed EDP for insulation on the bus bars and a transmitting power at frequencies Unibus until 1962 when EDP became 16 ventilated steel housing. An internal from 180 to 20,000 Hz. Cutler-Hammer a wholly owned subsidiary of Eaton. ground bus was not available with this High Frequency BV (balanced voltage) Eaton successfully marketed Unibus product line but provisions were made Busway was also marketed during the until the product line was discontinued 17 for mounting an external ground bus late 1950s and early 1960s. Westing- in 1974. directly to the busway housing. Low house High Frequency Busway and Impedance Feeder and Standard Plug- Cutler-Hammer BV Busway both found In 1966, Westinghouse introduced its 18 in Busway accounted for the majority success in aircraft manufacturing plants, first true sandwich bus design with of busway business written by West- industrial induction heating systems, H5000 feeder busway. H5000 was also 19 inghouse through the 1950s and into military missile and radar bases. the first single bolt joint design offered the 1960s. Low Impedance Plug-in by Westinghouse and it initially Electric Utility Busway was also intro- utilized a PVC shrink tubing and later Busway was introduced in 1961. With ா 20 this design, the product offering was duced by Westinghouse in 1958 and a Mylar wrap for bus bar insulation. expanded to a maximum of 5000 was designed to conduct direct current A combination of steel and aluminum amperes for feeder and 4000 amperes with low voltage drop. By 1963, Elec- channels were used to form a light- 21 for plug-in. tric Utility Busway had been expanded weight non-magnetic housing. The to meet the growing industrial market grounding method for H5000 was sim- During the 1950s, various other designs for direct current power and was mar- ilar to Low Impedance Busway and an 22 were introduced to meet specific cus- keted simply as dc Busway. This prod- external ground bus mounted onto the tomer needs. Westinghouse Lifeline uct line was applied to feeding plating housing was the only offering. H5000 Unibus, rolled out in 1955, provided processes, welding installations, mill Plug-in Busway rolled out in 1968 as a 23 low impedance characteristics with drives and motors. non-sandwich design with separated plug-in openings and incorporated and uninsulated bus bars. flexible armored cable into the design 24 for use as elbows, offsets and flat to edgewise adapters. 25 For more information visit: www.EatonElectrical.com CA08105001E YES_Book.book Page 3 Monday, February 27, 2006 10:20 AM Busway (Low Voltage) 9-3 Electrical Aftermarket Products and Services March 2006 Aftermarket Solutions, Ref. No. [177] Product History (Continued) Product History Time Line 1 In 1970, the Eaton’s Cutler-Hammer Bethlehem, PA plant introduced CP2 Product 1935 1940 1945 1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 Present SAFETYBUS which utilized an innova- Power Distribution Bus 2 tive single bolt, bridge joint design with a steel housing for plug-in and a Victory Bus Duct 3 combination of steel and aluminum Standard Plug-in channels for the feeder housing. CP2 used a Mylar wrap for bus bar insulation Low Impedance Bus 4 ா and an Alstan process for plating. Life Line Unibus The feeder busway was a sandwich design while the plug-in design uti- High Frequency Bus 5 lized separated bus bars which were Cutler-Hammer BV Bus braced and supported by corrugations formed in the housing sides. Current Limiting Bus 6 Westinghouse introduced the Pow-R- Electric Utility Bus Way product line in 1971. Pow-R-Way dc Busway 7 employed the sandwich design in both feeder and plug-in. At that time Pow- 100 Ampere Busway 8 R-Way utilized a combination of PVC, Low Impedance Plug-in applied by the fluidized bed process, and Mylar sheeting for bus bar insula- Cutler-Hammer Unibus 9 tion which achieved a Class A, 105°C H5000 Feeder rating. Silver-plating of all joint and contact surfaces was applied by a Zin- H5000 Plug-in 10 cate process. Pow-R-Way is a bolt-end/ Cutler-Hammer CP2 slot-end design with a single bolt con- nection at the joint and is rated from Pow-R-Way 11 600 to 5000 amperes. Pow-R-Way II Pow-R-Way II was rolled out in 1975 with ratings of 225 and 400 amperes in feeder and Cutler-Hammer CP3 12 plug-in. Pow-R-Way II is a single, cap- tive, bolt per bar design for indoor, Cutler-Hammer CP4 13 horizontal applications only. Pow-R-Way III During 1980, the Cutler-Hammer Figure 9-1. Product History Time Line 14 busway design was upgraded and they began marketing CP3 SAFETY- In 1988, Westinghouse moved the Cutler-Hammer Pow-R-Way III was BUS. CP3 featured an improved bridge busway product line to the Green- introduced In 1997. As in the past, spe- 15 joint package and a polyethylene wood, SC manufacturing facility. At cific customer needs have driven the terephthalate wrap for bus bar insula- that time an improved Alstan plating design of this product line. High short tion. CP3 maintained the CP2 housing process was implemented for silver- circuit ratings, finger safe protection at 16 design with bus bar separation in the plating the joint and contact surfaces. the plug-in openings, integral housing plug-in product configuration. In 1993, the automated fluidized bed ground path, two-piece extruded alu- process was changed to Class B, 130°C, minum housing, and an optional 200% 17 Cutler-Hammer CP4 SAFETYBUS was epoxy insulation. neutral are just some of the features introduced in 1985 and incorporated with this product line. the sandwich design into the plug-in 18 busway. CP4 featured a ULா recognized case ground path rating, and 130°C Mylar bus bar insulation. CP4 utilized 19 the CP3 bridge joint package and accepted CP2 and CP3 Bus Plugs. 20 The CP4 product line was successful in both the commercial and industrial markets until it was discontinued 21 in 1994. 22 23 24 25 CA08105001E For more information visit: www.EatonElectrical.com YES_Book.book Page 4 Monday, February 27, 2006 10:20 AM 9-4 Busway (Low Voltage) Electrical Aftermarket Products and Services March 2006 Plug-in Units Aftermarket Solutions, Ref. No. [178] 1 Replacement Capabilities Vintage Busway Products Table 9-1. Replacement Capabilities ■ Replacement pieces or additions to Busway Bus Adapter ᕃ Plugs vintage Cutler-Hammer bus (CP2, CP3, 2 Types CP4) are being handled whenever possible by making transition to our Power Distribution Bus No No No current design Pow-R-Way III bus.