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BULLETINSpectra series buswayBusway vs. wire and conduit

TA B L E O F C O N T E N T S3Table of contents01 Heavy-duty power in alight package02 – 10 Spectra series busway

4S P E C T R A S E R I E S B U S WAY B U S W AY V S . W I R E A N D C O N D U I THeavy-duty power in a light packageSpectra series busway makes the most sense for commercial andindustrial electrical distribution applications that require up to 6000amps of capacity with short-circuit protection.Since Spectra series busway is lighter than wireand conduit, it’s easier to handle and hang. Itscompact design is ideal for applications wherespace is critical and eliminates the time-consumingtasks of stripping, preparing and pulling wire.All of these advantages translate into lower deliverycosts, simple storage and handling, lower totalinstalled costs, and increased space for moreequipment. Spectra series busway providesmaximum flexibility. In contrast to the fixed natureof wire and conduit, busway will grow as facilitiesexpand.Due to its modular design, busway runs can beeasily added, or disassembled and relocated withminimal effort. The greatest testimonial to ABBbusway is actual field experience. ABB is a marketleader and preferred product for a wide varietyof demanding applications. Many of our buswayproducts are still being used in these environmentsafter more than 30 years.From every point of view – flexibility, performanceand initial cost – Spectra series busway is the clearchoice for your next installation.

BULLETIN5Spectra series buswayCustomer feedback and structured focus groupsprovided the foundation for this busway product.Customers asked for lighter and smaller power bussystems that were flexible enough to expand orrealign in facilities as needs changed. They neededhigher amperage tap-offs and the ability to isolatesections without taking the entire structure offline.They asked for joints that were sturdy, safe andeasy to maintain, but were flexible enough toaccommodate late-point installation issues.Simpler is betterABB produced a compact design resulted in theseimprovements over wire and conduit installations: 50% minimum decrease in size Up to 50% decrease in weight Increased adaptability and versatility Higher short circuit ratings Improved installation and operational safety Fully tested and certified to UL, ANSI, CSAand ASTA standardsKey features and benefitsDecreased sizeIn a typical 1200 amp ceiling-hung application,busway will run 4.5"x7" vs. 4"x16" with wire andconduit. This allows busway to run in more placesaround and in between existing pipe and ductwork.Decreased weightIn the same 1200 amp, 3 wire application,aluminum busway weighs only 8 lbs./foot vs.19 lbs./foot with copper wire and EMT conduit.This dramatically saves on structural weightallowance making more efficient distributiondesigns possible and reduces installation time(per NECA labor standards).Frequent high amperage tap-offsA bolted power take off device provides up to1600 amps protection at every joint, plug-in orfeeder. Additionally, tap-off provisions on standardbusway allow for 10 locations per 10 foot section.These features offer maximum flexibility indesigning or modifying distribution systems.Section isolation without long shutdownsRemovable isolation joints allow an operator tocleanly and safely remove a section of busway andallow the remaining system to come back on-line.This allows ease of maintenance and modificationwith minimal facility downtime.IBC 2015 and OSHPD Seismic certificationstandardSpectra series busway can be used in seismicconditions without restrictions, special bracing,connections to equipment, or hangers. This saveson installation time and costs due to additionalcomponents.Virtually no maintenanceWhen fully torqued, Belleville joint washers have ahigh deflection, losing only 14% of their contactforce over an expected 50 year life. This preventsoverheating joints – the primary cause of buswaymaintenance.

6S P E C T R A S E R I E S B U S WAY B U S W AY V S . W I R E A N D C O N D U I TSmaller sizeSpectra series busway dimensions begin at4.5"x4.4" for 225-800 ampere ratings, and rangeup to only 4.5"x23" for the highest ratings. A singledrop-rod hanger per 10-foot section can be usedfor ratings up to 2000 amp for aluminum buswayand 2500 amp for copper busway.FlexibilitySpectra series Plug-In busway has tap-offprovisions at 24-inch intervals on both sides,leaving a total of ten locations per 10-foot section.This allows safe and quick connection of a switch(up to 600 amp) or circuit breaker (up to 800 amp).Load-side cable connections from the buswaycircuit breaker, fuse or plug to the equipmentare short and direct.A Spectra series busway plug can be installed orremoved safely within a matter of minutes. Theplug-assist and position plug locators simplifyoperation, ensuring a safe and positive connection.In addition, a 1/2" adjustability built into everySpectra series busway joint allows greaterfreedom during installation and adjustment.Safe operationSpectra series busway has many features thatensure safe operation by personnel: Conductors that are fully enclosedEnsures the highest standards for safetyare maintained per UL guidelines Polarized plug-in unitsPolarized engagement of the plug to the buswayprovides the installer with positive plug/phasealignment Plug-in units on installation are automaticallygroundedFirst-Make-Last-Break type contactors helpprotect the user during installation and removalof bus plugs Cover, device and plug interlocksHelps to protect the installer by prohibitingthe opening of the plug door or removal whenthe plug is in the ON position Provision for padlocking the plugin the OFF positionWith up to 3 lock positions per plug, this productfully supports Lock-Out/Tag-Out (LOTO)programs to prevent unauthorized user accessto the electrical distribution system Integral housing groundThe all-aluminum housing forms a complete360 high level ground path for ground faultsand serves as a continuous bond betweenbusway sections, fittings and bus plugs4.5”114 mm3.5”89 mm8.5”22 cm83”211 cm—Common application – 2000 amp, 600 volt, 3 phase / 4 wireand nuts.Requirements: 12, 500 MCM cables in 6" rigid conduit.—Compact 1.506000-29.75Dimensions: Representative in inches for aluminum and copperhousings. All depths are 4.5".—Low 6886Pounds / 1 foot run: Representative for aluminum and copper housingswith 3 wire and 4 wire applications.

BULLETINLongevity and durabilityInsulation is at the heart of any electricaldistribution system, and a durable, long-life epoxyinsulation is used in Spectra series busway. Spectraseries busway 130 C Class B epoxy insulation isunique in the world of low- voltage busway. Epoxyinsulation has been in use with busway for the past30 years. When compared to PVC and Mylar, testresults show that epoxy has a significantly longerlife (50 years), higher impact strength (150 lbs) andsuperior chemical and water resistance. Epoxy isimpervious to acids, alkalis, acetones, machiningoils and lubricants commonly foundin industrial environments.Epoxy-coated busway tested for flammability wererated self-extinguishing by UL laboratories. This isin contrast to PVC, which emits poisonous fumes ina fire. The Belleville spring joint design has beentested in over 35 years of field experience.7Once properly tightened, it does not have to beretightened each year, as some manufacturersrecommend. It only requires a periodic visualinspection.Fully testedSpectra series busway has undergone thoroughtesting according to ANSI/UL 857, NEMA BU-1,federal specification W-B-811b, CSA and ASTA.Testing included (but was not limited to) heatrise, short circuit and ground fault.Seismic certificationThe complete standard commercial offering ofSpectra series busway is certified for IBC 2015Seismic conditions as witnessed and approved(by the tests performed) at Wyle Laboratories inHuntsville, Alabama. The maximum acceptableparameters are below.Parameters according to vertical riser and horizontal configurationsMaximum acceptable parametersVerticalHorizontalRatings5000A CU; 4000A AL6000A CU; 4000A ALVoltage600V600V16 feet10 feetN/Ax¹x¹x¹Edgewise and flatwise orientationDistribution plug-in and feederStandard hangersHanger spacingFull threaded drop rodDrop rod connectionBus plugsFittingsCable tap boxesEnd boxesAll applications approvedProximity to walls¹ – Drop rod must be bolted through ceiling/floor and secured on both sides with standard washers and nuts.

8S P E C T R A S E R I E S B U S WAY B U S W AY V S . W I R E A N D C O N D U I TAdaptability and versatilityA wide variety of Spectra series busway optionsare available to fit specific applications. Mostapplications will fall into four categories.Installation labor costsAluminum housingLabor hrs / ft.432108001000120016002000250030004000Wire and ConduitBuswayInstallation labor costsCopper housingLabor hrs / ft.4321080010001200160020002500300040005000Wire and ConduitBuswaySpectra series busway plug-in labor measurements are the sameas feeder labor measurements Service entranceBrings power from utility transformers into amain disconnect or distribution switchboard Single loadA long horizontal busway run that feeds asingle load, such as a switchboard or motorcontrol center Multiple loadUsed where power requirements are distributedover a large area, such as with productionmachinery RiserVertical run to economically feed high-risebuildingsSpectra series busway is available in bothsilver-plated aluminum and tin-plated copperat amperage capacities of 225-6000 AC and600-8000 DC for low voltage applications.Variations and components are available for allindoor, drip-proof and outdoor applications. ABBalso offers a wide variety of tap-off devices, ofwhich fusible switches and molded case circuitbreakers are the most common. Busway plugsavailable in E, F, G and K frames provide thefollowing benefits: Simplified field changeover with adjustabletrip-amp rating plug More accurate and reliable trip interruptionwith true digital sensing Higher interruption capacity Optimal service life, performance and safety

BULLETINWeather protectionSpectra series busway provides optimumperformance in even the most severe weatherenvironments. WeatherShield Epoxy Joint Insulatorsare designed for long life and help to reducemaintenance. Joint bolt access is via easilyremoveable, UL listed/CSA certified rain-tightsantoprene plugs In addition to our standard housing draw holes,extra drainage channels through die cast housingspacers help eliminate standing water near joints—Splash-proof applicatipos: Innovative Joint Shield designprovided with drip-proof, splash-proof and outdoor bus9 Gasketing materials and sealants are rated forextreme temperatures (-40 to 250 F and -40 to 200 F respectively) and are tested to verifysuperior UV resistance and excellent stabilitywhen subjected to long term thermal aging.The joint shield, as shown in the photo below,uses an integral spring latch clamping system.This system provides optimum gasketcompression at all joint connections, andeliminates the need for additional jointcover hardware—Outdoor applications: Complete outdoor run of Spectra series buswayWeather joint protectionConstruction typeIEC degree requiredJoint insulatorIndoorFeeder (NEMA 1), Plug-in, RiserIP-40StandardDrip ProofFeeder, Plug-in, RiserIP-43StandardSplash ProofFeeder, Plug-in, eeder (NEMA 3R)