Busway Series B60, B100C, B100, B160, · PDF fileBusway Series B60, B100C, B100, B160, B225 Products, Components and Accessories

Busway SeriesB60, B100C, B100, B160, B225Products, Components and Accessories

www.uecorp.com

For an authorized dealer or more information call toll free 800-333-3490 or 412-221-4400

Contents

General Information 1-2

B60 Busway Series 3-14

B100C Busway Series 15-16


B100N Busway Series 26-27


Busway Accessories 35

Starline Track Busway vs. Conduit and Wire 36

Starline and Trunk Busways Combination 37-38

Starline Layout Guidelines 37

25 Foot Tap Rule 38

Lighting Busway 39

Busway Applications 40

Retail Store Custom Layout 41

Data Centers and Mission Critical Industries 42

Application Illustrations 42-44

Specifications 45


Track Busway is the best way!

No more conduit and wire!See page 36 for details.

1

-Continued

Starline Plug-InBusway System

The Busway Solution

Features• Extruded aluminum housing

that is rugged and attractive

• Solid copper conductors —not aluminum

• Continuous access slot inhousing for plug-in units

• Continuous insulation aroundbus bars

• Standard lengths of 5, 10 and20 feet

• Support spacing 10 feet

• Can be rod or cable suspended,ceiling surface mounted orrecessed in a drop ceiling

• 100% capacity groundstandard or isolated

• 100% and 200% capacityneutral sizes available

• UL and CUL listed. Meets ULstandard 857, Busways andAssociated Fittings. Complieswith Article 364 of NationalElectrical Code.

• 60, 100, 160 and 225 amperecontinuous, 300, 600 or480Y/277 volts, 2, 3 or 4 pole,with ground, 200% neutral,60 and 400 Hertz

• Compact

• Lightweight — about halfthe weight of steel enclosedbusway

• Variety of plug-in units

• All plug-in units are polarized

• Electrical connection is notmade until twist plug is fullyinserted and rotated

• Suitable for feeder or branchcircuit applications

• Easily extended, removedor relocated

• Snap-in closure strip closesplug-in slot

General Information

Starline Track Busway is thesimple, versatile, fast andeconomical solution for supplyingpower to electrical loads. Thebusway can be tapped at anylocation with a variety of plug-inunits. Eliminated are panelboards, long runs of conduit andwire and expensive installationcosts. The UL/CUL listed buswayis for indoor use as a feeder orbranch circuit as covered inArticle 364 — Busways of theNational Electrical Code.

A continuous slot on the bottomof the busway housing permits

insertion of plug-in units. Thebusway is available in 2, 3 or 4poles and rated at 60, 100, 160and 225 amperes, 300 and 600volts. The extruded aluminumhousing is approved as 100%capacity ground. The solid copperconductors are continuouslyencapsulated in insulation andcomply with the latest ULrequirements for protectionagainst accidental contact of liveelectrical parts. Standard lengthsare 5, 10 and 20 feet. Standard20 foot sections mean fasterinstallation and fewer splices inthe conductor. A busway sectionweighs about half the weightof a steel enclosed busway.

The housing is compact, yetrugged enough to be supportedat 10 foot intervals.

The extruded aluminum housinghas a modern attractiveappearance not found in steelenclosed busways. Buswayimproves the appearance ofevery application. The electricalconductors are available only incopper for better conductivity.

Visit our Web site for more information, including our video sequence of the“turn-and-lock” Starline Track Busway feature! www.uecorp.com


Continuous Access Busway, Turn-and-Lock Plug-in Units

General Starline TrackBusway Information

Continued-

Standard ells and accessoriescomplete the installation. Plug-inunits include the economicaloutlet box, circuit breaker,fuses and terminal blocks. Thepolarized electrical connection ismade by inserting the plug headinto the slot of the busway.Electrical connection is madewhen the box is rotated. Powerfeed options include end or top-feed boxes as well as power feedplug-in units.

ApplicationsStarline Track Busway Systemsare ideal for a wide variety ofuses. Because the sizes aresmaller than most buswaysystems, they meet the needsand budgets of applicationswhere larger busway systems arenot normally used. In addition,Starline Track Busway is alsoideal for branch busway linescoming off of larger feederbusway systems.

Popular Applications Include:• Electronics manufacturing

• Work stations power supply

• Machine shops/factories:machine power supply

• Production/assembly lines

• Sewing machines

• Factory lighting

• Commercial/retail lighting

• School shops/Vo-Tech centers

• Lab equipment power supply

• Clean room power supply

• Office environment: built intodrop ceilings; use with plug-inpoles

• Branch busways from largerfeeder busway systems

2

Install busway plug-in units in seconds, with no tools, with the “turn-and-lock” feature shown above. Insert plug-in unit intocontinuous access slot of energized busway section, turn 90 degrees, and unit is installed. Some units also use mounting bolts.Units may be removed without turning off power to the busway.

Starline Track Busway is ideal for supplying power to all kinds of electrical loads, such as production equipment,machine tools, sewing machines, appliances, etc.


B60 Busway Series

B60 Plug-in Busway Series

∂ Solid Copper ConductorsCopper rather than aluminumis standard since copper isuniversally acknowledged asthe best choice. 60 amps,300 and 600 volt ratings —2, 3 or 4 pole, 10,000 ampshort circuit rating.

∑ Continuous MountingChannelContinuous mounting channeldoes not require exact spacingof supports. Hanger spacingup to 10 feet apart.

∏Continuous InsulatorThe busway insulator iscontinuous and complies withthe UL “Finger Safe Probe”standard. Other busbarsystems place an insulatorspacer at 12 to 18 inchintervals only. The B60Busway insulator and coppercan also be supplied andinserted into the busway runin one piece.

π Continuous Access SlotThe continuous access slotallows the plug-in units to beattached to the busway at anylocation. They can be as closetogether or as far apart asdesired.

∫ Extruded Aluminum HousingHousing design combinesstrength, lightweight and cleanappearance. The lightweighthousing, about half the weightof steel-enclosed busway,makes 20 feet sections notonly possible but practical. Thealuminum enclosure is superiorfor 400 Hertz systems.

Polarizing LipThe aluminum housing has apolarizing lip on one side ofthe access slot. This prevents“backwards” installation ofplug-in units. All buswaysections are installed withthe polarizing lip on thesame side.

❻Ground ConductorThe extruded aluminumhousing is 100% capacityground. There is no need topurchase and install specialground kits for the plug-inunits. This is standardequipment, not an extra.

❼Plug-in UnitsMany types of plug-in unitsare available. These includethe outlet box, fused,receptacle, terminal block,and circuit breaker plugs.They can be installed at anylocation along the busway runby simply inserting the plughead and rotating 90 degrees.

Voltage Drop:Length of busway for a one voltdrop in the line to line voltagefor a distributed load of 60amperes:Three phase, .8 PF 45 feetSingle phase 40 feet

Elevated TemperatureOperation:

Amp RatingAmbient Temp. Multiplier40˚C / 104˚F 1.0045˚C / 113˚F 0.9550˚C / 122˚F 0.9055˚C / 131˚F 0.8560˚C / 140˚F 0.8065˚C / 149˚F 0.7470˚C / 158˚F 0.67

3


Plug-in Busway Sections

Catalog # Description Length WeightB60-5-2 60 amp, 2 pole ground 5 feet 5.0 lbsB60-10-2 60 amp, 2 pole ground 10 feet 10.0 lbsB60-20-2 60 amp, 2 pole ground 20 feet 20.0 lbsB60-5-3 60 amp, 3 pole ground 5 feet 6.0 lbsB60-10-3 60 amp, 3 pole ground 10 feet 12.0 lbsB60-20-3 60 amp, 3 pole ground 20 feet 24.0 lbsB60-5-4 60 amp, 4 pole ground 5 feet 6.2 lbsB60-10-4 60 amp, 4 pole ground 10 feet 12.5 lbsB60-20-4 60 amp, 4 pole ground 20 feet 25.0 lbsB60-xxC-4 60 amp, continuous, 4 pole groundB60-xxC-3 60 amp, continuous, 3 pole groundB60-xxC-2 60 amp, continuous, 2 pole ground

Legend Color With polesN white or yellow 2, 3 & 4Ø blue 2, 3 & 4Ø black 3 & 4Ø red 4

ground housing

Typical Busbar Configuration

xx = total length of busway run, up to 200 feet standard.

Above catalog numbers are for the 300 volt rated system.For 600 volt rated system, add “-600” to the catalog number.

Busway SectionDiagrams

B60 Busway Series

B60 Busway Parts

B60 Busway SectionsStandard busway sections comein 20, 10 and 5 foot lengths.The system meets the require-ments of Underwriters Laborato-ries Inc. UL857 Standard. Ratedat 60 amps continuous duty,600, 300 and 480Y/277 voltstyles. The solid aluminumhousing is approved as a 100%capacity ground. Sections areavailable in 2, 3 and 4 polewith ground. Short circuitcurrent rating at 10,000 amps.UL listed.

Power feed to the buswaysections may be wired to matchstandard wire color coding of theplug-in units. This is especiallyhelpful when single phase loadsare to be tapped off of four polebusway, to obtain a balancedload. See chart.

Busway sections can be suppliedin painted colors to match jobrequirements. Consult thedistributor or factory for moreinformation. Also see page 37,“Starline Track Busway LayoutGuidelines.”

Continuous BuswayB60 systems can also beprovided with continuous rollsof insulator and busbars with nojoints. Rolls of pre-assembledinsulator with busbars are cutand shipped for the specificlength of the busway run.Standard lengths are up to200 feet long. Consult factoryabout longer continuous runs.Insert the insulator/busbars intothe housing at one end of thebusway run, and push it in.See illustration at right.

4

1.790(45.5)

(65.

5)

2.580


6”

HC-1Housing CouplerDiagrams

B60 Busway Series

B60 Busway Parts

Housing CouplerSections of B60 Busway arejoined mechanically by means ofa housing coupler. The standardhousing coupler, design typeHC-2, is comprised of anextruded aluminum plate. Insertthe coupler into the top cavityof the end of the sections to bejoined. Tighten the bolts tocomplete the installation.

Design type HC-1 telescopesover the busway housing andalso covers the ends of thesections to be joined. Securethe coupler by tightening thetwo bolts on the top.

Housing Coupler Designs

Catalog # Description WeightHC-1 coupler, wrap around 0.4 lbHC-2 coupler, plate 0.8 lb

5

HC-2

2.6”

1.750

6.000


B60 Busway Series

B60 Busway Parts

Bus ConnectorSections of B60 Busway arejoined electrically by means of abusbar connector. This is shownin the figure to the right. Busconnectors are available in 2, 3and 4 pole configurations, andhave a voltage rating of 600volts. The connector is installedby inserting it in each end ofthe sections to be joined, thentightening the compressionscrews to make a reliable busbarconnection. The same busconnectors are used for theB100C series, and are UL listedfor 100 amps.

End CapsThe end cap is used to close offthe open ends of the buswayrun. It is made of steel andinserts into the end of a buswaysection. The end cap is securedto the housing with a set screw.

End Cap Design

Catalog # Description WeightEC60 end cap 0.2 lb

Bus ConnectorDiagram

InstallationDiagram

Bus Connector

Catalog # Description WeightBC-2 connector, 2 pole 0.3 lbBC-3 connector, 3 pole 0.3 lbBC-4 connector, 4 pole 0.4 lb

1.83”

2.44”

6

End CapDiagram

6.0001.740


WHR-1

B60 Busway Series

B60 Busway Parts

HangersB60 Busway features theconvenience of a continuoushanger access slot. This allowshanger support anywhere alongthe busway run. Typical hangersupport spacing is 10 feetmaximum.

The standard hanger, typeTHB-3 fits in the mounting slotin the top of the busway. It hasa 3/8 - 16 by 1 inch stud forrigid mount. It can be insertedin the middle of a buswaysection, with its twist-in design.

Type RHB-3 is designed for fast-ening to all thread rods. A 3/8inch rod coupler, lock washerand square cinch plate are addedto the standard hanger.

The weight hook ring, catalognumber WHR-1, can be used asa hanger for suspending thebusway from chains or cables.It is also used to hang loads upto 50 pounds under the busway,such as light fixtures, tools, andbalancers. It can be attached tothe top or bottom channel ofthe busway housing. The ACH-1and ACH-2 aircraft cable hangerassembly includes a B100 hangerplate, and an easy grip clampassembly for steel cable. Cable isnot included.

The T-bar hanger clip is used tomount the busway system to theinverted T-bar of a drop ceiling,just below the ceiling tiles. Theclip locks onto the T-bar and thebusway fastens to the stud onthe clip. The T-bar must beadequately anchored to thebuilding. Not recommended forheavy loads.

Hanger Designs

Catalog # Description WeightTHB-3 twist-in hanger 0.2 lbRHB-3 rod mount hanger 0.3 lbWHR-1 weight hook ring 0.2 lbTHB-4 T-bar mounting hanger 0.1 lbACH-1 cable suspension hanger assembly,

1/16” cable 0.3 lbACH-2 cable suspension assembly,

3/32” cable 0.3 lbTHB-1/4 hanger with 1/4” stud 0.2 lb

7

THB-3 RHB-3 ACH-1


Power Feed Designs

Catalog # Description WeightEPF60-2 end power feed, 2 pole 3.3 lbsEPF60-3 end power feed, 3 pole 3.3 lbsEPF60-4 end power feed, 4 pole 3.5 lbsEF60-2 end feed, 2 pole 3.3 lbsEF60-3 end feed, 3 pole 3.3 lbsEF60-4 end feed, 4 pole 3.5 lbsEFC60-2 end feed connector, 2 pole 2.0 lbsEFC60-3 end feed connector, 3 pole 2.0 lbsEFC60-4 end feed connector, 4 pole 2.3 lbsPF60-2 universal, 2 pole 4.5 lbsPF60-3 universal, 3 pole 4.7 lbsPF60-4 universal, 4 pole 4.8 lbs

B60 Busway Series

B60 Power Feed Units

End Power Feed ConnectorStandard power supply to theStarline Track Busway is with theend power feed connector unit.It consists of a steel junctionbox with removable side, apower feed connector to insertinto the busway run, andterminal block in the box forfield connections. The unit isbolted to the first section of thebusway run. UL listed at 600volts.

End Power FeedThis is the same as the aboveunit, except it has a six inchsection of busway feedinginto one end of the box. A busconnector and housing coupler(not included) is used toconnect it to the busway run.600 volt rating. UL listed.

Universal Power FeedThe universal power feed isdesigned to be installedanywhere along the run of thebusway. Insert the power feedhead into the busway run wheredesired during installation, andsecure it with a hanger bolt(supplied). A terminal block isprovided in the box for fieldconnections. Power cord is fedin from under unit. 600 voltrated. UL listed at 60 amps.

End Feed ConnectorThis design of power feed isused primarily in applicationswhere aesthetic appearanceis important. Wire leads arepreassembled to the connectorunit and eliminate the junctionbox on the busway. Twenty-fourinch wire length is standard, butany length can be supplied.

UniversalPower Feed

End PowerFeed

8

4”

8”

6”

8”

End FeedConnector

3”

4”


B60 Busway Series

B60 Power Feed Units

Center Feed SectionThe center feed section is usedto supply power in the middleof a busway run. CF60 seriesconsists of a 2-foot section ofbusway, with a junction boxconnected to the top of thebusway and a 60A rated terminalblock inside.

For aesthetic applications, thePW60 series center feed 2-footsection without the junction boxis available. A 1 inch conduitsize access hole is in top forothers to run wires to the con-nection lugs inside the buswaysection. 1 inch conduit mount-ing adapter included. Busbarconnectors and housing couplers(not included) are used toconnect center feed sectionsto adjacent sections. UL listed.

The universal power feed isanother type of center feed,see page 8.

End Power Feed withAdapter to Trunk BuswayStarline Track Busways areideal as branch busway runs,to reduce the overall cost ofbusway. This unit provides thecomponents needed to connecta trunk busway tap box to theStarline end feed assembly and4 feet of flexible conduit andcable, 60A rated. See page 37for more details.

Center Feed Units

Catalog # Description WeightCF60-4 center feed, with box, 4 pole 5.0 lbsCF60-3 center feed, with box, 3 pole 5.0 lbsCF60-2 center feed, with box, 2 pole 4.8 lbsB60-X-4PW center feed, without box, 4 pole 2.0 lbsB60-X-3PW center feed, without box, 3 pole 2.0 lbsB60-X-2PW center feed, without box, 2 pole 2.0 lbsPFA60-4 power feed & adapter, 60A, 4 pole/ground 4.5 lbs

X = Busway section length.

End Power Feed withAdapter Designs

Center Feedwithout Box

Center Feedwith Box

9

24”

24”


Ell and Tee Designs

Catalog # Description WeightEL60-2-IH, EH ell connector, 2 pole internal, external 0.5 lbEL60-3-IH, EH ell connector, 3 pole internal, external 0.5 lbEL60-4-IH, EH ell connector, 4 pole internal, external 0.5 lbBT60-4IR tee, 4 pole, internal right 1.0 lbBT60-4IL tee, 4 pole, internal left 1.0 lbBT60-4ER tee, 4 pole, external right 1.0 lbBT60-4EL tee, 4 pole, external left 1.0 lb

B60 Busway Series

Starline Track BuswayElls and Tees

EllsElls are used for making a90 degree turn in the busway.Each ell consists of two powerconnectors wired together, and acorner box assembly. Insert theconnectors into standard buswaysections at the corner, and slidethem onto the corner box topplates. For vertical ells, consultfactory.

TeesTees operate similarly to ells,however, it is important tospecify correct wiring to thebranch run. Specify internal orexternal polarizing lip, left orright tee. See diagrams.

CrossoversCrosses are typically used forgridwork designs. They operatesimilar to the tees, however,special design requirementsapply. See page 37, layoutguidelines. Consult thedistributor or factory formore information.

TC60-4

BT60-4-IRInternal Right

BT60-4-ILInternal Left

BT60-4-ELExternal Left

BT60-4-ERExternal Right

ELC60-4

On projects requiring multiple Tees or Ells, contact factory for assistance at 800-333-3490

10

5.500 5.500

5.5009.000


11

Starjack Designs

Catalog # Description WeightOB60-15-2 outlet box Starjack, 15A, 2 pole 1.0 lbOB60-15-3 outlet box Starjack, 15A, 3 pole 1.1 lbsOB60-15-4 outlet box Starjack, 15A, 4 pole 1.3 lbsOB60-30-2 outlet box Starjack, 30A, 2 pole 1.1 lbsOB60-30-3 outlet box Starjack, 30A, 3 pole 1.2 lbsOB60-30-4 outlet box Starjack, 30A, 4 pole 1.3 lbsDRF60-A fused duplex receptacle Starjack, blue phase A 1.4 lbsDRF60-B fused duplex receptacle Starjack, black phase B 1.4 lbsDRF60-C fused duplex receptacle Starjack, blue phase C 1.4 lbs

*Add “-1F, -2F or -3F” for 1, 2 or 3 fuses in outlet box unit catalog number.

*Outlet box units 300 volts rated. For 600 volts, add “-600” to catalog number.

*Standard DRF units are 15 amp. Add ”-20” for 20 amp receptacle.

Outlet BoxStarjackDiagram

DuplexReceptacleStarjack Diagram

Fuses are available for Starjacksas an option. Fuseholders are forclass CC fuses, (i.e. Bussmantype KTK-R or Littelfuse typeKLK-R) UL listed for branchcircuit protections. Fuse dimen-sions are 13/32" diameter by1-1/2". Order fuses separately.

B60 Busway Series

B60 Plug-in Units

StarjacksPlug-in units are used to tap offthe power from the busway, forelectrical loads. The simplestdesign of plug-in units are calledStarjacks.

All Starline Track Busway plug-inunits have a special plug headwhich inserts into the buswaycontinuous slot, and twists90 degrees to make electricalconnection. All plug-in unitsare polarized to inhibit reverseinstallation, and come with abolt-on mounting tab and atwist lock clip which providesthe ground connection for thebox and the load.

Outlet Box StarjackOutlet box Starjacks include ajunction box, available in 15 or30 amps, and 300 or 600 volts.A screw cover, ground lug, wirenuts and cord grip are included.UL listed.

Duplex Receptacle StarjackThe duplex receptacle Starjack isthe same as the outlet box Star-jack, except it also features a 110volt, 15 or 20 amp rated duplexreceptacle, and includes a 15 ampfuse and holder. UL listed.


B60 Busway Series

B60 Plug-in Units

Starjack with Circuit BreakerStarjacks with circuit breakerconsist of a full-sized junctionbox with a hinged lid, plughead and an externally operablecircuit breaker. Insert the plughead in the busway and rotate90 degrees to make electricalconnections. The units arenormally supplied with thebreakers installed, or can besupplied without them, forcustomer to install onto snap-on mounting plate. Optionalreceptacles can be added tostandard circuit breaker units,as shown on right.

Circuit breakers can be 15 to30 amps (specify the rating),250 volt max or 480 volt max,1, 2 or 3 pole units. Units withmultiple circuit breakers areavailable and are UL listed.For ratings over 30 amps, andmultiple circuit breakers, consultfactory. Units have coppergrounding lug in the box, fitsup to #6 wire, mounting tabsand 2 hangers to secure unitto the busway. Units have1/2 inch and 3/4 inch conduitknockouts on 3 sides. UL listed.

Circuit Breaker Plug-in Units

Catalog # Description WeightCB60-WW-1-3 3 pole plug, 1 pole breaker, 250V max 3.3 lbsCB60-WW-2-3 3 pole plug, 2 pole breaker, 250V max 3.7 lbsCB60-WW-3-3 3 pole plug, 3 pole breaker, 250V max 4.2 lbsCB60-WW-1-4 4 pole plug, 1 pole breaker, 250V max 3.3 lbsCB60-WW-2-4 4 pole plug, 2 pole breaker, 250V max 3.7 lbsCB60-WW-3-4 4 pole plug, 3 pole breaker, 250V max 4.2 lbsCB60-WW-3-3-480 3 pole plug, 3 pole breaker, 480V max 4.0 lbsCB60-WW-3-4-480 4 pole plug, 3 pole breaker, 480V max 4.2 lbs

WW=Specify the ampere rating, 15 to 30 amps.

Starjack withCircuit BreakerDiagram

9.25”

2.5”

12

4.25”


13B60 Busway Series

B60 Plug-in Units

Starjack with Fuse BlockStarjacks with internal fuseblock consist of a full-sizedjunction box with a hinged lid,and a plug head. Insert the plughead in the busway slot androtate 90 degrees to makeelectrical connection.

A Class CC, 3 pole phenolic fuseblock is mounted in the box.600 volts max, 30 amp maxFor ratings over 30A, consultfactory. Fuses not included inunits, but can be orderedseparately. See page 35.

All units include a coppergrounding lug, mounting tabsand 2 hangers to secure unit tothe busway. Units have 1/2 inchand 3/4 inch conduit knockoutson 3 sides. UL listed.

Fused Starjack withExternal DisconnectStarjacks with internal fuseblock consist of a full-sizedjunction box with a hinged lid,plug head and an externallyoperable disconnect switch.Rocker handle disconnectscircuit before box can beopened. Insert the plug headin the busway slot and rotate90 degrees to make electricalconnection.

A Class H, 3 pole phenolic fuseblock is mounted in the box.600 volts max, 30 amps max.For ratings over 30A, consultfactory. Fuses not includedin units, but can be orderedseparately. See page 35.

Fused Plug-in Units

Catalog # Description WeightFD60-30-3-250-4 fuse block unit, 3 pole, 30A, 250V,

ext handle 5.2 lbsFD60-30-4-250-4 fuse block unit, 3 pole + 4W, 30A, 250V,

ext handle 5.2 lbs

3.25”

Fused Starjackwith ExternalDisconnect

10.37”6.37”

Fused Starjacks without theexternal disconnect assembly areavailable, but external discon-nect units are recommended.

All units include a coppergrounding lug, mounting tabsand 2 hangers to secure unit tothe busway. Units have 1/2 inchand 3/4 inch conduit knockoutson 3 sides. UL listed.


B60 Busway Series

B60 Lighting BuswayComponents

Internal PlugThe internal plug is ideal forapplications where the plugshould not be visible, suchas light fixtures and retail/commercial areas. It fits insidethe Starline Track Buswaysection, and is energized byturning the two circuit selectors90 degrees. A mounting platewith a 1/4 inch conduit sizeopening is for fixture connection.Small unit is rated 13A, (for16 AWG wires) 300V max, singlephase, with or without optionalfusible feature (class CC fuse notincluded) and wire nuts. Forballast or fixture applications,200°C high temperature wireis available.

The internal plug is alsoavailable rated at 25A max,(for 12 AWG wires) 300V singlephase, with optional fusiblefeature and has mini junctionbox and larger wire nuts.Optional 15A receptacleavailable in mini box.

The internal plug can also besupplied with a 3 meter SJO cordattached, and no mini box, ratedat 15A (14/3 SJO), or 20A (12/3SJO). Units are available withbasic cord grip or wire mesh cordgrip. UL listed.

Busway Light FixturesSeveral standard busway lightfixtures are available, includinglow bay, high bay, fluorescentsand floods. Consult factory. Seepage 7 for details on ACH-1cable suspension assembly.

Internal Plug Designs

Catalog # Description WeightIP60-A internal plug, unfused, phase blue 0.5 lbIP60-B internal plug, unfused, phase black 0.5 lbIP60-C internal plug, unfused, phase red 0.5 lbIP60-S internal plug, unfused, selectable to

phase blue or red 0.5 lb

Add “F” to above catalog numbers for fusible option.

Add “H” to above catalog numbers for a strain relief in mounting plate.

Add “MB” to above catalog numbers for a 25A unit with mini box.

Add “C15” to above catalog numbers for a 15A cord attached, 3M.

Add “C20” to above catalog numbers for a 20A cord attached, 3M.

Add “L10” to above catalog numbers for high temperature fixture wire.

Add “R” to above catalog numbers for built-in receptacle.

14

2.19”

3.19”

4.23”

4.23”


15


Catalog # Description Length WeightB100C-5-2 100 amp, 2 pole ground 5 feet 6.4 lbsB100C-10-2 100 amp, 2 pole ground 10 feet 13.0 lbsB100C-20-2 100 amp, 2 pole ground 20 feet 26.0 lbsB100C-5-3 100 amp, 3 pole ground 5 feet 7.0 lbsB100C-10-3 100 amp, 3 pole ground 10 feet 14.0 lbsB100C-20-3 100 amp, 3 pole ground 20 feet 28.0 lbsB100C-5-4 100 amp, 4 pole ground 5 feet 8.0 lbsB100C-10-4 100 amp, 4 pole ground 10 feet 16.0 lbsB100C-20-4 100 amp, 4 pole ground 20 feet 32.0 lbs

B100C Busway Series

B100C Plug-in Busway Series

B100C series plug-in buswaycombines the compact size of theB60 series with 100 amp ratedconductors. The result is a compact100 amp busway system with thecost efficiency of the 60 ampsystem. Plug-in units from the B60series are used, which also providegreater cost efficiency.

B100C Busway SectionsThe B100C busway sections arerated at 100 amps, 600 volts, 2,3 or 4 pole with ground. All thestandard design features of theB60 Busway series are included:copper conductors, aluminumhousing, continuous plug-in accessslot, insulator and mountingchannel, etc. The key differenceis the larger copper busbars,which have a rating of 100 amps.UL listed.

B100C Busway PartsThe B60 series housing couplers,bus connectors, end caps, hangers,closure strip and related parts(except power feeds) are usedfor the B100C series. See pages5-7. The bus connectors areUL listed at 100 amps.

B100C Plug-in UnitsAll plug-in units in the B60series may be used with theB100C series, including outletbox, receptacle, fuse block,circuit breaker and terminalblock plug-in units, as wellas the Internal Plug. Refer tothe B60 section of this catalogfor selections. See pages 11-14.UL listings on the B60 plug-inunits apply to the B100C seriesas well. If plug-in units over30 amps are required, use theB100 series Starline Track Busway.

Typical Busbar Configuration

Legend Color With PolesN white/yellow 2, 3, & 4Ø blue 2, 3, & 4Ø black 3 & 4Ø red 4ground housing

2.58”

1.79”


B100C Power Feed Designs

Catalog # Description WeightEPF100C-2 end feed, 100 amp 2 pole 3.5 lbsEPF100C-3 end feed, 100 amp 3 pole 4.0 lbsEPF100C-4 end feed, 100 amp 4 pole 4.0 lbsTF100C-2 top feed, 100 amp 2 pole 8.0 lbsTF100C-3 top feed, 100 amp 3 pole 8.5 lbsTF100C-4 top feed, 100 amp 4 pole 8.5 lbsEL100C-2-x elbow, 100 amp 2 pole 1.1 lbsEL100C-3-x elbow, 100 amp 3 pole 1.5 lbsEL100C-4-x elbow, 100 amp 4 pole 1.5 lbs

“x” = IH for internal or EH for external polarizing lip on housing.Tees and crossovers: consult factory for catalog number and design.

Use B60 Busway Series parts and plug-in units, on pages 5 to 14.

B100C Busway Series

B100C Power Feed Series

End Power FeedThe end feed power supply con-sists of a steel junction box, a100 amp, 600 volt terminal block,ground lug, and busbar connectorassembly. Insert the connectorinto the end of the busway run,fit the busway into the powerfeed box, and secure it with thehanger clamp. UL listed.

Top FeedThe top feed unit is for use whenpower supply comes from above,or in the middle of a busway runwhen a box out the end of thebusway is not wanted. A junctionbox with 100 amp terminals andground lug is connected to thetop of a two foot piece of busway.The same busway connectionsas the end feed are required.UL listed.

End Power Feed WithAdapter to Trunk BuswayStarline Track Busways are idealfor branch busway circuits toreduce the overall cost of abusway. An end power feed unitwith a four foot piece of 100 amprated flex conduit is provided toconnect to a tap box for a largertrunk busway run. Similar to unitsshown on page 9.

Ells, Tees and Custom WorkAn ell can be used for left or rightturns but specify if the polarizinglip is on the inside or outside, seepage 10. Tees and crossovers havemore than one configuration, —details are available from factory.Custom designed and built layoutscan be provided by supplying alayout drawing.

16


17B100 Busway Series

B100 Plug-in Busway SeriesDesign

∂ Solid Copper ConductorsCopper is a better conductorthan aluminum, and a betterelectrical performer. Systemrated at 100 amps, 600 volts,3 or 4 pole with ground.Busbars are channel shaped,and plug-in units have acompression fit into them.

∑ Continuous MountingChannelExact spacing of hangers notrequired. Hanger spacing upto 10 feet apart.

∏Continuous InsulatorThe busway insulator iscontinuous rather than 12 to18 inches apart like othersystems. The design complieswith the UL “Finger SafeProbe” standard.

π Continuous Access SlotPlug-in units can be attachedto the busway at any locationand density. Other systemslimited to one plug-in unitevery 2 feet or more.

∫ Extruded Aluminum HousingHousing design combinesstrength, lightweight andpleasing appearance. Abouthalf the weight of steelenclosed busway. Aluminumhousing is superior for 400Hertz systems.

❻Ground ConductorThe extruded aluminumhousing is 100% capacityground. No ground kitsneeded for the plug-in units.

❼Plug-in UnitsMany types of plug-in unitsare available, including unitswith outlet box, in-line fuses,fuse blocks, terminal blocks,and circuit breakers. They canbe installed anywhere alongthe busway run by simplyinserting the plug head androtating 90 degrees. Units arepolarized to inhibit incorrectinstallation.

Voltage Drop:Length of busway for a one voltdrop in the line to line voltagefor a distributed load of 100amperes:Three phase, .8 PF 62 feetSingle phase 53 feet

Elevated TemperatureOperation:

Amp RatingAmbient Temp. Multiplier40˚C / 104˚F 1.0045˚C / 113˚F 0.9550˚C / 122˚F 0.9055˚C / 131˚F 0.8560˚C / 140˚F 0.8065˚C / 149˚F 0.7470˚C / 158˚F 0.67


Typical Busbar Wiring

Legend Color With polesN white or yellow 3 & 4R red 3 & 4Bk black 3 & 4Bu blue 4ground housing

B100 Busway Series

B100 Plug-in Busway Sections

Standard busway sections comein 20, 10 and 5 foot lengths.The busbars are solid copper,and have a channel configura-tion. The sections includethe busbars protruding at oneend, which fit into the busbarchannel of the next section. Aspecial installation tool is usedwith each system, to push thesections together. The stabsof the plug-in units push intothe busbar channel for a solidelectrical connection. Housingcouplers join adjacent buswaysections, ordered separately.The busway sections havecontinuous insulator for the fulllength of the section, providingsuperior short-circuit protection,and a finger-safe design.

Rated at 100 amps, 600 volts,50/60 Hertz. It is also ideal for400 Hertz applications. Thealuminum housing is approved asa 100% capacity ground.Sections are available in 3 and 4pole with ground. Short circuitcurrent rating at 10,000 amps.UL and CUL listed.

Power feed to the buswaysystem should be wired to matchthe wire color coding of theplug-in units, especially whensingle phase loads are to betapped off of four pole busway.See chart at right.

Neutral Sizing with Harmonics:When the load on the buswaycreates significant harmoniccurrents, consideration must begiven to the rating of the neutralconductor(s). See page 26 forStarline Track Busway with 200%neutral and isolated ground bars.


Catalog # Description Length WeightB100-3PG-5 100 amp, 3 pole/ground 5 feet 12.5 lbsB100-3PG-10 100 amp, 3 pole/ground 10 feet 25.0 lbsB100-3PG-20 100 amp, 3 pole/ground 20 feet 50.0 lbsB100-4PG-5 100 amp, 4 pole/ground 5 feet 13.0 lbsB100-4PG-10 100 amp, 4 pole/ground 10 feet 26.0 lbsB100-4PG-20 100 amp, 4 pole/ground 20 feet 52.0 lbs

18

2.375”

4.187”


19

Busway Parts Designs

Catalog # Description WeightBHC-1 housing coupler, pair 0.2 lbEP-1 end piece, for B100 1.0 lbEC-1 end cap, for B100 0.1 lbCS-1 closure strip, for B100 0.1 lb/feetB100IT installation tool 2.5 lbs

B100 Busway Series

B100 Busway Parts

Housing CouplerThe standard housing coupler isused to join adjacent buswaysections mechanically. Suppliedin pairs, for top and bottom ofhousing positions. Order onepair per busway section.

End PieceThe end piece is a 6 inch pieceof housing and insulator, andend cap. It is used to coverthe protruding copper busbarconnector blades at the end ofa run. Some runs do not requirean end piece, if the protrudingblades are used for the end feedpower connections.

End CapThe end cap closes off the openends of a busway run. It insertsinto the end of the last buswaysection, and is secured in placewith a set screw.

Closure StripThe closure strip is an optionalitem, used to close the continu-ous access slot of the busway.It is made of white rigid PVCand snaps into place. It isrequired for safety only whenbusway is mounted less than8 feet above the floor. It maybe used for aesthetic purposes,for keeping dust and dirt fromentering the busway, or as anadded safety measure. It comesin 20 foot max pieces, and can becut in the field, to be installedbetween the plug-in units.

Other Busway AccessoriesOther accessories for B100 Seriesare available, including cordgrips, cord assemblies, recep-tacle boxes, plugs, fittings,fuses, brackets, etc. See page 35for details.

End CapDiagram

ClosureStrip

End Piece

HousingCoupler

6”

3.875”

2.5”

6”


BH-1 BRH-1 WHR-2

Hanger Designs

Catalog # Description WeightBH-1 standard hanger 0.2 lbBRH-1 rod mount hanger 0.3 lbWHR-2 weight hook ring 0.2 lbACH-1 cable suspension hanger assembly 0.3 lbSCL-1 safety cable loop 0.2 lb

B100 Busway Series

B100 Busway Parts

HangersB100 Busway features theconvenience of a continuoushanger support anywhere alongthe busway run. Slide the hangerinto the busway mountingchannel into position. Typicalhanger support spacing is10 feet max.

Standard hanger designs includetype BH-1 which has a 3/8 inchx 1 inch stud for rigid mount.Type BRH-1 has a rod couplingnut assembly added to thehanger for 3/8 inch rod mount.

The weight hook ring, typeWHR-2 can be used as a hangerfor suspending the buswayfrom chains or wires, or to hangloads up to 50 pounds under thebusway, such as light fixtures,tools, and balancers.

Cable SuspensionB100 Starline Track Busway canbe suspended below a ceilingor trusses with steel cables. TheACH-1 aircraft cable hangerdevice includes a hanger plate,and has an easy grip feature forsteel cable. Cable not included.The WHR-1 may also be used forhanging the system.

Safety Cable LoopThis assembly provides backupprotection to heavy loadssuspended from the busway,such as light fixtures or tools,as a backup safety feature. Thecable loops over the buswayloosely.

20



B100 Busway Parts

End Power Feed UnitsStandard power supply to theB100 Busway consists of a steeljunction box, 10 inch x 8 inch x4 inch with removable side, lugsand shrink tubing. The powerfeed box fits over the maleend of the first busway sectionand is secured to it with twohangers, included. UL listed.

Top Feed UnitsThe top feed power supply isused to supply power from abovethe busway run, when a box atthe end or below a busway runis not wanted. A power feed boxis connected to a two-foot pieceof busway, which is positionedat the end of a busway run. Aterminal block in the power feedbox is supplied for up to 2/0wire connections. UL listed.

Bottom Feed UnitsPower feed connections canbe made from below thebusway, using the 100 ampterminal block plug-in unitshown on page 25. The wireconnections in the box aremade to the incomingpower supply wires.

End Power Feed with Adapterto Trunk BuswayStarline Track Busways are idealas branch busway runs, toreduce the overall cost ofbusway. This unit provides thecomponents needed to connecta trunk busway tap box to theStarline power feed box. Itincludes the Starline end feedassembly, 4 feet of flexibleconduit and 100 amp ratedcables. See page 9 forillustration.

Top FeedUnits

End PowerFeed

Power Feed Designs

Catalog # Description WeightEF100-3 end feed, 100A, 3 pole/ground 6.0 lbsEF100-4 end feed, 100A, 4 pole/ground 6.0 lbsTF100-3 top feed, 100A, 3 pole/ground 12.5 lbsTF100-4 top feed, 100A, 4 pole/ground 12.5 lbsPFA100-4 power feed & adapter, 100A, 4 pole/ground 8.0 lbs

End Power Feedwith Adapter

4

8”

10”

6.750

12.75 7.125

24

7


Ell and Tee Designs

Catalog # Description WeightEL3-L ell, horiz, 3 pole, left 5.5 lbsEL3-R ell, horiz, 3 pole, right 5.5 lbsEL4-L ell, horiz, 4 pole, left 5.5 lbsEL4-R ell, horiz, 4 pole, right 5.5 lbsEL4-U ell, up, 4 pole 5.5 lbsEL4-D ell, down, 4 pole 5.5 lbsBT3-ER tee, 3 pole, external right 8.0 lbsBT3-EL tee, 3 pole, external left 8.0 lbsBT4-ER tee, 4 pole, external right 8.0 lbsBT4-EL tee, 4 pole, external left 8.0 lbsBT4-IR tee, 4 pole, internal right 8.0 lbsBT4-IL tee, 4 pole, internal left 8.0 lbs

B100 Busway Series

B100 Ells and Tees

EllsElls are used for making a90 degree turn in the busway.Horizontal and vertical ells areavailable. Specify if the ell isa left or right ell, up or down,according to which way theorientation of the internal bus-bars assemble. See illustrationbelow. Plug-in units cannot beplugged into an ell. UL listed.

TeesTees are used for creating abranch in a busway system. Theyoperate similarly to ells. Whenlaying out a system, specify thecorrect busbar orientation ofthe tee. Indicate right or left,external or internal busbars.External tees are preferred. Seeillustration below. UL listed.

Male-Male AdapterThe male-male adapter isused to change the gender ofa tee, ell or busway section toconstruct a particular configura-tion. It may also be used whenlocating a power feed at thefemale end of a busway section.UL listed.

Left Ell

Right Ell

BTx-ERExternal Right

BTx-ELExternal Left

BTx-IRInternal Right

BTx-ILInternal Left

22

12” 12”

12” 12”

6”

24”

12”


23

Outlet BoxPlug-in Unit

Plug-in Units Designs

Catalog # Description WeightOB100-40-3 outlet box unit, 40A, 3 pole 1.2 lbs

OB100-40-4 outlet box unit, 40A, 4 pole 1.5 lbs



DRF100-15-3 duplex receptacle unit, 15A, fused, for 3 pole 2.0 lbs

DRF100-15-4 duplex receptacle unit, 15A, fused, for 4 pole 2.2 lbs

Add “-1F, -2F or -3F” to the catalog number of the OB unit to add 1, 2 or 3external fuse holders. Order type CC fuses separately.

B100 Busway Series

B100 Busway Plug-in Units

Plug-in units are used to tap offthe power from the busway. Theplug-in units have a special plughead which inserts into thebusway continuous slot, andtwists 90 degrees to makeelectrical connection. Thecopper contact blades fit intothe busbar channel for acompression connection.

All plug-in units are polarized,and have mounting tabs and twobolt-on hangers to secure theunit to the busway.

Outlet Box Plug-in UnitOutlet box plug-in unit is themost economical unit, andconsists of the plug headmounted on a junction box.It is available in 40 amps witha 4 inch square box, or 60 ampswith a 4 11/16 inch square box.One, two or three external fuseholders, type CC, 30A max, maybe added, with 4 11/16 inchbox. Order fuses separately.Direct wire connections to theload or a drop cord assembly aremade in the box. A screw-oncover and wire nuts are included.UL listed.

Fused & Unfused DuplexReceptacle UnitsThese units are similar to theoutlet box unit, with an addedduplex receptacle in a standard4 inch square box, rated at 15A,125 V max. An external fuseassembly with a 15 amp type CCFuse (included) is provided, orunfused receptacle units are alsoavailable. 20 amp receptacles,and several NEMA configurationsare also available upon request.Standard models are UL listed.

Fused DuplexReceptacleUnit



Catalog # Description WeightCB100-XX-1-250-3 250V, 1 pole, for 3 pole busway 5.5 lbsCB100-XX-2-250-3 250V, 2 pole, for 3 pole busway 6.0 lbsCB100-XX-3-250-3 250V, 3 pole, for 3 pole busway 6.5 lbsCB100-XX-1-250-4 250V, 1 pole, for 4 pole busway 5.5 lbsCB100-XX-2-250-4 250V, 2 pole, for 4 pole busway 6.0 lbsCB100-XX-3-250-4 250V, 3 pole, for 4 pole busway 6.5 lbs

“XX” = Specify the desired ampere rating of the circuit breaker. Change “250” to“480” on above items for 480 volt max circuit breakers. To order without thebreaker, omit the second “B” in the catalog number.

Add ”-DIS” to above catalog number for an externally operable version.

B100 Busway Series


Plug-in units with circuit breakerconsist of a full-sized junctionbox with a hinged lid, plughead, and externally operablecircuit breaker. Insert the plughead in the busway and rotate90 degrees to make electricalconnection. The units arenormally supplied with thebreaker installed, or can besupplied without them with asnap-on mounting plate.

Circuit breakers are availablefrom 15 to 100 amps, 250 or480 volt max, 1, 2 and 3 pole.Units with multiple circuitbreakers are available and areUL listed. All units include acopper grounding lug for up to#6 wire, mounting tabs and twohangers to secure unit to thebusway. 4 pole unit also includesa neutral wire and wire nut, orneutral block over 40 amps.UL listed.

Circuit Breaker withExternal Disconnect

A Starline plug-in unit externallyoperable disconnect switch isavailable with all circuit breakerunits. Rocker handle disconnectscircuit breaker before box canbe opened. UL listed.

CircuitBreaker Unit

24

Circuit Breaker Unit withDisconnect

6.75” 12.25”

2.5”



Fuse Block Plug-in Units

Plug-in units with an internalfuse block consist of a full-sizedjunction box with hinged lid,and a plug head. Insert the plughead in the busway slot androtate 90 degrees to makeelectrical connection.

Units are available in 30, 60 and100 amp max fuse block sizes,and in 250 or 600 volt maxratings. A Class H, 3 polephenolic fuse block is mountedin the box. Fuses are notincluded, but can be ordered asa separate item. See page 35.

All units include a coppergrounding lug, mounting tabs,and two hangers to secure unitto the busway. Four pole unitsalso include a neutral wire, withwire nut, or a neutral block over40 amps. Units have 1/2 inchand 3/4 inch conduit knockoutson 3 sides. UL listed.

Fused Starjack withExternal DisconnectA similar fused unit is availablewith the added feature of anexternally operable disconnectswitch. Rocker handle discon-nects circuit before box can beopened. UL listed.

Terminal Block UnitsPlug-in units with a 3 or 4 poleinsulated terminal block areavailable, in a full-sized wiringbox with hinged lid. These unitsinclude a 40 or 100 amp max,3 pole terminal block and copperground lug. Four pole unit alsoincludes a neutral wire and wirenut, or neutral block over40 amps. UL listed.

Fused and Terminal Block Plug-in Units

Catalog # Description WeightFD100-30-3-250-3 fused disconnect unit, 30A, 250V, 3 pole 5.5 lbs

FD100-30-3-250-4 fused disconnect unit, 30A, 250V, 4 pole 5.5 lbs



TB100-40-3 terminal block unit, 40A, 600V max, 3 pole 5.5 lbs

TB100-100-3 terminal block unit, 100A, 600V max, 3 pole 6.0 lbs

Change “300” to “600” on above FD units for 600 volts max rated units.

Fused Starjackwith ExternalDisconnect

6.5” 10.37”

3.25”


26 B100N Busway Series

200% Neutral, Isolated Ground

Starline Track Busway isavailable with a 200% ratedneutral busbar, as well as anisolated ground busbar. Hightech and electronics applicationsusually have these electricalrequirements to handle potentialharmonic loads and sensitivegrounding needs. Available in100 amp busway with 200 ampneutral, 600V. Optional 100 ampisolated ground busbar is 300volts rating standard, with 600volts rating available. 22,000amp short circuit rating. TheB225 installation tool is used toinstall the B100N buswaysections. UL pending.

Power Feed UnitsPower feed units with oversizedneutral connections are usedwith this series. A fifth busbarconnector is added for theisolated ground bar. UL pending.

Other Busway PartsUse the same housing couplers,end pieces, end caps, hangers,closure strip, etc. as the B100system. See pages 19 - 20 forselection details.

Ells and TeesThe B100N and B100NG buswayseries has ells and tees avail-able. The design, description andcatalog numbers are the same asthe B100 series, shown on page22, except for the fifth busbaradded, and the letters “N” or“NG” are added to the catalognumbers.

Busway Components Designs

Catalog # Description Length WeightB100N-4PG-5 100 amp/200% neutral Busway 5 feet 14.0 lbsB100N-4PG-10 100 amp/200% neutral Busway 10 feet 28.0 lbsB100N-4PG-20 100 amp/200% neutral Busway 20 feet 56.0 lbsB100NG-4PG-5-300 100 amp/200%N/isol ground 5 feet 15.0 lbsB100NG-4PG-10-300 100 amp/200%N/isol ground 10 feet 30.0 lbsB100NG-4PG-20-300 100 amp/200%N/isol ground 20 feet 59.0 lbsEF100NG-4-300 end power feed, 200%N/isol ground 17.0 lbsB225IT installation tool 1.0 lb

End Power Feed

4.187

2.375


27B100N Busway Series

Plug-in Units

For the 100 amp busway with200% neutral, use the B225Series plug-in units, see pages32 - 34. The phase load on eachunit must not exceed 100 amps,and the unit must be properlyrated for the expected neutralload.

Special plug-in units must beused with the 100 amp buswaywith 200% neutral and isolatedground busbar. They includea fifth stab for the isolatedground. See illustration. Outletbox units, fused units, recep-tacle units and circuit breakerunits are available, similar tothe B225 series. 4 pole circuitbreakers are available whenspecified. Some of thoseunits are listed to the right.UL pending.


Catalog # Description WeightOB100NG-30-4 outlet box unit, 4 Pole, N, gnd, 30 amp 4.2 lbsOB100NG-60-4 outlet box unit, 4 Pole, N, gnd, 60 amp 4.2 lbsDRF100NG-X fused receptacle unit, 15A 4.3 lbsCB100NG-aa-3-240-4 circuit breaker unit, 240V max, 3 poleCB100NG-aa-3-480-4 circuit breaker unit, 480V max, 3 pole

X = A, B or C for phase bar wiring.aa = See page 33 for amp ratings to 100 amps and box dims.

Outlet Box Unit Circuit Breaker Unit

6”

4” 6”WL

H


28 B225 Busway Series

B225 and B160 Plug-in BuswaySeries Design

The Starline Track Busway Seriesis available in 225 and 160 ampratings, with the B225 BuswaySeries. The design combinesStarline’s features and flexibilitywith greater cost efficiency thanconventional busway systems.It is available in 3 or 4 pole,600 volts maximum, and thealuminum housing is approvedas a 100% capacity ground.It is UL listed, and CUL listedfor Canada, 22,000 amps shortcircuit rating, and passes theUL “Finger Safe Probe” andgrounding standards.

1. Copper BusbarsAll busbars are hard temper solidcopper. Patent pending busbarshape allows a compression fitelectrical connection of adjacentbusway straight sections, as wellas the turn-and-lock plug-inunits. No bolts or screws arerequired.

2. Continuous InsulatorThe busbar insulator is continu-ous and has slots for insertion ofthe plug-in-unit stabs.

3. Extruded Aluminum HousingThe housing design combinesstrength, lightweight and pleasingappearance. It is about half theweight of steel enclosed busway.Aluminum housing is superiorfor 400 Hertz power systems.

4. Ground ConductorThe aluminum housing is a 100%capacity ground conductor. Nogrounding kits needed for plug-in units.

5. Continuous Mounting ChannelExact spacing of hangers notrequired. Hanger spacing is upto 10 feet apart.

6. Continuous Access SlotPlug-in units can be attachedto the busway at any locationand density, and is easily donewith the turn-and-lock feature.Simply insert the unit into thebusway slot, turn 90 degreesand the electrical connectionis complete.

7. Plug-In UnitsPlug-in units for the B225 andB160 busways include fuseddisconnect, circuit breaker andterminal block units. The outletbox unit for direct wiring andfused receptacle units aresimilar to the B60 and B100Series.

Voltage DropLength of busway for a onevolt drop in the line to linevoltage for a distributed loadof 225 amperes:

B160 three phase, .8 PF 69 feetB160 single phase, .8 PF 59 feetB225 three phase, .8 PF 49 feetB225 single phase, .8 PF 42 feet

B225 perspectiveillustration



B225 and B160 BuswaySections

Starline Track Busway sectionscome in 20, 10 and 5 footstandard lengths. The 160 and225 amp busbars are hardtemper solid copper, and havea channel configuration. The225 amp rated busbars are tinplated. The sections includethe busbars and coupling cover(patent pending) protruding atone end, which fit into the endof the next section. To connectbusway sections together, usethe B225 Installation Tool, seepage 30, to push the protrudingbusbars into the busbar channelof the next section. Housingcouplers ordered separately, joinadjacent busway sections.

The busway sections havecontinuous insulator for thefull length of the section.They provide industry standardclearances and are finger safe.

Rated at 600 volts max,50/60 Hertz, and is ideal for400 Hertz application. Thealuminum housing is approvedas a 100% capacity ground.Sections are available in 3 phase3 wire and 3 phase 4 wire withground. UL and CUL listed.

Power feed to the buswaysystem should be wired tomatch the wire color codingof the plug-in units, as shownin the chart at far right.

Neutral SizingWhen the load on the buswaycreates significant harmoniccurrents, or has single phasetap off of a 3 phase primary,consideration must be given tothe ampere rating of the neutralconductor(s).


Catalog # Description Length WeightB225-3PG-5 225 amp busway, 3 pole/ground 5 feet 16.0 lbs

B225-3PG-10 225 amp busway, 3 pole/ground 10 feet 29.0 lbs











B225G-4PG-10-300 225 amp busway, 4 pole/isol.gd. 10 feet 35.0 lbs

B225G-4PG-20-300 225 amp busway, 4 pole/isol.gd. 20 feet 68.0 lbs

2.375

4.187



B225 and B160 Busway Parts

Housing CouplerUsed to join adjacent buswaysections mechanically. Suppliedin pairs, for top and bottom ofhousing positions. Specify onepair per busway section.

End Piece6 inch piece of housing withinsulator, and end cap. Use onlyif the protruding busbar bladesare exposed at the end of abusway run.

End CapThe end cap closes off the endof a busway run. It fits aroundthe end of the busway section,and is secured in place with aset screw.

HangersAll hangers, weight hook rings,cable loops, etc. shown on page20 for the B100 series are alsoused for the B225 series. Selectfrom that list.

Installation ToolUsed during installation tomake the electrical compressionconnection of the busbars inadjacent sections. Deposit onitem is refunded when tool isreturned. One tool is typicallyneeded per project.

Closure StripThe closure strip is an optionalitem for aesthetic purposes.See page 19 for more details.

Busway Parts Designs

Catalog # Description WeightBHC-1 housing coupler, pair 0.2 lbB225IT busbar installation Tool 2.5 lbsEP-2 end piece, for B225/B160 1.2 lbsEC-1 end cap, for B225/B160 0.1 lbCS-1 closure strip 0.1 lb/feetUse hangers as shown on page 20 for this series.

Housing Coupler End Piece End Cap

6”

Installation Tool

6”



B225 and B160 Busway Parts

End Power Feed UnitsThe standard end feed units forB225 and B160 connect to themale end of a busway run. Theyconsist of a 12 inch x 16 inch x5 inch steel junction box, withremovable side, connected toa 1 foot piece of busway. Thebusbars in the unit have wireconnection lugs, ground lug andinsulated shrink tubing included,for wire sizes up to 300 MCM.End feed units for connection tothe female end of a busway runare also available. UL and CULlisted.

Ells and TeesElls and tees must specify if theyare left or right. Tees must alsospecify the orientation of thebusbars, either internal orexternal, according to theillustration below. External teesare preferred. Plug-in units cannot be plugged into an ell ortee. UL and CUL listed.

Male-Male AdapterUsed to connect two femaleends together, for buswaysections, tees, or for connectingan end feed at the female endof a busway run (not shown).

Other Busway PartsOther accessories and buswaysections are available, as wellas custom designing. Consultfactory with a project layout,or special requirements.See page 35 and 37 formore details.

Components Designs

Catalog # Description WeightEF225-4 end feed, 225A, 4 pole/ground 16.5 lbsEF225-3 end feed, 225A, 3 pole/ground 16.0 lbsEF225-4M end feed, 225A, 4 pole/ground with male busway end 16.5 lbsEF225-3M end feed, 225A, 3 pole/ground with male busway end 16.0 lbsEF160-4 end feed, 160A, 4 pole/ground 16.5 lbsEF160-3 end feed, 160A, 3 pole/ground 16.0 lbsEF160-4M end feed, 160A, 4 pole/ground with male busway end 16.5 lbsEF160-3M end feed, 160A, 3 pole/ground with male busway end 16.0 lbsEL225-4-L Busway ell, 225A, 4 pole left 8.0 lbsEL225-4-R Busway ell, 225A, 4 pole right 8.0 lbsEL225-3-L Busway ell, 225A, 3 pole left 6.6 lbsEL225-3-R Busway ell, 225A, 3 pole right 6.6 lbsT225-4-IL Busway tee, 225A, 4 pole internal left 9.2 lbsT225-4-EL Busway tee, 225A, 4 pole external left 9.2 lbsT225-4-IR Busway tee, 225A, 4 pole internal right 9.2 lbsT225-4-ER Busway tee, 225A, 4 pole external right 9.2 lbs

*For 160 amp ells and tees, change “225” to “160” in catalog number.

End feed

Left Ell Right Ell

External Right

Internal Left

12” 5”

16”12”

12” 12” 12” 12”

24”

12”

24”

12”



B225 and B160 Plug-in Units

Starline plug-in units are usedto tap off the power from thebusway. The plug head insertsin the busway slot, and a90 degrees, turn-and-lockmotion makes the electricalconnection. The copper contactstabs fit into the busbar channelfor a compression connection.Mounting tabs and two bolt-onhangers secure the unit to thebusway. Most plug-in units listedare usable on both the 225 and160 amp busways.

Outlet Box and FusedReceptacle Plug-in UnitsThe outlet box plug-in unit isthe most economical, comprisedof a 6 inch x 6 inch x 4 inch boxwith knockouts for direct wireand ground connections. Outletbox units are 30 or 60A, 600Vrated. Up to 3 type CC externalfuse holders can be added, witha 30 amp maximum rating. A20A, 125V max rated duplexreceptacle unit with a fuse andholder mentioned above isincluded in the fused receptacleplug-in unit. Receptacle plug-in units with a circuit breakerare also available with a 30Amaximum rating. Other NEMAconfigurations are availableupon request. Standard modelsare UL and CUL listed.

Terminal Block UnitsPlug-in units with a 3 or 4 poleinsulated terminal block, ratedat 100, 160 or 225 amps areused for direct wire tap off, orfor a center power feed-in. Allunits include a ground lug, and4 pole units also have a neutralblock. 100A box dimensions are12.5 inch x 6.5 inch x 2.5 inch.160 and 225A box dimensions

Outlet Box Unit Fused ReceptacleUnit

TerminalBlock Unit


Catalog # Description WeightOB225-30-4 outlet box unit, 30A, 4 pole* 4.2 lbsOB225-30-3 outlet box unit, 30A, 3 pole* 4.0 lbsOB225-60-4 outlet box unit, 60A, 4 pole 4.2 lbsOB225-60-3 outlet box unit, 60A, 3 pole 4.0 lbsDRF225-20-4 fused receptacle unit, 20A 4.3 lbsDRB225-20-4 receptacle unit with 20A breaker 5.0 lbsTB225-100-4 terminal block unit, 100A, 600V, 4 pole 16.0 lbsTB225-160-4 terminal block unit, 160A, 600V, 4 pole 17.0 lbsTB225-225-4 terminal block unit, 225A, 600V, 4 pole 17.0 lbs

*Add “-1F, -2F or -3F” to catalog number to add fuse holders.*Add “-1B, -2B or -3B” to catalog number to add standard circuit breaker.

6”

4” 6”

6”

4” 6”L

W

H




Circuit breaker plug-in units forStarline B225 and B160 buswaysystems come in a variety ofratings. Basic specifications forthese units should include ampand voltage rating, number ofpoles for the breaker and thebusway system, standard(10K AIC) or high interruptingcapacity (shown below). Unitsup to 160 amps are usable onB225 and B160 busways. Allcircuit breakers are mountedinternally, and have an exter-nally operable disconnectmechanism, except the 240Vstandard type unit, which has afront operable circuit breaker.UL and CUL listed.

The most common configura-tions are listed below. Consultfactory for additional listings.Drop cord assemblies can also besupplied as needed. See page 35.

Catalog # Description Weight

CB225S-aa-y-240-4 240V 10K AIC w/breaker, 4 pole busway 6.3 lbs

CB225S-aa-y-240-3 240V 10K AIC w/breaker, 3 pole busway 6.3 lbs

CB225HS-aa-y-240-4 240V 22K AIC w/breaker, 4 pole busway 8.0 lbs

CB225HS-aa-y-240-3 240V 22K AIC w/breaker, 3 pole busway 8.0 lbs

CBP225HS-100-3-240-4 240V 22K AIC w/circuit breaker base only 8.2 lbs

CB225-cc-1-277-4 1 pole 277V breaker, 4 pole Busway 19.0 lbs

CB225-cc-1-277-3 1 pole 277V breaker, 3 pole Busway 19.0 lbs

CB225H-dd-1-277-4 1 pole 277V 22K AIC, 4 pole Busway 19.0 lbs

CB225H-dd-1-277-3 1 pole 277V 22K AIC, 3 pole Busway 19.0 lbs

CB225-dd-2-480-4 2 pole 480V breaker, 4 pole Busway 20.0 lbs


CB225H-ee-2-480-4 2 pole 480V 22K AIC 4 pole Busway 29.0 lbs






Circuit Breaker Plug-in Units Designs

Ratings & Box Dims: Length Width Height

aa=10 to 100 amp circuit breaker 12.00 inch 6.00 inch 4.0 inch

cc=15 to 100 amp circuit breaker 18.00 inch 11.25 inch 5.0 inch

dd=15 to 150 amp circuit breaker 18.00 inch 11.25 inch 5.0 inch

ee=15 to 150 amp circuit breaker, and 18.00 inch 11.25 inch 5.0 inch

175 to 225 amp circuit breaker 21.25 inch 13.50 inch 5.5 inch

y=1, 2 or 3 pole circuit breaker

Front Operable Unit Floor Operable Unit

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Fused Disconnect Plug-in Units

Fused disconnect plug-in unitsfor Starline B225 Series areavailable in several sizes.The units are 600 volt maxrated, and 30, 60, 100 and200 amp max, fuse block sizes.Standard fuse blocks take classJ fuses. The 100 and 200 ampunits will also accept adaptersfor class T fuses. Fuses are notincluded, but can be orderedseparately. See page 35.

The external disconnectmechanism is floor operablewith chains or a stick. All unitsinclude two mounting bolts, aground lug, and 4 pole unitsalso include a neutral connec-tion. Knockouts are provided ontwo sides. Drop cord assembliesare also available as needed. Seepage 35. UL and CUL listed.

Fused Disconnect Unit

Fused Disconnect Unit Designs

Catalog # Description Weight Length Width HeightFD225-30-600-3 fused disconnect unit, 30A, 600V max 3 pole 16.0 lbs 18.00 inch 11.25 inch 5.0 inchFD225-30-600-4 fused disconnect unit, 30A, 600V max 4 pole 16.5 lbs 18.00 inch 11.25 inch 5.0 inchFD225-60-600-3 fused disconnect unit, 60A 600V max 3 pole 17.5 lbs 18.00 inch 11.25 inch 5.0 inchFD225-60-600-4 fused disconnect unit, 60A 600V max 4 pole 18.0 lbs 18.00 inch 11.25 inch 5.0 inchFD225-100-600-3 fused disconnect unit, 100A 600V max 3 pole 18.5 lbs 18.00 inch 11.25 inch 5.0 inchFD225-100-600-4 fused disconnect unit, 100A 600V max 4 pole 19.0 lbs 18.00 inch 11.25 inch 5.0 inchFD225-200-600-3 fused disconnect unit, 200A 600V max 3 pole 40.0 lbs 21.25 inch 13.50 inch 8.0 inchFD225-200-600-4 fused disconnect unit, 200A 600V max 4 pole 40.7 lbs 21.25 inch 13.50 inch 8.0 inch

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35Busway Accessories

∂ Cord Drop AccessoriesA wide variety of drop cordassemblies for the plug-in unitscan be made-to-order by thefactory, with various fittings,boxes, devices, NEMA configura-tions, cord lengths, colors, etc.Consult distributor or factoryfor the design and prices.Catalog ordering informationshown below.

∑ The Wire Mesh Cord Gripis for use on Starjacks, formaximum strain relief to dropcord. Connects to bottom ofStarjack box.

∏ Surface Mount to CeilingThe surface mount clip can beused to mount a busway systemdirectly to a ceiling surface.Screw clip to surface, andconnect busway to clip.

π Installation ToolUsed during installation tomake the electrical compressionconnection of the busbars inadjacent sections. Deposit onitem is refunded when tool isreturned. One tool is typicallyneeded per project.

∫ Closure StripThe closure strip is used to closethe continuous access slot ofthe busway. It is made of white,rigid plastic, and snaps intoplace. It is required for safetyonly when busway is mountedless than 8 feet above the floor.It may be used for aestheticpurposes, for keeping dust anddirt from entering the busway,or as an added safety measure.It is easily cut in the field tobe installed around the plug-inunits.

❻ FusesFuses are available for theStarjacks with fuse holders orfuse blocks, type OB60, DRF andFP Series. Fuses are Class CC orClass H, depending on the plug-in unit. Class J fuse is used withthe B225 busway series fuseddisconnect units. Specify theampere rating desired.

❼ Cord Reel UnitA plug-in unit with a cord reelattached is available in severalsizes. See the distributor orconsult factory for choices.

Ω Receptacle Plug-In UnitsA wide variety of NEMAreceptacles may be pre-installedin plug-in units. Consultdistributor or factory for designand price.

Drop Cord Ordering Information

Drop cord unit catalog numbers must contain the following specifications:

DC60 - 15 - L520C - 4Busway size (60, 100 or 225) Number of poles in busway

Length of cord (1 to 25 feet standard) Style C=cord connector; R=receptacleD=duplex; Q=quad receptacle

NEMA configuration of unit

1.75”

Busway Accessories Designs

Catalog # Description Weight

SJG-1/2 wire mesh grip, 1/2”, .43”-.54” diameter cable 0.1 lb

SJG-3/4 wire mesh grip, 3/4”, .54”-.73” diameter cable 0.2 lb

MC60-R rod mount clip for 3/8” rod 0.1 lbCS-60 closure strip, B60 0.1 lb/feetF-CC-## class CC fuse, ## = amp rating (1-30)F-H-## class H fuse, ## = amp rating (1-100)F-J-## class J fuse, ## = amp rating (10-200)SM60-1 mounting bracket for holding ceiling tiles 0.2 lbB100IT installation tool for B100 1.0 lbOB225-L630-4 plug-in receptacle with fuse 4.3 lb


36

Starline Track Busway vs. Conduit and Wire

Compare:Why Busway is Better

The following comparisonsshow the advantages ofusing Starline Track BuswaySystems instead of conduitand wire.

1. Lower installed cost,especially when there arenumerous pieces of equip-ment and electrical loads toconnect. Starline TrackBusway installs faster thanconduit and wire, savingon the labor cost. The lowmaterial cost of Starline TrackBusway is comparable toconduit and wire materialcosts, and is much lowerpriced than larger, conven-tional busway products. Eachplug-in unit can be wired onthe ground, and plugged ineasily overhead. Conduit canrequire overhead wire pulling,stripping and connecting. Thesavings increase dramaticallyas the number of connectedloads increases.

2. Easy to add equipment.Adding more machines afterthe initial installation iseasily done by adding aplug-in unit. Plug it into thecontinuous access slot closestto where needed, in seconds.You need not worry aboutrunning a new run of conduitand wire, or whether yourpanel board has space foranother circuit breaker.

3. Easy to relocate equipment.Relocating or removing amachine is much easier withStarline Track Busway. Simplytwist and remove the plug-inunit, move the machine, andplug it back into the nearestbusway location. Usuallyremoved wire and conduithas to be scrapped, and a newrun must be put up, at muchgreater expense.

4. Busway is reusable. Forchanging plant layouts,busway can be easilydisassembled and reinstalledas needed, normally withno wasted parts. Conduitand wire usually has to bescrapped.

5. Better appearance. StarlineTrack Busways have a pleasingappearance, with its alumi-num satin finish, and is verycompact, so as to be hardlynoticeable. Plug-in units arealso very compact.

6. Lightweight. Starline TrackBusway Systems are light-weight, with its aluminumhousing sections. This makesit easier and faster to handle,with less weight to suspendfrom ceilings.

When the comparisonsare made, it is easy to seewhy Starline Track BuswaySystems have so much moreto offer.

Installed Cost

Starline TrackBusway

Conduit &Wire

Material

Labor

Relocation


37Starline and TrunkBusways Combination

Starline Track Busways makesignificant savings possible, asbranch busway runs, coming offof larger-sized feeder busway.The cost of the Starline TrackBusway sections and plug-inunits are much lower, and all thefeatures of busway are gained.See typical illustration at right,which shows 100 and 60 ampStarline Track Busway runscoming off of a 400 amp feederbusway run, made by others, andavailable from the distributor orUniversal. See page 38 for moreinformation.

Starline Track BuswayLayout Guidelines

Starline Track Busway systemscan be custom built for specialprojects, according to thespecifications provided bythe designer.

The illustration to the rightshows an actual job where aStarline Track Busway layoutwas designed according to thecustomer’s existing floor plan.Attention must be given towhich side the busbars arelocated in the busway section,relative to the male and femaleends of each section, as well asthe left, right, external andinternal orientation of the ellsand tees.

Grids, special angles, lengths ofbusway section, power feeds,special circuit routing diagram,painting the busway, etc. canbe provided by the factory. Seepage 41 for a custom retail storelayout example.

Equipment List6 bending machines, 440V, 3Ø, 39A12 drops for general use, 110V5 tube welders, 440V, 3Ø, 15A5 work benches

Bill of Material8 B225-4PG-20 Busway 225A, 20 feet 5 B60-20-4 Busway 60A, 20 feet2 B225-4PG-10 Busway 225A, 10 feet 4 BC-4 Busbar connector1 B225-4PG-5 Busway 225A, 5 feet 4 HC-2 housing coupler1 EL225-4-R Busway ell 12 RHB-3 hanger1 EL225-4-L Busway ell 1 EC-60 end cap1 T225-4-IL Busway tee, left 1 EF-60-4 end feed1 T225-4-ER Busway tee, right 12 OB60-30-2 plug-in units, 110V1 EF225-4 end feed assembly 30A, with 14 feet drop cord

26 BRH-1 hangers18 BHC-1 housing couplers2 EC-1 end cap2 EP-2 end piece5 CB225-15-3-480-4 plug-in units,

with 15A, 3P circuit breaker & 14 feet drop cord6 CB225-40-3-480-4 plug-in units,

with 40A, 3P circuit breaker & 14 feet drop cord

180 FEET

LIGHTING BUSWAY 110V, 60A

BRANCH PLUG-IN BUSWAY 110/220V, 100A



BRANCH PLUG-IN BUSWAY 110/220V, 100AFEED

ER B

USW

AY 1

10/2

20V,

400

A

40 F

EET


38 Starline and TrunkBusways

Continued-

Photo shows an electronicsmanufacturer using StarlineTrack Busways as branchbusways from a larger trunkbusway system. The end feedwith adapter includes a 4 footflex conduit section which isconnected to the fused plug-inunit of the larger busway.

25 Foot Tap RuleSavings with StarlineTrack Busway

The National Electrical Code(NEC) Article 240-21, section 2,“25 Foot tap rule” makes signi-ficant savings possible in manyapplications. The economicaloutlet box unit can be used inlieu of a fused or circuit breakerplug-in unit, where all thefollowing conditions are met.

a. The length of the tapconductors does not exceed25 feet.

b. The ampacity of the tapconductors is not less than1/3 that of the feederconductor or overcurrentprotection from which theyare tapped.

c. The tap conductors terminatewith single circuit breaker ora single set of fuses that willlimit the load to the ampacityof the tap conductors.

d. The tap conductors aresuitably protected fromphysical damage and areenclosed in a raceway.

Starline technical people areavailable to discuss implementa-tion of the 25 foot tap rule andits cost savings with you.

15A plug-in unit

3 wires rated at 20Aor higher, not over25’ long in raceway

15A circuit breaker orfuse protection at load

40A plug-in unit



30A plug-in unit



60A plug-in unit



Busway circuitprotection at 60A

Busway circuitprotection at 60A


39Starline Track Buswayfor the Lighting Industry

Starline Track Busways are usedas lighting track in retail stores,grocery stores, conventioncenters, museums, commercialbuildings, warehouses, factories,over assembly lines, and manyother applications.

The 4 pole Starline Track Buswayat 120/208 volts can run 3circuits. The 60 amp StarlineTrack Busway can supply up to7200 watts per circuit, or the100 amp system up to 12000watts. 277 volt lighting is alsoideal for Starline.

Select lighting manufacturersuse Starline Track Busway fortheir projects which requirelarger track capacities. BecauseStarline is approved as a bus-way system, it does not have thelimitations of track lighting.

The Starline internal plug iswired directly to the light fixture(see top photo), or it may bewired in the field. Outlet boxplug-in units are also convenientfor connecting fixtures (seetop left photo). The buswayis strong enough to hang thefixtures from using the weighthook rings. Power drops to otherelectrical requirements are donefrom the same busway.

Starline Track Busway can bepainted to match color themerequirements (see lower photo).Grids and special lighting systemdesigns can also be accommo-dated, such as those shown onpage 41. Consult the distributoror factory technical support forcustom design assistance.


40 Busway Applications

Workstation Power Supply

Hundreds of work stations,benches and testing equip-ment tables use Starline TrackBusway for power supply at thiselectronics manufacturer. Theflexibility of Starline for easyrelocation or addition of thework stations results in moreefficient production in thefactory. Several stations aretypically interconnected toa single drop cord from thebusway overhead.

Drop Cords

Bottom photo shows a typicaldrop cord assembly on a plug-inunit. The factory can supplycustom cord sets convenientlyand efficiently. Eliminaterunning new conduit runs,or a network of conduit outletboxes throughout the building.More details about drop cordsand other accessories areon page 35.

Data Center PowerDistribution

This is one of six data centersfor a telecommunicationscompany, using Starline TrackBusway. Reliability is anabsolute requirement, with noequipment downtime tolerated.The patented continuouspressure design of the plug-inunits to the busbars, andredundant busway runs, providethe level of uptime demandedby the owner of the facility.


41



42 Starline Track Buswayfor Data Centersand Mission CriticalIndustries

Facility managers and consultingengineers around the world areturning to Starline Track Buswayfor power distribution tocomputers, servers and otherequipment, where even a slightbreak in the power supply couldresult in major revenue losses.Absolute reliability is the mostcritical need, 24 x 7 x 365.Typical applications are in ISPs,ASPs, computer co-locationfacilities, e-businesses and theInternet, financial and invest-ment institutions, telecommuni-cations, large corporate computercenters, and emerging technol-ogy applications. Key needs arereliability, ability to add powerunits without busway shutdown,and high density of plug-inunits.

Power Monitoring systems arealso available, to monitor powerusage, and other functions. Thesystem is built into the buswaysystem, and is customized foruser needs. Call factory for moredetails.

Busway for Office, Retailand LabsStarline Track Busway is ideal foroffices, food and retail stores,engineering labs, schools anduniversity labs and shops, cleanrooms, commercial kitchens, etc.Recess the busway into a dropceiling using the bracketsshown. The closure strip givesa hidden appearance, but giveseasy-access power overhead. Thebusway runs can also be flushmounted under a drop ceilingusing the T-bar hanger (seepage 7). Painted busway runscan be provided, to give apleasing appearance. Consultfactory for details.

Engineering lab with Starline Track Busway recessed inceiling over its workbenches and tables.

Office areas use surface mount Starline Track Buswaywith Universal’s power poles plugged into busway.

Surface MountBracket

Drop Ceiling

PVC Closure StripDrop Ceiling

Recessed MountBracket

Drop CeilingBracket


43Application Illustrations

Right: Manufacturing companyuses B100 Starline Track Buswayfor power supply to its machines,tools and electrical accessories.Moving and adding machines issimple, fast and a minimal cost.Rows of low bay lights are alsopowered by B60 Busway.

Far Right: A typical productionmachine plugged into StarlineTrack Busway. When productionrequirements change, relocatingmachines such as this is fastand easy. Using the 25 foot taprule, see page 38, a low costplug-in unit can be used, sincethere are fuses in the machine’scontrol box.

Right: Starline Track Busways areideal for commercial and retailapplications such as this grocerystore chain. The busway ispainted to match the lightingand ceiling, and has a pleasingappearance for lighting andpower supply to coolers, freezers,heating units, etc.


44

Automotive industry usesStarline Track Busways abovethe automobile assembly lines,for supplying power to lights,electrical accessories, fans,tools, video displays, etc. Otherplants also use it for low andhigh bay lighting. Plugging inthe receptacle units is as easy asinsert and twist. Position theconnections wherever desired.

Electronics industrymanufacturer uses Starline forpower distribution throughoutseveral plants, for power dropsto work stations, testing equip-ment, etc. Over 16,000 feet of100 and 60 amp busway wereinstalled in this plant, and over1000 plug-in units. Photo showsone of the production floorareas. This area has over 80 runsof Starline, ranging from 47 to160 feet long per run, with twomezzanines on the right usingruns of Starline recessed in dropceilings. Production can bechanged, and Starline TrackBusway drops quickly relocatedto the new setup.

Garment Industry usesStarline Track Busway for sewingmachines and related equip-ment. Starline is the modern,economical choice of thegarment industry.

Application Illustrations

Specifications

Starline Track Busway SystemsElectrical busway system shallconform to the following designspecifications. Material andinstallation shall comply withNational Electric Code, and shallbe UL listed.

Busway Sections: Buswaysections shall be made ofextruded aluminum housingscontaining solid copper busbars.Aluminum busbars shall notbe permitted.

Busbars shall have anelectrical rating of:

60 amps (B60 Series)

100 amps (B100 and B1OOC Series)

160 amps (B160 Series)

225 amps (B225 Series) continuous duty, 600 volts or less.

The housing shall be acceptableas a 100% capacity groundcircuit, and shall provide apolarizing feature to avoidincorrect installation of plug-inunits. Busbars shall be enclosedin a continuous insulator, withopenings sufficient for the plug-in units to make contact.

LIMITED WARRANTY

Universal Electric Corporation warrants all products sold by it to be free from defects in material or workmanship for a period of one yearfrom the date of delivery. Liability on this warranty shall be limited to the repair or replacement of any product which is returned to theCorporation, freight prepaid, within one year of the date of delivery and which is found by the Corporation to be defective in material orworkmanship; provided, however, that no product shall be returned without the Corporation’s prior written authorization. The Buyer willbe responsible for the cost of removing and reinstalling a defective part or its replacement and all labor and material and all other costsor expenses incurred in connection therewith.

Where required, a 200% capacityneutral busbar shall be provided.Where required, an isolatedground busbar shall be provided,and a ground contact on eachplug-in unit.

Busway section lengths shall be20, 10 or 5 foot lengths, andspecial lengths where specifiedin the system layout. 2, 3, or4 busbars shall be provided,to meet the electrical servicerequirements. A continuousaccess slot for the plug-in unitsshall be provided in the buswaysections, such that the design ofthe openings in the busway andinsulator pass the UL hypotheti-cal finger probe test.

Busbar Connections:(B60 and B100C Series): Busbarconnectors shall be provided,which insert into the ends ofadjacent busway sections.Busbar connectors shall becopper, shall make contact withbusbars, and be tightened byset screws to make reliableconnections.

(B100, B160, B225 Series):Busbar connectors shall beprovided, consisting of copperstabs protruding from one end ofeach busway section. The stabsshall insert into the oppositeend of the next section, and usea tool provided by the manufac-turer to make a compression fitinto the busbar channel for areliable connection.

Housing Couplers: Housingcouplers shall be provided withadequate mechanical strengthso that busway and couplers willsupport up to 100 pounds per10 foot interval, with 10 foothanger spacing. Housingcouplers shall be secured inplace with bolts provided.

Accessories: Standard hangerspacing shall be 10 feetmaximum. Hanging method shallbe ceiling mount, rod mount orcable suspension mount, asrequired. Power feed connectionswith junction boxes, end caps,ells, tees and special fittingsshall be provided to completethe system as needed.

Plug-In Units: Busway plug-inunits shall be of the types andelectrical ratings indicated, withUL listing where applicable.Units shall consist of a plughead assembly designed tofit into the access slot of thebusway sections, and rotate 90degrees to make the electricalconnection. Units shall bepolarized, to avoid incorrectinstallation. Each plug stab shallhave wire color coding indicatedon the unit. A grounded junctionbox shall be provided on theplug-in unit. Direct wireconnections, fusing, circuitbreakers or other circuitprotection devices, shall beprovided as required. The unitsshall have locking clips or bolt-on tabs to secure units to thebusway.

Cord grips and fittings, drop cordassemblies, and other electricaldevices are to be furnishedaccording to specifications.

45

Represented/Distributed by:

Other fine products from Universal:

Tri-Bar/Four-Bar Span-Guard SmartRail

3089 Washington PikeBridgeville, PA 15017 USA(412) 221.4400(800) 333.3490(412) 221.6828 Faxwww.uecorp.com

CAT NO. 1-01

Documents

Busway Series B60, B100C, B100, B160, · PDF fileBusway Series B60, B100C, B100, B160, B225 Products, Components and Accessories