the next generation of flexible power distribution

powerwave bus systemtm

www.pdicorp.com2

3

table of Contentsintroduct ion – eng ineered for Cr it ical powerDesigned specifically for the Critical Power Market ....................................................... 4

Decentralize your system – what makes up PowerWave Bus System™.............................. 6

Advantages of PowerWave Bus System™ ....................................................................... 8

System features ........................................................................................................... 9

Components and d imens ionsTechnical specifications ............................................................................................. 13

Component listing and general description ................................................................. 14

Dimensions ......................................................................................................... 15, 16

Standard layout advice .............................................................................................. 17

des ign gu ide and spec if icat ionsTap off selection guide .............................................................................................. 18

Configuration logic ................................................................................................... 19

Enclosure specifications ............................................................................................ 19

Standard circuit breaker ............................................................................................ 19

powerwave bus systemtm

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p o w e r w a v e bus system tm des igned spec if ically for the Cr it ical power MarketPowerWave Bus Systems™ have been specifically designed for the critical power market by PDI Corp, a leading

manufacturer in the critical power arena. With over 30 years serving the data center, banking, processing center and

industrial markets, PDI has gained an expertise in product development and reliability for critical power facilities.

Through our extensive background and experience we know that up time and reliable clean power are critical to our

customers and, more importantly, to their customers.

Our new patent pending structured bus design incorporates over 59 specific pending claims driven from

our incorporated communications capability, our unique Camtough™ structured joint technology, and our

Toughrail Technology™ supporting structure. In an industry where up time, reliability and serviceability

are critical, isn’t it about time that a structured bus was designed specifically for you?

seCtion 1

designed speCifiCally for the CritiCal power Market

5

Critical design features of the powerwave bus system™

• Reliability Tested at up to 200% of rating our

PowerWave Toughrail Technology™ is built to last.

• tRaceability Clearly defined distribution

with zero footprint allows for easy visible tracing

of circuits.

• ReconfiguRe Move it, re-use it, add to it, or

change direction – all without any waste, and all

with only minor disruption.

• communications Optional integrated

communication through provides all the

features used in our Power Distribution Units or

Remote Power Panels with complete integration

to our current Branch Circuit Monitoring System

(BCMS) Hub.

• configuRable Lay it out, change your mind,

move an move an aisle ... no problem – everything

is easier with a distributed bus system.

• low Heat souRce Heat is an electrical

systems killer. So by reducing its concentration

within a distributed power system, heat is more

easily distributed throughout with no hot

spots, potentially reducing spot

cooling measures, smoothing

cooling demand.

• Reusable Put it up, take it down, store it,

and re-use it. This is all possible with no waste

with PowerWave™ Structured Bus.

• Recycle Made of 99% recyclable

environment-friendly

components.

• tap off units

Continuous bus allows for distribution of Tap

Off Units at any location along the system. Tap

Off Units can be added or removed at any time.

(Proper safety procedures should always be used

when working on live components.)

• load-specific Tap Off Units are completely

configurable to meet your load demands, and

specific load requirements including monitoring.

• Visual installation indicatoRs Our

system is designed so that there are visible

installation features that allow you to check that

your configuration is securely installed prior to

start up.

q

q

B C M S H U B

PDI

T A P O F F T A P O F F T A P O F F T A P O F F

B U S W A YE N D F E E D

T A P O F F T A P O F F T A P O F F T A P O F F

B U S W A YE N D F E E D

T A P O F F T A P O F F T A P O F F T A P O F F

B U S W A YE N D F E E D

T A P O F F T A P O F F T A P O F F T A P O F F

B U S W A YE N D F E E D

bCMs panel d isplay

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powerwave bus systemtm s imple yet robustFrom preliminary concept to the final installation you

can count on PDI and PowerWave Bus System™.

The design of our new PowerWave Bus System™

improves your installation, enhances system

flexibility and ensures uninterrupted operation life

of your critical electrical system. The PowerWave

Bus System™ is built and tested to the stringent

UL 857 standards, and tested and certified by ETL.

geneRal

PowerWave Bus System™ with PowerWave Tough Rail

Technology™, manufactured by PDI Corporation, offers

a complete line of fully compatible, continuous opening

plug-in busway with all the required fittings to

complete your job. The PowerWave Bus System™ is

a flexible, easy to install, high-efficiency structured

busway system that completes your low voltage

power distribution system for any critical power,

industrial or commercial application.

Our broad range of PowerWave Tough Rail Technology™

busway systems are based on a continuous plug-in

bus design with nickel-plated copper conductors and

contacts. The patented PowerWave Tough Rail

Technology™ system is available in three-pole and

four-pole designs with optional 150% fully rated

neutral configurations for system voltages of 480

Volts and is rated for 100% current flow on a

continuous basis.

System installations are performed

quickly and easily. Our rugged

yet lightweight design allows

for easy handling and

installation with claims

of upward of 60% savings

in time and labor over competitive cable and

conduit methods of installations. This significant

savings is inherent to the design of our Toughrail

system. Busway systems have been available for

years. Most systems applied to the data center are

mere adaptations of industrial or commercial

systems that have not been designed for critical

power loads. Now, PDI has created a robust,

elegant bus system designed specifically for critical

power and data center installations.

tougHRail tecHnology and

constRuction

PowerWave Tough Rail Technology™ with our

unique open and accessible design, and oversized

bus bars provides superior voltage drop characteristics.

The extruded aluminum housing is of a one-piece

design with no welds or bolts along the

seCtion 2

siMple. robust. effiCient.

7

straight sections, reducing weight, improving the

ground path, and enhancing the stability and

strength while minimizing the EMI of the system.

Toughrail Technology™ incorporates one of the most

unique section-to-section joints available today.

Our patented cam-action connection method

assures you a secure, thermally-efficient,

maintenance-free connection. Our design allows

for minimal resistance and minimal voltage drops

across the connection. And by utilizing 12 foot sec-

tions of bus versus the traditional 10 foot, two joint

connections for every 100' of run can be eliminated.

The unique continuous open bottom design allows

you to place distribution points at any

location along the run, reducing cabling

and improving the overall look and

functionality of your system.

Within the same ampere rating, all PowerWave

Toughrail Technology™ systems are fully compatible

between each add on component (i.e.: 250A to 250A).

Hassle-fRee continuous Run design

PowerWave Bus System™’s open channel design

allows the installer and end user the greatest

flexibility on the market today. With no

predetermined tap off points, our system allows you

to place distribution needs directly over loads. The

total system enhances the workability of the

installation as well as improving the analysis of

direct loads. With our Tough Rail Communications

system, you can monitor individual loads

remotely, improve visibility of critical load

factors, and even monitor thermal

activity on the system.

www.pdicorp.com8

poweRwaVe bus system™

adVantages of stRuctuRed bus

betteR foR tHe enViRonment

reCyCle : Our PowerWave Bus Systems™ are a 99%

recyclable system.

Components are reusable, and all

packaging material is completely

recyclable. There is no

environmental impact during

our assembly process.

For the installation, PDI will ship all components in

recycled containers and/or with recyclable packaging.

non tox ic : All components of the PowerWave Bus

System™ are strictly made in accordance with all

standards to eliminate any toxicity in case of a fire in

your facility

non propogat ion : In the case of a fire in your facility

you can rest assured that the PowerWave Bus System™

is self extinguishing and will not propagate the path

of the flame.

energy eff iC ient : The potential for substantial energy

savings is created by the patented design of the

PowerWave Bus System™:

• Distributedbusremovesenergy-wastinghotspots

from the data center due to electrical cable congestion

• Distributedbushaslessvoltagedropthan

conventional wiring methods, allowing for a more

efficient energy consumption

• Distributedbusreducesthefootprintallocatedto

electrical systems in your facility allowing you to

size your power infrastructure more accurately

• Distributedbusenhancesyourpowerfactorrating

due to the low line-to-line voltage loss

lower voltage

dropsenhancedpowerfactorrat ing

9

generalPowerWave Toughrail Technology™ structured bus

has a thermally efficient design, eliminating the

need for de-rating regardless of mounting position

or angle. Our design can be overhead mounted,

side wall mounted or in some cases (depending on

local regulation), mounted under raised floors.

Rugged & compact

eliminates floor space foot print

The PowerWave Toughrail Technology™ structured

bus system is a rugged, yet compact system. Our

unique Toughrail Technology™ allows for power

and communication in a single run, enhancing load

communications, and reducing the space required

compared to multiple cable and conduit runs.

Intrinsic to our design is the elimination of the

floor space foot print

commonly associated with

distributed loads. Our system

is placed out of the way, and

with minimal requirements

for mounting tap off points,

gives you greater flexibility

and convenience.

constRuction and finisH

PowerWave Toughrail Technology™ system housing

is created from a single-piece aluminum extrusion

with a black anodized finish which increases the

heat dissipation along the bus, reducing hot spot

concentrations. This effectively reduces the overall

heat concentration generated by loads and helps

reduce the spot cooling needs of your facility.

With optional finish colors to meet your needs, the

PowerWave Bus System™ with Toughrail Technology™

is aesthetically pleasing and can enhance the look

of your installation. Our construction design allows

you the ability to easily label runs, add logos to the

housing, add optional communication functionality

and reduce annual maintenance.

insulation

The insulation used in the PowerWave Toughrail

Technology™ system is manufactured with a Class

220 rated 149°C (300°F) material. Our insulation is

formed to wrap around each bus bar giving perfect

separation from phase-to-phase and phase-to-ground.

Created in a continuous section with end run

spacing, there are no gaps even where tap off

devices are added, improving your systems safety

and long-life efficiency.

seCtion 3

systeM features

communicationsisolated ground

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plating

To improve system conductivity and reduce

resistance the PowerWave Bus System™ is only

available with nickel-plated copper bus bars. This

proven system improves the overall contact surface,

reducing surface-to-surface resistance and minimiz-

ing corrosion. We do not use silver flash plating,

as our testing has determined that this finish is not

rugged, nor sustainable over time. Our plated

finish will stand up to use, ensuring years of

uninterrupted service.

poweRwaVe bus system™

integRal gRound patH

PowerWave Toughrail Technology™ incorporates an

integral ground system, – a feature of its extruded,

one-piece aluminum housing. By utilizing the hous-

ing design for our grounding system, we ensure the

path, improve the capacity, and encase the com-

plete system.

sHoRt ciRcuit stRengtH

PowerWave Toughrail Technology™ system receives

high marks for our short circuit ratings. With our

unique design for low voltage distribution, the AIC

ratings achieved for unprotected bus are up to 42,000

RMS. Our testing has been completed and certified

by an independent third party and is not reliant on

in-house certifications.

Voltage dRop

Because of its extremely low resistance,

PowerWave Toughrail Technology™ has very low

voltage drop. This has been a key design criterion

when we developed our system specifically for the

critical power and data markets.

dielectRic testing

UL® and CSA require a one-time

dielectric test prior to certification

at two times rated voltage plus 1000

VAC (2200 VAC). Our PowerWave

Toughrail Technology™ easily passes this criterion.

Furthermore, every part of our system has been

tested with a 7500 Vdc “hi-pot” test.

N

Cu better conduct iv ity=

11

cam-actuated camtougH™ tecHnology

The PowerWave Toughrail Technology™ distribution

system incorporates one of the most unique and

practical designs in the industry. Our patented

cam-actuated Camtough™ connection technology

provides an outward force on the bus of over

70 lb-ft ± 10 lb-ft pounds/square inch. The cam

action evenly distributes the contact points across

all busway joints, and is utilized in our tap off

technology as well.

By improving the contact area connection while

allowing for expansion and contraction of the

system, our unique design serves as a complete

connection with visual indicators of installation

success as well as adding strength and rigidity to

the connection point.

The Camtough™ joint assembly is standard on all

our systems. Ground connections are made through

a direct connection of the Splice Grounding plates,

ensuring a reliable maintenance-free assembly.

Visual indicators have been incorporated into the

connection design that makes site inspection prior

to start up an easy function.

With our Camtough™ connection there is no need

for special tooling. All torque requirements are met

as soon as the cams are turned to their pre-aligned

locations.

saVe time saVe money

PowerWave Toughrail Technology™ systems will

install in a shorter time period than traditional

distribution methods. By simply placing the hangers

and installing the bus, you have reduced installation

time, dramatically improving on-site performance

and eliminating costly labor.

fiRe safety

PowerWaveToughrail Technology™ is rated as a

non-propagating system, there are no components

within the system that will add to the propagation

in case of an emergency. All material is non toxic.

Note: PowerWave Toughrail Technology™ systems

will require the installation of an internal barrier

when passing through walls or floors.

designed foR Quality in cRitical

poweR facilities

PowerWave Toughrail Technology™ systems are

manufactured by PDI. We conform to ETL and UL

and perform 100% testing on each and every part

of the system prior to shipping.

www.pdicorp.com12

detail of CoMMuniCation systeMtap off box showing breakers / branch circuit monitoring system

detail of tap off box displayshows tap off box bcms power data

circuitbreakers

currenttransformers communications

circuit board

T A P O F F T A P O F F T A P O F F T A P O F F

B U S W A YE N D F E E D

busway monitoRing and communications

PDI’s integrated Branch Circuit Monitoring System

delivers the measurement and management of the

Bus and Tap Off loads to the customer’s building

management system.

The PowerWave Bus System™ Monitor / Commu-

nications system monitors and provides all power

calculations for the total input power for each

busway run.

Voltage (L-L, L-n) for all three phases

demand & percent Load current

overvoltage/undervoltage alarm threshold

crest factor

current-phase, ground, & neutral

kw, kVa, kVar, power factor, kwh

minimum & maximum current

It is housed inside End Feed Box, and is able to

monitor two independent sources for dual run

applications. The power parameters / calculations

being communicated from the Tap Off units are:

B C M S H U B

PDI

T A P O F F T A P O F F T A P O F F T A P O F F

B U S W A YE N D F E E D

T A P O F F T A P O F F T A P O F F T A P O F F

B U S W A YE N D F E E D

T A P O F F T A P O F F T A P O F F T A P O F F

B U S W A YE N D F E E D

T A P O F F T A P O F F T A P O F F T A P O F F

B U S W A YE N D F E E D

13

specifications powerwaVe™

notations

ampacity system 160 225 250 400

protection housing ip42 ip42 ip42 ip42

safety intrusion ip2x ip2x ip2x ip2x

rated voltage system 208/480V 208/480V 208/480V 208/480V

rated insulation voltage protection 1000V 1000V 1000V 1000V

voltage drop/100’ at 80% pf 1.45 1.17 1.23 2.03

conductor material cu cu cu cu

frequency rating 50/60 50/60 50/60 50/60

allowable short circuit rating (kaic) at 80% pf 22ka 22ka 22ka 22ka1

copper dimension per phase 3/16" x 1" 3/16" x 1" 3/16" x 1" 1/4" x 11/4"

housing finishanodized aluminum

black black black black

housing material extruded aluminum aluminum aluminum aluminum

uL listed as uL857 uL857 uL857 uL857

cse approved yes yes yes yes

nom compliant yes yes yes yes

iec rated as 60439.2 60439.2 60439.2 60439.2

system weight per foot 6.8 6.8 6.8 9.6

support distance (max. on centers) system 10' 10' 10' 8'

seismic rating per design consult factory for suspension design

flame propagation (*non-propogating) rating Vø* Vø* Vø* Vø*

seCtion 4

teChniCal speCifiCations

1 42ka @ 208V

www.pdicorp.com14

Catalog logiC

type code ampacity code kaic code configuration code neutraL code item description code Length code

busway hpw 160 160 22 a 1p3w a 100% 1 straight s 12 144

225 225 2p3w b 150% 2 tee t 10 120

250 250 3p4w c 200% 3 cross c 6 072

400 400 ig 100n 4 elbow Left eL 5 060

ig 150n 5 elbow right er 3 036

ig 200n 6 elbow up eu 2 024

feed breaker bf 1.5 018

hanger h special

type code bus ampacity

code kaic code configuration code breaker poLes*

code item description

code configured receptabLe

code

tap off units hpp 160 160 22 a 1p3w a 1 1 15 1 L5-20 1

225 225 2p3w b 2 2 20 2 L5-30 2

250 250 3p4w c 3 3 30 3 L6-20 3

400 400 4 4 40 4 L6-30 4

5 5 60 5 L21-20 5

6 6 80 6 L21-30 6Building a catalogue number: 250 Amp 3P4W Tap off plug with an isolated ground and 150% neutral – 3 20Amp breakers:

hpp (250)(a)(C)(6)(2)(5)

Building a catalog number: 250 Amp 3P4W 22Kaic straight busway with 12 foot lengths with optional isolated ground and 150% neutral:

hpw (250)(a)(C)(5)(s)( 144)

seCtion 5

CoMponent listing & general disCription

15

bus straight seCtions: 160-400Note: Height and Depth are common across the 160, 225, 250, 400 range of product

range/size standardLength

height depth ampacity VoLtage weight

160 inches 120 5.2 2.3 160 208/480 6.8 lbs/ft

cm 304.8 13.2 5.8

225 inches 120 5.2 2.3 225 208/480 6.8 lbs/ft

cm 304.8 13.2 5.8

250 inches 120 5.2 2.3 250 208/480 6.8 lbs/ft

cm 304.8 13.2 5.8

400 inches 120 5.2 2.3 400 208/480 9.6 lbs/ft

cm 304.8 13.2 5.8

elbow seCtions: 160-400Note: Height and Depth are common across the 160-400 range of product

range/size height depth ampacity VoLtage weight

160-250 inches 5.2 2.3 160-400 208/480 13.6 lbs

cm 13.2 5.8

400 inches 5.2 2.3 160-400 208/480 19.2 lbs

cm 13.2 5.8

tee seCtions: 160-400Note: Height and Depth are common across the 160-400 range of product

range/size height depth ampacity VoLtage weight

160-250 inches 5.2 2.3 160-400 208/480 24.3 lbs

cm 13.2 5.8

400 inches 5.2 2.3 160-400 208/480 34.3 lbs

cm 13.2 5.8

seCtion 6

diMensions & statistiCs

160, 225, 250, 400 aMph

ld

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end feed seCtions: 160-400range/size height width depth

160-250 inches 16.0 16.0 8.0

cm 41 41 20

400 inches 18.0 22.0 9.0

cm 46 56 23

bus hanger: 160-400Note: Height and Depth are common across the 160-400 range of product

range/size height depth weight

160-250 inches 5.2 2.3 0.8 lbs

cm 13.2 5.8

400 inches 5.2 2.3 0.8 lbs

cm 13.2 5.8

bus seCtion end Cap: 160-400Note: Height and Depth are common across the 160-400 range of product

range/size height depth weight

160-250 inches 5.2 2.3 0.8 lbs

cm 13.2 5.8

400 inches 5.2 2.3 0.8 lbs

cm 13.2 5.8

Cross seCtions: 160-400Note: Height and Depth are common across the 160-400 range of product

range/size height depth ampacity VoLtage weight

160-250 inches 5.2 2.3 160-405 208/480 32.4 lbs

cm 13.2 5.8

400 inches 5.2 2.3 160-405 208/480 45.7 lbs

cm 13.2 5.8

17

By following a few key concepts, the design of a

horizontal distribution system is quick, easy, and

keeps your overall design very straightforward:

1. Review the basic system specification for details

on size, electrical characteristics and any specific

site details or horizontal plane intrusions. Note all

special conditions regarding HVAC, fire suppression,

changes in general construction, expansion joints,

additional electrical systems and all plumbing

systems.

2. Perform a simple design evaluation. This is not a

detailed layout of the design. It is used to help you

determine where system runs will be most effec-

tive and the load concentration will be. From this

study you should gain a working knowledge of the

amount, ampacity, and electrical configuration of the

busway system to be used, the amount and type of

the Tap Off Units to be incorporated and finally, the

number of variable fittings (elbows, tee’s, etc.) that

will be required. The key to a horizontal system is that

it allows you to design your layout without having the

complete details of the installations.

3. Installation of the system can be modified as

building issues arise; however, it is best to follow a

single plane as much as possible to avoid the need

for special lengths or fittings.

4. Review, from the electrical characteristics and

mounting requirements, the size and location of

the bus system to be used.

5. Review the area to assure that you have captured

all the special requirements of the job site.

6. Measure from a fixed point in the location and

determine the busway runs, change in direction

and plane adjustments, making sure to leave at

least 4" on the side and top of the bus system and

ensure that any Tap Off Unit will have an ample

clearance for the installation and wiring needs.

7. Route the busway in a manner that allows for

a solid support surface either from a side wall

mount or from the building’s permanent ceiling

supports.

8. Create your bill of material – if you have any

questions or concerns, PDI’s experienced team

will be happy to assist you.

9. Keep in mind that the maximum supporting

interval is 8 feet.

seCtion 7

standard layout adviCe

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PowerWave Bus System™ Tap Off Units allow you

complete power distribution control with virtually

unlimited customization for a safe, tested, and certified

mini-power distribution unit specifically designed for

each of your designated loads. The flexibility of our

manufacturing and design system allows for almost

unlimited variations and configurations. The Tap Off

Units are UL and IEC certified, and allow for a wide

range of configurable loads. Each Tap Off Unit is

designed for safety, ease of insertion, and easy relocation

on your busway system. Design flexibility allows you

to decide and tailor your loads and distribution as

needed. PowerWave Bus System™ is unique in that it

features a field-modifiable phase distribution system,

allowing your team to easily modify the tap off

scheme to best address your load distribution, as your

installation is completed.

With our unique mast-style Tap Off Unit, you never

need to worry about rotation, phasing, spacing, or

security. Our positive-locking cam system and our

single-plane insertion design, assure you the highest

level of flexibility and security in your load placement.

The selection and configuration of a Tap Off Unit is

per your specification, and will conform to the needs

of your site. Tap Off Units come in four size variants,

with multiple breaker outlet and pole configurations

as well as a large assortment of receptacle and cord

end styles. From straight-pin to twist-lock to pin-

in-sleeve, the PDI PowerWave Bus System™ Tap Off

system gives you the most flexibility on the market

today. If you can imagine, it we can make it.

seCtion 8

tap off seleCtion guide

mastmechanical bus/rail connection

cam-accuation lever

breakers

contacts

19

enClosure speCifiCations:

cat style small medium Large customdimension 10.3" x 9.5" x 3.3" 10.3" x 11.0" x 3.3" 10.3" x 14.0" x 3.3"

code S M L Client

poles 6 6 9 Client

Voltage max 480V 480V 480V 480V

ampacity max 30 60 100 100

protection Breaker Breaker Breaker Breaker

devices NEMA/IEC NEMA/IEC NEMA/IEC NEMA/IEC

number of devices 4 6 6 Client

drop cord 4 6 6 Client

communications No Yes Yes Client

max kaic 22 22 22 22

weight Loaded (est) 6.1 lbs. 8.3 lbs. 10.5 lbs. Varies

monitoring No Yes Yes Client

ip rating IP-40 IP-40 IP-40 IP-40

color Black Black Black Black

standard CirCuit breakers:

breaker type brand ampacity kaic VoltageQou Schneider/Square D 10-100A 22 KAIC 120/240V

aCCessories tap off box:

description catalog numberFloor Operated Hook Stick 8' hpp-hs-8Floor Operated Hook Stick 12' hpp-hs-12

Configuration logiC:

type size breakercount

breaker devicescount

type shortcircuit rating

Voltage special features

ppowerwave tap off unit

S,M,L,C

S= SmallM= MediumL = LargeC = Custom

1-6Number

of Breakersrequiredfor the

designatedcircuit

Square DQOU

X=1,2,3,4 Pole

YYY = Ampacity 10-100

1-6

Number of Breakers

requiredfor the

designatedbox

NemaConfiguration

TypeSee Chart

A = 10B= 22

10 KAIC22 KAIC

A = 120V B = 240VC = 277VD = 347VE = 480V

Breaker ordevice

I = Isolated GroundB = BCMSA = AlarmC = Door contactsE = Communications Port

Power Distribution, Inc. | 4200 Oakleys Court | Richmond, VA 23223800.225.4838 | 804.737.1703 fax | web site: www.pdicorp.com

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