the next generation of flexible power distribution ... · PDF fileThe design of our new...
Transcript of the next generation of flexible power distribution ... · PDF fileThe design of our new...
the next generation of flexible power distribution
powerwave bus systemtm
www.pdicorp.com2
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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
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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.
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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.
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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
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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=
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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.
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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
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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
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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
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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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