Maximizing Power Distribution with Track Busway Systems

The type of electrical panel used in a facility determines how power may be distributed to equipment. In the U.S., electrical panels in commercial buildings are typically 208Y/120V three-phase systems, while residential panels are configured as 240/120V single-phase systems. This blog focuses on how track busway systems effectively distribute voltage options from 208Y/120V three-phase panels in commercial settings.

Understanding Three-Phase Power Drops (208V)

Three-phase equipment is powered from connecting all three phase conductors (A, B, and C), delivering 208V phase-to-phase. The continuous, balanced power flow of three-phase systems is ideal for motors, compressors, and HVAC systems. Three-phase power is rarely tapped for other equipment in commercial settings, as most devices operate on single-phase power.

Understanding Single-Phase Power Drops (120V)

Single-phase power is simply derived from one phase conductor (A, B, or C) and a neutral, providing 120V. 

Benefits of Single-Phase over Three-Phase

Track busway systems are designed to efficiently distribute both 3-phase and single-phase power. Since most commercial equipment operates on single-phase power, let’s explore the advantages of single-phase systems.

When powering single-phase equipment, each conductor is capable of carrying a system's max amperage. For example, 40amp 3-phase track busway system is capable of 120amps if powering single-phase equipment. 

In contrast, a 40-amp three-phase system can only supply 40 amps of 208V three-phase equipment. Since most equipment in commercial settings operate on single-phase power, a three-phase track busway system can support 3x more single-phase equipment than if powering three phase equipment.

 A key advantage of track busway systems is in their ability to distribute power efficiently across multiple loads, but some track busway systems do a better job of effectively doing so than others.

Choosing the Right Phase

With a clear understanding of voltage options, the choice between track busway systems becomes crucial for flexible power distribution. This blog post compares the voltage options using a traditional aluminum track busway, and explains how Steel Track Busway is better because it simplifies the installation and enhances wiring capabilities.

As facilities evolve, where power is located in a space can become a hurdle that is costly to overcome. Thus, modern facilities often include overhead distribution systems for localized power delivery. Track busway systems fill that need for electrical flexibility with easy access for upgrades and maintenance, but how you may tap the correct phase for certain voltages varies between track busway systems.

How Aluminum Track Busway Meets Common Voltage Options:

Aluminum track busways can handle up to 600 volts whether alternating or direct current. In North American, the power supplied is typically 120/208 or 277/480 alternating current. 

A typical 4-wire aluminum track busway system comprises:

• Three phase conductors (A, B, C)
• One neutral conductor (N)

Aluminum track busway system is for a wide range of voltage options and for different applications including:

Voltage Type	Aluminum Track Busway	Common Applications
120V Single-Phase	Tap 1 of 3 available hot conductors (A, B, or C) and neutral. Each hot requires a separate plug-in unit.	Lighting, outlets, small appliances.
208V Single-Phase	Tap any two conductors (A-B, B-C, or C-A).	HVAC systems, medium-sized equipment.
208V Three-Phase	Tap all three phase conductors (A, B, C).	Motors, compressors, large industrial loads.

These aluminum systems require specific plug-in units to tap a certain phase and cannot be modified on site. For instance, a 120V plug-in unit must tap the neutral and a specific phase conductor. These keyed fittings do not allow for selection between phases — increasing cost and with no room for on-the-spot adjustments in load balancing.

In short, phase specific plug-in units can cause delays when last minute changes are necessary.

How Steel Track Busway Meets Common Voltage Options:

Voltage options have never been so easy to manage than with Steel Track Busway. Power drops with flip-fittings allow the user to simply plug into the busway and connect their equipment. 

The Steel Track Busway system eliminates the need for such things as keyed fittings, with the ability to rotate phase-to-neutral fittings 180 degrees to select between the phases.

This Plug & Play simplicity translates to faster installations for changing floor plans.

Here’s how Steel Track Busway supports some common voltages:

Voltage Type	Steel Track Busway fittings	Advantages Over Aluminum Track Busway
120V Single-Phase	Tap any single phase conductor (A, B, or C) and neutral.	No keyed fittings required; select which phase to tap in-the-field.
208V Single-Phase	Tap any two phase conductors (A-B, B-C, or C-A).
208V Three-Phase	Tap all three phase conductors (A, B, C).

The Unique Advantage of Double-Deck Track Busway

Where Steel Track Busway really shines is in the 6-wire system, with capabilities beyond aluminum 4-wire systems. With two more conductors than 4-wire aluminum systems, Steel Track Busway can meet the most stringent of electrical requirements. 

Steel Track Busway standard lengths are double-decked when additional wiring capacity is needed. The steel system's modular design allows the 3-wire sections to be stacked together in the field. Investigate double deck lengths for use with 3 phase power distribution to machinery.

With two single lengths stacked vertically in a double-deck design, there are 6-poles total. Whether it’s 100% copper grounding, or low-voltage 0-10v dimming, the two more wires in 6-wire Steel Track Busway offer unprecedented flexibility to meet modern infrastructure demands.

As shown in the comparison table below, Steel Track Busway is the optimal choice for facilities with demanding requirements, such as dedicated grounding or low voltage controls (like 0-10V dimming).

Feature	Aluminum Track Busway	Double-Deck Track Busway
Wiring Configuration	4 wires (3-phase + neutral).	6 wires (3-phase + neutral + 2 extras).
Additional Wiring	Not available.	Dedicated ground or 0–10V dimming capability.
Grounding Capability	Shared neutral/ground limitations.	Dedicated 100% copper ground wire.
Low-Voltage Control	Not supported.	Supports modern lighting controls.
Installation Simplicity	Requires keyed fittings for 120V taps.	No keyed fittings; field connections.

With Steel Track Busway, all 3 phases are tapped with a plug-in unit's factory installed whip fitting. Please see 3-Phase Drop Cord product below.

With double-deck track busway overhead, this power drop supplies electricity to 3-phase motors.

Practical Advantages for Steel Track Busway

There has never been a better time for flexible, efficient, and scalable power distribution systems, from data centers to manufacturing floors.

• Data Centers:

  • Facilities like data centers demand 100% copper grounding, which Steel Track Busway supports with its additional wiring capacity in double-deck configurations.

• Industrial Facilities:

  • Steel Track Busway is capable of powering various equipment types, such as high loads (208V 3-phase) or medium loads (208V single-phase).

Steel Track Busway: The Simple Solution to Voltage Options

Track busway systems have become the standard for flexible, scalable, and effective power distribution in modern facilities. Steel Track Busway stands out with its modular design, double-deck configuration, and advanced wiring capabilities.

Whether ensuring robust grounding for sensitive equipment, integrating advanced lighting controls, or powering high-demand industrial machinery, double-deck Steel Track Busway offers unparalleled flexibility and reliability. Its modularity allows for quick reconfiguration, making it ideal for facilities that need to adapt or expand.

Upgrade your setup today with Steel Track Busway to ensure your power infrastructure is ready for today’s demands and tomorrow’s innovations.