Comparing Track Busway Power Distribution Solutions
As power needs have evolved across industries, prominent power distribution methods have emerged in steel and aluminum track busway. Both track housings offer flexible and efficient power distribution, but they have distinct features and advantages. Let's compare these innovative track busway solutions:
Material and Construction
Aluminum Track Busway is an extruded aluminum housing with copper conductors.
Steel Track Busway also includes copper conductors but consists of 12-gauge steel; combining the flexibility of a track system with the structural advantages of strut.
Amperage and Voltage Ratings
Aluminum Track Busway includes a wide-variety of products to meet different amperage ratings, including:
T1 Series: 40-60A
T2 Series: 60-100A
T3 Series: 100-225A
T4 or T5 Series: Higher amperage options up to 1250A
Steel Track Busway is one modular solution. Single lengths include three #8AWG wires. Lengths can be stacked together for (3) additional wires, totaling SIX wires per section! Because each hot wire in Steel Track Busway is listed for up to 40 amps per circuit, this system is able to distribute up to 160 amps when double-decked (4 circuits x 40 amps).
An additional feed can be added if needed after any Steel Track Busway mechanical joiner. By removing that mechanical joiner sleeve's electrical insert, the circuitry stops because of the end blocks built into the Steel Track Busway lengths, and you can therefore simply add new circuitry by plugging-in an additional feed.
Steel Track Busway and aluminum Track Busway are both certified to UL 857 (Busway) standards. These busway systems are capable of carrying and distributing power in a way that ordinary lighting tracks cannot. Low voltage busways are for use with up to 600V.
Flexibility
Both Steel and aluminum Track Busway have a continuous access slot along the entire length of the system, so plug-in units can be easily inserted and repositioned. This design enables quick reconfigurations without power interruptions.
Distinct to Steel Track Busway are single-circuit plug-ins capable of tapping any available busway circuit (no keyed fittings required like with Starline Track Busway).
Also unique to the steel system are 'bridge' lengths that may be added or moved as needed, with criss-cross intersections for seamless layout changes.
Unique Features
Both systems offer plug-in units with a turn-and-lock feature for easy installation. However, there are more unique features to the Steel Track Busway system:
aluminum Track Busway
- u-shaped copper design for constant tension.
- Optional metering capabilities for real-time power monitoring.
Steel Track Busway
- Criss-cross intersections and jumpers for layout flexibility.
- Bridging capability for precise power drop and/or light fixture placement.
- Trunking design to reduce the number of homerun power feeds.
Maintenance and Installation
Aluminum track busways typically have no nuts or bolts in the joints that would need to be tightened periodically, making it technically a maintenance free product. Aluminum offers fast installation times.
Steel Track Busway is the kind of system that can be easily installed and with minimal maintenance. The strong structural properties of steel make the maintenance and installation of the system very efficient.
The installation process of a track busway system is designed to be simple and with the least possible disruption to labor and downtime. The following are the basic steps and guidelines for a standard installation:
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Preparation
- Determine the track lengths and components required based on the layout.
- Marking the locations for suspension points to align with structural elements such as beams or studs.
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Suspension System Installation
- Hangers or brackets should be attached to the ceiling at max 10-foot intervals (or to manufacturer’s specifications) to guarantee support and stability.
- For UL standards on track busway systems, loads should not exceed 100 pounds between support points.
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Track Assembly
- Assemble the pre-wired tracks at the finished height, or even working height (lift later).
- To join multiple sections together, use electromechanical connectors to guarantee a secure and gapless connection.
- Lift the assembled tracks to the finished height (if assembled at working height).
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Plug-In Units Installation
- Place plug in units, like power drops, in the continuous access slot of the pre-wired track.
- Place units where power is required and ensure even distribution of the phases across the work area.
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Lighting Integration
- If applicable, attach lighting fixtures to the track system.
- Using plug and play connections, makes the installation easy and with minimal on-site wiring required (if any).
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Testing and Commissioning
- All connections should be checked to make sure they are secure and properly grounded.
- The system should be energized and the power drops, lighting fixtures, and any other plug-ins should be tested to ensure they are working correctly.
Following these steps and the manufacturer’s guidelines, track busway systems can be installed quickly and efficiently, helping to minimize downtime and labor costs. Check the manufacturer's product manual for further installation requirements.
Material Cost Comparison: Steel vs. Aluminum Track Busway in 2019
When comparing material costs, Steel Track Busway offers a clear advantage over traditional aluminum track busway systems.
| System | Components Included | Total Cost (USD) | Price per Linear Foot (USD) |
|---|---|---|---|
| Aluminum Track Busway (100A) | Straight Section, Joiner, Feed, 2 End Caps | $1,652.00 | $165.20 |
| Aluminum Track Busway (225A) | Straight Section, Joiner, Feed, 2 End Caps | $2,083.00 | $208.30 |
| Aluminum Track Busway (250A) | Straight Section, Joiner, Feed, 2 End Caps | $2,620.00 | $262.00 |
| Aluminum Track Busway (400A) | Straight Section, Joiner, Feed, 2 End Caps | $4,227.00 | $422.70 |
| Steel Track Busway (40A) Single-Phase |
Straight Section, Joiner, Feed, 2 End Caps |
$315.48 | $31.55 |
| Steel Track Busway (40A) 3-Phase | 10 ft Section, Double-Deck Joiner, Feed | $630.95 | $63.10 |
Applications
Track busway systems are suspended over various facilities; and some of these project types include:
Data Centers
Track busway systems are typically recognized for their ability to provide versatile power distribution in data centers, but they are also useful for lighting solutions. These systems provide overhead power distribution with easily accessible access slots that change with alterations in server configurations for data center use. Additionally, the lighting capabilities of overhead track busways are useful for data center applications.
Industrial facilities
Track busway systems are beneficial in various types of industrial facilities such as manufacturing plants, logistic warehouses, and assembly lines due to the number of benefits that they present:
Manufacturing
In manufacturing environments, track busways are used for flexible power distribution that can adjust to changing production needs. These systems let you easily rearrange power access points as production lines change without a lot of electrical work to change out the layout of power distribution. This flexibility reduces downtime when making changes to the layout of your plant and is compatible with high power machinery and tools, so that manufacturing operations can become more efficient with less interruption.
Logistic Warehouses
For the modern warehouse with its dynamic nature, track busways provide versatile solutions. They serve as a flexible power distribution for conveyor systems and sorting equipment, and also allow for the easy installation of lighting and power drops at workstations. This is crucial for changing storage layouts and picking zones, in support of the ever evolving needs of logistics operations. Additionally, track busways can handle power needs for automated guided vehicles (AGVs) and robotic systems, which help implement warehouse automation plans.
Assembly Lines
For assembly line operations, track busways offer easily reconfigurable power access for different assembly stages. This flexibility is supportive to mobile workstations and power tools and they are quickly adaptable to new product lines or assembly processes. The integration of lighting and power in a single overhead system simplifies the assembly environment and enhances efficiency and worker comfort.
Conclusion
Both busway systems provide new approaches to flexible power distribution.
The traditional track busway systems, consisting of an aluminum housing, offer a wide range of amperage options.
The Steel Track Busway uses the strength of steel, focusing on the structural advantages and the seamless integration of power and lighting.
These choices will be based on specific project requirements such as power needs, structural considerations and the level of flexibility desired. Both solutions are a great improvement over the conventional power distribution systems and enable businesses to respond swiftly to changing power needs in our rapidly changing technological environment.