Configure a 40A Row
Build a 40A row, add feeds and PowerDrops, see the system in 3D, and review the BOM and pricing.
Open the 40A Configurator →Design Your Track Busway System
Plan your track busway layout—from system capacity and run configuration to feed locations, PowerDrops and future expansion.
Still deciding which products fit your project? Start with our Buyer’s Guide.
Plan Your Track Busway System Step-by-Step
Use the steps below to choose the right Track Busway system — from selecting system capacity and layout to determining feed locations, PowerDrops, and future expansion.
Step 1 — Select System Capacity
Selecting the correct system capacity ensures the busway can support current equipment loads while allowing room for future expansion.
T40 is our 40A system; T225 is our 225A system.
The system rating is per feed. Each tap-off has its own marked current rating, voltage, pole count and protection requirements.
Select the busway family first, then the tap-off configuration; T40 and T225 tap-offs are not interchangeable.
Choose between 40A standard runs or 225A high-capacity systems based on your application and load requirements.
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40A Track Busway (Standard Runs)
- Up to 40A per phase
- Single-phase in single-deck layouts
- Three-phase in double-deck layouts
- Expand total capacity by adding feeds
View 40A Track Busway System -
225A Track Busway (High-Capacity Systems)
- Up to 225A per phase (3-Phase, 4-Wire)
- Designed for distributed feed layouts
- Supports high-density equipment loads
- Optional isolated ground and 200% neutral
View 225A Track Busway System
Build and Price Your Track Busway Row in 3D
Explore your selected system in 3D, then continue through the guide to plan layout, feed locations and PowerDrops.
Open the 40A Configurator →Configure a 225A Row
Choose run length, PowerDrops, feeds and splitter options. Explore the layout in 3D and review component pricing.
Open the 225A Configurator →Once system capacity is defined, select your circuit type:
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Single-Phase (1-Pole or 2-Pole)
Common voltage options:
- 120V
- 208V single-phase
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Three-Phase Supply
Common voltage options:
- 208V three-phase
- 480V three-phase
Step 2 — Choose Your Physical Layout (ROW, GRID, or RECTANGLE)
Track Busway layouts follow your workflow.
Straight ROWs
Use Straight ROWs when power needs to be distributed linearly along workstations, equipment lines, or aisles.
ROW configurations provide a simple, scalable backbone for overhead power and allow PowerDrops to be positioned anywhere along the run.
Ideal for:
- Assembly lines
- Conveyor paths
- Linear workstations
- Production environments
Advantages:
- Minimal feeds
- Easy future lengthening
- PowerDrops can be moved anywhere along the run
GRIDs and RECTANGLEs
GRID layouts create a fully flexible overhead power matrix unique to USA TrackBusway. By intersecting multiple ROWs, power becomes accessible in two directions across the ceiling plane — a capability not available in fixed-tap busway systems.
RECTANGLE layouts define power around a fixed zone such as a room, cell, or production area.
By enclosing the space, power and PowerDrops remain accessible from all sides without running conduit through the center of the area.
Ideal for:
- Labs and R&D
- Automotive bays
- Manufacturing cells
- Worktable clusters
Advantages:
- Continuous power across multiple directions
- Supports lighting + power in the same overhead structure
- Excellent for multi-operator environments
BRIDGEs
BRIDGEs connect separate ROW, GRID, or RECTANGLE sections to span open areas or obstacles.
They maintain electrical continuity while allowing layouts to extend across walkways, aisles, or structural interruptions.
Ideal for:
- Crossing an aisle
- Connecting separated work zones
- Feeding power across open areas
Step 3 — Determine Feed Locations
Plan feed quantity and locations for the selected T40 or 225A system. Match the feed family and conductor configuration to your layout, calculated loads and project requirements.
40A Feed Planning
40A Track Busway feed locations are flexible by design, allowing engineers to balance loads, reduce homerun wiring, and plan for future expansion. Unlike fixed-tap busway, feeds can be placed where they make the most electrical and operational sense—now and as layouts evolve.
- The end of a ROW
- The center of a GRID
- A branch point feeding two directions
- A midpoint where loads are balanced
- General guidelines:
- Each standard run supports up to 40A per phase from a single feed.
- If loads exceed 40A, use:
Feed-left / Feed-right strategy
Double-deck (2x3-pole) layouts to split loads
- Junction-box splitters allow one feed to serve two directions per NEC tap rules.
This makes Track Busway highly adaptable and simpler than conduit-based overhead systems.
T225 end feed shown with Critical Power Monitoring. Also available without monitoring.
225A End Feed Options
Match T225 end feeds to your busway configuration. T40 and T225 feeds are not interchangeable.
- Standard: standard neutral configuration.
- 200% Neutral (N2): additional neutral capacity.
- Isolated Ground (IG): a separate isolated-ground path.
- 200% Neutral + Isolated Ground (N2IG): both options.
All four configurations are available with No Power Monitoring (no meter or display) or Schneider Critical Power Monitoring. Confirm the meter and communications for your project.
Match feeds, busway lengths, electrical joiners and compatible tap-offs to your configuration. Plan feed quantity and locations for calculated loads; extra feeds do not increase a section’s rating.
Without monitoring · With Critical Power Monitoring
Power monitoring · Neutral & grounding · Compare feed images
View T225 Feed Options →Step 4 — Plan Your Plug-In PowerDrops
PowerDrops are added last, after equipment locations are known — but they should be planned early.
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PowerDrop Selection
- 1-Pole: 120V or 277V receptacles
- 2-Pole: 208V or 480V
- Three-phase: 120/208V with three phase conductors and neutral. Match the tap-off and protective-device pole count to the selected system and equipment.
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Placement Strategy
- Plan for known equipment and future moves.
- Qualified in-house personnel may relocate compatible breakered T40/T225 PowerDrops with the busway energized.
- Keep tap-off breakers OFF throughout removal, relocation and installation; switch ON only after the unit is fully installed and locked.
- Follow system instructions, site procedures and applicable codes.
Step 5 — Validate Loads & Future Expansion
Before finalizing, confirm:
With loads and future needs planned, modular expansion can reduce new wiring, conduit work and downtime. Plan any busway, feed or joint changes under the selected system’s installation procedure and required de-energization.
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Electrical Checks
- Total amperage per phase
- Equipment diversity factor
- Any 200% neutral considerations
- Continuous vs non-continuous loads
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Future-Proofing
Design for:
- Additional equipment
- Changing production lines
- Robotics or automation growth
- New lighting layouts
- Aisle reconfiguration
Track Busway’s modularity can simplify facility changes. Plan any required shutdowns and use qualified personnel for electrical work.
All USA TrackBusway systems are Listed to UL 857 Busway Standards and designed in accordance with NEC Article 368 requirements.
Power Tap-Off Units available in 1-Pole, 2-Pole, or 3-Pole Configurations
Click the red + on the wiring diagram to view all supported system voltages, including 120V, 208Y, 208V 3-phase 4-wire, and 480V.
Panelboard ‘A’ may be 120/208V or 277/480V depending on building service.
Available: 208/480V
Line to Neutral Available: 120/277V
Line to Line Available: 1Ph-208V or 1Ph-480V
Available: 208/480V
WATCH: Movable TrackBusway Lengths — Adaptable Layouts Made Easy
This video shows a movable bridge-kit layout with flexible PowerDrops. Repositioning follows the selected system’s instructions and approved site procedures; electrical installation, feed and joint changes require qualified personnel.
Track Busway supports evolving workspaces with a sustainable, plug-in power system that reduces waste, speeds up changes, and keeps overhead power exactly where it’s needed.
