Choose your System
Use this guide to choose the right Track Busway system for your project.
Compare electrical capacity, layout type, feed placement, plug-in PowerDrops, and expansion needs so your overhead power system is planned correctly from the start.
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.
Choose between 40A standard runs or 225A high-capacity systems based on your application and load requirements.
-
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
Once system capacity is defined, select your circuit type:
-
Single-Phase (1-Pole or 2-Pole)
Common voltage options:
- 120V
- 208V single-phase
-
Three-Phase (1x4-Pole)
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.
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
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 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
Track Busway does not restrict feed points like older fixed-tap busway systems. You can place feeds at:
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.
Step 4 — Plan Your Plug-In PowerDrops
PowerDrops are added last, after equipment locations are known — but they should be planned early.
-
PowerDrop Selection
- 1-Pole: 120V or 277V receptacles
- 2-Pole: 208V or 480V
- 3-Phase: 120/208V (4-pole: 3H + N)
-
Placement Strategy
- Start with known equipment
- Add spare drops for future relocations
- Use the continuous slot to reposition drops as layouts change
- No electrician required for moves or additions
Step 5 — Validate Loads & Future Expansion
Before finalizing, confirm:
Track Busway systems are designed to evolve over time. By validating loads upfront and planning for future equipment, automation, or layout changes, facilities can expand without rewiring, conduit modifications, or operational downtime
-
Electrical Checks
- Total amperage per phase
- Equipment diversity factor
- Any 200% neutral considerations
- Continuous vs non-continuous loads
-
Future-Proofing
Design for:
- Additional equipment
- Changing production lines
- Robotics or automation growth
- New lighting layouts
- Aisle reconfiguration
Track Busway’s modularity enables facility changes without rewiring, cutting conduit, or creating downtime.
All USA TrackBusway systems are ETL-listed to UL 857 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
As equipment layouts change, sections of busway can be repositioned—without conduit, rewiring, or electricians. This video shows how Track Busway adapts with your facility using a modular bridge kit and flexible PowerDrops.
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.
