Busway Busrail Splice Connector

The PowerWave Bus System Splice Connector:

The splice connector enables multiple sections of busrail to be joined thus creating an almost unlimited number of overhead power distributions layouts. The cam-actuated junction allows the busway sections to be joined both electrically and mechanically with a single component. This two-step process of mechanical fit, then electrical engagement creates a more controlled environment and is thus is inherently safer. Cam-action ensures a stable and complete connection of the busway, while at the same time allowing for visual inspection from below to ensure all junctions are properly connected. Each splice connector is factory tested prior to shipping with ratings up to 42 KAIC.

The images below detail the primary components of the splice and associated tools.

Splice Connector Components:

Busway Splice Connector
1Low Maintenance Contact - This low maintenance contact is made up of multiple ribbons of copper beryllium strips that make contact with the bus bars in the assembly. This processed and bonded material eliminates surface oxidation, maximizing surface-to-surface contact point and thus better electrical connections which in turns improves kAIC ratings and minimizes maintenance. The contacts are attached to copper beryllium coated bus bars thus when compressed against the bus bars in the aluminum busrail an electrical connection is made.


2Splice Housing - The busbars and contacts are housed in a machined Noryl insulator plate. Noryl is a high performance plastic used in electrical systems.


3Cam and Cam Tool Insert Holes - Non conductive "cam fingers" and cam installation tools are inserted into these holes allowing for pressure to be applied to the contacts and copper busbars.

Splice Tools and Support Components:

1Cam Installation Tool - The Cam Installation Tool enables pressure to applied between the contacts and the busbars allowing the non-conductive cam fingers to be rotated and thus hold a continuous pressure after the tools has been removed.


2E-Clips - The E-Clip holds the open channel of the busrail closed so that pressure can be applied between the contacts and the busbars. An E-Clip is installed on each section of busrail being joined together by the splice connector.


3Grounding Plate - The grounding plate slides into the top channel of the aluminum busrail. Set screws or stud nuts are used to ground one section of busrail to the next based on the system rating.


4Side Support Plates - Side support plates reinforce the side walls of the aluminum busrail as the splice is installed.

When joined together the E-Clips, Grounding Strap and Side Support Plates create a boxed re-enforcement around all four sides of the aluminum busrail. This allows for 70 lbs. per square inch to be applied between the connector and busbars enabling the PowerWave Bus System to achieve ratings of up to 42 kAIC.

Splice Support Components Assembled:

1Grounding Plate - The grounding plate slides into the top channel of the aluminum busrail. Set screws or stud nuts are used to ground one section of busrail to the next based on the system rating.


2Side Support Plates - Side support plates reinforce the side walls of the aluminum busrail as the splice is installed.

Splice Support Components Shown Inserted Below:


1Splice Connector - The Splice Connector is shown inserted into the Busrail.


2Side Support Plates - Side support plates reinforce the side walls of the aluminum busrail as the splice is installed.


3Cam Fingers - The Non-Conductive Cam Finger holds the pressure created by the Cam Installation Tools after they have been removed. The white tips enable visual installation after the splice has been installed. If the slot in the cam finger is perpendicular to the busrail it is not holding pressure between the contacts and the busbars. The cam fingers in this image have not been installed thus the splice can be slid back and forth within the busrail. When the slot in the cam finger is parallel to the busrail then the cam fingers are holding pressure and installed correctly.


4E-Clips - The E-Clip holds the open channel of the busrail closed so that pressure can be applied between the contacts and the busbars. An E-Clip is installed on each section of busrail being joined together by the splice connector.

Installed Splice:


1Side Support Plates - Side support plates reinforce the side walls of the aluminum busrail as the splice is installed.


2Cam Fingers - The Non-Conductive Cam Finger holds the pressure created by the Cam Installation Tools after they have been removed. The white tips enable visual installation after the splice has been installed. If the slot in the cam finger is perpendicular to the busrail it is not holding pressure between the contacts and the busbars. The cam fingers in this image have been installed thus the splice thus they are holding pressure and installed correctly.


3E-Clips - The E-Clip holds the open channel of the busrail closed so that pressure can be applied between the contacts and the busbars. An E-Clip is installed on each section of busrail being joined together by the splice connector.