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CATALOG

WavePro-R Cast Resin Busway

• Unparalleled safety and protection

measures
• Wide range of designs meeting
customer’s stringent requirements
• Lower installation and maintenance
costs
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ABB Busway provides a safe, reliable and Table of Contents
cost-effective means of distributing
electrical power in commercial and
industrial applications.
004 WavePro-R Busway Overview

As an alternative to cable, ABB’s busway 005 Technical Data

solutions offer a range of products to 006 Product Features

ensure safe, flexible, and reliable cost-
effective distribution of electrical power. 007 BDM Software

008 Electrical Data

009-015 Physical Data

016-017 Busway Installation

018 Numbering System

019 Check list

4 WavePro-R Cast Resin Busway WavePro-R Cast Resin Busway 5

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WavePro-R Busway Overview Technical Data

ABB WavePro-R Cast Resin Busway is a high performance low-voltage busbar system. The cast resin forms an external surface
which provides a water tight barrier around the current carrying conductors. It’s up to 5000A rated current and IP68 protection Standards IEC 61439-1 2011: LV switchgear and control gear assemblies – Part 1: General rules
level. Insulation material is halogen free, non-toxic and non-flammable. IEC 61439-6 2012: LV switchgear and control gear assemblies – Part 6: Busbar trunking systems
(busways)
Test certificates KEMA KEUR*
Phase and earthing arrangement: L1, L2, L3, with N, PE & N and PEN. Neutrals are 100%, PE is available as 50%. PEN (isolated
Electrical data
and ground) is rated at 100%. The PE/PEN bar material is the same as the phase bar.
Rated frequency (fn) 50Hz
Rated current (InA) 400A - 5000A
WavePro-R busway features excellent performance. It is especially suitable for subway, shipyards, chemical industry, and other Rated short-time withstand current (Icw) 30kA - 100kA
demanding applications with high requirements on waterproofing and corrosion resistance. Rated peak withstand current (Ipk) 63kA - 220kA
Rated operational voltage (Ue) 690V
Rated insulation voltage (Ui) 1000V
Rated impulse withstand voltage (Uimp) 8kV
Construction
Degree of protection IP68
Material of enclosure Epoxy resin mixture
Protection against electric shock (indirect contact) Protective Earthing and Insulating Material
Busbars Protective Earthing and Insulating Material, silver plating as an option
Insulation class Class B (130°C)

*: 400A - 1250A Rating CQC certificate available.

6 WavePro-R Cast Resin Busway WavePro-R Cast Resin Busway 7

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Product Features BDM Software

• A unique formulation of epoxy resin that has been developed for WavePro-R busway. The resin is mixed BDM is a software dedicated for WavePro busway routing design, segmentation and BOM generation.
in a sealed vacuum to ensure a consistent quality with even distribution of the mixture with no air voids
BDM built in detailed busway product parameters and related design standards, seamless integration
• Under controlled temperature and pressure conditions, the materials in the mold will set gradually. After with ERP system:
curing, the result is an insulated busway that is compact, void-free, has low internal stress and a smooth
• 3D layout generation (direct drawing
outer surface
or generate from polyline)
• Non-standard unit customization
• The protection degree is up to IP68 for feeder busway which comply with the requirements of IEC 60529
• Wall / floor setting up
degrees of protection provided by enclosures. The IP68 designed product can work under water over a
• Tap-off units, hangers and customized
certain period of time or be laid in cable conduit
units’ insertion
• Busway segmentation automatically
• WavePro-R copper conductor is machined by polish-saw process, ensured a high quality bar end finish.
or manually
This process is better than cutting and avoids secondary damage to insulation materials
• Labeling
• BOM output

Bill of Material
Description ERP Code Specification Qty Unit Section
No.
Flanged end with elbow WP2C125154-FELH-X0.75 L1=750 (210) 1 Pcs 1
（0.21）/Y0.42 L2=420
Straight length WP2C125154-1.13 L=1130 1 Pcs 2
Elbow - flatwise WP2C125154-LL-X0.3/Y0.3 L1=300 1 Pcs 3
L2=300
Straight length WP2C125154-2.25 L=2250 2 Pcs 4
Elbow - flatwise WP2C125154-LR-X0.3/Y0.3/ L1=300 1 Pcs 5
A120 L2=300
Elbow - flatwise WP2C125154-LL-X0.3/Y0.3/ L1=300 1 Pcs 6
A120 L2=300
Straight length WP2C125154-2.24 L=2240 1 Pcs 7
Elbow - edgewise WP2C125154-LV-X0.32/Y0.32 L1=300 1 Pcs 8
L2=300
Straight length WP2C125154-1.32 L=1320 1 Pcs 9
Riser WP2C125154-3-1CKF L=3000 4 Pcs 10
(F: L1=1.5) F: L1=1500
Terminal cover WP2C125154-ZD 1 Pcs 11
Joint WP2C125154-LJQ 13 Pcs 12
Spring Hanger THZJ 4 Pcs 13

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1 Casting machine for cast resin mixture
8 WavePro-R Cast Resin Busway WavePro-R Cast Resin Busway 9

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Electrical Data Physical Data
Straight lengths

Ground resistance (DC) For feeder busway, the minimum length is 400mm,
3L+N+50%PE, 20℃ambient） [Data source: calculation] and the maximum length is 3000mm.
No. Rated Current（A） Resistance（10-6Ω/m） Other lengths can be customized.
1 400 197.4 L
2 630 148.1
3 800 118.5
4 1000 98.7
L
5 1250 74.0
6 1600 56.4
7 2000 42.3
8 2500 32.0
9 3200 24.7
10 4000 19.1
11 5000 14.8

Voltage drop [Data source: calculation]

N L3 L2 L1 PE PEN L3 L2 L1
Rated Rated short-time Rated peak 20℃ Rated Load/steady state（50Hz）
Current1 withstand current
DC
(Icw) (Ipk) Resistance Reactance Impedance Line-to-line voltage drop (V/m) - Concentrated load①
Resistance
A kA/s kA （10-6Ω/m，phase-to-neutral） cosφ=0.6 cosφ=0.7 cosφ=0.8 cosφ=0.9 cosφ=1.0
400A 30 63 98.7 120.7 76.5 142.9 0.093 0.096 0.099 0.099 0.084
630A 74.0 94.6 64.6 114.6 0.118 0.122 0.125 0.124 0.103
800A 59.2 78.2 59.2 98.1 0.131 0.134 0.136 0.134 0.108
1000A 50 105 49.4 66.5 49.3 82.8 0.137 0.141 0.143 0.141 0.115 N L3 L2 L1 PE PEN L3 L2 L1
1250A 37.0 51.0 45.9 68.6 0.146 0.148 0.148 0.143 0.111
1600A 80 176 26.9 39.9 41.1 57.3 0.157 0.158 0.157 0.150 0.111
2000A 18.5 27.7 30.8 41.4 0.143 0.143 0.141 0.133 0.096
2500A 14.8 23.4 24.9 34.2 0.147 0.148 0.146 0.139 0.102
3200A 100 220 11.8 17.8 19.7 26.6 0.147 0.147 0.145 0.137 0.099
4000A 9.3 14.5 15.3 21.1 0.145 0.146 0.144 0.137 0.100
5000A 7.4 11.6 11.5 16.3 0.140 0.141 0.140 0.134 0.100

Note:
①Concentrated load: Voltage drop= I（Rcos + sin ） Distributed Ioad: voltage drop= [ I（Rcos + sin ）]/2
120 100 120 100

Busway weight

Rated Current（A） H（mm） Weight（kg/m） Fig. No.

3L+PEN 3L+N+50% PE
400 60 19.1 22.4 Fig. 10-1
630 70 23.1 26.4
800 80 27.3 31.2
1000 90 31.4 35.9
1250 110 39.7 45.3
1600 140 53.1 60.7
2000 190 77.3 88.1
2500 230 92.7 105.7
3200 310 118.9 135.6 Fig. 10-2
4000 380 147.7 168.7
5000 460 178.5 203.9
10 WavePro-R Cast Resin Busway WavePro-R Cast Resin Busway 11

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Physical Data Physical Data
Elbows Tees

Edgewise Elbow Edgewise Tee

mm L2 mm
L1
L2 Rated Minimum Size Standard Size Rated Minimum Size Standard Size
current L1 L2 L1 L2 current L1 L2 L3 L1 L2 L3
(A) (A)
250 300 300 400 400 L3 400 300 355 355 400 400 400
400 300 300 400 400 630 300 365 365 400 400 400
630 300 300 400 400 800 300 375 375 500 500 500
800 300 300 400 400 1000 300 385 385 500 500 500
1000 300 300 400 400 1250 300 405 405 500 500 500
1250 300 300 400 400 1600 300 435 435 500 500 500
1600 300 300 400 400 2000 300 485 485 500 600 600
2000 300 300 400 400 2500 300 525 525 500 600 600
2500 300 300 400 400 L1 3200 300 450 450 500 600 600
3200 300 300 400 400 4000 300 485 485 600 600 600
4000 300 300 400 400 5000 300 525 525 600 600 600
5000 300 300 400 400

Flatwise Elbow
Flatwise Tee
L2 L1
mm
L2 mm
Rated Minimum Size Standard Size
current Rated Minimum Size Standard Size
L1 L2 L1 L2
(A) current L1 L2 L3 L1 L2 L3
(A)
400 270 270 400 400
630 275 275 400 400
L3 400 270 270 270 400 400 400
630 275 275 275 400 400 400
800 280 280 400 400
800 280 280 280 400 400 400
1000 285 285 400 400
1000 285 285 285 400 400 400
1250 295 295 400 400
1250 295 295 295 400 400 400
1600 310 310 400 400
1600 310 310 310 400 400 400
2000 335 335 400 400
2000 335 335 335 400 400 400
2500 355 355 400 400
L1 2500 355 355 355 400 400 400
3200 395 395 500 500
3200 395 395 395 500 500 500
4000 430 430 500 500
4000 430 430 430 500 500 500
5000 470 470 500 500
5000 470 470 470 550 550 550
12 WavePro-R Cast Resin Busway WavePro-R Cast Resin Busway 13

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Physical Data Physical Data
Offsets Other Fittings

Edgewise offsets Expansion unit

L1 mm The standard length L=1500mm
Rated Minimum Size Standard Size
current L1 L2 L3 L1 L2 L3
(A)
L2 400 300 240 300 400 300 400
630 300 240 300 400 300 400
800 300 240 300 400 300 400
L3 1000 300 240 300 400 300 400
1250 300 240 300 400 300 400 L
1600 300 240 300 400 300 400 69
L2 L3 2000 300 240 300 400 300 400
0
2500 300 240 300 400 300 400
L1 3200 300 240 300 400 300 400
4000 300 240 300 400 300 400
5000 300 240 300 400 300 400
0
45
Flatwise offsets
L1 mm
Rated Minimum Size Standard Size
current L1 L2 L3 L1 L2 L3
(A)
L2
400 270 180 270 400 300 400

H+30
630 275 190 275 400 300 400
800 280 200 280 400 300 400
L3
1000 285 210 285 400 300 400
L2 L3 1250 295 230 295 400 300 400
1600 310 260 310 400 300 400
L1 2000 335 310 335 400 400 400
2500 355 350 355 400 400 400
Reducer
3200 395 430 395 500 500 500
The standard length L=1000mm
4000 430 500 430 500 500 500
5000 470 580 470 600 600 600

Combination offsets
L1
mm
Rated Minimum Size Standard Size 30 L
current L1 L2 L3 L1 L2 L3
0
(A)
400 300 210 270 400 300 400
630 300 215 275 400 300 400
800 300 220 280 400 300 400
L1
0
L2

1000 300 225 285 400 300 400

18

H+60
1250 300 235 295 400 300 400
L2

1600 300 250 310 400 300 400

L3 2000 300 275 335 400 300 400
2500 300 295 355 400 400 400
3200 300 335 395 400 400 400
4000 300 370 430 400 400 500
L3
5000 300 410 470 400 500 500
14 WavePro-R Cast Resin Busway WavePro-R Cast Resin Busway 15

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Physical Data Physical Data
Flanged End Other Fittings

Flanged end Wall Flange

The standard length L=1000mm Wall flange cutout dimensions
minimum length L=650mm Rated current External dimension of Dimension of cutout External dimension of wall Internal dimension of wall
(A) busway W×H A×B（≥） flange W1×H1（≥） flange W2×H2（≥）
400 120×60 220×160 210×360 135×75
L 630 120×70 220×170 210×370 135×85
800 120×80 220×180 210×380 135×95
1000 120×90 220×190 210×390 135×105
0
13 1250 120×110 220×210 210×410 135×125
1600 120×135 220×235 210×435 135×150
2000 120×170 220×270 210×470 135×185
2500 120×215 220×315 210×515 135×230
3200 120×300 220×400 210×600 135×315
4000 120×370 220×470 210×670 135×385
5000 120×460 220×560 210×760 135×475
120 120 120
Notes:
1. One SKU includes two wall flanges (one per side)
End tap box
2. Wall flange is fixed against the wall with internal expansion bolt
End tap boxes are used where a run of busway is fed by cable. The standard size is 1000mm × 1000mm × 1000mm, while we are
also able to supply with nonstandard boxes according to customer requirements.
Busway

Concrete Wall flange

Concrete

W1 W1

W1/2 W1/2
H
H

50
Wall flange

A
W2
W

50 50

H1
H2
H

B
L W L W

Terminal unit
length(L) is customized

50
Wall flange

Flexible connection (Copper)

50 25

D
Φ

A
15 0
0 18 100

h
Notes:
1. Standard length is 400mm, other lengths can be customized.
L 2. φD: φ14 or φ16
H+60
16 WavePro-R Cast Resin Busway WavePro-R Cast Resin Busway 17

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Busway Installation

Horizontal Mounting Vertical Mounting

The horizontal mounting includes wall support and suspending. The distance between two hangers shall not exceed 1.5m. Two Space between 2 vertical hangers shall not exceed 4 meters.
pieces of hangers is recommended for one piece of standard 3m feeder. There should be hangers at two sides of joint, but the
hangers can't be installed on the joint. The min. spaces of installing see Figures below.

Trapeze hangers

Initial adj. Nut

H＞500

Final adj. Nut

H＞500
Upper Nut

Wall support
H＞500

W＞150
H＞500

W＞150

Fig. A Fig. B Fig. C Fig. D

Busway current and Spring hangers

Rated current Rated current (A) Number of springs
(A)
400 Fig. A
630
800
1000
1250 Fig. B
1600
2000
2500 Fig. C
3200
4000 Fig. D
5000
18 WavePro-R Cast Resin Busway WavePro-R Cast Resin Busway 19

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Numbering System Check list

Technical standards IEC 61439-1 2011 & IEC 61439-6 2012

Code Phase configuration
Relative humidity (%) at + 20℃ ≤100
40 3L+100% PEN Altitude (m) <2000
Code Current rating 41 3L+100%N+50% internal ground Max. temperature (℃) 40
Min. temperature (℃) -25
04 400A
Average temperature (℃) 35
06 630A Conductor Copper
08 800A Conductor plating □ Full length tin-plating □ Other

Code IP Rating Rated operating voltage (V) 690

10 1000A Rated insulation voltage (V) 1000
12 1250A 68 IP68 Rated frequency (Hz) 50
Rated current (A) □ 400 □ 630 □ 800 □ 1000 □ 1250 □ 1600 □ 2000 □ 2500 □ 3200 □ 4000 □ 5000
16 1600A
Number of phases 3P
20 2000A Phase Configuration □ 3L+100%N+50% internal ground

25 2500A □ 3L+100%PEN
Code Fitting type
□ Other:
32 3200A / Straight length Degree of protection □ IP68
40 4000A EL Elbow Housing color □ Standard:Light gray □ Other:
Phase sequence □ PE, L1, L2, L3, N □ L1, L2, L3, PEN
50 5000A FE Flanged End □ Other
TE TEE System grounding □ TN-S □ TN-C
Installation Horizontal installation Hanger type □ Trapeze hangers □ Bracket arm
JT Joint
Hanger accessories □ Horizontal hanger clamps
ETB End tap box Vertical installation Hanger type □ Spring hanger □ Vertical fixed hanger

WF Wall flange Hanger accessories □ U-steel base □ Vertical hanger clamps

Code Phase
Copper busbar connection, flexible □ ABB provides plain copper bar, and the user bending and fabricates on site
C Cu TC Terminal unit connection □ Other:
R Reducer Other special requirements

EU Expansion unit
Code Busway type
WPR WavePro-R List of attachments

Code Length
XX In meter

WPR □ □□ □□ 68 - □□ - □□
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ABB Ltd.
Distribution Solutions
Electrification
P.O. Box 8131
CH-8050 Zurich, Switzerland

abb.com/contact

1SXH3432011_EN REV A 01.2021