Power Xpert XP2Power Xpert XP2

Installation ManualInstallation Manual

www.eaton.eu\busbars

OHSAS 18001:2007OHS 533652

ISO 9001:2008FM 12680

ISO 14001:2004No: EMS 566536

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Introduction

Eaton supply all busbar sections

tested in accordance with type test

requirements as detailed in IEC61439-

6 and are subject to a full Quality Check

before packaging.

In order to ensure that the Busbar remains

in this condition during transport,

unpacking and installation on site, it is

important to study this document.

If the guidelines outlined within this

document are not adhered to, this could

give rise to the damage of the product,

electrical failure of the Busbar, personal

injury, or even death.

Manual Lifting

In accordance with Manual Lifting

Regulations the guidelines below are

provided to reduce risk of injury to

personnel and damage to equipment

during transport and installation of

busbar section.

PPE (Personal Protection Equipment)

should be worn at all times in accordance

with Health and Safety Regulations and

specifi c site requirements. When lifting

Busbar sections, care must be taken to

lift each section along its centre and not

by the end sections or conductors.

Mechanical Lifting

Some sections of Busbar may require

mechanical lifting due to their weight.

Options for mechanical lifting includes

Genie® Lift™, forklift, scissor lift,

platform lift and block and tackle. A full

assessment of the risks should be carried

out by the installer before commencing

work.

The Busbar must be safely secured to

the lifting apparatus before lifting.

Always check that the load does not

exceed the safe working load of the

lifting apparatus. Ensure that equipment

is used as per manufacturer’s guidelines.

Storage

The Busbar will be delivered to the

customer neatly stacked on a wooden

pallet for ease of removal. The maximum

weight of the pallet will not exceed

2500kg.

The Busbar is protected from minor

water ingress by means of an overall

outer polythene wrap and individual

polythene stretch wrap around the

ends of each busbar. The stretch wrap

should be left in position until the bar is

mounted and Joint Pack fi tted.

If the Busbar is not to be installed

immediately upon delivery it should be

stored in a heated, clean, dry area not

exposed to wind, rain, frost, or physical

damage.

Busbar should never be stored outdoors.

This Installation Manual is designed to assist in the Safe Handling and Installation

of the Eaton Power Xpert XP2. These instructions are in addition to normal safe

working practices as required by the local health and safety regulations. These

instructions do not in any way advocate a departure from these requirements. THIS EQUIPMENT

OPERATES AT

MAX 600V PHASE

Ensure COMPLETE electrical isolation, verifi cation and lock off of supply device in accordance with isolation procedures for the particular installation prior to carrying out any installation, inspection, or maintenance.

Only Eaton approved installation personnel may carry out installation of this product. If training is required contact Eaton using the details at the back of the brochure and specify the nature of the training requirements. Training can be provided on site or at our manufacturing facility.Handling

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Installation

Busbar

The Busbar Sections are secured to a framing system, such as Unistrut®, using the

Fixing Brackets as shown to the right. The bar can be secured both on its fl at and on

its edge.

Before lifting a Busbar Section, ensure that a detailed risk assessment is carried out

for the lifting procedure being performed in that specifi c area.

Eaton recommend that the fi xing brackets must be mounted no more than 500mm

from the centre of the joints. For vertical riser installation of sections greater than 2

metres it may be easier to lower the Busbar trunking from the fl oor above where it is

to be installed or from a fi xing on the ceiling of the same fl oor if at the end of the run.

Care is to be taken not to damage ends of the trunking when raising from horizontal

to vertical position.

Edge

Flat

Max

500

mm

Max

500

mm

This image shows how to lift a Busbar section vertically.

275

±1m

m

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Eaton recommend the fi xing brackets be mounted no more

than 1.5 metres apart. Ensure that each section of busbar has

at least one set of fi xing brackets fi tted and that the Busbar is

level and plumb before fi nal tightening of all joints.

It is the responsibility of the support system supplier to ensure

their system can safely support the weight of our product.

* Please note: Eaton fi xing bracket’s must be used.

Drilling or cutting the busbar on site is prohibited

MAX DISTANCE 1.5 MTRS

Fire Barriers

When installing a Busbar section with a fi re barrier

ensure that the fi re barrier protrudes from both

sides of the wall.

Final sealing between fi re barrier and wall to be

completed by contractor.

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Spring Hanger Bracket

Step 1.

Fix Unistrut Size (41 x 41) on fl oor/ wall as per layout

drawing.

Step 2.

Lower busbar into place and connect to Joint

Pack. Ensure the weight of the busbar is supported

throughout.

Only hand tighten joint pack at this stage.

Step 3.

Attach Spring Hanger Brackets to Unistrut with M10

Hex Bolt and Lock Nut, tighten the bolts to 45Nm

±5Nm.

Step 4.

Attach Spring Hanger Brackets to Busbar using fi xing

brackets.

Step 5.

Tighten the joint pack to 65Nm ±5Nm once the spring

hanger bracket has been attached.

Step 6

After inspecting the arrangement to ensure it is

securely installed the hanging support can be removed

from the busbar.

Spring Hanger Brackets are used to support weight of a vertical installation and compensate for minimal building movement

and thermal expansion.

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Joint Pack

Step 1.

Mount Busbar A fi rmly to the Unistrut®

Step 2.

Attach the rear joint pack cover to

Busbar A

Busbar A

Socket screw X2

Rear joint pack cover

Step 3.

Install joint pack, never

force the joint or strike it

with any object, as this

may damage the joint or

the busbar section. The

joint should be inserted

by means of constant

force i.e. pushing by hand

or means of a suitable

clamping arrangement. The

images show 2 methods of

installing the joint pack.

* Before joining the two

separate sections of the

Busbar trunking, ensure

that all contact surfaces

are:

free from contaminates

unblemished

not damaged

correctly aligned

Step 4.

a) Position

Busbar B as shown

in the image. Ensure

that the Earth side plate is not

overlapping the Expansion Rib.

Ensure the 2 sections of Busbar

trunking are 275mm ±1mm apart

and that the joint pack is centred

between them.

b) Mount Busbar B fi rmly to the

Unistrut®.

c) Attach the rear joint pack cover to

the Busbar B.

Busbar AEarth side plate

Expansion Rib

Busbar B

The steps below outline best practice, the Busbar orientation and site conditions may restrict installers from adhering to this

methodology. In these cases installers must be cautious and ensure the joint pack is installed correctly. Ensure all parts are

meggered and visually inspected prior to installation.

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Step 5.

Tighten the joint pack assembly using a 19mm spanner until the

shear nut breaks and the indicator disk drops off then tighten

to 65Nm ±5Nm using a calibrated torque wrench with a 19mm

socket. If installed correctly the joint will appear level and no

overlapping should appear. If overlapping of the Expansion

Ribs is apparent then the joint is not installed correctly.

The shear nut will break when torqued to 65Nm ±5Nm in a

clockwise direction. This will cause the indicator disc to fall off.

Step 6.

Megger the installed joint pack to ensure it is fi tted correctly.

Following a visual inspection to ensure that there are no

anomalies such as foreign material etc, install the front

joint pack cover.

Joint pack cover

Sign & date the label on the joint cover

for the quality control records.

Joint Pack Elbow

Ensure all parts are meggered and visually inspected

prior to installation.

Step 1.

Mount Busbar to frame.

Step 2.

Install the Joint Pack Elbow to Busbar, never force the joint

or strike it with any object as this may damage the Joint or

Busbar section. The joint should be inserted by means of

a constant force, i.e. pushing in by hand or by means of a

suitable clamping arrangement.

Step3.

Position second busbar as shown in image overleaf. Ensure

the Earth Side Plates are not over lapping the Expansion Ribs.

The Earth side plates should sit approx 2mm back from the

Expansion Rib when positioned correctly.

Step 4.

Mount the second Busbar section fi rmly to the frame work.

Step 5.

Attach the rear Joint Pack Cover to Parts.

Step 6.

Tighten the Joint Pack assembly to the correct torque level

(65Nm ±5Nm). If installed correctly the joint will appear

level and no overlapping should appear. If overlapping of

the Expansion Ribs is apparent then the Joint is not installed

correctly.

Step 7.

Megger the installed joint pack to ensure it is fi tted correctly.

This is on a visual inspection for any anomalies such as

foreign material etc. Now attach the front Joint Pack Cover to

the Busbar.

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Cable End Box

This is generally the fi rst component to be mounted on a rising busbar.

The entire route should initially be inspected for any obstructions before installation.

The box should be installed at the correct height in accordance with the approved

drawings.

A plumb line should be applied at this point from the start of the run to the end of

the run, as a guide for the vertical installation of the Busbar Run.

4 of M10x20 bolts c/w Bellville washers and a 17mm socket are required to install the

Cable End Box following the instructions shown.Unistrut rail

Access cover

Gland plate

2

3

M10 Channel Nut

M10 Bolt

[1] Unistrut rail

[2] Access cover

[3] Gland plate

Tap Off Cover

Busbar

Tap Off Slot Cover

Distribution Busbar lengths are available with up to 5 tap

off positions on a 3 metre length.

Each tap off position is IP2X in accordance with IEC61439-2.

With a standard tap off installed the rating is IP54 but this can

be improved if required.

A cover is required over unused tap off positions to increase

the ingress protection (IP) level to the required standard.

When fi tting a new tap off, this cover is to be removed.

The drawing opposite shows the removal of the cover.

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Tap Off Modules

Step 1.

In accordance with isolation procedures and risk

assessments to be carried out by the installer, ensure

complete isolation of the electrical busbar by proving dead.

Step 2.

Following removal of the tap off unit from its packaging,

check the device is not damaged and tap off contacts are

visually in line.

Step 3.

Open door using key provided and release both clamping

mechanisms by using a 6mm t-bar in an anticlockwise

direction.

Tap off box

MCCB

Lock

Secure rear fi xing brackets

Step 4.

Offer the tap off box up to the shutter housing and visually

line up the earth contact bracket and actuator to ensure

correct location of the tap off contacts.

The box cannot be inserted upside down as the design of

the actuator mechanism prevents this.

Insert the tap off box until base of tap off box fi nishes fl ush

with busbar assembly.

Use the 6mm t-bar to clamp the tap off box to the busbar

assembly by rotating the clamping mechanism in a

clockwise direction.

Step 5.

Install the rear fi xing brackets as illustrated below.

Step 7.

Megger test installation prior to re-energisation of busbar.

Step 8.

Before turning the Breaker “ON”, ensure the neutral link is

connected and tightened.

Handle

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Maintenance of Busbar

Prior to carrying any maintenance work (other than thermal

imaging), ensure the Busbar is completely electrically

isolated by isolation, verifi cation and lock off of the supply

device in accordance with isolation procedures / method

statement.

Familiarisation with IEE Wiring Regulations or similar Local

Safety Standards should be understood in order to ensure

safe isolation of the Busbar Trunking.

Thermal Imaging should be conducted along the Busbar

route to identify any possible problems.

Once identifi ed a preventative maintenance program should

be instigated with the Busbar isolated as described above

before carrying out any work.

If joints are found to be loose they should be re-torqued

to the correct torque level as outlined in the Installation

Detail. If a joint is found to be loose but it shows no sign

of overheating simply re-torque the joint and conduct an

Insulation Resistance test prior to re-energising.

If slight discolouration occurs remove the joint and clean the

conductor with a fi ne grade (240) abrasive paper. Re-install

the joint and megger test.

If adverse overheating has occurred, please contact Eaton

for further details.

Megger test results at this point could be lower than those

taken during the fi rst installation test. As long as the reading

does not measure below 5M at 100VDC the system is

atisfactory for re-energisation.

Maintenance of Tap Off Module

As with the main Busbar system the joints require checking on the Tap Off connections. Thermal Imaging can identify localised heat spots. As previously described, upon identifying a local

problem preventative maintenance should be investigated with the busbar isolated.

If discolouration has occurred on the contact due to overheating, ensure the gap between contact’s are consistent and have not been damaged during transport, if they have, please contact Eaton.

If the joints show slight discoloration, clean them and re-tighten. If adverse overheating has occurred, please contact Eaton for further instruction. Visually check the installation of the Tap Off Module, check clamping mechanism, check door-interlocking device to ensure it still operates correctly. Check outgoing cable connections and gland tightness / integrity. Check the operation of the switching device positive ‘ON’, ‘OFF’ operation. Examine protective device for sign of short circuit operation. If a short circuit has occurred on the equipment connected to the tap off module check operation of device and the integrity of the device.

Energising

The Busbar should be energised immediately after following

steps 1 to 6 (shown above).

Only authorized, competent personnel should energise

electrical circuits in line with „switching procedures” and

„permit to work’ forms provided by the Site Electrical

Supervisor.

All connected load to the Busbar Trunking via tap offs for

example should be isolated prior to energizing the bar.

The Main Supply switch to the Busbar is to be energised

fi rst.

The Protection Settings should be at the circuit breakers

minimum protection level.

Only when the Busbar is being put into service are the

Protection Settings set to the specifi ed fi gures.

Following the successful closing off the supply breaker, close

the circuit breaker(s) supplying the connected loads (via Tap-

Offs) one by one.

Visually inspect the energised Busbar route to look for any

anomalies. Listen for noises from the system as this could

indicate untightened cover plates.

Prior to Energising

3 test must be completed prior to energising

Step 1. A continuity test to verify the run is complete.

Step 2. A ductor test to check the resistance of the joints

through the entire length.

Step 3. A megger test, 1000VDC between each conductor

and Earth. Readings will vary widely between site to site due

to length of run, humidity, temperature and site conditions.

If readings less than 5M are obtained, measures must be

taken to identify the location of the low resistance level and

take appropriate measures to increase the resistance level.

This test should only be carried out by competent personnel.

Step 4. Ensure all tap off boxes have been correctly installed

as instructed and are in the ‘ON’ position for insulation

resistance testing.

Step 5. Ensure all connections to the Busbar / tap offs have

been disconnected.

Step 6. Verify that all joints have been torqued according to

the recommended setting and have not been subsequently

loosened. Ensure all joint covers are fi rmly secured.

Step 7. When reconnecting the system prior to energisation,

ensure correct Phase Rotation is achieved by testing prior to

energising the supply.

Step 8. Ensure all tap offs are turned off again prior to

Energising.

Step 9.The testing procedure should be performed and

documented as per Eaton standard testing procedure

available on request.

Eaton is a power management company with 2015 sales of $20.9 billion. Eaton provides energyeffi cient solutions that help our customers effectively manage electrical, hydraulic and mechanical power more effi ci-ently, safely and sustainably. Eaton has approximately 97,000 employees and sells products to customers in more than 175 countries.

For more information, visit www.eaton.eu.

Eaton Electric Ltd

270 Bath RoadSlough, Berkshire, SL1 4DXTel: 01753 608 700Email: systemquotes@eaton.com www.eaton.com

To contact an Eaton salespersonor local distributor/agent, please visitwww.eaton.eu/electrical/customersupport

Eaton Industries Manufacturing GmbH

EMEA Headquarters

Route de la Longeraie1110 MorgesSwitzerland

© 2016 Eaton Industries (Austria) GmbHSubject to technical modifi cations. No responsibility is taken for misprints or errata.Printed in Austria (07/16)Publication number

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