Eaton Current-Limiting Reactor User manual

p/n: P-164001115
Revision 02
Installation Manual
Eaton©Current-Limiting Reactor (2500A)

Eaton reserves the right to change specifications without prior notice Eaton is a registered trademark of Eaton Corporation or its
subsidiaries and affiliates PDI, JCOMM, Quad-Wye, ToughRail Technology, and WaveStar are registered trademarks of Power
Distribution Inc All other trademarks are held by their respective owners All other trademarks are property of their respective
companies
©Copyright 2023 Eaton, Raleigh, NC, USA All rights reserved No part of this document may be reproduced in any way without the
express written approval of Eaton
IMPORTANT SAFETY INSTRUCTIONS - SAVE THESE INSTRUCTIONS
This manual contains important instructions that you should follow during installation and maintenance
of the equipment. Please read all instructions before operating the equipment and save this manual
for future reference.
CONSIGNES DE SÉCURITÉ IMPORTANTES — CONSERVER CES INSTRUCTIONS
Ce manuel contient des instructions importantes que vous devez suivre lors de l'installation et de la
maintenance de l'équipement. Veuillez consulter entièrement ces instructions avant de faire
fonctionner l'équipement et conserver ce manuel afin de pouvoir vous y reporter ultérieurement.
This is a product for restricted sales distribution to informed partners EN/IEC 62040-2). Installation
restrictions or additional measures may be needed to prevent electromagnetic disturbances.

Dear Customer,
On behalf of everyone at Eaton, we thank you for partnering
with us, for trusting us to maintain your business continuity and
for preventing downtime at your facility.
Our suite of backup power, power distribution and power
management products are designed to protect you from a host
of threats including power outages, surges, and lighting strikes,
and enable you to monitor and control your power
infrastructure.
We trust that our products will deliver high quality, reliable power
for your business, and we are committed to your success.
Please read this manual, which details the installation and
operation processes for your new Eaton product.
Thank you for choosing Eaton!

Eaton Current-Limiting Reactor (2500A) Installation Manual P-164001115—Rev 02 v
TTaabbllee ooff CCoonntteennttss
11 IInnttrroodduuccttiioonn....................................................................................................................................................................................................................................................................................................11
1.1 Intended Use.............................................................................................................................................1
1.2 Description................................................................................................................................................1
1.3 Using This Manual ......................................................................................................................................2
1.4 Conventions Used in This Manual ..................................................................................................................2
1.5 Symbols, Controls, and Indicators ..................................................................................................................2
1.6 Getting Help..............................................................................................................................................2
1.7 Warranty and End User License Agreement ..................................................................................................... 3
22 SSaaffeettyy......................................................................................................................................................................................................................................................................................................................55
33 IInnssttaallllaattiioonn ......................................................................................................................................................................................................................................................................................................77
3.1 Receiving and Unpacking the Current-Limiting Reactor .......................................................................................7
3.2 Moving the Current-Limiting Reactor .............................................................................................................. 7
3.3 Clearances ................................................................................................................................................8
3.4 Anchoring the Current-Limiting Reactor to the Floor ...........................................................................................8
3.5 Installing the Optional Side Car ......................................................................................................................9
44 PPoowweerr CCaabblliinngg.......................................................................................................................................................................................................................................................................................... 1111
4.1 Cable Entry ............................................................................................................................................. 11
4.1.1 Cable Entry Panels .............................................................................................................................. 11
4.1.2 Side Car Cable Entry............................................................................................................................ 11
4.2 Power Connections................................................................................................................................... 12
4.3 Wiring the PT100 Sensor............................................................................................................................ 13
55 SSeerrvviiccee aanndd MMaaiinntteennaannccee ........................................................................................................................................................................................................................................................ 1177
5.1 The Service Promise ................................................................................................................................. 17
5.2 Preventive Maintenance ............................................................................................................................ 17
5.3 Eaton Provides Flexibility and Commitment.................................................................................................... 17
5.4 Time and Materials ................................................................................................................................... 17
5.5 Startup ................................................................................................................................................... 17
5.6 Infrared Scanning ..................................................................................................................................... 17
22550000AA CCuurrrreenntt--LLiimmiittiinngg RReeaaccttoorr SSppeecciiffiiccaattiioonnss ............................................................................................................................................................................................ 1199
77 CCuurrrreenntt--LLiimmiittiinngg RReeaaccttoorr 22550000AA DDrraawwiinnggss............................................................................................................................................................................................................ 2211

vi Eaton Current-Limiting Reactor (2500A) Installation Manual P-164001115—Rev 02
Table of Contents

Eaton Current-Limiting Reactor (2500A) Installation Manual P-164001115—Rev 02 vii
LLiisstt ooff FFiigguurreess
Figure 1. Current-Limiting Reactor 2500A Dimensions........................................................................................ 1
Figure 2. Reactor and Side Car Dimensions ......................................................................................................8
Figure 3. Reactor Anchor Locations ................................................................................................................9
Figure 4. Side Car Configurations ...................................................................................................................9
Figure 5. Side Car Joining ........................................................................................................................... 10
Figure 6. Cable Entry Panels ....................................................................................................................... 11
Figure 7. Side Car Cable Entry ..................................................................................................................... 12
Figure 8. Side Car and Reactor Conduit Panels ................................................................................................ 12
Figure 9. Power Connections ...................................................................................................................... 13
Figure 10. PT100 Sensor.............................................................................................................................. 14
Figure 11. PT100 Sensor Wiring .................................................................................................................... 15

viii Eaton Current-Limiting Reactor (2500A) Installation Manual P-164001115—Rev 02
List of Figures

Eaton Current-Limiting Reactor (2500A) Installation Manual P-164001115—Rev 02 1
CChhaapptteerr 11 IInnttrroodduuccttiioonn
11..11 IInntteennddeedd UUssee
Reactor Power Panels RPPs) make maintenance of downstream equipment safer by limiting fault current and
reducing the risk of arc flash. The 2500A Current-Limiting Reactor is designed to be used as part of a reserve
power source for multiple downstream RPPs with Bypass Cabinets. An Current-Limiting Reactor, when used
as a component of a reserve power source, allows multiple downstream RPPs to be taken offline for
maintenance while the Current-Limiting Reactor temporarily provides the same safety benefits as the offline
RPPs.
11..22 DDeessccrriippttiioonn
The Current-Limiting Reactor is a stand-alone unit with no operational controls. Switching to reserve power
occurs at the downstream RPP Bypass Cabinet. For operational procedures on switching downstream RPPs to
reserve power, see these companion Eaton manuals:
• Reactor Power Panel V2 250A) Installation and Operation P–164001118.
• Retrofit Bypass Cabinet for Reactor Power Panels 250A) Installation and Operation P–164001119
Cable entry can be from top or bottom of the unit. An Current-Limiting Reactor can also have an optional side
car that provides additional cable entry space for conduit. The side car allows already installed floor conduit to
align with the unit. See section Chapter 4 Power Cabling.
Left and right front panel doors enable infrared scanning from the front of the unit.
The 2500A Current-Limiting Reactor cabinet structure and dimensions are shown below.
Figure 1. Current-Limiting Reactor 2500A Dimensions
Front panels allow
infrared scanning.
Top and bottom panels
on all four sides lift off.
SIDE VIEW
FRONT VIEW
[2284]
90" H
[914]
36"D
[1183]
46" W

2 Eaton Current-Limiting Reactor (2500A) Installation Manual P-164001115—Rev 02
11..33 UUssiinngg TThhiiss MMaannuuaall
Read this manual thoroughly and make sure you understand the procedures before you attempt to install, set
up, operate or carry out any maintenance work on this Eaton product.
Read through each procedure before beginning the procedure. Perform only those procedures that apply to the
unit being installed or operated.
11..44 CCoonnvveennttiioonnss UUsseedd iinn TThhiiss MMaannuuaall
This manual uses these type conventions:
NOTE Some conventions only apply to display screens if installed).
•Bold type highlights important concepts in discussions, key terms in procedures, and menu options, or
represents a command or option that you type or enter at a prompt.
•Italic type highlights notes and new terms where they are defined.
•Screen type represents information that appears on the screen or LCD.
Icon Description
Information notes call attention to important features or instructions
[Keys] Brackets are used when referring to a specific key, such as [Enter] or [Ctrl]
11..55 SSyymmbboollss,, CCoonnttrroollss,, aanndd IInnddiiccaattoorrss
The following are examples of symbols used on the reactor or accessories to alert you to important
information:
Special Symbols
The following are examples of symbols used on the UPS or accessories to alert you to important
information:
RISK OF ELECTRIC SHOCK - Observe the warning associated with the risk of
electric shock symbol.
CAUTION: REFER TO OPERATOR'S MANUAL - Refer to your operator's manual for
additional information, such as important operating and maintenance
instructions.
This symbol indicates that you should not discard the UPS or the UPS batteries
in the trash. This product contains sealed, lead‐acid batteries and must be
disposed of properly. For more information, contact your local recycling/reuse or
hazardous waste center.
This symbol indicates that you should not discard waste electrical or electronic
equipment (WEEE) in the trash. For proper disposal, contact your local
recycling/reuse or hazardous waste center.
Eaton, Powerware, and BladeUPS are registered trademarks of Eaton Corporation or its subsidiaries and affiliates.
Phillips and Pozidriv are registered trademarks of Phillips Screw Company.
ECopyright 2008–2010 Eaton Corporation, Raleigh, NC, USA. All rights reserved. No part of this document may be
reproduced in any way without the express written approval of Eaton Corporation.
RISK OF ELEC RIC SHOCK - Observe the warning associated with the risk of electric shock symbol
Special Symbols
The following are examples of symbols used on the UPS or accessories to alert you to important
information:
RISK OF ELECTRIC SHOCK - Observe the warning associated with the risk of
electric shock symbol.
CAUTION: REFER TO OPERATOR'S MANUAL - Refer to your operator's manual for
additional information, such as important operating and maintenance
instructions.
This symbol indicates that you should not discard the UPS or the UPS batteries
in the trash. This product contains sealed, lead‐acid batteries and must be
disposed of properly. For more information, contact your local recycling/reuse or
hazardous waste center.
This symbol indicates that you should not discard waste electrical or electronic
equipment (WEEE) in the trash. For proper disposal, contact your local
recycling/reuse or hazardous waste center.
Eaton, Powerware, and BladeUPS are registered trademarks of Eaton Corporation or its subsidiaries and affiliates.
Phillips and Pozidriv are registered trademarks of Phillips Screw Company.
ECopyright 2008–2010 Eaton Corporation, Raleigh, NC, USA. All rights reserved. No part of this document may be
reproduced in any way without the express written approval of Eaton Corporation.
CAU ION: REFER O OPERA OR'S MANUAL - Refer to your operator's manual for additional
information, such as important operating and maintenance instructions
Special Symbols
The following are examples of symbols used on the UPS or accessories to alert you to important
information:
RISK OF ELECTRIC SHOCK - Observe the warning associated with the risk of
electric shock symbol.
CAUTION: REFER TO OPERATOR'S MANUAL - Refer to your operator's manual for
additional information, such as important operating and maintenance
instructions.
This symbol indicates that you should not discard the UPS or the UPS batteries
in the trash. This product contains sealed, lead‐acid batteries and must be
disposed of properly. For more information, contact your local recycling/reuse or
hazardous waste center.
This symbol indicates that you should not discard waste electrical or electronic
equipment (WEEE) in the trash. For proper disposal, contact your local
recycling/reuse or hazardous waste center.
Eaton, Powerware, and BladeUPS are registered trademarks of Eaton Corporation or its subsidiaries and affiliates.
Phillips and Pozidriv are registered trademarks of Phillips Screw Company.
ECopyright 2008–2010 Eaton Corporation, Raleigh, NC, USA. All rights reserved. No part of this document may be
reproduced in any way without the express written approval of Eaton Corporation.
This symbol indicates that you should not discard waste electrical or electronic equipment (WEEE) in
the trash For proper disposal, contact your local recycling/reuse or hazardous waste center
11.. GGeettttiinngg HHeellpp
If help is needed with any of the following:
• Scheduling initial startup
• Regional locations and telephone numbers
• A question about any of the information in this manual
Introduction

Eaton Current-Limiting Reactor (2500A) Installation Manual P-164001115—Rev 02 3
• A question this manual does not answer
Please call the Eaton Help Desk at:
United States:1-800-84 -94 or 1-919-870- 028
Canada:1-800-461-9166 ext 260
All other countries:Call your local service representative
Please use the following e-mail for manual comments, suggestions, or to report a technical error in this manual.
[email protected]
11..77 WWaarrrraannttyy aanndd EEnndd UUsseerr LLiicceennssee AAggrreeeemmeenntt
To view the warranty please click on the link or copy the address to download from the Eaton website:
Eaton Product Warranty
https://www.eaton.com/content/dam/eaton/products/backup-power-ups-surge-it-power-distribution/backup-
power-ups/portfolio/eaton-three-phase-ups-warranty.pdf
https://www.eaton.com/content/dam/eaton/products/backup-power-ups-surge-it-power-distribution/
backuppower-ups/portfolio/eaton-three-phase-ups-warranty.pdf
To view the End User License Agreement please click on the link or copy the address to download from the
Eaton website:
Eaton End User License Agreement
https://www.eaton.com/content/dam/eaton/products/support-systems/software-and-cad-registration-form/
eaton-end-user-software-license-agreement.pdf
Introduction

4 Eaton Current-Limiting Reactor (2500A) Installation Manual P-164001115—Rev 02
Introduction

Eaton Current-Limiting Reactor (2500A) Installation Manual P-164001115—Rev 02 5
CChhaapptteerr 22 SSaaffeettyy
Follow safe electrical work practices:
• Read, understand, and follow the instructions before installing this product.
• Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel
and in accordance with all local safety codes. Power Distribution, Inc. assumes no responsibility for any
consequences arising out of the use of this manual. This document should not be viewed as sufficient by
otherwise non-qualified personnel to operate, service, or maintain the equipment discussed.
• Disconnect and lock-out all power supplying equipment before working on or installing components. Use a
properly rated voltage sensing device to confirm power is OFF.
• Severe or fatal injury can result from electrical shock during contact with high voltage conductors,
monitoring PCBs, or similar equipment.
• Disconnect power before drilling holes, attaching conduit, or connecting power cables or control wiring.
• Use Lock Out/Tag Out procedures.
• Wear suitable personal protective clothing and use protective equipment for performing mechanical and
electrical installations.
• Leave ample space for attaching and routing wires.

6 Eaton Current-Limiting Reactor (2500A) Installation Manual P-164001115—Rev 02
Safety

Eaton Current-Limiting Reactor (2500A) Installation Manual P-164001115—Rev 02 7
CChhaapptteerr 33 IInnssttaallllaattiioonn
33..11 RReecceeiivviinngg aanndd UUnnppaacckkiinngg tthhee CCuurrrreenntt--LLiimmiittiinngg RReeaaccttoorr
Current-Limiting Reactors and optional Side Cars are shipped bolted to shipping pallets and protected by two
layers of external plastic covering. Units are first covered by a large plastic bag and then shrink-wrapped. Finally
each unit is secured to its pallet with metal retaining bands.
For moving the Current-Limiting Reactor or Side Car on its pallet, Eaton recommends that you leave the
retaining bands intact until you have moved the unit to a convenient location for removing it from its pallet.
Inspect the shipped unit twice, upon receipt and after removing packaging materials.
1. Upon receiving an Current-Limiting Reactor or Side Car pallet and before removing packaging, inspect the
packaging for visible damage. If damage is evident notify the shipping company and Eaton see below for
Eaton contact information).
2. Carefully cut the retaining bands, making sure that they do not scrape the exterior of the unit or scratch the
paint.
• Metal retaining bands are under tension. Exercise caution when cutting them.
• Wear protective clothing including eye, face, and hand protection when cutting retaining bands.
3. Carefully remove the outer layer of protective shrink wrap from the unit and the interior plastic covering
bag. Use care to not puncture or scratch the Current-Limiting Reactor with cutting tools.
4. After removing the outer external packaging, inspect the unit’s exterior panels and doors for any visible
damage such as scratches, dents, or cracks. If you discover any damage, notify the shipping company and
Eaton service.
33..22 MMoovviinngg tthhee CCuurrrreenntt--LLiimmiittiinngg RReeaaccttoorr
Move the Current-Limiting Reactor off its pallet with a forklift as follows:
1. The Current-Limiting Reactor or its Side Car is bolted to a pallet. With the pallet resting on the floor,
remove the bolts.
2. Insert forklift forks under the Current-Limiting Reactor Cabinet or optional Side Car from any side.
3. Move each unit to its installation location and withdraw the forklift. Units have no casters and should be
precisely positioned with the forklift.

8 Eaton Current-Limiting Reactor (2500A) Installation Manual P-164001115—Rev 02
Figure 2. Reactor and Side Car Dimensions
Height: 90" [2284 ]
Width: 24"[610]
Depth: 36"[914]
Weight: 200 lbs
approx. [91 kg]
Height: 90" [2284]
Width: 46.6"[1184]
Depth: 36" [914]
Weight: 8000 lbs
approx. [3629 kg]
Current-Limiting Reactor
2500A Side Car
33..33 CClleeaarraanncceess
Clearances:
• Service clearance, front: 30 inches [762 mm]
• Cabling clearance, one side 30 inches [762 mm] for installing conduit and pulling conductors)
NOTE Panels lift off; there is no door swing.
• Ventilation clearance:
–Min. 6" [152 mm] front, top, and one side
• Unit may be backed up to a wall without rear clearance. See detailed drawings in
Chapter 7 Current-Limiting Reactor 2500A Drawings.
33..44 AAnncchhoorriinngg tthhee CCuurrrreenntt--LLiimmiittiinngg RReeaaccttoorr ttoo tthhee FFlloooorr
The base frame of the Current-Limiting Reactor has 4) holes for anchoring the unit to the floor. Customer
provides the ½” [13 mm] hardware for securing the unit to the floor.
Installation

Eaton Current-Limiting Reactor (2500A) Installation Manual P-164001115—Rev 02 9
Figure . Reactor Anchor Locations
Hole at each corner
for securing unit to
the loor.
Current-Limiting Reactor
Bottom View
33..55 IInnssttaalllliinngg tthhee OOppttiioonnaall SSiiddee CCaarr
The Current-Limiting Reactor will sometimes be installed over existing conduit in a concrete floor and the
position of the conduit may not match the unit’s cable entry panels. To accommodate the spacing of existing
conduit, an optional Side Car provides more cable entry space.
The Side Car has removable side panels allowing it to be attached to either side of an Current-Limiting Reactor.
1. On the sides to be joined together:
a. On the Current-Limiting Reactor, remove the top and bottom side panels.
b. On the Side Car, remove the top and bottom side panels.
NOTE Side Car side panels can be removed from either side to make a Left-Hand or Right-
Hand Side Car.
Figure 4. Side Car Configurations
Installation

10 Eaton Current-Limiting Reactor (2500A) Installation Manual P-164001115—Rev 02
2. Move the Side Car up against the Current-Limiting Reactor so that edges and holes align.
3. Bolt units together at 4) bolt locations 2 upper, 2 lower) in the upper and lower frames.
4. Secure the Side Car to the floor using customer-provided ½" [13 mm] hardware as for the Current-Limiting
Reactor.
Figure 5. Side Car Joining
Current-Limiting Reactor
Panels Off
Side Car
Panels Off
Bolt units
together at (4)
locations.
Installation

Eaton Current-Limiting Reactor (2500A) Installation Manual P-164001115—Rev 02 11
CChhaapptteerr 44 PPoowweerr CCaabblliinngg
44..11 CCaabbllee EEnnttrryy
44..11..11 CCaabbllee EEnnttrryy PPaanneellss
The Current-Limiting Reactor has 2) top and 2) bottom cable entry panels. Installers can create up to 5) 4.0"
[102 mm] cut-outs in each panel. The unit supports internal cable bend radius for cables up to 600 MCM.
Figure 6. Cable Entry Panels
36"
(914 mm)
TOP VIEW
46"
(1168 mm)
Top Conduit Panels
are 33.5"x 8.0"
(851 x 203 mm).
46"
(1168 mm)
BOTTOM VIEW
Bottom Conduit Panels
are 28"x 6.5"
(711 x 165 mm).
44..11..22 SSiiddee CCaarr CCaabbllee EEnnttrryy
When installing an Current-Limiting Reactor over existing conduit in the concrete floor, conduits may not align
with the bottom cable entry panels. The Current-Limiting Reactor can have an optional side car that provides
additional cable entry space to enable conduit installed in the concrete floor to correctly align with cable entry
panels.
The side car interior is open with no panels between the side car and the Current-Limiting Reactor bus bars,
providing easy access to bus bars.

12 Eaton Current-Limiting Reactor (2500A) Installation Manual P-164001115—Rev 02
Figure 7. Side Car Cable Entry
Side Car, Bottom View
Conduit Panel removed
Two (2) lashing bars are provided for tying cables.
Figure 8. Side Car and Reactor Conduit Panels
Side Car Bottom Conduit
Panel 28"x 18.75"
(711 x 476 mm)
Bottom Conduit Panels
Each 28"x 6.5"
(711 x 165 mm)
Side Car Top Conduit
Panel 33.5"x 21.5"
(851 x 546 mm).
BOTTOM TOP
Top Conduit Panels
Each 33.5"x 8.0"
(851 x 203 mm)
44..22 PPoowweerr CCoonnnneeccttiioonnss
!
IMPORTANT
• A licensed electrician must install the Current-Limiting Reactor and connect external wiring.
• Installers should use Lock-Out/Tag-Out procedures and observe other precautions listed in the introductory
Safety section.
Power Cabling