Eaton Power Xpert XP2 User manual

Power Xpert XP2
Power Xpert XP2
Installation Manual
Installation Manual
www.eaton.eu\busbars
OHSAS 18001:2007
OHS 533652 ISO 9001:2008 FM 12680 ISO 14001:2004 No: 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
specific 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 fitted.
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, verification 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 flat 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 specific area.
Eaton recommend that the fixing 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 floor above where it is
to be installed or from a fixing on the ceiling of the same floor 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 500mm
Max 500mm
This image shows how to lift a
Busbar section vertically.
275
±1mm

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Eaton recommend the fixing brackets be mounted no more
than 1.5 metres apart.
Ensure that each section of busbar has
at least one set of fixing brackets fitted and that the Busbar is
level and plumb before final 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 fixing 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 fire barrier
ensure that the fire barrier protrudes from both
sides of the wall.
Final sealing between fire barrier and wall to be
completed by contractor.

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Spring Hanger Bracket
Step 1.
Fix Unistrut Size (41 x 41) on floor/ 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 fixing
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 firmly 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 firmly to the
Unistrut®.
c) Attach the rear joint pack cover to
the Busbar B.
Busbar A
Earth 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 fitted 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 firmly 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 fitted 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 first 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 fitting 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 fixing 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 finishes flush
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 fixing 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, verification 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 BusbarTrunking.
Thermal Imaging should be conducted along the Busbar
route to identify any possible problems.
Once identified 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 fine 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 first installation test. As long as the reading
does not measure below 5Mat 100VDC the system is
atisfactory for re-energisation.
Maintenance ofTap Off Module
As with the main Busbar system the joints require checking
on theTap 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 theTap 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 BusbarTrunking via tap offs for
example should be isolated prior to energizing the bar.
The Main Supply switch to the Busbar is to be energised
first.
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 specified figures.
Following the successful closing off the supply breaker, close
the circuit breaker(s) supplying the connected loads (viaTap-
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 firmly 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 energyefficient solutions that help our customers
effectively manage electrical, hydraulic and mechanical power more effici-
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 Road
Slough, Berkshire,
SL1 4DX
Tel: [phone]
Email: [email protected] www.eaton.com
To contact an Eaton salesperson
or local distributor/agent, please visit
www.eaton.eu/electrical/customersupport
Eaton Industries Manufacturing GmbH
EMEA Headquarters
Route de la Longeraie
1110 Morges
Switzerland
© 2016 Eaton Industries (Austria) GmbH
Subject to technical modifications. No
responsibility is taken for misprints or errata.
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