LEGRAND XL3 160 User manual

WORKSHOP SPECIFICATIONS
XL³ 160
DISTRIBUTION CABINETS
THE GLOBAL SPECIALIST IN ELECTRICAL AND
DIGITAL BUILDING INFRASTRUCTURES

XL³ 160 cabinets are “fully modular” cabinets, with 2
to 6 rows of 24 modules supplied ready to use (rails
and faceplates fitted).
They are available in 3 versions:
- Class II insulated cabinets, with 2 to 6 rows
- Metal cabinets, with 2 to 6 rows
- Flush-mounting cabinets, with 3 to 6 rows
They can take, depending on the version, DPX³ 160,
Vistop up to 160 A, single or three-phase French
electricity tariff plates and a “monitored-power” plate.
The XL³ 160 cabinet has been designed for ease
of wiring and connection. These cabinets provide,
amongst other things, a large amount of space for
wiring, wide connection areas (200mm top and bottom
faceplates), a removable chassis, clever solutions
for cable feedthrough and fixing, fasteners that are
common to the whole range... all with a modern design
and finish.
LEGAL INFORMATION
Presentation pictures do not always
include Personal Protective Equipment
(PPE), but this is a legal and regula-
tory obligation that must be scrupulously
respected.
In accordance with its continuous improve-
ment policy, Legrand reserves the right to
change the specifications and illustrations
without notice. All illustrations, descrip-
tions and technical information included
in this document are provided as indica-
tions and cannot be held against Legrand.

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WORKSHOP SPECIFICATIONS
XL³ 160
CONTENTS
Safety instructions .............................................................. 2
Class II insulated cabinets............................................. 4
Preparing the cabinets ........................................................... 6
Mounting devices .................................................................... 8
Wiring and connection .......................................................... 10
Installation and finishes ....................................................... 14
Vertical joining ...................................................................... 17
Metal cabinets..................................................................... 20
Preparing the cabinets .......................................................... 22
Mounting devices ................................................................... 23
Wiring and connection ........................................................... 24
Installation and finishes......................................................... 27
Flush-mounting cabinets .............................................. 30
Preparing the cabinets .......................................................... 32
Flush mounting ...................................................................... 33
Mounting devices ................................................................... 34
Wiring and connection ........................................................... 35
Finishes .................................................................................. 37
Distribution ........................................................................... 38
Supply busbars, terminal blocks, distribution terminals
and modular distribution blocks ........................................... 38
Appendices............................................................................ 41
Fitting key barrels .................................................................. 41
Dimensions............................................................................. 42
Accessories........................................................................... 44
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SAFETY
INSTRUCTIONS
■Use only the products and accessories recommended by the Legrand Group in the catalogue, instructions, technical data sheets
and all other documents provided by Legrand (hereinafter referred to as «the Documentation») in compliance with the installation
rules.
■Improper installation and/or use may result in the risk of arcing in the enclosure, overheating or fire. The enclosures must be used
under normal conditions, they must not be subjected to Voltage / Current / Temperature values other than those specified in the
Documentation.
■Legrand declines all responsibility for any modification or repair of the equipment making up the enclosure that is not authorized by
the Legrand Group, as well as any failure to comply with the rules and recommendations specified by Legrand in the Documentation.
In addition, in the cases mentioned above, the warranty granted by Legrand will not be applicable.
■It is necessary to check that the characteristics of the products are appropriate for their environment and use during maintenance
operations, and to refer to the Documentation. If you have any questions or require clarification, please contact Legrand Group.
■The installation, use and maintenance of the enclosures and their components must be carried out by qualified, trained and
authorized personnel, in accordance with the regulations in force in each country.
RISK OF ELECTRIC SHOCK, BURNS AND EXPLOSION.
■People working on the installation must have the appropriate electrical authorizations for the work to be carried out.
■Wear the PPE (Personal Protective Equipment) necessary to work on live products.
■Respect the safety rules related to electrical work.
■Improper electrical and mechanical use of equipment can be dangerous and may result in personal injury or damage to property.
■Depending on the maintenance operations to be carried out, partial or total power cuts of the enclosure concerned should be
planned before any work.
■When performing operations that involve access to the inside of the enclosure, be aware of the risk of burns before touching any
products or metal parts.
■Before turning the power back on, make sure that there are no foreign bodies and that all physical protections have been put back
in place (e.g.: screens, covers, shields).
General information

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WORKSHOP SPECIFICATIONS
XL³ 160
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Any failure to strictly apply the procedures and to respect these recommendations, could lead to serious risk of accident,
endangering people and property (in particular, without limitation, risk of burns, electric shocks, etc.).
The rules and recommendations in this document are based on our knowledge of the typical conditions of use of our
products in the fields of application usually encountered. However, it is always the customer’s responsibility to verify and
validate that Legrand products are suitable for its installation and use.
The customer must ensure proper installation, maintenance and operation of the equipment to avoid any risk of injury to person-
nel or damage to property in the event of product failure, especially for applications that require a very high level of safety (e.g.,
those in which the failure of a component may endanger human life or health).
The rules for storage, handling, installation and maintenance and the appropriate precautions and warnings must be strictly
observed and applied.

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XL³ 160 insulated cabinets are cabinets
with dimensions optimised for
distribution up to 160 A.
These cabinets are divided into:
- “Fully modular” cabinets with 2 to
6 rows. These can take DPX³ 160 and
Vistop up to 160 A without the need for
any accessories.
- Cabinets with dedicated space and 3 or
4 modular rows, for integrating limited/
monitored-power kits.
The XL³ 160 insulated cabinet has
been designed to simplify wiring and
connection:
- side panels can be removed individually
- removable chassis
- frame can be dismantled
XL³ 160 cabinets also offer original
solutions for holding and running the
wiring, a large working area and a high-
quality finish.
CHARACTERISTICS
• Class II insulated cabinet
• Short-circuit resistance Ipk: 20 kA
•IP 30 without door, IP 40 with door and
IP 43 with door and seal
• IK 04 without door, IK 07 with door
• Door opening angle: 120°
• Conforming to standards IEC 61439-2
and IEC 61439-3
• Fireproof according to IEC 60695-2-11-
750°C/5 s
• Suitable for installations in public
buildings
• Can take devices up to 160 A
• Colour RAL 7035
• Supplied complete with rails and
faceplates, wire guide rings for vertical
wiring and terminal block for protective
conductors.
CLASS II
INSULATED CABINETS

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WORKSHOP SPECIFICATIONS
XL³ 160
“FULLY MODULAR” CABINETS
CABINETS WITH
DEDICATED SPACE FOR
DPX³ 160 OR LIMITED/
MONITOREDPOWER KIT
Cabinet Cat. Nos. 4 018 02 4 018 03 4 018 04 4 018 05 4 018 06 4 018 15 4 018 16
External height (mm) 450 600 750 900 1050 900 1050
Number of modular rows 2345634
Number of modules 48 72 96 120 144 72 96
Raised
doors
Solid 0 202 52 0 202 53 0 202 54 0 202 55 0 202 56 0 202 55 0 202 56
Glass 0 202 62 0 202 63 0 202 64 0 202 65 0 202 66 0 202 65 0 202 66
Flat
doors
Solid 0 202 72 0 202 73 0 202 74 0 202 75 0 202 76 0 202 75 0 202 76
Glass
0 202 82 0 202 83 0 202 84 0 202 85 0 202 86 0 202 85 0 202 86
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After removing the top and bottom faceplates, remove the
4faceplate frame retaining screws
XL3160 insulated cabinets are supplied
fitted with 2rails on a removable
chassis, faceplates, wire guide rings for
vertical wiring, and a brass terminal block
for connecting protective conductors.
The cardboard packaging can be re-used
for delivery to the site.
To obtain maximum access for wiring, XL3160 cabinets can be completely
dismantled.
Simply remove the faceplate support frame and all the side panels.
XL3160 offers you three possibilities, to suit your preferred way of
working:
Removing the side
panels individually
CLASS II INSULATED CABINETS
Removing the
chassis
Removing the
faceplate support
frame and side panels
PREPARING THE CABINETS
XL3160 TERMINAL BLOCK TYPE
Enclosure Plastic Flush-mt Metal
France Auto Screw Screw
Export Screw Screw Screw
1WIRING AT THE BACK OF THE CABINET
Cadre amovible Flancs démontables
individuellement
Châssis extractible

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WORKSHOP SPECIFICATIONS
XL³ 160
2WIRING ON CHASSIS ONLY
The chassis can be removed from the enclosure so that the
wiring can be carried out in the workshop if the enclosure is
already installed on site.
After completely
removing the
frame and side
panels, there is
full access to the
wiring
With the
faceplates
removed, the
chassis can be
removed from
the cabinet after
unscrewing
the 4retaining
screws
Each side panel is held in place by 2 screws
It is very easy
to work on the
chassis once
it has been
removed from
thecabinet
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It is also possible to remove the side panels independently.
Inthis case, it is not necessary to remove the faceplate support
frame. Simply unscrew the side panel retaining screws.

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CLASS II INSULATED CABINETS
MOUNTING DEVICES
• DPX3160
Is mounted on an omega rail or on a plate in XL3cabinets
and enclosures. A height spacer (Cat. No. 4 052 26) can be
added in order to mount modular devices on the same row
(see page 34).
Vistops with side/front handle are supplied with the
accessories needed to locate the handle on the outside of the
enclosure.
Example of mounting a Vistop with side handle:
Mounting the DPX³ on the adaptor
Mounting the assembly on the chassis by
removing the plastic rail support
A template is provided with the side/front
handle for drilling the side panel
1MOUNTING THE DPX³ 2MOUNTING VISTOP 63 TO 160 A

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WORKSHOP SPECIFICATIONS
XL³ 160
Cabinets with dedicated space
Cat. Nos. 4 018 15 and 4 018 16 can take
all limited-power connection solutions
using kits Cat. Nos. 0 202 30 and
0 202 31. Kit Cat. No. 0 202 30 has two
2 x 8-module rails to optimise the space
when installing modular devices next to
the incoming circuit breaker.
Kit Cat. No. 0 202 30 for subscriber circuit
breaker only (single-phase 90 A or three-phase
60 A) with plates Cat. Nos. 4 011 82/91, or
subscriber circuit breaker + Linky-compatible
single-phase meter Cat. No. 4 011 81
Kit Cat. No. 0 202 31 supplied with connection
plate for subscriber circuit breaker + Linky
three-phase electronic meter
The plates are fixed on the chassis uprights
using the screws provided (M6x10 mm):
- 4th and 14th holes for kit Cat. No. 0 202 30
- 1st and 13th holes for kit Cat. No. 0 202 31
SUITABLE DOORS ACCORDING TO THE
CONFIGURATION
Kit + plate Flat doors Raised doors
solid glass solid glass
0 202 30 +
4 011 81/82/91
0 202 31
3MOUNTING LIMITEDPOWER KITS
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WIRING AND CONNECTION
• Guide rings
XL3160 cabinets are equipped with
guide rings for vertical wiring (1 per
row). These rings can be mounted on
the right or left. They simply clip onto
the insulating supports of the 2rails.
Insert the ring on the side of the support then
push it towards the back
Holding vertical wiring in place
CLASS II INSULATED CABINETS
XL3160 cabinets take guide rings
Cat.No. 0 200 94 for horizontal wiring.
These rings are fixed directly below the
rails.
• Lina 25 ducting
Supports Cat. No. 0 200 70 are used
for installing Lina 25 vertical ducting
(40x60).Thesupportscliponinthesame
way as the vertical wiring guide rings.
The ducting is fixed using the insulating
rivets provided.
The cabinet chassis can be connected
to earth using the threaded holes.
XL3160 cabinets are supplied with a
brass terminal block for protective
conductors with 2 x 35 mm2holes and
36 x 10 mm2holes. As the cabinet is
reversible, the terminal block can be
placed at the top or the bottom.
Terminal block for protective conductors
pre-installed in XL3160 cabinets
Fitting a guide ring for horizontal wiring
XL3160 cabinets also take Lina 25 horizontal
ducting: use insulating screws Cat. No. 0 367 74
(M6x10 mm screws) to fix them horizontally (40 x
60) directly on the uprights.
1WIRING 2ENSURING EQUIPOTENTIAL
BONDING

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WORKSHOP SPECIFICATIONS
XL³ 160
A second terminal block
Cat.No.37300 can be installed either
on the built-in supports, or on the
guide rings Cat. No. 0 200 94.
Guide rings Cat. No. 0 200 94 enable an
additional brass terminal block Cat. No. 0 373 00
to be installed between the rows
It is also possible to use IP 2X terminal
blocks for protective conductors (see
below).
Legrand IP 2Xterminal blocks are installed on 12 x 2 flat bars Cat. No. 0 048 19, fixed
either on the built-in insulating supports, or on supports Cat. No. 0 200 50.
The slots provided at the back of the cabinet allow these bars to be installed
horizontally or vertically, on the right or the left.
Screw the supports Cat. No. 0 200 50 to the back
of the cabinets
Horizontal terminal block
Vertical terminal blocks
3IP 2X DISTRIBUTION TERMINAL BLOCKS
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CLASS II INSULATED CABINETS
• Three-phase horizontal distribution using auto HX34-pole
supply busbar, ½ row (Cat. No. 4 052 31). This model is supplied
with fixing lugs for mounting on omega rail.
It has 4 x 3 phase outgoing lines + 8 neutral outgoing lines.
• Single-phase vertical distribution using 63 A optimised
VX3supply busbar, for cabinets with 2, 3 and 4 rows
(Cat.Nos. 4 050 03/04/05).
• Three-phase vertical distribution using auto VX3supply
busbar available in 63 A (3, 4, 5 and 6 rows) or 125 A (4, 5 and
6 rows). These models are equipped with automatic output
terminals.
XL3160 cabinets can take various horizontal and vertical distribution systems.
4 052 24
4 052 40
• Three-phase horizontal distribution using 125 A
plug-in HX3supply busbar with 24 modules Cat.
No.4052 40 using accessory Cat. No. 4 052 24.
4DISTRIBUTION SYSTEMS

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WORKSHOP SPECIFICATIONS
XL³ 160
The upper and lower side panels of the
cabinet can be cut in order to insert
cables. Two guidelines are marked
to give the cutting heights for 50 and
65mm ducting.
The side panels are easy to cut using a jigsaw
Plate Cat. No. 0 200 71 with knockout cable
entries can be installed instead of an upper or
lower side panel.
The DLP/cabinet joining strip
Cat.No. 0 201 60 improves the
finish and increases the cable
spreading volume.
The cables can be anchored at the back of the cabinets using Colson™ cable ties.
Knocking out the feedthroughs Anchoring the cables
5INSERTING AND FIXING CABLES
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CLASS II INSULATED CABINETS
INSTALLATION AND FINISHES
• Internal fixings
Remove the insulating screw covers
from the 4 internal fixing points on the
cabinet, then knock out the keyhole-
shaped holes. Fix the cabinet using four
Ø 6 mm screws and washers.
• External fixings
Wall-mounting lugs Cat. No. 0 201 50 can be installed in a horizontal or vertical
position.
To comply with class II it is essential to put the
insulating screw covers back in position
The keyhole-shaped openings are used to
attach and detach the cabinets Knock out the holes corresponding to the
position of the lugs
Place the special nut and the plastic cover in
position, then screw in the lug from the back
of the cabinet
INTERNAL AND EXTERNAL FIXING CENTRES CABINET COMBINATION
Cabinets A (mm) B (mm) C (mm)
Vertical
Fixing
centre (mm)
Horizontal
Fixing centre
(mm)
4 018 02 500 305 343 107 325
4 018 03 650 455 493 107 325
4 018 04 800 605 643 107 325
4 018 05/15 950 755 763 137 325
4 018 06/16 1100 905 943 107 325
D
E
425 mm
ABC
625 mm 250 mm
D
E
425 mm
A
BC
625 mm 250 mm
D
E
425 mm
AB
C
625 mm 250 mm
D
E
425 mm
A
BC
625 mm 250 mm
D
E
425 mm
A
BC
625 mm 250 mm
1FIXING THE CABINETS

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WORKSHOP SPECIFICATIONS
XL³ 160
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The faceplates are locked using a sealable 1/4 turn fastening. The doors can be fitted to open to the
left or the right. Slots for the hinges and
the door release are provided on both
sides of the cabinet.
The shape of the faceplates makes them easy
to handle
As well as the label-holders on all modular devices, a plastic marking strips Cat.No 3 397 55 (24
modules) or Cat.No 3 397 56 (36 modules) are available as accessories, supplied with the sets of
labels
Sealing the faceplate, in locked position
Remove the blanking plates then fit the hinges
on the frame
The door release is fitted on the opposite side
to the hinges using the 2 screws provided
When fitting the handle, it is essential to fit the
metal bracket so that the door locks correctly
The door pins are designed to be
inserted and removed without a tool
2FACEPLATES AND MARKING 3FITTING THE DOORS

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CLASS II INSULATED CABINETS
IP 43 is achieved by fitting seal Cat.
No.0 201 30 around the door.
For class II installations, the cables
supplying the control and signalling
units must be treated as class II,
and attached and protected using a
continuous insulated sheath to prevent
them being pulled out and becoming
accidentally detached.
If the control voltage is higher than
50V, the door must be connected using
an equipotential link conductor, and
the circuits supplying the control and
signalling units must be protected with
devices providing protection against
indirect contact.
The seal must join up at the bottom of the door
A wide range of finishes and accessories:
For more information,
consult workshop specifications EN
61439-1 & 2 available from
www.legrand.com/ecatalogue
4ACHIEVING IP 43
5AUXILIARIES ON DOOR
All-metal flat door
All-metal raised door Glass raised door
Self-adhesive document holder
Cat. No. 0 365 82
Glass flat door
Osmoz control and
signalling units have
a plastic insulated
body and the contact
blocks provide IP 2X
protection

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WORKSHOP SPECIFICATIONS
XL³ 160
Cabinets in the XL3160 range are not designed to be joined together, but can be
combined vertically fairly simply.
Set of 2 joined
cabinets, with
meter and
incoming circuit
breaker at the
supply end
Mark the cutting limits on the side panels of the cabinets to be joined together, and
mark where the 4 holes are to be drilled.
Use the terminal block supports as marking
guides.
Drill both sides at the same time
(Ø 6.5 mm)
Cut the side panels to make the opening for
inserting the wiring.
After refit the drilled and cut side panels, place
the 4 screws and 4 M6 nuts in position, but do
not tighten them fully.
VERTICAL JOINING
1MOUNTING
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CLASS II INSULATED CABINETS
If there are closed cut-outs in the side
panels, the cabinet is class II. If not, it
is essential to create an insulated seal
between the backs of the two cabinets.
Position the cabinets on their sides to align
them perfectly, then carry out the final
tightening
The joined unit can be reinforced using using kit Cat. No. 0 200 22.
Kit Cat. No. 0 200 22
The kit strengthens joining by bolting the
2chassis together
2COMPLYING WITH CLASS II
3STRENGTHENING JOINING
Space to be insulated with a seal on the back
of the cabinets
25 mm
25 mm
100 mm