Eaton XAP-C Operating instructions

Brand: Eaton

Model: XAP-C

Type: Operating instructions

This manual is also suitable for

Eaton XAP-C is a reliable and versatile busduct system designed to meet the demands of various electrical distribution applications. Engineered to provide optimal performance and safety, the XAP-C excels in industries, commercial buildings, and critical facilities. Its compact design allows for easy installation even in space-constrained areas.

Instruction Booklet IB

Effective January 2017

XAP Series Busduct

Storage, Installation, and Maintenance

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unloading and Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparation and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Joint Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Joint Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Expansion Joint Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

End Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Settlement Joint Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horizontal Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vertical Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wall Penetrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Busduct Joint Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tap-off Unit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attentions for Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Construction after Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steps for Energizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tap-off Unit Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Note. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Joint cover

XAP Series Busduct

Tap-off Units

Contents

Description Page

1 EATON CORPORATION www.eaton.com.cn/electrical

Instruction Booklet IB

Effective January 2017

XAP Series Busduct

Storage, Installation, and Maintenance

DANGER

HAZARD OF ELECTRICAL SHOCK OR BURN. TURN THE POWER TO THE

BUSDUCT OFF BEFORE INSTALLING, REMOVING, OR WORKING ON THIS

EQUIPMENT.

WARNING

LIVE EQUIPMENT MAY LEAD TO PHYSICAL HARM. UNLESS OTHERWISE

STATED, THE EQUIPMENT MUST BE POWEROFF BEFORE INSTALLING,

INSPECTION AND MAINTAINS.

WARNING

DAMP BUSDUCT MUST BE TREATED PROPERLY. AND THE INSULATION

RESISTANCE MUST BE TESTED POSITVELY BEFORE INSTALLATION.

Introduction

This publication contains instructions for the storage, handling,

installation, and maintenance of the Eaton XAP busduct. Only those

qualified and trained in accordance with established safety procedures

should handle, install, and maintain the XAP busduct. Failure to follow

danger, warning labels and established safety procedures could result

in property damage, serious personal injury, or death.

This publication does not cover all the details or variation in equipment

and hardware nor cover every possible contingency regarding storage,

handling, installation, and maintenance for XAP busduct systems.

Eaton does not make representation or warranty, expressed or implied

and does not assume responsibility for the accuracy or completeness

of information contained herein.

Receiving

Once the material is received, inspect each box/crate for damage. Also

check for concealed damage. Should any damage be found, notify the

carrier immediately and file any claims as required by the carrier. If no

visible or concealed damage is found, the product is ready for storage

or installation.

Do not remove the busduct from the original shipping container until

ready for installation. This will help prevent damage to the busduct

from occurring prior to installation.

Unloading and Handling

Suitable device should be used to unload the busduct to avoid damage.

Forklift is recommended to use.

When lifting or hoisting the busduct, make sure the weight of the

busduct is distributed and balanced. Use lifting devices that will not

damage the busduct. Terminals of busduct cannot be used to support

the weight of busduct.

Storage

The Eaton XAP busduct should be stored in a covered, clean, dry space

which is climate controlled to prevent condensation. Do not allow the

busduct to come in contact with corrosive fumes, liquids, salts, or

forms of concrete.

Storing the busduct outdoors should be avoided at all possible.

However, if it cannot be avoided, it must be stored off the ground and

securely covered to provide protection from dirt and moisture.

Temporary electrical heating must be provided and evenly distributed

beneath the cover to prevent condensation. At least 3 watts per cubic

foot is adequate for average environments. Failure to properly store

and protect the busduct may cause damage and will void the warranty.

Outdoor-rated busducts are not rated for outdoor applications until they

are completely and properly installed. They should be treated as indoor

busducts prior to complete installation.

Preparation and Inspection

Qualification and Training

Only qualified professionals should install, operate and maintain the

XAP busduct. Professionals should:

1. Fully understand the structure, installation, operation of XAP as well

as the danger during operation;

2. Well trained about charging and test of the equipment;

3. Equipped with PPE such as safety helmet, working cloths.

Instrument and tool

The following instruments and tools will be used during installation:

1. Insulation tester 1000V;

2. 8-10, 10-12 wrench, sleeve and torque wrench;

3. Straight and cross screwdriver;

4. Gradienter, tape and filament;

5. Scaffold, hoist and herringbone ladder;

6. Drill, cutting machine, welding machine etc.

Inspection

Deliver all busduct sections and components to the installation location

prior to unpacking, if possible. This will help prevent damage. Each

crate/box is clearly marked with its contents and quantities.

Unpack and inspect each piece for any signs of visible damage. Check

the housing for dents or cracks caused by physical damage. Inspect

the XAP busduct joints to ensure they are clean and that the insulators

are not cracked or broken.

Consult the factory regarding any physical damage.

Perform an insulation resistance test on each busduct section by

Megger testing at 1000 volts, phase-to-phase, phase-to-neutral, and

phase-to-ground 20M to ensure system integrity.

Record the readings of each item and of each installed run. Provide

these readings as part of the permanent maintenance records.

Once inspected and tested, each busduct section is ready for installa-

tion.

2EATON CORPORATION www.eaton.com.cn/electrical

Instruction Booklet IB

Effective January 2017

XAP Series Busduct

Storage, Installation, and Maintenance

Installation

One set of construction drawings is sent with the initial shipment of

each busduct order. This drawing package will contain the layout of each

run, showing where each piece of the run is located, and other possible

cut sheets and instructions. The installer should review these drawings

prior to and during installation to ensure proper installation.

Identification

Each piece of the Eaton XAP busduct has a nameplate label as shown in

Figure 1. This label identifies each piece and its ratings. It is recommend-

ed that each piece be installed sequentially, starting at the beginning

point of the run. This would typically be the cable tap box, transformer,

switchboard, or switchgear connection.

Figure 1. Nameplate Label

Phasing and Orientation Labels

Each piece of the Eaton XAP busduct has “N” labels as shown. The "N"

label indicates phasing. From the “N” side of the busduct, the standard

phasing is N-L3-L2-L1-PE.

Figure 2. Phasing and Orientation Label

The XAP busduct construction is not symmetrical. It is imperative for

all sections of the busduct to be installed with all of the labels aligned

and consistent throughout the run and per Eaton-supplied construction

drawings. Failure to do so may result in damage to the busduct as well

as property damage, physical harm or death.

Joint Installation

When connecting pieces of the Eaton XAP busduct together, make

certain that contact surfaces are clean and free from contaminants.

Some section may have electrical lubricant on the contact surfaces,

which was applied by the factory. This will aid in joint installation. Align

the left end of one section to the right end of the adjoining section with

the "N" label in alignment. Figure 3 illustrates correct joint installation.

Figure 3. Joint Installation

Torque Indication Bolt

When the two sections have been properly joined together, the joint

bolt may be tightened. This joint bolt is a special torque-indicating bolt

with two bolt heads to ensure that the proper installation torque is

achieved. Fall away instruction tags are provided between the upper

and lower bolt heads. Torque should only be applied to the upper bolt

head. When the proper torque is achieved, this bolt head will shear off,

allowing the tag to fall to the floor.

Figure 4. Torque Indicating Bolt as Shipped

Figure 5. Torque Indication Bolt after Installation

Any joint bolt that is improperly tightened will retain the highly visible tag

and should be retightened. The lower bolt head remains intact for future

maintenance.

DANGER

FAILURE TO INSTALL THE BUSDUCT CORRECTLY MAY RESULT IN

DAMAGE TO THE BUSDUCT AS WELL AS PROPERTY DAMAGE, PHYSICAL

HARM, OR DEATH.

Orange

instruction Tag

Figure 4. Figure 5.

Compact Busway

Type

Standard

Name of contract

Contract No.

Installation No.

Manufacture Date

Principal/Producers

Production enterprise

Eaton Electrical Equipment Co.,LTD.

Chongqing Yiwan Electric Co., LTD.

Ue =

Ui =

In =

Icw =

f =50/60Hz

IP65

<XAP>

IEC61439-1/-6

16-M6*25

Hexagon bolts

End cover

8*30 screws

EATON CORPORATION www.eaton.com.cn/electrical

Instruction Booklet IB

Effective January 2017

XAP Series Busduct

Storage, Installation, and Maintenance

Joint Cover Installation

After the connectors are tightened, the joint covers may be installed in

turn and tightened with bolts. In the case of four wire housing, please

connect ground bolts and ground copper braiding to ground holes.

Figure 6. Joint Cover Installation

Expansion Joint Installation

This is a transition section to compensate for expansion and contrac-

tion due to long time operation of busduct. For detailed mounting

position, refer to the installation drawing. The expansion joint has been

tightened and assembled in factory. Check the connecting bolts of

expansion joints. Make sure that the expansion position has not been

damaged due to vibration during transportation.

When connect the expansion joint to the straight busduct, please be

noted to align the N phase line, to avoid incorrect phase sequence after

connection. Expansion joints have the same installation sequence as

for the straight busduct. For detailed installation clearance, refer to the

installation clearance table and the installation drawing

Notes: after completion of one line installation, it is necessary to

loosen all M6*25 bolts in the expansion joints to ensure expansion

effect (see Figure 7).

Figure 7. Expansion Joint Installation

End Cover Installation

End Cover is the end of a busduct system. It is composed of insulating

pieces and manufactured for field requirements. End Cover is placed

onto the end of busduct with correct phase sequence.

Figure 8. End Cover Installation

Settlement Joint Installation

Settlement joint is to compensate height difference caused by vertical

offset at the joint of two workshops. For detailed mounting position,

refer to the installation drawing. The settlement joint has been

tightened and assembled in factory. Check the connecting bolts of

settlement joints. Make sure that the settlement position has not been

damaged due to vibration during transportation.

When connect the expansion joint to the straight busduct, please be

noted to align the N phase line, to avoid incorrect phase sequence after

connection. Settlement joints have the same installation sequence as

for the straight busduct. For detailed installation clearance, refer to the

routing plan supplied upon delivery.

Notes: after completion of one line installation, it is necessary to

loosen the M8*30 bolts in the settlement joints to ensure settlement

effect.

Figure 9. Settlement Joint Installation

Joint cover

Maximum clearance loading weight (kg

Mounting clearance (m)

XAP-C (kg/m)

XAP-A (kg/m)

1.2

50.4

1.6

22.6 50.4

22.6

EATON CORPORATION www.eaton.com.cn/electrical

Instruction Booklet IB

Effective January 2017

XAP Series Busduct

Storage, Installation, and Maintenance

Horizontal Mounting

For over-head mounting of the Eaton XAP busduct, all-thread drop rods

must be provided by the installer and should not be spaced more than

2m apart.

1. The mounting clearance for straight busduct should not be longer

than 2m. Detailed clearance requirements shall be requested during

routing design according to field conditions and loading situations,

and shall be specified in installation drawing.

2. Mounting supports shall be placed at both ends of the joint.

Maximum clearance is no longer than 1m. No load shall be burdened

at the joints.

3. Care should be given when locating drop rods in order to avoid

placing hangers at joint and tap-off unit locations. Adequate ceiling

clearance must be allowed for tap-off units.

Vertical Mounting

For mounting the busduct vertically, vertical spring hangers must be

used. A vertical hanger must be used on every floor or a maximum of

every 16 ft. (4.9m). Intermediate hangers are required for floor heights

exceeding 16 ft. (4.9m) as shown in Fig. 10.

Maximum tolerance for busduct installation is 5mm per 10m.

Figure 10. Vertical Busduct Mounting Support

Wall Penetrations

When an Eaton XAP busduct passes through a wall or vertical barrier,

the opening should be at least 100 mm larger than the outside

dimensions of the busduct.

For individual and multiple runs of Eaton XAP busduct, thought must be

given to horizontal and vertical clearances between runs, walls, and

ceilings.

Figure 11. Horizontal Wall Penetration Installation

Figure 12. Vertical Floor Penetration Installation

Busduct

Busduct Busduct

Busduct

Lock

Anchor B

Lock

Anchor A

EATON CORPORATION www.eaton.com.cn/electrical

Instruction Booklet IB

Effective January 2017

XAP Series Busduct

Storage, Installation, and Maintenance

Tap-off Unit Installation

Phase sequence shall be made according to field application require-

ments and construction drawings.

Remove the bolts on the busduct socket cover and open the socket

protection cover. (See Figure 16).

Open the tap-off unit door. Open Lock Anchor A and B. Then, aim at the

slot in the socket, and insert in the unit smoothly until the unit bottom is

closely contacted with the cover (PE pin shall contact the housing first to

ensure safe grounding). Move the two lock anchors of A and B inwards

to lock up busduct cover (Figure 19). When Lock Anchor A and B are in

place, close the unit door and tighten the bolts.

Note: When Lock Anchor A and B are in place, it means they are vertical

to the cover plate and in parallel to the side of the tap-off unit.

Figure 16. Socket

Figure 17. Tap-off Unit Installation

1. After the Tap-off unit is installed onto the busduct, fasten the cable to

its support in the case that the unit is connected to devices with

cable, to avoid movement.

2. Tap-off unit shall not be burdened with load directly. Loads at the rear

end shall be fastened onto the busduct or other fixed positions in

accordance with regulations.

3. When not plugging in busduct, socket protection cover shall not be

opened. Otherwise, it will influence the protection degree of

busduct system.

Busduct Joint Clearances

Busduct joint sections may not fall within walls or floors. Figures 13

through 15 illustrate the minimum clearances required as measured

from the center-line of the joint to the wall, floor and ceiling.

Note: Busduct joints on outdoor rated busduct should have a minimum

of 10 in. (254 mm) clearance on either side of walls.

Figure 13. Minimum Outdoor Joint Clearances

Note: Busduct joints on Indoor rated busducts should have a minimum

of 8 in. (203.2 mm) clearance on either side of walls.

Figure 14. Minimum Indoor Joint Clearances

Note: Busduct joints on vertically mounted busduct should have a

minimum of 8 in. (203.2 mm) clearance before ceilings and a minimum

of 16 in. (406.4 mm) clearance above floors or curbs if used.

Figure 15. Minimum Floor/Ceiling Joint Clearances.

WARNING

WHEN UNPLUGGING TAP-OFF UNITS, DISCONNECT LOADS. BEFORE

BUSDUCT SYSTEM POWERS ON, LEAD WIRES OF ALL TAP-OFF UNITS

SHALL BE CONNECTED TO ELECTRICAL DEVICES AND DISCONNECTED

OR PROTECTED. CABLES SHALL NOT BE EXPOSED.

6EATON CORPORATION www.eaton.com.cn/electrical

Instruction Booklet IB

Effective January 2017

XAP Series Busduct

Storage, Installation, and Maintenance

Preventative Measures

Care should be taken to protect the busduct from contaminants. For

in-door applications, inspect the busduct routing area looking for

possible moisture points from roof leaks, pipe leaks, dripping conden-

sation from pipes and HVAC equipment, and exhaust fans blowing dust

and debris onto the busduct. The busducts should be protected from

these hazards. All damaged equipment should be replaced. All

equipment subject to moisture intrusion should be replaced.

Busduct Inspection

1. Check the voltage of incoming terminals to make sure the busduct

system is de-energized;

2. Clean the busduct removing accumulated dust, dirt, and other

debris. Do not use water, liquid detergent, or chemicals to clean the

busduct;

3. Perform a visual inspection on the busduct looking for stress or

damage and moisture intrusion;

4. Inspect the joint unit bolts for tightness;

5. Check the insulation resistance and keep the record;

6. Perform an infra-red thermal scan on all electrical connections, joint

connections, and busduct enclosures while the busduct is fully

energized and operating under full load conditions. If readings

change with time, further inspection and corrections may be

required.

If damaged and/or over heating has been found, it is recommended the

following procedures be performed.

1. After the busduct has been de-energized, remove the joint covers

and visually inspect the joints looking for gaps in the contact surface

areas, cracks in the insulators, and contaminants or corrosion;

2. Clean, replace damaged parts, and re-torque (70±6 N•m) torque as

required;

3. Perform an insulation resistance test prior to re-energizing;

4. If moisture intrusion be found, remove and replace all affected

pieces.

Attentions for Installation

1. Surface of busduct terminals and joint units must be kept clean

during installation;

2. Busducts must be adjusted and kept in the same line before

fastening the bolts of joint units. Tolerance of assembly in horizon

and vertical direction are 5mm per 10m;

3. Socket protection cover shall not be opened during installation;

4. Equipment should be power off and grounded safely when

connecting the busducts to equipment.

Construction after Installation

1. Complete the decoration work;

2. Protective grid, rail and fire protection isolation device should be

completed;

3. Isolation for all living parts should be completed;

4. No construction impacts installed busducts should be carried out;

5. Equipment for construction should be removed and the place should

be cleaned.

Steps for Energizing

1. The entire busduct systems should be tested by Megger at 1000V

and insulation resistance should be higher than 0.5 MΩ;

2. Inspect the tightness of each joint unit to avoid any loosen bolt;

3. Make sure all tap-off units are in the open position;

4. Make sure the phase sequence of busducts is the same as incoming

system;

5. Busducts system should not be loaded before energizing;

6. Bustucts system should be energized without load for 24 hours

before carrying out a full load operation.

Maintenance Procedures

A preventative maintenance schedule should be established in order to

achieve the best possible service from your Eaton XAP busduct.

It is recommended that an annual maintenance check and necessary

procedures be conducted at a minimum. Busducts subjected to severe

operating conditions may require more frequent maintenance.

It is recommended that a permanent maintenance record be kept

recording the dates of service, work performed and any measured

data.

DANGER

HAZARD OF ELECTRICAL SHOCK OR BURN. TURN THE POWER TO THE

BUSDUCT OFF BEFORE INSTALLING, REMOVING, OR WORKING ON THIS

EQUIPMENT.

WARNING

ONLY THOSE TRAINED AND QUALIFIED IN RECOGNIZED SAFETY

PRACTICES SHOULD PERFORM MAINTENANCE ON THE BUSDUCT.

WARNING

FOR THE FOLLOWING PROCEDURES, THE BUSDUCT MUST BE SHUT OFF

AND DE-ENERGIZED.

WARNING

FAILURE TO FOLLOW SAFETY PROCEDURES MAY CAUSE PROPERTY

DAMAGE, SERIOUS PERSONAL INJURY AND DEATH.

7 EATON CORPORATION www.eaton.com.cn/electrical

Instruction Booklet IB

Effective January 2017

XAP Series Busduct

Storage, Installation, and Maintenance

Tap-off Unit Inspection

When inspecting and performing maintenance on tap-off units, ensure

the breaker is in the open position and that the power to the busduct is

turned off.

1. Make sure the breaker is in the open position;

2. Turn off power to the busduct;

3. Using a multi-function meter, open the tap-off unit door and check to

ensure there is no voltage present on the line side of the unit;

4. For fusible units, check the fuse clip contact pressure and contact

means. If there are any sign of over-heating, replace fuse clips;

5. Look for any signs of deterioration of insulating materials and

protective barriers;

6. Check the operation of all mechanical components.

7. Check the mechanisms of all electrical and mechanical interlocks

and padlocking means;

8. Check for missing or broken parts, rusting, corrosion, dirt, and

excessive wear;

9. Check the line and load connections to ensure proper torque.

10. Clean off any arc spatter or soot deposits;

11. Replace any damaged parts;

12. Operate each switch or circuit breaker several times to ensure

proper working order.

Note

These maintenance instructions and procedures do not represent an

exhaustive list of maintenance steps required to maintain safe

operation of the busduct and tap-off units under all applications.

Specific applications may require additional steps and procedures. For

additional information or assistance with issues not covered sufficiently

in this publication, contact the local Eaton sales office.

DANGER

HAZARD OF ELECTRICAL SHOCK OR BURN. TURN THE POWER TO THE

BUSDUCT OFF BEFORE INSTALLING, REMOVING, OR WORKING ON THIS

EQUIPMENT.

WARNING

RECOGNIZED SAFETY PROCEDURES MUST BE FOLLOWED PRIOR TO ANY

WORK OR MAINTENANCE BEING PERFORMED.

Eaton is a power management company with 2016 sales of

$19.7 billion. We provide energy-efficient solutions that help our

customers effectively manage electrical, hydraulic and mechani-

cal power more efficiently, safely and sustainably. Eaton is

dedicated to improving the quality of life and the environment

through the use of power management technologies and

services. Eaton has approximately 95,000 employees and sells

products to customers in more than 175 countries. For more

information, visit www.eaton.com.

Electrical Sector Asia Pacific

No.3, Lane 280, Linhong Road,

Changning District, Shanghai

Printed in Singapore

June 2017

Eaton is a registered trademark

of Eaton Corporation.

All trademarks are property of their

respective owners.

Eaton XAP-C Operating instructions

Brand: Eaton

Model: XAP-C

Type: Operating instructions

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Eaton XAP-C Operating instructions

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