XAP Series Busduct Storage, Installation, and Maintenance

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1 Instruction Booklet IB Joint cover Tap-off Units Contents Description 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 Page

2 Instruction Booklet IB 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. Preparation and Inspection Qualification and Training Only qualified professionals should install, operate and maintain the XAP busduct. Professionals should:. Fully understand the structure, installation, operation of XAP as well as the danger during operation; DANGER. Equipped with PPE such as safety helmet, working cloths. HAZARD OF ELECTRICAL SHOCK OR BURN. TURN THE POWER TO THE BUSDUCT OFF BEFORE INSTALLING, REMOVING, OR WORKING ON THIS EQUIPMENT. 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.. Well trained about charging and test of the equipment; LIVE EQUIPMENT MAY LEAD TO PHYSICAL HARM. UNLESS OTHERWISE STATED, THE EQUIPMENT MUST BE POWEROFF BEFORE INSTALLING, INSPECTION AND MAINTAINS. DAMP BUSDUCT MUST BE TREATED PROPERLY. AND THE INSULATION RESISTANCE MUST BE TESTED POSITVELY BEFORE INSTALLATION. Instrument and tool The following instruments and tools will be used during installation:. Insulation tester 000V;. 8-0, 0- wrench, sleeve and torque wrench;. Straight and cross screwdriver; 4. Gradienter, tape and filament; 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 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. 5. Scaffold, hoist and herringbone ladder;. 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 000 volts, phase-to-phase, phase-to-neutral, and phase-to-ground 0M 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 installation.

3 Instruction Booklet IB 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. This label identifies each piece and its ratings. It is recommended 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. 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 illustrates correct joint installation. PE L L L N Type <XAP> Compact Busway Figure. Joint Installation Standard IEC49-/- Ue = V In = A f =50/0Hz Ui = V Icw = ka IP5 Name of contract Contract No. Installation No. Manufacture Date Principal/Producers Eaton Electrical Equipment Co.,LTD. 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. Production enterprise Chongqing Yiwan Electric Co., LTD. Figure. 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-L-L-L-PE. Orange instruction Tag Figure 4. Figure 5. 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. PE L L L N Figure. 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. DANGER FAILURE TO INSTALL THE BUSDUCT CORRECTLY MAY RESULT IN DAMAGE TO THE BUSDUCT AS WELL AS PROPERTY DAMAGE, PHYSICAL HARM, OR DEATH.

4 Instruction Booklet IB 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. 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. End cover Joint cover Figure. Joint Cover Installation Expansion Joint Installation This is a transition section to compensate for expansion and contraction 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 M*5 bolts in the expansion joints to ensure expansion effect (see Figure 7). 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*0 bolts in the settlement joints to ensure settlement effect. -M*5 Hexagon bolts Figure 7. Expansion Joint Installation 8*0 screws Figure 9. Settlement Joint Installation

5 Instruction Booklet IB 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 m apart.. The mounting clearance for straight busduct should not be longer than m. Detailed clearance requirements shall be requested during routing design according to field conditions and loading situations, and shall be specified in installation drawing. Wall Penetrations When an Eaton XAP busduct passes through a wall or vertical barrier, the opening should be at least 00 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. Maximum clearance loading weight (kg Mounting clearance (m) XAP-C (kg/m) XAP-A (kg/m) Mounting supports shall be placed at both ends of the joint. Maximum clearance is no longer than m. No load shall be burdened at the joints.. 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. Busduct Busduct 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 ft. (4.9m). Intermediate hangers are required for floor heights exceeding ft. (4.9m) as shown in Fig. 0. Figure. Horizontal Wall Penetration Installation Maximum tolerance for busduct installation is 5mm per 0m. Busduct Busduct Figure. Vertical Floor Penetration Installation Figure 0. Vertical Busduct Mounting Support 4

6 Instruction Booklet IB Busduct Joint Clearances Busduct joint sections may not fall within walls or floors. Figures through 5 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 0 in. (54 mm) clearance on either side of walls. Tap-off Unit Installation Phase sequence shall be made according to field application requirements and construction drawings. Remove the bolts on the busduct socket cover and open the socket protection cover. (See Figure ). 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 9). 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. Minimum Outdoor Joint Clearances Note: Busduct joints on Indoor rated busducts should have a minimum of 8 in. (0. mm) clearance on either side of walls. Figure. Socket Lock Anchor A Lock Anchor B Figure 4. Minimum Indoor Joint Clearances Note: Busduct joints on vertically mounted busduct should have a minimum of 8 in. (0. mm) clearance before ceilings and a minimum of in. (40.4 mm) clearance above floors or curbs if used. Figure 7. Tap-off Unit Installation. 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.. 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.. When not plugging in busduct, socket protection cover shall not be opened. Otherwise, it will influence the protection degree of busduct system. 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. Figure 5. Minimum Floor/Ceiling Joint Clearances. 5

7 Instruction Booklet IB Attentions for Installation. Surface of busduct terminals and joint units must be kept clean during installation;. 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 0m;. 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. Complete the decoration work;. Protective grid, rail and fire protection isolation device should be completed;. 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. The entire busduct systems should be tested by Megger at 000V and insulation resistance should be higher than 0.5 MΩ;. Inspect the tightness of each joint unit to avoid any loosen bolt;. 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;. Bustucts system should be energized without load for 4 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. 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 condensation 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. Check the voltage of incoming terminals to make sure the busduct system is de-energized;. Clean the busduct removing accumulated dust, dirt, and other debris. Do not use water, liquid detergent, or chemicals to clean the busduct;. 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;. 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. FOR THE FOLLOWING PROCEDURES, THE BUSDUCT MUST BE SHUT OFF AND DE-ENERGIZED. FAILURE TO FOLLOW SAFETY PROCEDURES MAY CAUSE PROPERTY DAMAGE, SERIOUS PERSONAL INJURY AND DEATH.. 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;. Clean, replace damaged parts, and re-torque (70± N m) torque as required;. Perform an insulation resistance test prior to re-energizing; 4. If moisture intrusion be found, remove and replace all affected pieces. ONLY THOSE TRAINED AND QUALIFIED IN RECOGNIZED SAFETY PRACTICES SHOULD PERFORM MAINTENANCE ON THE BUSDUCT.

8 Instruction Booklet IB 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. DANGER HAZARD OF ELECTRICAL SHOCK OR BURN. TURN THE POWER TO THE BUSDUCT OFF BEFORE INSTALLING, REMOVING, OR WORKING ON THIS EQUIPMENT. RECOGNIZED SAFETY PROCEDURES MUST BE FOLLOWED PRIOR TO ANY WORK OR MAINTENANCE BEING PERFORMED.. Make sure the breaker is in the open position;. Turn off power to the busduct;. 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;. 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. 0. Clean off any arc spatter or soot deposits;. Replace any damaged parts;. 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. 7

9 Eaton is a power management company with 0 sales of $9.7 billion. We provide energy-efficient solutions that help our customers effectively manage electrical, hydraulic and mechanical 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 75 countries. For more information, visit Electrical Sector Asia Pacific No., Lane 80, Linhong Road, Changning District, Shanghai 07 Eaton Corporation All Rights Reserved Printed in Singapore June 07 Eaton is a registered trademark of Eaton Corporation. All trademarks are property of their respective owners.

SECTION ENCLOSED BUS ASSEMBLIES

SECTION ENCLOSED BUS ASSEMBLIES SECTION 262500 ENCLOSED BUS ASSEMBLIES PART 1 - GENERAL 1.1 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification