Instruction Booklet IB Effective January 2017

XAP Series Busduct

Storage, Installation, and Maintenance

Joint cover

XAP Series Busduct

XAP Series Busduct
Tap-off Units

Contents
Description Page
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Unloading and Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Preparation and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Joint Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Joint Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Expansion Joint Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
End Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Settlement Joint Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Horizontal Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Vertical Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wall Penetrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Busduct Joint Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tap-off Unit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Attentions for Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Construction after Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Steps for Energizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Maintenance Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Tap-off Unit Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Note. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Instruction Booklet IB
Effective January 2017
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.
DANGER
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.
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.
1 EATON CORPORATION www.eaton.com.cn/electrical
XAP Series Busduct
Storage, Installation, and Maintenance
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.
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.
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 ≥20MΩ 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.
XAP Series Busduct Instruction Booklet IB
Storage, Installation, and Maintenance Effective January 2017

Installation Joint 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.
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.

Identification

PE

L3
L1
L2

N
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.

Compact Busway
Type： <XAP>
Figure 3. Joint Installation

Standard： IEC61439-1/-6

Ue = V In = A f =50/60Hz
Torque Indication Bolt
Ui = V Icw = kA IP65 When the two sections have been properly joined together, the joint
Name of contract： bolt may be tightened. This joint bolt is a special torque-indicating bolt
Contract No.： with two bolt heads to ensure that the proper installation torque is
achieved. Fall away instruction tags are provided between the upper
Installation No.：
and lower bolt heads. Torque should only be applied to the upper bolt
Manufacture Date：
head. When the proper torque is achieved, this bolt head will shear off,
Principal/Producers： Eaton Electrical Equipment Co.,LTD. allowing the tag to fall to the floor.
Production enterprise： Chongqing Yiwan Electric Co., LTD.

Orange
Figure 1. Nameplate Label
instruction Tag

Phasing and Orientation Labels

Figure 4. Figure 5.
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
Figure 4. Torque Indicating Bolt as Shipped
phasing is N-L3-L2-L1-PE.
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
L1
L2
L3
N

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.

DANGER
FAILURE TO INSTALL THE BUSDUCT CORRECTLY MAY RESULT IN
DAMAGE TO THE BUSDUCT AS WELL AS PROPERTY DAMAGE, PHYSICAL
HARM, OR DEATH.

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

Instruction Booklet IB
Effective January 2017
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.
Joint cover
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).
16-M6*25
Hexagon bolts
Figure 7. Expansion Joint Installation
3 EATON CORPORATION www.eaton.com.cn/electrical
XAP Series Busduct
Storage, Installation, and Maintenance
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
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.
8*30 screws
Figure 9. Settlement Joint Installation
XAP Series Busduct Instruction Booklet IB
Storage, Installation, and Maintenance Effective January 2017

Horizontal Mounting Wall Penetrations

For over-head mounting of the Eaton XAP busduct, all-thread drop rods When an Eaton XAP busduct passes through a wall or vertical barrier,
must be provided by the installer and should not be spaced more than the opening should be at least 100 mm larger than the outside
2m apart. dimensions of the busduct.

1. The mounting clearance for straight busduct should not be longer For individual and multiple runs of Eaton XAP busduct, thought must be
than 2m. Detailed clearance requirements shall be requested during given to horizontal and vertical clearances between runs, walls, and
routing design according to field conditions and loading situations, ceilings.
and shall be specified in installation drawing.

Maximum clearance loading weight (kg）

Mounting clearance (m) 1.2 1.6 2
XAP-C (kg/m) ≥50.4 22.6 ≤ 50.4 ≤22.6
XAP-A (kg/m) ≥50.4 22.6 ≤ 50.4 ≤22.6

Busduct Busduct
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 Figure 11. Horizontal Wall Penetration Installation

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.

Busduct Busduct

Figure 12. Vertical Floor Penetration Installation

Figure 10. Vertical Busduct Mounting Support

EATON CORPORATION www.eaton.com.cn/electrical 4

Instruction Booklet IB
Effective January 2017
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.
5 EATON CORPORATION www.eaton.com.cn/electrical
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
Lock
Anchor A
Lock
Anchor B
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.
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.
XAP Series Busduct
Storage, Installation, and Maintenance
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.
Instruction Booklet IB
Effective January 2017
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.
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.
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.
EATON CORPORATION www.eaton.com.cn/electrical 6
Instruction Booklet IB XAP Series Busduct
Effective January 2017 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.

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.

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.

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

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