Selection and Application Guide. busway system. Cost-effective Power Distribution Compact Design

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1 Selection and Application Guide busway system XJ-L Cost-effective Power Distribution Compact Design

2 Specifications New for A XJ-L Busway XJ-L Busway is available up to 400A. First introduced in 1960, XJ-L continues to be the leading power distribution solution for demanding applications that require reliable, high quality power. Now, Siemens meets increased market demand for a cost effective solution for low to medium power distribution with the new 400A XJ-L. Why Change Perfection? XC100 and X200 XJ-L busway have led the market in cost-effective busway solutions up to 225A for over 45 years. Recently, there is increased demand for low cost power distribution requiring up to 400A. Conforming with Siemens tradition of continuous improvement, Siemens Engineers and Product Management investigated numerous low-medium power solutions. The result of the investigation is to expand the proven XJ-L technology. The new 400A XJ-L is built from the same basic components used in X200 busway. The 400A bus bar is.125 x 2.12" compared to the.125 x 1.0" bar used in X200. To ensure reliable electrical and thermal performance, a second spring clip assembly is installed at the joint. Specifications and Ratings: Current Rating: 400A Voltage: 600V max Bus Bar Material:.12 x 2.12 Copper Short Circuit Rating: 35kA Configurations: 3Ø3W, 3Ø4W Neutral: 100%, 200% * (IG) Ground: Std Housing (Hsg), Internal (G), Isolated* (IG) Ingress Protection: 2X, IP40 with XOC installed Electrical Standards: UL 857 and CSA 22.2 * Note: 200% neutral and isolated ground utilize the same bus bar. The system can be configured as either isolated ground or 200% neutral. For more information on this and other Busway Products, please visit: Key competitive advantages: Compact Size small cross section for applications where busway routing is constrained Joint Connection dual spring clamp assemblies ensure reliable, maintenance-free joints Safety plug-in outlets are IP 2X finger safe (optional XOC outlet covers increase system to IP40) Reliability fundamental design has a 60 year history of reliability Service simple snap together installation, maintenancefree joints, factory stock of critical components and large distribution inventory of bus plugs ensure quick and easy serviceability Fittings elbow, tee, cross, flanged end, and tap boxes are offered in standard and custom configurations Compatibility the full range of XJ-L bus plugs can be interchanged between 100A, 225A and 400A busway 2

3 Overview XJ-L Busway XJ-L Busway is well known for its outstanding performance, providing convenient, cost-effective power distribution for high-tech environments, computer centers, laboratories, and other applications requiring consistent, quality power distribution. Key XJ-L design features include optional isolated ground ampere ratings of 100A, 225A, and 400A. For maximum availability, XJ-L Busway is maintained as a stock product to meet your quickship requirements. As a result, XJ-L Busway is an intelligent choice for contractors and users concerned with designing superior electrical distribution systems. The compact design is ideal for limited working areas in computer manufacturing, laboratory or test facilities, schools, hospitals, and machine shops. With XJ-L Busway, you get an exclusive, optional isolated ground design that ensures clean power. Unlike bonded ground designs that may convey surges from one electrical devce to another, the XJ-L optional isolated ground system is well suited for high-tech computer intensive environments. The ground bar is the same size as the phase bars, with the same ampere rating. Installation is easy, joining one XJ-L busway section to another is as simple as matching ends and snapping them together. Bus bars are held securely in place by spring pressure clips located in the joint insulator. The joint is secured when the external housing plate is attached with captive screws. Thanks to built-in flexibility and a low initial cost, you also benefit from future savings when you need new equipment. Time to add on busway for new or expanded facilities? The XJ-L Busway you installed years ago matches the XJ-L Busway you specify today and years from now the new busway sections, components or system-compatible bus plugs will still fit. Dependability First introduced in 1960 and having well over one million feet in service, XJ-L busway has a proven track record of trouble-free power distribution. The joints are easy to install and maintenance free. The copper bus bars and steel housings are designed to provide years of dependable service. Flexibility XJ-L offers the flexibility of a 3 or 4 wire system, isolated or internal ground, and 200% neutral capacity where isolated ground is not required. Busway sections and additional plugs can be easily added to meet changing demands. Each 10 foot section features twelve plug-in openings for easy accessibility. Different loads can be powered by a single multi-receptacle plug. These plugs can be configured to provide specific load switching and protection. Application specific hangers are available to accomodate installation requirements. Cost Overall, XJ-L offers a more costeffective power distribution system than the typical cable and conduit installation. XJ-L is lightweight and easy to handle, installation is less expensive, faster and cleaner. In addition, XJ-L busway can easily be reconfigured to accommodate changes in load requirements when needed. Equipment Protection Critical equipment is protected via fuse or circuit breaker plugs. Due to their proximity, the plugs provide a localized method of protection and disconnection. Space Space in critical power/data center facilities is at a premium. XJ-L Busway requires less space than conventional power distribution methods such as cable and conduit. Availability XJ-L busway and plugs are stocked to meet your quick-ship requirements. Once you factor in all the advantages, XJ-L is clearly the best choice for reliable, flexible, and economical power distribution for data centers, light industrial, and high tech applications. 3

4 Specifications XJ-L Busway is available in 100A, 225A and 400A ratings making it the right choice for light industrial and commercial applications where low initial startup and maintenance costs are prerequisites. XJ-L Busway is the most logical choice for high tech, computer intensive environments, especially when isolated ground is required. Housing XJ-L Busway features a totally enclosed, non-ventilated, steel housing. The housing is covered with an electrostatically applied light gray ANSI 61 polyester urethane powder paint. The paint is scratch resistant and has a 500 hour salt spray rating. Conductors The conductors are fabricated from 98% conductivity copper. The bars are spaced-in-air and held securely in the housing by the plug-in outlets and joints. Neutral 100% neutral is available as standard, 200% neutral is offered as a custom product. Ground The internal ground bus is 100% rated for 100A, 60% rated for 225A, and 50% for 400A busway. Isolated ground is rated at 100% for both amperages. Plating The bus bars are tin plated over their entire length to ensure good electrical contact at all joint and plug tap-off points. The plating also serves to protect the bars from corrosion. Optional silver plating is available. Plug-in Base XJ-L Busway features multiple plug-in locations. The plastic, non-tracking outlets are located on 20 inch centers and support the bus bars providing bracing during short circuit conditions. The plug-in outlets are IP2x (finger safe). Optional plug-in base covers (XOC) are available separately or they can be factory installed. Joint Connection Busway sections are connected via a maintenance-free, spring pressure joint. The busway ends are easily aligned and bus bar ends are held securely in place by spring pressure clips located in the joint insulator. The housings are connected via external housing plates and captive screws. Bus Plugs There are twelve plug-in outlets on each 10 foot (3.048 m) section, six openings on 5 foot (1.524 m) sections and two outlets on 2 foot (.616 m) sections. Bus plugs are available with amperages ranging from 15A to 100A. Plugs feature circuit breakers or fusible switch disconnects. Testing Each piece of XJ-L busway is factory tested prior to shipment. A dielectric test is performed to ensure product integrity. XJ-L Busway is manufactured and inspected in accordance to an ISO 9001 registered Quality Management System. Compatibility XC100 copper busway is fully compatible with the X100 aluminum busway. Standards XJ-L Busway products meet the following standards: UL 857 NEMA BU1 CSA C22.2 Ratings Amperage: Voltage: Short Circuit: 100A, 225A and 400A 600 VAC max 100A 10kAIC 225A 22kAIC 400A 35kAIC R, X, Z, and Voltage Drop Bus Bar Width Ohm x 10-3 per 100 ft. Voltage Drop Concentrated Loads, Line-to-Line per 100 ft. Ampere x.125 in. (3.2 mm) Line to Neutral at 100% Rated Load, 35 C Ambient Power Factor Rating Thick R X Z (13.0) (25.4) (54.1)

5 Straight Sections Straight Sections Available in 10 foot (3.048 m), 5 foot (1.524 m) or 2 foot (.616 m) standard plug-in lengths, XJ-L Busway offers layout flexibility to meet custom requirements. XJ-L offers twelve plug-in outlets, six per side on 10 foot sections. For convenience, the openings are located in alternate positions from side to side and are all useable simultaneously. XJ-L 100 and 200A Cross Section XJ-L Busway also features an exclusive rotating cover plate to facilitate inspection of the joints. The light weight design of the busway and plugs makes the installation of XJ-L quick and trouble-free. XJ-L 400A Cross Section Isolated Ground or 2nd Neutral A Phase B Phase C Phase Neutral Internal Ground Housing Width Straight Sections, Dimensions (standard/min.) Short 3-Pole 4-Pole Ampere Busbar Bar Bar Housing Housing Max Circuit Catalog Catalog Rating Material Thickness Width Width Height Voltage Rating Length Number Weight Number Weight 100 Copper.125 (3.2).5 (12.7) 2.0 (50.8) 6.13 (156) 600V 10kA 10.0 (3.05) XC XC Copper.125 (3.2).5 (12.7) 2.0 (50.8) 6.13 (156) 600V 10kA 5.0 (1.52) XC XC Copper.125 (3.2).5 (12.7) 2.0 (50.8) 6.13 (156) 600V 10kA 2.0 (.61) XC XC Copper.125 (3.2) 1.0 (25.4) 2.5 (63.5) 6.13 (156) 600V 22kA 10.0 (3.05) XC XC Copper.125 (3.2) 1.0 (25.4) 2.5 (63.5) 6.13 (156) 600V 22kA 5.0 (1.52) XC XC Copper.125 (3.2) 1.0 (25.4) 2.5 (63.5) 6.13 (156) 600V 22kA 2.0 (.61) XC XC Copper.125 (3.2) 2.12 (53.8) 3.6 (91.7) 6.13 (156) 600V 35kA 10.0 (3.05) XC XC Copper.125 (3.2) 2.12 (53.8) 3.6 (91.7) 6.13 (156) 600V 35kA 5.0 (1.52) XC XC Copper.125 (3.2) 2.12 (53.8) 3.6 (91.7) 6.13 (156) 600V 35kA 2.0 (.61) XC XC Note: A ground in the diagram is available for all XJ-L Busway systems. For systems so equipped, add suffix letter G to the catalog number. The neutral bar N is omitted on 3-Pole busway. The isolated ground (suffix letter IG) or second neutral bar is positioned above the A Phase bar. 5

6 Elbows Flat Elbow Catalog Numbers Ampere Catalog Number Rating Poles Right Hand Left Hand XC1003L1 XC1003L XC1004L1 XC1004L X2003L1 X2003L X2004L1 X2004L X4003L1 X4003L X4004L1 X4004L3 Flat Elbows Right hand or left hand XJ-L Busway system 90 degree flat elbows are available. When specifying be sure to use the proper catalog number suffix to identify the required fitting. Edge Elbow Catalog Numbers Ampere Catalog Number Rating Poles Right Hand Left Hand XC1003L2 XC1003L XC1004L2 XC1004L X2003L2 X2003L X2004L2 X2004L X4003L2 X4003L X4004L2 X4004L4 Edge Elbows Right hand or left hand XJ-L Busway system 90 degree edge elbows are available. When specifying, be sure to use the proper catalog number suffix to identify the required fitting. for isolated ground bus or 200% neutral. Left Elbow (-4) Right Elbow (-2) 15.0" (381 mm) 15.0" (381 mm) Insulator 11.0" (279 mm) 11.0" (279 mm) Top 4.0 (122 mm) 4.0 (122 mm) Top 6

7 Tees and Crosses Cross Catalog Numbers Ampere Catalog Number Rating Poles Right Hand Left Hand X1003CR2 XC1003CR XC1003CR2 XC1003CR X2003CR2 X2003CR X2004CR2 X2004CR X4003CR2 X4003CR X4004CR2 X4004CR4 Cross Crosses are fittings used to interconnect two busway runs which are located at right angle to each other. Tee Catalog Numbers Ampere Catalog Number Rating Poles Right Hand Left Hand XC1003T2 XC1003T XC1004T2 XC1004T X2003T2 X2003T X2004T2 X2004T X4003T2 X4003T X4004T2 X4004T4 Tee Tees permit a second run of busway to extend at right angles to a straight busway run. Left Hand (-4) Right Hand (-2) 22.0" (559 mm) Insulator End Insulator End Top 18.0" (457 mm) 18.0" (457 mm) 4.0" (102 mm) C L 4.0" (102 mm) Top 18.0" (457 mm) 18.0" (457 mm) Insulator End 22.0" (559 mm) Insulator End C L 4.0" (102 mm) 4.0" (102 mm) 7

8 Tap Boxes 100A Plug-In Tap Box Catalog Numbers Ampere Catalog Rating Poles Number X103PB X104PB Bonded Ground Kit W62890 Isolated GroundKit W A Plug-In Tap Box Plug-in cable tap boxes are non-fusible devices used for end or center feed. The 100A tap boxes can be attached at any plug-in opening. Lug Sizes for Plug-In Tap Boxes Ampere Phase and Rating Neutral Ground 100 (1) #1-10 AWG (1) #2-14 AWG Knockouts: 1/2, 3/4, 1, 1 1/4, 1 1/2, 2 conduit knockouts in both sides. 200A Plug-In Tap Box Catalog Numbers Ampere Catalog Rating Poles Number X2003PB X2004PB Bonded Ground Kit W62892 Lug Sizes for Plug-In Tap Boxes Ampere Phase and Rating Neutral Ground 200 (1) #6-250MCM (1) #4-14 AWG 200A Plug-In Tap Box Plug-in cable tap boxes are non-fusible devices used for end or center feed. The 200A tap box requires two adjacent openings. Knockouts: 1, 1 1/4, 1 1/2, 2, 2 1/2 conduit knockoutsin both sides. Center Tap Box Catalog Numbers Ampere Catalog Rating Poles Number X2003M X2004M X4003M X4004M Center Cable Tap Box Center tap boxes are non-fusible devices utilized to feed to or take off power from the busway run. When loads served by the busway run do not require over-current protection, center tap boxes may be used. If the application requires additional wiring bending space, extended center tap boxes are available. Center tap boxes are an actual part of the busway run and require a space of 32 in. (810 mm) for installation. 8

9 Tap Boxes and Flanged Ends End Tap Box Catalog Numbers Ampere Catalog Rating Poles Number XC1003ETVB XC1004ETVB X2003ETVB X2004ETVB X4003ETVB X4004ETVB End Tap Box End tap boxes are devices used to connect cable and conduit to the end of a busway run or where busway runs connect without the need for over-current protection. End tap boxes may be installed at the end or beginning of a run. 5.2" (132.1 mm) 2.8" (71.1 mm) 16.5" (419.1 mm) 5.2" (132.1 mm) 26.0" (660.4 mm) 16.0" (406.4 mm) 9.2" (233.7 mm) Flanged End Flanged End Catalog Numbers Ampere Catalog Rating Poles Number XC1003FE XC1004FE X2003FE X2004FE X4003FE X4004FE Flanged End Flanged ends are used to connect busway to switchboards. Flanged ends come complete with bus bar extensions to facilitate the making of electrical connections. 9

10 Bus Plugs Bus Plugs for XJ-L are available from 15A to 100A, with molded case circuit breakers or Vacu-Break fusible switches. Bus plugs may be operated with a pull chain or hookstick from the floor. Lightweight and portable, plugs are easily moved from one location to another. Captive hardware allows for easy removal and re-installation. This is especially important in high tech areas requiring frequent movement of equipment. The XQ-R bus plug has provisions for BQ or QP breakers as in the XQ, but it has added wiring space allowing for receptacle installation. Additional add on features, such as shunt trips, alarm switches, and auxillary contacts are also available for XEC and XLEC bus plugs. For XJ-L Busway there are five basic bus plug designs: XQ accepts plug-in or bolt-on type breakers XQR accepts plug-in or bolt-on type breakers and has receptacle provisions XEC accepts heavy duty ED2 and ED4 circuit breakers XLEC accepts ED2, ED4 and ED6 circuit breakers XLVB features the Vacu-Break switch XQ Series Bus Plug Catalog Numbers Breaker Catalog Number Breaker AC No. of Ampere 3Ph/ 3 Ph/ Type Volts Spaces Rating 3 Wire 4 Wire QP and BQ 120/ XQ35 XQ45 Enclosures Only XQ Series XQ Bus Plugs accept QP (plug-in) or BQ (bolt-on) circuit breakers. The plugs feature knockouts to facilitate quick installation. XQ-R Series Bus Plug Catalog Numbers Breaker Catalog Number Breaker AC No. of Ampere 3Ph/ 3 Ph/ Type Volts Spaces Rating 3 Wire 4 Wire QP and BQ 120/ XQ35R XQ45R Enclosures Only XQR Series XQR Bus Plugs accept QP (plug-in) or BQ (bolt-on) circuit breakers. The plugs feature knockouts to facilitate quick installation. Accessories for XQ and XQ-R Series XEQH W62890 W68101 Floor Operating Handle with ON/OFF Labels Bonded Ground Kit Isolated Ground Kit XEQH W68101 W

11 Bus Plugs XEC Series Bus Plug Catalog Numbers Breaker Catalog Number Breaker AC Amp 3Ph/ 3 Ph/ Type Volts Rating 3 Wire 4 Wire ED XEC3100 XEC4100 ED XEC3100IG XEC4100IG Enclosures Only XEC SERIES (Cover Operable, 100A Max) XEC bus plugs accept ED2 and ED4 circuit breakers. The plugs feature a spacious chassis which allows room for wire bending and knockout provisions. Isolated ground plugs are available from the factory. Accessory for XEC and XLEC Series W62890 Bonded Ground Kit W62890 Knockouts: 1, 1 1/4, 1 1/2, 2 conduit knockouts in both sides XLEC Series Bus Plug Catalog Numbers Breaker Catalog Number Breaker AC Amp 3Ph/ 3 Ph/ Type Volts Rating 3 Wire 4 Wire ED XLEC3100 XLEC4100 ED XLEC3100 XLEC4100 ED XLEC3100 XLEC4100 Enclosures Only XLEC Series (Floor Operable, 100A Max) XLEC bus plugs accept ED2, ED4 and ED6 circuit breakers. The plugs feature a spacious chassis which allows room for wire bending and knockout provisions. These plugs may be operated from the floor with a pull chain or hookstick. Knockouts: 1, 1 1/4, 1 1/2, 2 conduit knockouts in both sides XLVB Series Bus Plug Catalog Numbers Ampere Catalog Number Volts Rating 3 Pole 4 Pole XLVB321 XLVB421N XLVB322 XLVB422N XLVB323 XLVB423N XLVB351 XLVB451N XLVB352 XLVB452N XLVB353 XLVB453N Fusible Vacu-Break Switch Plugs XLVB Series (Floor Operable, 100A Max) XLVB fusible bus plugs utilize the Vacu-Break switching principle, which minimizes arcing and reduces maintenance costs. The Vacu-Break bus plugs are quick-make and quick-break, cover interlocked, horsepower rated, and may be operated from the floor with a pull chain or hookstick. Accessory For XLVB Series W47185 ON/OFF Labels W47185 Knockouts: 1, 3/4, 1, 1 1/4, 1 1/2, 2 conduit knockouts in both sides 11

12 Accessories Ampere Catalog Dimensions Rating Number A 100 XH XH XH3 4.0 Busway Hanger XH2 and XH3 Hangers are used to support XJ-L Busway. Two hangers are furnished with each 10 foot straight section and can be used with customer supplied rods up to 3/8 inch in diameter. Hangers are adaptable for wall mounting or ceiling suspension arrangements, either edge or flat. Ampere Catalog Dimensions Rating Number A B 100 XE /16 15/ XE /16 1 7/ XE /16 2 1/2 End Closer An end closer is used to terminate busway runs. To extend the run, simply remove the end closer and add new sections as needed. 6.29" (160 mm) A 4.97" (126 mm) 4.97" (126 mm) A.47" (12 mm) 4.27" (108 mm) 6.29" (160 mm) 1.94" (49 mm) 4.27" (108 mm) B XOC Outlet Covers Optional outlet covers are available for closing off the plug-in outlets when desired. 12

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15 Siemens Energy & Automation, Inc Old Milton Parkway Alpharetta, GA Siemens Energy & Automation, Inc. All Rights Reserved. Siemens is a registered trademark of Siemens AG. Product names mentioned may be trademarks or registered trademarks of their respective companies. Specifications are subject to change without notice. BUSA-XJL New 4M0807CW Printed in USA