ZUCCHINI XCM Busbar Trunking Systems

Product Information

Specifications

• Product Name: XCM Busbar Trunking Systems
• Model Number: LE13878AA-01GF-23W20
• Manufacturer: Legrand
• Country of Origin: France
• Website: www.legrand.com

Product Overview

The XCM Busbar Trunking Systems consist of various components
designed for electrical power distribution. The system includes
straight elements, additional elements, routing components, tap-off
boxes, connection interfaces, end covers, and fixing supports.

System Concept

The XCM Busbar Trunking Systems provide a flexible and efficient
solution for distributing electrical power in buildings. The system
allows for easy installation and maintenance, ensuring reliable
power distribution.

Certifications

The XCM Busbar Trunking Systems have undergone rigorous testing
and have obtained various certifications to ensure compliance with
safety standards. These certifications include company approval
certifications and other relevant certificates.

Product Usage Instructions

1. Introduction

1.1 Safety Information

Before using the XCM Busbar Trunking Systems, it is important to
read and understand the safety information provided in the user
manual. This includes important information regarding installation,
operation, and maintenance.

1.2 Safety Tips

Follow these safety tips when using the XCM Busbar Trunking
Systems:

• Ensure that the power is turned off before installing or
  servicing the system.

• Use appropriate personal protective equipment (PPE) when
  working with electrical systems.

• Do not overload the system beyond its rated capacity.

• Regularly inspect the system for any signs of damage or
  wear.

1.3 Purpose of the Document

This document serves as an installation and user manual for the
XCM Busbar Trunking Systems. It provides detailed instructions on
how to properly install, operate, and maintain the system.

2. Material Preparation and Arrangement

2.1 Equipment and Tools

Before starting the installation process, ensure that you have
the necessary equipment and tools. This includes lifting and
handling equipment, supports for positioning and installing, as
well as any other tools specified in the user manual.

2.2 Storage

Proper storage of the XCM Busbar Trunking Systems components is
important to prevent damage. Store the components in a clean and
dry area, away from direct sunlight and extreme temperatures.

2.3 Weight Table

Refer to the weight table provided in the user manual to
determine the weight of each component. This will help in planning
the installation process and ensuring proper handling and lifting
techniques are used.

2.4 Handling and Lifting

When handling and lifting the XCM Busbar Trunking Systems
components, follow these guidelines:

• Use appropriate lifting equipment to avoid strain or
  injury.

• Do not exceed the recommended weight limits for lifting.

• Ensure that the components are securely fastened during lifting
  and transport.

2.5 Missing or Damaged Components

Before starting the installation, carefully inspect all
components for any signs of damage or missing parts. If any
components are damaged or missing, contact the manufacturer for
assistance.

2.6 Product Type Identification

Each XCM Busbar Trunking Systems component has a specific
identification code. Refer to the user manual to understand how to
identify and differentiate between different types of
components.

3. Installation

3.1 Checks before Installation

Prior to installation, perform the following checks:

• Perform visual and electric checks to ensure that the
  installation area is suitable for the XCM Busbar Trunking
  Systems.

• Follow general rules for installing supports and ensure that
  all fixing accessories are available.

3.2 Installation of Wall Supports

Follow these steps for installing wall supports:

1. Determine the installation sizes, distances, and positioning
   logics based on the user manual guidelines.

2. Drill holes in the wall for fixing the brackets and ensure
   proper alignment.

3. Pre-assemble the wall brackets according to the provided
   instructions.

4. Securely fix the wall brackets to the wall using appropriate
   fasteners.

Frequently Asked Questions (FAQ)

Q: What certifications does the XCM Busbar Trunking Systems

have?

A: The XCM Busbar Trunking Systems have obtained company
approval certifications and other relevant certificates to ensure
compliance with safety standards.

Q: What should I do if I find missing or damaged

components?

A: If you find any missing or damaged components, contact the
manufacturer for assistance. Do not proceed with the installation
using damaged or incomplete parts.

LE13878AA-01GF-23W20

XCM Busbar Trunking Systems
Installation and user manual
LEGRAND BP 30076 87002 Limoges Cedex France www.legrand.com

XCM Busbar Trunking Systems

EN ENGLISH

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Installation and user manual

XCM Busbar Trunking Systems
General information
The information in this installation manual offers general descriptions and takes into account the general technical features of the products discussed, with the object of guiding the user through the installation of the XCM busbar. Therefore, product reliability for specific user applications cannot rely on this manual to ensure suitability or reliability of the busbar. Each user must assess the specific risks and test the product based on their own specific application. Neither Legrand, nor any of its subsidiaries or controlled companies shall be held responsible for the improper use of the information contained in this document. For any suggestions of any kind regarding this manual, please contact Legrand directly. The user hereby agrees not to reproduce this manual in full or in part for commercial use, or for any other use that is not strictly personal. The reproduction of this manual is also prohibited, on any supports whatsoever, including multimedia or internet publication, without the explicit written consent of Legrand. The publication of any types of hyperlinks to this manual or part thereof is also strictly prohibited. The user of this manual agrees to use it exactly as it is written, and always at their own risk. Only the manufacturer has the authority of intervening on individual components for replacement and repair purposes, in order to ensure the compliance of those described in this document. The instructions of this manual must always be followed, to ensure correct installation of the components within the system. Failure to comply with such instructions can cause injury or damage to system components and equipment.
Safety instructions This product should be installed in compliance with installation rules, preferably by a qualified electrician. Incorrect installation and/or incorrect use can lead to risk of electric shock or fire. Before carrying out the installation, read the instructions and take account of the product’s specific mounting location. Do not open up, dismantle, alter or modify the device except where specifically required to do so by the instructions. All Legrand products must be opened and repaired exclusively by personnel trained and approved by Legrand. Any unauthorised opening or repair completely cancels all liabilities and the rights to replacement and guarantees. Use only Legrand brand accessories.
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Index

1. Introduction

6

1.1 Safety Information

6

1.1.1 Important Information

6

1.2 Safety tips

7

1.3 Purpose of the document

7

1.4 Product overview

8

1.4.1 Straight elements

8

1.4.2 Additional elements

8

1.4.3 Routing components

8

1.4.4 Tap-off boxes

9

1.4.5 Connection interfaces

9

1.4.6 End Cover

9

1.4.7 Fixing supports

9

1.5 System concept

10

1.6 Certifications

12

1.6.1 Company approval certifications

12

1.6.2 The certificates

14

2. Material preparation and arrangement

15

2.1 Equipment and Tools

15

2.1.1 Introduction

15

2.1.2 Lifting and handling equipment

15

2.1.3 Supports for positioning and installing

15

2.2 Storage

16

2.3 Weight table

17

2.4 Handling and lifting

18

2.5 Missing or damaged components

21

2.6 Product type identification

22

3. Installation

24

3.1 Checks before installation

24

3.1.1 Visual / electric checks

24

3.1.2 General rules for installing supports

24

3.1.3 Fixing accessories

25

3.2 Installation of wall supports

34

3.2.1 Installation sizes, distances and positioning logics

34

3.3 Detailed instructions for vertical installation

35

3.3.1 Definition of the maximum distance (Dmax) between two subsequent suspension bracket with springs 36

3.3.2 Wall and busbar drilling. Fixing the brackets to the wall

37

3.3.2.1 Pre-assembly of the wall brackets

38

3.3.2.2 Wall brackets

40

3.3.2.3 Standard bracket

45

3.3.3 Busbar mounting in line

48

3.4 Joint installation

50

3.5 Data center Straight element (IP40)

53

3.6 Fire barrier installation

56

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XCM Busbar Trunking Systems

3.7 Product installation

61

3.7.1 Operating instructions on how to design riser mains

61

3.7.2 Panel end cap installation

62

3.7.3 Feed Unit

63

3.7.4 End cover

69

3.7.5 Tap-off boxes overall dimensions

70

3.7.6 Plug-In box installation rules

83

3.7.7 Assembly instruction Plug-In box 63A-125/160A empty

86

3.7.8 Assembly instruction Plug-In box 250A empty

91

3.7.9 Assembly instruction Plug-In box 630A empty

95

3.7.10 Assembly instruction fiberglass plastic T1

99

3.7.11 Assembly instruction fiberglass plastic T2/T3 – empty

103

3.7.12 Assembly instruction Bolt-on type

109

3.7.13 Adapter MR / XCM

111

3.7.14 Busbar post-installation checks

112

4. Best Practice

113

4.1 General Rules

113

4.1.1 TOB

113

4.1.2 TOB. Heavy / Large Boxes

115

4.2 External Fire Barriers

117

5. Starting-up

118

5.1 Busbar pre-energising checks

118

5.1.1 Electrical safety tests

118

5.2 Electric checks

118

5.2.1 Conductors

118

5.2.2 Tap-off boxes

118

5.3 Filling the check form

119

5.3.1 Busduct record form for inspections and controls

119

5.3.2 Inspections after installation

119

6. Verification

120

6.1 Definition of the check sequence

120

6.1.1 Busduct periodic inspections are to be carried out yearly

120

6.1.2 Tap-off boxes annual periodic inspections

120

6.1.3 Annual periodic inspections carried out one year after energizing and every other following year 121

6.1.4 Inspections after installation and yearly

122

6.1.5 Straight element

123

6.1.6 Straight element with outlets

124

6.1.7 Horizontal elbow

125

6.1.8 Vertical elbow

126

6.1.9 Troubleshooting table

127

7. Disposal

128

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1. Introduction
1.1 Safety Information 1.1.1 Important Information Here above general information concerning with signalling to take into account for all operative phases of the installation This symbology and these messages are used all through the manual in order to highlight any potential dangerous situations or to arouse attention to procedures
The addition of symbol to a “Danger” or “Warning” safety label indicates that an electrical hazard exists which will result in personal injury if the instructions are not followed. This is safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE NOTICE is used to address practices not related to physical injury. PLEASE NOTE Electrical equipment should be installed, operated, serviced, and verified only by qualified personnel. No responsibility is assumed by Legrand for any consequences arising out of the use of this material. A qualified person is one who has skills and knowledge related to the construction and operation of electrical equipment and its installation, and has received safety training to recognize and avoid the hazards involved.
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Installation and user manual

XCM Busbar Trunking Systems
1.2 Safety tips WARNING
HAZARD OF CRUSHING AND FRACTURES · Wear personal protective equipment when handling and installing the products (long sleeved jacket, trousers, gloves,
safety shoes, helmet, and safety glasses). · Only personnel who have been trained in safety regulations may work on construction sites to install busbar trunking
systems. · Work with extreme caution and follow the instructions provided in the manual. Failure to follow these instructions can result in death, serious injury, or equipment damage.
1.3 Purpose of the document The present manual contains all the information necessary for the installation of Legrand XCM busbar trunking system (Medium Rating). It contains the rules and procedures to be taken into account during the different phases involved in the whole process related to the realization of the plant and its final power up. In particular all preliminary requirements, specific installation procedures and overall recommendations are explained along the present manual. Topics exposed can be divided into different sections: · check of the equipment and of all the tools necessary for plant assembly · check of all the material availability and its correct identification (both as an individual component and inside the whole
system) · pre-installation checks on connections among different components · detailed operative installation procedures Also checks to be carried out after installation and before to power up (“putting into service”) are exposed in this manual A final part related to the periodic checking of the plant during its life is also illustrated (with the definition of the types and frequency of the checks to be performed) This manual is addressed to trained technical personnel
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1. Introduction
1.4 Product overview
1.4.1 Straight elements Supplied with its pre-installed monobloc.
Feeder elements: – standard length: 3 m – special length: from 0,6m to 3m
Distribution elements with tap-off outlets: – standard length: 3 m – standard tap-off outlets:
· spaced at 1000mm intervals on both sides for Standard straight elements (IP55)
· spaced at 500mm intervals on one side for vertical installation (IP55)
· spaced at 600mm or 800mm on both sides for Data Center straight elements (IP40)
1.4.2 Additional elements Supplied with its pre-installed monobloc. Elements able to meet any installation requirement.
Elements with fire barrier Elements with phase balancing (only on request)

Fire barrier

1.4.3 Routing components Supplied with its pre-installed monobloc. Elements able to meet any change of direction with standard or special solutions.
Elbows Double elbows T, X elements

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Installation and user manual

1.4.4 Tap-off boxes Elements used for connecting and energizing electric loads.
Plug-in tap-off boxes from 32A up to 630A: (can be installed with busbar energized) – empty – with 3P fuse holders – with switch disconnector and fuse holder – for MCCB circuit breakers
Bolted tap-off boxes from 630A to 1000A: – with switch disconnector and fuse holder

XCM Busbar Trunking Systems

1.4.5 Connection interfaces Elements used for connecting the busbar to the electric board or transformer.
1.4.6 End Cover Component that ensures protection at the end of the line
1.4.7 Fixing supports Elements used for fixing the busbar to the structure of the building. Options for horizontal installations Options for vertical installations
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1. Introduction
1.5 System concept Group synergy allows for immediate integration between busbar trunking systems, cast resin transformers and Legrand XL³ cabinets. Cast resin transformers can be ordered with a pre-installed interface connection for the busbar trunking systems.
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Installation and user manual

XCM Busbar Trunking Systems
The cabinets XL3 can be fitted by the panelbuilder with a XCM standard board connection. Thanks to a reinforcement kit it is possible to quickly and easily install any kind of board connection to the roof or bottom of the cabinet. The safety and the performance of the Legrand system are guaranteed by the system approval certification, obtained following stringent tests carried out in the most important international labs.
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1. Introduction
1.6 Certifications
1.6.1 Company approval certifications
THE QUALITY MANAGEMENT SYSTEM Legrand has always considered Quality, one of the strategic points of its policy, and therefore implements a strict Quality Management System. The efficacy of the procedures devised and the level of organisation required for their implementation, have enabled the company to obtain the approval certification of its Quality Management System in accordance with the latest edition of the UNI EN ISO 9001 standard. All company processes, from Marketing to Product Development, Manufacturing, Sale and Technical Support, contribute to meeting the requirements for obtaining and keeping such Approval Certification. The certifying body used is Bureau Veritas. With its presence in over 140 countries, and over 100 years of experience in approval certification, Bureau Veritas is highly recognised by over 30 accreditation bodies, and is today among the world leaders in the field.

ACCREDITATION OF TEST LABORATORY The test labs have a fundamental role in ensuring the Company Quality, both in terms of development, and as a complement to the design stage, as well as in ensuring that the product complies with the standards (type tests). The suitability and reliability of the BTicino/Legrand Test Room is guaranteed by the approvals obtained with ACAE (Associazione per la Certificazione delle Apparecchiature Elettriche ed Elettroniche – Association for the Certification of Electric and Electronic Equipment) in accordance with LOVAG procedures, on the basis of EN ISO/IEC 17025. The test laboratory is where some of the main type tests required for obtaining product approval certification are carried out. With the support of the BTicino test laboratory, and of prestigious international labs, Legrand products undergo: · overtemperature limits tests; · dielectric properties tests; · protection circuit efficiency tests; · aerial and surface insulation distance tests; · mechanical operation tests; · busbar trunking system electric characteristics tests; · construction strength tests; · thermal cycling test; · crushing resistance tests. Moreover, in order to ensure maximum product quality, and in addition to the requirements of the product approval certification, BTicino test laboratory also carries out electromagnetic compatibility measurements on all lines.

TESTING AUTHORIZATION
ACAE (Associazione per la Certificazione delle Apparecchiature Elettriche), Member of LOVAG (Low Voltage Agreement Group)
authorizes the Laboratory

BTICINO SPA Via XXV Aprile, 10 25080 Castrezzone ­ Muscoline (BS)
Laboratory codification number: IZ 01

to carry out the tests listed in the following, for the purpose to certify the products as stated in the Certificate n° 070B and its enclosure, issued to ACAE by ACCREDIA.

List of the authorized tests on the low – voltage components:
Verification of dielectric withstand Verification of temperature ­ rise limit Verification of the auxiliary circuits Mechanical operation and operational performance capability
The laboratory has demonstrated to the ACAE’s inspector to fulfil the basic requirements of IEC EN 17025 Standard for the above purposes. ACAE will witness the tests according to its Quality Procedure PA 5.2.1 “Test supervision”. The renewal of the authorization is subjected to annual audit.

First issue date: 2013-05-14

Current issue date: 2022-06-07

ACAE General Secretary Mr. Virginio Scarioni

PRD N°070 B
Membro degli Accordi di Mutuo Riconoscimento EA, IAF e ILAC
Signatory of EA, IAF and ILAC Mutual Recognition Agreements

A C A E

ASSOCIAZIONE PER LA CERTIFICAZIONE

DELLE APPARECCHIATURE ELETTRICHE

Via Tito Livio 5 – 24123 Bergamo BG – ITALY

Tel: +39 035 4175244 Fax: +39 035 4534662

e-mail: acae@acaecert.it

www.acaecert.it

C.F. 03260610104

P.IVA IT 02911610166

R.E.A. N. 333322 C.C.I.A. BG

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Installation and user manual

XCM Busbar Trunking Systems

CERTIFICATION AND QUALIFICATION MARKS Once compliance with IEC 61439-6 product standard has been confirmed, the various product lines may be further marked and approved for special applications. The compliance of a product to the specific standards can be certified by the manufacturer declaration and the application of the “CE” symbol, or through the concession of a mark by an appointed third-party body that ascertains its compliance. In the case of manufacturer declaration, the responsibility for compliance with the standards lies with the manufacturer itself; If a quality mark is granted by a third- party body, this body will only do so subject to the approval of the manufacturer and the prototype, through type tests, and subsequently following tests on the products sold on the market, which must comply with the requirements of the tests carried out on the prototypes themselves. The same range of products can therefore be granted several quality or conformity marks.

LOVAG CERTIFICATES LOVAG is the Low Voltage Agreement Group, which is a Mutual Agreement Group of Certification Bodies founded in 1991, which has achieved a high level of competence in testing and certification of low voltage equipment. LOVAG’s main purpose as an Agreement Group shall be for the mutual recognition of test reports and/or certificates of conformity by its signatories.

Membership

LOVAG presently has five signatories (Certification Bodies) to the Agreement: ACAE (Italy), Applus+ Laboratories (Spain), ASEFA (France), IMQ (Italy), and SGS Belgium NV Division SGS CEBEC (Belgium) and employs more than 30 Testing Laboratories.

Certificates

LOVAG Certificates are issued by the LOVAG Certification Bodies using verification reports and certificates in a common and recognisable format in the market. They are recognised and accepted in the European Economic Area and elsewhere in the world.

LOVAG Instructions LOVAG uses common Instructions for verification by Testing, Comparison or Assessment of the International and Standards covered by the Agreement and signatories to the Agreement abide by these when verifying for LOVAG Certification.

Qualifications

All signatory bodies to the Agreement are accredited to ISO IEC 17065 by accreditors being members of IAF, the International Accreditation Forum. They are located in a member country of the EU and their laboratories are accredited and/or assessed to EN ISO/IEC 17025.

For further information contact your local certification body or the Secretariat of LOVAG by e-mail or by fax from the list below.

LOVAG Certification Bodies and LOVAG Secretariat:
ACAE
Via Tito Livio 5 I-24123 Bergamo ITALY Fax: + 39 035 453 4662 e-mail: acae@acaecert.it Web : www.acaecert.it

ASEFA
33 Av du General Leclerc F-92260 Fontenay-aux-roses FRANCE
e-mail: contact@asefa-cert.com Web: www.asefa-cert.com

Applus+ Laboratories
Campus UAB E-08193 Bellaterra (Barcelona) SPAIN Fax: + 34 93 567 20 01 e-mail: info.appluslaboratories@applus.co Web: www.applus.corp.com
IMQ S.p.A.
Via Quintiliano 43 20138 Milano ITALY Fax: +39 0250991510 e-mail : lovag@imq.it Web: www.imq.it

SGS Belgium N.V.
Division SGS CEBEC Business Riverside Park Av Internationalelaan, 55 B-1070-Brussels BELGIUM
Fax: + 32 2 556 00 36 e-mail: silvio.piras@sgs.com Web: www.cebec.sgs.com
LOVAG Secretariat
at ETICS aisbl Rue des Deux Églises, 29
B-1000-Brussels – BELGIUM
e-mail: secretariat@etics.org Web: www.lovag.net

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1. Introduction
1.6.2 The certificates The XCM line has been given Type- Approval Certifications by the most prestigious Electro-technical agencies: · Certificate of Compliance with Standard: IEC 61439-6 · GOST Type-Approval (Russia) In order to obtain these
recognitions, the XCM range has undergone the following type tests, as confirmation of their quality: · Fire Barrier Test · IEC 60331-1 / CEI EN 50362 – Fire Resisting Test · XCM product has been subjected to seismic tests in accordance with IEEE Std 693-2018 and consequently certified.
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Installation and user manual

XCM Busbar Trunking Systems
2. Material preparation and arrangement
2.1 Equipment and Tools 2.1.1 Introduction Here below the tools, equipment and materials you need to have before starting the installation of Zucchini XCM Busbar Trunking System. 2.1.2 Lifting and handling equipment
Crane or forklift truck capable of lifting 1.5 tons (minimum). In function of the plant and the typology of components.

2.1.3 Supports for positioning and installing
Measuring tape (metric).
Socket wrench with sockets (8…24 mm).
Two slings for handling the components.
Set of screwdrivers.
Carpenters square.

Drilling machine capable of drilling through concrete.
Set of flat or ring spanners (8…24 mm).
Levelling instrument (spirit level).
Insulation tester (Megohmmeter 1000 Vdc)
Torque wrench only for periodic check inspection or when an element is placed for the second time.
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2. Material preparation and arrangement
2.2 Storage Below are the instructions to follow for a correct storage of the materials. Failure to comply with the indications supplied may cause damage to the materials, and make the product warranties void. Store the material in a dry place, protected from weather conditions such as rain and humidity, to prevent the formation of condensation inside the busbars. Also ensure that the busbars are protected from smoke, water, soil, mud, dust, or dirt in general. Position the material in a way that prevents a physical damage to it. It is recommended that the material is stored indoor, in a dry location. In case of storing the busbars outside for shortmedium periods, ensure that it is appropriately protected, to avoid accidental infiltration of water, which will result in them being damaged. The material can be transported and stored at a temperature between -25°C and +55°C. Handling operations must be carried out implementing all the necessary precautions to ensure the integrity of the materials. The manufacturer shall not be held responsible for any material damage caused by failure to ensure appropriate protection.
Material handling
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Installation and user manual

2.3 Weight table

XCM AL (4 conductors)

In [A] 160 250 315 400 500 630 800 1000

[kg/m] 7,1 7,6 8,3 11 12,7 14 15 17

XCM CU (4 conductors)

In [A] 250 315 400 630 800 1000

[kg/m] 9,5 10,4 14,3 19,8 25,4 29,5

XCM Busbar Trunking Systems

XCM AL (5 conductors)

In [A] 160 250 315 400 500 630 800 1000

[kg/m] 7,3 7,8 8,7 11,8 13,9 15,5 16,8 19,2

XCM CU (5 conductors)

In [A] 250 315 400 630 800 1000

[kg/m] 10,2 11,3 15,9 22,5 29,5 34,6

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2. Material preparation and arrangement
2.4 Handling and lifting WARNING
All lifting operations refer to a single component.
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Fig. 1 Do not lift the busbars from their ends.
Fig. 2 Do not use belts or other systems to lift them to the junction windows.
Fig. 3 Do not use belts or other systems to lift the busbars in unbalanced positions.

XCM Busbar Trunking Systems
Fig. 1 Fig. 2 Fig. 3
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Installation and user manual

2. Material preparation and arrangement

Fig. 4 Correct way of lifting the busbars.
Fig. 5 Handle the busbars
with due care and attention. Do not
subject busbars to torsions, dents, violent impact, or sharp movements that may damage
their internal components.
Fig. 6 When lifting not linear shape path components, pay particular attention to their own centre
of gravity. Use equipment that will not damage
surfaces.
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Fig. 4 Fig. 5 Fig. 6

Installation and user manual

XCM Busbar Trunking Systems
2.5 Missing or damaged components GOOD RECEPTION Upon receipt of the goods check the following: 1) integrity of the packaging, and the goods, if delivered in a see-through package. 2) consistency of the material with the delivery note and the packing list, if supplied. 3) consistency of the material with the order acknowledgement details. In case of any disclaims, please inform us in writing following the instructions found in the notifications section. NOTIFICATIONS In case of any disclaim, please forward your official complaint to a Legrand referent. When notifying that a wrong item has been received, please indicate the item code no. found on the packaging, and the item code no. found on the part (if possible include a photo of the labels).
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2. Material preparation and arrangement
2.6 Product type identification Before beginning installation, you must compare the plan which you received from the design office project al layout of the building. For custom-made products based on specific projects, check the system drawing to ensure that the components match.

WARNING In case of several straight components with standard length of 3 m, these will all have the same generic common label.

L1 – 6600

300(0L1.04)

300(L1.03)
(L1.033) 00 L1 – 196(L81.021)418

(L1.012) 50

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300(0L1.05)

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XCM Busbar Trunking Systems

300(L1.06)

Code ZU-53401122 ZU-53400142 ZU-53400302 ZU-53400102 ZU-50485202 ZU-50403101 ZU-50632001 ZU-53401132 ZU-53400312

Description XCM4 250A AL END FEED UNIT RH IP55 XCM4 250A AL STR.LEN. L<=1,5M 1+1 OUT XCM4 250A AL HORIZONTAL ELBOW RH XCM4 250A AL STRAIGHT LENG. L=3M IP55 XCM PLUGIN BOXPLAST 63A FUSE HOLDER 3xCH2 XCM END COVER IP55 XCM FIXING KIT HANGER SIZE A XCM4 250A AL END FEED UNIT LH IP55 XCM4 250A AL HORIZONTAL ELBOW LH

(L1.063) 00

(L1.017L)212-01520

Details of the adhesive label found on each
component.
Bar code EAN12 Year and week of production Insulation voltage
Frequency
Short circuit current Standard reference Data matrix with Serial number of piece Degree of protection

Type of busduct

Conductors Rated

material

Current

Item Item Code Description

Address

Brand

Marking

Configuration
Reference line () Item position () Internal project Name () Order confirmation number () Position in the order confirmation ()
() Optional field

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3. Installation
WARNING Where not differently specified, dimensions indicated in the manual are to be intended in millimeters (mm). 3.1 Checks before installation 3.1.1 Visual / electric checks Before the installation, all material should be inspected for damage. When installing the busbars comply with the following: 1 Do not position the busbars near pipes containing liquids. 2 For the installation only use bracketing systems supplied by Legrand, and follow the instructions found in the catalogue
or enclosed with the item. 3 Only use accessories supplied by Legrand. 4 Check that the operating voltage coincides with that indicated on the product plate. 5 Check that the system operating current does not exceed the product rated current, downgrade it if required. 6 Check if the busbar capacity must be downgraded (for example due to high ambient temperature, presence of harmonics, etc.) 7 Do not install the standard product in particular environments (high concentration of chlorine, explosive atmosphere, etc.). 8 For outdoor installations, protect the busbar with a protection canopy. The IP55 protection degree can be affected by
unsuitably protected outdoor installation. 3.1.2 General rules for installing supports Hazard of improper installation Before installation: be sure to have understood well the layout plan During installation: be sure to consider correct separation distances between the supports. These have to be levelled, so to guarantee final levelling also for path components. Be sure that all supports are able to sustain the weights of the path components. Failure to follow these instructions can result in injury or equipment damage. Introduction Correct installation of supports is fundamental to realize a proper installation of path components. Here below, a list of rules to take into account during installation of supports and path components. General Installation rules for supports Follow these general rules for installing supports: · All path components have to be correctly sustained · To get advantage in installation, be sure to use more than one support for each path component · The load capacity of the support must be at least the weight of the path component plus 90 kg, in accordance with
IEC 61439-6. Flatwise horizontal installation:
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Installation and user manual

XCM Busbar Trunking Systems
· Use different support for components at the terminal ends of the path. · Be sure to not sustain weight of end components by transformers or switchboards. · Sustain vertical branches near to the elbow angle. · Even if supports have be to installed near joint blocks, they shall not to be put exactly over a joint block. 3.1.3 Fixing accessories A
50632205

B

50632001

AI 160A ­ 315A

Cu 250A ­ 400A

50632003 AI 400A ­ 1000A Cu 630A ­ 1000A

15Nm

OK
25

3. Installation
C
15Nm

D
26

15Nm
OK

Installation and user manual

XCM Busbar Trunking Systems
400÷1500

260

148

7×15

110

7×15

208 142

=

146

146

260

146

=

53

53

9×30
160A÷315A Al 250A÷400A Cu

53

6×12

9×30

9×30

400A÷1000A Al 630A÷1000A Cu

27

3. Installation
Supports Flatwise Installation For flatwise installations, the maximum recommended distance between supports is 2600 mm. In addition, a support must be placed at a maximum distance of 750 mm from the joint block axis.
1500÷2600
28

Installation and user manual

XCM Busbar Trunking Systems
Attached to the wall. · Provide support for flatwise path components from the bottom. · Supports are NOT provided within the busbar. · Fix the bar on the wall support.
A
1/4

B
50632212 50632213 50632214
17
50Nm

C
1/4

29

3. Installation
D
13 20Nm

10 15Nm

AI 160A ­ 315A Cu 250A ­ 400A

Al 400A-1000A Cu 630A ­ 1000A

30

Installation and user manual

XCM Busbar Trunking Systems

30×11

L 450 / 550 / 750

P

50

30×11

40

40

L 450 mm 550 mm 750 mm

P 80 kg 68 kg 50 kg

500 50 170

Note For flat line mounting, use the suspension brackets facing up.
31

3. Installation
WARNING All the dihedral angle components must be supported at the point of the change of direction. Use dedicated supports for components at the terminal ends of the path. Be aware to have enough space to connect cables by customer.
Supports for flatwise elbows components
32

Installation and user manual

Supports for T components

XCM Busbar Trunking Systems

Supports for edgewise elbow components with a vertical branch Follow these rules to support edgewise elbows with a vertical branch.
33

3. Installation

3.2 Installation of wall supports
3.2.1 Installation sizes, distances and positioning logics Below are some precautions that may be useful to avoid problems during the assembly, which we recommend should be taken into account during the design.

Minimum distances from the structure The minimum distance from the walls, to avoid problems during edgewise installation of the busbar, is 80 mm. The variables that must be taken into account for correct assembly are: · position of the bolt for tightening the Monobloc; the minimum required distance is 120 mm; · sizes of the distribution element (box) selected for the collection of power (at least 300 mm); · any brackets and their assembly; · accessibility to the screws for the installation of the brackets and the closing of the junctions; · any material required for the actual installation in order to compensate for wall imperfections. In case of rising mains installation, if the system does not require fire barriers, the bracket supporting can be directly secured to the wall. Otherwise, allow for a spacing support between the bracket and the wall, to ensure that the back of the busbar remains at a distance of 100 mm from the wall, therefore ensuring enough space for the positioning of the fire barriers.

Minimum distance of the wall / ceiling elements

Ceiling/Wall

5063 22 05

Wall 80

120 300

• When there is a tap-off box
  installed above the busbar, check the
  overall dimension of the open cover of the
  tap-off unit used in the specific section.

Ceiling/Wall Wall
80

Ceiling Wall
300

34

Installation and user manual

XCM Busbar Trunking Systems
3.3 Detailed instructions for vertical installation
Standard bracket

Suspension bracket with springs, suitable for riser mains over 4 m, in accordance with the table on page 36

Suspension bracket for vertical elements, suitable for riser mains up to 4 m and for weights up to 300 kg

When installing a vertical busbar, strictly follow the instructions below: 3.3.1 Definition of the maximum distance (Dmax) between two subsequent brackets with springs 3.3.2 Wall and busbar drilling. Fixing the brackets to the wall 3.3.3 Busbar mounting in line
35

3. Installation

3.3.1 Definition of the maximum distance (Dmax) between two subsequent suspension bracket with springs
Depending on the capacity of the busbar, the quantity and the type of brackets being installed, checked that the selected distance (D) is the same or less than the maximum distance (Dmax) between two subsequent bracket with springs.

XCM AL (4 Conductors)

In [A] 160 250 315 400 500 630 800 1000

D max [m] 19 19 18 15 14 13 13 12

XCM AL (5 Conductors)

In [A] 160 250 315 400 500 630 800 1000

D max [m] 19 18 17 15 13 12 12 11

XCM CU (4 Conductors)

In [A]

D max [m]

250

17

315

16

400

13

630

10

800

9

1000

8

XCM CU (5 Conductors)

In [A]

D max [m]

250

16

315

15

400

12

630

9

800

8

1000

7

Note
N.B. The max load applicable to the brackets is 300Kg. The values in the table have been calculated taking into consideration, in addition to the weight of the busbar, also the estimated weight of the accessories (25Kg for each element).

36

Installation and user manual

XCM Busbar Trunking Systems
3.3.2 Wall and busbar drilling. Fixing the brackets to the wall Drill the required floor and wall holes for fixing all the brackets
Standard bracket
Suspension bracket Suspension with spring bracket
Below are the procedures for drilling the holes for each type of bracket. 37

3. Installation
3.3.2.1 Pre-assembly of the wall brackets Suspension bracket 50403711
A

13
20 Nm

13
20 Nm

B
Wall 80

C
50632205

50632205

20 Nm
13

38

Installation and user manual

Suspension bracket with springs 50403712 A
13

XCM Busbar Trunking Systems
13

B
Wall 80

C
50632205
50632205

20 Nm
13

100 mm
39

3. Installation
3.3.2.2 Wall brackets Suspension bracket with spring
Bracket Screw Spring Shelf
WARNING Refer to the diagram on page 83. 1) Set the bracket position on the busbar.

Suspension bracket
Bracket Screw Shelf

40

Installation and user manual

2. Place the bracket on the
   busbar in the fixing position and mark the element in the 4 points where to
   drill.

Suspension bracket with springs

3. Measure the distance T from the upper side of the shelf to the lower end of the
   busduct.

WARNING

T

The measurement

must be taken

from the longer

side plate and not

from the bars

4. Drill the busbar at the four marks
   just made

Suspension bracket

T

XCM Busbar Trunking Systems
hole ø7 mm 4x 4x
hole ø7 mm 4x
4x

41

3. Installation
5) On the wall, mark the position Z of the two upper holes of the shelves
(indicated in the magnified view), calculated as follows:
Z = T – 30 (measurements in
millimeters).

WARNING Check that the hole
marks are aligned with the busbar

WARNING

The Z dimension

330

must be measured

from the long side

plate of the already

installed adjoining

busbar.

Z

Wall bracket with spring

Wall bracket

30

ZT

42

Installation and user manual

6. On the wall, mark the
   position of the bottom holes of
   the shelves, in accordance with the values below
7. Drill the holes at the marked
   positions. Check that the hole marks are
   aligned with the busbar
   330 143
   Z

143 110

143 110

XCM Busbar Trunking Systems
Wall bracket with spring
180 ø6
11 x 30 330
Wall bracket
180 ø6
11 x 30 330

43

3. Installation
8) Match the brackets with
the holes previously drilled on the wall and fix them with the
screws
11 mm
44

Installation and user manual

XCM Busbar Trunking Systems

3.3.2.3 Standard bracket The wall spacer (50632205), required when the bracket needs to be fixed directly to the wall (40mm), is not supplied but must be requested when ordering.
Wall spacer 50632205

1. Set the bracket position on the busbar.
   WARNING Refer to
   the diagram on page 83.

Suspension bracket 50632001/3

2. Place the bracket on the busbar and mark its upper side.

3. Measure the

distance W from

the mark just made

to the bottom cap

of the busbar.

W

WARNING The measurement must be from the
busbar cap and not the bars.
45

3. Installation

4. On the wall,

mark the position

143

U for fixing the

wall spacer,

calculated as

follows:

U = W + 58

(measurements in

millimeters).

WARNING The U value must be measured from the upper cap of
the already installed adjoining
busbar.
5) Drill the holes at the marked positions.

2000

58
U W

U

46

Installation and user manual

6. Fix the wall spacer to the A wall and attach the bracket to it
   C

11 mm

XCM Busbar Trunking Systems

B 50632205

10 15 Nm

11 mm

50632001 AI 160A – 315A Cu 250A – 400A
50632003 AI 400A – 1000A Cu 630A – 1000A
OK

10 15 Nm

47

3. Installation
3.3.3 Busbar mounting in line 1) Position the element on the wall and make the
connection between the two
elements, observing the
assembly sequences shown
in the reference instruction
48

Installation and user manual

2. Close the suspension
   brackets, previously fixed
   to the wall, by inserting the
   special plate and locking it with the supplied
   screw, as shown below:

3. Hook the

suspension

brackets to the

3 Nm

holes previously

8

made on the

element, using

the appropriate

screws provided

in the kit

(tightening

couple 3 Nm)

4. For brackets with springs, unscrew the spring nuts

WARNING

The nut must be

fully unscrewed,

3 Nm

therefore

releasing the

8

springs

XCM Busbar Trunking Systems
15 Nm
OK
PH2 mm
PH2

49

3. Installation
3.4 Joint installation
Mandatory: Don’t remove
19
WARNING Remove residues with mild reagents not corroding or creating abrasion on surface treatment (zinc, tin, silver coating) or on contact surface (copper).
50

Installation and user manual

XCM Busbar Trunking Systems

DANGER
MR + XCM
A
Note for b. Only for straight elements with special length.
C
OK

B

a
10 mm
D

a
OK
OK
10 mm
bb

OK

PH2

2,5 Nm

OK
AI 160A÷315A Cu 250A÷400A 35 Nm
AI 400A÷1000A Cu 630A÷1000A 85Nm

PH3 3 Nm
51

3. Installation
E
90°
Leave enough free space in front of the flanges to hold the screwdriver correctly when installing the screws.
52

Installation and user manual

XCM Busbar Trunking Systems

3.5 Data center Straight element (IP40)

DANGER

MR + XCM

B

A

A
Note for b. Only for straight elements with special length.
C

50403103 50403104

OK

a
10 mm
D

a
OK
OK
10 mm
bb

OK PH2 2,5 Nm
OK
AI 160A÷315A Cu 250A÷400A 35 Nm AI 400A÷1000A Cu 630A÷1000A 85Nm

IP40
PH3 3 Nm
53

3. Installation
Data Center Straight Element (IP40). A

50403103 50403104

B

C

53403601

IP55

IP30
PH3 3 Nm 54

Installation and user manual

XCM Busbar Trunking Systems

DANGER LOSS OF IP55 PROTECTION RATING The path components must be correctly aligned. Failure to follow these instructions can result in equipment damage.
The alignment must be checked on both sides of the path components: Check the aligment on the loop of the run components:

1000

=

=

Max 1°

Check alignment on the side of the run components:

1° 1°
Max 1°
1° 1°
55

3. Installation

3.6 Fire barrier installation Fire barrier elements EI (EN 1366-3)

158

55

55

D

C

C

218

84

84

D

C

C

245 205 165 245 205 165

BA

AB

BA

AB

C

C

D

75

160÷315A Al 250÷400A Cu

C

C

D

135

400÷1000A Al 630÷1000A Cu

In order to ensure the maximum resistance class it is necessary to fit at the factory an internal fire barrier. It is therefore necessary to indicate at the order stage what elements will cross fire resistant walls or ceilings.

No fire barrier

200

630

No fire barrier 200

No fire barrier

200

630

Fig. 1

=

=

=

=

Fire barrier Fig. 2

The external fire barrier can be used on any trunking component in compliance with the operating instructions specified in figures 1 and 2.

56

Installation and user manual

Refer to Horizontal assembly Best Practice Paragraph 4.2.
A A
C C

XCM Busbar Trunking Systems
B B
D

PZ 2
C C
57

3. Installation
PZ 2 D
E E
E PZ 2
E
WARNING Once the barrier is assembled, fill all the joints between panels with the Promaseal paste and then work it with putty knife to obtain a smooth and homogeneus aspect. To simplify assembly, keep the panels in position with bench vise.
58

Installation and user manual

Vertical assembly
Place a support bracket “F” before the assembly to hold the barrier in place while proceeding.
E

XCM Busbar Trunking Systems
A E
A

B B

C C

C C

59

3. Installation
PZ 2 D
D
PZ 2 E E
WARNING Once the barrier is assembled, fill all the joints between panels with the Promaseal paste and then work it with putty knife to obtain a smooth and homogeneus aspect. To simplify assembly, keep the panels in position with bench vise. 60

Installation and user manual

XCM Busbar Trunking Systems

3.7 Product installation
3.7.1 Operating instructions on how to design riser mains 1) Use a LH end feed unit.
This allows the Neutral bar to be positioned on the left side of the busbar, hence the cable exit of the tap-off boxes is located downwards
2) Use straight elements with 5 outlets on one side
3) Use a straight element with fire barrier for each compartment floor. It is necessary to specify the position of the internal fire barrier before placing an order
4) The tap-off boxes can be installed in the tap-off outlets and near the connection between the elements
5) At the end of the riser mains, position the IP55 end cover. Before installing the end cover remove the monobloc located on the last element
A) Use one or more suspension brackets for the vertical elements, according to the weight of the whole rising mains. For risers that are shorter than 4 meters, fix to the base with code 50403711; when longer, use a suspension bracket code 50403712 every 300 kg of rising main
B) Use a standard suspension bracket with a 40mm spacer every 2 meters of rising mains

5

B

4

3

2

80

A

1 N L1 L2 L3
61

3. Installation
3.7.2 Panel end cap installation
75 75 75 75
1
5 125 235
125 285
2
850 600
3
62

Installation and user manual

3.7.3 Feed Unit

XCM Busbar Trunking Systems
A

B

C

ø max 60mm
D

6 10 Nm

PH2 2 Nm

PG max 48 (3x120mm + 1x70mm 3x150mm)

63

3. Installation

A

B

13

C

D

40

40

85

WALL

13
MAX 10 Nm

PH2 2,5 Nm

PH2 2,5 Nm

E

PH2 2,5 Nm
64

Installation and user manual

Power supply

XCM Busbar Trunking Systems

65

3. Installation
66

Installation and user manual

XCM Busbar Trunking Systems

A

B

C
PH2 2,5 Nm
E

D
AI 160A÷315A Cu 250A÷400A
OK 35 Nm
AI 400A÷1000A Cu 630A÷1000A 85Nm

67

3. Installation

F

G

PH3 3 Nm
H

OK

2,5 Nm

OK

90°

8

I 68

L
M 13
10 Nm

Al 160A÷400A Cu 250A÷630A
CLICK

Installation and user manual

3.7.4 End cover A

XCM Busbar Trunking Systems
50403101 50403102

B
OK
C
OK
PH2 2 Nm
69

300 105 130 52.5 50 55 75

3. Installation

• When there is a tap-off box
  installed above the busbar,
  check the overall dimension of
  the open cover of the tap-off unit
  used in the specific section.

3.7.5 Tap-off boxes overall dimensions
When there are tap-off units along the busbars, the minimum distances depend on the dimensions of the tapoffs selected.

Ceiling

Ceiling

Wall

Wall

80

300

Metal T1 Empty / fuse holders version overall dimensions

222

270

240

195

** Be sure to have enough space beneath and
around the TOB to easily access and handle it (see also best practice
section).
70

76 165 40

50 80

0 577 56

0 577 15 0 577 26

0 577 13 0 577 12 0 577 17

** 295

R 436

591

665

74

280

430

270

360

130

760

70 130 105
105 75
Installation and user manual

XCM Busbar Trunking Systems

Metal T2 Empty / fuse holders version overall dimensions

282

390

260

360

114

146

** Be sure to have

enough space

beneath and

around the TOB

to easily access

and handle it (see

495

also best practice

section).

205 40

76

400

0 577 56

0 577 16 0 577 23

0 577 18 0 577 14 0 577 19

**
R 560

754

828

74

550

161

480

130

771

71

3. Installation

Metal T3 Empty / fuse holders version

overall dimensions

390

270

370

250

160 140

160 140

1038

1111

** Be sure to have

enough space

beneath and

around the TOB

to easily access

and handle it (see

also best practice

545

section).

**
R 774
R 192

50

275

76

450

750

139

678

287

1105

72

74

Installation and user manual

Metal T1 MCCB ready overall dimensions

XCM Busbar Trunking Systems

52.5 50 55 75

105 130

195

50

222

80

** Be sure to have enough space beneath and
around the TOB to easily access and handle it (see also best practice
section).

76

165 70

0 577 56

0 577 15 0 577 26

0 577 13

0 577 12 0 577 17

** 295

R 436

591

665

74

280 430

270

360

130

760

73

3. Installation

Metal T2 MCCB ready

overall dimensions

282

390

260

360

114

146

70 130 105
105 75

828

** Be sure to have enough space beneath and
around the TOB to easily access and handle it (see also best practice
section).
74

76

205

70

0 577 56

0 577 16 0 577 23

0 577 18 0 577 14 0 577 19

**
R 560
495

754

74

400

550

161

480

130

771

160 140 160 140
Installation and user manual

Metal T3 MCCB ready overall dimensions

XCM Busbar Trunking Systems

390

270

370

250

** Be sure to have

enough space

beneath and

around the TOB

to easily access

and handle it (see

also best practice

section).

545

**
R 774
R 192

1038

1111

70

275

74

76

450

750

139

678

287

1105

75

3. Installation
Metal T1 MCCB ready removable cover overall dimensions

195

50

222

80

105 130 52.5 50 55 75

** Be sure to have enough space beneath and
around the TOB to easily access and handle it (see also best practice
section).
76

76

165 70

0 577 56

0 577 15 0 577 26

0 577 13

0 577 12 0 577 17

295

**

25

264

74 166

280

430

360

130

490

130 105
105 75
Installation and user manual

XCM Busbar Trunking Systems

Metal T2 MCCB ready removable cover overall dimensions

390 282

260

360

114

146

** Be sure to have enough space beneath and
around the TOB to easily access and handle it (see also best practice
section).

76

205

70

0 577 56

0 577 16 0 577 23

0 577 18 0 577 14 0 577 19

495

**

25

304

205

74

400

550

480

130

610

77

3. Installation
Metal T3 MCCB ready removable cover overall dimensions
390 270
370 250

160 140

160 140

** Be sure to have

enough space

545

beneath and

around the TOB

70

to easily access

and handle it (see

also best practice

section).

275

76

450

78

**

25

373

274

74

750

678

106

785

Installation and user manual

Fiberglass plastic T1 overall dimensions

XCM Busbar Trunking Systems
132 158

75

84

237

174

79

677

3. Installation

Fiberglass plastic T2 Empty / fuse holders version

overall dimensions

150 26

110

f airleads

ISO 16:14

ISO 21:10

ISO 25:6

ISO 40:3

ISO 50:2

34 85

70 70

f airleads ISO 16:14 ISO 21:9 ISO 25:6 ISO 40:2 ISO 50:1

87 20 72

603

74

** Be sure to have enough space beneath and
around the TOB to easily access and handle it (see also best practice
section).

76 159 70

76 159

R 480

** 275

420

250

482

346

122

949

R 480

** 275

420

250

482

346

122

949

603

74

677

0 577 56

0 577 15 0 577 26

0 577 13

0 577 12 0 577 17

80

90 28.5 74
44 95
Installation and user manual

XCM Busbar Trunking Systems

885

Fiberglass plastic T3 Empty / fuse holders version

overall dimensions

180

25

138

FAIRLEADS ISO 16:17 ISO 21:13 ISO 25:7 ISO 40:3 ISO 50:2

121

70

FAIRLEADS ISO 16:20 ISO 21:12 ISO 25:9 ISO 40:2 ISO 50:1

811

74

** Be sure to have enough space beneath and
around the TOB to easily access and handle it (see also best practice
section).

76 169 70

76 169

**

R 674

373

350

615

677

541

121

1339

**

R 674

373

350

615

677

541

121

1339

811

74

885

0 577 56

0 577 16 0 577 23

0 577 18 0 577 14 0 577 19

81

3. Installation

Tap-off boxes bolt-on type from 630A to 1000A overall dimensions

From 630A to 1000A

Cable input (F x G)
A

D C

630A
(cables imput) 160 x 270

** Be sure to have

enough space

beneath and

around the TOB

to easily access

and handle it (see

also best practice

270

section).

800A – 1000A
(cables imput) 210 x 380

450

38 160

400

658

B
**

280 345

640 ref.outlets
Usable internal space 253 752 792

400 19 10 19 10 20 5

TERMINALS Phase Neutral Earth

40

40

M10 M10

30 M8

**

727

300

360

35 210

380
82

450

937 ref.outlets

TERMINALS Phase Neutral Earth

25 4 20 12 20 6

Usable internal space 195 1050 1090

45 M16

30

30

M10

M8

Installation and user manual

XCM Busbar Trunking Systems

3.7.6 Plug-In box installation rules Not all boxes can be installed in any position. The following figures show where the various Plug-in boxes may be installed on elements with standard setup.
Side S

Side D
Different combination of boxes in straight elements of XCM:

3+3 OUTLET WINDOWS IP55 JUNCTION COVER

3S 3D

2S 2D

1S 1D

5 OUTLET WINDOWS IP55 JUNCTION COVER

5S

4S

3S

2S

1S

5+5 OUTLET WINDOWS IP40 JUNCTION COVER

5S

4S

3S

2S

1S

5D

4D

3D

2D

1D

83

3. Installation
3+3 OUTLET WINDOWS

RISER MAINS 5 OUTLET WINDOWS

1S

1S

2S

70mm MINIMUM

2S

3S

3S

5S

NOT USABLE
h1 125mm h2 L-65mm
L
84

Installation and user manual

XCM Busbar Trunking Systems

1S

5S

IP40 JUNCTION

ELEMENT TYPE
3+3 OUTLET WINDOWS
5 OUTLET WINDOWS
5+5 OUTLET WINDOWS

POSITION
1S 2S 3S 1D 2D 3D 1S 2S 3S 4S 5S 1S 2S 3S 4S 5S 1D 2D 3D 4D 5D

METAL size 1, size 2, size 3 size 1, size 2, size 3 size 1, size 2 size 1, size 2 size 1, size 2, size 3 size 1, size 2, size 3 size 1, size 2, size 3 size 1 size 1, size 2, size 3 size 1 size 1 size 1, size 2, size 3 size 1 size 1, size 2, size 3 size 1 size 1, size 2, size 3 size 1, size 2, size 3 size 1 size 1, size 2, size 3 size 1 size 1, size 2, size 3

TAP OFF BOX
PLASTIC size 1, size 2, size 3 size 1, size 2, size 3 size 1, size 2 size 1, size 2 size 1, size 2, size 3 size 1, size 2, size 3 size 1, size 2, size 3 size 1, size 2 size 1, size 2, size 3 size 1, size 2 size 1, size 2 size 1, size 2, size 3 size 1, size 2 size 1, size 2, size 3 size 1, size 2 size 1, size 2, size 3 size 1, size 2, size 3 size 1, size 2 size 1, size 2, size 3 size 1, size 2 size 1, size 2, size 3

• when mounted in this position the outlet window on next element will be unused.

85

3. Installation
3.7.7 Assembly instruction Plug-In box 63A-125/160A empty A
B
86

Installation and user manual

XCM Busbar Trunking Systems
C

D 63A

125A – 160A

87

3. Installation
E

XCP

XCM

XCP

OPEN

CH8

XCP

XCM

XCM

BOTTOM VIEW

88

Installation and user manual

XCM Busbar Trunking Systems
F
Refer to Best Practice Paragraph 4.1
89

3. Installation
G

H
Option for line maintenance

35 mm

ø 6 mm 1/4

PH2
90

When installing the tap of box on the low XCM (160/250/315A AL and 250/315/400A CU) they must be removed

Installation and user manual

XCM Busbar Trunking Systems
3.7.8 Assembly instruction Plug-In box 250A empty A
B
91

3. Installation

C

D

E 92

Installation and user manual

XCM Busbar Trunking Systems
F
Refer to Best Practice Paragraph 4.1
93

3. Installation
G

H
Option for line maintenance

35 mm

ø 6 mm 1/4

PH2
94

When installing the tap of box on the low XCM (160/250/315A AL and 250/315/400A CU) they must be removed

Installation and user manual

XCM Busbar Trunking Systems
3.7.9 Assembly instruction Plug-In box 630A empty A
B
95

3. Installation

C

D

E 96

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XCM Busbar Trunking Systems
F
Refer to Best Practice Paragraph 4.1
97

3. Installation
G

H
Option for line maintenance

35 mm

ø 6 mm 1/4

PH2
For more information on how
to wire the Tap-off boxes DPX³ ready
and the Tap-off boxes with fuse carriers, refer to the relative assembly
instructions.
98

When installing the tap of box on the low XCM (160/250/315A AL and 250/315/400A CU) they must be removed

Installation and user manual

XCM Busbar Trunking Systems

3.7.10 Assembly instruction fiberglass plastic T1

A

B

C

D 99

3. Installation
E
F G
100

Installation and user manual

H
Refer to Best Practice I Paragraph 4.1

XCM Busbar Trunking Systems

101

3. Installation
L
M ATTENTION Cable not supplied by Legrand.
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3.7.11 Assembly instruction fiberglass plastic T2/T3 – empty A
103

3. Installation
B
104

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XCM Busbar Trunking Systems
C

FE

PE

L1 L3 N L2

105

3. Installation
D
106

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E
Refer to Best Practice Paragraph 4.1
107

3. Installation
F

PH2
108

When installing the tap of box on the low XCM (160/250/315A AL and 250/315/400A CU) they must be removed

Installation and user manual

XCM Busbar Trunking Systems

3.7.12 Assembly instruction Bolt-on type Bolt on tap-off box

A

B

C
PH2 2,5 Nm
E

D
PH3 3 Nm
85 Nm OK
109

3. Installation

F

G

CH8 2,5 Nm
I
CH10 3 Nm
H
L
PH2
110

CH13 25 Nm

CH17 50 Nm

CH13 25 Nm

CH17 50 Nm

CH24 100 Nm

CH13 25 Nm

Installation and user manual

XCM Busbar Trunking Systems

3.7.13 Adapter MR / XCM The MR is an obsolete product. In order to allow customers to add elements to line MR, special adapters have been made.
1100÷1500 600

MR

XCM

ADAPTER MR / XCM TYPE RIGHT

XCM

1100÷1500 600

MR

ADAPTER MR / XCM TYPE LEFT
Note In case of replacement of an element inside an MR line, contact LGR.

111

3. Installation
3.7.14 Busbar post-installation checks Bus duct inspections after installation After installation, following inspections have to be carried out before running the plant: Bus duct installation Check if elements are correctly aligned. If not, align them correctly. Refer to the diagram on page. 55 “Alignment junction”. JUNCTIONS Open a random sample (10%) of mechanical junctions and verify that: 1 the block has been installed in the correct direction and that the mechanical guides (pins and slots) correctly correspond. If
not, remove the block and mount it again correctly, after checking it is sound. Otherwise wholly replace it. 2 plastics are sound, in particular that there are neither slits nor chips, and that there is neither dust nor grime. If the
insulating parts are damaged, wholly replace the monobloc. If there are dust or grime, clean them off. 3 the block is correctly centred with the bars of the element. If not, centre it after having checked it is undamaged. 4 the tightening torque of the self-breaking bolts is correct (30÷40 Nm and 80÷90 Nm), use a calibrated torque
wrench. During the measurement the line has to be at ambient temperature. If the tightening torque is lower than the specified value, re-establish it. SWITCHBOARD CONNECTION On switchboard connections verify that: 1 the air distances between bars with different potentials are over 40 mm wide. If it is not the case, contact Eng. Dept. Zucchini Brand to evaluate the employment of correct insulating material. 2 the tightening torque of connecting screws is correct (required values: 85 Nm for M12, 100 Nm for M14, 120 Nm for M16, 170 Nm for M18, 25 Nm for M8 and 50 Nm for M10). The above-mentioned inspections have to be carried out by personnel with a proper technical background and with controlling function/responsibility in the installation activities. Tap- off boxes inspections after installation These inspections always have to be carried out with a non-energized plant and after having earthed the phases after the tap-off box, in order to unload possible static discharges in the downstream circuit (with an insulated device). BOLT-ON Carry out the same inspections planned for junctions. Verify the correct torque moment of the screws joining the mechanical junction and the collector bars. If necessary, retighten the connecting screws.
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4. Best Practice
4.1 General Rules 4.1.1 TOB

XCM Busbar Trunking Systems

113

4. Best Practice
TOB Plastic T1 114

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4.1.2 TOB. Heavy / Large Boxes

XCM Busbar Trunking Systems

TOB METAL T3

115

4. Best Practice

TOB METAL T3 A~694mm

A ZU-506320-Z17001

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N

L1

L2

L3

XCM Busbar Trunking Systems
BOLT ON TOB
4.2 External Fire Barriers
PZ 2 PZ 2
117

5. Starting-up
5.1 Busbar pre-energising checks 5.1.1 Electrical safety tests Carry out all tests described in the applicable technical installation norms, verify that insulating test between phases neutral and to earth at 1000 V has a minimum value of 1M, for every line stretch. If the insulating value is lower than 1M, it is necessary to verify the plant completely, starting from the insulating parts of each monobloc. If the insulation is still inadequate, divide the plant in two parts and verify each one separately to identify the element with low insulation. Continue the splitting, if the insulation keeps being inadequate. If insulation test is made to every piece the value minimal is 100M. 5.2 Electric checks 5.2.1 Conductors Thermal tests After having run the plant at the maximal working current, and having let it work for at least 6 hours, carry out a thermal test. Stick labels on the hottest parts and mark them with progressive numbers to identify the element. Carry out the thermal test again on the labels. Fill the attached form with the measured values, together with ambient temperature and working current (forms for thermal tests at pages 126-129). Thermal tests can be carried out with contact temperature sensors, with optical pyrometers or thermal cameras. 5.2.2 Tap-off boxes Thermal tests Carry out a thermal test on the cover near the lock, using contact temperature sensors, optical pyrometers or thermal cameras. The test has to be carried out with tap-off boxes running at working current for at least 6 hours. Fill in the attached form together with ambient temperature and working current.
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5.3 Filling the check form 5.3.1 Busduct record form for inspections and controls

PLANT CLIENT CONFIRMATION OF ORDER N. MANUFACTURING YEAR INSTALLATION YEAR INSTALLING COMPANY

5.3.2 Inspections after installation
PERSON IN CHARGE OF INSPECTIONS COMPANY (if different from installing company) INSPECTION DATE SIGNATURE

Element alignment

YES

NO

Junctions

Checked junctions (quantity)

Total junctions (quantity)

Correct installation

YES

NO

Soundness of insulating parts

YES

NO

Correct centring

YES

NO

Correct coupling clamp (85 Nm) – write value

Connection to switchboard Correct air distance between bars Correct coupling clamp

Tests on electrical safety
Insulating resistance between L1 and neutral (L1-N) Insulating resistance between L2 and neutral (L2-N) Insulating resistance between L3 and neutral (L3-N) Insulating resistance between L1 and L2 (L1-L2) Insulating resistance between L2 and L3 (L2-L3) Insulating resistance between L3 and L1 (L3-L1) Insulating resistance between L1 and earth (L1-PE) Insulating resistance between L2 and earth (L2-PE) Insulating resistance between L3 and earth (L3-PE) Insulating resistance between neutral and earth (N-PE) Test voltage

Note N.B. Write the measured value of the insulating resistance

Thermal tests Fill in the attached table, with reference to the inspected element. As per the measurement point and the plate present on the measurement side, fill in the relative box with the measured temperature value.

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6. Verification
6.1 Definition of the check sequence 6.1.1 Busduct periodic inspections are to be carried out yearly THERMAL TESTS In order to perform inspections over installations, it is raccomanded to de-energise the busbar. After having run? the plant at the maximal working current for at least 6 hours, carry out a thermal test, taking in particular consideration the points where labels had been sticked on during installation. Fill in the attached form with the measured values, together with ambient temperature and working current (form for thermal tests at pages 126-129). If the measured temperature (DT) is higher than 55 K or is 15 K higher than the temperature measured during installation, get in contact with Customer Care. This thermal test should be carried out with contact temperature sensors, optical pyrometers or thermal cameras. JUNCTIONS It is recommended to open a random sample (10%) of the mechanical junctions, and for every junction verify that: 1 plastics are sound, in particular there are no slits, and plastic colour has not changed. If it is not the case, wholly
replace the monobloc. 2 there are no water, scale-marks or foreign materials (dust, grime, etc.) on the protective flanges of the mechanical
junctions. In case they are found, also verify the bars near the block. Dry possible wet parts with hot air at a temperature not higher than 80 °C and remove residues with mild reagents not corroding or creating abrasion on surface treatment (zinc, tin, silver coating) or on contact surface (copper). 3 blocks correctly adhere on bars at least of 50% of the conductor’s surface. 4 the tightening torque of the self-breaking bolts with a torque wrench calibrated at 35 / 85 Nm. During the measurement the line has to be at ambient temperature. If the torque is lower than the required value (35 / 85 Nm), re- establish it. 5 insulation test at 1000V, with minimum value of 1M, for every separated line stretch. The insulation test has to be carried out between phases, between phases and neutral, and between every single phase and the casing. If results are unsuccessful, identify the stretch and in case replace it or carry out further tests. If insulation test is made on a single piece the minimal value is 100M. In case the inspections carried out have negative results, extend the inspections on all junctions and get in contact with Customer Care.
6.1.2 Tap-off boxes annual periodic inspections Carry out a thermal test on the cover near the lock, using contact temperature sensors, optical pyrometers or thermal cameras. The test has to be carried out with tap-off boxes running at working current for at least 6 hours. Fill in the attached form together with ambient temperature and working current. If the measured relative temperature (DT) is higher than 55 K or is 15 K higher than the temperature measured during installation, get in contact with Customer Care. Verify if joining screws are correctly tightened.
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6.1.3 Annual periodic inspections carried out one year after energizing and every other following year

PERSON IN CHARGE OF INSPECTIONS COMPANY (if different from installing company) INSPECTION DATE SIGNATURE

Junctions

Checked junctions (quantity) Total junctions (quantity)

Soundness of insulating parts

YES

NO

Absence of water, scale and dust in flanges

YES

NO

Correct centring

YES

NO

Correct coupling clamp (35 / 85 Nm) – write value

Connection to switchboard
Correct air distance between bars Correct coupling clamp Tests on electrical safety Insulating resistance between L1 and neutral (L1-N) Insulating resistance between L2 and neutral (L2-N) Insulating resistance between L3 and neutral (L3-N) Insulating resistance between L1 and L2 (L1-L2) Insulating resistance between L2 and L3 (L2-L3) Insulating resistance between L3 and L1 (L3-L1) Insulating resistance between L1 and earth (L1-PE) Insulating resistance between L2 and earth (L2-PE) Insulating resistance between L3 and earth (L3-PE) Insulating resistance between neutral and earth (N-PE)

Note N.B. Write the measured value of the insulating resistance

Thermal tests Fill in the attached table, with reference to the inspected element. As per the measurement point and the plate present on the meausurement side, fill in the relative box with the measured temperature value.

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6. Verification

6.1.4 Inspections after installation and yearly

PERSON IN CHARGE OF INSPECTIONS COMPANY (if different from installing company) INSPECTION DATE SIGNATURE
Correct coupling clamp of connecting screws

Thermal tests
Tap-off box n. Tap-off box n. Tap-off box n. Tap-off box n. Tap-off box n. Tap-off box n. Tap-off box n. Tap-off box n. Tap-off box n. Tap-off box n. Tap-off box n. Tap-off box n.

Measured T Measured T Measured T Measured T Measured T Measured T Measured T Measured T Measured T Measured T Measured T Measured T

Dt = Measured T – Ambient T Ib = working current

Ambient T Ambient T Ambient T Ambient T Ambient T Ambient T Ambient T Ambient T Ambient T Ambient T Ambient T Ambient T

Dt

Ib

Dt

Ib

Dt

Ib

Dt

Ib

Dt

Ib

Dt

Ib

Dt

Ib

Dt

Ib

Dt

Ib

Dt

Ib

Dt

Ib

Dt

Ib

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6.1.5 Straight element ELEMENT IDENTIFICATION PERSON IN CHARGE OF INSPECTIONS COMPANY (if different from installing company) INSPECTION DATE SIGNATURE N.B. Stick on the element a label with a progressive number for identification.
C

E

D

A

G F

Measured T. (°C)
C D E F G H

Al I. (A)

Cu I. (A)

Pe N L1 L2 L3
H

Ambient T. (°C)

Working I. (A)

DIM. A

N° POS

123

6. Verification
6.1.6 Straight element with outlets
ELEMENT IDENTIFICATION PERSON IN CHARGE OF INSPECTIONS COMPANY (if different from installing company) INSPECTION DATE SIGNATURE N.B. Stick on the element a label with a progressive number for identification.
C

E

D

A

G F

Pe N L1 L2 L3
H

Measured T. (°C)
C D E F G H

Al I. (A)

Cu I. (A)

Ambient T. (°C)

Working I. (A)

DIM. A

N° POS

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XCM Busbar Trunking Systems
6.1.7 Horizontal elbow ELEMENT IDENTIFICATION PERSON IN CHARGE OF INSPECTIONS COMPANY (if different from installing company) INSPECTION DATE SIGNATURE N.B. Stick on the element a label with a progressive number for identification.

C
D E
B

F A

G
L3 L2 L1 N Pe
H

Measured Al

T. (°C)

I. (A)

C

D

E

F

G

H

Cu I. (A)

Ambient Working

T. (°C)

I. (A)

DIM. A

DIM. B

N° POS

125

6. Verification
6.1.8 Vertical elbow
ELEMENT IDENTIFICATION PERSON IN CHARGE OF INSPECTIONS COMPANY (if different from installing company) INSPECTION DATE SIGNATURE N.B. Stick on the element a label with a progressive number for identification.

B C
D

E
A G

F

Pe N L1 L2 L3

H

Measured Al

T. (°C)

I. (A)

C

D

E

F

G

H

Cu I. (A)

Ambient Working

T. (°C)

I. (A)

DIM. A

DIM. B

N° POS

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6.1.9 Troubleshooting table

Problem’s signals

Where?

Causes:

Abnormal heat on:

Monoblock or along busbar plant or elbow

Couple loosing Nut not broken
Wrong mounting Monoblock tooth wrong

Solutions:

Materials are damaged:
Request spare parts

Materials are ok: Strength the torque

Change way to mounting

Burnished point on: casing or insulating broken insulating overload on the line

request spare parts

Low insulating measure

apply “half plant” technique, to find out:

mechanical damage water inside broken insulating

request spare parts

Mccb break on

apply “half plant”

panel board, on feed technique, to find

unit, on TOB:

out:

– electrical overload – bad electrical contact – short circuit on load – short circuit inside
TOB – broken MCCB – wrong mounting
MCCB – too much hot
environment – water inside

request spare parts

127

7. Disposal
For the identification of the materials and the disposal instructions visit www.bticino.com/disposal.
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129

130

Legrand: LEGRAND Pro and Consumer Service BP 30076 – 87002 LIMOGES CEDEX FRANCE www.legrand.com
Installer stamp
Legrand reserves at any time the right to modify the contents of this booklet and to communicate, in any form and modality, the changes brought to the same.

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