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Eaton PowerWave 2 Installation And Operations
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Eaton PowerWave 2 Installation And Operations

Eaton PowerWave 2 Installation And Operations

Bus system 250–1000 a
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Instruction Leaflet IL017003EN
Effective June 2024
PowerWave 2 bus system 250–1000 A
installation and operation

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Summary of Contents for Eaton PowerWave 2

  • Page 1 Instruction Leaflet IL017003EN Effective June 2024 PowerWave 2 bus system 250–1000 A installation and operation...
  • Page 2 Instruction Leaflet IL017003EN PowerWave 2 bus system 250–1000 A installation and operation Effective June 2024 Contents Description Page Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 System summary .
  • Page 3 Read, understand, and follow the instructions before that can be deployed quickly using easy-to-assemble kits . installing this product PowerWave 2 bus systems allow any voltage ≤ 600 V and are • Disconnect and lock-out all power supplying equipment before available in 250 A, 400 A, 600 A, 800 A, and 1000 A systems .
  • Page 4 Monitoring is recommended to track loads and to assess whether Determine if bus run reserve capacity is needed for load spikes or you are approaching the bus run’s limits . PowerWave 2 Branch expansion . Circuit Monitoring (BCM) integrates monitoring and communications into the same bus run as power distribution .
  • Page 5 Using older tap-off boxes PowerWave 2 bus runs have no physical length limitation . However, Older tap-off boxes can be used in PowerWave 2 bus runs . voltage delivered along a bus run drops off with bus run length . The...
  • Page 6 Instruction Leaflet IL017003EN PowerWave 2 bus system 250–1000 A installation and operation Effective June 2024 Power connections Customers provide their own wiring and conduit to power feeds . Lugs, wires, and torque specifications Power feeds (standard end feeds, compact end feed, and center Customer power connection lugs by power feed type: feed) do not have knock-outs .
  • Page 7 PowerWave 2 bus system 250–1000 A Instruction Leaflet IL017003EN installation and operation Effective June 2024 Torque power connections as follows: Power and ground, standard end feed, 250–400 A • Standard end feed (250–400 A): 3/8-inch-16 screws; torque Connect ground wires before connecting power wires .
  • Page 8 Instruction Leaflet IL017003EN PowerWave 2 bus system 250–1000 A installation and operation Effective June 2024 Power and ground, standard end feed, 600–1000 A Power connections for a 600 A compact end feed are directly to the starter rail, the same as for 600–1000 A standard end feeds . See Power and ground connections for 600–1000 A bus systems are...
  • Page 9 PowerWave 2 bus system 250–1000 A Instruction Leaflet IL017003EN installation and operation Effective June 2024 Power and ground, center feed, 250–400 A Center feeds are pre-assembled with starter rails . Because neutral must be in the same position throughout the bus run, one starter rail is right-hand and the other starter rail is left-hand .
  • Page 10 HAND PROTECTION WHEN CUTTING RETAINING BANDS. Installation sequence 6. Carefully remove the protective bubble wrap bag and remove Eaton recommends that you have an Installation Plan with an components from boxes . Use care to not puncture or scratch installation sequence, such as the following: the components with cutting tools .
  • Page 11 Step 1: Create the overhead support structure The following installation instructions are based on 250–400 A bus PowerWave 2 bus systems are hung from an overhead support system installation . Installation procedures for 250 A and 400 A structure, such as a Unistrut or grid structure .
  • Page 12 Figure 7. Hanger components and placement on rail Vertical hanger spacing on bus rails Eaton recommends three vertical hangers per 12 ft (3 .66 m) of bus rail . One hanger is should be installed within 12 inches (30 .5 cm) from the end of each bus rail and one hanger should be centered between them .
  • Page 13 PowerWave 2 bus system 250–1000 A Instruction Leaflet IL017003EN installation and operation Effective June 2024 Vertical hangers (600–1000 A) Hangers for 600–1000 A bus systems can be inserted into bus rails at any point, making it easy to add them at any time during installation .
  • Page 14 Instruction Leaflet IL017003EN PowerWave 2 bus system 250–1000 A installation and operation Effective June 2024 Step 2: Hang the starter rail and standard end feed Typically the starter rail is hung first, but some customers Hang the starter rail prefer to hang the standard end feed before the starter rail, for...
  • Page 15 PowerWave 2 bus system 250–1000 A Instruction Leaflet IL017003EN installation and operation Effective June 2024 Attach starter rail to the standard end feed Remove 4 bolts from the standard end feed and use them to attach the starter rail flange .
  • Page 16 Instruction Leaflet IL017003EN PowerWave 2 bus system 250–1000 A installation and operation Effective June 2024 Attach ground wire to enclosure lug Attach (optional) dedicated ground wire The starter rail has a ground wire that is always connected Dedicated ground similar to isolated ground shown on Figure 14, to the rail on the neutral side .
  • Page 17 PowerWave 2 bus system 250–1000 A Instruction Leaflet IL017003EN installation and operation Effective June 2024 Step 2 Alternate: Install compact end feed (250–1000 A) The compact end feed is an alternative end feed for vertical 5. Hang the cable feed entry panel from overhead unistruts or horizontal busway applications where there is limited or other support .
  • Page 18 Instruction Leaflet IL017003EN PowerWave 2 bus system 250–1000 A installation and operation Effective June 2024 7. 600 A bus systems only ote: The top bracket can also be repositioned to the bottom of the cable feed entry panel . Attach compact end feed to starter rail . Remove the unit’s starter rail face plate and discard, but retain attachment hardware .
  • Page 19 PowerWave 2 bus system 250–1000 A Instruction Leaflet IL017003EN installation and operation Effective June 2024 9. Replace the enclosure section that you removed in Step 3 on page 17 . Attach each section with 8 retained screws (¼ x 20 x 5/8 inches) .
  • Page 20 Instruction Leaflet IL017003EN PowerWave 2 bus system 250–1000 A installation and operation Effective June 2024 Step 3: Complete the bus run structure Install standard rails Adjust bus rail C-clips Usually the bus run is extended beyond the starter rail with Bus rails have C-clips along the mast channel to stiffen the channel .
  • Page 21 PowerWave 2 bus system 250–1000 A Instruction Leaflet IL017003EN installation and operation Effective June 2024 End cap 600–1000 A Every exposed bus rail (or other component) end must be covered by an end cap . 1. Loosen lug and washer from outer ground bolt .
  • Page 22 Instruction Leaflet IL017003EN PowerWave 2 bus system 250–1000 A installation and operation Effective June 2024 Step 4: Install couplers Installing a 250–400 A coupler 2B: Important! Slide bus rails together until 6 .5 inches (16 .5 cm) the fit between the bus rails and divider is snug .
  • Page 23 Re-insert 2 screws and tighten over ground jumper plate PowerWave 2 bus system 250–1000 A Instruction Leaflet IL017003EN installation and operation Effective June 2024 4. 4A: Remove and retain 2 ground screws from the top ends 5. 5A: Insert the enclosed bolt into the top center hole of the of the bus rails .
  • Page 24 Instruction Leaflet IL017003EN PowerWave 2 bus system 250–1000 A installation and operation Effective June 2024 8. 8A: Insert the bottom cover under the coupler . Installing a 600–1000 A coupler The 600–1000 A bus system coupler has a similar structure to the 250–400 A coupler and the installation is also similar .
  • Page 25 PowerWave 2 bus system 250–1000 A Instruction Leaflet IL017003EN installation and operation Effective June 2024 3. Insert the two provided 0 .250-20 x 6 .50 hex bolts along with the 5. Using a 5/16 wrench, attach the ground strap across the top of provided flat washer and lock washer in conjunction with the the coupler with the 4 ground nuts .
  • Page 26 Instruction Leaflet IL017003EN PowerWave 2 bus system 250–1000 A installation and operation Effective June 2024 7. Slide the 2 side plates across the coupler and line up hole Horizontally oriented bus runs (250–400 A) with the center line of coupler (where bus rail housings meet) .
  • Page 27 PowerWave 2 bus system 250–1000 A Instruction Leaflet IL017003EN installation and operation Effective June 2024 On horizontal layouts, the neutral conductor should be on the top side . Like vertical hangers, there should be a horizontal hanger no more than 1 ft from the center of the coupler or end cap, but hangers should be spaced no more than 4 ft apart .
  • Page 28 Instruction Leaflet IL017003EN PowerWave 2 bus system 250–1000 A installation and operation Effective June 2024 Horizontally oriented bus runs (600–1000 A) 600–1000 A bus runs can be horizontally oriented: The compact end feed is not rotated . It is designed for attachment to bus rails in either vertical or horizontal orientation .
  • Page 29 Standard tap-off boxes can be installed nearly anywhere along Tap-off boxes are inserted into bus rails in a safe two-stage process: a PowerWave 2 bus run . The bus run should be tested before 1. Ground and optional isolated ground connections are installing all tap-off boxes .
  • Page 30 Instruction Leaflet IL017003EN PowerWave 2 bus system 250–1000 A installation and operation Effective June 2024 Coupler overlap 250–400 A Because ground clips on the left and right side of the tap-off box are cross-connected, a tap-off box can overlap a coupler on one side while being grounded on the other side in 250–400 A bus...
  • Page 31 PowerWave 2 bus system 250–1000 A Instruction Leaflet IL017003EN installation and operation Effective June 2024 Installing a tap-off box To install a tap-off box: Step 1. Prepare tap-off box for installation 1A. Set contact engagement knob all the way left (CAMs disengaged).
  • Page 32 Instruction Leaflet IL017003EN PowerWave 2 bus system 250–1000 A installation and operation Effective June 2024 Clip the two retainer clips onto the bus rail just outside the left and right sides of the tap-off box . Tap-off boxes can be installed adjacent to one another (touching) .
  • Page 33 PowerWave 2 bus system 250–1000 A Instruction Leaflet IL017003EN installation and operation Effective June 2024 3C. Slide retainer clips over the tap-off box lip about 1 inch in from the sides . 3D. Slide contact engagement knob all the way right into its keyhole and tighten .
  • Page 34 Verify that the coupler connection is installed correctly per this manual . An Eaton certified technician or the installer should execute the following checklist to verify correct operation before applying loads b. Verify that the side plates at each coupler are positioned to tap-off boxes .
  • Page 35 PowerWave 2 bus run . Load bank tap-off box The load bank tap-off box inserts into a PowerWave 2 bus rail in the same way as a tap-off box . The bus run is not modified for the load bank test . A load bank can connect directly to the unit’s Cam-Loks for testing .
  • Page 36 Only one unit can be installed on a bus run at a time . An removed from the last bus rail and the load bank end feed is installation video is available on the PowerWave 2 product attached to the bus rail with a coupler . A load bank connects page at www.eaton.com .
  • Page 37 DANGER Spares kits specialized for different configurations are available for PowerWave 2 bus systems and are specific to the amperage THIS PRODUCT MUST BE INSTALLED AND INSPECTED BY LICENSED of the bus system . (For amperage in tables below, substitute ELECTRICIANS OR BY EATON-AUTHORIZED TECHNICIANS.
  • Page 38 Instruction Leaflet IL017003EN PowerWave 2 bus system 250–1000 A installation and operation Effective June 2024 Glossary One-phase Two-phase Three-phase American wire gauge Coupler A component used to join bus rails, elbows, and tees into a bus run . Intertek’s ETL listed mark, North American certification...
  • Page 39 This instruction booklet is published solely for information purposes Specifications and should not be considered all-inclusive . If further information Eaton PowerWave 2 bus system guide specifications ( .docx and .pdf) is required, you should consult an authorized Eaton sales representative .
  • Page 40 Instruction Leaflet IL017003EN PowerWave 2 bus system 250–1000 A installation and operation Effective June 2024 For more information on the PowerWave 2 bus system, contact sales at LVB-NSBSalesGreenwood@Eaton.com Eaton 1000 Eaton Boulevard Cleveland, OH 44122 United States Eaton .com © 2024 Eaton All Rights Reserved Eaton is a registered trademark.