TAP-OFF BOXES
GRP* and metal
XCP distribution bars are equipped with outlets suitable for the range of dedicated tap-off boxes.
The tap-off boxes are available in two different construction materials:
• GRP* composite with rating up to 250 A, plug-in type (to be installed on outlets)
• painted steel enclosure with rating up to 630 A for plug-in type (to be installed on outlets)
and up to 1250 A for bolt-on type (to be installed on the junction)
They are universal and therefore can be used on both (XCP-S and XCP-HP) product lines.
The new tap-off boxes guarantee: SAFETY SYSTEM (PADLOCK)
ON TAP-OFF BOX
Safety
Optimised dimensions
Reduced maintenance costs
Pre-fitted for MCB/MCCB circuit breakers
SAFETY SYSTEM
FOR HANDS
NEW CONNECTION SYSTEM -
SAFE AND QUICK TO ASSEMBLE
The design of the outlets enables the installation of GRP*
tap-off boxes in addition to the painted steel version.
The degree of protection of the outlets and the system
is IP 2x with the cover open and IP 55 with the cover
closed or with tap-off unit installed.
* GRP = glass reinforced plastic
CATALOGUE XCP 11
Tap-off boxes for XCP are available in two different Tap-off boxes can be installed and removed when the
materials: GRP* and metal, both characterised by a simple busbar is energised and it can be assembled with
installation and fast connection thanks to the new layout of DPX3 moulded case circuit breakers.
hooks that offer safety and speed of assembly.
GRP* version:
Range from 32 A to 250 A
Optimised installation of Legrand circuit breakers (MCB/MCCB)
Optimised for P17 Tempra Pro CEE sockets
Ready for data centre applications
Empty or with fuse carrier version available
Total insulation
Plug-in / plug-out under live voltage
GRP VERSION FROM 32 A TO 250 A
Painted steel version:
Range from 63 A to 630 A
Optimised installation of Legrand circuit breakers (MCCB)
Optimised for P17 Tempra Pro CEE sockets
Ready for data centre applications
Empty or with fuse carrier version available
Equipped with :
- anti-manoeuvre security system
- anti-accidental closing and opening of the box
PAINTED STEEL VERSION FROM 63 A TO 630 A
- guard for open covering
- safer vertical installation (the cover remains in an open position)
Plug-in / plug-out under live voltage
Other devices available on request
*GRP = glass reinforced plastic Contact us on +44 (0) 370 608 9020
Tap-off boxes: accessories
Tap-off boxes are ready to be assembled with Legrand
circuit breakers and industrial sockets** P17 SOCKETS
DPX3 DIN MODULES
** Accessories not supplied. To be purchased separately.
12
SELECTION GUIDE
CONTENTS
14 Busbar selection based on the rated transformer data
14 Temperature impact on the rating of the busbar trunking system
15 Joule effect losses in busbar
16 Busbar trunking system selection based on voltage drop
17 Short circuit withstand
17 Characterisation of short circuit current
19 Harmonics
CATALOGUE XCP 13
technical information
n Selection of the busbar based on the rated n Temperature impact on the rating of the busbar system
transformer data The ambient temperature where the busbar trunking
During the design stage of the power supply system, it system is installed impacts on its rating
is necessary to consider all the technical specifications During the design stages, it will be necessary to multiply the
and standards for the equipment selected rating value at the reference temperature by a correction
The designer not only needs to specify the technical coefficient referred to the final operating temperature
requirements but the economical performance of the system
Each element of the electrical system (transformer, switchboards, All Legrand products have been sized and tested for an average
protection devices and busbar) should be sized accordingly to support ambient temperature specific for each line. For installation
the peak loads and the short circuit current in the event of a fault in environments with different average daily temperatures,
The table below shows popular transformer ratings with the rated current of the busbar must be multiplied by a
their rated current and their peak short circuit current k1 factor, which gives the correct value to consider
Iz = Iz0 · Kt
RATED CURRENTS AND SHORT CIRCUIT CURRENTS OF STANDARD TRANSFORMERS
Where:
Rated voltage Un
400 V, 50 Hz 690 V, 50 Hz • Iz0 is the current that the busbar trunking system can carry
Rated short circuit voltage Uk Rated short circuit voltage Uk for an indefinite time at its reference temperature
4% 6% 4% 6%
• Kt is the correction coefficient for ambient temperature values other
Rated power Rated Short circuit current Rated Short circuit than the reference temperature, as shown in the following table
current current
[kVA] current In [A] Ik [kA] In [A] Ik [kA]
400 577 14·4 9·6 335 8·4 5·6
KT CORRECTION COEFFICIENT FOR AMBIENT TEMPERATURE
500 722 18·0 12·0 418 10·5 7·0
630 909 22·7 15·2 527 13·2 8·8 XCP-S
800 1155 28·9 19·2 669 16·7 11·2 Ambient temperature [°C]
1000 1443 36·1 24·1 837 20·9 13·9 -5 0 5 10 15 20 25 30 35 40 45 50
1250 1804 45·1 30·1 1046 26·1 17·4 1·24 1·21 1·18 1·15 1·12 1·09 1·06 1·03 1 0·97 0·93 0·90
1600 2309 57·7 38·5 1339 33·5 22·3 kt thermal correction factor
2000 2887 72·2 48·1 1673 41·8 27·9
2500 3608 90·2 60·1 2092 52·3 34·9 XCP-HP (Al)
3150 4547 113·7 75·8 2636 65·9 43·9 Ambient temperature [°C]
4000 5774 144·3 96·2 3347 83·7 55·8 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
In 1·38 1·34 1·31 1·28 1·25 1·21 1·18 1·15 1·11 1·07 1·04 1 0·96 0·92 0·88 0·84
P Ik = In • Ik = Ik • Un
In = P = In • 3 • Un Uk kt thermal correction factor
3 • Un
Using the above table, a designer can cross reference their load XCP-HP (Cu)
requirements and select a busbar trunking system suited to their design Ambient temperature [°C]
-5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
The first selection criteria for the appropriate busbar is based on the
transformers rated current (In). The busbar rating should exceed the 1·43 1·40 1·37 1·33 1·30 1·26 1·23 1·19 1·16 1·12 1·08 1·04 1 0·96 0·92 0·87
transformers rated current. The second selection criteria is based upon kt thermal correction factor
the short circuit current. The designer should select a busbar rating
that exceeds the Ik when compared to the busbar's peak current (Ipk)
Note: The above applies to standalone transformers. For transformers
in parallel, ring or mesh networks, the short circuit current (Ik) will
increase (i.e for transformers in parallel the Ik would be double)
Selection example:
Using the following transformer :
P = 1000 kVA
Uk = 6%
Un = 400 V
and the calculation and table above,
P 1000000
In = In = = 1443 A ;
3 • Un 3 • 400
In 1443
Ik = Ik = = 24,05 kA
Uk 6% • 1000
The choices are :
• XCP-S (50 Hz, Al, 4C) having In=1600 A
and short-circuit rating Icw = 42 kA
• XCP-HP (50 Hz, Al, 4C) having In=1600 A
and short circuit rating Icw = 70 kA
To select other system trunking paths (not just the main
units at the transformer output), you need to consider
and calculate the parameters on the following pages
14
technical information
n Joule effect losses in busbar
Losses due to the Joule effect are caused by the electrical • Three phase regime losses are :
resistance of the busbar
Lost energy is transformed into heat and contributes to Pj = 3 • Rt • Ib2 • L
the heating of the conduit within the environment
The calculation of power loss is required to allow the 1000
correct sizing of the building air conditioning system
• In single phase regime :
Pj = 2 • Rt • Ib2 • L
1000
• Where :
Ib = utilisation current (A)
Rt = phase resistance for unit of length of the busbar
trunking system, measured at thermal regime (mΩ/m)
L = busbar length (m)
For an accurate calculation of distribution busbar, losses must be assessed based on the distribution load, taking into account
the reduction in current, for example, in the case of the distribution of the loads represented in the table below
Length Transiting current Losses
1st tap-off point L1 I1+I2+I3 P1 = 3RtL1 (I1+I2+I3)2
2nd tap-off point L2-L1 I2+I3 P2 = 3Rt (L2-L1) (I2+I3)2
3rd tap-off point L3-L2 I3 P3 = 3Rt (L3-L2) (I3)2
Total losses in the busbar trunking system Pt = P1+P2+P3
L3
L2
L1
I1+I2+I3 I2+I3 I3
l1 l2 l3
L L L
n Losses based on the installation method
Thermal dispersion, rating and IP protection degree are independent from the type of installation (edgeways, flat, vertical)
This means that it is possible to install the XCP busbar trunking system as preferred, without having to consider a possible system downgrade
Edgeways Flat
15
technical information
n Busbar trunking system selection based on n Calculation of the voltage drop with loads not
voltage drop evenly distributed (continued)
It will be necessary to check the value of the voltage drop The current distribution factor 'b' depends on how the circuit is fed
For systems with power factor (cosϕm) no lower than 0·8, the and on the distribution of the electric loads along the busbar :
voltage loss can be calculated using the following formulas :
Table 1 - The distribution factor of the current 'b'
THREE PHASE SYSTEM
Ib
b•√3•Ib•L•(Rt•cosϕm + x•sinϕm) b=1 Supplies at one end and load Ib
at the other end of the line L
∆v =
1000
b = 1/2 Supplies at one end and with Ib
load evenly distributed
SINGLE PHASE SYSTEM L
Ib Ib
b•2•Ib•L•(Rt•cosϕm + x•sinϕm) b = 1/4 Supplies at both ends and
∆v = with load evenly distributed L
1000
Ib
b = 1/4 Central supply with loads Ib Ib
The percentage voltage drop can be obtained from : at both ends 2 L 2
∆v% = ∆v • 100 b = 1/8 Central supply with load Ib
Vr distributed evenly
Where Vr is the system rated voltage
Example : XCP 2000 A Al for riser mains feed
In order to limit the voltage drop in case of very long busbar Ib = 1600 A operating current
trunking systems, it is possible to allow for a power supply at
b = 1/2 load evenly distributed
an intermediate position, rather than at the terminal point
k = 27·3 27·3 • 10-6 • 1600 • 100
Dv% = • 100 = 1·09%
(XCP 2000 A Al cosϕ = 0·85) 400
cosϕ = 0·85
L = 100 m line length
Vn = 400 V operating voltage
LOADS LOADS Legend :
Ib = the current that supplies the busbar [A]
Busbar trunking
system intermediate Vn = the voltage power supply of the busbar [V]
power supply point
L = the length of the busbar [m]
Dv% = the voltage drop percentage
n Calculation of the voltage drop with loads not b = the distribution factor of the current
evenly distributed k = corresponding voltage drop factor
a cosϕ [V/m/A]
In cases where the load cannot be considered evenly distributed, cosϕ m = Average power factor of the loads
the voltage drop may be determined more accurately using the
relationships shown below x = phase reactance by unit of length of the busbar (mΩ/m)
For the distribution of three phase loads, the voltage drop can Rt = phase resistance by unit of length of the busbar (mΩ/m)
be calculated using the following formula, on the assumption cosϕ mi = i-th load average power factor
(generally verified) that the section of the busbar trunking system li = i-th load current (A)
is consistent :
Li = distance of the i-th load from the origin of the busbar
∆v = √3 [Rt (I1L1cosϕ1 + I2L2 cosϕ2 + I3L3 cosϕ3) trunking system
+ x (I1L1sinϕ1 + I2L2 sinϕ2 + I3L3 sinϕ3)]
In general terms this becomes :
∆v = √3(Rt•∑Ii•Li• cosϕmi + x•∑Ii•Li• sinϕmi)
1.000
If the three phase system and the power factor are not lower than
cosϕ = 0·7, the voltage loss may be calculated using the voltage drop
coefficient shown in table 1
k • Ib • L • 100
∆v% = 2b • Vn
L3
L2
L1
l1 l2 l3
L L L
16
technical information
n Short circuit withstand
The BS 7671 standard indicates that, for the protection of the
circuits of the system, it is necessary to allow for devices aimed at
interrupting short circuit currents before these become dangerous due
to the thermal and mechanical effects generated in the conductors
and the connections. In order to size the electric system and the
protection devices correctly, it is necessary to know the value of
the estimated short circuit current at the point where this is to be
created. This value enables selection of the correct protection
devices based on their own tripping and closing powers, and to
check the resistance to electro-dynamic stress of the busbar supports
installed in control panels, and/ or of the busbar trunking system
n Characterisation of short circuit current
The estimated short circuit current at a point of the user system is the Short circuit current
current that would occur if in the considered point a connection of Current (I)
negligible resistance was created between conductors under voltage Unidirectional component
The magnitude of this current is an estimated value that represents
the worst possible condition (null fault impedance, tripping time long
enough to enable the current to reach the maximum theoretical values)
In reality, the short circuit always occurs with
significantly lower effective current values
Time (t)
The intensity of the estimated short circuit current
essentially depends on the following factors :
• Power of the cabin transformer, meaning that the Symmetric component
higher the power, the higher the current
• length of the line upstream the fault, in the sense
that the longer the line, the lower the fault
In three phase circuits with neutral it is possible to
have three different types of short circuit :
• phase-phase Current (I)
• phase-neutral 2 Icc
• balanced three phase (most demanding condition)
The formula for the calculation of the symmetric component is : In
Time (t)
Icc = E
ZE+ZL
Where :
• E is the phase voltage
• ZE is the secondary equivalent impedance of the
transformer measured between the phase and the neutral
• ZL is the impedance of the phase conductor only 3 E
ZE IccFF =
2ZE + 2ZL
Icc3~ IccFN
ZE
ZE E
IccFN =
ZE + 2ZL
E
Icc3~ =
ZE + ZL
IccFF
E = phase voltage
17
technical information
n Analytical determination of short circuit currents
In order to calculate the value of the estimated short circuit current L (m)
at any point of the circuit, it is sufficient to apply the formulas shown
below, knowing the impedance calculated at the origin
of the system up to the point being assessed
In the formulas shown below, the value of the short circuit power is S (mm2)
considered infinite and the short circuit impedance is equal to 0
This makes it possible to define short circuit current values higher P (kVA)
than the actual ones
Line resistance RL = resistance of the line upstream (m)
RL = r • L r = specific line resistance (m/m)
L = upstream line length (m)
Line reactance XL = upstream line reactance (m)
XL = x • L x = specific line reactance (m/m)
Transformer resistance RE = transformer secondary equivalent resistance (m)
1000 Pcu Pcu = transformer copper losses (W)
RE =
3In2 In = transformer rated current (A)
ZE = transformer secondary equivalent impedance (m)
Transformer impedance Vc = phase voltage (V)
ZE = Vcc% V c
2
Vcc% = percentage short circuit voltage
100 P P = transformer power (kVA)
Transformer reactance
XE = transformer secondary equivalent reactance (m)
XE = ZE2 – RE2
Short circuit impedance
Zcc = total short circuit impedance (m)
Zcc = (RL + RE)2 + (XL + XE)2
Estimated short circuit current lcc = symmetric component of the short circuit current (kA)
Icc = Vcc
3 • Zcc
XCP-S 4C (AL)
Rated current In [A] 630 800 1000 1250 1600 2000 2500 3200 4000 5000
Rated short-time current (1 s) Icw [kA]rms 25* 25* 36 42 42 50 65 80 100 120
Peak current Ipk [kA] 53 53 76 88 88 105 143 176 220 264
Rated short-time current of the Icw [kA]rms 15* 15* 22 25 25 30 39 48 60 72
neutral bar (1 s)
Peak current of the neutral bar Ipk [kA] 30 30 46 53 53 63 82 101 132 158
XCP-S 4C (CU)
Rated current In [A] 800 1000 1250 1600 2000 2500 3200 4000 5000 6300
Rated short-time current (1 s) Icw [kA]rms 25 36 42 42 50 65 80 100 120 150
Peak current Ipk [kA] 53 78 88 88 105 143 176 220 264 330
Rated short-time current of the Icw [kA]rms 15 22 25 25 30 39 48 60 72 90
neutral bar (1 s)
Peak current of the neutral bar Ipk [kA] 30 46 53 53 63 82 101 132 158 198
* Icw value at 0·5 s.
XCP-HP 4C (AL)
Rated current In [A] 630 800 1000 1250 1600 2000 2500 3200 4000 5000
Rated short-time current (1 s) Icw [kA]rms 36 36 50 70 70 85 120 120 150 150
Peak current Ipk [kA] 76 76 105 154 154 187 264 264 330 330
Rated short-time current of the Icw [kA]rms 22 22 30 42 42 51 72 72 90 90
neutral bar (1 s)
Peak current of the neutral bar Ipk [kA] 45 45 63 88 88 112 158 158 198 198
XCP-HP 4C (CU)
Rated current In [A] 800 1000 1250 1600 2000 2500 3200 4000 5000 6300
Rated short-time current (1 s) Icw [kA]rms 36 50 70 70 85 120 120 150 150 150
Peak current Ipk [kA] 76 105 154 154 187 264 264 330 330 330
Rated short-time current of the Icw [kA]rms 22 30 42 42 51 72 72 90 90 90
neutral bar (1 s)
Peak current of the neutral bar Ipk [kA] 45 63 88 88 112 158 158 198 198 198
18
