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Instruction Booklet 

IB015001EN

Effective June 2015

Power Xpert Solar DC 

breaker recombiner 

  

EATON 

www.eaton.com

Wire/cabling

When cable connections are used, either mechanical set screw or 

compression lugs are typically supplied (see 

Figure 15

 .) See factory 

drawing for specific lug terminations and wire ranges .  

Figure 15. Screw and compression lugs

Unless a Recombiner specifically restricts entry to a single means or 

area, cables may enter through the top, bottom, side, or back of the 

section . These restrictions are typically required to conform to wire 

bending space requirements of the NEC . Consult the manufacturer’s 

drawings for conduit entry data .
Once the conductors are pulled inside the Recombiner, the cables 

should be formed in the space provided . Clearly identify and 

segregate conductors by phase . Care should be taken in forming 

insulated cables to ensure that no insulation is forced permanently 

against the edges of any metal parts .
Using appropriate tools, the installer must strip the conductor 

insulation sufficiently to fill the entire barrel of the connector with 

bare, uninsulated conductor . Conductor must be stripped without 

damage to the conductor strands . Bare strands should be of equal 

length (flush) on the end cut .
Do not strip off more insulation than needed . Exposure of bare 

conductor outside lug can compromise clearances .
The connector and conductor should be free of all foreign debris .
Never clip cable/wire strands in order to fit within connectors .  

If cable/wire does not match the rating of the connector, contact  

the manufacturer .
Mechanical set screw lugs are the most common . Use an 

antioxidant compound, if required . Insert bare conductor into lug  

so the bare conductor fills the full length of the lug body . Tighten lug, 

then torque to levels indicated on the Recombiner label .
If compression lugs are used and supplied with the Recombiner, the 

lugs will be mounted on the outgoing lug pad . Remove lugs from 

the pad . Use an antioxidant compound, if required . Use a crimping 

tool approved for that specific lug manufacturer and lug size . Follow 

instructions provided by the manufacturer of the crimp tool .
Once the lug is affixed to the conductor, reinstall the lug on the lug 

pad using the existing hardware . Torque hardware using information 

provided on Recombiner labeling . Refer to 

Appendix A, Table  1

 for 

torque values . 

Pre-energizing procedures and inspection

Before energizing any Recombiner, perform a comprehensive 

inspection to make certain that the Recombiner is ready to be 

energized . This includes the following steps:

1. 

Verify that the Recombiner is not energized . 

2. 

Visually inspect the Recombiner and remove all foreign  

materials, such as tools, scraps of wire, and other debris  

from all Recombiner sections .

3. 

Remove and discard all packing materials and temporary shipping 

braces from the Recombiner .

4. 

Any accumulation of dust and dirt should be removed with a 

vacuum cleaner . Use a lint-free cloth to remove dust and dirt 

on other surfaces . Never use compressed air as this may blow 

contaminants into electrical and/or electronic components . 

Never use solvents or other chemicals to clean surfaces or 

components .

5. 

Visually inspect all ventilation points to ensure that there is no 

blockage or debris . Remove any debris that is present .

6. 

Verify that all field bus and wire connections have the proper 

torque per instructions on the Recombiner and on components .

7. 

All factory connections are made using calibrated power tools . 

However, vibrations do occur in transit and handling . Verify 

factory connections by checking at least 10% of the total factory 

connections for tightness . If this spot check reveals loose 

connections, proceed to check all factory connections . These 

connections include bus hardware connections, circuit breaker 

and other connections, including the incoming terminals .

8. 

Visually inspect Recombiner insulators, busbar, and conductors 

for damage . DO NOT ENERGIZE IF DAMAGE FOUND .  

Contact Eaton .

Overcurrent devices

Overcurrent devices are typically shipped in either the open (OFF) 

or “tripped” position . Manually close, and then open these devices 

to ensure that they are functioning properly . At the completion of 

this process, be sure that the overcurrent device is in the OFF or 

“tripped” position .
Inspect overcurrent devices for any visible damage . If damage is 

found, DO NOT ENERGIZE the Recombiner . Contact Eaton .

Mechanical set 

screw lug

Standard one-hole

compression-type lug

Summary of Contents for Power Xpert

Page 1: ...biner Contents Description Page Safety measures 2 Pre installation receiving handling and storage 3 Pre installation preparation 5 Considerations for seismic qualified installations 5 Electrical conne...

Page 2: ...D WITHOUT THE SAFETY ALERT SYMBOL INDICATES A POTENTIALLY HAZARDOUS SITUATION THAT IF NOT AVOIDED CAN RESULT IN PROPERTY DAMAGE Eaton s liability for any errors or omissions in this document is limite...

Page 3: ...t from dust dirt moisture and damage until ready for installation The Recombiner should remain attached to its shipping skid until it has been moved into its final installation position Handling WARNI...

Page 4: ...which are top heavy equipment The forks or blades of the forklift must run through the entire Recombiner shipping length and be extended to the outermost sides of the wooden shipping skids see Figure...

Page 5: ...ional requirements The entire area around the Recombiner should be thoroughly cleaned of all debris Considerations for seismic qualified installations Recombiners are seismic qualified and in seismica...

Page 6: ...talled cables wire used to connect components between sections from damage when moving Recombiner sections into place An outdoor multi section Recombiner will ship with uninstalled intermediate roof c...

Page 7: ...type washer see Figure 11 Holes are provided on the side of each Recombiner section for this purpose Three holes are located on the side of each section toward the front and back see Figure 12 Figure...

Page 8: ...BUS OR COMPONENTS To accommodate future serviceability the manufacturer recommends that the head of the carriage bolt be mounted from the rear of the Recombiner for FRONT ACCESSIBLE Recombiners with t...

Page 9: ...r of the crimp tool Once the lug is affixed to the conductor reinstall the lug on the lug pad using the existing hardware Torque hardware using information provided on Recombiner labeling Refer to App...

Page 10: ...s on the Recombiner using hardware supplied by the manufacturer Take caution that conductors are not pinched between parts when installing the deadfront cover plates side sheets and filler plates All...

Page 11: ...T AC DIELECTRIC MEGGER TESTING DAMAGE TO COMPONENTS WILL OCCUR A test resulting in readings at or above 1 mega ohm is satisfactory Compare these test readings with prior readings and retain with previ...

Page 12: ...ts such as short circuits and overloads until the cause of the event has been identified and corrected After the event has been rectified test equipment per the maintenance process described in this p...

Page 13: ...the part Drawing numbers Rating of part s Electrical equipment has a limited life span As such the manufacturer cannot guarantee the availability of obsolete equipment or parts Equipment replacement m...

Page 14: ...VE POSITIVE Ground NEGATIVE Ground Date All overcurrent devices closed Phase to phase connections Phase to ground connections POSITIVE NEGATIVE POSITIVE Ground NEGATIVE Ground Notes Date All overcurre...

Page 15: ...s Secondary control wiring Clean ventilation Date Checklist 3 Notes and actions taken Cleaning Bus and cable connections Insulation inspection Overcurrent device inspection Controllers Other protectiv...

Page 16: ...eir respective owners Instruction Booklet IB015001EN Effective June 2015 Power Xpert Solar DC breaker recombiner Eaton 1000 Eaton Boulevard Cleveland OH 44122 United States Eaton com 2015 Eaton All Ri...

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