busbar systems 160800 a -...

www.eae.com.tr

Busbar Systems

160...800 A

Cakmakli Mahallesi, 2. Cadde,

119. Sokak, No:12 34522

Kirac-Hadimkoy-Istanbul-TURKEY

Tel: +90 (212) 886 23 90

Fax: +90 (212) 886 24 20

T E

ME 04

IEC 60439-2 sISO9001

14001

QUALI

TY

AN

DEN

VIR

ONMENTAL MANAGEM

EN

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CONTENTS

Introduction

Design

Order Code System

Technical Characteristics

Standard Components

Elbows

Standard Components

Feeder Boxes

Selection Of Feeder Boxes

Panel Connections

Tap-off Boxes

Fixing Elements

Fire Barrier

Determination of Special Length

Installation of End Closer

Mounting nstructions for Joints

E Declaration Of Conformity

Certificates

I

C

Product Overview

Project Design Form

2-3

4

5

6

7

8-

1 -1

1 -1

1

1

1 -

2

2

2

2

2

2

11

2 3

4 5

6

7

8 20

21-22

3

3

4

4

5

6

27

28

55 Nm

2

Introduction

E KO-LINE

E-Line KO- Busbar System distributes electrical energy,

both vertically and horizontally at premises where there

is a need of electricity between 160 A and 800 A.

It provides a prefabricated and flexible electrical

distribution system for all factories engaged in mass

production, like automobile plants, textile plants,

furniture factories and for buildings where there is a

need for frequent energy supply like business

centers, hotels, hospitals, warehouses and

all high rise buildings.

Modern Outlook

E-Line KO-Other than its functional advantages

busbar system also creates a modern outlook at

buildings where it is used.

Busbar components can be added, deleted or

relocated after the initial installation, saving time

and money.

Lower Life Cycle Cost

Tap-off Points

E-Line KO-Energy can only be supplied by tap-off

boxes. Where necessary the use tap-off points can be

limited by sealing. Dust covers protect the system from

any accidental contacts and also prevents the access

of pollution from the environment.

Fast, Flexible Engineering

Fast and Easy Mounting

E-Line KO-

Safe Energy Distribution and Transportation

Lower Total Installed Cost

Flexible Power Supply

The large number tap-off points makes it possible to

engineer the power supply systems at an early stage,

even before the final disposition of loads is known.

Energy is easly supplied to machines by .

The erection of the system does not require any

expertise. Supports and accessories are available for

mounting the system either to the celling or to the wall.

E-Line Busbar Systems increase personnel safety

by their special structures.

Busbar Material costs are often equal or less than

wire and counduit.

Tap-off points at short intervals make electrical power

available in all locations, the power supply can be

adapted to different production processes simply

by relocating the tap-off units.

Being built up of basic elements, it can at any time

be extended, modified, dismantled and re-used.

Conductors

-

KO-

Copper and Aluminium conductors are continously

plated.

- Cross-section of neutral conductor is the same as

phase conductor.

- Upon request group of busbars can be

manufactured also with 5 conductors.

Secured Energy Take Off

The earth of the tap-off box first contacts the

busbar and ensures the safety, of the box and

the system that’s been fed.

Busbar ystemS

KO- KB Busbar

System

“One Bolt Joint”

E-Line KO- Busbars are easily installed by

tightening the “one bolt joint”. Belleville

spring washers on both ends of the bolt

retains the original contact pressure ensuring

a more secure and reliable joint.

Tap-off Boxes

Energy upto 400A can be supplied by

tap-off boxes. Standard tap-off boxes are

equipped with interlock mechanism which

prevents the cover of tap-off boxes to be

opened before the energy is turned off.

Tap-off boxes are easily mounted to the

busbar without any additional mounting

equipment. Boxes are fixed to

Busbar by a safety bolt.

The standard type tap-off boxes with fused

switches can not be disconnected from

busbar mechanicaly if the power is on.

E-Line

KO-

3

E KO-LINE

Broken

Nut

Double

Headed Nut

While designing an electrical distribution

system with E-Line KO- a few approximate

details will be necessary.

E-Line KO-

E-Line KB

E-Line MK-KAP E-Line KO-

Rated Current

Location, number, type and approximate

ratings of loads,

Transformer rates and short-circuit capacities,

Utilization factor =

System co-ordination with other distribution

systems (heat, water, etc.)

Determining the route of on layouts,

Deciding on suitable supports,

If necessary, co-ordination of

and with runs.

The current is calculated using the following

equation.

Busbar Current rating is chosen as equal to or

higher then the calculated I current.

After the voltage drop calculation if the chosen

current rate is not convenient, a higher rating

is chosen.

�

Applications

Utilization Factor ( )�

B

B

P.�

� �3.U.cosI =

BIP

U

= (A)= (W)==

Operating Current

Installed Load

Utilization Factor

Supply Voltage

Location and dimensions of the shaft

where busbar will be installed,

Number, height and ceiling thickness of each storey,

Connected load for each storey,

Supply type of the vertical line (Busbar or Cable).

(h=)

(a=)

(p=)

Utilization factor( ) depends on the type and number of loads.

It is usually around 0.7 or lower. The utilization factor of a line

that supplies electricity to motors and lighting systems is

usually 0.6 It is as low as 0.5 in weld shops of car factories,

( ) can be 1 in lines where only one big load is supplied.

�

�

As each building’s structure is different than the other for

vertical and horizantal applications special projects has to be

designed.

The details on this page briefly explain the necessary informations for drawing a vertical

applications project.

The details below should be sent to our Project and Design Department for Pre-Project

design and cost analysis.

Vertical Disribution

Pre-Project Design and cost Analysis

�

4

Design

E KO-LINE

Tap-

off P

oint

Fire

Barrier

Plug-İn Tap-off Box (H) H

eigh

t of s

tore

y m

easu

red

from

cei

ling

(cm

)

( a ) C

eiling

Thickness (cm)

1. Plug-in Point

3. Plug-in Point

Spec

ial L

engt

h B

usba

rSt

anda

rd L

engt

h B

usba

rEx

pans

ion

Uni

t

a= ......

a= ......

a= ......

a= ......

a= ......

a= ......

a= ......

a= ......

a= ......

a= ......

h=

.....

.h

= ..

....

h=

.....

.h

= ..

....

h=

.....

.h

= ..

....

h=

.....

.h

= ..

....

2.Floor

3.Floor

4.Floor

9.Floor

8.Floor

7.Floor

6.Floor

5.Floor

10.Floor

End Of Line

Figure 1

Supply From

Panels

P

P

P

P

P

PP

PP

P

14

13

12

11

10

9

8

7

6

5

AB

Vertical

Support

Vertical

Support

KO A 06 5 B5 - - - DDT

IP 55 5

Aluminium A

Copper C

UNPAINTED

PAINTED

-

B

Busbar Type

Conductor Type

Busbar Code

Protection Degree

Paint

BUSBAR TYPE

CONDUCTOR TYPE

BUSBAR CODE

PROTECTION DEGREE

CONDUCTOR CONFIGURATION

UNPAINTED / PAINTED

COMPONENT

160

250

315

400

500

600

250

315

400

600

800

01

02

03

04

05

06

02

03

04

06

08

6x20

6x25

6x30

6x50

6x62,5

6x75

6x20

6x25

6x30

6x50

6x75

Busbar

Rated Current

Alu

min

ium

Co

pp

er

Busbar

Code

CodeL1 L2 L3 N PE

½PE

CPE½

CPE

PE(Housing)

Number of

Conductors

4

5

6

7

9

Conductor Configuration

Configuration

4 wire

5 wire

4 ½ wire

5 wire

4 ½ wire

( )

( )

CPE

CPE

5

Order Code System

E KO-LINE

Plug-in Standard Length

Plug-in Special Length

Feeder Standard Length

Feeder Special Length

Right Elbow

Left Elbow

Downwards Elbow

Upwards Elbow

Right Upwards Combined

Left Upwards Combined

Right Downwards Combined

Left Downwards Combined

Upwards Right Combined

Upwards Left Combined

Downwards Right Combined

Downwards Left Combined

Upwards Vertical Offset

Downwards Vertical Offset

Right Horizontal Offset

Left Horizontal Offset

“T” Component

Cross

Reductions

End Closer

Horizontal Expansion

Vertical Expansion

Flexible

Feeder Box 1

Feeder Box 2

Central Feeder Box 1


Panel Connections

Panel Connections

STD

X

FTD

FX

R

L

A

Y

KRU

KLU

KRD

KLD

KUR

KUL

KDR

KDL

UV

DV

RH

LH

T

D

RD

S

YDT

DDT

F

B1

B2

BO1

BO2

P10

P11

Components

Voltage Drop Calculation

Voltage drop of a busbar system can be calculated with the following

formula taking into account the “ “ load distribution constant.�

Load Distribution Factor

L

L1

L1

L1

L1

L2

L2

L2

L3

L3

L3

L2

L4

L4

L4

F

F

F

F

FF

L

F= Supply

L= Load

F= Supply

L1,L2,L3,L4

Load

F= Supply

L1,L2,L3,L4

Load

F= Supply

L1,L2,L3,L4

Load

F=

L1,L2

Supply

Load

1.00

0.50

0.125

0.25

0.25

� �� U 3.L.I.(R .Cos X .Sin ) 10= +1 L

-3

= Voltage Drop (V)

= Load Distribution Constant

= Line Length (m)

= Line Current (A)

= Resistance (m /m)

= Inductive Reactance (m /m)

= Load Factor

�

�

�

�

�

U

L

I

R

XL

Cos

1

�

Volt

Standards

Busbar Code

L1, L2, L3, N

PE (for 5 Conductors)

Weight - 4 Conductors

Weight - 5 Conductors

Fire Load (3 Plug-in Points)

Housing Cross Section(Steel Sheet)

PE (for 4 ½ Conductors )

Rated Operational Voltage

Conductor Size

Resistance at SteadyState Temperature

Reactance(Rated Current and 50 Hz)

Impedance at Steady StateTemperature

Rated Short-timewithstand Current (N)

Rated Short-timeWithstand Current (PE)

Rated Peak WithstandCurrent (N)

Rated Peak WithstandCurrent (PE)

Loses at Rated Current

Rated Peak WithstandCurrent

Rated Short-time WithstandCurrent (1 sec)

R 20°C20

Impedance

Rated Insulation Voltage

Rated Frequency

Protection Degree

Aluminium Conductor (KOA)

Rated Current

Copper Conductor (KOC)

mm²

mm²

kg/m

kg/m

kW/m

mm²

mmxmm

mm²

V

V

Ue

Ui

m /m�

m /m�

m /m�

kAIcw

kAIcw

kAIp

kAIp

W/m3I²R1

kAIp

AIn

kArmsIcw

m /m�R20

R1

X1

Z1

m /m�Z

f Hz

IP

01 02 03 04 05 06

120 150 180 300 375 450

120 150 180 300 375 450

7,0 7,5 8,0 10,0 11,0 12,0

7,3

6,46

8,0

6,46

8,7

6,57

11,0

6,66

12,0

6,66

13,0

6,66

583 593 603 643 668 693

60 75 90 150 187,5 225

1000

6x20 6x25 6x30 6x50 6x62,5 6x75

0,286 0,246 0,204 0,125 0,109 0,094

0,205 0,183 0,165 0,118 0,103 0,088

0,349 0,319 0,270 0,182 0,157 0,135

6 9 9 18 18 21

6 9 9 18 18 21

10,2 15,3 15,3 36 36 44,1

10,2 15,3 15,3 36 36 44,1

21,96 46,13 60,73 60,00 81,75 101,52

17 30 30 63 63 73,5

160 250 315 400 500 600

10 15 15 30 30 35

0,242 0,193 0,161 0,097 0,077 0,064

0,333 0,274 0,243 0,166 0,139 0,118

1000

50 / 60

55

0302 04 06 08

150120 180 300 450

150120 180 300 450

11,010,0 12,5 16,0 18,0

12,5

6,46

11,0

6,46

14,0

6,57

19,0

6,66

21,0

6,66

593583 603 643 693

7560 90 150 225

6x256x20 6x30 6x50 6x75

0,1640,180 0,144 0,078 0,068

0,1540,173 0,145 0,117 0,083

0,2350,254 0,207 0,144 0,110

10,810,8 15 21 21

10,810,8 15 21 21

21,621,6 30 44,1 44,1

21,621,6 30 44,1 44,1

48,8233,75 69,12 84,24 130,56

3636 52,5 73,5 73,5

315250 400 600 800

1818 25 35 35

0,1200,150 0,100 0,060 0,040

0,2090,238 0,193 0,134 0,102

6

Technical Characteristics

E KO-LINE

IEC 60439-2: 2000

Current Aluminium Copper

(A) (A)mm

(A)mm

Please call us for non-standard components.

Busbar cross-section dime sionsn

Electrical Energy up to 400A can be supplied

from the busbar by Tap-off boxes.

Busbar is manufactured in 3m as

standard, special lengths can be manufactured

on request.

E-Line KO-

A

180

L1

L2

L3

NPE

-707580-

100125

707580

100112125

-

160250315400500600800

625 500

500375 500 500

3000

500 625

500 500 500 375

3000

X

X

Plug-in

Standard Length

7

Standard Components

3000

Feeder

Standard Length

E KO-LINE

Minimum special length that can

be manufactured is 35 cm.

L1

L2

L3

NPE

X Special

Straight Length

(cm)

L1

L2

L3

NPE

X Special

Straight Length

(cm)

L1

L2

L3

NPE

Plug-in

Special Straight Length

Feeder

Special Straight Length

Sample Order:

250 A, Aluminium, Plug-in,

IP 55, 4 Conductors

KOA 0254- -STD STD

FTD

Sample Order:

400 A, Copper, Plug-in,

IP 55, 85 cm. 5 Conductors

KOC 0455- -85

Sample Order:

315 A, Aluminium, Feeder,

IP 55, 5 Conductors

KOA 0355- - TDF

Sample Order:

160 A, Aluminium, Feeder,

IP 55, 60 cm, 4 Conductors

KOA 0154- -60

-

-

L1

L2

L3

NPE

X

FX

KO - - -

BUSBAR TYPE

CONDUCTOR TYPE

BUSBAR CODE

PROTECTION DEGREE


UNPAINTED / PAINTED

COMPONENT

160250315400500600

800

250315400600

180185190210222235

180185190210235

145147150160166172

145147150160172

200200200200200200

200200200200200

290290290290290290

290290290290290

A B C D

B

A

B

A

C

D

C

D

AB

AB

C D

D

C


Sample Order:

250 A, Aluminium, IP 55, 4 Conductors

Sample Order:

600 A, Copper, IP 55, 5 Conductors

Sample Order:


Sample Order:


KOA 0254 - - R

KOC 0655 - - L

KOA 0454 - - A

KOC 0655 - - Y

Right Elbow

Left Elbow

Downwards Elbow

Upwards Elbow

R

L

A

Y

L1

L1

L1

L1

L2

L2

L2

L2

L3

L3

L3

L3

N

N

N

N

PE

PE

PE

PE

Current

Alu

min

ium

Co

pp

er

8

Elbows

E KO-LINE

KO - - -

BUSBAR TYPE

CONDUCTOR TYPE

BUSBAR CODE

PROTECTION DEGREE


UNPAINTED / PAINTED

COMPONENT

160250315400500600

800

250315400600

180185190210222235

180185190210235

145147150160166172

145147150160172

200200200200200200

200200200200200

290290290290290290

290290290290290

A B C D

CD

Y

Y

BA

CD

BA

X

A

B

AB

X

Right Horizontal

Offset

Left Horizontal

Offset

Upwards Vertical

Offset

Downwards

Vertical Offset

L1

L2

L3

NPE

L1

L2

L3

NPE

L1

L2

L3

NPE

L1

L2

L3

NPE

Sample Order:

315 A, Aluminium, IP 55,

5 Conductors

Sample Order:


4 Conductors

UV

DV

RH

LH

Current

Alu

min

ium

Co

pp

er


Sample Order:


4 Conductors

X= min. 20 cm.

KOA 0254 - - UV

Sample Order:

400 A, Copper, IP 55,

5 Conductors

Y= min. 15 cm.

X= min. 20 cm.

Y= min. 15 cm.

KOC 0455 - - DV

KOA 0355 - - RH

KOA 0154 - - LH

9

Elbows

E KO-LINE

KO - - -

BUSBAR TYPE

CONDUCTOR TYPE

BUSBAR CODE

PROTECTION DEGREE


UNPAINTED / PAINTED

COMPONENT

160250315400500600

800

250315400600

180185190210222235

180185190210235

145147150160166172

145147150160172

200200200200200200

200200200200200

290290290290290290

290290290290290

A B C D

L1

L2

L3

NPE

L1

L2

L3

NPE

L1

L2

L3

NPE

L1

L2

L3

NPE

Y

BA

X

X

Y

BA

B A

B

A

Right Downwards

Combined Offset

Left Downwards

Combined Offset

Right Upwards

Combined Offset

Left Upwards

Combined Offset

Sample Order:


4 Conductors

Sample Order:


5 Conductors

Sample Order:


5 Conductors

Sample Order:


4 Conductors

KRU

KLU

KRD

KLD


KOA 0254 - - KRU

KOC 0455 - - KLU

KOA 0355 - - KRD

KOA 0154 - - KLD

10

Elbows

Y= min. 20 cm.

Y= min. 20 cm.

X= min. 20 cm.

X= min. 20 cm.

E KO-LINE

KO - - -

BUSBAR TYPE

CONDUCTOR TYPE

BUSBAR CODE

PROTECTION DEGREE


UNPAINTED / PAINTED

COMPONENT

Current

Alu

min

ium

Co

pp

er

160250315400500600

800

250315400600

180185190210222235

180185190210235

145147150160166172

145147150160172

200200200200200200

200200200200200

290290290290290290

290290290290290

C

C

D

D

Y

Y

B

C

D

A

D

C

B

B

X

X

A

A

AB

Downwards Right

Combined Offset

Downwards Left

Combined Offset

Upwards Right

Combined Offset

Upwards Left

Combined Offset

L1

L2

L3

NPE

L1

L2

L3

NPE

L1

L2

L3

NPE

L1

L2

L3

NPE

Sample Order:


4 Conductors

Sample Order:


5 Conductors

Sample Order:


5 Conductors

Sample Order:


4 Conductors

KUR

KUL

KDR

KDL


KOA 0254 - - KUR

KOC 0455 - - KUL

KOA 0355 - - KDR

KOA 0154 - - KDL

11

Elbows

Y= min. 20 cm.

Y= min. 20 cm.

X= min. 20 cm.

X= min. 20 cm.

E KO-LINE

A DCBCurrent

Alu

min

ium

Co

pp

er

KO - - -

BUSBAR TYPE

CONDUCTOR TYPE

BUSBAR CODE

PROTECTION DEGREE


UNPAINTED / PAINTED

COMPONENT


Sample Order:


4 Conductors

Sample Order:


4 Conductors

Sample Order:

400-250 A, Aluminium,

IP 55,5 Conductors

KOA 0254 - - T

KOA 0654 - - D

KOA 0455 - - RD2

“T” Component

Cross

Reduction

RD

D

T

AB

AA

Reduced

Current

160 A 1

250 A 2

315 A 3

400 A 4

500 A 5

600 A 6

Reduction

Is used to change the busbar

cross section.

BACurrent

160250315400500600

800

250315400600

290295300320332345

290295300320345

145147150160166172

145147150160172

Alu

min

ium

Co

pp

er

L1

L2

L3

NPE

12

Standard Components

E KO-LINE

KO - - -

BUSBAR TYPE

CONDUCTOR TYPE

BUSBAR CODE

PROTECTION DEGREE


UNPAINTED / PAINTED

COMPONENT

640

L1

L2

L3

N

L1

L2

L3

NPE

PE


* Please indicate X, Y, Z and ø measurement on order.

Sample Order:


Sample Order:


Sample Order:

600 A, Aluminium, 4 Conductors 55 cm.

Sample Order:


KOC 0255 - - S

KOA 0254 - - YDT

KOA 0454 - - F55

KOC 0255 - - DDT

End Closer


Flexibles

Vertical Expansion

DDT

YDT

F

S

260

1000

*

Y

L

ZX

L(Cm)

End Closer

Is used to close the end of busbar run.


For long horizontal runs and for crossing

the building expansions.

Vertical Expansion

For vertical applications in many storey

buildings.

Flexibles

Are used for panel-busbar connections.

700

L1

L1

L2

L2

L3

L3

N

N

PE

PE

13

Standard Components

E KO-LINE

KO - - -

BUSBAR TYPE

CONDUCTOR TYPE

BUSBAR CODE

PROTECTION DEGREE


UNPAINTED / PAINTED

COMPONENT

Feeder Box sample equipped with MCB

Please call us for special applications or for applications with MCB's

Feeder Box 1

Feeder Box 2

B2

B1

L1

L2

L3

NPE

Y Y

X

X

X

X

D

A

B

B

C210

210

200

200

A C D X YBCurrent

160 550 350 350 180 85 55

550 350 350 180 85 52,5

550 350 350 180 85 50

550 350 350 180 85 40

550 350 350 240 85 65

550 350 350 240 85 57,5

250

Alu

min

ium

315

400

500

600

550 350 350 180 52,585

550 350 350 180 5585

550 350 350 180 5085

550 350 350 180 4085

550 350 350 240 57,585

Co

pp

er

250

315

400

600

800

Sample Order:


5 Conductors

KOC 0255 - - B1

Sample Order:

250 A, Aluminium IP 55,

4 Conductors

KOA 0254 - -B2

L1

L2

L3

NPE

14

Feeder Boxes

E KO-LINE

KO - - -

BUSBAR TYPE

CONDUCTOR TYPE

BUSBAR CODE

PROTECTION DEGREE


UNPAINTED / PAINTED

COMPONENT


KOA 0654 - - BO1


Sample Order:


4 Conductors

KOA 0654 - - BO2


BO2

BO1

600

210

210

365

365

60

0

L1

L1

L2

L2

L3

L3

N

N

PE

PE

230

600

210

210

60

0

230

15

Feeder Boxes

E KO-LINE

KO - - -

BUSBAR TYPE

CONDUCTOR TYPE

BUSBAR CODE

PROTECTION DEGREE


UNPAINTED / PAINTED

COMPONENT

Sample Order:


4 Conductors

In vertical installation the neutral

conductor should be on the right side.

It is important for tap-off box connections.

Selection of Feeder Boxes

Application of

Tap-off Boxes for

Horizontal Lines

Application of Tap-off Boxes

for Vertical Lines

FRONT

2. Plug-in Point1. Plug-in Point

In horizontal installation the neutral

conductor is situated as shown above.

Ceiling

Ceiling

Wall

16

L1

L2

L3

N PE

B1

B1

B2

B2

B2

B1

E KO-LINE

L1

L2

L3

NPE

15

0 m

m.

15

0 m

m. 150 mm.

Sp

ecia

l Len

gth

Bu

sbar

Ver

tical

Exp

ansi

on

Sta

nd

ard

Len

gth

Bu

sbar

Fire

Barrier

Vertical

Support

Panel Connections

Figure 1 Figure 2

160250315400500600

00

2503154006008

2025305062.575

2025305075

404040403333

4040404033

202020202020

2020202020

8,5x178,5x1712x2412x241414

8,5x178,5x1712x2412x2414

----

2626

----

26

111122

11112

Alu

min

ium

Co

pp

er

ACurrent x y z t Figure

BUSBAR TYPE

CONDUCTOR TYPE

BUSBAR CODE

PROTECTION DEGREE


UNPAINTED / PAINTED

COMPONENT

A

yy

xxzz

t

17

KO - - -

E KO-LINE

70707040

180

26

0 21

0

50

Panel ConnectionPlate

Panel ConnectionPlate

E-Line KO-Busbar

Note: 230x460mm flange platedimensions are standard forall busbar types.

Opening on the panel board

15

0

41

0

15

15

10

01

00 1

50

400

145

460

145 15140

L1

L1

L2

L2

L3

L3

N

N

PE

PE

20

0

41

0

20

0

41

0

Busbar Feeder

Panel Feeder


Sample Order:

600 A, Aluminium, IP 55, 5 Conductor

Sample Order:

600 A, Aluminium, IP 55, 5 Conductor

KOA 0655 - - P11

KOA 0655 - - P10

P11

P10

Panel Feeder

Busbar Feeder

KO

BUSBAR TYPE

BOX TYPE

BOX RATINGPROTECTION

DEGREE

FUSED

SWITCHES TYPE

IP 55 5

S- STANDARD SYK

B- EMPTY

15P

160 A - 16

250 A - 25

400 A - 40

Cable Gland Plates

Tap-Off Boxes

with Fused Switches (SYK)

Mat.Cable

Gland Type

Order

Code

Inner

Diameter

(mm)Sheet

Metal

RP0----

Sheet

MetalRP1 25M32

M40Sheet

Metal

RP2 32

Sheet

Metal

RP3 63Special

AL RP4 632xSpecial

RP5 18

RP6 25

RP7 32

RP8 25

AL 4xM25

AL 4xM32

AL 4xM40

AL 8xM32

CURRENT Cable

Gland


Fused Switches (SYK)

Tap-off boxes are equipped with

EAE syk fused switches that;

Can operate under load,

Are equipped with NH fuse holders,

Have Interlock mechanism

Padlock applicable

Tap-off boxes can be equipped with

other brand of fused switches on request.

Tap-off boxes are painted in red

as standard.

Continuous current of tap-off boxes

with fused switch should not exceed 80% of

tap-off box current rating.

KOP 1651-S

KOP 2551-S

KOP 4051-S

A

B

B

A

18

E KO-LINE

L1L2L3N

L1L2L3N

A30 30

50

B

A

L1L2L3N

GlandPlates

(at tw

osides)

GlandPlates

(at th

ree

sides)

GlandPlates

(at th

ree

sides)

KOP 160

250

400

KOP

KOP

AmmA

Bmm

Cmm

RP2

RP3

RPK1370

0

625

48

3 0

380

380

0 195

245

255

5W

Order No.

49795

49797

95053

NH 00

NH 1

NH2

KYA

KYA

SYK

Fused

SwitchesFuse

Size

KOP 160

250

400

KOP

KOP

AmmA

Bmm

Cmm

RPK3

RP3

RPK220

5 0

6 5

4

0

7

3 0

3 0

3 0

0

0

0

2

2

2

20

20

20

35484

35486

35504

KO

BUSBAR TYPE

BOX TYPE


DEGREE

FUSED

SWITCHES TYPE

IP 55 5

15P

160 A - 16

250 A - 25

400 A - 40

KOP 1651-M1

KOP 1651-B1

KOP 4051-M1

KOP 4051-B1

KOP 2551-M1

KOP 2551-B1

19

E KO-LINE

B

A30 30

L1L2L3N

L1L2L3N

L1L2L3N

50

A

A

A

Cable Gland Plates

Special Cable Gland Plates

GlandPlates

(at th

ree

sides)

GlandPlates

(at th

ree

sides)

GlandPlates

(at th

ree

sides)

Mat.Cable

Gland TypeOrder

Code

Inner

Diameter(mm)

Sheet

Metal

RP0---- ----

Sheet

Metal

RP1 25M32

M40Sheet

Metal

RP2 32

Sheet

Metal

RP3 63Special

AL RP4 632xSpecial

AL RP5 184xM25

AL RP6 254xM32

AL RP7 324xM40

AL RP8 258xM32

Mat.Cable

Gland Type

Sheet

Metal

----

Sheet

MetalM25

M32

M40

1xSpecial

Sheet

Metal

Sheet

Metal

Sheet

Metal

Order

Code

Inner

Diameter(mm)

RPK0 ----

RPK1 18

RPK2

RPK3

RPK4

25

32

63

Tap-Off Boxes

for MCCB’s


* EAE tap-off boxes can be designed for all

brands of MCCB’s.

5W

Order No.Current

Cable

Gland


KO 15P

BUSBAR TYPE

BOX TYPE


DEGREE

SWITCH TYPE

IP 55 5

B1 -Transparent hinged lid / Empty tap off box

B2 -Transparent fixed lid / Empty tap off box

W -Equipped with MCB

40 A - 04

80 A - 08

3x6 A

3x10 A

3x16 A

3x20 A

3x25 A

3x32 A

3x40 A

3x50 A

3x63 A

3x80 A

1

1

KOP 045 -B1

KOP 085 -B1

KOP 0451-B

KOP 0851-B

2

2

20

Tap-Off Boxes

Sample Order:

40 A, IP 55, 5 wire, transparent

hinged lid, suitable for MCB,

empty tap off box

Sample Order:

40 A, IP 55, 5 wire, transparent

fixed lid, suitable for MCB,

empty tap off box

KOP 0451 - B1

KOP 0451 - B2

13

5

18

1

10

5

23

0

20

19

0

30

330

290

23

0

20

19

0

30

330

14

6

19

2

10

5

290

E KO-LINE

Extension

Part

Threaded

Rod

Steel Nut

Washer

21

Fixing Elements

E KO-LINE

Current Aluminium Copper

(A) (A)mm

(A)mm

-707580-

100125

707580

100112125

-

160250315400500600800

EAE

Pull-off

Dowel

Diameter of the

hole to be drilled

Busbar cross-section dimensions

ASU2A

KO-UT

Tij

TijKO-UT

KO-UT

KO-UT

UAS-K4

L Support

M8.......Ø12

M10.....Ø14

L

Tray Supports

Tray Supports

CodeL(mm)

ASU2A-1

ASU2A-2

ASU2A-3

ASU2A-4

ASU2A-5

Description

99536S

99535S

99534S

99533S

97043S

CodeL(mm)

UAS-K4 SUPPORT (1)

UAS-K4 SUPPORT (2)

UAS-K4 SUPPORT (3)

UAS-K4 SUPPORT (4)

UAS-K4 SUPPORT (5)

UAS-K4 SUPPORT (6)

UAS-K4 SUPPORT (7)

UAS-K4 SUPPORT (8)

UAS-K4 SUPPORT (9)

Description

67136S

67135S

67134S

67133S

67132S

67131S

67130S

67129S

67128S

200

250

300

350

400

500

600

700

1100

135

250

500

1000

2000

Connection Parts

CodeL(mm)

BRA 11-05 Threaded Rod (M8)




Description

99974

99973

99356

98876

500

1000

500

1000

40

40

L

L

4

BRA 10 Extension Part (M8)

BRA 13 Extension Part (M10)

BRA 9 EAE Pull-off Dowel (M8)

BRA 9 EAE Pull-off Dowel (M10)

M8 Steel Nut

M10 Steel Nut

M8 Washer

M10 Washer

-

-

-

-

-

-

-

-

98877

98874

98878

98703

01444

01445

01422

01424

31,5

46

2

Flat

application sample

Flat

application sample

Edgewise

application sample

Edgewise

application sample

22

Fixing Elements

E KO-LINE

Vertical Support Set

Wall Type


(Z) Type


(VS) Type

Code

Vertical Support Set Wall Type

Description

66916

Code

Vertical Support Set (Z) Type

Description

91202

CodeCurrent A(mm)

KOA - 1 UT Clamp

KOA - 2 UT Clamp

KOA - 3 UT Clamp

KOA - 4 UT Clamp

KOA - 5 UT Clamp

KOA - 6 UT Clamp

KOC - 2 UT Clamp

KOC - 4 UT Clamp

KOC - 6 UT Clamp

KOC - 8 UT Clamp

Description

97524

97527

97523

97526

97385

97525

97524

97523

97526

97525

160

250

315

400

500

600

250

400

600

800

115

120

125

145

157

170

115

125

145

170

Code

Vertical Support Set (VS)-40

Vertical Support Set (VS)-60

Description

96017

95996

A(mm)

40

60

KO-UT

Clamp

TMP 8

ASU2A

KT

90

10x30

A

TS

25

11x16

7x16

A

90

13x35

10,5x35

30

A

235

A

90

4

13

5

7,5

12

25

125155

10

5

Ø10

14x20

15x35

12x20

70

75

KT 200 Tray Support

KT 250 Tray Support

KT 300 Tray Support

KT 400 Tray Support

KT 500 Tray Support

KT 600 Tray Support

TS 200 Tray Support

TS 200 Tray Support

TS 200 Tray Support

TS 200 Tray Support

TS 200 Tray Support

TS 200 Tray Support

TMP 8 Ceiling Support Unit

Coupling

99525S

99524S

99523S

99522S

99521S

98715S

99517S

99516S

99515S

99514S

99513S

67876S

99196S

98869

A(mm)

235

285

335

435

535

635

205

255

305

405

505

605

-

-

Coupling

CodeDescription

Ø13Ø11Ø9

Ø1010x20

42,5

35

Fire Barriers

Dimensioning of Fire Barrier

KO-

Fire barriers are used to prevent the transition of flame and smoke

from one zone to another in case of fire. Chimney effect of air

insulated busbars are diminished.

While placing an order for fire barriers that will be installed into Busbar

below listed information should be given:

1- Thickness of floor or wall in cm. (A cm)

2- Centerline dimension of the fire barrier should be measured from the side

without the block joint. (Y cm)

3- There will be no plug-in points at fire barrier location.

4- EAE Supplies 30 cm thick fire barrier as standard when wall or floor

thickness is not stated.

5- The minimum length for these special elements with fire barrier can be 60cm.

1

2

A

Y

FloorSample Order:


Fire Barrier

KOC 0255- -STD-150-40Fire

Barrier

Block Joint

Please call us for more information.

N

23

Fire Barriers

After installation of standard busbar 3m lengths, you will be in need of special lengths which are smaller then 3m.

The minimum length for these special elements can be 35 cm. Please measure the lengths of these modules as shown below.

Determination of Special Lengths

A

E KO-LINE

A (cm): Thickness of Fire Barrier

Y (cm): Centerline of Fire Barrier

KO B

BUSBAR TYPE

CONDUCOR TYPE

BUSBAR CODE

PROTECTION DEGREE

NUMBER OF CONDUCTORS

COMPONENT

UNPAINTED / PAINTED

Y DIMENSION

A DIMENSION

Measure “A” length in cm, to determine the length of

special busbar subtract 12 from “A”.

X=A-12 (cm) X=Length of Special Busbar

Fire B

arr

ier

KO- Installation of End Closer

1-

(Figure a and b)

.

Busbar run ends with or

without a block joint

. For both

cases installation procedures

are same

2- Dismantle the screws on the

end closer and busbar.

3-

.

Place the end closer

and install the screws

4-

.

Busbar run with end

closer

1-

. (Pieces marked as 1a shall be

thrown away.)

Remove joint top cover plate, joint side

cover plate and the screws from non-block

joint bolt

2-

.

Introduce bolted and non-bolted ends of

the busbar into each other carefully, till joint

side cover plate screws can be put on

3-

.

Fix the joint side cover of the block

joint

4- Tighten the double headed

nut untill upper nut is broken.

7-

or

Ensure that the insulation

plates of the joint, are not

cracked broken.

KO- Mounting instructions for Joints

8- If removal is required for any reason,

tighten nut by calibrated torque wrench

adjusted to 55 Nm (40 lbft) after re-fixing

block joint set.

6-

-II .

Install top and bottom joint cover plates. Check the joint

before fitting the last joint side cover plate. Fit the joint cover

side plate and tighten and screws. Check the position of the

earth conductor when installing KO with five conductors

5- Take away the broken nut

and plastic seperator.

1

a

b

24

32 4

E KO-LINE

3

8

55 Nm (40lbft)

7

65

21

2a

Figure 3

1a

1a

4

25

E L E K T R İ K

Directive

EAE Elektrik A.S.

EC DECLARATION OF CONFORMITY

Product Group

Standard :

Manufacturer

E-Line KO-II Busbar Energy Distribution System

IEC 60439-1

IEC 60439-2

EAE Elektrik Asansor End. Insaat San. ve Tic. A.S.

EAE Elektrik Asansor End. Insaat San. ve Tic. A.S.

This is to attest, under our sole responsibility, that the aforementioned products conforms with

the regulations and guidelines of the following standards.

Date

11.09.2002

According to EC - Directive

2006/95/EEC “Low - Voltage - Directive”

Tests

1- Temperature-rise limits

2- Dielectric properties

3- Short-circuit strength

4- Effectiveness of the protective circuit

5- Clearances and creepage distances

6- Mechanical operation

7- Degree of protection

8- Electrical Characteristics

9- Structural Strength

10- Crushing resistance

11- Resistance of insulating materials to abnormal heat

12- Fire barrier

E KO-LINE

Akcaburgaz Mahallesi, 119. Sokak, No:10 34510 Esenyurt-Istanbul

Tel: +90 (212) 866 20 00 Fax: +90 (212) 886 24 20 www.eae.com.tr

Akcaburgaz Mahallesi, 119. Sokak,

No:10 34510 Esenyurt-Istanbul

26

Certificates

E KO-LINE

27

Product Overview

160A 800A BUSBAR SYSTEM

PRODUCT OVERVIEW (E-LINE KO-II)

Standards & Certification:- Busbar system shall be designed and manufactured as per IEC 60439-2 standard. Each individual rated busbar shall have separate type test certificate from an independentinternationally accredited laboratory.-- Busbar system shall have CE marking.- Each product shall have a “Type Label”, which indicates the brand, type of the unit, conductor number and electrical details.

Manufacturing facility of busbar systems shall have ISO 9001 and ISO 14001 certification.

Joint Structure:- Electrical and mechanical connection shall be made at joints by “single bolt” joint construction and each joint shall have two “Belleville” washers.- Insulators of the joint shall be manufactured of glass-reinforced polyester.- Joints shall be realized by a torque spanner (wrench) set at 55 Nm.- To prevent the joints from transportation damages, they shall be protected by metal caps, which shall be removed before installation.- Joint bolt shall be locked from both sides (Bolt head and nut).

Tap Off Boxes:- Rating of plug-in tap off boxes shall be up to and including 400A. Plug-in tap off boxes shall be installed, when the busbar line is energized.- Tap off boxes shall have an electrical interlock mechanism, which ensures that plug-in tap off box cannot be removed mechanically from the busbar, when the switch is at “ON”position. Mechanical interlock mechanism shall prevent the cover of the box from opening, when the switch is at “ON” position.- When the switch is at “OFF” position and the cover is open, tap off box shall provide IP2X protection level. (There shall not be any accessible live part in the box).- Tap Off boxes shall be suitable for any brand of MCB.- Contacts of plug-in tap off box shall be silver-plated copper.- While inserting the contacts of Plug-in tap off boxes, earth contact shall make first contact.- Tap off boxes up to 80A shall be manufactured of (850 GLW) type plastic material. Tap off boxes from 160A up to 400A shall be manufactured of sheet steel and epoxy paintedRAL 3020.

Installation and Commissioning:- Busbar systems shall be installed as per single-Line drawings respect to required ampere rates and manufacturer installation guide (torque values, lockers, etc.).Electrical installer shall run an insulation test after installation according to manufacturer's test procedures. The results of the test shall be reported to the manufacturer.Minimum insulation value shall be 1Mohm.

Housing and Structure:- Busbar system shall be of air insulated type. The bars shall be supported by insulators installed into the housing at every 25 cm.- On a three meter standard length busbar the distance between the plug-in points on one side shall be 50cms. The points shall be on both sides of the busbar making theaverage distance of plug-in points 25cm.- To prevent wrong alignment of the phase sequence during installation there shall be mechanical barriers on the joint that shall ensure correct mounting.- IP Plug-in covers of the busbar system should be hinged.Plug-in windows shall have automatic shutter system. This shutter shall open automatically when the earth contact oftap-off box is inserted.- Busbar system shall have all necessary accessories (elbows, offsets, panel-transformer connections, reductions, etc). Manufacturer shall supply special dimensioned units inshort time, if the project conditions requires.- For horizontal runs, a horizontal expansion unit shall be used at every 40m and expansion points of the building.- For vertical applications, a vertical expansion unit shall be used at every floor. Busbar system shall be rigidly fixed by supports at every floor.

General Structure of Products:- Busbar system shall be Air-Insulated and Plug-in type. Aluminium or Copper conductors shall be tin plated along the entire length. Housing shall be galvanized steel or if requiredRAL7038-Electrostatic painted.

Electrical Characteristics:

-

- Busbar systems nominal insulation voltage shall be 1000V.- As per ampere rates, minimum short circuit values shall be like below;

Temperature rise shall be maximum 50K over 40°C ambient temperaturefor both tin plated Aluminium and Copper conductor busbars.

Conductors:- Busbar system shall have Nickel and Tin-plated 6101 class aluminium conductors (160-600A). / Busbar system shall have Tin-plated Electrolytic copper conductors (250-800A).- Busbar system shall have below number of conductors and phase configuration;

a) 4 Conductors:(4 full size conductors + Housing ( earthing )b) (4 full size conductors + ½ earth conductor + Housing)c) ( 5 full size conductors + Housing (earthing) )d) ( 5 full size conductors, 5th bar shall be used as clean earth + Housing).

- Neutral conductor shall have the same cross-section (100%) of phase conductors.

4 ½ Conductors :

5 Conductors :

5 Conductors :

Insulation:- Busbars shall have air-insulation system.- Rated insulation voltage of the system shall be 1000 V.

Protection:- Protection degree of the busbar system shall be minimum IP55.

1-

2-

2.1-

2.2-

2.3-

2.4-

2.5-

2.6-

3-

4-

1sec/rms-10kA, Peak-17kA1sec/rms-15kA, Peak-30kA1sec/rms-30kA, Peak-63kA1sec/rms-35kA, Peak-73,5kA

160A:250 and 315A:400 and 500A:

600A and above:

E KO-LINE

Quantit

yC

om

po

nen

t

Co

mp

on

en

t Lis

t

Item

Project Design Form

28

E L E K T R İ K

E KO-IILINE

Ple

ase d

ub

licate

th

is p

ag

e fo

r yo

ur

ow

n u

se.

Nam

e:

Date

:

Sig

natu

re:

Prepared by

Co

mp

an

y:

Pro

ject

:

Pro

ject

No

:

PRODUCTTYPES

Compact Busbar Distribution System800...6300A

Plug-in Busbar Distribution System160...800A

Small Power Plug-in Busbar Distribution System100-160-225A

Plug-in Busbar Distribution System40-63A

Multi-conductor Lighting Busbar System25-32-40A

Lighting Busbar System25-32-40A

Multi Conductor Trolley Busbar System35...250A

Underfloor Ducting Systems

Raised Floor Energy Distribution Systems25...63A

CableTray Systems

E-LINE KB

E-LINE MK

E-LINE KAP

E-LINE DL

E-LINE KAM

E-LINE TB

E-LINE DK

E-LINE DKY

E-LINE UK

busbar systems 160800 a -...

Documents