EAE E-Lineko-II User manual

E-LINEKO-II
MANUAL
www.eaeelectric.com

E-LINEKO-II

CONTENTS
Introduction
General
Handling & Storage
Points To Be Taken Into Consideration Before Installation
Joint Structure
Determination of Special Lengths & Offset Sizing
Busbar Mounting Instructions For Joints
Fire Barriers
Points To Be Taken Into Consideration After Installation
KOP 40/80 Tap Off Boxes
KOP 160-250-400 Tap Off Boxes
Feed Box Installation (B10, B11)
Energizing / Before Energizing
Energizing The Equipment
Maintenance
2
3-4
5-6
7-8
9
10
11-12
13
14-15
16
17
18
19
20
21

KO-IIMANUAL
2www.eaeelectric.com
www.eaeelectric.com
Dear Customer,
EAE Elektrik A.Ş. Products are designed to provide the maximum benet in efciency and service.
Our products are manufactured in accordance with IEC standards and EAE is quality assured to
ISO9001 standards in their modern factories in Istanbul .
The components that you have purchased are manufactured in a completely environment conscious,
that is ISO 14001 certied.
These instructions should be read carefully and acted upon before taking delivery of equipment on
site.
Handling, installation and operation of busbar systems should be carried out only by skilled, trained
and authorized personnel using all associated equipment such as rubber gloves, helmet, safety
glasses or face shields and flash resistant clothing in accordance with established safety practices.
Please do not handle the equipment in any other way than the instructions in this manual to be
indicate.
These instructions should be read carefully and acted
upon before taking delivery of equipment on site.
9001
14001
18001
27001
ISO
N
T
E
S
M
Y
E
S
G
T
A
E
N
M
A
S
M
Introduction

KO-IIMANUAL
3
www.eaeelectric.com
www.eaeelectric.com
1- Installation according to the project of the
busbar system, planning and coordination with
other distribution systems (mechanical, heat,
steam, air installation etc.) is crucial.
2- Operational Success of the Busbar
systems is ensured by adhering to the right
transport, proper installation and design.
Improper application may cause malfunction
of the system, personal injury and damage to
operating systems.
3- The installation, operation and maintenance
of the busbar system should only be carried out
by qualied personnel who know the dangers
associated with installation a, construction
and operation of electrical equipment for the
purposes of this manual. Additionally, this
personnel ;
* Knows the requirement of applicable electrical
laws, other laws and standards.
* Be trained and authorized to test, energize,
clean, ground, label and lock the system and
equipment suitable for occupational safety
applications.
* Be trained in the use and maintenance
of personal protective equipment such as
rubber gloves, helmets,protective goggles or
face shields and gauze-resistant clothing in
accordance with relevant work safety practices
and potential hazard levels.
* Must be trained in rst aid.
WARNING:
Dangerous voltage levels in the electrical
components may result in the hazardous injury
and death.
Installation, monitoring and maintenance must
be carried out on de-energized busbar electrical
equipment. In this way, unintentional contact to
the equipment under the energy is prevented.
must be followed all warnings and related
instructions.
WARNING :
Operation of the busbar damaged by water or
moisture can caused damage property, serious
personal injury or death. To ensure proper
installation resistance and to ensure that the
moisture source is removed, observe the notes
in section on page 16 item 13 you receive.
General

KO-IIMANUAL
4www.eaeelectric.com
www.eaeelectric.com
General
N
N
BUSBARS SHOULD
NOT BE IN TOUCH WITH
ANY LIQUID MATERIAL
Dry
Envoirement Rain
Drops
Please use canopy
for outdoor
applications.
Please use porch
for outdoor.
Please use porch
for outdoor.
Please use canopy
for building expension
points.
Chemicals Urine
Water
CLOSE
INDIRECT or DIRECT
WATERWAYS
BUSBARS THAT ARE NOT
ASSEMBLED COMPLETELY
HAVE NO PROTECTION
AGAINST TO WATER

KO-IIMANUAL
5
www.eaeelectric.com
www.eaeelectric.com
Handling & Storage
1- General guidelines are given to protect
the busbar straight lengths and modules
and reduce the risk of personal injury and
equipment damage during handling on site.
2- As soon as the container or truck arrives on
site, a suitable forklift is required for easy and
convinient unloading from vehicle directly to
the ground level.
3- All pallets should be checked by unpacking
them sufciently to inspect them for possible
transit damage and to determine that the
shipment is complete and correct as per
Packing List provided.
* If any of the items is missing from the
Packing List or any piece is damaged during
transportation, Insurance Company must be
informed immediately for proper reporting with
all required documents for further action.
4- All busbar straight lengths and modules
should be handled with care to avoid damage
to internal components and the twisting of
housing or its nish.
KEEP DRY
HANDLE WITH
CARE STOCK VERTICALLY MAX 3 PALETTES

www.eaeelectric.com
www.eaeelectric.com
KO-IIMANUAL
6www.eaeelectric.com
www.eaeelectric.com
Handling & Storage
5- When the lengths and modules are required
to be taken from the pallets to the erection area,
those should be hoisted using metal rods or
bars passed through the 2 sets of holes at each
end of the housing body by ensuring the load is
stable and safely secured. Then adequate sling
and slinging method can be used for shifting
from one place to another.
6- The removal of the products from one floor
to the other floor must be done by means of
a suitable electric and mechanical crane or
elevator.
7- Repack the Busbar if you need to store or
hold before installation (Refer to chapter5.) as
long as conditions permit, do not disassemble
the busbar until it reaches the lastest
installation point.
8- Storage area should be a clean, dry space
with a uniform temperature to prevent
condensation and having adequate air
circulation and protected from dirt, fumes,
water. Storage area should be free of vehicle
trafc to prevent physical damage to the
products.
9- When busbar straight lengths and modules
are to be stored for certain time before
installation, restore the packing for protection
during that period and cover them with
waterproof sheet in very well protected area
from dust and any kind of liquid on sufcient
quantities of wooden bearers.
10- The busbar designed for the outdoor
environment are not weatherproof until the
insallation is complete and in accordance
with the instructions and above recommended
storage conditions must be applied for other
busbars.

7
KO-IIMANUAL
www.eaeelectric.com
www.eaeelectric.com www.eaeelectric.com www.eaeelectric.com
min.150cm - max.200cm
Points to be taken into consideration before installation
Installation
IMPORTANT!
1- Please read this instruction manual before
commencing the busbar installation. Incorrect
or incomplete mounting may cause damage to
the equipment or system.
2- Installation of the busbar system should
commence after reading through busbar
application drawings. Locate the positions of
individual pieces such as transformer-panel
connections, expansion units, feeder units,
end feeder units etc. and check that they are in
accordance with the project drawings.
3- ⚠ Seismic support systems should be
used in earthquake risk areas. Please contact
our company for details of seismic support
products and project planning.
The recommended distance between supports
is 1.5m, the maximum distance is 2m. Make
sure that support positions do not block either
joint covers or tap off points.
4- DDT modules should be used at min. 20cm
distance to the each floor concrate.
5- If the busbar lines are used in the transition
of building dilatations, appropriate dilatation
module should be chosen. Please contact our
company for support.
6- Busbar system should be handled with
care either by forklift, crane or any other
means which will not damage the product
while transporting or lifting.When transporting
busbar , position its weight evenly. Generally
vertical installation is provided in vertical lines.
Please read additional installation instructions.

www.eaeelectric.com
www.eaeelectric.com
8
KO-IIMANUAL
www.eaeelectric.com
www.eaeelectric.com
Installation
7- When install horizontal and vertical , it must be
aligned correctly to prevent collapses and bends.
8- Protect the busbar against water and
moisture from unnished roofs and walls during
installation.
Min. From 4 points
9- Tools required for the installation,
Micrometer type adjustable/calibrated torque
spanner
½ inch square drive size 10mm, 13mm and
19mm socket
Drilling Machine
Size 10mm Spanner/Socket
Screwdriver
Hoist with cloth sling
10- The busbar to be installed needs to be
hanged min 4 points, as shown in below
picture.
Points to be taken into consideration before installation

KO-IIMANUAL
9
www.eaeelectric.com
www.eaeelectric.com www.eaeelectric.com www.eaeelectric.com
Joint Structure
1
5
3.2
3.4
6
2
47
3
3.3
3.1
8
KX busbars are manufactured in 3m lengths as standard, with special lengths as detailed on
the project drawings. All modules have a block joint end and the other end of the module has not
block joint.
(See as shown Figure 1)
1- 1st Busbar
2- 2nd Busbar
3- Block Joint
3.1-Locker Piece
3.2-Insulators
3.3-Double Headed Nut
3.4-Plastic Seperator Piece
4-Conductors
5-Front Cover Plate
6-Top Cover Plate
7-Joint Protection Plate
8-Bottom Cover Plate
Figure 1
Figure 2
a
b

www.eaeelectric.com
www.eaeelectric.com
KO-IIMANUAL
10 www.eaeelectric.com
www.eaeelectric.com
C
D
X
Determination of Special Lengths of Offset Sizing
1- Special length (particular or custom size)
busbars are used in places where standard
sizes do not t when the busbar is mounted
and in other similar places. The minimum
length for these special element is 35cm.
Please measure the lengths of these modules
as shown below.
2- Length A is measured between housing
of 2 busbars in cm. "A". The special length
is calculated by deducting 25cm from this
measured length.
X=A-25 (cm) X=Length of Special Busbar
(The busbar module will be manufactured as
per X value.)
3- In the case in where custom-made
intermediate-size busbars are required, both
ends of the intermediate-size busbars can
be produced with or without block joints. In
such cases, please contact our company for
technical support and technical information.
Note: Please send a drawing for combined
offsets when ordering. Indicate bolted and
non-bolted ends on the drawing.
A
Current A B C D
Aluminium
160 180 145 200 290
250 185 147 200 290
315 190 150 200 290
400 210 160 200 290
500 222 166 200 290
600 235 172 200 290
800 270 190 200 290
Copper
250 180 145 200 290
315 185 147 200 290
400 190 150 200 290
600 210 160 200 290
800 235 172 200 290
Vertical Offset
min = 200 mm
min = 200 mmX=min:150mm
Horizontal Offset Combined Offset
Y
B
A
A
B
Y
D
C
B
A

11
KO-IIMANUAL
www.eaeelectric.com
www.eaeelectric.com www.eaeelectric.com www.eaeelectric.com
Installation
1- Remove joint top cover plate, joint side
cover plate and the screws from non-block
joint bolt. (Pieces marked as 1a should be
thrown away.)
3- Fix the joint side cover of the block joint.
5- Take away the broken nut and plastic
seperator.
2- Introduce bolted and non-bolted ends of
the busbar into each other carefully, until the
cover plate screws can be put in.
Figure 3
4- Tighten the double headed nut untill upper
nut is broken.
6- Install top and bottom joint cover plates.
Check the joint before tting the last joint side
cover plate. Fit the joint cover side plate and
tighten the screws. Check the position of the
earth conductor when installing KO-II with ve
conductors.
1
1a
1a
3
5
2a
2
4
6
Busbar Mounting Instructions For Joints

12
KO-IIMANUAL
www.eaeelectric.com
www.eaeelectric.com
Installation
Installation of End Closer
7- Ensure that the insulation plates of the
joint, are not cracked or broken.
8- If removal is required for any reason, tighten
the nut using a calibrated torque wrench
adjusted to 55 Nm (40 lbft) after re-tting the
block joint set.
7
1
1
2
3
4
3
1
2
3
4
5
1
2
3
4
2
4
6
55 Nm (40lbft)
8
Busbar Mounting Instructions For Joints

13
KO-IIMANUAL
www.eaeelectric.com
www.eaeelectric.com
Installation
1
2
A
Y
N
Sample Order: 250 A, Copper, IP 55, 5 Conductors Fire Barrier
KOC 0255- II -STD-150-40
Fire Barriers
Fire barriers are used to prevent the transition of flame and smoke
from one zone to another in case of re. The re barriers prevent the
chimney effect of air insulated busbar.
Block Joint
Floor
Internal
Fire
Barrier
Fire Barriers
Dimensioning of Fire Barrier
When placing an order for re barriers to be installed in the KO-II
busbar, the following information is required :
1. Thickness of floor or wall in cm. (A mm)
2. Centreline dimension of the re barrier should be measured
from the side without the block joint. (Y mm)
3. There will be no plug-in points at the re barrier location.
4. EAE Supplies a 300 mm thick re barrier as standard when
wall or floor thickness is not stated.
5. The minimum length for these special elements with re
barrier is 600 mm.
Fire Barriers

14
KO-IIMANUAL
www.eaeelectric.com
www.eaeelectric.com
Installation
1- When the installation has been completed,
please check the position of the neutral
conductor along the busbar run. (Taking special
care at locations where the run makes turns and
offsets)
2- Carry out insulation test (minimum 1000V
AC). Make sure that no protective device (switch,
disconnector, etc.) is connected to the system
and that the earth - neutral line is separate.
All tap of boxes on the line must be set to «0».
Keep in mind that the results can vary according
to the busbar length, width or number of bars.
The results may also vary according to the
moisture content. Values should not be less than
1 MegaOhm / 30 meters. It is recommended
that no energy is supplied to the line even if the
insulation test is completed successfully.
2.3- After the busbar system is energized, loads
must be switched in sequence (main and sub
feed).
2.4- When the busbar is used properly, it will
have a moderate hum. Excessive noise may
be an indication of hardware that has not been
extruded or incorrectly mounted metal parts.
2.5- Spark formation at any point along the
busbar is not normal. The busbar must be de-
energized and de-energized until the spark
condition is corrected.
3- Do not try to install ve conductor units to
four conductor units or vice versa.
4- Do not apply any kind of oil or chemical at
the joints or to the contacts of tap off boxes.
2.1- When the busbar system is energized for
the rst time, qualied electrical personnel must
be present. If short circuits and earth faults are
detected due to any damage or faulty installation
practices, serious damage can occur if the power
is turned on.
2.2- When the power is supplied, there must be
no electrical load in the busbar.
Points To Be Taken Into Consideration After Installation

15
KO-IIMANUAL
www.eaeelectric.com
www.eaeelectric.com
Installation
5- Do not use any other means than original
tap off boxes to supply energy from the busbar.
6- Current rating of the busbar run should be
equal to the rating of the breaker. Do not exceed
busbar nominal current during operation.
7- Make sure that any additional loads to the
system following do not exceed the nominal
current capacity of the busbar.
8- Do not use busbar system as a supporting
structure for other systems.
9- Do not use busbar system as a walk way.
10- Do not light a re or use welding equipment
near the busbar.
11- Take care when handling the system
components. Do not drop the units.
12- Do not cut or drill the busbar units.Please
consider below picture when installing the
busbar for vertical applications. Please do not
drill the busbar at any place where is marked
with red on the picture.
13- Take precautions against adverse
environmental conditions such as rain and
snow. In addition, the busbar dripping cement,
etc. inside the building. Protect from water,
malfunctioning piping and all fluids that may
come from water jets. Cover if necessary. Cap
the ends to the busbar joint points that have
not been installed at the end of the work.
14- Ensure the selected degree of protection (IP
rating) of the system is suitable for the working
environment.
15- You can remove paint defects on product’s
surface which could happen during transporting
and installation operation by retouching with
spray paint. (Also you can have information
about the paint color that you have ordered from
the manufacturer) We recommend you to clean
up surfaces with a dry cloth in advance where
painting process will be.
Points To Be Taken Into Consideration After Installation

16
KO-IIMANUAL
www.eaeelectric.com
www.eaeelectric.com
Installation
1- Open the cover of the plastic tap off box.
3- Carefully align the tap off box contacts and
push the box towards the busbar.
2- Hold the box in parallel to the busbar, check
the position of the earth contact.
4- When the box is secured to the busbar
housing, closed the box cover and tighten the
screws.
1
3
2
4
Important!
When the cover is the closed, due to interlock security mechanisms,
tap off box can not be installed or removed from the busbar.
Attention!
Check the box once more before making connections.
KOP 40/80 Tap Off Boxes

17
KO-IIMANUAL
www.eaeelectric.com
www.eaeelectric.com
Installation
1- Open Plug-in cover by using screw driver.
3- Carefully align the tap-off box contacts
and push right side of tap-off box towards to
busbar and be sure xing tap-off box rmly.
2- Release the plastic headed bolt to loosen
mechanical xing clamps. Push left side of
tap-off box towards busbar and lock xing
clamps to the busbar. Tight back the plastic
headed bolt to hold busbar rigidly.
4- Tight the plastic headed bolt on the right
side to x the tap-off box mechanicaly to the
busbar.
1
3
2
4
Important!
When the cover is the closed, due to interlock security mechanisms,
tap off box can not be installed or removed from the busbar.
KOP 160-250-400 Tap Off Boxes

18
KO-IIMANUAL
www.eaeelectric.com
www.eaeelectric.com
Energizing
1- When installing the feeder boxes B10, B11
make sure that the phase sequence of the
feed box matches the phase sequence of the
busbar. (Care is to be exercised ensuring the
neutral is correctly connected)
2- For multiway busbars check the position of
the paralelling conductor link, make sure that
they are available and tted correctly. Do not
remove these conductor links.
3- Cable glands should be selected according
to the size and number of feeder cables. Please
consult to factory for requirements other the
standard supplied ones.
4- Make sure that the incoming feeder cables
to the box are all the same length for each
phase.
5- Do not cut or drill the feeder units.
Energizing
Before Energizing
WARNING: HIGH VOLTAGE VALUES CAN CAUSE
DEATH OR SERIOUS INJURIES. MAINTENANCE,
INSTALLATION AND OBSERVATIONS IN THE
CONSEQUENTIAL CONDITIONS; THE ENERGY
AND THE CONNECTION MAY BE DONE ON THE
BUSBARSCUTOFFANDELECTRICALISOLATED.
THEREFORE, ACCIDENTAL RESPONSE TO BE
CONTACTED BY PARTS UNDER ELECTRICALLY.
FOLLOW ALL MANUFACTURER'S WARNINGS
AND INSTRUCTIONS
1- Make sure that all joint zone connections
are correct. Follow the manufacturer's
recommended torque.
2- Make sure that all bolt-on and plug-in boxes
are in the "off" position. Boxes without power
interrupts must be removed from the busbar
if they cannot be isolated with auxiliary power
breakers.
3- Make sure that the connections between the
busbar and the panel, transformer and other
connections are interrupted.
4- Resistance testing is to be carried out with
a resistance tester of 1000 volts per part of
the busbar to ensure that the system does not
contain short circuit and ground faults. (Phase-
earth, phase-neutral, phase-to-phase). Record
the results of the test and deliver it to the
project or the responsible company. Note that
the results may vary depending on the busbar
length, width, or number of bars. The results
may also vary according to the humidity. If the
values are less than 1 MegaOhm / 30 meters,
please contact the manufacturer.
5.1- Before connecting the busbar to the
transformer, panel and other connections,
make sure that the phase of the system and
the phase of the busbar overlap.
5.2- Make sure that the ventilation and
drainage holes are open. Make sure that the
screws and plugs in the drain holes for the
outdoor busbars are removed according to the
manufacturer's instructions.
Feed Box Installation (B10, B11)