EAE E-LINEKX-III User manual

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E-LINEKX-III
MANUAL

E-LINEKX-III

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CONTENTS
Introduction
General
Handling & Storage
Points To Be Taken Into Consideration Before Installation
Joint Structure
General View Of The Joint
Determination Of Special Lengths & Offset Sizing
Mounting Instructions For Joints (Bolt-on / Plug-in)
Points To Be Taken Into Consideration After Installation
Standard Application Precautions
Plug-in Busplug
Busplug
Cable Feed Box Installation (B10, B11)
Energizing / Before Energizing
Operation / Busplug
Maintenance
Product Overview
2
3-6
7-9
10-11
12
13
14
15-17
18-20
21
22
23-24
25
26-27
28
29-31
32

KX-IIIMANUAL
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Introduction
These instructions should be read carefully and acted
upon before taking delivery of equipment on site.
Dear Customer,
EAE Elektrik A.S. Products are designed to provide the maximum benet in efciency and service.
Our products are manufactured in accordance with Management Systems standards and EAE
quality principles in our modern production plants in Istanbul.
The components that you have purchased are manufactured by a completely environment conscious
with the relevant Environmental management Standards and accordance with the principles of
information Security Management systems, in accordance with the rules of occupational safety
and health.
Handling, installation and operation of produc 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.

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General
Safety Information
Read these instructions carefully and look at the equipment to become familiar with the device
before trying to install, operate, service, or maintain it. The following special messages may appear
throughout this bulletin or on the equipment to warn of hazards or to call attention to information
that claries or simplies a procedure.
The addition of either symbol to a “Danger” or “Warning” safety label
indicates that an electrical hazard exists which will result in personal injury if
the instructions are not followed. This is the safety alert symbol. It is used to
alert you to personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates a hazardous
situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a hazardous
situation which, if not avoided, could
result in death or serious injury.
NOTICE is used to address practices
not related to physical injury. The
safety alert symbol is not used with
this signal word.
CAUTION indicates a hazardous
situation which, if not avoided, could
result in minor or moderate injury.
DANGER
CAUTION
WARNING
NOTICE

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General
Follow all safety precautions provided in this bulletin and all safety label instructions on this
equipment.
General Danger Safety Label
NEMA Publication BU 1.1 is provided with each busway project as a guide for proper
installation, operation, and maintenance of busway products. This publication
addresses such areas as inspection of all electrical joints and terminals for tightness,
preventing the entry of water and contaminants into the busway, instructions for what
to do if water and contaminants do enter the busway, and other maintenance topics.
EAE recommends to help ensure the highest quality of product performance are as follows:
— NFPA 70–National Electrical Code (U.S.)
— NFPA 70B–Maintenance of Electrical Equipment
— NEMA BU 1–Busway Standard published by the National Electrical Manufacturers Association
— CSA C22.1–Canadian Electrical Code, Part 1
• Apply appropriate personal protective equipment (PPE) and follow safe electrical work
practices. See NFPA 70E, NOM-029-STPS-2011, or CSA Z462.
• This plug-in unit or busway systems must be installed and serviced only by qualied electrical
personnel.
• Handle this equipment carefully and install, operate, and maintain it correctly in order for it
to function properly. Neglecting fundamental installation and maintenance requirements may
lead to personal injury, as well as damage to equipment or other property.
• Follow the safety label instructions on the equipment and inside this bulletin.
• Perform such work only after reading and understanding all of the instructions contained in
this bulletin.
• Turn off power to busway before installing or removing plug-in unit.
• Do not install, operate, or remove plug-in unit with cover open or removed.
• Turn off power to busway before working on line side of plug-in unit.
• Turn off plug-in unit before opening or working inside enclosure.
• Always use a properly rated voltage sensing device at all line and load side fuse clips to conrm
the plug-in unit is off.
• Before closing the door or replacing the cover-mechanism, carefully inspect the switch area to
ensure no tools or objects have been left on or inside the equipment.
• The successful operation of this equipment depends upon proper handling, installation,
operation, and maintenance.
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Failure to follow these instructions will result in death or serious injury.
DANGER

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General
1-Installation according to the project of the
busway system, planning and coordination
with other distribution systems (mechanical,
heat, steam, air installation etc.) is crucial.
2-Operational Success of the Busway
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 busway 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.
Operation of the busway 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 17 item 13 you receive.
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 busway
electrical equipment. In this way, unintentional
contact to the equipment under the energy is
prevented.must be followed all warnings and
related instructions.
WARNING
WARNING

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+
General
BUSWAY 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.
BUSWAY THAT ARE NOT
ASSEMBLED COMPLETELY
HAVE NO PROTECTION
AGAINST TO WATER.

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Handling & Storage
Busway
1- General guidelines are given to protect
the busway 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 busway straight lengths and modules
should be handled with care to avoid damage
to internal components and the twisting of
housing or its nish.
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe electrical work
practices. See NFPA 70E.
• Protect this equipment from contaminants such as water, salts, concrete, and other corrosive
environments before, during, and after installation.
• Do not sit, walk, or stand on this equipment.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
KEEP DRY
HANDLE WITH
CARE STOCK VERTICALLY MAX 3 PALETTES
WARNING
2
3

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10- The busway 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
busway.
11- When busway 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.
NOTE: Never drag the busway across the
ground.
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 Busway if you need to store or
hold before installation (Refer to chapter5.) as
long as conditions permit, do not disassemble
the busway 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 busway 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.
8
10
8
10
10
8

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Handling & Storage
Busplug
Plug-in units are shipped in corrugated cartons. Do not drop or perforate the cartons. Handle the
plugin units with care to avoid damage to internal components and the enclosure or to its nish.
Avoid subjecting plug-in units to twisting, denting, dropping, or any other rough handling. Ensure the
equipment at the installation site is adequate to handle the plug-in unit. Verify the lifting capacity
of the crane or other available lifting equipment. Refer to the appropriate busway systems manual
for weight specications. If using a forklift, position the plug-in unit on the forks to distribute the
weight properlyTake care not to damage the metal housing. Avoid using objects with sharp edges
to lift the plug-in unit.
NOTE: Never drag the plug-in unit.
NOTE: If the plug-in unit is not going to be installed and energized immediately, store it indoors in a
clean, dry place with a uniform temperature. Protect the unit from contaminants such as water, salt,
concrete, and other corrosive elements.
NOTICE
POTENTIAL EQUIPMENT CONTAMINATION
• Store the equipment in a clean, dry location.
• Protect the equipment from contaminants such as
water, salts, concrete, and other corrosive elements.
Failure to follow these instructions can result in
equipment damage.

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IMPORTANT!
1- Please read this instruction manual before
commencing the busway installation. Incorrect
or incomplete mounting may cause damage to
the equipment or system.
2- Installation of the busway system should
commence after reading through busway
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 busway lines are used in the transition
of building dilatations, appropriate dilatation
module should be chosen. Please contact our
company for support.
6- Busway system should be handled with
care either by forklift, crane or any other means
which will not damage the product while
transporting or lifting. If hoisting the busway
with a crane, use nylon straps to distribute the
Installation
Points to be taken into consideration before installation
weight of the section. If using cables, insert
spreaders to avoid damage to the busway.
If using a forklift, position the busway on the
fork to distribute the weight properly. Take
care not to damage the metal housing, which
could result in a failure of the busway. Avoid
using objects with sharp edges to lift the
busway. When transporting busway , position
its weight evenly. Generally vertical installation
is provided in vertical lines.
Please read additional installation instructions.
7- When install horizontal and vertical , it must
be aligned correctly to prevent collapses and
bends.
8- Protect the busway against water and
moisture from unnished roofs and walls
during installation.
8
Please cover
top of the shaft.
8
3

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10
Installation
Points to be taken into consideration before installation
9- Tools required for the installation,
Micrometer type adjustable/calibrated torque
spanner
9-a ½ inch square drive size 10mm, 13mm and
9-b 19mm socket
9-c Drilling Machine
9-d Size 10mm Spanner/Socket
9-e Screwdriver
9-f Hoist with cloth sling
10- The busway to be installed needs to
be hanged min 4 points, as shown in below
picture.
Min. From 4 points
10

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Joint Structure
1. Extruded Aluminium Housing
2. PE Fixing Piece
3. Insulation Layers (Epoxy+polyester lm)
4. Joint Insulators
5. Joint Cover
6. Belleville Washer
7. Alignment Pin (removable)
8. Conductors
9. IP55 Nut Locking Piece
10. Protection Plastics
11. IP55 Joint Cover Gasket
12. Alignment Pin Slot NB Protective
covers 10 are discarded.
KX busway 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.

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Installation
General Overview Of The Joint
Bolt-on Box Fixing Point
Plug-in Box Fixing Point
Use special hand clamps if it is difcult to move.

KX-IIIMANUAL
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Determination of Special Lengths of Offset Sizing
1- Special length (particular or custom size)
busway are used in places where standard sizes
do not t when the busway 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 busway in cm. "A". The special length
is calculated by deducting 25cm from this
measured length.
X=A-25 (cm) X=Length of Special Busway (The
busway module will be manufactured as per X
value.)
3- In the case in where custom-made
intermediate-size busway are required, both
ends of the intermediate-size busway 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.
325
A
X
Y
250
325
250
325
B
B
A
250
B
Y
A
A
Aluminium Copper A B X
Rated
Current
Busway
Code
Rated
Current
Busway
Code
(mm) (mm) (mm)
400 04 550 05 252 214 427
500 05 650 06 257 217 432
630 06 800 08 267 222 442
800 08 1000 10 282 229 457
- - 1250 12 297 236 472
1000 10 1350 14 307 241 482
- - 1600 17 322 249 497
1250 12 - - 337 256 512
1350 14 2000 23 352 264 527
1600 17 - - 387 281 562
2000 20 2500 25 427 301 602
2500 27 - - 477 326 652
- - 2000 22 377 276 552
- - 2500 27 407 291 582
2500 25 3300 32 487 331 662
- - 3600 36 517 346 692
3150 32 4000 40 547 361 722
3200 33 - - 587 381 762
4000 40 5000 50 667 421 842
5000 51 - - 767 471 942
- - 6300 63 907 541 1082
6300 63 - - 1057 617 1232
Vertical Offset
min = 250 mm
max = 490 mm
min = 300 mm
X=min:280mm, max:
Use table.
Horizontal Offset
Combined Offset

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Installation
Mounting Instructions For Joints (Bolt-on / Plug-in)
1- Align the two busway so that the parts
with and without block joints are opposed.
2- Remove the protective covers on the side
with no block joints.
3- Remove the nut locking piece on the
busway joint and loosen the joint. Remove
the protective covers after loosening the joint.
4- Ensure that the insulation plates of the
joint, are not cracked, broken or damaged in
anyway. Wipe the conductor surfaces with a
cloth to clean dust, which can cause serious
damage.
5- Align the block joint to the other busway's
end.
6- Loosen the nut at the joining point
completely.
1
3
5
2
4
6

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Installation
Mounting Instructions For Joints (Bolt-on / Plug-in)
7- Adjust the channel in order to pivot the
alignment piece to the housing.
8- Push the two busway until they rest on
each other.
11- If there is more than one bolt per
phase,the bolts should be tightened by hand to
approximately 20-30 Nm as per the sequence
shown above.Then nally torque to 83Nm
using the same sequence.
12- Remove the joint covers and reverse
mount them with the gaskets facing in.
8
250mm
9- Assemble both the joint covers with the
gaskets facing out.
10- Adjust the torque wrench to 83 Nm (60
lbft) and tighten the joint nut.
PE housing
Final Torque
(83 Nm)
Firs Torque
(20 Nm)
8
109
11 12
7

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Ek / Attach
No:
Nm
83
Block Joints have been done according to
manual and applied related Nm value to
the main bolts.
Tarih / : ........./........./................Date
Ad Soyad / First / Last
: .........................................................................
İmza / : ....................................Signature
Ek montajı, talimatına uygun yapılmıştır ve
yanda yazılı Nm değerinde ek torklanmıştır.
Ek / Attach
No:
Nm
83
Block Joints have been done according to
manual and applied related Nm value to
the main bolts.
Tarh / : ........./........./................
Date
Ad Soyad / First / Last
: .........................................................................
İmza / : ....................................
Sgnature
Ek montajı, talimatına uygun yapılmıştır ve
yanda yazılı Nm değerinde ek torklanmıştır.
Abdullah Eldelekli
Abdullah Eldelekli
20 04 2014
20 04 2014
14
13
40
Nm
Ek / Attach
No:
Nm
83
Block Joints have been done according to
manual and applied related Nm value to
the main bolts.
Tarih / : ........./........./................Date
Ad Soyad / First / Last
: .........................................................................
İmza / : ....................................Signature
Ek montajı, talimatına uygun yapılmıştır ve
yanda yazılı Nm değerinde ek torklanmıştır.
Ek / Attach
No:
Nm
83
Block Joints have been done according to
manual and applied related Nm value to
the main bolts.
Tarh / : ........./........./................
Date
Ad Soyad / First / Last
: .........................................................................
İmza / : ....................................
Sgnature
Ek montajı, talimatına uygun yapılmıştır ve
yanda yazılı Nm değerinde ek torklanmıştır.
Abdullah Eldelekli
Abdullah Eldelekli
20 04 2014
20 04 2014
14
13
40
Nm
Installation
Mounting Instructions For Joints (Bolt-on / Plug-in)
13- Finally tighten the locking piece to 40 Nm
to complete the installation.
14- Please ll in the necessary places to verify
that you are performing torque according to
the specied norm. Attach to the joint cover.
13 14

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Installation
Points To Be Taken Into Consideration After Installation
1- When the installation has been completed,
please check the position of the neutral
conductor along the busway 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 busway 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 busway system is energized,
loads must be switched in sequence (main and
sub feed).
2.4- When the busway 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
busway is not normal. The busway 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 busway 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 busway.
4
4