EAE E-LINEKX User manual

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E-LINEKX
MANUAL

E-LINEKX

CONTENTS
Introduction ................................................................................................................ 2
General ....................................................................................................................3-4
Handling & Storage ..................................................................................................5-6
Points To Be Taken Into Consideration Before Installation.......................................7-8
Joint Structure ............................................................................................................ 9
General View Of The Joint......................................................................................... 10
Determination Of Special Lengths & Offset Sizing .................................................... 11
Mounting Instructions For Joints (Bolt-on / Plug-in).......................................... 12-14
Points To Be Taken Into Consideration After Installation .................................... 15-17
Things to be taken into consideration in vertical distribution project........................ 18
Plug-in Busbar Tap Off Boxes (KXP) ................................................................... 19-21
Bolt-on Busbar Tap Off Boxes (KXB)................................................................... 22-25
Cable Feed Box Installation (B10,B11) ...................................................................... 26
Energizing / Before Energizing .................................................................................. 27
Energizing The Equipment ........................................................................................ 28
Maintenance .............................................................................................................29

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KXMANUAL
2
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.
9001
14001
18001
27001
ISO
N
T
E
S
M
Y
E
S
G
T
A
E
N
M
A
S
M

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KXMANUAL
3
General
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.

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KXMANUAL
4
+
General
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

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KXMANUAL
5
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
2
3

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KXMANUAL
6
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.
8 10

7
KXMANUAL
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Installation
Points to be taken into consideration before 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.
7- When install horizontal and vertical , it must
be aligned correctly to prevent collapses and
bends.
3
min. 150cm - max. 200cm
+
Please cover
top of the shaft.

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KXMANUAL
8
Installation
Points to be taken into consideration before installation
8- Protect the busbar against water and
moisture from unnished roofs and walls
during installation.
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.
Min. From 4 points
10

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KXMANUAL
9
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 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.

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10
KXMANUAL
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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.

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KXMANUAL
11
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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.
325
A
X
Y
250
325
250
325
B
B
A
250
B
Y
A
A
Aluminium Copper A B X
Rated
Current
Busbar
Code
Rated
Current
Busbar
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

12
KXMANUAL
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Installation
Mounting Instructions For Joints (Bolt-on / Plug-in)
1-Align the two busbars so that the parts with
and without block joints are opposed.
5-Align the block joint to the other busbar's end.
1
3-Remove the nut locking piece on the busbar
joint and loosen the joint. Remove the protective
covers after loosening the joint.
3
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.
4
5
6-Loosen the nut at the joining point completely.
6
2- Remove the protective covers on the side with
no block joints.
2

13
KXMANUAL
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250mm
PE
L3
L2
L1
N
PE
L3
L2
L1
N
8
Installation
Mounting Instructions For Joints (Bolt-on / Plug-in)
PE housing
7-Adjust the channel in order to pivot the
alignment piece to the housing.
8-Push the two busbars 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.
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.
7
910
83
Nm
11
1
5
2
6
3
7
4
8
İlk Torklama
(20 Nm)
Nihai Torklama
(83 Nm)
12
12

14
KXMANUAL
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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
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.
T
ar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

15
KXMANUAL
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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 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.
4

16
KXMANUAL
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Installation
Points To Be Taken Into Consideration After 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.
8
K
K
G
G
1
34
5
2
12

17
KXMANUAL
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Installation
Points To Be Taken Into Consideration After Installation
WITHSTAND PERIODS AGAINST TO WATER AS PER STANDARD.
IP55 & IP65
Vertical Shaft Application
Pressure Water 3 Min.
1- The neutral bar of KX busbar shall be at the
bottom for horizontal busbar lines and on the
left for vertical busbar lines. (Figure 1)
2- In order to maintain the neutral bar at the
bottom and in the vertical busbar on the left, it
is required to use the phase changing module.
(Figure 1)
Phase Sequence Changer
Under water 30 min.
IP67
L3
L2
L1
N
L3
L2
L1
N
N L1 L2 L3 N L1 L2 L3
1

18
KXMANUAL
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Things to be taken into consideration in
vertical distribution project
As each building's structure is different than the other for vertical applications of E-Line KX special
projects has to be designed.
The details on this page briefly explain the necessary information.
In multipath busbars in high-rise vertical shaft applications;
Due to floor heights, floor thickness and product tolerances, the window
or additional point alignments on the upper floors may not be the same.
In order for the Tap off boxes to be aligned and the joint point not to
coincide with the floor transitions, the assembly should be continued by
making measurements on each floor.
N L1 L2 L3 N L1 L2 L3 N L1 L2 L3 N L1 L2 L3
150 150150 150
Installation
EAE is not responsible for the potential risks that may occur in cases
where the products in our catalogue are used outside of the standard
phase sequences as shown in the catalogue.