EAE KO-II User manual

Introduction
Technical Features
Joint Structure
Handling
Storage
Determination of Special Lengths & Offset Sizing
Installation
Points To Be Taken Into
Consideration Before Installation
Mounting Instructions For Joints
Installation of End Closer
Fire Barriers
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1.
2.
3.
4.
5.
6.
7.
7.1
7.2
7.3
7.4
2
3
4
5
6
7
8
9
11
Points To Be Taken Into
Consideration After Installation
KOP 40-80A Plastic Tap Off Boxes Installation
KOP 160-250-400A Tap Off Boxes Installation
Cable Feed Box Installation (B10, B11)
Energizing
Before Energizing
Energizing The Equipment
Maintenance
EC Decleration of Conformity
Product Overview
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7.5
7.6
7.7
7.8
8
8.1
8.2
9.
10.
11.
12
13
14
14
15
18
19
20
22
23
23
ENGLISH
CONTENTS

Introduction
Dear Customer,
EAE Elektrik A.Ş. Products are designed to provide the
maximum benefit in efficiency 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 certified.
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.
The busbar system's successful operation depends on
correct handling, installation, operation and
maintenance. Improper installation may cause
personal injury and the failure of the busbar system
and damage to other property.
Please do not handle the equipment in any other way than the instructions in this manual to be indicate.
2
ENGLISH
KO-IIMANUAL

Technical Features
Ui
Ue
f
IP
Icw
Ip
R
Z
1
1
V
V
Hz
kA
kA
mm
m/m
m/m
kg/m
kg/m
rms
2
W
W
160
01
250 315 400 500 600 250 315 400 630 800
02 03 04 05 02 04 06 080306
1000
1000
50/60
55
10
17
583
0,286
0,349
7,0
7,3
15
30
593
0,246
0,319
7,5
8,0
15
30
603
0,204
0,270
8,0
8,7
30
63
643
0,125
0,182
10,0
11,0
30
63
668
0,109
0,157
11,0
12,0
35
73,5
693
0,094
0,135
12,0
13,0
18
36
583
0,180
0,254
10,0
11,0
18
36
593
0,164
0,235
11,0
12,5
25
52,5
603
0,144
0,207
12,5
14,0
35
73,5
643
0,078
0,144
16,0
19,0
35
73,5
693
0,068
0,110
18,0
21,0
Rated Current
Conductor Type Aluminium (KOA) Copper (KOC)
Busbar Code
KO-IIMANUAL
Standards
Rated Insulation Voltage
Rated Operational Voltage
Rated Frequency
Protection Degree
Rated Peak Withstand Current
Weight - 4Conductors
Rated Short-time Withstand
Current (1s)
Mean Ohmic Impedance at the Steady
State Operation Temp. (1)and at Inθ
HousingCross Section (Aluminium)
Mean Ohmic Resistance at the Steady
State Operation Temp. (1)and at In θ
Weight - 5Conductors
TSEN / DIN EN / BSEN / IEC60439-1/2
3
ENGLISH

Joint Structure
KO-
(a) (b) (Figure 1)
Busbars are manufactured in 3m lengths as
standard,with special lengths as detailed on the
project drawings. All modules have a block jointed
end and a non-block jointed end .
(See as shown Figure 2)
1- 1 Busbar
2- 2 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
st
nd
1
5
3.2
3.4
6
2
47
3
3.1
3.3
8
KO-IIMANUAL
Figure 2
Figure 1
a
b
4
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2
3
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
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
All pallets should be checked by unpacking
them sufficiently 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.
2-
.
3-
.
*
4-
.
5-
.
6-
All busbar straight lengths and modules should
be handled with care to avoid damage to internal
components and the twisting of housing or its finish
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
When busbars need to be moved between floors,
platform lifts or elevators, either manually or power
operated, can be used advantageously by checking
the weight of modules.
Handling
KO-IIMANUAL
5
ENGLISH

KEEP DRY STOCK VERTICALLY
HANDLE WITH CARE MAX 3 PALETTES
2
3
4
1
1
15 cm
2
Storage
1-
.
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 traffic to prevent physical damage
to the products
2- When busbar straight lengths and modules are
to be stored for a 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 sufficient quantities of wooden bearers.
3- Busbars should not be stored outdoors.
KO-IIMANUAL
6
ENGLISH

Combined Offset
X=min:200mm
min = 20 cm
A
C
D
X
Current A B C D
160
250
315
400
500
600
800
250
315
400
600
180
185
190
210
222
235
180
185
190
210
235
145
147
150
160
166
172
145
147
150
160
172
200
200
200
200
200
200
200
200
200
200
200
290
290
290
290
290
290
290
290
290
290
290
Aluminium
Copper
Y
B
A
A
B
Y
D
C
B
A
Determination Of Special Lengths
Or Offset Sizing
1- 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 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-12 (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.
Vertical Offset Y=min:15 cm, standard
dimensions: Use table.
Horizontal Offset
KO-IIMANUAL
7
ENGLISH

3
Installation
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, feeder units, end feeder units etc. and check that
they are in accordance with the project drawings.
3- The recommended distance between supports is 2m. Make
sure that support positions do not block either joint covers or
tap off points.
usbar system should be handled with care either by forklift,
crane or any other means which will not damage the product
while transporting or lifting.
4- The b
Points To Be Taken Into Consideration Before Installation
Important!
5- a
5- b
5- 1-Tools required for the installation,
a- Micrometer type adjustable/calibrated torque spanner
b- ½ inch square drive size 10mm,
c- 13mm and 19mm socket or spanner
d- Screwdriver
e- Hoist with cloth sling
5-c 5- d 5- e
KO-IIMANUAL
8
ENGLISH
min.150cm - max.200cm

1- Remove joint top cover plate, joint side cover
plate and screws from non-block joint bolt. (Pieces
marked as shall be thrown away.)1a
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.
3
1
1a
1a
2
2a
Figure 3.
Installation
Mounting Instructions For Joints
KO-IIMANUAL
9
ENGLISH

4- Tighten the double headed nut untill upper nut is
broken.
5- Take away the broken nut and plastic seperator.
Installation
Mounting Instructions For Joints
KO-IIMANUAL
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
7-
or
Ensure that the insulation plates of the joint, are not
cracked broken.
10
ENGLISH
7
5
6
4

Installation
Mounting instructions for Joints
8
55 Nm (40lbft)
Installation of End Closer
KO-IIMANUAL
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.
11
ENGLISH
12
1
2
3
4
451
2
3
4
3
1
2
3
4
6

Installation
Fire Barriers
1
2
A
Y
Floor
Fire
Barrier
Block Joint
N
Fire Barrier
A (cm): Thickness of Fire Barrier
Y (cm): Centerline of Fire Barrier
KO B
BUSBAR TYPE
CONDUCOR TYPE
BUSBAR CODE
PROTECTION DEGREE
UNPAINTED / PAINTED
Y DIMENSION
A DIMENSION
NUMBER OF CONDUCTORS
COMPONENT
KO-IIMANUAL
Sample Order:
250 A, Copper, IP 55, 5 Conductors
Fire Barrier
KOC 0255- -STD-150-40
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.
12
ENGLISH

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- Run an insulation test with an insulation tester. There
must be no one working on the system during the test.
(Minimum 1000V AC). Ensure there is no protective device
connected to the system, open any ACB/MCCB/Fuseswitch
and that the earth/neutral link (if fitted) is disconnected.
3- Do not try to install five 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.
KG
Oil
4
8
KO-IIMANUAL
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 fire or use welding equipment
near the busbar.
11- Do not cut or drill the busbar units.
ENGLISH
13

Installation
Points To Be Taken Into Consideration After Installation
12- Take care when handling the system components.
Do not drop the units.
13- Ensure the selected degree of protection (IP rating)
of the system is suitable for the working environment.
KO-IIMANUAL
ENGLISH
14

Installation
1
4
3
2
KO-IIMANUAL
KOP 40-80A Plastic Tap Off Boxes Installation
1- Open the cover of the plastic tap off box.
2- Hold the box in parallel to the busbar,
check the position of the earth contact.
3- Carefully align the tap off box contacts and
push the box towards the busbar.
4- When the box is secured to the busbar housing,
closed the box cover and tighten the screws.
Attention:
Check the box once more before making connections.
Attention:
When the cover is the closed, due to interlock security
mechanisms, tap off box can not be installed or removed from
the busbar.
ENGLISH
15

3
Installation
2
4
1
KO-IIMANUAL
KOP 160-250-400A Tap Off Boxes Installation
1- Open Plug-in cover by using screw driver.
2- Release the plastic headed bolt to loosen
mechanical fixing clamps. Push left side of tap-off box
towards busbar and lock fixing clamps to the busbar.
Tight back the plastic headed bolt to hold busbar rigidly.
3- Carefully align the tap-off box contacts and push
right side of tap-off box towards to busbar and be sure
fixing tap-off box firmly.
4- Tight the plastic headed bolt on the right side
to fix the tap-off box mechanicaly to the busbar.
ENGLISH
16

3. Any type of blower or compressed air should not be used
to avoid blowing dust into busbar joints, tap off boxes or
circuit breakers. If there is accumulation of dust and dirt,
clean it off by using a soft brush, vacuum cleaner, or clean lint
free rags.
4. All joints should be correctly tightened according to the
torque value given and should be marked. Then install the
locking plates and transparent cover correctly.
5. All Tap Off boxes fed from the busbar should be in the
''OFF'' position.
6. The busbar runs should be isolated by disconnecting all
connections to transformers, switchboards, meters, etc.
7. Insulation resistance test with an insulation resistance test
equipment rated at 1000V AC should be conducted to verify the
integrity of the system.This test should be performed between
all phases, neutral and earth. Permanent records should be kept
of resistance readings. If the insulation reading appears to be
lower than 1 Mohm, then the cause should be investigated.
8. The system phase squence should be checked in order to
match the busbar phases sequence before reconnecting all
connections to transformers, switchboards, meters, etc.
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. (Make sure the neutral is correctly
connected)
2- For multiway busbars check the position of the paralleling
conductor link, make sure that they are available and fitted
correctly. Do not remove these conductor links.
3- Cable glands should be selected according to the size and
number of feeder cables. Please consult our protection plant
for requirements other than the standard supplied.
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
1.
.
All busbar ratings, routings and supporting systems
should be checked as per the final isometric drawings.
2. All busbar systems should be checked visually to be
certain that they are clean and secure. Loose and/or
contaminated connections increase electrical resistance
which can cause overheating
KO-IIMANUAL
Installation
Cable Feed Box Installation (B10, B11)
ENGLISH
17

1.The equipment should be only energized by
authorised person.
2.There should be no electrical load on the busbar system
when it is energized.
3.Hazardous voltages in electrical equipment can cause
severe personal injury or death. Energizing a busbar run
for the first time is potentially dangerous. Therefore system
opertional voltage should be checked .
4.The connected equipment should be energized in sequence
by starting at the source to end of the system.
5.After all overcurrent protection devices have been turned on,
loads such as lighting circuits, contactors, heaters and motors
may be turned ''ON''.
6.EAE busbar system is particularly quiet when operating normally.
In some installations however there may be a moderate hum.
Excessive noise may be an indication of hardware that has not
been tightened or of metal parts that have been improperly
assembled and this should be checked after de-energizing the
system and isolating it safety.
KO-IIMANUAL
Energizing
Energizing The Equipment
ENGLISH
18

KO-IIMANUAL
Maintenance
Busbar Runs
Important!
Caution
Hazardous voltages in electrical equipment can cause
severe personel injury or death unless otherwise specified.
Installation, inspection and preventive maintenance should
only be performed on busbar system to which power been
turned off, disconnected and electrically isolated so that no
accidential contact can be made with energized parts.
Operation of busbar trunking which has been contacted with
water or moisture damaged can cause property damage, severe
personal injury, or death. Observe the precautions to assure
adequate insulation resistance and that sources of moisture
had been eliminated.
Latest IEC 60439- 1/2 and locally applicable safety related
work practices should be followed at all times.
Hydrocarbon spray propellants and, hydrocarbon based sprays or
compounds will cause degradation of certain plastics. Contact
EAE before using these products to clean, dry, or lubricate
components during installation or maintenance.
1. An external inspection of the system should be carried out
once a year.
2. Any dripping or other source of moisture onto the busbar
modules should be eliminated from installed area.
Contact EAE for guidance giving full details of the system
and desing conditions.
Tap Off Boxes With Protective Devices
1. EAE tap off boxes are not equipped with any protective
device unless they are required by customer. Any type of
devices can be fixed in tap off boxes providing specific
informations about device prior to manufacture in order to
adjust interlock mechanism.
2. Tap off boxes operating mechanisms of all electrical &
mechanical interlocks should be exersized to determine
that they operate freely to their full on and off positions.
3. The total continuous load current should be measured
by proper instrument that does not exceed the current
rating on the busbar name plate or the designated design
current.
4. After performing all of the above inspections and
necessary repairs, it may be desirable to perform an
infra-red temperature test on all electrical connections
after busbar system is re-energized in order to be sure
not to reach a stabilized operating temperature.
ENGLISH
19

Directive
ELEKTRİK
EAE Elektrik A.Ş.
EC DECLARATION OF CONFORMITY
Product Group
Standar :d
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..
Akcaburgaz 0 10 Esenyurt
600
Mahallesi, 119. Sokak, No:1 345 -Ýstanbul
Tel: [phone] Fax: [phone] http://www.eae.com.tr
EAE Elektrik Asansor End. Inşaat San. ve Tic. A.Ş.
Akçaburgaz
0 10 Esenyurt
Mahallesi, 119. Sokak,
No:1 345 -Ýstanbul
This is to attest, under our sole responsibility, that the aforementioned products conforms with
the regulations and guidelines of the following standards.
According to EC - Directive
2006/95/ ”EEC “Low - Voltage - Directive
Tests
KO-IIMANUAL
Date
30.12.2006
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
(8.2.1)
(8.2.2)
(8.2.3)
(8.2.4)
(8.2.5)
(8.2.6)
7- Degree of Protection
8- Electrical Characteristics
9- Structural Strength
10- Crushing Resistance
11- Resistance of Insulating Materials
to Abnormal Heat
13- Fire Barrier
(8.2.7)
(8.2.9)
(8.2.10)
(8.2.12)
(8.2.13)
12- Resistance to Flame-propagation (8.2.14)
(8.2.15)
ENGLISH
20